WO2022208518A1 - Ensemble stator - Google Patents

Ensemble stator Download PDF

Info

Publication number
WO2022208518A1
WO2022208518A1 PCT/IN2022/050215 IN2022050215W WO2022208518A1 WO 2022208518 A1 WO2022208518 A1 WO 2022208518A1 IN 2022050215 W IN2022050215 W IN 2022050215W WO 2022208518 A1 WO2022208518 A1 WO 2022208518A1
Authority
WO
WIPO (PCT)
Prior art keywords
stator
unit
wire
teeth
holding unit
Prior art date
Application number
PCT/IN2022/050215
Other languages
English (en)
Inventor
Dey ANKAN
Nair SREEJU S
Jayajothijohnson V
Original Assignee
Tvs Motor Company Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Tvs Motor Company Limited filed Critical Tvs Motor Company Limited
Publication of WO2022208518A1 publication Critical patent/WO2022208518A1/fr

Links

Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/46—Fastening of windings on the stator or rotor structure
    • H02K3/52—Fastening salient pole windings or connections thereto
    • H02K3/521—Fastening salient pole windings or connections thereto applicable to stators only
    • H02K3/522—Fastening salient pole windings or connections thereto applicable to stators only for generally annular cores with salient poles
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/32—Windings characterised by the shape, form or construction of the insulation
    • H02K3/38—Windings characterised by the shape, form or construction of the insulation around winding heads, equalising connectors, or connections thereto
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K2203/00—Specific aspects not provided for in the other groups of this subclass relating to the windings
    • H02K2203/06—Machines characterised by the wiring leads, i.e. conducting wires for connecting the winding terminations
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K2203/00—Specific aspects not provided for in the other groups of this subclass relating to the windings
    • H02K2203/12—Machines characterised by the bobbins for supporting the windings
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/46—Fastening of windings on the stator or rotor structure
    • H02K3/48—Fastening of windings on the stator or rotor structure in slots
    • H02K3/487—Slot-closing devices

Definitions

  • the present subject matter generally relates to a stator assembly.
  • the present subject matter specifically but not exclusively relates to a stator assembly of an electric machine such as a BLDC motor.
  • An electric machine is majorly composed of a stator and a rotor.
  • the rotor for different machines is constructed differently, based on machine topology.
  • the rotor, in one configuration is disposed outside the stator and in another configuration, the rotor is disposed inside the stator.
  • Fig. 1 illustrates perspective view of the stator assembly.
  • FIG. 2 illustrates a vertical perspective view of the insulating device with a bobbin unit and wire holding unit, as per an aspect of the invention.
  • FIG. 3 illustrates a perspective view of the disassembled bobbin unit, as per an aspect of the invention.
  • Fig. 4 illustrates an exploded view of the stator unit and the upper member of the bobbin unit, as per an aspect of the invention.
  • Fig. 5 illustrates a perspective view of the wire holding unit integrated with the upper member of the bobbin unit without the stator unit, as per an aspect of the invention.
  • Fig. 6 illustrates a top view of the stator assembly, as per an aspect of the invention.
  • Fig. 7 illustrates an exploded perspective view of the insulating device where the wire holding device has a cover unit to cover the wire holding unit, as per an aspect of the invention.
  • FIG. 8 illustrates another embodiment of the present invention wherein the insulating device with wire holding unit on a stator slot wedges, as per an aspect of the invention.
  • Fig. 9 illustrates exploded view of the alternate embodiment of the present invention, as per an aspect of the invention.
  • Fig. 10 illustrates an exploded view of the alternate embodiment of the present invention, as per an aspect of the invention.
  • FIG. 11 illustrates a top view of the stator unit and the stator slot wedges, as per an aspect of the invention.
  • Fig. 12 illustrates an exploded view of the stator slot wedges integrated to the wire holding unit, as per an aspect of the invention.
  • FIG. 13 illustrates a cross-section of the stator assembly, as per an aspect of the invention.
  • Fig. 14 illustrates a flow chart of the assembly if the stator assembly, as per an aspect of the invention.
  • An electric machine is usually composed of stator and rotor.
  • the rotor for different machines are constructed differently, based on machine topology.
  • the rotor, in one configuration is disposed outside the stator and in another configuration, the rotor is disposed inside the stator.
  • the electric motor having an inner rotor configuration have a rotor mounted onto the shaft and comprises plurality of permanent magnets.
  • the electric motor having an outer rotor configuration have a rotor surrounding the stator and the rotor have magnets encircling the stator.
  • the stator is an arrangement made up of staked metal laminations, stacked over one another, having stator poles also called stator teeth directing radially in an outward direction.
  • Stator is constructed by stacking the lamination sheets either LASER cut, or stamped. These laminated sheets are usually of the same shape and size all through the length. This forms the extruded look of the stator along the length. The winding is usually done around the stator teeth to result in the desired winding pattern.
  • stator Even before the stator teeth is wounded with the phase winding, the teeth of stator, which is generally made up of steel, needs to be insulated.
  • the winding on each stator tooth is generally made up of cooper metal or the like.
  • the winding over each stator tooth need to be electrically insulated from the stator tooth otherwise it can result in an short circuit.
  • each phase comprising of one or more coils which forms a positive wire and a negative wire .
  • the lead wires comprise of a positive terminal and neutral wire comprising all the negative terminals for a star configuration. For a delta configuration all phase terminal wires will form lead wires and there will not be any neutral wire.
  • These lead wires need to be routed within the stator which requires additional space due the number of wires and the space taken for routing the wires in order to bunch then at a specific location.
  • the lead wires are routed through routing means which are directly mounted on top of the stator coils.
  • the present invention dislcoses a compact stator assembly which eliminates the problem associated with the increase in the overhang length of the winding in an electric machine such as a motor.
  • An aspect of the present invention provides a stator assembly which comprises of a stator unit.
  • the stator unit has stator teeth and the stator teeth is wounded by a wire to form stator coils.
  • the stator teeth are covered by insulating devices such a bobbin unit.
  • the insulating device comprises a wire holding unit.
  • the wire holding unit is integrally disposed on an inner periphery member of the insulating device which reduces the overhang length.
  • the insulating device has an outer periphery member which comprises a bobbin unit in one embodiment and a stator slot wedge in an another embodiment .
  • Yet another aspect of the present invention provides a stator assembly with a wire holding unit.
  • the wire holding unit has one or more wire routing paths to route the phase lead wires.
  • the wire routing paths are separated by concentric slotted projections.
  • the concentric slotted projections are an outermost concentric slotted projection, a second concentric slotted projection, a third concentric slotted projection and an innermost concentric slotted projection.
  • the concentric slotted projections are arranged in a tiered, coaxial and sequential fashion and at a different height levels and wire hooks are attached to an outer surface of the outer most concentric projection
  • Still another aspect of the present invention provides a stator assembly with a wire holding unit which has slot openings located in line with a flange gap of a bobbin unit.
  • the slot openings allow winding of the wire over the stator teeth.
  • FIG. 1 illustrates a perspective view of the stator assembly (100).
  • the stator assembly (100) comprises a stator unit (1).
  • the stator unit (1) is circular in shape.
  • the stator unit (1) comprises stator teeth (401) (refer fig 4) onto which a metal wire is wounded in form of coils called the stator coils (3).
  • the stator coil (3) converts the electric energy into mechanical energy and vice a versa based on the concept of electromagnetic induction.
  • the stator unit (1) is insulated from stator unit (1) by a bobbin unit (2) which forms a part of an insulating device.
  • the insulating device comprises an outer periphery member and an inner periphery member and the outer periphery member comprises a bobbin unit (2) whereas the inner periphery member comprises a wire holding unit (4).
  • the bobbin unit (2) of the insulating device is disposed inside the stator unit (1) and then the metal wire is wound around the bobbin unit (2).
  • the bobbin unit (2) removably integrates with the stator unit (1) by disposing the bobbin unit (2) within the gaps formed by the stator teeth (401).
  • the bobbin unit (2) encapsulates the stator teeth (401) (refer fig. 4) to create an insulation layer over the stator teeth (401) and then the wiring is done over the bobbin unit (2).
  • the wire holding unit (4) forming the inner periphery member of the insulating device is configured to face away from the stator unit (1).
  • the insulating device comprising the wire holding unit (4) and the bobbin unit (2) is disposed on top of the stator unit (1). Once the wire is wound around the bobbin unit (2) encapsulating the stator teeth (401), wire from each phase are grouped together and formed into bunches of phase lead wires (5) projecting away from the stator coils (3).
  • Fig. 2 illustrates a vertical perspective view of the insulating device with a bobbin unit (2) and wire holding unit (4).
  • the wire holding unit (4) is covered by a cover unit (6).
  • the cover unit (6) is removably attached to the wire holding unit (4).
  • the bobbin unit (2) comprises an upper member (2a) and a lower member (2b). Both the upper member (2a) and the lower member (2b) are provided with teeth insulating member (202).
  • the upper member (2a) is a part of insulating device whereas the lower member (2a) is a separate part.
  • the teeth insulating member (202) are arranged in a radially concentric manner.
  • the teeth insulating member (202) are moulded to a base portion (201) of the upper member (2a) and the lower member (2b).
  • the teeth insulating member (202) gets securely disposed on top of the stator teeth (401) whereas each flange gap (203) accommodates the stator slot (402).
  • the teeth insulating member (202) are perpendicular to the base portion (201) of the upper member (2a) and the lower member (2b).
  • the upper member (2a) is pushed into the stator unit (1) from the upper side of the stator unit (1) and the lower member (2b) is pushed into the stator unit (2) from the lower side of the stator unit (2).
  • FIG. 3 illustrates a perspective view of the disassembled bobbin unit (2).
  • the upper member (2a) of the bobbin unit (2) is integrated with the wire holding unit (4).
  • the wire holding unit (4) is located on the inner periphery member of the upper member (2a) of the bobbin unit (2). Therefore, the wire holding unit (4) is not mounted on the top of the stator coils (3) thereby making the stator assembly (100) compact in size by reducing the overhang length.
  • the wire holding unit (4) uses the hollow space (302) (refer fig. 3) of the stator assembly (100) to route the phase wires coming out of the stator coils (3) and keeps the lead wires free from entanglement.
  • the base portion (201) of the upper member (2a) forms a circular vertical wall at the outer periphery member of the upper member (2a).
  • the base portion (201) of the lower member (2b) also forms a circular vertical wall at the outer periphery member of the lower member (2b ).
  • the wire holding unit (4) is projecting in an outward axial direction, away from the upper member (2a) of the bobbin unit (2). Between the wire holding unit (4) and the base portion (201) of the upper member (2a) of the bobbin unit (2) a cavity (301) is formed.
  • the cavity (301) accommodates the stator coils (3) which are wound around a teeth insulating member (202) encapsulating the each of the stator teeth (401).
  • the teeth insulating member (202) forms a part of the bobbin unit (2) and functions as an insulating layer between the stator teeth and the wounded wire over the stator teeth to prevent any short circuit.
  • the wire holding unit (4) is annular ring like structure which is hollow and enables an axle to be disposed through the hollow space (302) to attach with a rotor (not shown).
  • the hollows space (302) is surrounded by the stator unit (4).
  • FIG. 4 illustrates an exploded view of the stator unit (1) and the upper member (2a) of the bobbin unit (2).
  • the stator unit (1) comprises plurality of stator teeth (401) arranged in a circular fashion. Each of the tooth of the stator are separated by a consistent teeth gap (402). Within the teeth gap (402) the upper member (2a) of the bobbin unit (2) is disposed.
  • Fig. 5 illustrates a perspective view of the wire holding unit (4) integrated with the upper member (2a) of the bobbin unit (2) without the stator unit (1).
  • the wire holding unit (4) comprises wire routing paths (601,602,603) (refer para 6) arranged in a tiered fashion.
  • the wire routing paths (601,602,603) are separated by concentric slotted projections (501,502,503,504).
  • the concentric slotted projections (501, 502,503,504) comprise of an outermost concentric slotted projection (501), a second concentric slotted projection (502), a third concentric slotted projection (503) and an innermost concentric slotted projection (504).
  • Each of the concentric slotted projection (501, 502, 503, 504) are arranged in a tiered fashion and at different heights.
  • the concentric slotted projections (501,502,503,504) are arranged in a sequential and coaxial fashion such that each of the concentric slotted projections (501,502,503,504) has a different radii and thereby creating gaps in between each of the consecutive concentric slotted projections (501,502,503,504).
  • On the outer surface of each outermost slotted concentric projections (501) a wire hook (505) is fixedly attached.
  • the wire hook (505) is moulded with the wire holding unit (4) and it is attached to the outer surface of the outer most concentric projection (501).
  • the wire hook (505) supports the neutral phase wires of the stator coils (3).
  • Fig. 6 illustrates a top view of the stator assembly (100).
  • the wire holding unit (4) comprises of wire routing paths (601,602,603).
  • the first wire routing path (601) is located between the outermost concentric slotted projection (501) and a second concentric slotted projection (502).
  • the second wire routing path (602) is located between the second concentric slotted projection (502) and the third concentric slotted projection (503) and the third wire routing path (603) is located between the third concentric slotted projection (503) and an innermost concentric slotted projection (504).
  • the wire routing paths (601,602,603) for a three phase machine enables separating the phase wire and enables proper distribution of the phase wires.
  • the wire holding unit (4) has multiple inlets (605) provided on the surface of the concentric slotted projections (501,502,503,504) which enables the wire to be drawn from different phases of the stator coil (3) of the stator unit (1) and then routed along the wire routing paths (601,602,603).
  • the wire holding unit (4) comprises slot openings (604) which are located in line with the flange gap (203) of the bobbin unit (2).
  • the wire holding unit (4) is integrated with the bobbin unit (2) such that the slot openings (604) of the wire holding unit (4) enables the coiling of the wire around the stator teeth (401) without the requirement of first winding coil and then assembling the wire holding unit (4) with the bobbin unit (2).
  • This way the requirement of first winding the coil and then assembling a separate wire holding unit (4) gets eliminated as the wire holding unit (4) comprising the slot opening (604) enables easy and fast winding process.
  • Fig. 7 illustrates an exploded perspective view of the insulating device where a cover unit (701) to cover the wire holding unit (4).
  • the lead wires coming out of multiple phases of the stator coils need to be routed through wire routing paths (601,602,603) and bunched together in groups in order to make the electrical connection convenient.
  • the cover unit (701) is provided with passage means (702) such as holes punched into the cover unit (701). Through the passage means, the phase lead wires (703,704,705) are bunched together and routed out of the wire holding unit (4).
  • the neutral wire (706) is routed around the wire holding unit (4) with the support of the wire hooks (505) mounted at the outer surface of the outermost slotted concentric projections (501).
  • the cover unit (701) keeps all the wire routed through the wire routing paths (601,602,603) intact at one place.
  • the phase lead wires (703,704,705) are routed adjacent to the stator coil (3) so that the space which is not occupied by the stator coil (3) can be occupied by the phase lead wires (703,704,705) without increasing the overhang length and thereby keeps the stator assembly (100) small and compact.
  • the phase lead wires (703,704,705) are routed on the inner periphery member of the wire holding unit (4) and adjacent to the stator coil (3).
  • Fig. 8 illustrates another embodiment of the present invention wherein the insulating device comprises of a wire holding unit (4) integrated with a stator slot wedges (801).
  • the bobbin unit (2) is replaced by stator slot wedges (801) then for the insulation is provided between the winding and the stator teeth (401) slot liners (not shown).
  • the slot liners can be made up of pulp material and the such slot liners keeps the stator teeth insulated from the winding wire..
  • the stator sot wedges (801) are teeth like structure which helps in holding the stator coil (3) at a fixed place after completion of the winding.
  • the stator slot wedges (801) are inserted from the top side of the stator unit (1) and in between the stator teeth (401).
  • Fig. 9 illustrates an exploded view of the alternate embodiment of the present invention.
  • the stator teeth (401) arranged in a circular fashion are separated by the teeth gap (402) and the stator slot wedges (801) is adaptively disposed within the teeth gap (402).
  • the stator slot wedges (801) are located at the inner periphery member formed by the stator teeth (401) which makes the stator slot wedges (801) function as a stopper to stop the stator coil (3) coming out from the stator teeth (401).
  • the insulating device comprising the wire holding unit (4) and the stator slot wedges (801) is disposed at the centre of the stator unit (1) instead of top of the stator unit (1).
  • This configuration helps in reducing the overhang length of the winding of the stator which reduces the size of the wounded stator therefore making it compact in shape and size. Further, the integrated wire holding unit (4) with the bobbin unit and the stator slot wedges (801) eliminates the assembly time and cost of producing a new part.
  • FIG. 10 illustrates a top view of the stator unit (1) and the insulating device with the stator slot wedges (801) and the wire holding unit (4).
  • the stator teeth (401) of the stator unit (1) comprises a head portion (401a) and a stem portion (401b).
  • the stator slot wedges (801) are disposed between the head portion (401a) of a stator tooth and the adjacent stator tooth.
  • the space created between the stator shaft of one stator tooth and the stator shaft of the adjacent stator tooth is occupied by the stator coil (3).
  • the stator coil (3) remains at a fixed place and position and do not come out of the stator’s teeth gap (402).
  • FIG. 11 illustrates an exploded view of the insulating device and the cover unit (701).
  • FIG. 12 illustrates a top view of the stator assembly (100) with the phase lead wires (703,704,705) through the wire routing unit (4) of the insulating device after the wire is wounded on to the upper member (2a) of the bobbin unit (2) of the insulating device.
  • Fig. 13 illustrates the cross-section of the stator assembly (100).
  • Fig. 14 illustrates a flow chart of the stator assembly (100).
  • the insulating device comprising the wire holding unit (4) and the upper member (2a) of the bobbin unit (2) is inserted into the stator teeth (401) of the stator unit (1).
  • the winding of the wire 3 is carried out on the stator teeth (401), with a bobbin (2), through the slot opening provided in the insulating device.
  • the phase lead wires is routed to the wire holding unit (4) of the insulating device.
  • stator unit (1) stator coils (3) a second concentric slotted projection (502) bobbin unit (2) a third concentric slotted projection stator teeth (401) (503) wire holding unit (4)

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Insulation, Fastening Of Motor, Generator Windings (AREA)

Abstract

La présente divulgation concerne un ensemble stator compact (100) qui élimine le problème associé à l'augmentation de la longueur de surplomb de l'enroulement dans une machine électrique telle qu'un moteur. La divulgation concerne un ensemble stator comprenant une unité stator (1). L'unité stator comporte des dents de stator (401) et les dents de stator sont enroulées par un fil pour former une bobine de stator (3). Les bobines de stator sont recouvertes par des dispositifs isolants tels qu'une unité de bobine (2) ou une cale de fente de stator (801). Une unité de maintien de fil (4) est disposée d'un seul tenant sur un élément de périphérie interne du dispositif d'isolation de telle sorte que les fils de conducteur de phase sont enroulés dans l'unité de maintien de fil. L'emplacement actuel de l'unité de maintien de fil avec les fils de conducteur de phase dans l'unité de maintien de fil élimine l'augmentation de la longueur totale de la machine électrique, ce qui la rend compact et réduit également le temps d'assemblage.
PCT/IN2022/050215 2021-03-29 2022-03-09 Ensemble stator WO2022208518A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
IN202141014000 2021-03-29
IN202141014000 2021-03-29

Publications (1)

Publication Number Publication Date
WO2022208518A1 true WO2022208518A1 (fr) 2022-10-06

Family

ID=81328455

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/IN2022/050215 WO2022208518A1 (fr) 2021-03-29 2022-03-09 Ensemble stator

Country Status (1)

Country Link
WO (1) WO2022208518A1 (fr)

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20070103014A1 (en) * 2005-11-04 2007-05-10 Denso Corporation Electric motor and fuel pump having the same
US20090015084A1 (en) * 2005-08-23 2009-01-15 BSH Bosch und Siemens Hausgeräte GmbH Rotor Cover and Electric Motor
DE102013212892A1 (de) * 2013-07-02 2015-01-08 Robert Bosch Gmbh Stator für eine elektrische Maschine
US20170126090A1 (en) * 2015-10-30 2017-05-04 Nidec Motor Corporation End cap for outer rotor motor
DE102015225189A1 (de) * 2015-12-15 2017-06-22 Robert Bosch Gmbh Elektrische Maschine
US20200395812A1 (en) * 2019-06-14 2020-12-17 Gogoro Inc. Wiring device, motor stator and wiring method

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20090015084A1 (en) * 2005-08-23 2009-01-15 BSH Bosch und Siemens Hausgeräte GmbH Rotor Cover and Electric Motor
US20070103014A1 (en) * 2005-11-04 2007-05-10 Denso Corporation Electric motor and fuel pump having the same
DE102013212892A1 (de) * 2013-07-02 2015-01-08 Robert Bosch Gmbh Stator für eine elektrische Maschine
US20170126090A1 (en) * 2015-10-30 2017-05-04 Nidec Motor Corporation End cap for outer rotor motor
DE102015225189A1 (de) * 2015-12-15 2017-06-22 Robert Bosch Gmbh Elektrische Maschine
US20200395812A1 (en) * 2019-06-14 2020-12-17 Gogoro Inc. Wiring device, motor stator and wiring method

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