STATOR, ELECTRIC MACHINE, APPARATUS AND METHOD FOR PREPARING A STATOR

Abstract

The invention relates to a stator (100) which may be used within an electric rotating machine, an electric machine, an apparatus for preparing a stator and a method for preparing a stator. The stator (100) comprises a stator core (10) having a plurality of slots (11) arranged in a circumferential direction (C) of the stator core (10). At least a first conductor (12) and at least a second conductor (13) are arranged along a radial direction (R) of one slot (11). Axial end sections (22, 23) of the conductors (12, 13) are electrically connectable or connected and the axial end sections (22, 23) of radially adjacent conductors (12, 13) are distanced from each other. The distance (28) between the proximal end (29) of the axial end section (22) of a first conductor (12) and the stator core (10) is longer than the distance (26) between the distal end (27) of the axial end section (23) of a second conductor (13) and the stator core (10).

Claims

1-14. (canceled)

15. A stator for a rotating electric machine comprising: a stator core which has a plurality of slots arranged in a circumferential direction of the stator core; and at least a first conductor and at least a second conductor arranged next to each other along a radial direction of one slot, wherein axial end sections of the conductors; wherein the axial end sections of radially adjacent conductors are distanced from each other, characterized by at least one of: the axial end sections being axially distanced from each other, wherein the distance between a proximal end of the axial end section of a first conductor and an axial surface of the stator core is longer than the distance between a distal end of the axial end section of a second conductor and the axial surface of the stator core, or the conductors being radially distanced from each other by a distancing member in the slot.

16. The stator according to claim 15, wherein the conductors are radially distanced from each other by a distancing member in the slot by a distance of at least 1-2 mm.

17. The stator according to claim 15, wherein at least one insulating member made of an insulating material is disposed between the first conductor and the second radially adjacent conductor.

18. The stator according to claim 15, wherein at least on one axial side of the stator core the first conductor protrudes from the stator core by a first distance and the second radially adjacent conductor element protrudes by a second distance, wherein the first distance is larger than the second distance by a third distance.

19. The stator according to claim 18, wherein the third distance is from 5-10 mm.

20. The stator according to claim 18, wherein at least one insulating member disposed between the first conductor and the second conductor protrudes by a distance from the stator core which is at least as large as the second distance.

21. The stator according to claim 15, wherein each conductor is wrapped by an insulating member.

22. The stator according to claim 21, wherein each conductor is wrapped by an individual pre-shaped insulator.

23. The stator according to claim 15, wherein the distancing member is formed by at least one radial spacer disposed between at least the first conductor element and the radially adjacent second conductor element.

24. The stator according to claim 23, wherein the distancing member is formed by a separation wall or separating abutments.

25. The stator according to claim 23, wherein the radial spacer is formed by two opposing projections, having a substantially rectangular or substantially triangular shape in a plane perpendicular to the stator axis.

26. The stator according to claim 15, wherein the conductors are formed by strands of conducting wires.

27. An electric machine comprising: a stator for rotating the electric machine, the stator comprising: a stator core which has a plurality of slots arranged in a circumferential direction of the stator core; and at least a first conductor and at least a second conductor arranged next to each other along a radial direction of one slot, wherein axial end sections of the conductors; wherein the axial end sections of radially adjacent conductors are distanced from each other, characterized by at least one of: the axial end sections being axially distanced from each other, wherein the distance between a proximal end of the axial end section of a first conductor and an axial surface of the stator core is longer than the distance between a distal end of the axial end section of a second conductor and the axial surface of the stator core, or the conductors being radially distanced from each other by a distancing member in the slot.

28. An apparatus for preparing a stator, the apparatus comprising: a first insertion station for inserting at least two conductors into a slot of a stator, such that the axial end sections of the conductors are electrically connectable; and a control unit for controlling the insertion of the conductors such that the axial end sections of radially adjacent conductors are distanced from each other, characterized by at least one of: the axial end sections being axially distanced from each other, and the distance between the proximal end of the axial end section of a first conductor and an axial surface of the stator core is longer than the distance between the distal end of the axial end section of a second conductor and the axial surface of the stator core, or the conductors being radially distanced from each other by a distancing member in the slot.

29. The apparatus as claimed in claim 28, wherein the apparatus is an apparatus for preparing a stator, the stator comprising: a stator core which has a plurality of slots arranged in a circumferential direction of the stator core; and at least a first conductor and at least a second conductor arranged next to each other along a radial direction of one slot, wherein axial end sections of the conductors; wherein the axial end sections of radially adjacent conductors are distanced from each other, characterized by at least one of: the axial end sections being axially distanced from each other, wherein the distance between a proximal end of the axial end section of a first conductor and an axial surface of the stator core is longer than the distance between a distal end of the axial end section of a second conductor and the axial surface of the stator core, or the conductors being radially distanced from each other by a distancing member in the slot.

30. The apparatus as claimed in claim 28, wherein the conductors are radially distanced from each other by a distancing member in the slot by a distance of at least 1-2 mm.

31. The apparatus as claimed in claim 28, wherein the apparatus comprises an second insertion station for inserting insulating members into the slots of the stator core, and wherein the control unit is adopted to insert the insulating members such that a first pre-shaped insulating member axially protrudes by a distance from the stator core which is larger than a distance by which a second pre-shaped insulating member protrudes from the stator core, the second pre-shaped insulating member being radially adjacent to the first pre-shaped insulating member in the same slot.

32. The apparatus as claimed in claim 28, wherein the apparatus comprises at least one feed station, at least one of the at least one feed station comprising at least one of: (a) a cutter, (b) an embossing station, (c) a bending station, or (d) a supply unit.

33. A method for preparing a stator, the method comprising: inserting at least two conductors into a slot of a stator core, such that axial end sections of the conductors are electrically connectable, and such that the axial end sections of radially adjacent conductors are distanced from each other, characterized by at least one of: the axial end sections being axially distanced from each other, and the distance between the proximal end of the axial end section of a first conductor and an axial surface of the stator core is longer than the distance between the distal end of the axial end section of a second conductor and the axial surface of the stator core; or the conductors being radially distanced from each other by a distancing member in the slot.

34. The method as claimed in claim 33, wherein the stator is a stator comprising: a stator core which has a plurality of slots arranged in a circumferential direction of the stator core; and at least a first conductor and at least a second conductor arranged next to each other along a radial direction of one slot, wherein axial end sections of the conductors; wherein the axial end sections of radially adjacent conductors are distanced from each other, characterized by at least one of: the axial end sections being axially distanced from each other, wherein the distance between a proximal end of the axial end section of a first conductor and an axial surface of the stator core is longer than the distance between a distal end of the axial end section of a second conductor and the axial surface of the stator core, or the conductors being radially distanced from each other by a distancing member in the slot.

35. The method as claimed in claim 33, wherein the conductors are radially distanced from each other by a distancing member in the slot by a distance of at least 1-2 mm.

36. The method as claimed in claim 33, comprising inserting insulating members into the slots of the stator core, such that a first pre-shaped insulating member axially protrudes by a distance from the stator core which is larger than a distance by which a second pre-shaped insulating member protrudes from the stator core, the second pre-shaped insulating member being radially adjacent to the first pre-shaped insulating member in the same slot.

Description

[0069] The invention will now be described with reference to preferred embodiments and the drawings, which show:

[0070] FIG. 1 a first embodiment of a stator according to the invention in a perspective view;

[0071] FIG. 2 a detail of the stator according to FIG. 1;

[0072] FIG. 3 a second embodiment of a stator according to the invention in a perspective view;

[0073] FIG. 4 a detail of the stator of FIG. 3 in top view;

[0074] FIG. 5 a detail of an alternative embodiment of the stator core in top view;

[0075] FIG. 6 a detail of a further alternative embodiment of the stator core in top view;

[0076] FIG. 7 a schematic representation of an apparatus according to the invention;

[0077] FIG. 8 the stator according to FIG. 1 in a sectional view in an axial plane;

[0078] FIG. 9 an alternative embodiment of a stator according to FIG. 1 in a sectional view in an axial plane.

[0079] FIG. 1 shows a first embodiment of a stator 100 according to the invention in a perspective view.

[0080] The stator 100 comprises a stator core 10 which has a plurality of slots 11 arranged in a circumferential direction C of the stator core 10.

[0081] In each of the slots 11 a first conductor 12 and a second conductor 13 are arranged along a radial direction R of the respective slot 11.

[0082] The conductors 12, 13 protrude from the slots 11 on the shown axial side 15 of the stator core 10.

[0083] The conductors 12, 13 comprise protruding portions 42, 43 which protrude from the slots 11.

[0084] The protruding portions 42, 43 of the conductors 12, 13 have axial base sections 52, 53 closer to the axial surface 30 of the stator core 10 and axial end sections 22, 23, farther from the same axial end surface 30. The axial base sections 52, 53 are covered by insulation members 17, 18.

[0085] FIG. 2 shows a detail of the stator 100 according to FIG. 1.

[0086] Between radially adjacent conductors there is an insulating member 14. In this embodiment the conductors 12, 13 are individually wrapped by pre-shaped insulating members 17, 18.

[0087] Axial end sections 22, 23 of the conductors 12, 13 protruding from an axial surface 30 of the stator core 10 on one axial side 15 (see FIG. 1) of the stator core 10 are electrically connectable. The axial end sections 22, 23 of the conductors 12, 13 are free from the insulating member 14, 17, 18 along a respective axial length 24, 25.

[0088] The first conductor 12 of a slot 11 protrudes from the stator core 10 by a first distance 31. The second conductor 13 in the same slot 11 protrudes from the stator core 10 by a second distance 26. The first distance 31 is larger than the second distance 26.

[0089] The insulating member 14 between the first conductor 12 and the second conductor 13 protrudes from the stator core 10 by a third distance 28, which is also longer than the second distance 26.

[0090] Thus, in this embodiment the axial end sections 22, 23 of radially adjacent conductors 12, 13 are axially distanced from each other.

[0091] The second distance 26 between the distal end 27 of the axial end section 23 of the second conductor 13 and the axial surface 30 of the stator core 10 is smaller than the distance 28 between the proximal end 29 of the axial end section 22 of the first conductor 12 and the axial surface 30 of the stator core 10, and is equal to the third distance 28.

[0092] Each conductor 12, 13 is wrapped by an individual insulating member 17, 18.

[0093] The first pre-shaped insulating member 17 wrapped around the first conductor 12 axially protrudes from the stator core 10 by a distance 28 which is larger than the distance 32 by which the second pre-shaped insulating member 18 wrapped around the second conductor 13 protrudes from the stator core 10.

[0094] FIG. 3 shows a second embodiment of a stator 100 according to the invention in a perspective view.

[0095] All conductors 12, 13 have the same axial length, but however, the axial end sections 22, 23 of radially adjacent conductors 12, 13 in one slot 11 are radially distanced from each other.

[0096] FIG. 4 shows a detail of the stator of FIG. 3 in top view.

[0097] The conductors 12, 13 are radially distanced from each other by a distancing member in the slot 11, formed by two opposing projections 20, having a basically rectangular shape. The conductors 12, 13 are separated by a radial distance 30.

[0098] As can be seen in FIG. 5 the distancing member may also be formed by a separation wall 19.

[0099] A further alternative is shown in FIG. 6. The distancing member may also be formed by projections 21 having a basically triangular shape as seen in top view.

[0100] FIG. 7 shows a schematic representation of an apparatus 90 according to the invention.

[0101] The apparatus 90 comprises a first insertion station 40 for inserting at least two conductors into a slot of a stator core 10 and a second insertion station 50 for inserting insulating members into the slots of the stator core 10.

[0102] The apparatus 90 also comprises a feed station 70 for supplying conductor elements and a feed station 80 for supplying pre-shaped insulating members.

[0103] The apparatus 90 further comprises a control unit 60, which controls the first insertion station 40, the second insertion station 50, the feed station 70 for supplying conductor elements and the feed station 80 for supplying pre-shaped insulating members.

[0104] FIG. 8 shows the stator 100 according to FIG. 1 in a sectional view in an axial plane.

[0105] On a first side 15 of the stator core 10 the first conductor 12 protrudes from the stator core 10 by a first distance 31. The second conductor 13 protrudes from the stator core 10 by a second distance 26. The first distance 31 is larger than the second distance 26.

[0106] As both conductors 12, 13 have the same axial length 32, on the second axial side 33 of the stator 10 the second conductor 13 protrudes from the stator core 10 by a longer distance 34 than the first conductor 12.

[0107] FIG. 9 showsan alternative embodiment of the stator 100 according to FIG. 1 in a sectional view in an axial plane.

[0108] As the axial length 35 of the first conductor 12 is longer than the axial length 36 of the second conductor 13, the distance 31 by which the first conductor 12 protrudes form the stator core 10 is larger than the distance 26 by which the second conductor 13 protrudes from the stator core 10 on both axial sides 15, 33 of the stator core 10.