METHOD FOR PRODUCING A WINDING OVERHANG ASSEMBLY FOR AN ELECTRICAL ROTATING MACHINE

Abstract

In a method for producing a winding overhang assembly for an electrical rotating machine, an insulating main body is produced at least partly from a dielectric material. Each of a plurality of conductors of a metal material is connected to the insulating main body via an intermediate layer, which is produced from a material which is different from the dielectric material of the insulating main body and from the metal material of the conductors and which is produced from silver, aluminum, antimony, magnesium, tin, zinc, lead, tantalum or from a mixture and/or from at least one alloy thereof. The conductors are hereby sprayed onto the intermediate layer by a thermal spraying method.

Claims

1.-18. (canceled)

19. A method for producing a winding overhang assembly for an electrical rotating machine, said method comprising: producing an insulating main body at least partly from a dielectric material; connecting each of a plurality of conductors of a metal material to the insulating main body via an intermediate layer; producing the intermediate layer from a material which is different from the dielectric material of the insulating main body and from the metal material of the conductors and which is produced from silver, aluminum, antimony, magnesium, tin, zinc, lead, tantalum or from a mixture and/or from at least one alloy thereof; and spraying the conductors onto the intermediate layer by a first thermal spraying method.

20. The method of claim 19, wherein the conductors are sprayed onto the intermediate layer by cold gas spraying as the first thermal spraying method.

21. The method of claim 19, wherein the intermediate layer is connected to the insulating main body by a positive connection.

22. The method of claim 19, wherein the intermediate layer is sprayed onto the insulating main body by a second thermal spraying method, in particular by means of cold gas spraying, with the second thermal spraying method differing from the first thermal spraying method.

23. The method of claim 22, wherein the second thermal spraying method differs from the first thermal spraying method with regard to speed and/or size of particles used in the first and second thermal spraying methods.

24. The method of claim 19, further comprising arranging the intermediate layer at least partly in grooves of the insulating main body.

25. The method of claim 24, wherein the grooves of the insulating main body have a profile to effect a positive connection between the intermediate layer and the insulating main body.

26. The method of claim 19, further comprising applying an electrical insulation onto the conductors to prevent short-circuiting of the conductors.

27. The method of claim 19, further comprising arranging cooling channels in the insulating main body.

28. The method of claim 19, further comprising arranging the conductors in at least two planes, in particular in at least two planes which are arranged behind one another in an axial direction.

29. The method of claim 28, further comprising connecting the conductors in the at least two planes to one another via connecting elements.

30. The method of claim 19, wherein the dielelectric material of the insulating main body has a dielelectric strength of at least 10 kV/mm.

31. The method of claim 19, wherein the metal material of the conductors has an electrical conductivity which is higher than an electrical conductivity of the material of the intermediate layer and/or the metal material of the conductors has a strength which is higher than a strength of the material of the intermediate layer.

32. A winding overhang assembly for an electrical rotating machine, comprising: an insulating main body made at least partly from a dielectric material; and a plurality of conductors made of a metal material and connected to the insulating main body via an intermediate layer from a material which differs from the dielectric material of the insulating main body and from the metal material of the conductors, with the conductors being sprayed onto the intermediate layer by a thermal spraying method, and with the intermediate layer being made from silver, aluminum, antimony, magnesium, tin, zinc, lead, tantalum or from a mixture and/or from at least one alloy thereof.

33. The winding overhang assembly of claim 32, wherein the intermediate layer is arranged at least partly in grooves of the insulating main body, said grooves of the insulating main body having a profile to effect a positive connection between the intermediate layer and the insulating main body.

34. The winding overhang assembly of claim 32, wherein the conductors are arranged in at least two planes, and, further comprising connecting elements configured to connect the conductors in the at least two planes to one another.

35. A stator for an electrical rotating machine, said stator comprising: a magnetic field-guiding stator element; and a winding overhang assembly arranged at an axial end of the magnetic field-guiding stator element, said winding overhang assembly comprising an insulating main body made at least partly from a dielectric material, and a plurality of conductors made of a metal material and connected to the insulating main body via an intermediate layer from a material which differs from the dielectric material of the insulating main body and from the metal material of the conductors, with the conductors being sprayed onto the intermediate layer by a thermal spraying method, and with the intermediate layer being made from silver, aluminum, antimony, magnesium, tin, zinc, lead, tantalum or from a mixture and/or from at least one alloy thereof.

36. The stator of claim 15, further comprising coil rods arranged at least partly in the magnetic field-guiding stator element and connected to the conductors of the winding overhang assembly.

37. The stator of claim 36, wherein the conductors are arranged essentially perpendicular to the coil rods.

38. An electrical rotating machine, comprising a stator as set forth in claim 35.

Description

[0033] The invention is described and explained in more detail hereinafter with reference to the exemplary embodiments shown in the figures.

[0034] The figures show:

[0035] FIG. 1 A longitudinal section of an electrical rotating machine,

[0036] FIG. 2 A three-dimensional representation of a winding overhang assembly for an electrical rotating machine,

[0037] FIG. 3 An enlarged cross-section of a first embodiment of a winding overhang assembly,

[0038] FIG. 4 A cross-section of conductors of a winding overhang assembly,

[0039] FIG. 5 A diagrammatic view of a method for producing a winding overhang assembly,

[0040] FIG. 6 An enlarged cross-section of a second embodiment of a winding overhang assembly,

[0041] FIG. 7 An enlarged cross-section of a third embodiment of a winding overhang assembly.

[0042] The exemplary embodiments explained hereinafter are preferred embodiments of the invention. In the exemplary embodiments, the described components of the embodiments each represent individual features of the invention which are to be considered independently of one another, which also develop the invention independently of one another and are therefore also to be regarded as part of the invention individually or in a combination other than the combination shown. Furthermore, the described embodiments can also be supplemented by further features of the invention already described.

[0043] The same reference characters have the same meaning in the various figures.

[0044] FIG. 1 shows a longitudinal section of an electrical rotating machine 2 which is designed as a synchronous machine by way of example. The synchronous machine has a rotor 6 which can be rotated about a rotation axis 4 and is designed as a salient pole rotor by way of example, and a stator 8 surrounding the rotor 6. Between the rotor 6 and the stator 8 there is a gap 10, which is designed in particular as an air gap. The rotation axis 4 defines an axial direction, a radial direction, and a circumferential direction. The rotor 6 comprises a shaft 12 and salient poles 14 with an excitation winding 16. Alternatively, the rotor 6 has permanent magnets or a squirrel cage.

[0045] The stator 8 comprises a magnetic field-guiding, in particular eddy current-suppressing, stator element 18 which is designed, for example, as a laminated core, and a stator winding 20. The stator winding 20 comprises coil rods 22 which are produced, for example, from copper and run in the axial direction through the magnetic field-guiding stator element 18. The axial ends of the coil rods 22 are each connected to a winding overhang assembly 24. Connections of the stator winding 20, for example to a terminal box, are not shown for reasons of clarity.

[0046] FIG. 2 shows a three-dimensional representation of a winding overhang assembly 24 for an electrical rotating machine 2. The winding overhang assembly 24 comprises, for example, two planes E1, E2 arranged one behind the other in the axial direction and each having an insulating main body 26, 28. The winding overhang assembly 24 is provided for a two-layer winding. The insulating main body 26, 28 essentially has a hollow cylindrical shape and is produced from a dielectric material, for example from a plastic or a ceramic material, with a dielelectric strength of at least 10 kV/mm. Each plane is assigned a plurality of conductors 30, the conductors 30 being connected to the respective insulating main body 26, 28. The conductors 30 have, for example, a rectangular or square conductor cross-section and are produced from a metal material, in particular copper, with a conductivity of at least 50 MS/m. Metallic connecting sections 32 are arranged on the conductors 30 in order to establish a connection of the conductors 30 to the respective coil rods 22. Furthermore, the conductors 30 of the respective planes E1, E2 are connected via electrically conductive connecting elements 34. For example, the connecting elements 34 are produced from copper. The further embodiment of the winding overhang assembly 24 in FIG. 2 corresponds to that in FIG. 1.

[0047] FIG. 3 shows an enlarged cross-section of a first embodiment of a winding overhang assembly 24. The conductors 30 are connected to the respective insulating main body 26, 28 by means of at least one intermediate layer 36 each, the intermediate layer 36 forming a conductor foundation and being connected to the respective insulating main body 26, 28 by means of a positive connection. The intermediate layer 36 is produced from a material which differs from the dielectric material of the respective insulating main body 26, 28 and from the metal material of the conductors 30. The intermediate layer 36 is produced, for example, from silver, aluminum, antimony, magnesium, tin, zinc, lead, tantalum or from a mixture and/or from at least one alloy thereof. Optionally, the intermediate layer 36 has additional fillers such as, for example, a ceramic material.

[0048] The conductors 30 are produced from electrically conductive solid particles which are sprayed on by means of a first thermal spraying method, in particular by means of cold gas spraying. The electrically conductive solid particles contain, for example, copper, wherein electrical conductivity of at least 50 MS/m is achieved by means of the first thermal spraying method.

[0049] The intermediate layer 36 is likewise produced from electrically conductive solid particles which are sprayed onto the insulating main body 26, 28 by means of a second thermal spraying method, in particular by means of cold gas spraying, wherein the second thermal spraying method differs from the first thermal spraying method. In particular, the second thermal spraying method differs from the first thermal spraying method with regard to the type of particles used, the speed of the particles and/or the size of the particles. Alternatively, the intermediate layer 36 is produced by means of another method, for example by means of casting or by means of a galvanic method. The further embodiment of the winding overhang assembly 24 in FIG. 3 corresponds to that in FIG. 2.

[0050] FIG. 4 shows a cross-section of conductors 30 of a winding overhang assembly 24, wherein the conductors 30 are each connected to an insulating main body 26 by means of an intermediate layer 36. The intermediate layer 36 is arranged in grooves 38 of the insulating main body 26 in each case. The grooves 38 have a profile 40 by means of which a positive connection is produced with the insulating main body 26. In particular, the groove 38 is profiled tapering toward the outside in order to ensure a positive connection between the respective intermediate layer 36 and the insulating main body 26. For example, the groove 38 is designed as a hammer head groove or as a dovetail groove. The further embodiment of the winding overhand assembly 24 in FIG. 4 corresponds to that in FIG. 3.

[0051] FIG. 5 shows a diagrammatic view of a method for producing a winding overhang assembly 24, an insulating main body 26 made of a dielectric material with grooves 38 first being provided. The grooves have a profile 40 by means of which a protrusion of the dielectric material of the insulating main body 26, for example in the area of an opening of the groove 38, is produced.

[0052] In a further step, an intermediate layer 36 which is essentially flush with a surface 42 of the insulating main body 26 is arranged in the grooves. The intermediate layer 36 is sprayed onto the insulating main body 26 by means of a second thermal spraying method, in particular by means of cold gas spraying. In order to homogeneously fill the groove 38 despite the profile 40, the particles of the second thermal spraying method are sprayed into the respective groove 38 from different directions. Alternatively, the intermediate layer 36 is introduced into the grooves 38 in a different manner, for example by means of casting or by means of a galvanic method.

[0053] In a further step, conductors 30 are sprayed onto the intermediate layer 36 by means of a first thermal spraying method, in particular by means of cold gas spraying. In particular, when particles of copper are used, which are sprayed onto the intermediate layer 36 by means of cold gas spraying, the intermediate layer 36 allows better adhesion and a greater particle density as the particles can be sprayed onto the intermediate layer 36 at a greater speed than onto the insulating main body 26. In addition to improved stability, the use of an intermediate layer 36 for the conductors 30 results in greater electrical conductivity. In a further step not shown in FIG. 5, electrical insulation is at least applied to the conductors 30. The further embodiment of the winding overhang assembly 24 in FIG. 5 corresponds to that in FIG. 4.

[0054] FIG. 6 shows an enlarged cross-section of a second embodiment of a winding overhang assembly 24. The conductors 30 are connected on both sides to an insulating main body 26 by means of an intermediate layer 36 each, wherein in each case one side of the insulating main body 26 forms a plane E1, E2 with the respective intermediate layers 36 and conductors 30 connected thereto. The conductors 30 of the planes E1, E2 are connected to one another by means of electrically conductive connecting elements 34 which are produced, for example, from copper. Furthermore, the winding overhang assembly 24 has at least one cooling channel 46 in order to cool the current-carrying conductors 30 of the winding overhang assembly 24 on both sides by means of a cooling fluid flow flowing through the at least one cooling channel 46. For example, the at least one cooling channel 46 is arranged in the axial direction. Additionally, or alternatively, the at least one cooling channel 46 is arranged at least partly in the radial direction. Air, process gas, water, oil, or other liquid and/or gaseous cooling media can be used as cooling fluid. The further embodiment of the winding overhang assembly 24 in FIG. 6 corresponds to that in FIG. 5.

[0055] FIG. 7 shows an enlarged cross-section of a third embodiment of a winding overhang assembly 24 comprising two planes E1, E2 arranged one behind the other in the axial direction with an insulating main body 26, 28 in each case. The insulating main bodies 26, 28 have cooling channels 46, at least one cooling channel 46 of the first insulating main body 26 being fluidically connected to at least one cooling channel 46 of the second insulating main body 28. The further embodiment of the winding overhang assembly 24 in FIG. 7 corresponds to that in FIG. 6.

[0056] In summary, the invention relates to a method for producing a winding overhang assembly 24 for an electrical rotating machine 2. In order to provide a winding overhang assembly 24 which, in comparison with the prior art, can be produced more simply and more economically, it is proposed that the winding overhang assembly 24 have at least one insulating main body 26, 28 which is produced at least partly from a dielectric material, a plurality of conductors 30 made of a metal material being connected to the insulating main body 26, 28 by means of at least one intermediate layer 36 each, the intermediate layer 36 being produced from a material different from the dielectric material and from the metal material, and the conductors 30 being sprayed onto the intermediate layer 36 by means of a first thermal spraying method.