Claw Pole Stator for a Transverse Flux Machine

Abstract

The invention relates to a claw pole stator (1) for a transverse flux machine (2). The claw pole stator (1) is made of a plurality of segments (3) that are arranged next to one another along a circumferential direction (4) so as to form the annular claw pole stator (1). Each segment (3) extends from an inner circumferential surface (5) along a radial direction (6) to an outer circumferential surface (7) and is delimited by a first lateral surface (8) and a second lateral surface (9) in the circumferential direction (4) and by a first end surface (11) and a second end surface (12) in an axial direction (10). Each segment (3) is connected to additional segments (3) via the lateral surfaces (8, 9) in order to form the annular claw pole stator (1), and adjacent segments (3) contact one another via a first contact surface (13) on the first lateral surface (8) or via a second contact surface (14) on the second lateral surface (9) and form a connection (15) which is interlocking in the circumferential direction (4) via the contact surfaces (13, 14).

Claims

1. A claw pole stator for a transverse flux machine, wherein the claw pole stator is formed by a multiplicity of segments which are disposed next to one another along a circumferential direction; wherein each segment, proceeding from an internal circumferential face, along a radial direction extends to an external circumferential face and in the circumferential direction is delimited by a first lateral face and a second lateral face, and in an axial direction is delimited by a first end face and a second end face; each segment by way of the lateral faces is connected to at least one further segment, wherein segments disposed so as to be mutually adjacent contact one another by way of a first contact face on the first lateral face or by way of a second contact face on the second lateral face and by way of the contact faces configure a connection which is form-fitting in the circumferential direction and in the radial direction; wherein a first clearance of the connection, present in the circumferential direction, is larger than a second clearance of the connection, present in the radial direction.

2. The claw pole stator as claimed in claim 1, wherein the second clearance is at most 50% of the first clearance.

3. The claw pole stator as claimed in claim 1, wherein the claw pole stator is configured so as to be encircling in the circumferential direction, and as a largest nominal diameter has a largest first diameter, wherein the claw pole stator as a result of the first clearance is deformable such that a largest second diameter of the deformed claw pole stator deviates from the first diameter by at least 2%.

4. The claw pole stator as claimed in claim 1, wherein each segment comprises a plurality of poles.

5. The claw pole stator as claimed in claim 1, wherein each segment has exactly one pole.

6. The claw pole stator as claimed in claim 1, wherein each of the segments is produced by powder metallurgy by pressing and heat-treating.

7. The claw pole stator as claimed in claim 1, wherein the claw pole stator is formed exclusively by identically embodied segments.

8. The claw pole stator as claimed in claim 1, wherein the segments at least conjointly with the external circumferential face or the internal circumferential face of the segments form a cylindrical contour, wherein a circumferential face of the external circumferential face and the internal circumferential face is formed by the poles of the segments.

9. A stator assembly, at least comprising a claw pole stator as claimed in claim 1 and a stator carrier, wherein the claw pole stator is disposed on the stator carrier, the latter at least in terms of an internal diameter or an external diameter of the claw pole stator predefining a nominal shape of the claw pole stator.

10. The stator assembly as claimed in claim 9, wherein a gap between at least two segments is at least partially filled by an at least electromagnetically conducting first material.

11. The stator assembly as claimed in claim 9, wherein the segments are at least partially encompassed by a second material such that a nominal shape of the claw pole stator is set by the second material.

12. A segment for a claw pole stator as claimed in claim 1, wherein the segment, proceeding from an internal circumferential face, along a radial direction extends to an external circumferential face, and in a circumferential direction is delimited by a first lateral face and a second lateral face, and in an axial direction is delimited by a first end face and a second end face; wherein the segment by way of the lateral faces is able to be connected to at least one further segment; wherein segments which are able to be disposed so as to be mutually adjacent contact one another by way of a first contact face of the first lateral face or by way of a second contact face of the second lateral face; wherein the contact faces are shaped such that a connection, which is form-fitting in the circumferential direction, to a contact face shaped in a complementary manner of a segment, the latter being able to be disposed so as to be adjacent, is in each case able to be configured by way of the contact faces.

13. The segment as claimed in claim 12, wherein at least one of the contact faces extends so as to be parallel to the axial direction.

14. A transverse flux machine, at least comprising a stator and a rotor, wherein the stator comprises at least two claw pole stators as claimed in claim 1, wherein poles of the first claw pole stator and poles of the second claw pole stator are disposed in an alternating manner and in each case mutually adjacent along the circumferential direction, and disposed so as to mutually overlap in the axial direction.

Description

[0060] FIG. 1: shows a segment in a first perspective view;

[0061] FIG. 2: shows the segment as per FIG. 1 in a second perspective view;

[0062] FIG. 3: shows the segment as per FIGS. 1 and 2 in a lateral view;

[0063] FIG. 4: shows a claw pole stator in a perspective view;

[0064] FIG. 5: shows the claw pole stator as per FIG. 4 in a view from below along the axial direction;

[0065] FIG. 6: shows the segment as per FIGS. 1 to 3 in a view from above along the axial direction;

[0066] FIG. 7: shows a form-fitting connection of two segments of the claw pole stator as per FIGS. 4 and 5 in a view from below along the axial direction;

[0067] FIG. 8: shows a form-fitting connection of two segments of another claw pole stator in a view from below along the axial direction;

[0068] FIG. 9: shows an illustration of a magnetic flux through a fragment of a claw pole stator as per FIG. 8 in a view of the claw pole stator from below along the axial direction;

[0069] FIG. 10: shows a detail of FIG. 9;

[0070] FIG. 11: shows a detail of FIG. 10;

[0071] FIG. 12: shows a sectional illustration of a first variant of embodiment of a stator assembly in a lateral view;

[0072] FIG. 13: shows a sectional illustration of a second variant of embodiment of a stator assembly in a lateral view;

[0073] FIG. 14: shows the stator assembly as per FIG. 12 in a perspective sectional view;

[0074] FIG. 15: shows the stator assembly as per FIGS. 12 and 14 in a perspective view; and

[0075] FIG. 16: shows the stator assembly as per FIGS. 12, 14 and 15, here having a second material, in a perspective view.

[0076] FIG. 1 shows a segment 3 in a first perspective view. FIG. 2 shows the segment 3 as per FIG. 1 in a second perspective view. FIG. 3 shows a segment 3 as per FIGS. 1 and 2 in a lateral view. FIGS. 1 to 3 will be conjointly described hereunder.

[0077] The segment 3, proceeding from an internal circumferential face 5, along a radial direction 6 extends to an external circumferential face 7 and in the circumferential direction 4 is delimited by a first lateral face 8 and a second lateral face 9, and in an axial direction 10 is delimited by a first end face 11 and a second end face 12. The segment 3 by way of the lateral faces 11 is able to be connected to further segments 3 so as to form the annular claw pole stator 1, wherein segments 3 disposed so as to be mutually adjacent contact one another by way of a first contact face 13 of the first lateral face 8 or by way of a second contact face 14 of the second lateral face 9. The contact faces 13, 14 are shaped such that a connection 15, which is form-fitting in the circumferential direction 4, to a contact face 14, 13 shaped in a complementary manner of a segment 3 which is able to be disposed so as to be adjacent is able to be configured by way of the contact faces 13, 14. Both contact faces 13, 14 extend so as to be parallel to the axial direction 10.

[0078] A pole 19 of the segment 3, proceeding from a base area 22, extends along the axial direction 10 and tapers herein.

[0079] Positioning aids 34 which interact with corresponding positioning aids 34 (here: elevations or depressions) on the opposite end faces 11, 12 of segments of another claw pole stator 1 disposed so as to be adjacent are provided on the end faces 11, 12 of the segments 3.

[0080] The contact faces 13, 14 extend so as to meander between a first radius 16 and a second radius 17 along the radial direction 10.

[0081] The poles 19 in the radial direction 6 are disposed outside the contact faces 13, 14.

[0082] One contact face 13, 14 is provided on each lateral face 8, 9 of the segment 3. The contact face 13, 14 comprises a partial face of the lateral face 8, 9. The contact faces 13, 14 extend in each case across the entire extent of the lateral face 8, 9 along the axial direction 10. The contact faces 13, 14 extend only across part of the extent of the lateral face 8, 9 along the radial direction 6.

[0083] The contact faces 13, 14 extend so as to meander along the radial direction 6, wherein the form-fitting connection 15 to a segment 3 which is disposed so as to be adjacent is formed by the meandering shape of the contact faces 13, 14. The contact faces 13, 14 along the meandering profile have a smallest curvature radius 18.

[0084] The contact faces 13, 14 along the meandering profile here have an exclusively curved profile. No rectilinear regions of the contact faces 13, 14 are thus provided in the radial direction 6 here. That is to say that each point of the contact faces 13, 14 along the radial direction 6 is formed by a curvature radius 18 (variable along the radial direction 6).

[0085] The contact faces 13, 14 along the meandering profile extend across a length 20 which is larger by a factor than a spacing 21 between the first radius 16 and the second radius 17 along the radial direction 6. As a result of the meandering profile, the contact faces 13, 14 are thus extended in length in the radial direction 6 (in comparison to a rectilinear profile between the first radius 16 and the second radius 17 along the radial direction 6) and are thus enlarged.

[0086] FIG. 4 shows a claw pole stator 1 in a perspective view. FIG. 5 shows the claw pole stator 1 as per FIG. 4 in a view from below along the axial direction 10. FIGS. 4 and 5 will be conjointly described hereunder. Reference is made to the explanations pertaining to FIGS. 1 to 3.

[0087] The claw pole stator 1 is formed by a multiplicity of segments 3 illustrated in FIGS. 1 to 3, said segments 3 being disposed next to one another along a circumferential direction 4 forming the annular claw pole stator 1. Each segment 3, proceeding from an internal circumferential face 5, along a radial direction 6 extends to an external circumferential face 7 and in the circumferential direction 4 is delimited by a first lateral face 8 and a second lateral face 9, and in an axial direction 10 is delimited by a first end face 11 and a second end face 12. Each segment 3 by way of the lateral faces 8, 9 is connected to further segments 3 so as to form the annular claw pole stator 1. Segments 3 disposed so as to be mutually adjacent contact one another by way of a first contact face 13 of the first lateral face 8, or by way of a second contact face 14 of the second lateral face 9, of the respective segment 3 (cf. also FIGS. 1 to 3) and by way of the contact faces 13, 14 configure a connection 15 which is form-fitting in the circumferential direction 4.

[0088] The poles 19 in the radial direction 6 are disposed outside the contact faces 13, 14.

[0089] Here, all segments 3 are embodied so as to be mutually identical such that the first segment 3 by way of the first contact face 13 thereof contacts the second segment 3 by way of the second contact face 14 thereof. The same then applies in an analogous manner to the other second lateral face 9 of the first segment 3 and to the second contact face 14 disposed thereon.

[0090] The claw pole stator 1 is configured so as to be encircling in the circumferential direction 4 and as a largest nominal diameter has a largest first diameter 29, wherein the claw pole stator 1 as a result of the first clearance 24 (cf. FIG. 7) is deformable such that a largest second diameter 30 (indicated in FIG. 5) of the deformed claw pole stator 1 deviates from the first diameter 29 by a minimum dimension.

[0091] FIG. 6 shows the segment 3 as per FIGS. 1 to 3 in a view from above along the axial direction 10. Reference is made to the explanations pertaining to FIGS. 1 to 5.

[0092] The larger first clearance 24 enables that a lower requirement can be set in terms of the tolerance of the segments 3 in the production of the segments 3. A first tolerance 41 in terms of the circumferential direction 4 can thus be enlarged in comparison to the second tolerance 42 in terms of the radial direction 6.

[0093] FIG. 7 shows a form-fitting connection 15 of two segments 3 of the claw pole stator 1 as per FIGS. 4 and 5, in a view from below along the axial direction 10. FIG. 8 shows a form-fitting connection 15 of two segments 3 of another claw pole stator 1 in a view from below along the axial direction 10. FIGS. 7 and 8 will be conjointly described hereunder. Reference is made to FIGS. 1 to 6.

[0094] As can be seen, the poles 19 of the other claw pole stator 1 are disposed on an internal circumferential face 5 of each segment 3.

[0095] The first clearance 24 between the adjacent segments 3 enables a mutual relative displacement of the segments 3 along the circumferential direction 4. The second clearance 25 between the adjacent segments 3 enables a smaller mutual relative displacement of the segments 3 along the radial direction 6.

[0096] Both claw pole stators 1 are configured so as to be encircling in the circumferential direction 4 and as a largest nominal diameter have a largest first diameter 29, wherein the claw pole stator 1 as a result of the first clearance 24 is deformable such that a largest second diameter 30 of the deformed claw pole stator 1 deviates from the first diameter 29. It is illustrated in FIG. 8 that the second diameter 30 in the case of pulled-apart segments 3 is larger than the first diameter 29.

[0097] As a result of the segments 3 being pulled apart or pushed together, and of adjusting a second diameter 30, the annular claw pole stator 1 can be more easily disposed on a stator carrier 32, for example be pushed on along an axial direction 10, for example while assembling the claw pole stator 1 or a stator assembly 31, respectively. The nominal diameter of the claw pole stator 1 upon the push-fitting or the disposing of the latter is then predefined by the stator carrier 32, for example, on which the claw pole stator 1 is then disposed, optionally without a clearance or a gap, respectively, by varying the first clearance 24.

[0098] A contact face 13, 14 in the region of the second clearance 25 runs substantially along the circumferential direction 4 and here parallel to the axial direction 10 and transversely to the radial direction 6.

[0099] A contact face 13, 14 in the region of the first clearance 24 runs substantially along the radial direction 6 and here parallel to the axial direction 10 and transversely to the circumferential direction 4.

[0100] A gap 33 arising, for example as a result of the first clearance 24, between the contact faces 13, 14 of two adjacent segments 3 can be filled by an at least electromagnetically conducting first material 35.

[0101] FIG. 9 shows an illustration of a magnetic flux 43 through a fragment of a claw pole stator 1 as per FIG. 8, in a view of the claw pole stator 1 from below along the axial direction 10 (thus viewed from the base area 22, or from the second end face 12, respectively). FIG. 10 shows a detail of FIG. 9. FIG. 11 shows a detail of FIG. 10. FIGS. 9 to 11 will be conjointly described hereunder. Reference is made to the explanations pertaining to FIGS. 1 to 8.

[0102] The flow direction 44 of the magnetic flux 43 through the claw pole stator 1 in the operation of the transverse flux machine 2 is illustrated in FIGS. 9 to 11. As can be seen, the flow direction 44 in the region of the contact faces 13, 14 and of the form-fitting connection 15 of the segments 3 runs primarily along the radial direction 6.

[0103] In the proposed disposal of the first clearance 24 (effective in the circumferential direction 4) and the smaller second clearance 25 (effective in the radial direction 6) it can be taken into account that only minor gaps 33 result between adjacent segments 3 in those regions that are passed through by the magnetic flux 43. To be taken into account here is the profile (the flow direction 44) of the magnetic flux 43 that arises in the operation of the claw pole stator 1.

[0104] It is highlighted in FIG. 11 that contact faces 13, 14 in the region of the second clearance 25 run substantially along the circumferential direction 4 and here parallel to the axial direction 10 and transversely to the radial direction 6. The only minor second clearance 25 ensures that no gaps 33, or only very small gaps 33, arise in these regions such that the magnetic flux 43 can be directed from one segment 3 to another segment 3 ideally without losses.

[0105] FIG. 12 shows a sectional illustration of a first variant of embodiment of a stator assembly 31 in a lateral view. FIG. 13 shows a sectional illustration of a second variant of embodiment of a stator assembly 31 in a lateral view. FIGS. 12 and 13 will be conjointly described hereunder. Reference is made to the explanations pertaining to FIGS. 1 to 8.

[0106] The stator assembly 31 comprises a plurality of (here six) claw pole stators 1, wherein a coil 40 that runs in the circumferential direction 4 is in each case disposed between two claw pole stators 1 which contact one another by way of the first end faces 11 thereof, the poles 19 of said two claw pole stators 1 being disposed next to one another along the circumferential direction 4 and here so as to mutually overlap in the axial direction 10. The stator assembly 31 furthermore comprises a stator carrier 32 on which the claw pole stators 1 are disposed. The stator carrier 32 predefines a nominal shape of the claw pole stators 1 in terms of an internal diameter (the latter extending between the internal circumferential face 5 of the claw pole stators 1). The claw pole stators 1 are pushed onto the stator carrier 32 as per FIG. 12 along the axial direction 10. To this end, the stator carrier 32 has a purely cylindrical external shape, the internal circumferential face 5 of the claw pole stators 1 bearing on said purely cylindrical external shape.

[0107] It is illustrated in FIG. 13 that the stator carrier 32 on a first end 38 and on a second end 39, proceeding from the otherwise cylindrical external shape, in the radial direction 6 has in each case outwardly extending shoulders 37. As a result of these shoulders 37, it is impossible for the claw pole stators 1 to be pushed on along the axial direction 10 when said claw pole stators 1 have a nominal shape. As a result of the first clearance 24, the individual segments 3 can now be pulled apart such that the claw pole stator 1 has an enlarged second diameter 30. The claw pole stators 1 in this state can be pushed onto the stator carrier 32 along the axial direction 10, even across the shoulder 37.

[0108] FIG. 14 shows the stator assembly 31 as per FIG. 12 in a sectional perspective view. FIG. 15 shows the stator assembly 31 as per FIGS. 12 and 14 in a perspective view. FIG. 16 shows the stator assembly 31 as per FIGS. 12, 14 and 15, here having a second material 36, in a perspective view. FIGS. 14 to 16 are conjointly described hereunder. Reference is made to the explanations pertaining to FIGS. 12 and 13.

[0109] The stator assembly 31 comprises the six claw pole stators 1, wherein a coil 40 that runs in the circumferential direction 4 is in each case disposed between two claw pole stators 1. The stator assembly 31 furthermore comprises a stator carrier 32 on which the claw pole stators 1 are disposed.

[0110] In the state according to FIGS. 12 to 15, a first material 35 can in particular be disposed such that potentially present gaps 33 between the contact faces 13, 14 of the segments can be filled with the first material 35.

[0111] It is illustrated in FIG. 16 that the claw pole stators 1, or the segments 3, respectively, are at least partially encompassed by a second material 36 such that a nominal shape of the claw pole stators 1 is set by the second material 36. The second material 36 during the application is in particular of low-viscosity or liquid such that even small voids in the claw pole stator 1, for example between the coil 40 and the segments 3, can be filled as a result.

[0112] A transverse flux machine 2 known from WO 2018/166858 A1 is indicated in FIG. 16. The transverse flux machine 2 comprises inter alia a stator 26 and a rotor 27, wherein the stator 26 here comprises six of the claw pole stators 1. Two claw pole stators 1 are in each case disposed next to one another along the axial direction 10, wherein said claw pole stators 1 contact one another by way of the first end faces 11, wherein the poles 19 of two claw pole stators 1 along the circumferential direction 4 are in each case disposed in an alternating manner and in each case so as to be mutually adjacent, and in the axial direction 10 are disposed so as to mutually overlap. The claw pole stators 1 here are mutually disposed such that the poles 19, proceeding from the base area 22, along the axial direction 10 extend to the other claw pole stator 1. One coil 40 is in each case disposed between these claw pole stators 1.

[0113] The axial direction 10 is aligned so as to be parallel to a rotation axis 32 of the transverse flux machine 2.

[0114] The rotor 27 extends in an annular manner and along the circumferential direction 4 has a multiplicity of permanent magnets 45, wherein an air gap encircling in the circumferential direction 4 is provided between the rotor 27 and the stator 26.

LIST OF REFERENCE SIGNS

[0115] 1 Claw pole stator [0116] 2 Transverse flux machine [0117] 3 Segment [0118] 4 Circumferential direction [0119] 5 Internal circumferential face [0120] 6 Radial direction [0121] 7 External circumferential face [0122] 8 First lateral face [0123] 9 Second lateral face [0124] 10 Axial direction [0125] 11 First end face [0126] 12 Second end face [0127] 13 First contact face [0128] 14 Second contact face [0129] 15 Connection [0130] 16 First radius [0131] 17 Second radius [0132] 18 Curvature radius [0133] 19 Pole [0134] 20 Length [0135] 21 Spacing [0136] 22 Base area [0137] 23 Taper [0138] 24 First clearance [0139] 25 Second clearance [0140] 26 Stator [0141] 27 Rotor [0142] 28 Rotation axis [0143] 29 First diameter [0144] 30 Second diameter [0145] 31 Stator assembly [0146] 32 Stator carrier [0147] 33 Gap [0148] 34 Positioning aid [0149] 35 First material [0150] 36 Second material [0151] 37 Shoulder [0152] 38 First end [0153] 39 Second end [0154] 40 Coil [0155] 41 First tolerance [0156] 42 Second tolerance [0157] 43 Magnetic flux [0158] 44 Flow direction [0159] 45 Permanent magnet