DE102015006203A1 - Method for producing a stator and stator - Google Patents

Abstract

The invention relates to a method for producing a stator (1) for an electrical machine, wherein a plurality of stator individual teeth (2.1 to 2.n) and / or a plurality of stator individual tooth groups are joined together to form a stator ring (2) and the stator ring (2) is arranged within a stator carrier (3) surrounding the stator ring (2) at least partially on its outer lateral surface. According to the invention, before the stator ring (2) is arranged in the stator carrier (3), surfaces (F1 to Fn) of a plurality of stator individual teeth (2.1 to 2.n) and / or of a plurality of stator individual tooth groups form a latent reactive adhesive (F1 to Fn). K1) applied and after arranging the stator ring (2) in the stator (3) of the latent reactive adhesive (K1) is activated so that between the lateral surface and the stator ring (2) an adhesive bond is generated.
Furthermore, the invention relates to a stator (1) for an electric machine, produced in such a method.

Description

The invention relates to a method for producing a stator for an electrical machine according to the preamble of claim 1.

The invention further relates to a stator produced in such a method.

From the DE 10 2011 111 806 A1 For example, a component and a component group of an electrical machine are known, wherein at least one thermally activatable foam or structural adhesive is arranged on, on and in the component or component group. The thermally activatable foam or structural adhesive has a foaming factor of up to 500 percent by volume. The component or group of components is a stator with stator support, the stator comprising a plurality of stator single teeth annularly disposed within a stator support. Furthermore, a method for producing such a component or component group of an electrical machine is described, wherein in a first process step, a thermally activatable foam or structural adhesive is sprayed as an additional layer on the component or component group and injected into cavities of the component or component group and sets. In a second process step, the thermally activated foam or structural adhesive is foamed by supplying thermal energy, wherein the thermally activated foam or structural adhesive increases its volume with a predetermined foaming factor by up to 400 percent by volume.

Furthermore, from the DE 10 2009 028 180 A1 A method for adhering or sticking a magnet on a surface or in a slot of a rotor or stator of an electric motor or a generator is known. In this case, a surface or surfaces of the magnet to be bonded is precoated with an adhesive which is not liquid at 22 ° C. and which does not harden without an activation step. Furthermore, the magnet with the adhesive-coated surface is placed on the surface of the rotor or stator and fixed or the magnet is inserted into a slot of the rotor or stator such that at least one adhesive-coated surface is opposite to an inner wall of the slot. Furthermore, the adhesive is activated by heating or by high-energy radiation in such a way that it hardens. Furthermore, a magnet is described, which is pre-coated with an adhesive which is not liquid at 22 ° C and which does not cure without an activation step.

The DE 10 2008 023 999 A1 describes a device for holding a magnet, in particular a magnet in a moving device in a rotor in a laminated core of an electric motor. The device comprises a holding pocket into which a magnet is mounted, which is attached by means of an adhesive which expands upon curing to a predetermined extent and which contains a blowing agent for foaming an adhesive. Furthermore, a method for producing such a device is described, wherein a holding pocket is formed with at least one lateral Vorratsausformung for receiving adhesive. The adhesive is filled in a Vorratsausformung and then the magnet is inserted into a magnet insertion opening of the holding pocket, which is fixed by means of the adhesive. The adhesive expands upon curing to a predetermined extent. The adhesive contains a blowing agent for foaming, so that the adhesive has a foam structure in the cured state.

Furthermore, it is well known in the art that a plurality of stator single teeth are assembled into a stator ring, wherein the composite stator ring is pressed into a stator at least partially surrounding the stator. In order to produce a secure hold of Statoreinzelzähne within the stator ring by means of the compression and at the same time to avoid damage to the Statoreinzelzähne in the compression, small tolerances of Statoreinzelzähne are required.

The invention is based on the object to provide a comparison with the prior art improved method for producing a stator for an electric machine and an improved stator for an electrical machine.

With regard to the method, the object is achieved by the features specified in claim 1 and in terms of the stator by the features specified in claim 8.

Advantageous embodiments of the invention are the subject of the dependent claims.

In the method of manufacturing a stator for an electric machine, a plurality of stator single teeth and / or a plurality of stator single tooth groups are assembled into a stator ring, and the stator ring is disposed within a stator support surrounding the stator ring at least partially on the outer peripheral surface thereof.

According to the invention, prior to arranging the stator ring in the stator carrier on the outer circumferential surface forming surfaces of a plurality of Statoreinzelzähnen and / or a plurality of Statoreinelzahngruppen applied a latent reactive adhesive and after placing the stator in the stator stator, the latent reactive adhesive is activated so that between the lateral surface and the stator ring an adhesive bond is generated.

In this case, a latently reactive adhesive is understood to be an adhesive which, after application, binds firmly in time, in particular abrasively or gripping, or is already applied in a set state. The activation of the adhesive takes place, for example, by supplying thermal energy and / or by radiation.

This results in significant ease in handling and during assembly of the components of the stator and in a temporary storage and transport thereof. Compared with conventional adhesives, for example two-component adhesives, handling and metering are simplified. Since the adhesive used is in particular designed to be non-dripping and firmly set, the risk of so-called adhesive carryover during handling, transport and assembly due to dripping, bleeding or wiping is minimized. Also, due to the firmly set adhesive, adhesion of dirt particles to the surface thereof and consequent subsequent reduction in stability of the bond produced is reduced.

The activation at a later time can be carried out in the already preassembled state of the components, wherein a direct accessibility of the adhesive to its activation in an advantageous manner is not required. Thus, by means of the adhesive, even complex sections of the stator individual teeth and / or stator individual tooth groups, which are no longer accessible after their assembly, can be bonded to the stator carrier. Also, the assembly is not time-bound due to the later activation of the adhesive, since the activation can be done at any time.

In this case, the adhesive is easily adaptable with regard to later use of the stator and consequent demands on strength, electrical insulation, vibration damping, structural reinforcement and fixing of the connection produced by means of the adhesive.

By means of the method according to the invention, it is also possible in a particularly advantageous manner to use Statoreinzelzähne and / or Statoreinzelzahngruppen with respect to compressed stators greater tolerances, because due to the bonding between the Statoreinzelzähnen and the stator and / or Statoreinzelzahngruppen and the stator longer distances than during a pressing possible are. Intermediate spaces resulting from these intervals are filled by the adhesive. Thus, the risk of damage to the individual components of the stator during assembly is significantly reduced. At the same time a permanent and secure bonding of the components is achieved due to the bonding. For these reasons, the stator can be easily preassembled with all tolerances and precision fits, with the individual components being fixed to one another in the finished preassembled state by activation of the adhesive and any tolerances which may be present being compensated by means of the adhesive.

In one possible embodiment, the latently reactive adhesive is designed such that, after its activation, it increases its volume, in particular forms a foam. By this increase in volume between the Statoreinzelzähnen and the stator and / or between Statoreinzelzahngruppen and the stator carrier existing interstices are filled by means of the adhesive. Thus, a vibration resistance, a thermal load capacity due to different expansion behavior and smoothness of the electrical machine are increased. Furthermore, this results in an advantageous manner a reduction of component vibrations during operation of the electrical machine and a resulting increase in lifespan. A size of the change in volume is adjustable in a simple manner depending on a later use of the stator.

Embodiments of the invention are explained in more detail below with reference to drawings.

Showing:

1 2 is a schematic of a first view of components of a stator for an electric machine during a plurality of steps of a method of assembling the stator of the prior art;

two schematically another view of the components according to 1 .

3 2 is a schematic of a first view of components of a stator for an electric machine during several steps of a method according to the invention for mounting the stator;

4 schematically another view of the components according to 3 .

5 schematically a flow of a first embodiment of a method for Applying an adhesive to a stator single tooth, and

6 schematically a flow of a second embodiment of a method for applying an adhesive to a Statoreinzelzahn.

Corresponding parts are provided in all figures with the same reference numerals.

In the 1 and two are components of a stator in different views 1 for an electrical machine, not shown, for example, a generator and / or motor, during several steps S1 to S4 of a method for mounting the stator 1 According to the state of the art.

First, in a first step S1, a plurality of stator single teeth 2.1 to 2.n to a stator ring two together. The stator single teeth 2.1 to 2.n comprise in known manner in each case a bobbin on which a coil is wound. In one possible embodiment, the coils are surrounded with an electrically nonconductive material, in particular encapsulated or encapsulated or at least partially surrounded by insulating paper, in order to make electrical contact between the adjacent stator individual teeth 2.1 to 2.n to avoid and to protect them mechanically.

Subsequently, in a second step S2, a compression of the individual teeth 2.1 to 2.n to a stator ring two and an arrangement of the stator ring two in a third step S3 within an annular stator carrier 3 , For such a compression, it is necessary that tolerances of Statoreinzelzähne 2.1 to 2.n are very small, so that they are in the compression in the stator 3 not be damaged and by means of the compression in the stator 3 a secure hold of the Statoreinzelzähnen 2.1 to 2.n formed stator ring two is achieved permanently.

Subsequently, on an end face of the stator ring two an adhesive K applied and in a fourth step S4 by means of the adhesive K, a bonding between the end face of the stator ring two and a contact ring 4 , The adhesive K is a two-component adhesive which cures with the addition of heat. The contact ring 4 is for contacting electrical contacts of the coils of the Statoreinzelzähne 2.1 to 2.n provided with a high-voltage connection of the electric machine, not shown.

The 3 and 4 show in various views components of a possible embodiment of a stator according to the invention 1 for an electrical machine (not shown), for example a generator and / or motor, during several steps S1 to S4 of a possible embodiment of a method according to the invention for mounting the stator 1 ,

Unlike in the 1 and two In a first step S1, in each case, an embodiment of the prior art illustrated is applied to a surface F1 to Fn of the stator individual teeth 2.1 to 2.n applied a latent reactive adhesive K1. The surfaces F1 to Fn form in the assembled state of the stator ring two an outer circumferential surface thereof. The adhesive K1 is designed in such a way that, after the application, it is fixed in a timely manner, in particular abraded or gripped, or is already applied in a set condition. The application takes place, for example, according to 5 by spraying the adhesive K1 in a so-called extrude-in-place process or the adhesive K1 is according to 6 applied as a molding on the surface F1 to Fn. Activation of the adhesive K1 takes place, for example, by supplying thermal energy and / or by radiation. Furthermore, the adhesive K1 is formed such that it increases its volume after its activation.

In an embodiment, not shown, of several Statoreinzelzähnen 2.1 to 2.n initially formed a plurality Statoreinzelzahngruppen on which the outer surface of the stator two forming surfaces of the latent reactive adhesive K1 is applied.

Alternatively, the adhesive K1 after the assembly of the Statoreinzelzähne 2.1 to 2.n and / or the stator single tooth groups to the stator ring 1 applied to the outer surface, in particular according to 5 by spraying the adhesive K1 in a so-called extrude-in-place process or by applying the adhesive K1 according to 6 as a molding.

In a further embodiment, not shown, in the first step S1 simultaneously with the application of the adhesive K1 to at least one of each for mechanical contacting with an adjacent Statoreinzelzahn 2.1 to 2.n provided side surface of Statoreinzelzähne 2.1 to 2.n applied another latent reactive adhesive. The further adhesive may be identical to or different from the first adhesive K1. The application of the further adhesive takes place in particular in the same manner as that of the adhesive K1.

In a particularly advantageous manner, this further reactive adhesive is designed to be electrically insulating, so that additional electrical insulation between the coils of the stator individual teeth 2.1 to 2.n can be omitted. This, in turn, a particularly high fill factor can be realized.

In an embodiment, not shown, of several Statoreinzelzähnen 2.1 to 2.n initially formed a plurality Statoreinzelzahngruppen, on the respective for mechanical contacting with an adjacent Statoreinzelzahn 2.1 to 2.n and / or an adjacent Statoreinzelzahngruppe provided side surface of the further latently reactive adhesive is applied.

Furthermore, in the first step S1, simultaneously with the application of the adhesive K1 to an end face of the stator ring two forming end faces SF1 to SFn of the stator single teeth 2.1 to 2.n Another latent reactive adhesive K2 applied. The further adhesive K2 may be identical to the first adhesive K1 or different from this. The application of the further adhesive K2 takes place in particular in the same manner as that of the adhesive K1.

In an embodiment, not shown, of several Statoreinzelzähnen 2.1 to 2.n initially formed a plurality Statoreinzelzahngruppen on which the end face of the stator two forming surfaces of the latent reactive adhesive K2 is applied.

After application of the adhesives K1, K2 and optionally further adhesive, not shown, the Statoreinzelzähne 2.1 to 2.n in a second step S2 annular to the stator ring two joined together and then inside the stator 3 arranged. In this case, there is no compression of Statoreinzelzähne 2.1 to 2.n , In one possible embodiment, the stator is 3 formed such that between this and the lateral surface of the stator ring two a gap is formed around the arrangement of the stator ring two inside the stator carrier 3 to facilitate.

Subsequently, in a third step S3, the contact ring 4 on the provided with the adhesive K2 end face of the stator ring two arranged.

After the arrangement of the stator ring two inside the stator carrier 3 the activation of the adhesives K1, K2 and optionally of the further adhesive, not shown, by supplying thermal energy and / or by radiation, so that between the corresponding components of the stator 1 a permanent adhesive bond is generated. At least the adhesive K1 is designed such that it increases its volume after activation such that the gap between the stator 3 and the lateral surface of the stator ring two is completed completely.

In particular, the adhesives K1, K2 and the optional further adhesive, not shown, are formed such that the components of the stator 1 , in particular the stator single teeth 2.1 to 2.n , inside the stator carrier 3 be arranged and positioned according to joining tolerances and at the same time the contact ring 4 is fixed in the appropriate position, without a new arrangement is necessary.

In another possible, but not shown embodiment is also on the contact ring 4 opposite end face of the stator ring two arranged a latent reactive adhesive, which for bonding the stator ring two with a fold, a flange, a ring or a bottom of the stator 3 is provided. The application of this adhesive takes place in particular according to the application of the adhesive K2.

In one possible embodiment, at least one of the adhesives K1, K2 or the other adhesives, not illustrated, is porous, in particular coarse-pored, after the production of the bond, and is permeable to oil, water or air, for example, so that these media can be passed through the bonds produced, to a cooling of the stator 1 to improve.

In particular, by means of at least one of the adhesives K1, K2 or the other adhesives, not shown, a decoupling and / or damping occurring vibrations of components of the stator 1 be improved and damped when using in a vehicle thus vibrations of the electric machine relative to the vehicle or decoupled. In particular, power shocks are reduced and mitigated by the damping effect of the adhesives K1, K2 or other adhesives, not shown, resulting in a reduced material stress. Transverse accelerations can also be damped by means of the adhesives K1, K2 or other adhesives, not shown. Particularly advantageously, the adhesives K1, K2 or other adhesives, not shown, act acoustically damping, so that noises and / or vibrations from the stator 1 not be forwarded to the housing of the electrical machine and so to the rest of the vehicle. As a result, the electric machine is acoustically decoupled and the ride comfort is increased.

In further possible embodiments, several of the adhesives K1, K2 or the other adhesives, not shown, have different activation properties, so that they can be activated selectively at different assembly steps and / or at different times. Also, several of the adhesives K1, K2 or other adhesives, not shown have different degrees of volume increase after activation. Thus, a targeted adaptation by means of the adhesives K1, K2 or the other adhesives not shown generated pressing forces within the stator 1 possible.

Also, by the different activation properties of the adhesives K1, K2 or other adhesives targeted activation of individual adhesives possible so that, for example, the adhesives can be applied together and then activated in individual different steps or unfold their adhesive effect at different activation times. For example, the stator single teeth 2.1 to 2.n with each other and / or with the stator 3 are glued to the adhesive K1, while the adhesive K2 for bonding the contact ring 4 not yet activated and so the contact ring 4 can also be added to the stator in a further step after activating the adhesive K1. By a later separate activation of the adhesive K2, for example, by a higher activation temperature of the adhesive K2 than the adhesive K1, because subsequently to the already bonded stator ring two the contact ring 4 be glued.

In 5 is a sequence of a first embodiment of a method for applying the adhesive K1 on a Statoreinzelzahn 2.1 shown. In the area F1, the stator single tooth 2.1 a recess A, within which the latently reactive adhesive K1 is disposed.

The adhesive K1 is in its original form as granules and is extruded in a so-called extrude-in-place process in the recess A on the surface F1. After the application, the adhesive K1 binds in a timely manner, in particular abrasion or grip, forming a dry layer. The adhesive K1 can be activated at any time by means of thermal energy and / or radiation. After activation, the adhesive K1 expands and crosslinks, the expansion and adhesive properties being predeterminable by a corresponding chemical composition of the adhesive K1.

6 shows a sequence of a second embodiment of a method for applying the adhesive K1 on a Statoreinzelzahn 2.1 ,

Unlike the in 5 illustrated embodiment, the adhesive K1 is applied as a molded part in the recess A on the surface F1, in particular placed or pressed. The molding is designed as a film, plate, film or tape and is produced for example in a cutting or stamping process.

LIST OF REFERENCE NUMBERS

1

stator

2

stator

2.1 to 2.n

Statoreinzelzahn

3

stator

4

contact ring

A

recess

F1 to Fn

area

K

adhesive

K1

adhesive

K2

adhesive

S1 to S4

step

SF1 to SFn

face

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• DE 102011111806 A1 [0003]
• DE 102009028180 A1 [0004]
• DE 102008023999 A1 [0005]

Claims (9)

Method for producing a stator ( 1 ) for an electric machine, wherein - a plurality of stator single teeth ( 2.1 to 2.n ) and / or a plurality of stator individual tooth groups to a stator ring ( two ) and - the stator ring ( two ) within a stator ring ( two ) at least partially on the outer circumferential surface surrounding stator ( 3 ), characterized in that - before arranging the stator ring ( two ) in the stator carrier ( 3 ) on the outer circumferential surface forming surfaces (F1 to Fn) of a plurality of Statoreinzelzähnen ( 2.1 to 2.n ) and / or a plurality of Statoreinzelzahngruppen a latently reactive adhesive (K1) is applied and - after arranging the stator ring ( two ) in the stator carrier ( 3 ) the latently reactive adhesive (K1) is activated such that between the lateral surface and the stator ring ( two ) an adhesive bond is produced. A method according to claim 1, characterized in that the latently reactive adhesive (K1) in each case in a recess (A) of the outer circumferential surface forming surfaces (F1 to Fn) is introduced. A method according to claim 1 or 2, characterized in that - before joining the Statoreinzelzähne ( 2.1 to 2.n ) and / or the stator single tooth groups a latently reactive adhesive on at least one for mechanical contacting with an adjacent Statoreinzelzahn ( 2.1 to 2.n ) and / or provided with an adjacent Statoreinzelzahngruppe side surface is applied and - after arranging the stator ring ( two ) in the stator carrier ( 3 ) the latent-reactive adhesive is activated such that between the Statoreinzelzähnen ( 2.1 to 2.n ) and / or Statoreinzelzahngruppen an adhesive bond is generated. Method according to one of the preceding claims, characterized in that - on at least one end face of the stator ring ( two ) or to the at least one end face forming end faces (SF1 to SFn) of Statoreinzelzähne ( 2.1 to 2.n ) and / or Statoreinzelzahngruppen a latently reactive adhesive (K2) is applied, - after the application of the adhesive (K2) on the front side of a contacting ring ( 4 ) is arranged and - and after arranging the Kontaktierungsringes ( 4 ) is activated on the front side of the latently reactive adhesive (K2) such that between the contacting ring ( 4 ) and the end face of the stator ring ( two ) an adhesive bond is produced. Method according to one of the preceding claims, characterized in that - before arranging the stator ring ( two ) in the stator carrier ( 3 ) on at least one end face of the stator ring ( two ) or to the at least one end face forming end faces of Statoreinzelzähne ( 2.1 to 2.n ) and / or Statoreinzelzahngruppen a latently reactive adhesive is applied and - after arranging the stator ring ( two ) in the stator carrier ( 3 ) the latently reactive adhesive is activated such that between the end face of the stator ring ( two ) and at least a portion of the stator carrier ( 3 ) an adhesive bond is produced. Method according to one of the preceding claims, characterized in that the latent-reactive adhesive (K1, K2) increases its volume after its activation and / or several latently reactive adhesives (K1, K2) increase their volume after their activation. Method according to one of the preceding claims, characterized in that the latently reactive adhesive (K1, K2) and / or a plurality of latently reactive adhesives (K1, K2) are applied as a prefabricated molded part, in a spraying process or an extrusion process. Stator ( 1 ) for an electrical machine produced in a method according to one of the preceding claims. Stator ( 1 ) according to claim 8, characterized in that the outer circumferential surface forming surfaces (F1 to Fn) of a plurality of Statoreinzelzähnen ( 2.1 to 2.n ) and / or a plurality of Statoreinzelzahngruppen each comprise at least one recess (A) for receiving the latently reactive adhesive (K1).

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