WO2020224694A1

WO2020224694A1 - Modularly constructed stator of an electrical machine

Info

Publication number: WO2020224694A1
Application number: PCT/DE2020/100172
Authority: WO
Inventors: Peter Schwanemann
Original assignee: Schaeffler Technologies AG & Co. KG
Priority date: 2019-05-09
Filing date: 2020-03-10
Publication date: 2020-11-12
Also published as: DE102019112053A1

Abstract

The invention relates to a modularly constructed stator (1) of an electrical machine, the stator having the following features: a first stator tooth (2) and a second stator tooth (3), which are interconnected and arranged adjacent to one another, each stator tooth (2, 3) having a base element (4, 5) for forming an outer stator ring (6) and having two tooth flanks (7, 8), which are inclined in relation to each other, the base element (4, 5) having, on the side of the first tooth flank (7), an engagement element (9), in particular a groove, for a receiving element (10), the base element (4, 5) having, on the side of the second tooth flank (8), a receiving element (10), in particular a tongue, for the engagement element (9), the engagement element (9) being designed to engage in the receiving element (10), each stator tooth (2, 3) having a head element (11), which has a connection region (12, 13) for interlocking connection to a slot wedge element (15); a prewound and preformed coil element (14), which is matched to the shape of a stator tooth (2, 3), the coil element (14) being slid onto a stator tooth (2, 3); and a slot wedge element (15), which is inserted between two adjacent stator teeth (2, 3) and is in engagement with a connection region (12, 13) of a head element (11) of each of said stator teeth (2, 3).

Description

Modular stator of an electrical machine

The invention relates to a modular stator of an electrical machine.

A stator known from the prior art usually comprises a plurality of stator slots in which so-called excitation windings are arranged.

A current flow through the field windings generates a magnetic field of the Sta sector, which z. B. interacts with a magnetic field of a rotor of an electrical Ma machine to produce a rotary motion.

In order to fix the excitation windings or coil elements in the stator slots or on the stator teeth or to prevent the excitation windings from slipping out of the stator slots, so-called slot wedges are inserted into the slots. The slot wedges close an opening in the stator slot.

In this context, a key factor in electrical machines (in addition to the price) is the power density that can be achieved in a defined installation space.

Here, the achievable active sheet metal length and the degree of copper filler that can be achieved in it, as well as the connection of the copper to the laminated core, are particularly relevant.

Because only at high power densities can electrical machines, for example, be reduced in size and thus weight saved, for example in an automobile.

Of course, the design of a stator also plays a role in achieving a high power density.

To achieve this, a simple structure is desirable, with which a precise manufacture of a stator can be achieved.

It is therefore the object of the present invention to specify a modular stator of an electrical machine, which can be manufactured cost-effectively and in a material-saving manner and which ensures an increase in the power density by optimizing existing topologies of an electrical machine.

This object is achieved according to the invention by the features of the independent patent claim. Further advantageous developments are the subject of the sub-claims. According to the present invention, a modular stator of an electrical machine comprises:

- A first stator tooth and a second stator tooth, which are connected to each other and arranged adjacent,

- Each stator tooth has a foot element to form an outer stator ring and two tooth flanks.

The two tooth flanks are preferably inclined towards one another. The stator tooth is preferably designed to be trapezoidal in cross section.

It is also preferred that the foot element has an engagement element, in particular a groove, for a receiving element on the side of the first tooth flank.

The foot element advantageously has a receiving element, in particular a spring, for the engagement element on the side of the second tooth flank.

The engagement element is preferably designed to engage in the receiving element.

Furthermore, it is advantageous if each stator tooth has a head element which has a connecting area for a positive connection with a Nutkeilele element.

The modular stator advantageously has a pre-wound and pre-formed coil element which is adapted to the shape of a stator tooth.

It is advantageous if the coil element is designed as a so-called concentrated Wick development.

It is advantageous if the coil element is pushed onto a stator tooth.

It is also advantageous if the modular stator comprises a slot wedge element that is inserted between two adjacent stator teeth and is in a handle with a respective connection area of a head element of the stator teeth. With the aid of a slot wedge element, a coil element can be fixed in the stator slots or on a stator tooth or secured against slipping out of the stator slots, the slot wedge element closing an opening in the stator slot. Conveniently, the use of slot wedge elements with ferrite in z. B. Axial flux stators to reduce the cogging torque. It is also advantageous if slot wedge elements are used for wedging or stabilizing the winding or the winding body within a slot. Namely, a coil element can thus be secured to a stator tooth.

In a preferred embodiment of the invention it can be provided that the modular stator of an electrical machine comprises the following combination of features:

- Each stator tooth has a base element to form an outer stator ring and two tooth flanks which are inclined to one another,

- The foot element having an engagement element, in particular a groove, for a receiving element on the side of the first tooth flank,

- The foot element having a receiving element, in particular a spring, for the engagement element on the side of the second tooth flank,

- The engagement element is designed to einzugrei fen into the receiving element,

- Each stator tooth has a head element which has a connecting area for a positive connection with a slot wedge element,

- a pre-wound and pre-formed coil element that is adapted to the shape of a stator tooth,

- wherein the coil element is pushed onto a stator tooth, and

- A slot wedge element, inserted between two adjacent stator teeth and in engagement with a respective connection area of a head element of the stator teeth.

The aforementioned combination of features has the particular technical advantage that a modular stator of an electrical machine can thus be specified, which can be manufactured cost-effectively and in a material-saving manner and enables a particularly large increase in power density. The coil element advantageously has a rectangular wire and / or a rod and / or a round wire.

Alternatively or in addition, it is advantageous if the coil element has a shaped wire which is adapted to the groove geometry between two adjacent stator teeth.

Furthermore, it is advantageous if the modular stator is designed as a solid core with distributed winding with rectangular wires (for example hairpin, I-pin, wave winding, etc.). Here, the flanks of the grooves of the stator preferably run parallel to one another. When using a rectangular wire, it is therefore preferably very close to the laminated core of the stator over the entire depth of the groove, so that there is advantageously a good thermal connection between the copper and the stator core.

The coil element is preferably designed with or without a coil body.

It is also possible that the coil element is formed out with or without insulating paper.

The modular stator is preferably designed as a single layer, where in this embodiment only every second stator tooth carries a coil element.

It is also possible for the modular stator to be designed as a double layer, with each stator tooth in this embodiment carrying a coil element.

In the case of the single layer, a coil element advantageously extends from one stator tooth and another.

On the other hand, it is advantageous if, in the double layer, one coil element abuts another. The diameters of the coil elements are thus preferably designed differently in the respective configurations.

Furthermore, it is advantageous if the wire of the preformed coil element is clamped in itself and / or is provided with an adhesive substance in order to lock the predetermined shape before it is attached to a stator tooth.

Furthermore, it is advantageous if the coil element is clamped and / or encapsulated and / or impregnated and / or already through the slot wedge element near the air gap to fix it in the slots of the fully assembled stator The clamping system used in the assembly and / or the adhesive material is held in place.

The slot wedge element advantageously has an engagement area, in particular two engagement areas, for engaging the connecting areas of a head element of the stator teeth.

Furthermore, it can be provided that the engagement area is geometrically designed such that it engages positively and / or frictionally in the connection area of a head element of the stator teeth. In other words, it is advantageous if the engagement area and the connection area form a type of dovetail connection.

It is also possible for the slot wedge element to be designed to be magnetically non-conductive and / or magnetically conductive.

The groove wedge element is preferably designed as a multi-component element which is partially magnetically conductive and partially non-magnetically conductive.

The slot wedge element preferably comprises a magnetically conductive component and a non-magnetically conductive component.

It is also advantageous if the magnetically conductive component has a parabolic profile in cross section within the slot wedge element.

The magnetically conductive component advantageously has a cross section within the slot wedge element which is based on a ship's anchor.

The shape or the course of the magnetically conductive component in cross section within a slot wedge element is designed to optimize the magnetic flux with regard to the respective design and application of the respective stator.

Furthermore, it can be provided that the engagement element is designed to engage in the receiving element in a form-fitting and / or frictional manner.

The modular stator advantageously has a multiplicity of stator teeth.

The inventive idea presented above is additionally expressed in other words below. A stator or an electric machine stator is advantageously constructed with concentrated windings.

A stator tooth of the stator expediently tapers in a trapezoidal shape, with preferably no tooth tips or head elements being formed.

The coils of the teeth or the coil elements are advantageously placed on the teeth. Depending on the design, the coil elements are preferably fixed in a slot of the stator by slot wedge elements that are not magnetically conductive or partially or completely magnetically conductive and / or treated by potting and / or impregnation.

The invention is explained in more detail below using exemplary embodiments in conjunction with the associated drawings. Here show schematically:

1 shows a plan view of a stator according to the invention which is built on a modular basis according to a first exemplary embodiment;

2 shows a plan view of a stator according to the invention, which is constructed in a modular manner, according to a second exemplary embodiment;

3 shows an enlarged illustration of part of FIG. 1;

FIG. 4 shows an enlarged illustration of part of FIG. 2; and

Fig. 5 th various design options of Nutkeilelemen.

In the following description, the same reference symbols are used for the same objects.

Figure 1 shows a plan view of a modular Sta tor according to the invention according to a first embodiment.

Shown more precisely, Figure 1 shows a modular stator 1 of an electrical machine's rule. This has a multiplicity of stator teeth 2, 3, a first stator tooth 2 and a second stator tooth 3, which are connected to one another and arranged adjacent to one another, are dealt with below by way of example.

Each of the aforementioned stator teeth 2, 3 has a foot element 4, 5 for forming an external stator ring 6 and two tooth flanks 7, 8 which are inclined towards one another.

Here, the foot element 4, 5 comprises a gripping element 9, in particular a groove, for a receiving element 10 on the side of the first tooth flank 7 and a receiving element 10, in particular a spring, for the engaging element 9 on the second tooth flank 8.

Described again in other words, the engagement element 9 is designed to engage with the receiving element 10 in a form-fitting and / or frictional-fitting manner.

Furthermore, each stator tooth 2, 3 has a head element 1 1, which has two connecting areas 12, 13 for a positive connection with one slot wedge element 15 each.

As can also be seen from FIG. 1, the stator 1 has a pre-wound and pre-shaped coil element 14 which is adapted to the shape of a stator tooth 2, 3 and is constructed as a concentrated winding.

This coil element 14 is or will be pushed onto a stator tooth 2, 3.

With reference to Figure 3, which shows an enlarged view of a part of Figure 1, it can be seen that the stator 1 has a slot wedge element 15 or various slot wedge elements 15, which are inserted between two adjacent stator teeth 2, 3 and in engagement with each have a connection area 12, 13 of a head element 1 1 of the stator teeth 2, 3.

According to FIGS. 1 and 3, the modular stator 1 is formed as a single layer, with only every second stator tooth 2 carrying a coil element 14 in this embodiment.

In contrast, according to FIGS. 2 and 4, the modular stator 1 is designed as a double layer, with each stator tooth 2, 3 carrying a coil element 14 in this embodiment. When comparing FIGS. 1 and 3 with FIGS. 2 and 4, it can be seen that in the first case the coil element 14 extends from one stator tooth and another. In the second case (FIGS. 2 and 4), however, one coil element strikes another. The diameters of the coil elements 14 are thus configured differently in the respective configurations.

Thus, FIG. 2 shows a plan view of a modular stator 1 according to the invention according to a second exemplary embodiment, FIG. 4 being an enlarged representation of a part of FIG.

It should be noted that the statements made with regard to FIGS. 1 and 2 with regard to the first exemplary embodiment also apply analogously to the second exemplary embodiment.

Accordingly, the following description of both execution examples applies.

Figures 1 to 4 show that the coil element 14 has a rectangular wire. It is also possible for the coil element 14 to have a rod and / or a round wire.

It is also possible for the coil element 14 to have a shaped wire which is adapted to the groove geometry between two adjacent stator teeth 2, 3.

In the present case, this coil element 14 is formed without a coil body and without insulation paper.

The wire of the pre-formed coil element 14 is also clamped in on itself and provided with an adhesive material in order to lock the predetermined shape before it is attached to a stator tooth 2, 3.

FIG. 5 shows various design options for slot wedge elements 15.

As can be seen in particular from FIGS. 3 and 4, the coil element 14 is clamped in place in the grooves 16 of the fully assembled stator 1 near the air gap in order to fix it.

In contrast, it can be seen in FIG. 5 that the slot wedge element 15 has two engagement areas 19, 20 for engaging the connecting areas 12, 13 of the head elements 11 of the stator teeth 2, 3. Each engagement area 19, 20 is geometrically designed in such a way that it is positively and frictionally engaged in the connection area 12, 13 of a head element 11 of the

Stator teeth 2, 3 engages.

Furthermore, FIG. 5 shows that the slot wedge element 15 can be designed to be magnetically non-conductive and / or magnetically conductive.

The first slot wedge element 15 shown as an example in FIG. 5 is designed to be exclusively magnetically conductive.

The other groove wedge elements 15 shown by way of example in FIG. 5, however, have a different configuration.

It can be seen from these designs that the slot wedge element 15 is designed as a multi-component element which is partially magnetically conductive and partially non-magnetically conductive.

In other words, the slot wedge element 15 has a magnetically conductive component 17 and a non-magnetically conductive component 18.

Thus, according to Figure 5, the magnetically conductive component 17 in cross section has a parabolic course within the slot wedge element 14, the magnetically conductive component 17 in a further embodiment has a course in cross section within the slot wedge element 14, which is based on a ship's anchor.

The shape or the course of the magnetically conductive component 17 in cross section within a slot wedge element 15 optimizes the magnetic flux with regard to the respective design and application of the respective stator 1.

In the following, FIGS. 1 to 5 are described again in different words.

The figures mentioned show that the stator 1 or the electric machine stator is constructed accordingly with concentrated windings.

A stator tooth 2, 3 is constructed in such a way that in the assembled state its tooth flanks 7, 8 of two adjacent individual teeth 2, 3 or stator teeth run parallel or only slightly obliquely to one another. The tooth thus tapers in a trapezoidal shape. The coils or coil elements 14 of the stator teeth 2, 3 are preformed from rectangle wires or rods (with or without bobbins and / or with / without insulating paper, depending on the application) and placed on the teeth 2, 3.

It is also possible to preform the coil elements 14 of the stator teeth 2, 3 from round wires (depending on the application with or without coil formers and / or with / without insulation paper) and to attach them to the teeth.

Furthermore, it is also conceivable to preform the coil elements 14 of the stator teeth 2, 3 from shaped wire adapted to the groove geometry (with or without Spulenkör by and / or with / without insulation paper, depending on the application) and to attach them to the teeth.

Several teeth 2, 3 are then joined together to form a stator 1, as shown in FIGS.

Here, depending on the design, the stator 1 can be constructed as a single layer (only every second tooth carries a coil - see FIGS. 1 and 3) or as a double layer (each tooth carries a coil - see FIGS. 2 and 4).

The aim is to use this structure to achieve a very high copper slot fill factor and thus also to achieve a good thermal connection between the copper and the laminated core (not shown) of the stator 1.

Since the smallest possible tolerances are expedient to achieve this goal, the exact positioning of the coil elements 14 on the stator teeth 2, 3 must be ensured in the assembly process.

For this purpose, the coil elements 14 are locked in their position via a clamping system and / or an adhesive material.

To fix the trace elements 14 in the slots 16 of the fully assembled stator 1, the coil elements 14 are clamped and / or potted and / or impregnated with a slot wedge element 15 near the air gap and / or by the clamping system and / or one already used in the assembly adhesive material held.

The slot wedge elements 15 listed as a variant cannot be made magnetically or magnetically conductive or can be constructed from multi-component elements, some of which are magnetically conductive and some are not magnetically conductive, in such a way that they form a tooth head ideal for the application for the respective adjacent teeth 2, 3 (compare FIG. 5).

This can be carried out identically and symmetrically for all teeth or stator teeth 2, 3 or with two or more variants for different designs of the individual teeth (for example alternating with tooth tip and without tooth tip or with varying tooth tip geometry).

Reference list of modular stator

first stator tooth

second stator tooth

Foot element

Stator ring

first tooth flank

second tooth flank

Engagement element

Receiving element

Head element

Connection area

Coil element

Slot wedge element

Groove

magnetically conductive component

non-magnetically conductive component engagement area

Intervention area

Claims

1. Modular stator (1) of an electrical machine having:

- A first stator tooth (2) and a second stator tooth (3), which are connected to one another and arranged adjacent,

- wherein each stator tooth (2, 3) has a foot element (4, 5) to form an external stator ring (6) and two tooth flanks (7, 8) which are inclined against one another,

- The foot element (4, 5) having a one on the side of the first tooth flank (7)

grip element (9), in particular a groove, for a receiving element (10),

- wherein the foot element (4, 5) on the side of the second tooth flank (8) has a receiving element (10), in particular a spring, for the engagement element (9)

- wherein the engagement element (9) is designed to engage in the receiving element (10),

- Each stator tooth (2, 3) has a head element (11) which has a connec tion area (12, 13) for a positive connection with a slot wedge element (15),

- a pre-wound and pre-formed coil element (14) which is adapted to the shape of a stator tooth (2, 3),

- The coil element (14) being pushed onto a stator tooth (2, 3), and

- A slot wedge element (15) inserted between two adjacent stator teeth (2, 3) and in engagement with a respective connection area (12, 13) of a head element (11) of the stator teeth (2, 3).

2. Modular stator according to claim 1,

- wherein the coil element (14) is a rectangular wire and / or a rod

and / or has a round wire, and / or

- wherein the coil element (14) has a shaped wire which is adapted to the groove geometry between two adjacent stator teeth (2, 3), - Preferably the coil element (14) is formed with or without a coil body,

- Preferably, the coil element (14) is formed with or without insulation paper.

3. Modular stator according to claim 1 or 2,

- wherein the modular stator (1) is designed as a single layer, in this embodiment only every second stator tooth (2) carries a coil element (14).

4. Modular stator according to one of the preceding claims,

- The modular stator (1) being designed as a double layer, with each stator tooth (2, 3) carrying a coil element (14) in this embodiment.

5. Modular stator according to one of the preceding claims,

- wherein the wire of the preformed coil element (14) is clamped in itself and / or is provided with an adhesive material in order to lock the predetermined shape before it is attached to a stator tooth (2, 3).

6. Modular stator according to one of the preceding claims,

- The coil element (14) for its fixation in the grooves (16) of the fully assembled stator (1) with the slot wedge element (15) near the air gap ver clamped and / or encapsulated and / or impregnated and / or already through the be The clamping system used in the assembly and / or the adhesive material are held in place.

7. Modular stator according to one of the preceding claims,

- wherein the slot wedge element (15) for engaging in the connecting areas (12, 13) of a head element (11) of the stator teeth (2, 3) has an engagement area, in particular two engagement areas (19, 20), - The engagement area (19, 20) being geometrically designed in such a way that the water engages positively and / or frictionally in the connection area (12, 13) of a head element (11) of the stator teeth (2, 3).

8. Modular stator according to one of the preceding claims,

- The slot wedge element (15) being designed to be magnetically non-conductive and / or magnetically conductive.

9. Modular stator according to one of the preceding claims,

- The groove wedge element (15) being designed as a multi-component element which is partly magnetically conductive and partly not magnetically conductive,

- wherein the slot wedge element (15) preferably comprises a magnetically conductive component (17) and a non-magnetically conductive component (18),

- the magnetically conductive component (17) preferably having a parabolic course in cross section within the slot wedge element (14),

- wherein the magnetically conductive component (17) preferably has a profile in cross section within the slot wedge element (14) which is based on a ship's anchor.

10. Modular stator according to one of the preceding claims,

- wherein the engagement element (9) is designed to engage positively and / or frictionally in the receiving element (10),

- Preferably the modular stator (1) has a plurality of

Has stator teeth.