WO2019215097A1 - Mehtod for producing a winding for a stator of an electrical machine and electrical machine - Google Patents

Abstract

The invention relates to a method for producing a winding for a stator (130) of an electrical machine according to a plug-in winding method with wave windings, in which winding elements (200) are inserted in grooves (131) of the stator, wherein the winding elements (200) are arranged in at least one layer (221, 222, 223) extending in the peripheral direction of the stator (130), and wherein straight sections of each winding element (200), which are to be arranged in the grooves (131) in the at least one layer (223), are arranged in a position at the same radial distance from an axis of rotation of the stator. The invention also relates to an electrical machine.

Description

 description

title

 Method for producing a winding for a stator of an electric

Machine and electric machine

The present invention relates to a method for producing a winding for a stator of an electric machine according to a Steckwicklungsverfah ren (or so-called. Hairpin method) with wave windings and an electric machine with such Wcklung.

State of the art

For producing windings for electrical machines such as Klauenpolgenera gates, there in particular for the stand, various Wckeltechniken can be used. There is the so-called. Retraction technique, a robust pro duction process with which can be made particularly low. However, only limited filling factors (electrical up to 50%) can be achieved. In addition, relatively wide slot slots and long Wckelköpfe be needed. The so-called Flachpaketwicklung allows significantly higher filling factors (electrical up to 65%) and short Wckelköpfe, with correspondingly higher produc- tion effort and also wide slot slots.

Another Wckeltechnik is the so-called. Steckwicklungsverfahren (also known as Hair Pin method). Thus, simple and distributed Wellenwicklun gene and loop windings for the stand or for the stator assembly can be performed. The term of the plug-in winding is due to the fact that individual winding elements are plugged separately into the stand or its grooves and then be connected only to a full Wcklung. An advantage of this technique, a high fill factor (or copper fill factor in Verwen tion of copper for the windings) in the stator slots, narrow slot slots of the stator or the stator iron and short end windings of the stator winding. This allows the design and construction of very small and high-power electrical machines, especially generators.

When Steckwicklungsverfahren is starting from mostly U-shaped or U-shaped, usually hairpin-shaped winding elements made of iso lated wire, usually copper wire, in several manufacturing steps, as they will be explained later, the end winding on the first so-called mating side restricted, the winding elements introduced into the stand, then the so-called. Switching side is limited and the corresponding conductor ends of the winding elements are interconnected, in particular by welding.

In this case, all winding elements are usually from one side of the electrical rule machine (usually so-called B-side) plugged and all interconnections or welds on the other side (usually so-called. A-side) running. As a result, as a rule, all further components or special elements which may be necessary, such as, for example, Connections, reversing connectors and the like on the Be te, from which the winding elements are plugged to lie.

Disclosure of the invention

According to the invention, a method for producing a winding for a stator of an electrical machine as well as an electric machine with the features of the independent claims are proposed. Advantageous embodiments are the subject of the dependent claims and the following description.

The invention is based on a plug-in winding method, as explained above, and a method for producing a winding for a stator of an electric machine according to a plug-in winding method, with wave windings in which winding elements are introduced into slots of the stator. As mentioned, the winding elements can be U-shaped, in particular hairpin-shaped. As will be explained later, however, individual winding elements can also be designed differently. The electrical machine is preferably a generator. gate, in particular a claw pole generator. Further fields of use are also electric synchronous motors, for example as an additional drive motor in a motor vehicle.

In the proposed method, the winding elements are arranged in one or more layers extending in the circumferential direction of the stator. In this case, be arranged in the one or one of the several layers in the grooves to be arranged straight sections each have a winding element in egg ner position with the same radial distance to a rotational axis of the stator.

In previously common Steckwicklungsverfahren, in particular with whom he thought wave windings (here the individual winding element are arranged in the form of a wave, as can also be seen from the figures), who arranged the individual winding elements such that the two gera the portions of the winding element , which are arranged in different grooves (and often referred to only as a ladder) are arranged in two different NEN layers, ie at different radial distances to the axis of rotation of the stator. This results in that a winding layer extends over two layers and that in the other position in the groove is a straight section of another winding element who the. Thus, there are only windings with an even number such straight from section or conductor in a groove.

By contrast, with the proposed method, it is now also possible to produce windings in which an odd number of such straight sections or conductors are arranged in a groove. This is a much more precise From mood of the winding to required power of the electric machine possible.

In this case, it is particularly expedient for the straight sections to be arranged in the slots to be arranged in a position with the same radial distance to a rotational axis of the stator, in that the straight sections are initially arranged in two layers with a different radial distance to the rotational axis. Are arranged axis of the stand and then spent in one position. The manufacturing process can therefore initially be started as for a winding with the winding elements in two layers with different radial distance from the axis of rotation of the stator, but are supplemented by one or possibly more intermediate steps, so the number of layers for the straight sections of the winding elements from reducing two layers to one layer.

In particular, while the straight portions for the one layer with moving chem radial distance when they are arranged in two layers with different radial distance from the axis of rotation of the stator (which is the case in the Her position of conventional Wickelungen initially), before an introduction in the slots of the stand are spent in one position. This can be done after the already mentioned cabinets, i. after the winding elements have been deformed so that they have received the desired orientation for the desired Wcklung. For this purpose, for example, suitable Schränkwerkzeuge can be used.

Furthermore, it is particularly useful if two conductor ends each of a winding element, in which the straight portions are arranged for the one layer with sliding chem radial distance, after insertion into the grooves of the stator in two layers with different radial distance to the Ro tationsachse of Stands are spent. This means that although the straight sections (or the ladder) are arranged in only one layer, the Lei terenden in Wckelkopf, which are interconnected, but brought back into two different positions. This allows a particularly simple interconnection, for example by welding, in the usual way.

Preferably, the winding elements are arranged in a plurality, extending in the circumferential direction of the stator Rich layers, wherein in at least egg ner, preferably all, the remaining layers, the straight sections are arranged in two layers with different radial distance from the axis of rotation of Stän DERS, wherein in each groove two straight sections of ver different winding elements are arranged. Among the remaining shale th are those of the multiple layers to understand in which the straight sections are not angeord net in a position with the same radial distance. In this way, therefore, a conventional arrangement of Wick are elements in layers with two layers and an array of Wick tion elements in a layer combined with only one layer. Thus, any odd number of straight portions of winding elements (or conductors) in the slots can be obtained.

It should be noted that any combination of these two different types of layers, any number, so both an even and an odd number of straight sections of winding elements (or conductors) can be obtained in the grooves. In particular, therefore, for example, a manufacturing device as needed for the production of a winding with an even or odd number of straight sections of Wick tion elements (or conductors) can be used in the grooves.

It should also be noted that even for an even number of straight sections of winding elements (or conductors) in the slots, layers with only one layer of straight sections of the winding elements can be used, then an even number of such layers.

It is preferred if the layer in which the straight portions of each winding element are arranged in a position with the same radial distance to a rotation axis of the stator is arranged as the radially innermost or radially outer layer in the stator. Thus, a radial transition of the winding heads, which is necessary by the mentioned arrangement of the conductor ends of the corre sponding layer in two layers, placed as needed. In particular special space problems are avoided, which would result from the expansion of the winding heads in layers that are not arranged on the edge.

Furthermore, it is preferable that the winding elements of a layer in which the winding elements are arranged in two layers at different radial distances from the axis of rotation of the stator, for a phase having a winding direction in and a winding direction against a circumferential direction of the stator (that is, in a forward direction and a reverse direction, as it were). The winding elements of the layer in which the Wick tion elements are arranged in a position with the same radial distance to the rotation axis of the stator are then for this phase with a winding direction in or a winding direction against the circumferential direction of the stator (ie either in the forward direction or in the reverse direction). This can be done a simple and fast arrangement and subsequent circuit or connection Ver the winding elements.

It is advantageous if winding elements are used with round wire cross-section ver, wherein the cross-sections are formed at least in the region to be arranged in the grooves straight portions of the winding elements in an angular, in particular rectangular, square or trapezoidal, cross-section to. Round wire cross-sections - as material comes here insbesonde re, as already mentioned, copper or copper wire in question - initially allow easy production of the winding elements. By means of the corresponding forming, however, the filling factor in the grooves can be increased significantly.

Advantageously, the winding elements are connected for several phases of the winding, in particular for three, five, six or nine phases.

It is also expedient if in each groove of the stator in each case three, five, seven or nine straight sections of the winding elements are arranged. In these, usually very often used types of windings, the advantages of the proposed method are particularly clear, especially in such, rather small numbers of straight sections or conductors in the grooves, by the possibility of odd numbers a particularly good Passing or vote to necessary services of the electrical machine is possible, please include.

It is also preferred if the winding, that is to say the winding elements or at least a plurality of the winding elements, is or are arranged such that they come to lie or lie in a radial cooling air flow of the electrical machine. For a particularly effective cooling is possible during later operation of the electric machine. The invention furthermore relates to an electric machine having a stator and a winding in the form of a plug-in winding with wave windings, in which winding elements, preferably U-shaped winding elements, are introduced into slots of the stator. The electric machine is preferably a generator, in particular a claw-pole generator. In this case, the winding elements are arranged in one or more, extending in the circumferential direction of the stator Rich layers, and in the one or more layers to be arranged in the grooves straight sections depending Weil a Wcklungselements are in a position with the same radial distance to a rotation axis of the Stand arranged.

Conveniently, the electric machine is manufactured according to a process according to the invention inventively, i. in particular it has the properties described above, as they result from the mentioned method.

With regard to the concrete, preferred embodiments and their advantages, reference is therefore made to the above statements on the method to avoid repetition, which apply here accordingly.

Further advantages and embodiments of the invention will become apparent from the loading and the accompanying drawings.

The invention is illustrated schematically by means of exemplary embodiments in the drawing and will be described below with reference to the drawing.

Brief description of the drawings

FIG. 1 shows schematically an electrical machine according to the invention in a preferred embodiment. Figures 2 to 7 show sections of a stator of an electric machine according to the invention in a preferred embodiment.

Figure 8 shows a section of a stator of an inventive electrical cal machine in a further preferred embodiment.

Embodiment (s) of the invention

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS In a preferred embodiment, FIG. 1 shows a schematic and simplified electrical machine 100 in longitudinal section, which is used as an AC synchronous generator with a claw pole rotor (or claw pole generator) with regulated electrical excitation of the pole wheel for use in motor vehicles is trained.

The electric machine 100 has a multi-part housing, in particular a metal housing, consisting of a respective bearing plate 110 and 120 at both end faces. The end shields 110 and 120 are cup-shaped, in particular with end and peripheral recesses for a cooling air duct.

Axially between the two end shields 110 and 120, a stator 130 is fastened, which in the embodiment shown is formed out of a disk set and a polyphase winding or stator winding 140 arranged therein. The disk pack can be made in a conventional manner from a plurality of laminations.

The stator winding 140 is divided into winding strands, which are housed in axially and mutually parallel, radially inwardly open grooves. Within the cylindrically shaped disk set a claw polläufer 150 is arranged and rotatably mounted in the bearing plates 110 and 120 about a Rotati onsachse R. A rotor shaft 155 carries two oppositely poled Polradhälften. Each pole wheel half is preferably made of iron, is formed mas siv and has along the circumference of a plurality of axially extending claws, which are shaped substantially trapezoidal and arranged with uniform angular pitch in the circumferential direction. Both Polradhälften are arranged on the rotor shaft 155 such that they face each other and their claw-like Polfinger mutually engage as south and north poles. They cover an annular excitation winding 160, which is located on a pole core 165, which keeps the two Polradhälften at a distance.

At axial end surfaces of the Polradhälften fan can be arranged and attached to them. Corresponding air currents then enter axially through the frontal openings in the end shields are sucked by the two fans and pass radially through openings on the periphery of the end shields again, so that the winding heads of the stator winding 140 are in a radial cooling air stream.

On the drive side opposite end of the rotor shaft 130, in the figure on the right, a slip ring pair 170 is arranged, which serves the power supply of the exciting coil 160 He. A DC current of the excitation winding 160 generates a resting with respect to the rotor axial magnetic field, which is deflected by the Klauenpo le in a radial direction. By the rotation of the rotor ent is for the stator 130, a magnetic rotating field.

This rotary field rotates with synchronous speed to the pole wheel and induces an AC voltage in each of the string or each phase of the stator winding 140. The individual strand alternating voltages are shifted by an angle (Phasenver shift angle) in time against each other. For example, for a symmetrical three-phase winding, the three sinusoidal alternating voltages are shifted by 120 ° with respect to each other. The same applies to the alternating currents.

Carbon brushes which are pressed against surfaces of the slip rings 170 are mounted in a brush holder 175, which together with a regulator 180, which can regulate the induced voltages in the windings to a speed and load independent, constant voltage, a unit here , The output from the stator winding 140 alternating current can be supplied via a rectifier circuit to a vehicle electrical system of a motor vehicle, the rectifier assembly 190, for example, outside the rear bearing plate 120 is arranged. The rectifier arrangement 190 and the controller 180 are covered by a protective cap 185 on the rear end side of the electric machine 100 Ma.

A method according to the invention in a preferred embodiment or an electrical machine according to the invention in a preferred embodiment, of which in particular the winding, will be explained below with reference to FIGS. 2 to 7. In the example shown, a stator with 80 slots is used and the winding is divided into five phases, with five conductors or straight sections of the winding elements being arranged in each slot.

It should be noted that in the figures it appears in places as if there were more than five layers in the grooves. However, this is caused by sectional views, not the straight portions of the Wicklungsele elements, but show bent portions of the plug or switch side. In particular, as shown in Figure 6 (d), there are only five layers in each groove.

In Figure 2 are different views of the stator 130 with only one phase of the winding, which consists of several individual winding elements 200, ge shows. FIG. 2 a shows a side view of the stand 130. In particular, two connection elements 230 for connecting the phase or the winding to, for example, a rectifier can also be seen. These connection elements are formed here by extended conductor ends of two possibly special winding elements.

FIG. 2b shows a sectional view of FIG. 2a. Here are beispielswei se mentioned five conductors or straight sections of the winding elements in a groove to see. FIG. 2c shows a top view of the stator 130 from a plug-in side S1. The term plug-in side is understood to mean that from or on this side, the individual winding elements 200 in the grooves, one of which is here denoted by 131, are inserted. This corresponds to the upper side in FIG. 2a. In addition, the rotation axis R can be seen.

FIG. 2d shows a top view of the stator 130 from a switching side S2. The term switching side is to be understood that on this page, the ends or conductor ends of the individual winding elements, which protrude from the grooves, in each case connected in pairs, in particular welded. This corresponds to the lower side in FIG. 2a. One of these ends is labeled 210. These conductor ends can be stripped before introducing the first fully iso lated Wcklungselemente so that they can be welded. After welding, the corresponding pairs of conductors can then be isolated again.

In Figure 3, the views of Figures 2c and 2d are shown in greater detail. In this case, zei gene 3a, the plug side S1 and 3b, the switching side S2.

In both figures or views also three layers 221, 222 and 223 are shown, in which the Wcklungselemente 200 and their straight sections (which run into the plane of the drawing in this view) are arranged or who the. While in the layers 221 and 222 two layers are provided with difference Lichem radial distance from the axis of rotation of the stator, in which the straight sections are arranged, only such a layer is provided in the layer 223.

It can be seen, in particular, on the right edge of the region of the stator 130 visible in FIG. 3a that the radially innermost cooling element 200 has an additional bend relative to the two further radially outward wedge elements, thereby achieving that both straight sections of this winding element in FIG same situation are arranged. In Figure 4, the same views (Figures 4a to 4d) are shown as the figures 2a to 2d, but here are the total winding elements for all five Pha sen of the winding in the stator 130 and its grooves 131 arranged. Accordingly, there are also a total of ten connection elements 230.

FIG. 5 shows perspective views of the winding, as shown in FIG. Here, Figure 5a shows the plug side S1, Figure 5b shows the switching page S2.

In Figure 5a, the three layers 221, 222 and 223 are also shown, where it can be clearly seen that in the radially innermost layer in the winding winding less winding elements 200 are present. This is due to the fact that in the layer 223 only one layer with straight sections 240 is arranged and thus in comparison to the other layers only half of Wicklungsele elements.

In Figure 5b in particular the individual ends or conductor ends 210 are hen to se, which are connected in pairs. It can also be seen that there are alternately two and three such pairs in the starting direction.

In Figure 6, the winding is for a phase in a developed representation, i. without stand and elongated, shown. 6a shows a plan view of the switching side S2, FIG. 6b shows a side view, with the plug side S1 at the top and the switching side S2 at the bottom, FIG. 6c a plan view of the plug side S1 and FIG. 6d a sectional view in the slot region, i. through the straight from sections 240 of the winding elements.

In FIG. 6d, the five individual layers can be seen in particular. For this purpose, the individual layers are labeled from top to bottom with L1 to L5. The top two layers L1 and L2 form the radially outermost layer, the two layers L3 and L4 form the middle layer and the bottom layer L5 bil the radially innermost layer. Again, as in FIG. 3 a, it can be seen that the winding elements, in particular with respect to the straight-line winding sections, are designed such that both straight portions of a Wick lungselements can be arranged in one or the same position.

In FIG. 7, the winding or phase shown in FIG. 6 is shown even further deviated, namely, according to individual winding elements with associated juxtaposition and winding direction.

In the following, this winding will be explained starting from the top right with the individual winding elements and their arrangement. The winding begins with a connection element 230, which is part of a (half or specially trained) winding element, followed by seven identical winding elements, also referred to as series elements. This represents a forward winding direction.

In the second row from the top then follows, beginning left, first a so-called. Reverse connector as a winding element, followed by seven other elements Serienele. This then represents a backward winding direction. The first two rows from above form the radially outermost layer of the winding elements.

The third and fourth row from above corresponding to the first and second Rei hey, with the exception that the third row, starting right, with a so-called. Intermediary connector as a winding element, not with a Anschlus selement. The third and fourth row from above form the radially middle layer of the winding elements.

The bottom row begins, from the right, again with an intermediate connector, followed by seven series elements and a connection element 230 at the very end. This bottom row forms its own, namely the radially innermost layer.

It should also be noted here that the reversing or intermediate connectors differ from the series elements as winding elements only insofar as that one of the leaders is bent in a different direction. This can be done for example by means of a suitable tool.

FIG. 8 shows a detail of a stator of an electric machine according to the invention in a further preferred embodiment, where in particular here too only the stator 130 with the winding is shown. The views shown here in Figures 8a and 8b are similar to the views of Figure 3 (Figures 3a and 3b). However, in this embodiment, the layer in which the straight portions of the coil members are disposed in the same layer is the radially outermost layer.

In comparison with FIG. 3, it can be seen that the pairs of conductor ends to be connected on the switching side S2 come to lie radially further outward.

Claims

claims 1. A method for producing a winding (140) for a stator (130) of an electrical machine (100) according to a Steckwicklungsverfahren with Wel lenwicklungen in which in grooves (131) of the stator Wcklungselemente (200) are introduced,  wherein the winding elements (200) in one or more, in the circumferential direction of the stator (130) extending layers (221, 222, 223) are arranged, and  wherein in the one or one (223) of the plurality of layers in the Nu th (131) to be arranged straight portions (240) each of a Wcklungs- element (200) in a position (L5) with the same radial distance to an axis of rotation (R) of Stand are arranged. 2. The method of claim 1, wherein the straight sections (240) to be arranged in the grooves (131) are arranged in a position equidistant from an axis of rotation of the stator by first placing the straight sections (240) in two layers of different radial From stood stood to the axis of rotation of the stand and then spent in the one layer (L5). 3. The method of claim 2, wherein the straight portions (240) for the one layer (L5) with the same radial distance, if they are arranged in two layers with different radial distance from the axis of rotation of the stand, prior to introduction into the Grooves (131) of the stand are spent in a ne situation. 4. The method according to any one of the preceding claims, wherein two conductor ends (210) each of a Waklungselements (200), in which the straight Abschnit te (240) for the one layer (L5) arranged with the same radial distance be spent after insertion into the grooves (131) of the stator in two La conditions with different radial distance from the axis of rotation of the stand. 5. The method according to any one of the preceding claims, wherein the winding elements (200) in several, erstre in the circumferential direction of the stator erstre ckenden layers (221, 222, 223) are arranged, and wherein in we least one, preferably all, of the remaining layers (221, 222) the straight portions (240) are arranged in two layers (L1-L4) at different radial distances from the axis of rotation (R) of the stator, wherein in each groove (131) two straight sections (240) of different ones Wick lungselementen (200) are arranged. 6. The method of claim 5, wherein the layer in which the straight portions (240) each of a winding element (200) in a layer (L5) arranged at the same radial distance to an axis of rotation of the stator who the, as the radially innermost or radially outermost Layer in the stand (130) is arranged. 7. The method of claim 5 or 6, wherein the winding elements (200) egg ner layer in which the winding elements (200) are arranged in two layers with different radial distance to the rotational axis of the stator, for a phase with a winding direction in and a winding direction against a circumferential direction of the stator (130) are arranged, and wherein the winding elements of the layer in which the winding elements (200) are arranged in a position (L5) with the same radial distance to the axis of rotation of the stator, for this phase are arranged with a winding direction in or a winding direction against the order circumferential direction of the stator (130). 8. The method according to any one of the preceding claims, wherein Windlungsele elements (200) are used with a round wire cross-section, wherein the cross-sections at least in the region of the grooves (130) to be arranged straight portions (240) of the winding elements in a square, in particular special rectangular, square or trapezoidal, cross section to be shaped. 9. The method according to any one of the preceding claims, wherein the winding elements (200) for several phases of Wcklung, in particular for three, five, six or nine phases, are interconnected. 10. The method according to any one of the preceding claims, wherein in each groove (131) of the stator in each case three, five, seven or nine straight sections (240) of the winding elements are arranged. 11. The method according to any one of the preceding claims, wherein the Wcklung (140) is arranged such that it comes to rest in a radial flow of cooling air of the electric machine (100). 12. Electrical machine (100) with a stator (130) and a winding (140) in the form of a plug-in winding with wave windings, in which grooves (131) of the stator Wcklungselemente are introduced,  wherein the Wcklungselemente (200) in one or more, in order circumferential direction of the stator extending layers (221, 222, 223) are arranged, and  wherein in the one or one (223) of the plurality of layers in the Nu th (131) to be arranged straight portions (240) each of a Wcklungs- element (200) in a position (L5) with the same radial distance to an axis of rotation (R) of Stand are arranged. 13. Electrical machine (100) according to claim 12, which is prepared according to a method according to any one of claims 1 to 1 1.