ELECTRIC MACHINE HAVING MULTIPLE RIGID WINDING PIECES IN THE FORM OF HOLLOW CONDUCTORS

Abstract

The invention relates to an electric machine (1) having: a rotor (3); a stator (2); multiple winding pieces (5) which are in the form of hollow conductors, form different coils of a winding (4) of the electric machine (1) and are each part of a coolant circuit of the electric machine (1); and multiple external phase connections (L1-L3) which are electrically connected to the winding pieces (5). According to the invention, a hydraulic connection part (15) to which a number of the winding pieces (5) are hydraulically connected, and a seal (27) which has multiple passages (28), in each of which an end portion (8) of one of the winding pieces (5) is situated, are provided, the hydraulic connection part (15) and the seal (27) having opposing surfaces (29, 30) which rest against each other in order to ensure sealing of the individual connections of the winding pieces (5) to the hydraulic connection part (15).

Claims

1. Electric machine (1) having: a rotor (3); a stator (2); multiple winding pieces (5) which are in the form of hollow conductors and which are each part of a coolant circuit of the electric machine (1), a hydraulic connection part (15) to which a number of the winding pieces (5) are hydraulically connected, and a seal (27) which has multiple passages (28), in each of which an end portion (8) of one of the winding pieces (5) is situated, the hydraulic connection part (15) and the seal (27) having opposing surfaces (29, 30) which are pressed against each other in order to ensure sealing of the individual connections of the winding pieces (5) to the hydraulic connection part (15); characterised in that the winding pieces (5) form different coils of a winding (4) of the electric machine (1); multiple external phase connections (L1-L3) are provided, which are electrically connected to the winding pieces (5), and the seal comprises a potting compound which has been filled into a space (48) in which the end portions (8) of the winding pieces (5) are arranged, flows around the end portions (8) and is hardened after some time.

2. Electric machine according to claim 1, characterised in that fastening means (47) are provided to press the connection part (15) and the seal (27) firmly against each other.

3. Electric machine according to claim 1 or 2, characterised in that the seal (27) is made of an electrically insulating material.

4. Electric machine according to one of the preceding claims, characterised in that the seal (27) is designed such that at least a first group of the end portions (8) is electrically insulated from a second group of the end portions (8).

5. Electric machine according to one of the preceding claims, characterised is that the hydraulic connection part (15) has a channel (31, 32) which is fluidically connected to a number of the winding pieces (5) so that a coolant can be fed into the winding pieces (5) or a coolant exiting the winding pieces (5) can be collected.

6. Electric machine according to claim 5, characterised is that the at least one channel (31, 32) provided in the connection part (15) is in the form of a groove.

7. Electric machine according to one of the preceding claims, characterised in that the hydraulic connection part (15) is designed in such a way that the winding pieces (5) connected to it are hydraulically connected in parallel.

8. Electric machine according to one of the preceding claims, characterised in that the end portions (8) of the individual winding pieces (5) run through the seal (27) and project in the direction of the hydraulic connection part (15), where they each dip into a connection opening (46) of the hydraulic connection part (15).

9. Electric machine according to one of the preceding claims, characterised in that the passages (28) provided in the seal (27) are designed so that the end portions (8) of the winding pieces (5) are tightly received at their periphery.

10. Electric machine according to one of the preceding claims, characterised is that the connection openings (46) provided in the hydraulic connection part (15) have a larger cross-section than the end portions (8) of the winding pieces (5), and in that the end portions (8) are arranged in such a way that they do not touch the hydraulic connection part (15).

11. Electric machine according to one of the preceding claims, characterised is that the end portions (8) of the winding pieces (5) are glued in the seal (27).

12. Method for the hydraulic connection of multiple rigid winding pieces (5) of an electric machine (1) which are in the form of hollow conductors to a hydraulic connection part (15) which has multiple connection openings (46) for end portions (8) of the winding pieces (5), characterised by the following steps: arranging the end portions (8) in a space (48), pouring a potting compound into the space (48), which potting compound flows around the end portions (8) of the winding pieces (5) and after some time hardens and forms a seal (27), the amount of potting compound being such that the end portions (8) protrude from the seal (27), and placing the hydraulic connection part (15) on the seal (27) so that the protruding end portions (8) dip into the connection openings (46) of the hydraulic connection part (15), opposing surfaces (29, 30) of the hydraulic connection part and of the seal (27) being pushed against each other in order to seal the connections of the winding pieces (5) to the hydraulic connection part (15).

13. Method according to claim 12, characterised in that a further seal is inserted between the hydraulic connection part (15) and the seal (27).

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0048] The invention is explained in more detail hereinafter by way of example with reference to the accompanying drawing, in which:

[0049] FIG. 1 shows a sectional view of an electric machine with solid metal contact rings according to a first embodiment of the invention;

[0050] FIG. 2 shows a perspective view of a winding piece of an electric machine in the form of a hairpin;

[0051] FIG. 3a, 3b show different views of an arrangement formed of multiple distribution elements for dividing the current fed in at the external phase connections;

[0052] FIG. 4a to 4c show contact rings of the individual phases of an electric machine according to the invention;

[0053] FIG. 5 shows an assembled contact-ring arrangement of the contact rings of FIG. 4a-4c;

[0054] FIG. 6a, 6b show different views of a hydraulic connection part according to a first embodiment of the invention;

[0055] FIG. 7 shows a sectional view of a hydraulic connection part and a seal according to a particular embodiment of the invention;

[0056] FIG. 8 shows a sectional view of an electric machine with electrical contact rings in the form of printed circuit boards according to a second embodiment of the invention;

[0057] FIG. 9a-9d show various printed circuit boards of an electric machine which serve as contact rings for electrically contacting certain winding pieces of the winding of the electric machine; and

[0058] FIG. 10 shows a perspective view of an electrical contact arrangement comprising the distribution elements of FIG. 3a, 3b and the printed circuit boards shown in FIG. 8a-8d.

[0059] FIG. 1 shows a sectional view of an electric machine 1 with a stator 2, a rotor 3 and a winding 4 formed from multiple rigid winding pieces 5. The rigid winding pieces 5 are designed as hollow conductors and comprise a continuous channel 9 through which a coolant is passed in order to cool the electric machine 1. The individual winding pieces 5 are connected hydraulically in parallel and are each part of a coolant circuit of the electric machine 1

[0060] In the embodiment example of FIG. 1, the winding pieces 5 are each arranged individually in grooves 24 of the stator 2 of the electric machine 1. The cross-section of the winding pieces 5 is adapted to the cross-section of the grooves 24 so that they are accommodated in the grooves 24 with substantially no play. Alternatively, more than one winding piece 5 could also be provided per groove 24.

[0061] For example, an oil, Therminol, Galden or carbon dioxide can be used as a coolant.

[0062] The electric machine 1 further comprises a housing 13 with a housing cover 17 in which all components of the electrical and hydraulic connection arrangement are housed.

[0063] In addition, fastening means 47 are provided, which are designed here as screws and by means of which the housing is screwed. The electric machine is designed in such a way that the tightening of the fastening means simultaneously also presses a hydraulic connection part 15 against a seal 27. The design and function of the components mentioned will be explained in detail below.

[0064] In the electric machine 1 shown in FIG. 1, the winding pieces 5 are designed as so-called hairpins, as shown by way of example in FIG. 2. The winding piece 5 shown in FIG. 2 comprises two substantially parallel legs 6 and a curved transition region 10 which connects the two legs 6 to each other. The hairpin shown is in the form of a hollow conductor and comprises a continuous channel 9 which passes from one end portion 8 to the other end portion 8 and through which a coolant is passed in order to cool the winding 4 of the electric machine 1 during operation. The hairpin is open at each of its ends 33. One of the ends 33 can thus be used as a coolant inlet and the other end 33 as a coolant outlet.

[0065] The winding piece 5 shown in FIG. 2 can be made of copper, for example. It is preferably provided with an electrically insulating layer on its outer surface.

[0066] The winding piece 5 can have a round or angular profile, for example. The winding piece 5 can also have a different profile at different portions. According to a preferred embodiment, the profile at the end portions is round.

[0067] The electric machine 1 shown in FIG. 1 has a three-phase design and accordingly has three external phase connections L1, L2 and L3, to which the electrical phases U, V and W are fitted. The winding 4 of the electric machine 1 is designed here in such a way that it comprises multiple coils connected in parallel for each electrical phase U, V and W. The individual winding pieces 5 are accordingly electrically connected in such a way that in each case multiple winding pieces are connected in series to form a coil, and multiple such coils belonging to the same electrical phase U, V, W are connected in parallel in each case. According to a particular embodiment of the invention, each phase U, V, W may comprise, for example, eight parallel coils. The winding 4 of the electric machine can of course also have more coils or fewer coils connected in parallel.

[0068] The end portions 8 of those winding pieces 5 which are at the phase potential U, V and W are connected to an associated external phase connection L1, L2 or L3 respectively via an electrical contact arrangement, which will be discussed in more detail below.

[0069] In this embodiment, said electrical contact arrangement comprises a set of three distribution elements 11a, 11b, 11c, as shown by way of example in FIGS. 3a and 3b. Each of the distribution elements 11a, 11b, 11c is electrically connected to one of the external phase connections L1, L2, L3. In the depicted embodiment example, the distribution element 11a is electrically connected to the phase connection L1, the distribution element 11b to the phase connection L2 and the distribution element 11c to the phase connection L3. The three distribution elements 11a to 11c are arranged next to each other in the axial direction B of the electric machine 1 and are electrically insulated from each other.

[0070] Each distribution element 11a, 11b, 11c further comprises a plurality of receptacles 45 for electrical connection elements 12a-12d, which are preferably evenly distributed over the circumference of the distribution element. The individual distribution elements 11a, 11b, 11c basically serve to distribute the current suppled at the phase connections L1, L2, L3 over the circumference of the electric machine 1 and to conduct it to the subsequent contact rings 18a- 18d. Each of the distribution elements 11a-11d is electrically connected to a corresponding contact ring 18a-18d via multiple electrical connection elements 12a-12d.

[0071] FIGS. 4a-4c show various contact rings 18a-18c according to a specific embodiment of the invention. The contact ring 18a is electrically connected to the associated distribution element 11a and the phase connection L1, the contact ring 18b is electrically connected to the associated distribution element 11b and the phase connection L2, and the contact ring 18c is electrically connected to the associated distribution element 11c and the phase connection L3.

[0072] As can be seen in FIGS. 4a-4c, the electrical connection elements 12a-12c are each attached to their respective associated contact rings 18a-18c and are evenly distributed over the circumference of the contact rings 18a-18c. In the assembled state, the contact rings 18a-18c lie substantially transverse to the axial direction B of the electric machine 1, and the electrical connection elements 12a-12c run substantially in the axial direction B.

[0073] Each of the electrical contact rings 18a-18c comprises a plurality of arms 23 for electrically contacting end portions 8 of those winding pieces 5 which are fitted to a particular electrical phase U, V or W. In the present embodiment example, each contact ring 18a-18c comprises eight arms 23 for contacting one each of eight winding pieces 5 of eight coils connected in parallel. The arms 23 have a different length in order to contact radially further inward or further outward end portions 8 of the winding pieces 5. Each arm 23 comprises a contact opening 16 through which the end portion 8 of a winding piece 5 is inserted and soldered.

[0074] In an electric machine 1 according to the invention, the end portions 8 of the individual winding pieces 5 are preferably arranged in multiple, in particular circular, rows. The end portions 8 of the winding pieces 5 are preferably arranged in parallel next to each other and preferably all point in the axial direction B. The end portions 8 preferably all end at the same axial height, i.e. approximately in the same plane. This facilitates the electrical contacting of the individual winding pieces 5 as well as their hydraulic connection to the coolant circuit.

[0075] FIG. 5 shows the contact rings 18a-18c of FIG. 4a-4c in an assembled state. As can be seen, the individual contact rings 18a-18c are arranged next to each other in the axial direction B of the electric machine 1 and are electrically insulated from each other.

[0076] In addition to the electrical connection of individual winding pieces 5 to their respective associated external phase connections L1, L2, L3, it is also necessary to connect certain winding pieces 5 to each other in series to form the coils of the winding 4 of the electric machine 1. For the purpose of series connection, simple electrical conductors can be used, for example, which are soldered between the desired winding pieces.

[0077] According to a preferred embodiment of the invention, however, an electrical contact disc 39 with electrical connectors 40 is provided, as shown in FIG. 13. Before describing this contact disc 39, the hydraulic connection of the individual winding pieces 5 will first be discussed hereinafter:

[0078] FIGS. 6a and 6b show various perspective views of a hydraulic connection part 15 to which all winding pieces 5 are hydraulically connected. The hydraulic connection part 15 comprises multiple connections or connection openings 46, which are designed here as circumferential channels 31 or 32, which are each fluidically connected to a number of the winding pieces 5 and via which a coolant is fed into the winding pieces 5 or a coolant exiting the winding pieces 5 is collected.

[0079] The central channel 32 of the hydraulic connection part 15 is wider here than the other two channels 31 and spans two adjacently arranged annular rows of end portions 8. The other two channels 31, one of which is arranged radially outside and one radially inside the central channel 32, are each associated with a single annular row of end portions 8. All channels 31, 32 run substantially over the entire circumference of the hydraulic connection part 15.

[0080] In the present case, the coolant is fed into the winding pieces 5 connected thereto via the central channel 32 and exits at the other end of the winding pieces 5 either into the outer channel 31 or into the inner channel 31. In the region of the central channel 32, various passages 26 are provided, through which the coolant enters the channel 32. Furthermore, in the region of the outer channel 31, multiple passages 44 are provided, via which the coolant exits the hydraulic connection part 15. Further inlet or outlet openings can also be provided on the circumferential surface of the hydraulic connection part 15.

[0081] The hydraulic connection part 15 further comprises a plurality of passages 25, through which the connection elements 12a-12c between the contact rings 18a-18c and the distribution elements 11a-11c are inserted.

[0082] As can be seen in FIGS. 6a and 6b, the individual channels 31, 32 are formed as annular grooves which are arranged in a surface of the hydraulic connection part 15 pointing in the direction of the contact rings 18a-18d. In the first embodiment of the electric machine 1 of FIG. 1, the end portions 8 of the individual winding pieces 5 project into these grooves. The hydraulic connections of the winding pieces 5 are sealed here by means of a seal 27, as shown by way of example in FIG. 7.

[0083] FIG. 7 shows a seal 27 with multiple passages, each designed to receive an end portion 8 of a winding piece 5. The end portions 8 of the winding pieces 5 are each received with a form fit in the passages 28, which ensures the tightness of the arrangement. Alternatively or additionally, one or more seals (not shown) can also be provided on the seal 27.

[0084] The seal 27 and the hydraulic connection part 15 have opposing surfaces 29 and 30, respectively, which are of complementary design (in this case planar) and are pressed firmly against each other when assembled, thereby sealing the hydraulic connections of the individual winding pieces 5.

[0085] The seal 27 may, for example, be manufactured as a prefabricated component, e.g. from plastic. According to a preferred embodiment of the invention, the seal 27 comprises a potting compound which is poured into a space 48 in which the end portions 8 of the individual winding pieces 5 are located and then spreads around the end portions 8. After some time, the potting compound hardens and forms the actual sealant, as shown in FIG. 7. The end portions 8 protrude a little beyond the surface 29 of the seal 27. When the hydraulic connection part 15 is now placed on the seal 27 in a next process step, the end portions 8 dip into the various connection openings 46 or channels 31, 32. Coolant can now be fed into the winding pieces 5 or coolant escaping from the winding pieces 5 can be collected via the end faces 33 of the individual winding pieces 5. All winding pieces 5 are preferably connected hydraulically in parallel in the coolant circuit.

[0086] In the embodiment example of the electric machine 1 shown in FIG. 1, the coolant flows into the electric machine 1 via a coolant inlet 19 provided on the housing 13 of the electric machine 1 and is fed from there to the hydraulic connection part 15 via one or more channels. There, the coolant enters the central coolant channel 32 from the outside via the passages 26 and is then fed into the end portions 8 of the winding pieces 5 connected fluidically thereto, runs through the individual winding pieces 5 and exits again at the two channels 31. From there, the coolant is guided into a chamber 21 in which the distribution elements 11a-11c are located. The coolant lastly exits the electric machine 1 again at the coolant outlet 20.

[0087] The cross-section of the channels 31, 32 is selected in the embodiment example shown so that the end portions 8 of the individual winding pieces 5 can dip into the channels 31, 32 without touching the hydraulic connection part 15. A free space therefore remains between the end portions 8 of the winding pieces 5 and the walls of the channels 31, 32, whereby the end portions 8 are electrically insulated from the hydraulic connection part 15. Additional insulation elements can therefore be provided, but do not necessarily have to be. Furthermore, this makes it possible to manufacture the hydraulic connection part 15 also from an electrically conductive material, in particular metal.

[0088] Furthermore, power electronics of the electric machine 1 (not shown) can also be integrated into the coolant circuit and cooled by the coolant. By appropriate design of the coolant path through the electric machine 1, in principle any components can be cooled, if desired. A person skilled in the art will adapt the coolant path appropriately according to the requirements within the scope of his expertise.

[0089] FIG. 8 shows a sectional view of an electric machine 1 according to a second embodiment of the invention, which is largely identical in construction to the electric machine 1 of FIG. 1. In contrast to the first embodiment, however, the contact rings 18a-18b are not formed as solid metal rings, but consist of individual printed circuit boards 14a-14d, which are denoted here as a whole by the reference sign 14.

[0090] FIG. 9a-9d show perspective views of the aforementioned printed circuit boards 14a-14d. Some of them are contacted by the previously described distribution elements 12a-12c and are thus each electrically connected to one of the electrical phases U, V, W or to an external phase connection L1, L2, L3. The individual printed circuit boards 14a-14d preferably also comprise electrical conductor tracks (not shown) which electrically connect certain winding pieces 5 to each other and connect them in series to form the coils of the winding 4 of the electric machine 1.

[0091] Each of the printed circuit boards 14a-14d further comprises a plurality of through-openings 36 for the end portions 8 of the winding pieces 5. Since the winding pieces 5 are inserted through all printed circuit boards 14a-14d, the number of through-openings 36 is the same in each case. The end portions 8 of the individual winding pieces 5 are each soldered to one or more of the circuit boards 14a-14d, depending on the electrical connection.

[0092] In the depicted embodiment example of FIGS. 9 and 10, the printed circuit board 14a is arranged opposite the hydraulic connection part 15. This is followed by the individual printed circuit boards 14b, 14c and 14d. Alternatively, more than 4 printed circuit boards can be provided.

[0093] In the present case, the printed circuit board 14a is contacted by the connection elements 12a, the printed circuit board 14b is contacted by the connection elements 12b, and the printed circuit board 14c is contacted by the connection elements 12c. The printed circuit board 14d is at zero potential. As can be seen in FIG. 9b-9d, the individual printed circuit boards 14a-14c each have a plurality of through-openings 43 through which the connection elements 12a and/or 12b and/or 12c pass. Due to their arrangement in the printed circuit board stack, the printed circuit board 14a has the most through-openings 43 and the printed circuit board 14c has the least through-openings 43 for connection elements 12a-12c.

[0094] Lastly, FIG. 10 shows the entire contact arrangement in an assembled state. The individual printed circuit boards 14a-14d are arranged here in a stack of printed circuit boards 14 and are each electrically connected to one of the electrical distribution elements 11a-11c via associated connection elements 12a-12c.

[0095] The outermost printed circuit board 14a is pressed against the hydraulic connection part 15 in the assembled state and thus simultaneously assumes the function of the seal 27 described above, which seals the hydraulic connections of the winding pieces on the hydraulic connection part 15. Optionally, another seal 27 can also be inserted or moulded between the outermost printed circuit board 14a and the hydraulic connection part 15.