WO2011009515A1 - 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 is intended for fastening to a holding structure (44, 46) of the stator (42) by means of a fastening element (10), having a stator assembly segment (4, 4') and a winding (6) on the stator assembly segment (4; 4'), wherein the holding structure (44, 46) is 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 to a method for manufacturing the stator segment (2) and stator (42).

Description

 Stator segment and stator of a hybrid or electric vehicle

The invention relates to a stator of a stator of a hybrid or

Electric vehicle, a corresponding stator and each a method for producing a stator and a stator.

Stators and stator segments of the type mentioned are used for electric motors and generators. The electric motors or generators have a stationary component (stator) and a component that rotates relative to it (rotor). The stator is usually fixed to a housing.

Furthermore, electric or hybrid vehicles are known. Hybrid vehicles are

Vehicles that have at least two different drives, usually via an electric motor in combination with an internal combustion engine. These vehicles have advantages in terms of their energy consumption over conventional

Internal combustion engine vehicles, e.g. because they are energy when braking

and because they can deliver extra horsepower and torque, allowing for a speedy progress with smaller engines.

DE 10 2006 034 945 A1 discloses a drive arrangement for a hybrid vehicle with an internal combustion engine and an electric machine with a rotor and a stator. The stator of the electric machine has a plurality of on stator segments, each called a Statorpaketsegment, also called Statorzahn, with individual winding mounted thereon, the winding ends of a common

Interconnection device are interconnected by means of several connection 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 known from DE 199 20 127 C2. 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.

A disadvantage of the known stators that the radial attachment of

Stator segments caused a larger stator diameter and can have an influence on the magnetic field. In addition, the thermal connection to the

Overall system by the radial fasteners not optimal and compliance with low tolerances is in radial fixings by resulting

Tolerance chains difficult. A stator carrier which is absolutely necessary for the known structure moreover increases the production costs, in particular due to the integrated cooling fins.

The object of the invention is therefore to provide a stator of a stator of a hybrid or electric vehicle, a corresponding stator, a method for producing a stator and a method for producing a stator, which overcome the disadvantages of the prior art and in particular an improved thermal connection to allow the system and a fault-tolerant

Allow construction.

The object is achieved by a stator segment of a stator of a hybrid or electric vehicle according to claim 1, a corresponding stator according to the independent claim 11, a method for producing a stator segment of a hybrid or electric vehicle according to the independent 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.

A stator segment of a stator according to the invention has a stator packet segment and a winding on the stator packet segment. For attachment to a support structure of the stator, a fastening means is provided. The holding structure is arranged on at least one of the axial end faces of the stator segment.

By the invention) provided axial attachment of the stator to a support structure can be dispensed with a radial connection. In this way can be on the pressing of the individual stator segments in a usual

Statorträger be omitted, in which by the high number of individual

Stator segments and the associated high sum tolerance process-reliable press-in process can be realized only with great effort in a production.

Due to the lack of radial connection can also be the thermal

Improve connection to the overall system, since the cooling medium can flow directly past the stator plate.

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. This results in connection with the at least one fastening means each

Statorpaketsegment a small in the radial direction of construction.

According to a second advantageous embodiment, the fastening means as

formed at least one substantially axially aligned retaining pin. In this way, the stator segment according to the invention can be easily determined or arranged on the corresponding fastening means.

If the retaining pin is also designed as a welded rivet, the

Simplify production of the stator segment. Such weld rivets can be realized by two pins with the same or a slightly greater length than half the total necessary length of the pin. The weld rivets can after insertion into the Statorpaketsegment or after attaching

Statorpaketsegmentteilen be welded together. In this way, a bias of the stator packet segment can be achieved and the strength of the

Increase stator packet segment.

A particularly preferred embodiment of the invention provides that the

Stator packet segment has a plurality of stacked sheets which are positively, materially or adhesively connected to each other. This can be done

Simply make stator packet segments of different axial length. The axial length can be easily determined in this case by the number of stacked sheets. For positive connection, the sheets may preferably be stanzpaketiert. Backing lacquer can preferably be used for the cohesive or adhesive bond. According to a further advantageous embodiment, the sheets may have different contours or some of the sheets have a first contour, the one

Through hole for a fastener, in particular a retaining pin or a weld rivet and some sheets has a second contour, which has a return to the attachment to the attachment means. That way you can

Producing Statorpaketsegmente with complex shapes that may have, for example, cooling fins or cooling channels.

 In this case, the metal sheets with the first contour and the second contour are preferably stacked alternately in groups. Thus, regular cooling structures can be formed. Due to the size of the group, ie the number of sheets, the width of the cooling fins or the cooling channels can be determined. The respective groups can be the same or different.

According to a further preferred embodiment of the invention it is provided that the sheets have a non-mirror-symmetrical contours viewed in the axial direction, wherein the contours have a through-hole or a recess for a fastening means, in particular a retaining pin or a welded rivet. In this case, it is further preferably provided that the non-symmetrical sheets are stacked in groups alternately in different orientation. In this way, stator packet segments with more complex shapes can be represented, which can have further desired properties. This may include, for example, special channel shapes that create a turbulent flow. A turbulent flow has a different velocity profile than a laminar flow, in particular a lower radial velocity, and can therefore absorb more heat.

Furthermore, it is preferably provided that the through-passage or the

Return of the sheets based on the installed position of the stator is arranged radially outward. In this way, the influence of

Minimize through-hole or return to the magnetic field.

According to a further advantageous embodiment, it is provided that the

Stator package segment has an insulation or is completely or partially encapsulated with an insulation. This improves the heat transfer of the heat generated by the stator in the radial direction. A first further independent aspect of the invention relates to a stator for hybrid or electric vehicles having a plurality of substantially annular stator segments secured by a support structure, the support structure axially engaging the plurality of stator segments.

The axial attachment of the stator to the support structure causes that can be dispensed with a radial connection. In this way, can be dispensed with the pressing of the individual stator segments in a conventional stator, in which by the high number of stator segments and the associated high

Sum tolerance a process-safe press-in process can be realized only with great effort in a production.

 Due to the lack of radial connection can also be the thermal

Improve connection to the overall system, as the cooling medium directly on the

Stator packet segment can flow past.

According to a preferred embodiment of the invention, it is provided that some of the stator segments, preferably all stator segments, have axially aligned retaining pins which engage in receptacles provided for this purpose of the retaining structure. This facilitates the assembly of the stator according to the invention and allows a very precise alignment of the stator segments on the support structure.

According to an alternative embodiment, the arrangement of receptacles and projections may also be reversed or, in the case of several attachment points per stator segment, also be different, so that the support structure and the

Stator segments can each be equipped with recordings and projections.

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

According to a further advantageous development, some of the stator segments, preferably all stator segments, have the features of one or more of the above

described feature combinations on. This makes it possible to specify a stator which can be produced in a particularly cost-effective manner and whose thermal connection to the system is optimized. Another independent subject of the invention relates to a method for

Production of a stator segment of a hybrid or electric vehicle, in which a plurality of metal sheets with a given contour or given contours are stacked and connected to one another in a material-locking, positive-locking or adhesive manner. Furthermore, the sheets are provided with an axially aligned fastener. To connect the sheets, these can be provided, for example, with an adhesive agent, for example a baked enamel.

According to a development of the method according to the invention, two welding rivets are used as fastening means aligned in the axial direction, which are welded together. This allows the production of a stator segment, whose stator packet segment is biased, so that the stability of the

Statorpaketsegments is increased.

Preferably, the interconnected sheets are provided with insulation or encapsulated with an insulation. In this way, a targeted management of

Improve waste heat.

Furthermore, it can be provided that the plurality of sheets with a

Through hole or a rebound on a rivet or pin-like axial fastener pushed or fixed thereto. This is a particularly simple method for mounting the stator packet segment.

The invention relates, in a last independent aspect, to a method for manufacturing a stator of a hybrid or electric vehicle in which a plurality of stator segments are attached to an axial support structure. This can achieve the advantages described above.

According to a development of the invention, it is provided that the stator segments ^{' are produced} according to the method described above, whereby the advantages achievable in connection with the production of the stator segments can be achieved.

The present invention is applicable to both stator segments and stators of

Internal rotor machines as well as external rotor machines applicable. The invention will be explained with reference to several embodiments. Here are shown schematically:

Fig. 1 shows an inventive stator segment of a stator of a hybrid or

 Electric vehicle in a first embodiment;

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

FIG. 2b shows a single element for producing the stator packet segment according to FIG. 2a; FIG.

Fig. 2c, a further single element for the completion of the stator packet segment

 Fig. 2a;

Fig. 2d a finished stator core without winding according to the first

 embodiment;

3 shows a stator packet segment of a stator segment according to a second

 embodiment;

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

4b shows a further production stage of a stator according to the invention;

4c shows a finished stator according to the invention;

Fig. 5a, the stator according to the invention in a mounting situation in a

 Clutch housing of a hybrid vehicle as well

Fig. 5b shows a cross section through the coupling housing of Fig. 5a.

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

Embodiment.

The stator segment 2 has a stator packet segment 4 and winding 6 around the stator packet segment 4. The stator core segment 4 has, in the installed position, compare FIGS. 4a to 4c, externally arranged cooling ribs 8, which consist of a cooling medium, For example, air or a cooling liquid to be flowed around and the ohmic

Waste heat of the stator segments 2, which arises during operation dissipate.

Furthermore, a fastening pin 10 is shown, by means of which the individual sheets of the stator core segment 4 are additionally fixed and by which the stator segment 2 for producing the stator can be fastened to a fastening ring which serves as a holding structure.

Instead of a one-piece connecting pin 10 may 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 shortened

Weld rivet on cooling, whereby the laminated core is biased.

The winding 6 ends with two terminal ends 14, 16, which are both arranged on one side. About this terminal ends 14, 16, the winding 6 is electrically connected in the stator.

FIG. 2a shows the stator packet segment 4 in a partially completed state. To form the stator core segment 4, a series of stamped sheets are used, which are fastened to the fastening pin 10 or arranged on the fastening pin 10. In the presently illustrated embodiment, two different sheet metal shapes are used, which are shown in Figs. 2b and 2c.

The first sheet metal mold 18 according to FIG. 2b forms on the outside of the finished

Statorpaketsegments 4 raised ribs. The sheet metal form is essentially

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 packet segment 4 of the stator correspond and thus improve the stability of the stator. When viewed in the installed position in the stator outside area a through-passage 20 is provided for the implementation of the fastening pin 10. In the radially inner region are small projections 22, 24, so-called pole pieces, provided which prevent slippage of the winding 6 and substantially affect the torque ripple of the electric motor positively. The second form of a punching plate 26 according to FIG. 2c is smaller in the radial direction and, instead of a passage recess, has a recess 28 which partially surrounds the connecting pin 10 and with the aid of which the stamped sheet is held in position.

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

The connection of the laminated core is done, for example, punched packetizing or by means of a baked enamel. By the alternate arrangement of the sheets of the first mold 18 and the sheets of the second mold 26 cooling fins 8 are formed, as in

Connection with Fig. 1 already explained.

As shown in FIG. 2 d, the stator core segment 4 is partially encapsulated with an insulation 30. The encapsulation is provided above all in the area of the stator packet segment 4, which is wound with the winding 6. In this way, the heat input can be reduced by the ohmic waste heat of the winding 6 in the stator core 4 and increase in the radial direction, so that a larger part of the waste heat is transported directly in the direction of the cooling fins 8.

The stator packet segment 4 shown in FIG. 2d is ready to be wound around with the winding 6, so that the stator segment according to the invention, as shown in FIG. 1, is completed.

Fig. 3 shows an alternative embodiment of a stator packet segment 4 'to

Production of an alternative stator segment, in which cooling fins 8 ', unlike in the first embodiment, are not arranged such that they form substantially rectilinear channels, but are formed at the angled channels 32. 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. This can increase the heat transfer to the cooling medium. 4a shows a manufacturing stage of a stator 42 according to the invention. For this purpose, a multiplicity of stator segments 2, two of which are provided with reference numerals by way of example, are arranged annularly. The connecting pins 10 of the stator segments 2 point in an axial direction. Also, the terminal ends 14, 16 of the

Stator segments 2 aligned in the axial direction.

In the further production stage shown in FIG. 4b, the stator segments 2 are fixed by means of two fastening rings 44, 46. For this purpose, passage openings 48 are provided in the fastening rings 44, 46, through which the fastening pins 10 protrude. On the mounting ring 46 projections 50 are further provided which form a torsion protection for the stator 42, so that the stator 42 can not rotate relative to a housing due to acting on the stator 42 during operation moments. The attachment between the mounting rings 44, 46 and the stator segments 2 by means of the pins 10 and the through holes 48 may preferably be made by welding or riveting.

4c shows the stator 42 finished with a contacting unit 52 placed on the stator segments 2, with the aid of which the terminal ends 14, 16 of the stator segments 2 can be interconnected in the required manner. The contacting of the stator 42 takes place via contacts 54 provided in the contacting unit 52.

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

Fig. 5b shows a cross section through the clutch housing 62 with the stator 42 inserted therein. The cooling fins 8 of the stator segments 2 together with the clutch housing 62 closed cooling channels, which are sealed by seals 64 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. These

Separation can be beneficial for all cooling channels on a stator segment

correspondingly shaped sheets of Statorpaketsegment be realized. The Statorpaketsegment this Statorsegments then has over its entire axial extent a radial extent up to the coupling housing 62, whereby the flow of the cooling medium along the stator 42 is interrupted in this stator segment. The stator 42 according to the invention has the advantage that it does not require a stator support. The stator segments 2 are fixed by the axially offset mounting rings 44, 46 and by the mounting pins 10.

Claims

claims A stator segment of a stator (42) of a hybrid or electric vehicle, which is provided for attachment to a support structure (44, 46) of the stator (42) by means of a fastener (10), with a Statorpaketsegment (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. 2. stator segment according to claim 1,  characterized in that  the holding structure (44, 46) is arranged only on both axial end sides of the stator segment (2). 3. stator segment according to claim 1 or 2,  characterized in that  the fastening means is formed as at least one substantially axially aligned retaining pin (10). 4. stator segment according to one of the preceding claims,  characterized in that  the fastening means (10) comprises at least one weld rivet. 5. stator segment according to one of the preceding claims, characterized in that the stator packet segment (4; 4 ') has a plurality of stacked sheets (18, 26) which are connected to one another in a form-fitting, cohesive or adhesive manner. 6. 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 through-hole (20) for the fastening means (10), in particular a holding pin or a weld rivet, and some of the sheets (20 ) A second contour having a recess (28) for fixing the sheets (20) on the fastening means (10). 7. stator segment according to claim 6,  characterized in that  the sheets (18) with the first contour and the sheets (26) with the second contour are stacked alternately in groups. 8. 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 passage recess (20) or a recess (28) for the fastening means (10), in particular a retaining pin or a welded rivet, and in that the sheets (18, 26) in groups  alternately stacked in different orientation. 9. stator segment according to one of claims 6 to 8,  characterized in that  the passage recess (20) or the recess (28) of the sheets (18, 26) is arranged radially outward relative to an installation orientation of the stator segment (2). 10. stator segment according to one of the preceding claims,  characterized in that the stator packet segment (4, 4 ') has an insulation (30) or is completely or partially encapsulated with an insulation (30). 11. Stator for a hybrid or electric vehicle with a plurality of im  Substantially annularly arranged stator segments (2) which are fastened by means of a holding structure (44, 46),  characterized in that  the support structure (44, 46) acts axially on the plurality of stator segments (2). 12. Stator according to claim 11,  characterized in that  some of the stator segments (2), preferably all the stator segments (2), axially aligned retaining pins (10) which engage in receptacles provided for the support structure (44, 46). 13. Stator according to claim 11,  characterized in that  some of the stator segments (2), preferably all stator segments (2), have receptacles in the axially aligned projections provided for this purpose  Haltestruktur (44, 46) engage. 14. Stator according to one of claims 11 to 13,  characterized in that  the support structure (44, 46) has a projection (50) for supporting a moment with respect to a housing (62). 15. Stator according to one of claims 11 to 14,  characterized in that  some of the stator segments (2), preferably all stator segments (2), which have features of the stator segment (2) according to one of claims 1 to 10. 16. A process for producing a stator segment (2) of a hybrid or Electric vehicle, in which a plurality of sheets (18, 26) stacked and materially, positively or adhesively connected to each other and are provided with an aligned in the axial direction fastening means (10). 17. The method according to claim 16,  characterized in that  as an axially aligned fastener (10), two weld rivets are used, which are welded together. 18. The method according to claim 16 or 17,  characterized in that  the interconnected sheets (18, 26) are provided with an insulation (30) or are overmolded with an insulation (30). 19. The method according to any one of claims 16 to 18,  characterized in that  the plurality of sheets (18, 26) are slid or fixed to a through-hole (20) or a recess (28) on a rivet or pin-type axial fastener (10). 20. A method of manufacturing a stator (42) of a hybrid or electric vehicle in which a plurality of stator segments (2) are secured to an axial support structure (44, 46). 21. The method according to claim 20,  characterized in that  the stator segments (2) are formed by the method according to one of claims 16 to 19.