DE102009034238A1 - Stator segment and stator of a hybrid or electric vehicle - Google Patents

Abstract

The invention relates to a stator segment of a stator (42) of a hybrid or electric vehicle, which for fastening to a holding structure (44, 46) of the stator (42) by means of a fastening element (4; 4 ') and a winding (6) on the stator package segment (4; 4 '), the holding structure (44, 46) being arranged on at least one of the axial end faces of the stator segment (2). The invention further relates to a corresponding stator (42) and a method for producing stator segments (2) and stator (42).

Description

The The invention relates to a stator segment of a stator of a hybrid or electric vehicle, a corresponding stator and one each Method for producing a stator segment and a stator.

statures and stator segments of the type mentioned are for Electric motors and generators used. The electric motors or Generators have a fixed component (stator) and a the opposite rotating component (rotor) on. The stator is usually fixed to a housing.

Of Further, electric or hybrid vehicles are known. hybrid vehicles are vehicles that have at least two different ones Drives have, usually via an electric motor in combination with an internal combustion engine. These vehicles have In terms of their energy consumption advantages over conventional vehicles with internal combustion engine on, for. B. because they can recover energy when braking and because they deliver extra power and torque what can be done quickly with smaller ones Motors allows.

From the DE 10 2006 034 945 A1 shows a drive arrangement for a hybrid vehicle with an internal combustion engine and an electric machine with a rotor and a stator out. The stator of the electric machine has a plurality of stator segments, each of which comprises a stator packet segment, also called a stator tooth, with individual windings fastened thereto, the winding ends of which are interconnected via a common interconnection device by means of a plurality of interconnecting conductors in a predetermined manner. In the electric machine is a permanent-magnet synchronous machine in internal rotor type, the stator is fixed by means of a stator to a housing. The connection between the stator segments and the stator is provided in the radial direction.

A similar structure is from the DE 199 20 127 C2 known. In the disclosed there stator for an electric machine also a plurality of pre-wound stator segments are provided, which are arranged on a stator yoke. On a front side of the stator yoke a Verschaltungsanordnung is provided. The connection between the stator yoke and stator segment is also provided in the radial direction.

adversely on the known stators is that the radial attachment of Stator segments have a larger stator diameter conditioned and can have influence on the magnetic field. About that In addition, the thermal connection to the overall system through the radial fastener not optimal and compliance lower Tolerances in radial fixings by resulting Tolerance chains difficult. One for the known structure mandatory stator carrier increases in particular beyond that by the integrated cooling fins the production costs.

task The invention is therefore a stator of a stator of a stator Hybrid or electric vehicle, a corresponding stator Method for producing a stator segment and a method to provide for the manufacture of a stator, which the disadvantages of the prior Overcome the technology and in particular an improved allow thermal connection to the system and a allow more fault tolerant design.

The Task is solved by a stator of a stator a hybrid or electric vehicle according to claim 1, a corresponding stator according to the sibling Claim 11, a method for producing a stator of a Hybrid or electric vehicle according to the sibling Claim 16 and a method for producing a stator according to the independent claim 20. Advantageous embodiments of the invention are the subject of the dependent claims.

One Inventive stator of a stator has a stator packet segment and a winding on the stator packet segment on. For attachment to a support structure of the stator is a fastener intended. The support structure is on at least one of the axial End sides of the stator arranged.

By the inventively provided axial attachment of the stator segment to a support structure may be on a radial Connection waived. In this way, on the pressing of the individual stator segments in a conventional stator be waived, in which by the high number of individual stator segments and the associated high sum tolerance a process-reliable Pressing process only with great effort in a production to realize is. Due to the lack of radial connection can be about In addition, improve the thermal connection to the overall system, because the cooling medium flow directly past the stator plate can.

According to a first advantageous development, the holding structure is arranged on both axial end faces of the stator segment and has no part arranged on the radially outside of the stator segment or of the stator packet segment. Thus, in conjunction with the min at least one fastener per Statorpaketsegment a small construction in the radial direction.

According to one second advantageous embodiment, the fastening means as formed at least one substantially axially aligned retaining pin. In this way, the inventive Simply fix the stator segment to the corresponding fastener or order.

If the retaining pin in addition as a welded rivet is formed, can be the production of the stator segment simplify. Such weld rivets can by two pens with the same or a slightly larger one Length as half the total necessary length of the Pen be realized. The welding rivets can after insertion into the Statorpaketsegment or after plugging be welded together by Statorpaketsegmentteilen. In this way, can be a bias of the stator packet segment achieve and increase the strength of the Statorpaketsegments.

A Particularly preferred embodiment of the invention provides that the stator packet segment has a plurality of stacked plates, which positive, cohesive or adhesive together are connected. As a result, stator packet segments can be different easy axial length. The axial length In this case, the number of stacked sheets can be easily determined determine. For positive connection can the sheets preferably be stanzpaketiert. For cohesive or adhesive compound may preferably be used baked enamel become.

According to one Further advantageous embodiment, the sheets different contours or some of the sheets have a first Contour having a through-hole for a fastener, in particular has a retaining pin or a welded rivet and some sheets a second contour, which makes a return having attachment to the fastener. In this way can produce stator packet segments with complex shapes, For example, the cooling fins or cooling channels can have.

Prefers are the plates with the first contour and the second contour groupwise alternately stacked. This allows regular cooling structures form. Due to the size of the group, so the Number of sheets can be the width of the cooling fins or specify the cooling channels. The respective groups can be the same or different be.

According to one Another preferred embodiment of the invention provided that the sheets considered one in the axial direction do not have mirror-symmetrical contours, the contours a passage recess or a return for a fastening means, in particular a retaining pin or a Have weld rivet. In this case, further preferred provided that the non-symmetrical sheets alternately in groups stacked in different orientation. In this way can be stator packet segments with more complex shapes, which may have further desired properties. This can include, for example, special channel shapes, which create a turbulent flow. A turbulent one Flow has opposite to a laminar flow a modified speed profile, namely in particular a lower radial velocity, and therefore can absorb more heat.

Farther is preferably provided that the through-passage or the Return of the sheets relative to the installed position the stator is disposed radially outward. In this way can the influence of through-hole or recess minimize to the magnetic field.

According to one Further advantageous development is provided that the Statorpaketsegment has an insulation or in whole or in part with an insulation is overmoulded. This improves the heat transfer the heat generated by the stator in the radial direction.

One first further independent subject of the invention relates a stator for hybrid or electric vehicles, the one A plurality of substantially annularly arranged stator segments having, which are fastened by means of a support structure, wherein the support structure axially engages the plurality of stator segments.

The causes axial attachment of the stator segments to the support structure, that can be dispensed with a radial connection. To this Way can be on the pressing of the individual stator segments in one otherwise usual stator carriers are dispensed with, in which by the high number of stator segments and the associated high sum tolerance a process-safe press-fitting process only with high expenditure in a production is to realize.

By the missing radial connection can be over it In addition, improve the thermal connection to the overall system, since the cooling medium flow directly past the Statorpaketsegment can.

According to one preferred embodiment of the invention is provided that some the stator segments, preferably all stator segments, axially aligned Holding pins, in the appropriate receptacles engage the holding structure. This facilitates the assembly of the invention Stators and allows a very precise alignment of the stator segments at the support structure.

According to one alternative embodiment, the arrangement of shots and Projections also be reversed or in the case of multiple attachment points also vary differently per stator segment, so that the support structure and the stator segments each with receptacles and protrusions can be equipped.

According to one further advantageous embodiment of the invention, the holding structure at least one, preferably a plurality of projections for supporting of a moment in relation to a housing, in which the stator can be arranged.

According to one further advantageous development, some of the stator segments, prefers all stator segments, the features of one or more of the previously described feature combinations. Leave it specify a stator that can be produced particularly inexpensively and whose thermal connection to the system is optimized.

One further independent subject matter of the invention a method for producing a stator segment of a hybrid or electric vehicle, in which a plurality of sheets with given Contour or given contours stacked and cohesively, positively or adhesively connected become. Furthermore, the sheets with one in the axial direction provided aligned fasteners. To connect the sheets For example, these can be made with an adhesive Means be provided, for example, a baked enamel.

According to one Further development of the method according to the invention be considered as aligned in the axial direction fastener used two welding rivets, which welded together become. This allows the production of a stator segment whose Stator package segment is biased, so the stability of the stator packet segment is increased.

Prefers The interconnected sheets are provided with an insulation or with an insulation overmoulded. That way to improve a targeted management of waste heat.

Of Furthermore, it can be provided that the plurality of sheets with a passage recess or a recess on one pushed rivet or pin-like axial fastener or be fixed to it. This is a particularly simple procedure for mounting the stator packet segment.

The Invention relates according to a last independent Aspect of a method for producing a stator of a hybrid or electric vehicle, wherein a plurality of stator segments be attached to an axial support structure. Leave herewith to achieve the advantages described above.

According to one Further development of the invention is provided that the stator segments prepared according to the method described above which, in connection with the production of the Stator segments achieve achievable benefits.

The The present invention is applicable to both stator segments and stators internal rotor machines as well as external rotor machines applicable.

The Invention will be explained with reference to several embodiments. Here are shown schematically:

1 an inventive stator segment of a stator of a hybrid or electric vehicle in a first embodiment;

2a a partially completed stator core segment of a stator according to the first embodiment;

2 B a single element for the production of the stator packet according to 2a ;

2c another single element for the completion of the stator packet segment 2a ;

2d a completed Statorpaketsegment without winding according to the first embodiment;

3 a stator core segment of a stator segment according to a second embodiment;

4a a manufacturing stage of a stator according to the invention;

4b another stage of manufacture of a stator according to the invention;

4c a finished stator according to the invention;

5a the stator according to the invention in a mounting situation in a clutch housing of a hybrid vehicle and

5b a cross section through the clutch housing 5a ,

1 shows a stator according to the invention 2 according to a first embodiment.

The stator segment 2 has a stator packet segment 4 as well as winding 6 around the stator pack segment 4 on. The stator package segment 4 points in installation position, compare 4a to 4c , externally arranged cooling fins 8th on, which are flowed around by a cooling medium, such as air or a cooling liquid, and the ohmic heat of the stator segments 2 that is generated during operation.

Furthermore, a fixing pin 10 represented, by means of which the individual sheets of Statorpaketsegments 4 additionally fixed and through which the stator segment 2 for the production of the stator on a fastening ring, which serves as a support structure, can be fastened.

Instead of a one-piece connector pin 10 can also be provided a welded rivet, which is formed by two rivet halves, which each holds a part of the laminated core and which are interconnected by welding rivets. Since the rivet halves are hot during welding and thus extended in length, the weld rivet shortens during cooling, whereby the laminated core is biased.

The winding 6 ends with two connection ends 14 . 16 , which are both arranged on one side. About these connection ends 14 . 16 will the winding 6 electrically connected in the stator.

2a shows the stator packet segment 4 in partially finished condition. To form the stator packet segment 4 A series of stamped sheets are used on the fixing pin 10 attached or to the fixing pin 10 to be ordered. In the present embodiment illustrated two different sheet metal forms are used, which in the 2 B and 2c are shown.

The first sheet metal form 18 according to 2 B forms on the outside of the finished Statorpaketsegments 4 raised ribs. The sheet-metal form is substantially mirror-symmetrical and T-shaped, wherein in the radially outer region on one side a bulge and on the other side a recess are formed, which with the respective bulge or recess of the adjacent stator core segment 4 of the stator and thus improve the stability of the stator. When viewed in the installed position in the stator outer area is to carry out the fixing pin 10 a through-hole 20 intended. In the radially inner area are small projections 22 . 24 , so-called pole shoes, provided slipping the winding 6 prevent and substantially affect the torque ripple of the electric motor positively.

The second form of a stamped sheet 26 according to 2c is formed smaller in the radial direction and has a recess instead of a passage recess 28 on, the connecting pin 10 partially surrounds and with the help of the punching plate is held in position.

As in 2a shown, the sheets of the first form 18 and the sheets of the second form 26 depending on the desired width of the cooling fins 8th or the cooling channels individually or in groups, ie several identical sheets grouped alternately on the connecting pin 10 stacked. At the respective axially outer ends of the stator packet segment 4 For example, specially shaped punching sheets or more complexly shaped end sheets or bodies may be provided; in the present case, these end sheets are made slightly thicker than the sheets 18 . 26 ,

The connection of the laminated core is done, for example, punched packetizing or by means of a baked enamel. Due to the alternating arrangement of the sheets of the first form 18 and the sheets of the second form 26 be cooling fins 8th formed, as related to 1 already explained.

As in 2d is shown, the Statorpaketsegment 4 partly with an isolation 30 molded. The encapsulation is mainly in the range of Statorpaketsegments 4 provided with the winding 6 is wrapped. In this way, the heat input can be through the ohmic heat of the winding 6 in the stator packet segment 4 reduce and enlarge in the radial direction, so that a greater part of the waste heat directly in the direction of the cooling fins 8th is transported.

This in 2d illustrated stator pack segment 4 is ready for wrapping with the winding 6 so that the stator segment according to the invention, as in 1 shown, completed.

3 shows an alternative embodiment of a stator packet segment 4 ' for producing an alternative stator segment, in which cooling fins 8th' unlike the first embodiment, they are not arranged to form substantially rectilinear channels, but at the angled channels 32 are formed. In this way, the formation of a laminar flow is prevented and turbulence in the flow is generated, which significantly reduces the velocity of the flow duced. This can increase the heat transfer to the cooling medium.

4a shows a manufacturing stage of a stator according to the invention 42 , For this purpose, a plurality of stator segments 2 , two of which are exemplified by reference numerals, arranged annularly. The connecting pins 10 the stator segments 2 show in an axial direction. Also are the connection ends 14 . 16 the stator segments 2 aligned in the axial direction.

In the in 4b shown further manufacturing stage, the stator segments 2 by means of two fastening rings 44 . 46 fixed. These are in the mounting rings 44 . 46 through recesses 48 provided by the fixing pins 10 protrude. At the mounting ring 46 are furthermore projections 50 provided that a twist protection for the stator 42 form, so that the stator 42 not relative to a housing due to the on the stator 42 can rotate during operation. The attachment between the mounting rings 44 . 46 and the stator segments 2 by means of the pins 10 and the passage recesses 48 can preferably be made by welding or riveting.

4c shows the stator 42 finished with one on the stator segments 2 attached contacting unit 52 , with the help of which the connection ends 14 . 16 the stator segments 2 can be interconnected in the required manner. The contacting of the stator 42 takes place via in the contacting unit 52 intended contacts 54 ,

5a shows the stator according to the invention 42 in a mounting situation. The stator 42 is in a clutch housing 62 used and held against rotation in this.

5b shows a cross section through the clutch housing 62 with the stator inserted therein 42 , The cooling fins 8th the stator segments 2 form together with the clutch housing 62 closed cooling channels through seals 64 are sealed to the outside. In this way, a closed cooling circuit can be created. Particularly preferably, however, the cooling channels are interrupted in the circumferential direction at one point, wherein cool cooling medium is supplied on the one side of the separation and warm cooling medium is removed on the other side. This separation can be advantageously realized for all cooling channels on a stator by correspondingly shaped sheets of Statorpaketsegment. The Statorpaketsegment this Statorsegments then has over its entire axial extent a radial extent up to the clutch housing 62 on, reducing the flow of cooling medium along the stator 42 is interrupted at this stator segment.

The stator according to the invention 42 has the advantage that it does not require a stator support. The stator segments 2 be through the axially offset mounting rings 44 . 46 and through the mounting pins 10 fixed.

QUOTES INCLUDE IN THE DESCRIPTION

This list The documents listed by the applicant have been automated generated and is solely for better information recorded by the reader. The list is not part of the German Patent or utility model application. The DPMA takes over no liability for any errors or omissions.

Cited patent literature

• - DE 102006034945 A1 [0004]
• - DE 19920127 C2 [0005]

Claims (21)

Stator segment of a stator ( 42 ) of a hybrid or electric vehicle which is suitable for attachment to a support structure ( 44 . 46 ) of the stator ( 42 ) by means of a fastening means ( 10 ) is provided with a stator packet segment ( 4 ; 4 ' ) and a winding ( 6 ) on the stator packet segment ( 4 ; 4 ' ), characterized in that the support structure ( 44 . 46 ) on at least one of the axial end faces of the stator segment ( 2 ) is arranged. Stator segment according to claim 1, characterized in that the support structure ( 44 . 46 ) only on both axial end faces of the stator segment ( 2 ) is arranged. Stator segment according to claim 1 or 2, characterized in that the fastening means as at least one substantially axially aligned retaining pin ( 10 ) is trained. Stator segment according to one of the preceding claims, characterized in that the fastening means ( 10 ) has at least one weld rivet. Stator segment according to one of the preceding claims, characterized in that the stator packet segment ( 4 ; 4 ' ) a plurality of stacked sheets ( 18 . 26 ), which are positively, materially or adhesively connected to each other. Stator segment according to claim 5, characterized in that the sheets ( 18 . 26 ) have different contours or that some of the sheets ( 18 ) have a first contour, which has a passage recess ( 20 ) for the fastening means ( 10 ), in particular a retaining pin or a welded rivet, and some of the sheets ( 20 ) a second contour which is a return ( 28 ) for fixing the sheets ( 20 ) on the fastening means ( 10 ) having. Stator segment according to claim 6, characterized in that the sheets ( 18 ) with the first contour and the sheets ( 26 ) are alternately stacked in groups with the second contour. Stator segment according to claim 5, characterized in that the sheets ( 18 . 26 ) have a mirror-symmetrical contour viewed in the axial direction, wherein the contour has a through-hole ( 20 ) or a return ( 28 ) for the fastening means ( 10 ), in particular a retaining pin or a welded rivet, and that the sheets ( 18 . 26 ) are alternately stacked in different orientations in groups. Stator segment according to one of claims 6 to 8, characterized in that the passage recess ( 20 ) or the return ( 28 ) of the sheets ( 18 . 26 ) relative to a mounting orientation of the stator segment ( 2 ) is arranged radially on the outside. Stator segment according to one of the preceding claims, characterized in that the stator packet segment ( 4 ; 4 ' ) an isolation ( 30 ) or in whole or in part with insulation ( 30 ) is sprayed over. Stator for a hybrid or electric vehicle with a plurality of substantially annularly arranged stator segments ( 2 ), which by means of a holding structure ( 44 . 46 ), characterized in that the support structure ( 44 . 46 ) axially on the plurality of stator segments ( 2 ) attacks. Stator according to claim 11, characterized in that some of the stator segments ( 2 ), preferably all stator segments ( 2 ), axially oriented retaining pins ( 10 ), which are provided in receptacles of the support structure ( 44 . 46 ) intervene. Stator according to claim 11, characterized in that some of the stator segments ( 2 ), preferably all stator segments ( 2 ), Recordings, in the designated axially aligned projections of the support structure ( 44 . 46 ) intervene. Stator according to one of claims 11 to 13, characterized in that the support structure ( 44 . 46 ) a lead ( 50 ) for supporting a moment with respect to a housing ( 62 ) having. Stator according to one of claims 11 to 14, characterized in that some of the stator segments ( 2 ), preferably all stator segments ( 2 ), the characteristics of the stator segment ( 2 ) according to one of claims 1 to 10. Method for producing a stator segment ( 2 ) of a hybrid or electric vehicle, in which a plurality of sheets ( 18 . 26 ) are stacked and materially, positively or adhesively connected to each other and with an aligned in the axial direction of fasteners ( 10 ). A method according to claim 16, characterized in that as in the axial direction aligned fastening means ( 10 ) two welding rivets are used, which are welded together. A method according to claim 16 or 17, characterized in that the interconnected sheets ( 18 . 26 ) with insulation ( 30 ) or with insulation ( 30 ) overmoulded become. Method according to one of claims 16 to 18, characterized in that the plurality of sheets ( 18 . 26 ) with a passage recess ( 20 ) or a return ( 28 ) on a rivet or pin-like axial attachment means ( 10 ) be deferred or determined. Method for producing a stator ( 42 ) of a hybrid or electric vehicle, in which a plurality of stator segments ( 2 ) at an axial support structure ( 44 . 46 ) are attached. Method according to claim 20, characterized in that the stator segments ( 2 ) are formed according to the method according to one of claims 16 to 19.

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