STATOR, ELECTRIC MACHINE, AND MANUFACTURING PROCESS

Abstract

The invention relates to a stator for an electric machine, comprising a plurality of rod conductors and at least one insulation disk that is arranged in an end face region of the stator and includes a plurality of interconnection pieces. Rod conductor contact surfaces and interconnection piece contact surfaces have corresponding shapes such that a planar contact can be created; for this purpose, the interconnection piece protrude from the insulation disk in the radial direction at least along the interconnection piece contact surface such that a plurality of interconnection piece contact surfaces can simultaneously come into contact with the associated rod conductor contact surfaces. The invention further related to an electric machine and to a manufacturing process.

Claims

1. Stator for an electrical machine having a plurality of rod conductors, which are distributed radially about an axis of rotation of the stator and are arranged spaced apart from one another in each case, so that the rod conductors extend in the longitudinal direction of the axis of rotation, and having at least one insulation disk, which is arranged in an end face region of the stator, wherein the insulation disk has a plurality of interconnection pieces, in each case one interconnection piece being assigned to two rod conductors for forming an electrical connection, wherein a rod contact surface is formed at longitudinal ends of each rod conductor and interconnection piece contact surfaces are formed at ends of each interconnection piece, wherein the rod contact surfaces and the interconnection piece contact surfaces are each formed to correspond to one another so as to enable a surface contact, wherein the interconnection pieces protrude in the radial direction from the insulation disk at least along the interconnection piece contact surfaces, thereby enabling a plurality of interconnection piece contact surfaces to be contacted simultaneously with the respectively associated rod conductor contact surfaces.

2. Stator according to claim 1, wherein the rod conductor contact surfaces and the respectively associated interconnection piece contact surfaces are configured to be contacted with one another by rotating the insulation disk along the axis of rotation of the stator.

3. Stator according to claim 1, wherein the at least one insulation disk has a plurality of grooves for receiving the interconnection pieces, or the plurality of interconnection pieces is integrally cast in the insulation disk.

4. Stator according to claim 3, wherein the insulation disk comprises a resin or polymer for producing the insulation disk in a casting process.

5. Stator according to claim 1, wherein the interconnection pieces and the rod conductors form a resilient connection, for providing a preloaded surface contact between the mutually associated rod conductor contact surfaces and interconnection piece contact surfaces.

6. Stator according to claim 1, wherein the interconnection pieces that are in contact with the rod conductors form a zero gap along the interconnection piece contact surfaces and the rod conductor contact surfaces in each case, thereby enabling the interconnection pieces to be connected to the associated rod conductors in a force-locking or form-locking or material-locking manner, by means of a beam welding process, a resistance welding process, an ultrasonic welding process or a friction welding process.

7. Stator according to claim 1, wherein the longitudinal ends of the interconnection pieces are wedge-shaped or L-shaped.

8. Stator according to claim 1, wherein across the height of the rod conductor contact surfaces, the rod conductors are each designed to be point-symmetrical in cross section, in the form of a parallelogram, thereby enabling identical current path lengths to be present across the cross section of the rod conductors.

9. Electrical machine with a stator according to claim 1.

10. Method of manufacturing a stator or an electric machine according to claim 1, comprising the following steps: concentrically aligning the insulation disk with respect to the plurality of rod conductors radially distributed around the axis of rotation and spaced apart from each other, respectively; placing the insulation disk on a front end face of the stator so that a rod conductor contact surface and an interconnection piece contact surface are each opposite to each other; rotating the insulation disk about the axis of rotation so as to establish a surface contact between the rod conductor contact surfaces and the interconnection piece contact surfaces.

11. Method according to claim 10, wherein the rod conductors and interconnection pieces assigned to one another are connected to one another, in particular welded, along the rod conductor contact surfaces and interconnection piece contact surfaces that are in contact with one another in a force-locking or form-locking or material-locking manner.

12. Method according to claim 10, wherein a cover part is placed on the insulation disk.

13. Method according to claim 11, wherein the interconnection pieces are connected to the associated rod conductors in a force-locking and/or form-locking and/or material-locking manner after positioning of the cover part.

14. Stator according to claim 1, wherein the insulation disk is a annular insulation disk.

15. Stator according to claim 3, wherein the insulation disk comprises a castable or injectable resin or polymer for producing the insulation disk in a casting process.

16. Method of manufacturing a stator or an electric machine according to claim 1, wherein the surface contact is a preloaded surface contact.

17. Stator according to claim 2, wherein the at least one insulation disk has a plurality of grooves for receiving the interconnection pieces, or the plurality of interconnection pieces is integrally cast in the insulation disk.

18. Stator according to claim 17, wherein the insulation disk comprises a resin or polymer for producing the insulation disk in a casting process.

19. Stator according to claim 18, wherein the interconnection pieces and the rod conductors form a resilient connection, for providing a preloaded surface contact between the mutually associated rod conductor contact surfaces and interconnection piece contact surfaces.

20. Stator according to claim 19, wherein the interconnection pieces that are in contact with the rod conductors form a zero gap along the interconnection piece contact surfaces and the rod conductor contact surfaces in each case, thereby enabling the interconnection pieces to be connected to the associated rod conductors in a force-locking or form-locking or material-locking manner, by means of a beam welding process, a resistance welding process, an ultrasonic welding process or a friction welding process.

Description

[0049] In the drawings:

[0050] FIG. 1 schematically shows perspective exploded view of a stator according to the invention;

[0051] FIG. 2 schematically shows perspective view of the assembled windings of a stator according to the invention;

[0052] FIG. 3 schematically shows an illustration of a single phase of the composite windings according to FIG. 2;

[0053] FIG. 4 schematically shows perspective illustrations of insulation disks with associated interconnection pieces;

[0054] FIG. 5 schematically shows a perspective view of stacked insulation disks with interconnection pieces inserted;

[0055] FIGS. 6a-b schematically show perspective views of insulation disks according to FIG. 5a-b with cover part and insulation star;

[0056] FIGS. 7a-b schematically show illustrations of the pre-positioning of an insulation disk;

[0057] FIGS. 8a-b schematically show illustrations of the pre-positioning for an L-shaped geometry of the interconnection pieces;

[0058] FIGS. 9a-b schematically show illustrations of pre-positioning for a wedge-shaped geometry of the interconnection pieces;

[0059] FIG. 10 schematically shows an illustration of an exemplary shaped strand with parallelogram-shaped welding to compensate for a positioning error;

[0060] FIG. 11 schematically shows an illustration of welding the heads of shaped strands with current paths of unequal length;

[0061] FIG. 12 schematically shows an illustration of welding the heads of shaped strands with current paths of equal length;

[0062] FIG. 13 schematically shows a perspective illustration of fluid inlets and fluid outlets for a cooling fluid flow of a stator;

[0063] FIG. 14 schematically shows an illustration of a cooling fluid flow within the stator in a [0064] i. cross-sectional view; and

[0065] FIG. 15 schematically shows an illustration of cooling fluid flow in an isolation disk.

[0066] FIGS. 16a-b schematically show illustrations of pre-positioning for an angled geometry of the interconnect webs

[0067] FIG. 16c schematically shows an interconnection piece with angled ends analogous to FIG. 16a-b

[0068] FIGS. 17a-19b schematically show three different variants of an assembly process for establishing the surface contact by axial positioning of the interconnection pieces

[0069] FIGS. 20a-22b schematically show three different variants of an assembly process for establishing the surface contact by lateral movement of the interconnection pieces.

[0070] FIG. 23 schematically shows a possibility of holding the interconnection pieces by means of holding elements

[0071] FIG. 24 schematically shows a possibility of manufacturing holding elements

[0072] FIG. 1 shows a perspective exploded view of a stator 1 according to the invention. Accordingly, the components of the stator 1 are arranged concentrically along an axis of rotation X.

[0073] The stator 1 is formed with radially distributed and spaced-apart rod conductors 10, which extend in the longitudinal direction of the axis of rotation X. Longitudinal ends of the rod conductors 10 represent or form opposing end face regions 2; 3 of the stator 1.

[0074] Furthermore, the stator 1 has a plurality of insulation disks 30, each having a plurality of interconnection pieces 20.

[0075] An annular cover part 40 is arranged at each of the end face regions 2; 3 of the stator 1. The cover parts 40 constitute an enclosure of the insulation disks 30 and, thus, the terminations on both sides of the stator 1.

[0076] The cover parts 40 each have separating fins, which may extend, in particular in the longitudinal direction of the axis of rotation X, between the rod conductors 10 or the interconnection pieces 20, in particular for the respective spacing or insulation.

[0077] FIG. 2 shows a perspective view of the assembled windings of a stator 1 according to the invention.

[0078] In the end face regions of the stator 2; 3 and at the longitudinal ends of the rod conductors 10, respectively, several arrangements of interconnection pieces 20 are provided. Thus, the insulation disks 30 form different interconnection planes or layers with the interconnection pieces 20 in order to achieve an appropriate interconnection of the rod conductors 10 for providing composite windings.

[0079] Preferably, in addition to the individual interconnection planes, a connection plane with phase connections for current or voltage supply is further shown at the upper end face region 2, in particular for leading out the winding phase and/or for bringing together the winding phases to form a star point.

[0080] FIG. 3 shows a representation of a single phase of the composite windings according to FIG. 2.

[0081] In particular, it can be seen that the interconnection pieces 20 are each C-shaped. Thus, the interconnection pieces 20 may be interleaved to form an interconnection piece group.

[0082] According to FIG. 3, a phase runs along the rod conductors 10 between different planes of interconnection pieces 20. Thus, this allows interleaving the interconnection pieces 20 with the electrically connected rod conductors 10 to form different phases.

[0083] Referring to FIGS. 2 and 3, a space-saving arrangement or interconnection of the composite windings may be enabled by arranging the interconnection pieces 20 at different planes or layers.

[0084] In FIGS. 4a-e, perspective illustrations of insulation disks with associated interconnection pieces are shown.

[0085] It is clear from FIGS. 4a-e that the configuration of the insulating disks 30 with the interconnection pieces 20 may differ along the individual interconnection planes in order to enable an appropriate interconnection of the rod conductors 10 and thus an appropriate configuration of the composite windings.

[0086] Furthermore, in particular according to FIG. 4a, the insulation disk 30 is provided with grooves 31 for receiving the interconnection pieces 20. The interconnection pieces 20 may be inserted into or received in the grooves 31 of the insulation disk 30. Thus, a specific pre-positioning as well as a sectional electrical insulation of the interconnection pieces 20 may be accomplished by means of the respective insulation disk 30. Furthermore, FIG. 4c shows the design of the interconnection pieces 20 for providing a connection plane. In this way, the rod conductors 10 or interconnection pieces 20 may be appropriately supplied with current or voltage.

[0087] In FIGS. 5a-b, there is shown a perspective view of stacked insulation disks with inserted interconnection pieces 20.

[0088] The different insulation disks 30 with the respective interconnection pieces 20 are arranged directly on top of each other. The ends of the interconnection pieces 20 protrude in the radial direction from the insulation disks 30 in each case in order to permit appropriate electrical contacting. In particular, the interconnection pieces 20 protrude beyond an inner diameter of the annular insulation disks 30, and thus in the direction of the axis of rotation X of the stator 1.

[0089] The staggered arrangement of the ends of the interconnection pieces 20 enables advantageous interconnection and contacting with the rod conductors 10.

[0090] FIGS. 6a-b show a perspective view of the insulation disks 30 according to FIGS. 5a-b with cover part 40 and insulation star 60.

[0091] The cover part 40 terminates the arrangement of the insulation disks 30 in the longitudinal direction. The insulation star 60 is arranged concentrically to the insulation disks 30 and at the inner diameter of the annular insulation disks 30. Thus, the insulation star 60 terminates the arrangement of the insulation disks 30 with the interconnection pieces 20 in the radial direction, in particular for delineating with respect to a rotor to be accommodated or arranged for forming an electrical machine. Cover part 40 and insulation star 60 are formed as single pieces.

[0092] The insulation star 60 is formed with a circumferential surface, at the outer circumference of which partition walls are arranged so as to extend in a star-like shape. The partition walls extend in the longitudinal direction of the circumferential surface of the insulation star 60. By means of the insulation star 60, it is thus possible to provide appropriate electrical insulation of the rod conductors 10 from one another and contacting of the rod conductors 10 with the interconnection pieces 20 along the insulation disks 30.

[0093] In FIGS. 7a-b, there is shown an illustration of the pre-positioning of an insulation disk 30.

[0094] FIG. 7a shows the offset between the interconnection pieces 20 and the rod conductors 10 after concentric positioning of the insulation disk 30. Rod conductor contact surfaces 11 and interconnection piece contact surfaces 21 are still arranged separately from each other. According to FIG. 7a, the contact surfaces 11; 21 of the rod conductors 10 and the interconnection pieces 20 may be formed so as to correspond to each other, with ends of the interconnection pieces 20 and head ends of the rod conductors 10 each being wedge-shaped. The wedge shape here refers to a view perpendicular to the longitudinal axis X of the stator.

[0095] According to FIG. 7b, a preferably preloaded surface contact between the interconnection piece contact surfaces 21 and the rod conductor contact surfaces 11 is established in the course of a rotation of the insulation disk 30 for pre-positioning the interconnection pieces 20. Thus, a reliable contacting of the rod conductors 10 with the interconnection pieces 20 may be provided. In this contacted state, a simple and reliable connection of the rod conductors 10 with the interconnection pieces 20 may be established, preferably in the course of a welding process such as, for example, a beam welding, a resistance welding or an ultrasonic welding. Due to the wedge shape, in particular axial accessibility is maintained, so that welding may be performed with a welding beam perpendicular to the longitudinal axis of the stator X.

[0096] FIGS. 8a-b show a representation of the pre-positioning for an L-shaped geometry of the interconnection pieces 20 in a top view perpendicular to the stator axis X.

[0097] In the sense of FIGS. 7a-b, a relative displacement between the interconnection pieces 20 and the rod conductors 10 takes place according to FIGS. 8a-b in order to provide a contact in the course of the pre-positioning.

[0098] The rod conductors 10 may be rectangular or square or have a rectangular or square cross-section. The interconnection pieces 20 may be L-shaped at their ends.

[0099] In FIGS. 9a-b, an illustration of the pre-positioning for a wedge-shaped or wedge-shapedly configured geometry of the interconnection pieces 20 is shown.

[0100] In order to provide a preloaded surface contact along the mutually associated rod conductor contact surfaces 11 and the interconnection piece contact surfaces 21, a relative displacement is applied, in particular in the form of a rotation of the insulation disk 30 with the respective associated interconnection pieces 20. According to FIG. 9b, an incorrect positioning, e.g. of individual rod conductors 10 and/or interconnection pieces 20, may also be compensated here.

[0101] FIG. 10 shows an illustration of an exemplary shaped strand 50.

[0102] The shaped strand 50 consists of individual wires, which are electrically contacted with each other in the head region by electrode resistance welding. The shaped strand head is resistance welded in a parallelogram shape according to FIG. 10. In this way, a positioning error as shown in FIG. 9a-b may be circumvented or compensated for. The remaining shaped strand may have a different cross-sectional shape as shown here, for example trapezoidal.

[0103] FIG. 11 shows an illustration of the welding, by electrode heads E, of the heads of shaped strands 50 with current paths of unequal length. Due to the non-identical contact surfaces of the shaped strands 50, in particular a bevelled contact surface and a rectangular contact surface, current paths of unequal length dimensions are present. In the course of a resistance welding process, for example, this leads to electrical joints of inferior quality.

[0104] FIG. 12 shows an illustration of resistance welding, by electrode heads E, of the heads of shaped strands 50 with current paths of equal length. According to FIG. 12, the contact surfaces for resistance welding are each parallel and oblique, in particular point-symmetrical and corresponding to each other. Using identically long current paths, high-quality, reliable welds of the contact surfaces, i.e. of all wires of the shaped strands 50, may be produced.

[0105] FIG. 13 shows a perspective view of fluid inlets and fluid outlets for a cooling fluid flow of a stator 1.

[0106] In particular, arrangements may be made that a cooling fluid may enter and/or exit at the end face regions 2; 3 of the stator 1 (cf. directions of arrows in FIG. 13).

[0107] Preferably, the winding head or the assembled windings of the stator 1 may be cooled directly with the cooling fluid. Furthermore, the insulation disks 30 may be designed so as to allow a cooling fluid to flow through them.

[0108] FIG. 14 shows an illustration of a cooling fluid flow within the stator 1 in a cross-sectional view.

[0109] A cooling fluid may flow into the stator 1 at the end face region 2 of the stator 1 and pass through the cover part 40 to the insulation disks 30 (cf. directions of arrows in FIG. 14). Furthermore, the cooling fluid may flow through the insulation disks 30, for cooling the individual interconnection pieces 20 in the grooves 31 of the insulation disks 30.

[0110] Referring to FIG. 15, an illustration of cooling fluid flow in an insulation disk 30 is illustrated. Accordingly, a cooling fluid may be split into a partial flow for each groove 31 or interconnection piece 20 received therein. Thus, an identical cooling effect may be provided for all interconnection pieces 20. Local temperature increases in the insulation disks 30 may be avoided.

[0111] FIGS. 16a, 16b show, comparable to FIGS. 8, 9, a representation of the pre-positioning for interconnection pieces 20 with angled end face regions or angled contact surfaces 21 in a plan view perpendicular to the stator axis X. The angled areas, which form the contact surfaces of the interconnection pieces, are long, in particular longer than the corresponding contact surfaces 11 of the interconnection pieces 10. This means that even large tolerances may be compensated without affecting the quality of the electrical connection.

[0112] FIG. 16c shows an example of an interconnection piece 20 in a plan view, as it may be used in FIGS. 16a-b. The interconnection piece 20 is produced by cutting to length and then bending a semi-finished product with the cross-sectional shape of the interconnection piece, for example a copper rod.

[0113] In particular, the angled contact surfaces are formed by a bending process. This reduces the requirements for the cut-to-length process, since the cut-to-length process no longer has to provide functionally relevant surfaces. In contrast to, for example, FIGS. 16a, b, the rod conductor 10 is held with clearance in a groove 31 of an insulation disk 30. The interconnection piece may, thus, be moved laterally relative to the insulation disk. This allows tolerance dependencies for pre-positioning to be removed by twisting and/or axial placement and/or lateral movement. The clearance may be used or not used regardless of the selected shape of the interconnection pieces 20 or their contact surfaces 21.

[0114] FIGS. 17a-b, 18a-b, 19a-b each schematically show a contacting process to have contact surfaces 21, 11 of interconnection piece 20 and rod conductor 10 abut and to produce a zero gap, respectively, in a sectional plane parallel to and through the longitudinal axis X of the stator. For this purpose, the interconnection piece 20 is moved axially towards the rod conductor 10 fixed in the stator laminated core 4 or towards a stator end face 2;3. In FIG. 17, the interconnection piece 20 and the rod conductor 10 each have wedge-shaped ends. In FIGS. 18 and 19, ends of the interconnection piece 20 and the rod conductor 10 each have a cuboid block shape. The abutment or the formation of the zero gap are made here as a radial (FIG. 19) or axial (FIG. 18) butt joint. Insulation or retaining disks may be provided as in previous embodiments. An electrical connection may be made by welding. Welding may be performed axially and/or—in particular in the absence of axial accessibility, as can be seen, for example, from FIG. 18b—also obliquely. It is also conceivable and possible to weld through the interconnection piece 20 from axially above by using a suitable process such as electron beam welding.

[0115] FIGS. 20-22 each schematically show a contacting process for abutting contact surfaces 21, 11 of the interconnection piece 20 against the rod conductor 10 or for producing a zero gap in a sectional plane parallel to and through the longitudinal axis X of the stator. Here, the feeding is lateral, i.e. in a direction of movement perpendicular to the longitudinal axis of the stator. For this purpose, the interconnection pieces 20 are held laterally in grooves of insulation disks (not shown) in a displaceable manner, preferably loosely or with clearance. The clearance may be in the x-direction, in the y-direction or a superposition of the two directions, cf. coordinates in FIG. 16c. The lateral displaceability allows tolerance chains to be reduced, in particular tolerance chains/dependencies between several interconnection pieces 20 may be broken. In order to establish the surface contact by lateral feed motion, only the interconnection pieces are moved en bloc radially inwards by, for example, a robot arm individually or by a gripping device that grips several interconnection pieces.

[0116] As shown in FIG. 23, the interconnection pieces 20 may be held by nubs or holding elements 32 in grooves 31 of insulation disks 30. The interconnection pieces 20 may be elastically deformed or stressed to bend for insertion into the grooves. The nubs may be formed by an injection molding process. The nubs may also be formed by an ultrasonic process. In particular, the nubs 31 may be formed after the interconnection pieces 20 have been inserted. FIG. 24 shows a fastening process, in which an interconnection piece is fastened by nubs 32. The nubs are created by an ultrasonic tool or ultrasonic punch U by reshaping them from the material of the insulation disk. In this way, interconnection pieces 20 may be secured in particular against falling out of the grooves.

[0117] In summary, the present invention may be used to simplify the manufacturing of a stator 1 that additionally has a reduced installation space.

[0118] In particular, a pre-positioning and contacting by means of a pre-stressed surface contact of the rod conductors 10 with the interconnection pieces 20 enables a reliable electrical connection for the generation of composite windings. Efficient assembly of the stator 1 is ensured.

[0119] By making electrical contact in different planes or interconnection planes, an assembly space-efficient arrangement may be achieved. In addition, advantageous temperature control is available, in particular by means of insulation disks 30, through which cooling fluid may flow.

LIST OF REFERENCE SIGNS

[0120] 1 Stator [0121] 2 End face region of the stator [0122] 3 End face region of the stator [0123] 4 Stator laminated core [0124] 10 Rod conductor [0125] 11 Stator contact surface [0126] 20 Interconnection piece [0127] 21 Interconnection piece contact surface [0128] 30 Insulation disk [0129] 31 Groove [0130] 32 Retaining element [0131] 40 Cover part [0132] 50 Shaped strand [0133] 60 Insulation star [0134] E Electrodes (of a resistance welding device) [0135] U Ultrasonic tool [0136] X Rotation axis