THREE-PHASE STATOR ASSEMBLY
20220200397 · 2022-06-23
Inventors
Cpc classification
H01R4/2416
ELECTRICITY
H02K2203/06
ELECTRICITY
International classification
H02K5/22
ELECTRICITY
Abstract
An electric pump drive motor three-phase stator assembly (1) includes three sets of stator segments (S.sub.i,j), configured in a ring about a stator axis (R). Each set includes n≥2 stator segments arranged in an n-fold rotational symmetry about the stator axis. Each stator segment includes a coil (3) having a first coil wire end and a second coil wire end. A plurality of 3n−3 connection wires (W.sub.i,k) connect coils of a respective set of stator segments in series. A first and a second interposed stator segment are arranged in circumferential direction between the two connected coils of the respective set of stator segments. 3n−5 of the connection wires span across the first interposed stator segment at a distance (r.sub.1) to the stator axis and across the second interposed stator segment at a second distance (r.sub.2) to the stator axis (R). The second distance is larger than the first distance.
Claims
1. A three-phase stator assembly of an electric pump drive motor, the stator assembly comprising: three sets of stator segments, wherein the stator segments are configured as a ring arrangement about an axially extending stator axis, wherein each set of stator segments comprises n≥2 stator segments with an n-fold rotational symmetry about the stator axis, wherein each stator segment comprises a coil having a first coil wire end and a second coil wire end; and a plurality of 3n−3 connection wires arranged at an axial front side of the stator segments, wherein each connection wire connects two coils of a respective set of stator segments in series, wherein a first interposed stator segment and a second interposed stator segment of two other sets of the stator segments are arranged in circumferential direction between the two connected coils of said respective set of stator segments, wherein at least 3n−5 of the connection wires span across the first interposed stator segment at a first radial distance to the stator axis and across the second interposed stator segment at a second radial distance to the stator axis, wherein the second radial distance is larger than the first radial distance.
2. The three-phase stator assembly according to claim 1, wherein the at least 3n−5 of the connection wires have a same shape and length.
3. The three-phase stator assembly according to claim 1, wherein all connection wires extend over a full length thereof essentially in a common plane perpendicular to the stator axis.
4. The three-phase stator assembly according to claim 1, further comprising a star point wire connecting the first coil wire ends of the coils of the (j=n).sup.th stator segments of the three sets of stator segments with each other.
5. The three-phase stator assembly according to claim 1, further comprising a three-phase power input line with three phase, wherein each phase is connected to the second coil wire end of the coil of the (j=1).sup.st stator segment of a respective set of the stator segments.
6. The three-phase stator assembly according to claim 1, further comprising a wire guide element arranged at the axial front side of the stator segments, wherein the wire guide element defines a plurality of wire paths, wherein the wire paths are arranged in a 3n-fold rotational symmetry about the stator axis.
7. The three-phase stator assembly according to claim 6, wherein the wire guide element is comprised of a plurality of 3n separate and identical wire guide structures, wherein each wire guide structure is arranged at the axial front side of a respective stator segment.
8. The three-phase stator assembly according to claim 7, wherein the wire guide structures are spaced a distance to each other in circumferential direction.
9. The three-phase stator assembly according to claim 6, wherein the wire guide element is fixed to the axial front side of the stator segments by a positive fit.
10. The three-phase stator assembly according to claim 6, wherein the wire guide element is arranged radially between the first coil wire ends and the second coil wire ends of the coil of the respective stator segment.
11. The three-phase stator assembly according to claim 1, wherein the first coil wire end of the coil of each of the stator segments is arranged at a first lateral side of the respective stator segment and the second coil wire end of the coil of each stator segment is arranged at a second lateral side of the respective stator segment.
12. The three-phase stator assembly according to claim 1, wherein each stator segment further comprises: a first insulation displacement terminal for connecting the respective connection wire with the first coil wire end; and a second insulation displacement terminal for connecting the respective connection wire with the second coil wire end.
13. The three-phase stator assembly according to claim 12, wherein the first insulation displacement terminal is axially inserted into a first slot defined at the axial front side of the stator segment and the second insulation displacement terminal is axially inserted into a second slot defined at the axial front side of the stator segment.
14. The three-phase stator assembly according to claim 13, wherein the first slot or the second slot or both the first slot and the second slot extend essentially tangentially with respect to the ring arrangement of the stator segments.
15. The three-phase stator assembly according to claim 13, wherein: the first coil wire end and a first connection wire end extend radially across the first slot, wherein the first coil wire end is received in a first recess of the first insulation displacement terminal and the first connection wire end is received in a second recess of the first insulation displacement terminal; or the second coil wire end and a second connection wire end extend radially across the second slot, wherein the second coil wire end is received in a first recess of the second insulation displacement terminal and the second connection wire end is received in a second recess of the second insulation displacement terminal; or the first coil wire end and a first connection wire end extend radially across the first slot, wherein the first coil wire end is received in a first recess of the first insulation displacement terminal and the first connection wire end is received in a second recess of the first insulation displacement terminal and the second coil wire end and a second connection wire end extend radially across the second slot, wherein the second coil wire end is received in a first recess of the second insulation displacement terminal and the second connection wire end is received in a second recess of the second insulation displacement terminal.
16. The three-phase stator assembly according claim 15, wherein the first recess and the second recess of the first insulation displacement terminal or second insulation displacement terminal or both the first insulation displacement terminal and the second insulation displacement terminal are arranged at opposite axial sides of the respective insulation displacement terminal.
17. The three-phase stator assembly according to claim 1, wherein the connection wires are not crossing each other.
18. The three-phase stator assembly according to claim 1, wherein for each of the stator segments the first coil wire end is arranged at a radial inner side of the stator segment and the second coil wire end is arranged at a radial outer side of the stator segment.
19. The three-phase stator assembly according to claim 1, wherein all stator segments are essentially identical and differ only by one or more of a connection to the connection wires, input phases or a star point wire.
20. The three-phase stator assembly according to claim 1, wherein each connection wire spans at maximum across an azimuthal angular distance in the range of
21. The three-phase stator assembly according to claim 1, wherein the first coil wire end of a coil of a set of stator segments and the second coil wire end of a next-in-series connected coil of said set of stator segments have an azimuthal angular distance to each other in the range of
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] In the drawings:
[0034]
[0035]
[0036]
[0037]
[0038]
[0039]
[0040]
[0041]
[0042]
[0043]
[0044]
DESCRIPTION OF PREFERRED EMBODIMENTS
[0045]
[0046] For the figures to be more comprehensible, it is useful to define a cylindrical coordinate system as shown in
[0047] Each stator segment S.sub.i,j comprises a coil 3 having a first coil wire end 5 and a second coil wire end 7. Both, the first coil wire end 5 and the second coil wire end 7 are arranged at an axial front side 9 of the stator segments S.sub.i,j. The axial rear side 11 of the stator assembly 1 is facing away in
[0048] The three-phase stator assembly 1 as shown in
[0049] For instance, the first interposed stator segment S.sub.2,1 and the second interposed stator segment S.sub.3,1 are arranged in circumferential direction between the two connected coils of stator segments S.sub.1,1 and S.sub.1,2 of the first (i=1) set of stator segments. Analogously, the interposed first and second stator segments S.sub.3,1 and S.sub.1,2 are arranged between the stator segments S.sub.2,1 and S.sub.2,2 of the second (i=2) set of stator segments, and so forth. The six connection wires W.sub.i,k have the same shape and length. However, in an alternative embodiment, the first connection wire W.sub.1,1 and the last connection wire W.sub.3,2 may have more options for a somewhat different shape and/or length. Here, all connection wires W.sub.i,k span across the first interposed stator segment (the first stator segment of the other two sets of stator segments being arranged between the two connected coils of stator segments of a respective set of stator segments) at a first radial distance r.sub.1 to the stator R. Furthermore, each connection wire W.sub.i,k spans across the second interposed stator segment (the second stator segment of the other two sets of stator segments being arranged between the two connected coils of stator segments of said respective set of stator segments) at a second radial distance r.sub.2 to the stator axis R. The second radial distance r.sub.2 is larger than the first radial distance r.sub.1, i.e. r.sub.2>r.sub.1. This means that the connection wires W.sub.i,k do not follow a strict circular path coaxial with the stator axis R, but effectively extend radially outward on its path between the two connected coils of stator segments of the respective set of stator segments. For instance, the first connection wire W.sub.1,1 connects the coils of stator segments S.sub.1,1 and S.sub.1,2. The connection wire W.sub.1,1 crosses the first stator segment S.sub.2,1 at the first radial distance r.sub.1 and the second stator segment S.sub.3,1 at the second radial distance r.sub.2, wherein the second radial distance r.sub.2 is larger than the first radial distance r.sub.1. Thereby, the connection wire W.sub.i,k follow a “spiraling” path of a shape that resembles circular threats of a spider web with linear. In other words, the connection wires W.sub.i,k are spiraling radially outward along their path for connecting the coils 3 of the two stator segments S.sub.i,j and S.sub.i,j+1.
[0050]
the azimuth position φ.sub.2 between the neighbouring stator segments S.sub.2,1 and S.sub.3,1 is here defined to be 40°, and the azimuth position φ.sub.3 between the neighbouring stator segments S.sub.3,1 and S.sub.1,2 is here defined to be 80°. So, the connection wires W.sub.i,k span over an azimuthal angular range of more than 80°. In this range between φ.sub.1 and φ.sub.3, the radial distance r(φ) of the connection wire W.sub.i,k to the stator axis R varies along the length of the connection wire W.sub.i,k. As can be seen in
i.e. average radial distances in the respective azimuthal range may be compared. Alternatively, a median radial distance value in the respective azimuthal range may be compared. Alternatively, the radial distance values at the central azimuth positions 20° and 60° may be compared. It should be noted that the radial distance may continuously increase along the length of the connection wire W.sub.i,k, but it does not need to. As can be seen in
[0051] Back to
[0052] Each wire guide structure 13 defines a first essentially tangential path 13a for guiding a connection wire W.sub.i,k across the first interposed stator segment and an essentially tangential second path 13b for guiding another connection wire W.sub.i,k across the second interposed stator segment S.sub.i,j. The first path 13a is positioned radially more inward than the second path 13b. The wire guide structure 13 further defines an essentially tangential third path 13c for guiding a star point wire 16. The third path 13c is arranged radially more inward than the first path 13a. The star point wire 16 connects the first coil wire ends 5 of the coils 3 of the last (j=n) stator segments S.sub.1,3, S.sub.2,3 and S.sub.3,3 with each other. The star point wire 16 may have a larger diameter than the connection wires W.sub.i,k. The paths 13a-c are here all linear, but may be at least partially non-linear in other non-shown embodiments.
[0053] The second coil wire ends 7 of the first (j=1) stator segments S.sub.1,1, S.sub.2,1 and S.sub.3,1 of each set are each connected to one phase 17a, b, c of a three-phase power input line comprising the three phases 17a, b, c.
[0054]
[0055] The first slot 23a and the second slot 23b comprise V-shaped cut-outs into which the first coil wire end 5 and the second coil wire end 7, respectively can be placed. The V-shaped cut-outs in the first slot 23a and the second slot 23b form radially extending grooves 26a,b, into which the first coil wire end 5 and the second coil wire end 7, respectively, can be inserted.
[0056]
[0057]
[0058]
with n=9, whereas the wire guide structures 13 span across less than
e.g. across
about the azimuthal centre of the respective stator segment S.sub.i,j.
[0059]
to receive the next connection wire from the machine at the exactly same position. A first connection wire end 33a is thereby inserted into the second recess 31 of the first insulation displacement terminal 27a in the first slot 23a in parallel to the first coil wire end 5. Analogously, a second connection wire end 33b is pressed into the second recess 31 of the second insulation displacement terminal 27b in the second slot 23b in parallel to the second coil wire end 7. Thereby, the insulation displacement terminals 27a, b cut into an insulation coating of the connection wire W.sub.i,k at the first connection wire end 33a and the second connection wire end 33b, respectively, in order to establish an electrical contact with the respective coil wire end 5, 7.
[0060]
[0061] An alternative embodiment to the nine separate and identical wire guide structures 13 is shown in
[0062] While specific embodiments of the invention have been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles.
LIST OF REFERENCE CHARACTERS
[0063] 1 stator assembly [0064] 3 coil [0065] 6 first coil wire end [0066] 7 second coil wire end [0067] 9 axial front side [0068] 11 axial rear side [0069] 13 wire guide structure [0070] 15 wire guide element [0071] 15a, b, c wire paths [0072] 16 star point wire [0073] 17a, b, c phases of the three-phase power input line [0074] 19 core [0075] 21a front part [0076] 21b rear part [0077] 23a first slot [0078] 23b second slot [0079] 25a first lateral side [0080] 25b second lateral side [0081] 27a first insulation displacement terminal [0082] 27b second insulation displacement terminal [0083] 29 first recess [0084] 31 second recess [0085] 33a first connection wire end [0086] 33b second connection wire end [0087] i index for set of stator segments [0088] j index for stator segment within a set of stator segments [0089] k index for connection wire for a set of stator segments [0090] S.sub.i,j stator segment [0091] W.sub.i,k connection wire [0092] R stator axis [0093] φ azimuth angle [0094] A symmetry plane [0095] r.sub.1 first radial distance [0096] r.sub.2 second radial distance