DISTRIBUTED WINDING

Abstract

A distributed winding for an electric machine may include a coil body with numerous grooves distributed over its circumference, where there are at least two poles for the winding, where there are at least two parallel winding strands for each pole, where each winding strand is composed of at least one wire, which has at least one groove region that runs axially in a groove and a connection region at both ends, where the connection regions protrude axially above the coil body, where each winding strand has contact pins that form connection regions on both ends, and where at least some of the contact pins in the same phase are located in adjacent grooves. That at least one of the adjacent contact pins in the same phase may be bent along the circumference in order to minimize the spacing between the contact pins.

Claims

1. A distributed winding for an electric machine, comprising: a coil body with a plurality of grooves distributed over a circumference of the coil body; wherein there are at least two poles for the winding, at least two parallel winding strands for each pole, wherein each winding strand includes at least one wire, the at least wire having at least one groove region that runs axially in a groove and has a connection region at both ends, wherein the connection regions protrude axially above the coil body, wherein each winding strand has a plurality of contact pins that form connection regions on the both ends, and wherein at least some of the contact pins in the same phase are located in adjacent grooves, and wherein at least one of the adjacent contact pins in the same phase is bent along the circumference in order to minimize the spacing between the contact pins.

2. The winding according to claim 1, wherein the contact pins are bent in a circumferential direction such that the contact pins are each bent closer to the majority of the other adjacent contact pins that have the same phase.

3. The winding according to claim 1, wherein the wires have at least one turning region in the form of a hairpin, or form a wave-shaped conductor.

4. The winding according to claim 1, wherein the contact pins are twisted along the circumference.

5. The winding according to claim 1, wherein a plurality of groove regions of the wires lie in adjacent radial layers in each groove, and wherein the contact pins are located in an outer radial layer.

6. The winding according to claim 5, wherein the contact pins are also bent radially away from the other layers in order to increase the spacing to radially adjacent turning regions and/or connection regions.

7. An electric machine that has a winding according to claim 1, forming a stator winding and/or rotor winding.

8. A drive train for a vehicle that contains an electric machine according to claim 7.

9. A method for producing a winding, the method comprising: placing wires in corresponding grooves on a coil body to form at least two layers; bending at least some of a set of the contact pins such that the spacing therebetween along the circumference is reduced relative to an unbent orientation; and twisting the contact pins in a layer along the circumference.

10. The method according to claim 9, wherein a radial spacing, at least between the layer with the contact pins and the adjacent layer, is increased by bending at least one of the layers in the radial direction.

11. The method according to claim 9, wherein placing the wires in the corresponding grooves on the coil body occurs prior to bending the contact pins and twisting the contact pins.

12. The method according to claim 10, wherein bending the contact pins occurs prior to twisting the contact pins.

13. The method according to claim 9, wherein the contact pins that have been bent are shifted in the same direction along the circumference.

14. The method according to claim 9, wherein at least two contact pins are bent, and wherein these at least two contact pins are shifted in opposite directions along the circumference.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0037] The invention shall be described in greater detail below in reference to the drawings. The same or similar elements are indicated with the same reference symbols. Therein:

[0038] FIG. 1 shows a portion of a distributed winding according to the prior art;

[0039] FIG. 2 shows a portion of an exemplary embodiments analogous to that shown in FIG. 1;

[0040] FIG. 3 shows another, enlarged region containing a pole;

[0041] FIGS. 3A to 3C show alternative exemplary embodiments based on FIG. 3; and

[0042] FIG. 4 shows another exemplary embodiment.

DETAILED DESCRIPTION

[0043] FIG. 1 shows a portion of an axial region of a distributed winding. This is a distributed winding with the wires (D) forming hairpin turns. The connection regions (T) of the wires (D) in the coil body extend axially over the coil body. The connection pins (T) at each end of a winding strand are formed by the contact pins (K) and are longer in this exemplary embodiment that the rest of the connection regions (T).

[0044] Two adjacent poles in FIG. 1 that each have two contact pins (K) from parallel winding strands are indicated by a rectangular frame, which is not part of the winding.

[0045] The contact pins (K) are twisted to the same extent in the circumferential direction as the rest of the connection regions (T), for which reason they are flush in the radial direction with at least the equidistant connection regions in the circumferential direction. As a result, the contact pins (K) are also spaced apart equally. This results in the problem that, in order to connect the contact pins (K) to power electronics, they have to be connected to a wiring assembly individually, and the distance between different phases, in particular with regard to necessary creepage distances, particularly with high voltage applications, is very small and in some cases may be insufficient.

[0046] FIG. 1 therefore represents one possible initial situation that can be improved with the present invention

[0047] FIG. 2 illustrates a construction that is analogous to that in FIG. 1, for which reason reference is made to the above description. Unlike in FIG. 1, the contact pins (K) are bent along the circumference, as well as being twisted at an angle that is identical to that in the rest of the connection regions (T), in order to reduce the spacing between contact pins (K) of the same phase, or bring parallel winding strands in a pole closer together.

[0048] In this exemplary embodiment, there are two parallel winding strands in each case. As can be clearly seen in comparison to FIG. 1, the spacings between the contact pins (K) of different phases are increased, thus increasing the creepage distances and improving the insulation to one another.

[0049] FIG. 3 also shows, by way of example, two contact pins (K) on parallel winding strands in a pole. These are marked as “1” and “2” in FIG. 3. There are three ways in which these two contact pins (K) can be bent closer to one another in accordance with the invention. The paths along which they are bent in these three variations are indicated schematically in FIG. 3 by arrows indicated with the letters “A,” “B,” and “C.” The results of the three variations are indicated in the corresponding figures, FIGS. 3A, 3B, and 3C.

[0050] In FIG. 3A, the contact pin (K) with the numeral “2” is bent closer to the contact pin (K) with the numeral “1,” thus increasing the creepage distance to the components toward the right in FIG. 3.

[0051] In FIG. 3B, the contact pin (K) with the numeral “1” is bent closer to the contact pin (K) with the numeral “2,” thus increasing the creepage distance to the components toward the left.

[0052] In FIG. 3C, both contact pins (K), i.e. “1” and “2,” are bent closer one another, and thus lie between the connection regions (T) in the other adjacent layers. This increase the creepage distances on both sides, and also reduces the distance that the contact pins (K) are shifted in comparison with the variations shown in FIGS. 3A and 3B.

[0053] FIG. 4 shows another exemplary embodiment in an illustration analogous to that shown in FIGS. 3, 3A, 3B, 3C, in which there are three parallel winding strands, and therefore three adjacent contact pins (K), for each pole.

[0054] The individual contact pins (K) are numbered, i.e. “1,” “2,” and “3,” analogously to those in FIG. 3. In this exemplary embodiment, the contact pins (K) with the numerals “2” and “3” are bent closer to the contact pin (K) “1”, such that contact pin (K) “3” is shifted further than contact pin (K) “2.”

[0055] As shown in FIGS. 3B and 3C, the contact pins can be shifted in the other direction, or in both directions. When shifted as shown in FIG. 3C, the middle contact pin (K) “2” can remain in place, or it can be moved slightly toward one of the other two contact pins (K) “1” or “3.”

[0056] The invention is not limited to the embodiments described herein. It can also comprise only some of the advantageous features, or numerous advantageous features can be combined with one another, as explained above.

REFERENCE SYMBOLS

[0057] D wire [0058] T connection region [0059] K contact pin