DE102004062816A1 - Electric machine, in particular EC motor and method of its manufacture - Google Patents

Abstract

The invention relates to an electric machine, in particular an EC motor (10) having a stator (11) whose stator core (12) has uniformly distributed pole teeth (17) with a polyphase stator winding (25) over its circumference, each phase having at least one Winding strand has, consisting of several Einzelzahnspulen (18). The invention further relates to a method for producing this machine. DOLLAR A in order to produce the stator winding (25) manufacturing technology as simple as possible, it is proposed that for each winding strand, the Einzelzahnspulen (18) are wound continuously, the beginnings and / or ends of these Einzelzahnspulen (18) each have a common, a plurality of Einzelzahnspulen associated contact part (U, V, W, Stp1, Stp2) out and then connected to this electrically.

Description

State of technology

The The invention relates to an electrical machine, in particular to an electrically commutated motor according to the preamble of the claim 1 and to a method of manufacturing the machine after Genus of claim 9.

at So-called EC motors become the three phases of the stator winding electronically commutated to produce a rotating field. At six, nine, twelve- or multipolar machines are the individual pole teeth of the Stators usually wound with single tooth coils, each one belong to a winding strand. Each phase of the stator winding has at least one winding strand from several single tooth coils. Usually In this case, the single-tooth coils of the individual winding strands are related to one another connected in parallel or in series.

At the Use of small EC motors in motor vehicles, for example for high accuracy working actuators, these are of a relatively small size Supplied on-board voltage. Here is a series connection of the coils on the one hand advantageous because the coils of winding machines wound can be. The disadvantage, however, is that at low voltages and high power the coil wires due a relatively large one amperage with her relatively large Wire cross section a correspondingly high rigidity and thus a have relatively high wire tension. This is when winding pole teeth with small tooth width and low winding space problematic. At a Parallel connection of the coils of a winding strand can be Although this with the same engine power compared to a series circuit with a smaller wire cross section at higher number of turns lighter produce. However, the parallel circuit has the disadvantage that the coils of the winding strand are wound individually as their beginnings with the respective phase connection and their ends with a star point need to be contacted.

With the present solution is sought, in a parallel connection of the coils of a winding strand they are nonetheless consistent to be able to wrap.

Advantages of invention

The inventive machine with the characterizing features of claim 1 has the advantage that when winding the Statorpolzähne the Einzelzahnspulen due their parallel connection with a relatively small cross-section and accordingly larger number of turns are easy to produce in a confined space. As well as the beginnings as well the ends of these single-tooth coils each for parallel connection via common, several Single toothed coils associated contact parts are performed, now the single-toothed coils are wound continuously by winding machines. This is much cheaper to manufacture than a parallel connection of individually wound coils, since their coil wire ends otherwise individually contacted with a so-called Verschaltungselement would have to be. This solution is also cheaper in terms of winding, as they use thinner winding wires allows, what especially for small machines with narrow stator grooves for winding the stator teeth represents a considerable simplification. In addition, this solution gives more Degrees of freedom for the expression of Winding layers as with a few thick wires. At lower wire thickness In addition, the groove slot can be narrower, whereby, if necessary the magnetic flux in the stator and thus increases the engine torque and so on said cogging torques can be reduced.

By in the subclaims listed activities arise expedient embodiments and further developments of the features specified in claim 1 and 9.

There in most applications of the EC motor in the motor vehicle, the stator per phase with only one Winding strand is wound from a plurality of Einzelzahnspulen is it is advantageous for producing the stator winding, if at least two, preferably all windings be wound continuously. However you have to if necessary after contacting the individual tooth coils with the contact points to avoid short circuits between the individual phases of the stator winding a wound Break the connection between two contact parts. Conveniently, are all contact parts for parallel connection of the wound Single tooth coils arranged on one end face of the stator and each provided with a contact hook, at the respectively in a reliable manner by means of winding machines lying between two Einzelzahnspulen Section of the winding wire is hung. After winding are the hooked to the contact hook winding wires with electrically and mechanically connected to the respective contact part.

Conveniently, the beginnings and the ends of the winding strands are each hooked on the contact hook of a trained as a phase connection or neutral contact part and electrically contacted, preferably welded. Not at the neutral point interconnection of the three phases To have to hang all the ends of the single-tooth coils on a contact hook, it is proposed that the neutral point is formed from at least two spaced-apart contact parts, which are electrically connected to one another as required for potential equalization via a conductor. In order to ensure the hanging of the winding wire to the contact parts by means of winding machines as easily as possible, it is proposed that an insulating ring with axially projecting outer collar is attached to one end face of the stator, which carries the contact parts, preferably from an axially aligned sheet metal strip with free punched, after axially outside open contact hooks are made. In this case, the outer collar is expediently provided with radial recesses for the supply and removal of the winding wire of the radially inner single-tooth coils. The interconnection of the individual tooth coils is thus completely on the one end side of the stator. In order to lead the winding wires between the individual teeth coils as possible arranged to their respective contact part, the Isolierstoffring is provided on its outer side, preferably in the region of the outer collar with a plurality of mutually parallel circumferential grooves in which more or less many winding wire sections are added in sections.

drawing

The The invention is explained in more detail below by way of example with reference to FIGS. It demonstrate:

1 an EC motor in a simplified representation in longitudinal section,

2 a stator of the EC motor with frontal Isolierstoffring and contact parts, before winding, in three-dimensional representation,

3 a contact part in an enlarged spatial representation,

4 an outbreak of the insulating ring in an enlarged spatial representation,

5 the interconnection of the three winding strands with their respective three wound single-tooth coils on the contact parts as a first embodiment.

6 shows as a second embodiment, the interconnection of the single-tooth windings and the three wound winding strands with the contact parts,

7 shows an enlarged view of a cross section through the stator of the EC motor with schematically outwardly directed contact parts and their interconnection with the Einzelzahnspulen after 6 and

8th shows the stator teeth with the Einzelzahnspulen, the contact parts and their interconnection as a development of the stator 7 ,

description the embodiments

In 1 is as an inventive electric machine, an EC motor shown in longitudinal section and with 10 designated. He has a stator 11 with a stator package 12 and a housing 13 , Inside the stator pack 12 is a rotor 14 on a rotatably mounted motor shaft 15 attached. The rotor 14 is arranged with evenly distributed around the circumference arranged permanent magnets 16 provided with the stator package 12 of the stator 11 interact. The stator package 12 consists of a plurality of poles, each having a radially inwardly directed pole tooth 17 form. Every pole tooth 17 carries a single tooth coil 18 which belongs to one of three winding phases of a three-phase stator winding described below. In the example, it is a nine-pole stator 11 which interacts with a twelve-pole rotor.

2 shows the separately manufacturable stator 12 in spatial representation with its nine individual poles 12a before wrapping his pole teeth 17 , On the right side of the stator pack 12 is an insulating ring 19 attached, with an axially projecting outer collar 20 is provided. In the outer collar 20 are a total of five contact parts 21 embedded at a distance from each other or inserted into corresponding slots and anchored, which are made of a metal strip and the outer collar 20 protrude axially.

3 shows in enlarged spatial representation of such a contact part 21 , The outer portion of the sheet metal strip is as a connector tongue 21a formed, which is usable as a phase connection. On the metal strip of the contact parts 21 is also a contact hook 22 punched and bent radially inward as far back that the hook opening 22a directed axially outwards.

4 shows an enlarged view of an outbreak of Isolierstoffringes 19 out 2 to make it clear that in the area of the outer collar 20 the insulating ring 19 on its outside a plurality of mutually parallel, circumferential grooves 24 having. These grooves 24 serve to receive and guide the winding wire sections between the single-tooth coils, which - as explained below - each of one of the single-tooth coils 18 to one of the contact parts 21 led, there at the Kontaktha ken 22 hung and possibly from there to another single-tooth coil 18 must be continued. The outer collar 20 of the insulating ring 19 also has radial recesses 23 for the supply and discharge of winding wires of the radially inner single-tooth coils 18 on.

5 shows for the nine-pole EC motor 10 a three-phase stator winding 25 with three winding strands 26 . 27 . 28 , each three single-tooth coils 18 exhibit. In the first embodiment of the invention, only the three single-tooth coils are in each case 18 of each winding strand 26 . 27 . 28 wound through and each other via two contact parts 21 connected in parallel. For a better understanding, here are the nine pole teeth 17 numbered Z1 to Z9 and also the single tooth coils 18 with S1 to S9. The contact parts 21 , to which in each case the beginning of the winding strands is first hooked, form the phase terminals U, V and W. The contact parts 21 , at each of which the end of the winding strands 26 . 27 and 28 is hooked together form a star point and are therefore referred to as star point parts Stp1, Stp2 and Stp3.

For the first winding strand 26 Now, first the winding wire 29 at the contact hook 22 the phase connection part U hooked and then wound on the pole tooth Z1, the coil S1. Subsequently, the winding wire is hung on the star point part Stp1 and then continued to the pole tooth Z4. There, the coil S4 is wound and then the winding wire is hooked again to the phase connection part U. It is then led to the pole tooth Z7, on which the coil S7 is then wound. From there, the coil end is now again guided to the star point part Stp1, hung there and then cut the winding wire.

The same thing is repeated when winding through the single-toothed coils 18 for the second winding strand 27 Phase V. There, first, the winding wire 29 hooked on the contact hook of the phase connection part V and then wound on the pole tooth Z2, the coil S2. Subsequently, the winding wire is hooked to the star point part Stp2 and then continued to the pole tooth Z5. There, the coil S5 is wound and then the winding wire is hooked again to the phase connection part U. It is then guided to the pole tooth Z8, on which then the coil S8 is wound. From there, the coil end is now again guided to the star point part Stp2, hooked there and then cut off the winding wire.

The same is now repeated for the third phase winding 28 Phase W. Also there is first the winding wire 29 at the contact hook 22 the phase connection part W hooked and then wound on the pole tooth Z3, the coil S3. Subsequently, the winding wire is hooked to the star point part Stp3 and then continued to the pole tooth Z6. There will be the coil 56 wound and then the winding wire is hooked on the phase terminal U again. It is then guided to the pole tooth Z9, on which then the coil S9 is wound. From there, the coil end is now again guided to the star point part Stp3, hung there and then cut the winding wire.

Around the three winding strands 26 . 27 and 28 To interconnect to a star point, now the three star point parts Stp1, Stp2, and Stp3 must be connected to each other. For this connection, the triple cross section of the winding wire 29 needed because it must carry the current of the three parallel-connected coils of a winding strand. This connection is made in the simplest way by a correspondingly thick connecting wire 30 who is at the contact hook 22 the three star point parts is hung. Alternatively, this connection can also be made via a busbar in the insulating ring 19 or by repeatedly winding back and forth the winding wire 29 between the three star point parts.

After the three winding strands are made and the winding strand starts and ends as well as the connections between the single tooth coils 18 each at one of the contact hooks 22 are hooked, the contact hooks 22 now compressed and suspended there winding wires are connected together and with the respective contact part 21 electrically and mechanically contacted. After this contacting are now each of the three wound coils 18 of each winding strand 26 . 27 . 28 connected in parallel.

In the 6 to 8th is a second embodiment of the invention with a parallel connection of the three single-tooth coils 18 of each winding strand 26 . 27 and 28 represented, this time not only the three coils of a winding strand are wound through. Rather, here are the three winding strands and thus all single-tooth coils 18 wound through and then the coils of each winding strand are connected in parallel to each other and the three winding strands connected in a star. The names of the single tooth coils 18 , the pole teeth 17 and the contact parts 21 are the same as in the example below 5 , However, the third star point part Stp3 can be dispensed with here. To better understand the sequence of steps in the continuous winding of the nine Einzelzahnspulen on 6 directed. However, the winding sequence can also in the sectional view of the stator 11 to 7 as well as in the development of the stator 11 in 8th nachvoll be withdrawn.

The winding wire 29 will start with his first 29a at the contact hook 22 the phase connection part U hooked and guided from there to the pole tooth Z1. Now, the coil S1 is wound and then the winding wire 29 at the contact hook 22 of the star point part Stp2 hooked and led from there to the pole tooth Z4. Now the coil S4 is wound and then the winding wire in turn hooked to the phase terminal U. From there it goes to Polzahn Z7. The coil S7 is wound there and then you hang the winding wire on the contact hook 22 of the star point part Stp1. Then it goes to the pole tooth Z8, where the coil S8 is wound. Thereafter, the winding wire is hooked to the phase terminal part V and then continued to the pole tooth Z2. There, the coil S2 is wound and then the winding wire is hung again at the star point part Stp2. From there it goes to the pole tooth Z5 and it is wound the coil S5. Then, the winding wire is hooked again to the phase connection part V and looped from there to the phase connection part W. This connection 31 is shown in dashed lines, since it must be removed later. From the phase terminal part W, the winding wire 29 now led to the pole tooth Z6 and there the coil S6 is wound. Thereafter, the winding wire is hooked again to the star point part Stp2 and then guided to the pole tooth Z3. There, the coil S3 is wound and then the winding wire is also hung again on the phase connection part W. Now it goes to the pole tooth Z9 to wind the last coil S9. Thereafter, the winding wire 29 hooked on the star point part Stp1 and finally it ends with his 29b still led to the star point part Stp2. Now the connecting hooks 22 the contact parts 21 as in the example 5 compressed and suspended there winding wires are connected to the contact parts 21 contacted, suitably welded.

As a result of this contacting, the two star point parts Stp1 and Stp2 are connected to one another and the three individual toothed coils also become 18 each of the three winding strands 26 . 27 and 28 connected in parallel. To avoid a short circuit between the phases V and W finally the connection 31 separated out between the two phase connection parts V and W. As with a symmetrical design of the complex winding resistances of all Einzelzahnspulen 18 When operating the EC motor at the neutral point parts Stp1 and Stp2 practically always the same potentials can, if necessary, on the electrical connection 29c to be waived between them.

In 7 are the phase connection parts U, V and W and the neutral point parts Stp1 and Stp2 for better detection of the winding pattern radially outside the stator shown in cross-section 11 been moved. There is also recognizable that the beginnings and ends of the single-tooth coils 18 first radially outward and then in the circumferential direction must be performed to their associated phase connection or star point part. By the in 2 illustrated Isolierstoffring 19 with the outer collar 20 For this, the necessary order can be created by the beginnings and ends of the coils each through one of the recesses 23 moved from the inside to the outside. and then into one of the grooves 24 on the outer collar 20 be moved. Furthermore, it can be seen that the connection 31 between the phase connection parts V and W in the region of the recesses 23 of the outer collar 20 can be cut out relatively easily.

8th shows again the development of the stator 11 with the winding scheme for the nine single-tooth coils 18 , wherein the winding direction of the winding wire 29 each made recognizable by arrows. The contacting of the winding wire 29 with the contact parts 21 is shown in each case as a continuous connection of the wire to the respective contact part. Consequently, in the case of the connections shown in the region of the contact parts, there is no contact with them.

Alternative to the embodiment according to 6 to 8th With the three winding strands of the phases U, V and W wound one behind the other, it is just as possible that only the two winding strands of the phases U and V according to FIG 6 be wound through. The third winding strand for the phase W is now wound separately, according to 6 starting at the phase connection part W. After winding the coils 56 , S3 and S9, finally, the end of the phase W winding strand is hung on the star point part Stp2. In this alternative solution is therefore aware of the connection 31 in 6 omitted, since this must be removed anyway when winding through all three winding strands to prevent a short circuit between the phases V and W.

The winding according to the invention of the single-tooth coils of winding strands of the stator winding can be realized not only according to the described embodiments of nine-pole EC motors, but also perform on six-pole, twelve-pole or EC motors with even higher number of poles. To contact the parts 21 , z. B. when contacting several wires to the star point parts to avoid Kontaktierungsprobleme, where necessary, several contact hooks 22 be punched free to distribute the winding wires to be suspended there on these hooks to be able to.

Claims (12)

Electric machine, in particular electrically commutated motor ( 10 ) with a stator ( 11 ), whose stator ( 12 ) about its circumference uniformly distributed pole teeth ( 17 ) having a multi-phase single tooth winding, wherein each phase (U, V, W) comprises at least one winding strand ( 26 ; 27 ; 28 ), which consists of several individual toothed coils ( 18 ), characterized in that for each winding strand ( 26 . 27 . 28 ) the single tooth coils ( 18 ) are continuously wound and connected in parallel to each other by the beginnings and / or ends of these individual tooth coils ( 18 ) in each case via a common, a plurality of Einzelzahnspulen associated contact part ( 21 ) and are electrically connected therewith. Electrical machine according to claim 1, characterized in that at least two of the winding strands ( 26 . 27 . 28 ), preferably all winding strands are wound continuously. Electrical machine according to claim 1 or 2, characterized in that all contact parts ( 21 ) on one end face of the stator ( 11 ) and each with at least one contact hook ( 22 ) are provided on each of which at least one between two Einzelzahnspulen ( 18 ) lying portion of the winding wire ( 29 ) is mounted and electrically contacted. Electrical machine according to claim 3, characterized in that the beginnings and the ends of the winding strands ( 26 . 27 . 28 ) each at the contact hook ( 22 ) formed as a phase terminal part (U, V, W) or star point part (Stp1, Stp2) contact part ( 21 ) are mounted and electrically contacted. Electrical machine according to claim 4, characterized in that the star point of at least two spaced-apart contact parts (Stp1, Stp2) is formed, which, if necessary, via a conductor ( 29c ) are electrically connected to each other. Electrical machine according to one of claims 3 to 5, characterized in that on an end face of the stator 11 an insulating ring ( 19 ) with axially projecting outer collar ( 20 ) is attached, the contact parts ( 21 ), which preferably consists of an axially aligned sheet metal strip with punched, after axially outwardly open contact hook ( 22 ) are made. Electrical machine according to claim 6, characterized in that the outer collar ( 20 ) radial recesses ( 23 ) for the supply and discharge of the winding wire ( 29 ) of the radially inner single tooth coils ( 18 ) having. Electrical machine according to claim 7, characterized in that the insulating ring ( 19 ) on its outside, preferably in the region of the outer collar ( 20 ) a plurality of mutually parallel, circumferential grooves ( 24 ) for receiving winding wire sections between the single-toothed coils ( 18 ) having. Method for producing an electric machine according to the preamble of claim 1, characterized in that for each winding strand ( 26 . 27 . 28 ) the single tooth coils ( 18 ) are wound continuously, wherein the beginnings and / or ends of these single-tooth coils in each case via a common, a plurality of Einzelzahnspulen ( 18 ) associated contact part ( 21 ) and then electrically connected thereto. A method according to claim 9, characterized in that at least two of preferably three winding strands ( 26 . 27 . 28 ), preferably all winding strands are wound continuously one after the other. A method according to claim 9 or 10, characterized in that each between two Einzelzahnspulen ( 18 ) lying portion of the winding wire ( 29 ) on a contact hook ( 22 ) of the contact part ( 21 ) and then electrically connected to this, preferably welded. A method according to claim 11, characterized in that the beginnings of the winding strands ( 26 . 27 . 28 ) each at the contact hook ( 22 ) formed as a phase connection (U, V, W) contact part ( 21 ) and the ends of the winding strands ( 26 . 27 . 28 ) each at the contact hook ( 22 ) mounted as a star point contact part (Stp1, Stp2, Stp3) and then electrically connected to this, in particular welded.