WO2024028111A1 - Machine électrique - Google Patents

Machine électrique Download PDF

Info

Publication number
WO2024028111A1
WO2024028111A1 PCT/EP2023/070023 EP2023070023W WO2024028111A1 WO 2024028111 A1 WO2024028111 A1 WO 2024028111A1 EP 2023070023 W EP2023070023 W EP 2023070023W WO 2024028111 A1 WO2024028111 A1 WO 2024028111A1
Authority
WO
WIPO (PCT)
Prior art keywords
stator
hairpin wires
electrical machine
winding
hairpin
Prior art date
Application number
PCT/EP2023/070023
Other languages
German (de)
English (en)
Inventor
Matthias Kohlhauser
Birgit Lipp
Original Assignee
Magna powertrain gmbh & co kg
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 Magna powertrain gmbh & co kg filed Critical Magna powertrain gmbh & co kg
Publication of WO2024028111A1 publication Critical patent/WO2024028111A1/fr

Links

Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
    • H02K3/24—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors with channels or ducts for cooling medium between the conductors
    • 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
    • H02K3/34—Windings characterised by the shape, form or construction of the insulation between conductors or between conductor and core, e.g. slot insulation
    • 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
    • H02K3/34—Windings characterised by the shape, form or construction of the insulation between conductors or between conductor and core, e.g. slot insulation
    • H02K3/345—Windings characterised by the shape, form or construction of the insulation between conductors or between conductor and core, e.g. slot insulation between conductor and core, e.g. slot insulation
    • 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

Definitions

  • the invention relates to an electrical machine with a stator and a rotor, the stator having winding grooves for receiving hairpin wires.
  • the invention also relates to a method for producing an electrical machine.
  • stator is treated with a resin or the like in addition to fixing the winding in the winding slots as well as the winding heads on the stator.
  • resin or potting material is required to wet the entire stator.
  • stator must also be covered accordingly in certain areas, such as the stator inner diameter, in order to avoid excess material, for example in the air gap to the rotor.
  • the traditionally used waterproofing method is dipping. It is generally used for electric motors, generators and in the manufacture of transformers.
  • the parts are immersed in immersion tanks filled with a suitable waterproofing resin. After a certain period of immersion, the parts are placed in an oven to dry. This makes the wire winding and the core a solid and mechanically stable unit.
  • the impregnation is applied by preheating the components to process viscous impregnants.
  • the viscosity of resin and other sealing products can be reduced with preheated components, allowing for greater penetration. Little or no process monitoring is achieved.
  • the component With vertical dipping, the component is preheated and then completely immersed in the resin; the component is lowered at a certain angle and then follows the rest of the process until the resin or paint is sealed.
  • a mold or base is prepared and holds a preheated component. After the casting material has been poured into the component, the mold is pressed; It is also possible to set the mold first and then inject the potting material from below using a vacuum. This process ensures high quality of the end product and very good heat dissipation from the engine. Due to its complexity, this process has low productivity.
  • An electrical machine with a rotor and stator is known from US 2015076954 A1.
  • the stator includes an annular core, a plurality of stator wedges and a plurality of wedge holding structures.
  • the core includes a plurality of arcuately spaced teeth.
  • An overmolding essentially covers the entire core.
  • the overmolding comprises a synthetic resin material and most preferably comprises polyethylene.
  • the insulation is also permissible for the insulation to be provided additionally or exclusively by one or more discrete insulating structures (e.g., non-conductive tabs or coatings) and/or by at least partially coating the core with an electrically conductive layer.
  • the overmolding defines the wire routing structure and the stator mounting structure.
  • the walls are not concentric or the guidance is achieved via hooks and portals instead of the walls.
  • the overmolding of active parts of the electric machine is currently an effective means of meeting different requirements in electric traction drives.
  • Examples of known designs include the overmolded rotor, whereby the overmolding serves to position and fix the magnets and the electrical sheets to one another.
  • the task is solved with an electric machine with oil cooling with a rotor and a stator, the stator being made up of stator laminations have radially extending winding grooves, the winding grooves being at least partially filled with hairpin wires, devices being provided in the winding grooves and/or on the hairpin wires which, alone or in combination, allow the hairpin wires to be fixed in intended positions and so on Define cooling channels.
  • cooling channels are created that enable targeted cooling of the windings using oil in the stator.
  • the solution according to the invention provides freedom of design with regard to the arrangement of the cooling channels, namely inside, outside and between the hairpin wires in the winding groove.
  • the insulation of the winding slots includes retaining lugs as a system for winding wire, which are made with the same plastic from a further injection molding process. This makes it easy to manufacture these systems for the winding wire.
  • Inserts for retaining lugs can also be molded around as a system for a winding wire.
  • the retaining lugs not only serve as stops, but also as radial boundaries of cooling channels in the winding slots.
  • an excess in the thickness of the hairpin wires serves as a device so that they are pressed into the winding grooves. The compression takes place in the winding grooves that are sprayed with the insulation.
  • hairpin wires serve as a device, which have a wave shape in their longitudinal extent, which leads to contacts with the winding groove, more precisely the insulation of the winding groove.
  • a clamping device with an insert serves as a device. This makes it possible to form cooling channels that are predefined by the insert.
  • the insert also serves as a bearing against which the hairpin wires are clamped.
  • a casing or coating serves as a device, which can be connected to the plastic of the encapsulation by applying heat.
  • the device is an uncured encapsulation of the stator, into which the hairpin wires are inserted and inserted. Only then does the plastic with the positioned hairpin wires harden.
  • the task is also solved with a method for producing an electrical machine with the steps:
  • the task is also solved with a method for producing an electrical machine with the steps:
  • Fig. 1, Fig. 2 and Fig. 3 show sections through a stator with winding slots
  • Fig. 4 and Fig. 5 show enlargements of the winding slots
  • Fig. 6 shows an alternative embodiment
  • Fig. 7 and Fig. 8 show a further embodiment
  • Fig. 9, Fig. 10 show a further embodiment.
  • stator 1 to 3 show sections through an exemplary stator 2 of an electrical machine 1 with a rotor 3.
  • the stator 2 has stator laminations 10 in which winding grooves 4 are formed.
  • the winding grooves only extend up to a part of the radius r of the stator laminations 10.
  • a seal 8 to the rotor 3 is shown along the inner radius n of the stator 2. It is a plastic layer that is injected over the stator sheets. At the same time, winding grooves 4 are provided with insulation 9, which lines the winding grooves 4 with a plastic material. Both plastic layers merge into one another in the area of the seal 8 opposite the rotor 3.
  • this seal 8 of the stator space to the rotating rotor 3 is required.
  • FIG. 4 shows an enlarged version of a winding groove 4 with retaining lugs 6.
  • the retaining lugs serve to guide winding wire 5, which is introduced into the winding groove 4 in the form of hairpin structures.
  • the retaining lugs 6 also simultaneously define cooling channels 7 in the winding groove 4.
  • a series of cooling channels 7 is designed close to the seal 8.
  • two sets of cooling channels are produced by retaining lugs 6 keeping the two end regions of the winding slots 4 free.
  • a set of cooling channels 7 is produced in the middle of the winding slots 4 by providing retaining lugs 6 at a total of four positions of the winding slot 4.
  • FIG. 5 shows an alternative embodiment in which the retaining lugs 6 are replaced by inserts 6a.
  • the inserts 6a are introduced into the winding grooves 4 during the injection molding process of the insulation 9.
  • the exemplary stator 2 is directly overmolded and, in combination with the overmolded winding grooves 4, forms the supporting structure of the seal. This means that the sealing surface or wall thickness to the dry rotor space can be made as thin-walled as possible in order to keep the increase in the air gap as small as possible. In addition, the insulation paper is no longer required due to the encapsulation of the winding slots 4.
  • the cooling channels 7 are formed by specifically positioning the windings or hairpin wires 5 in the winding grooves 4.
  • Figure 6 shows an alternative solution.
  • the winding slots 4 are provided with insulation 9.
  • retaining lugs 6 are dispensed with in this version.
  • the hairpin wires 5 have an excess size compared to the gap width of the winding groove 4.
  • the hairpin wires 5 are pressed into the gap of the winding groove 4 and held by this clamping.
  • the hairpin wires 5 can then represent cooling channels 7 at different positions in the winding slots 4.
  • a further embodiment is shown in Figures 7 and 8.
  • the hairpin wires 5 are also clamped in this embodiment, but not by excess dimensions, but by a geometric shape. Especially in the sectional view of the long electrical machine, as shown in Figure 8, it can be seen that the hairpin wires 5 have a wave shape 5a.
  • the waveform 5a extends along the entire stator 2 of the electrical machine 1.
  • the hairpin wires 5 have contact with the insulation 9 of the winding slots 4 via the waveform 5a.
  • Several contact points along the longitudinal extent L of the winding slots 4 allow the hairpin wires 5 to be fixed.
  • the method for producing the electrical machine 1 has the following steps:
  • stator sheets 10
  • FIG. 9 Another embodiment is shown in Figures 9 and 10.
  • the hairpin wires 5 are insulated in the winding slots
  • Inserts 21 and clamping elements 20, for example corrugated springs, are used to hold the hairpin wires 5, which prevent the hairpin wires 5 from slipping.
  • the hairpin wires are connected via the clamping elements 20
  • the hairpin wires 5 pressed onto the inserts 21 and fixed in the winding groove 4.
  • an embodiment is also conceivable in which the hairpin wires 5 are inserted into a stator 2, the insulation 9 and seals of which have not yet hardened after the encapsulation. Only after the hairpin wires 5 have been inserted is the stator 2 cured with its encapsulation or casting.
  • stator sheets 10
  • the manufacturing process follows the steps:
  • stator sheets 10

Landscapes

  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacture Of Motors, Generators (AREA)

Abstract

L'invention concerne une machine électrique (1) à refroidissement par huile comprenant un rotor (3) et un stator (2), le stator (2) étant constitué de tôles de stator (10) présentant des rainures d'enroulement (4) s'étendant radialement, les rainures d'enroulement étant au moins partiellement remplies de fils en épingle à cheveux (5), des dispositifs étant disposés dans les rainures d'enroulement et/ou sur les fils en épingle à cheveux (5) qui, seuls ou en combinaison, permettent de fixer les fils en épingle à cheveux (5) dans des positions déterminées et ainsi de former des canaux de refroidissement (7).
PCT/EP2023/070023 2022-08-03 2023-07-19 Machine électrique WO2024028111A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102022208047.5A DE102022208047A1 (de) 2022-08-03 2022-08-03 Elektrische Maschine
DE102022208047.5 2022-08-03

Publications (1)

Publication Number Publication Date
WO2024028111A1 true WO2024028111A1 (fr) 2024-02-08

Family

ID=87474195

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/EP2023/070023 WO2024028111A1 (fr) 2022-08-03 2023-07-19 Machine électrique

Country Status (2)

Country Link
DE (1) DE102022208047A1 (fr)
WO (1) WO2024028111A1 (fr)

Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE924466C (de) * 1952-08-31 1955-03-03 Siemens Ag Aus mehreren Einzelleitern bestehender innengekuehlter Leiter fuer elektrische Maschinen
JPS5610075A (en) * 1979-07-03 1981-02-02 Japan Atom Energy Res Inst Super-conductive coil and method of assembling the same
US4994700A (en) * 1990-02-15 1991-02-19 Sundstrand Corporation Dynamoelectric machine oil-cooled stator winding
EP1543603B1 (fr) * 2002-09-23 2010-03-31 Alstom Technology Ltd Machine electrique comprenant un stator a demi-bobines refroidies
US20150076954A1 (en) 2013-09-16 2015-03-19 Nidec Motor Corporation Wedge for stator having overmolded insulation
DE102018213759A1 (de) * 2018-08-15 2020-02-20 Thyssenkrupp Ag Stableiter, Stator, Elektromotor, sowie Verfahren zur Herstellung eines Stators
DE102019113785A1 (de) * 2019-05-23 2020-11-26 Dr. Ing. H.C. F. Porsche Aktiengesellschaft Stator einer elektrischen Maschine
EP3934067A1 (fr) * 2020-06-30 2022-01-05 Siemens Mobility GmbH Système de bobinage pour machine électrique
CN114726138A (zh) * 2021-01-07 2022-07-08 福特全球技术公司 用于经涂覆定子的狭槽中冷却增强

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102017220123A1 (de) 2017-11-13 2019-05-16 Audi Ag Nutwandisolation für einen Stator eines Elektromotors
DE102018112347A1 (de) 2018-05-23 2019-11-28 Dr. Ing. H.C. F. Porsche Aktiengesellschaft Wicklung einer elektrischen Maschine, elektrische Maschine und Verfahren zum Herstellen der Wicklung
DE102020101023A1 (de) 2019-12-04 2021-06-10 Schaeffler Technologies AG & Co. KG Spule, Verfahren zur Herstellung einer Spule und elektrische Rotationsmaschine
DE102020109209A1 (de) 2020-04-02 2021-10-07 Schaeffler Technologies AG & Co. KG Leistungserzeugende Komponente einer elektrischen Rotationsmaschine und elektrische Rotationsmaschine

Patent Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE924466C (de) * 1952-08-31 1955-03-03 Siemens Ag Aus mehreren Einzelleitern bestehender innengekuehlter Leiter fuer elektrische Maschinen
JPS5610075A (en) * 1979-07-03 1981-02-02 Japan Atom Energy Res Inst Super-conductive coil and method of assembling the same
US4994700A (en) * 1990-02-15 1991-02-19 Sundstrand Corporation Dynamoelectric machine oil-cooled stator winding
EP1543603B1 (fr) * 2002-09-23 2010-03-31 Alstom Technology Ltd Machine electrique comprenant un stator a demi-bobines refroidies
US20150076954A1 (en) 2013-09-16 2015-03-19 Nidec Motor Corporation Wedge for stator having overmolded insulation
DE102018213759A1 (de) * 2018-08-15 2020-02-20 Thyssenkrupp Ag Stableiter, Stator, Elektromotor, sowie Verfahren zur Herstellung eines Stators
DE102019113785A1 (de) * 2019-05-23 2020-11-26 Dr. Ing. H.C. F. Porsche Aktiengesellschaft Stator einer elektrischen Maschine
EP3934067A1 (fr) * 2020-06-30 2022-01-05 Siemens Mobility GmbH Système de bobinage pour machine électrique
CN114726138A (zh) * 2021-01-07 2022-07-08 福特全球技术公司 用于经涂覆定子的狭槽中冷却增强

Also Published As

Publication number Publication date
DE102022208047A1 (de) 2024-02-08

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