STATOR OF ELECTRIC MACHINE

Abstract

A stator with concentrated windings includes a ferromagnetic core having a central axis, an electrical insulation system disposed on the ferromagnetic core and a winding disposed on the insulation system to be mechanically locked thereto and electrically insulated from the ferromagnetic core; the ferromagnetic core includes a plurality of radial teeth without pole shoe and each tooth has a radial length, an axial depth and a width orthogonal to the radial length and axial depth; the ratio between the slot pitch and the width of the tooth is between 1.2 and 1.5, preferably between 1.3 and 1.4.

Claims

1. A stator with concentrated windings, comprising a ferromagnetic core having a central axis, an electrical insulation system disposed on the ferromagnetic core and a winding disposed on the insulation system to be electrically insulated from the ferromagnetic core, the ferromagnetic core comprising an annular crown and a plurality of teeth which jut radially from the annular crown towards the central axis and which form a compact structure together with the annular crown, each tooth having a radial length, an axial depth and a width orthogonal to the radial length and axial depth, the winding comprising a plurality of coils, each positioned on a respective tooth, the insulation system comprising at least a first portion and a second portion disposed on opposite sides of the ferromagnetic core along the central axis, the first portion comprising a plurality of first radial elements which, on each tooth, extend from the annular crown towards the central axis, the second portion comprising a plurality of second radial elements which, on each tooth, extend from the annular crown towards the central axis, the stator being characterized in that the ratio between the slot pitch and the width of the tooth is between 1.2 and 1.5, preferably between 1.3 and 1.4, the teeth being without pole shoe.

2. The stator according to claim 1, wherein at least one tooth of the plurality of teeth is rectangular in shape in its cross section orthogonal to the central axis.

3. The stator according to claim 1, wherein the ratio between the width of the tooth and the axial depth of at least one tooth of the plurality of teeth is between 0.2 and 3, preferably between 0.7 and 1.5.

4. The stator according to claim 3, wherein the ratio between the width of the tooth and the axial depth of at least one tooth of the plurality of teeth is 1.

5. The stator according to claim 1, wherein all the teeth of the plurality of teeth are identical.

6. The stator according to claim 1, wherein the coils are self-supporting.

7. The stator according to claim 1, wherein the coils are made in a single layer.

8. The stator according to claim 1, wherein the coils are made in two or more layers.

9. The stator according to claim 1, wherein the coils are made from a wire having a substantially rectangular cross section.

10. The stator according to claim 1, wherein the winding is three-phase and the coils of each phase are connected in series.

11. The stator according to claim 1, wherein the insulation system is overmoulded on the ferromagnetic core.

12. The stator according to claim 11, wherein the ferromagnetic core and the insulation system overmoulded thereon together have, at each radial section, a predetermined total height, measured along the central axis, independent of the height of the ferromagnetic core alone at the same radial section.

13. The stator according to claim 11, wherein the first portion of the insulation system has, at each radial section, a predetermined height, measured along the central axis, independent of the height of the ferromagnetic core alone.

14. The stator according to claim 1, wherein the insulation system is thermally conductive.

15. The stator according to claim 1, wherein the first radial elements each comprise a base surface and at least one protrusion extending axially from the base surface.

16. The stator according to claim 15, wherein the protrusion comprises at least a first arm which extends radially for at least part of the radial length of the tooth.

17. The stator according to claim 15, wherein the protrusion comprises a second arm which extends in parallel with the width of the tooth.

18. The stator according to claim 15, wherein each coil comprises a first face which is positioned on a respective first radial element of the insulation system, the first face being plastically deformed towards the base surface so that each coil is stationary relative to the insulation system, since it is locked at least by the respective protrusion.

19. The stator according to claim 1, wherein the insulation system comprises, for each tooth, a first and a second flank, connecting the first radial element with the corresponding second radial element to form an insulating tube.

20. The stator according to claim 1, wherein the insulation system—preferably, the first portion thereof—is provided, at each tooth, with a groove where the ferromagnetic core is uncovered.

21. An electric motor comprising: a casing having a base wall and a side wall; a stator mounted in the casing and connected thereto; a rotor mounted in the casing and rotatably connected thereto; a lid for closing the casing to define an enclosure; a thermally conductive and electrically insulating spacer interposed between the stator and the base wall of the casing, the electric motor being characterized in that the stator is made according to claim 1 and the coils are at least partly abutted against the spacer at a predetermined distance from the base wall, the spacer being provided with a plurality of openings, each at a respective coil, the coils each having a second face orthogonal to the main axis, substantially entirely confronting a respective opening of the openings and placed in a heat exchanging relationship with the base wall by interposing a thermally conductive, electrically insulating material placed in the openings.

22. A method for assembling a stator according to claim 1, the method comprising a step of winding the coils outside the ferromagnetic core and a step of fitting each coil to a respective tooth, the coils being self-supporting.

23. The assembling method according to claim 22, comprising a step of plastically deforming a first face of the coils, the first face being positioned on a respective first radial element of the insulation system.

Description

[0091] The description is set out below with reference to the accompanying drawings which are provided solely for purposes of illustration without restricting the scope of the invention and in which:

[0092] FIG. 1 illustrates a detail of a stator according to the disclosure in a schematic perspective view;

[0093] FIG. 2 illustrates a detail of a stator according to the disclosure in a schematic plan view;

[0094] FIG. 3 illustrates a detail of a stator according to the disclosure in a schematic perspective view;

[0095] FIG. 4 illustrates a detail of a stator according to the disclosure in a schematic perspective view;

[0096] FIG. 5 illustrates a detail of an electric motor according to the disclosure in a schematic cross sectional view;

[0097] FIG. 6 illustrates a detail of an electric motor according to the disclosure in a schematic perspective view;

[0098] FIG. 7 illustrates a detail of an electric motor according to the disclosure in a schematic perspective view;

[0099] FIG. 8 illustrates a detail of a stator according to the disclosure in a schematic plan view.

[0100] With reference to FIG. 5, the numeral 100 denotes a permanent magnet brushless electric motor according to this disclosure.

[0101] The motor 100, having an axis of rotation, basically comprises a casing 101, a cap, not illustrated, for covering the casing 101, a stator, integral with the casing 101, a rotor and a drive circuit which are not illustrated and which are mounted in an enclosure delimited by the casing 101 and the cap.

[0102] In an embodiment, the enclosure is of the sealed type and the motor 100 is a sealed motor.

[0103] In an embodiment, the enclosure is provided, for example, with ventilation holes and the motor 100 is an open motor.

[0104] The motor 100 comprises a stator 1 according to this disclosure.

[0105] The stator 1 is a compact, concentrated winding stator.

[0106] The stator 1 comprises a ferromagnetic core 2, with a central axis A, preferably formed of a plurality of plates superposed along the axis A, not shown in the drawings.

[0107] The ferromagnetic core has an outer portion, having the shape of an annular crown 3, and a plurality of teeth 4a jutting radially from the crown 3 towards the axis A.

[0108] The teeth 4a are without pole shoe and delimit slots 4b.

[0109] The annular crown 3 and the teeth 4a form a compact, uninterrupted structure, in particular along the annular crown which extends uninterruptedly without breaks around the axis A.

[0110] Each tooth 4a has a radial length L1, an axial depth L2 and a width L3 orthogonal to the radial length L1 and axial depth L2.

[0111] In practice, the depth L2 corresponds to the length of the ferromagnetic core 2 measured along the axis A.

[0112] The ratio between the slot pitch, namely the distance between the centre lines or bisectors of two adjacent slots 4b, and the width L3 of the tooth is between 1.2 and 1.5.

[0113] In an embodiment, the ratio between the slot pitch and the width L3 of the tooth 4a is between 1.3 and 1.4.

[0114] In an embodiment, the ratio between the width L3 of the tooth and the axial depth L2 of each tooth 4a is between 0.2 and 3.

[0115] Preferably, the ratio between the width L3 of the tooth and the axial depth L2 of each tooth 4a is between 0.7 and 1.5.

[0116] In an embodiment, the ratio between the width L3 of the tooth and the axial depth L2 of each tooth 4a is 1.

[0117] In a preferred embodiment, the teeth 4a are identical.

[0118] Preferably, the teeth 4a are rectangular in shape in their cross section orthogonal to the central axis A.

[0119] At least in this embodiment, the stator 1 is preferably intended for what are known as “flat electric motors” normally used in the automotive engine cooling sector. In these applications, the ratio between the width L3 and the axial depth L2 of each tooth 4a is close to an optimum value equal to 1.

[0120] The stator 1 comprises an electrical insulation system 5, preferably thermally conductive, disposed on the ferromagnetic core 2 to insulate it from the electrical windings normally present.

[0121] The insulation system 5 comprises a first portion 6 and a second portion 7, disposed on opposite sides of the ferromagnetic core 2 along the central axis A.

[0122] The portion 6 comprises a plurality of radial elements 8 which, on each tooth 4a, extend from the annular crown 3 towards the central axis A.

[0123] The portion 7 comprises a plurality of radial elements 9 which, on each tooth 4a, extend from the annular crown 3 towards the central axis A.

[0124] In an embodiment, the insulation system 5 is overmoulded on the ferromagnetic core 2.

[0125] As illustrated by way of example, the insulation system 5 covers the ferromagnetic core 2 completely, at least at the teeth 4a.

[0126] The ferromagnetic core 2, together with the overmoulded insulation system 5, have, at each radial section, a predetermined total height H, measured along the central axis A.

[0127] At any one given section of the assembly formed of the ferromagnetic core 2 and the insulation system 5 overmoulded on the core 2, the height of the overmoulding, measured along the axis A, has one or more predetermined values independently of the height of the ferromagnetic core 2 alone at the same radial section.

[0128] That way, regardless of the height of the core 2, which may be influenced, even significantly, by the plate tolerances, the assembly formed of the core 2 and the insulation system has predetermined constant values.

[0129] In an embodiment, the portion 6 of the insulation system 5 has, at each radial section, a predetermined height H1, measured along the central axis A, independent of the height of the ferromagnetic core 2 alone.

[0130] In practice, during the step of overmoulding the insulation system 5, the height H1 of the portion 6 is kept constant and the height of the portion 7 is compensated accordingly so that the total height H of the insulation system 5 is also kept constant.

[0131] The insulation system 5 has a built-in winding locking system 10.

[0132] The locking system 10 is preferably provided in the portion 6 of the insulation system 5.

[0133] In an embodiment, illustrated by way of example in FIG. 4, the elements 8 each comprise a base surface 11.

[0134] The elements 8 comprise a protrusion 12 jutting axially from the base surface 11.

[0135] The protrusion 12 at least partly surrounds the surface 11 and, in practice, delimits a space or recess.

[0136] In a preferred embodiment, the protrusion 12 comprises an arm 13 which extends radially for at least part of the length L1 of the tooth 4a.

[0137] In the example illustrated, the protrusion 12 comprises two parallel arms 13.

[0138] In a preferred embodiment, the protrusion 12 comprises an arm 14 which extends radially for at least part of the length L3 of the tooth 4a.

[0139] In the example illustrated, the arms 13 and 14 are uninterrupted. In a preferred embodiment, the protrusion 12 has the shape of an L.

[0140] The stator 1 comprises a plurality of phase wires 15 disposed on the ferromagnetic core 2, specifically on the radial elements 8, 9 of the insulation system 5 to be electrically insulated from the core 2.

[0141] The wires 15 are wound to define a plurality of coils 16, each placed on the corresponding tooth 4a; the set of coils 16 defines what is known as the stator winding.

[0142] Preferably, the coils 16 are self-supporting.

[0143] Each coil 16 is formed of a predetermined total number N of turns.

[0144] The number of turns for each coil 16 and the cross section of the wires 15 are determined in substantially known manner at the motor design stage, in particular as a function of the expected performance of the motor.

[0145] The radial and axial dimensions of the stator teeth and the diameter of the wires, for example, contribute to determining the number of turns per coil.

[0146] Each coil 16 has two end faces 17, 18 aligned with each other along a direction parallel to the axis A.

[0147] The end faces 17, 18 each lie in a plane perpendicular to the axis A.

[0148] In an embodiment, the wire 15 of each coil 16 can be extended in such a way as to have elongated ends 15a, 15b that can be used to make the terminations of the winding and/or the connections between the coils 16.

[0149] In a preferred embodiment, the coils 16 are made in a single layer.

[0150] As illustrated, the coils 16 comprise a single conductive layer 15.

[0151] In a preferred embodiment, the coils are made from a wire 15 having a substantially rectangular or square cross section—that is to say, a wire commonly known as “ribbon wire”.

[0152] Advantageously, the use of ribbon wire to make single-layer coils allows making the most of the area available in the slot by changing the shape ratio of the wire with the same slot filling factor, even to make different versions of the same motor for different supply voltages.

[0153] FIG. 8 shows, for example, a coil 16a and a coil 16b which has twice as many turns as the coil 16a for the same coil size.

[0154] For example, the coil 16a is a coil of a 12 Volt stator and the coil 16b is a coil of a 24 Volt motor obtained, in particular, by keeping the single-layer winding and the coils connected in series.

[0155] In an embodiment, the coils are made with two or more superposed wire layers. In the case of coils wound in two or more layers, the wire 15 preferably has a circular cross section.

[0156] The wire with circular cross section allows the surface facing the casing to be kept wide and flat.

[0157] FIG. 8 shows a compact, self supporting multilayer coil 16c.

[0158] A multilayer coil 16c is used typically in higher voltage motors, for example, 400 or 800 Volts.

[0159] In an embodiment, the multilayer coil 16c is preferably made with self-bonding wire—that is to say, wire provided with a self-bonding covering.

[0160] In an embodiment, the compact, self supporting coil 16c is made with technologies that allow obtaining these features—by way of non-limiting example, by impregnating the coil in resin.

[0161] The coils 16a, 16b and 16c occupy substantially the same space in the slot 4b.

[0162] In a preferred embodiment, the winding of the stator 1 is three-phase and the coils 16 of each phase are connected in series.

[0163] In an embodiment, the electric insulation system 5 comprises insulating vanes 201, disposed at the entrance of the slots 4b. The vanes 201 extend along the axis A and serve to ensure electric insulation between adjacent coils 16. In proximity to the opening of the slot 4b, adjacent coils 16 are very close, owing to the preferred dimensional ratio between the teeth 4a and the slot pitch.

[0164] In a preferred embodiment, the face 17 of each coil 16 is plastically deformed to engage the respective tooth 4a and the locking system 10.

[0165] As illustrated for example in FIG. 7, the face 17 is positioned on a respective radial element 8 of the insulation system and is plastically deformed towards the base surface 11.

[0166] In practice, once the coil 16 has been fitted to the respective tooth 4a, the face 17 is deformed in such a way as to be at least partly inserted into the recess delimited by the protrusion 12.

[0167] Each coil is stationary relative to the insulation system 5, hence relative to the ferromagnetic core 2, since it is locked by the respective protrusion 12.

[0168] More specifically, the arm 14 stops it from moving radially, while the arms 13 stop it from moving tangentially.

[0169] In an embodiment, the insulation system 5—preferably, the portion 6 thereof—is provided, at each tooth 4a, with a groove 19 where the insulation system does not cover the ferromagnetic core 2.

[0170] The groove 19 defines a reference for a tool used to form the coils and place them in the stator.

[0171] In an embodiment, the insulation system 5 comprises, for each tooth 4a, a first and a second flank 20, 21, connecting the radial element 8 with the corresponding radial element 9 to form an insulating tube.

[0172] In an embodiment, the coils 16 are wound on the respective insulating tube which is then placed over a corresponding tooth 4a.

[0173] In use, the stator 1 is inserted in the casing 101.

[0174] The casing 101 comprises a side wall 102 and a base wall 103 which define a cup-like structure.

[0175] The motor 100 comprises a spacer 104 which is interposed between the stator 1 and the base wall 103.

[0176] The spacer 104, which is made of a thermally conductive material, is provided with openings 105 at the coils 16 so that the coil faces 18 can be placed in heat exchange relationship with the casing wall 103, for example by placing a thermally conductive, electrically insulating paste between them. In an embodiment, the openings 105 are in the form of recesses in a radially inner edge and/or in a radially outer edge of the spacer 104.

[0177] In an embodiment, in the case of coils 16 wound on a respective tube and then fitted to the tooth 4a, the coils are locked in place when the stator 1 is locked against the base wall 103 of the casing.

[0178] In an embodiment, the tube may be fitted to the tooth by a snap-on system, for example, comprising a protrusion on the tooth flank and a recess on the inside of the tube.

[0179] A method for assembling a stator 1 comprises a step of winding the coils 16 outside the ferromagnetic core 2.

[0180] The method comprises a step of fitting each coil 16 to the respective tooth 4a.

[0181] Preferably, the coils have a compact, self-supporting structure so they can be wound outside the stator and then fitted to the tooth.

[0182] In an embodiment, the method comprises a step of plastically deforming the face 17 of each coil 16 in such a way that the face 17 is at least partly inserted into the cavity delimited by the protrusion 12.

[0183] Preferably, the method comprises a step of holding the coil during the step of plastically deforming it.

[0184] The step of fitting each coil 16 to the respective tooth 4a comprises a step of axially and angularly aligning each coil relative to the tooth 4a, for example using the reference grooves 19.

[0185] In an embodiment, the method comprises a step of overmoulding the insulation system 5 on the ferromagnetic core 2.

[0186] Preferably, the step of overmoulding comprises a step of aligning the ferromagnetic core 2 at a fixed height in a mould, taking the groove 19 as a reference.

[0187] That way, any deviations from the axial height of the ferromagnetic core 2 determine a variation in the thickness of the overmoulding in the portion of the insulation system opposite to that where the groove 19 is formed.

[0188] In an embodiment, the method comprises a step of winding each coil 16 on a respective tube and a step of fitting the tubes, with the coils 16 on them, to the teeth of the ferromagnetic core 2.