METHOD AND DEVICE FOR PRODUCING AN ELECTRIC MACHINE, ELECTRIC MACHINE AND GROUP OF ELECTRIC MACHINES

Abstract

Method for producing an electric machine. Proceeding from a defined construction of the machine depending on one or more parameters that correspond to a maximum value of a mean current density over time in the one or more winding(s), and the price category, a design of the winding is allocated from a number of defined designs, wherein the designs comprise in particular a cast winding made of copper, a cast winding made of a copper alloy, a cast winding made of aluminium, a cast winding made of an aluminium alloy, a cast winding made of magnesium, a cast winding made of a conductive plastic, an insulating system, wherein the list from which the design of the insulating system is selected comprises insulating systems of the thermal class 180° C., the thermal class 250° C. and the thermal class 300° C., a cooling system selected from the designs of an air cooling system, a direct water cooling system, an indirect water cooling system, or a subselection of these designs.

Claims

1. A method for producing an electric machine comprising a laminated core and one or more windings, which each surround a tooth of the laminated core, the method comprising, proceeding from a defined construction of the electric machine comprising a defined laminated core of the electric machine to be produced, a winding design is allocated from a number of defined designs depending on one or more parameters comprising maximum torque, maximum power and minimal cooling power that correspond to a maximum value of a mean current density over time in the one or more windings and a price category, the defined designs comprising a cast winding made of copper, a cast winding made of a copper alloy, a cast winding made of aluminum, a cast winding made of an aluminum alloy, a cast winding made of magnesium, a cast winding made of a conductive plastics material, an insulating system, a list from which a design of the insulating system is selected comprising insulating systems of a 180° C. thermal class, 250° C. thermal class and a 300° C. thermal class, a cooling system, to which the one or more windings are connectable, selected from a group comprising an air cooling system, a direct water cooling system, an indirect water cooling system, or a subselection thereof.

2. The method according to claim 1, wherein the defined designs of windings available for selection in order to be allocated to the electric machine each have the same geometric dimensions.

3. The method according to claim 1, wherein a cast winding is equipped with cooling structures.

4. The method according to claim 1, wherein the permissible mean current density over time in the one or more cast windings made of copper or a copper alloy, for a time period, based thereon, of at least 1 minute, has a maximum value of greater than 10 A/mm.sup.2 when connected to an air cooling system, has a maximum value of greater than 20 A/mm.sup.2 when connected to an indirect water cooling system, has a maximum value of greater than 60 A/mm.sup.2 when connected to a direct water cooling system.

5. The method according to claim 1, wherein the permissible mean current density over time in the one or more cast windings made of aluminum or an aluminum alloy, for the 180° C. thermal class of the insulating system, for a time period, based thereon, of at least 1 minute, has a maximum value of greater than 6 A/mm.sup.2 when connected to an air cooling system, has a maximum value of greater than 12 A/mm.sup.2 when connected to an indirect water cooling system, has a maximum value of greater than 35 A/mm.sup.2 when connected to a direct water cooling system.

6. The method according to claim 1, wherein the permissible mean current density over time in the one or more cast windings made of aluminum or an aluminum alloy, for the 250° C. thermal class of the insulating system, for a time period, based thereon, of at least 1 minute, has a maximum value of greater than 7 A/mm.sup.2 when connected to an air cooling system, has a maximum value of greater than 14 A/mm.sup.2 when connected to an indirect water cooling system, has a maximum value of greater than 45 A/mm.sup.2 when connected to a direct water cooling system.

7. The method according to claim 1, wherein the permissible mean current density over time in the one or more cast windings made of aluminum or an aluminum alloy, for the 300° C. thermal class of the insulating system, for a time period, based thereon, of at least 1 minute, has a maximum value of greater than 8 A/mm.sup.2 when connected to an air cooling system, has a maximum value of greater than 16 A/mm.sup.2 when connected to an indirect water cooling system, has a maximum value of greater than 56 A/mm.sup.2 when connected to a direct water cooling system.

8. An apparatus for producing an electric machine comprising a laminated core and one or more windings, which each surround a tooth of the laminated core, the apparatus comprising a data-processing unit having a memory apparatus in which a plurality of different winding designs are stored which have the same outer dimensions, and the data-processing unit being configured to detect one or more parameters comprising maximum torque, maximum power and minimal cooling power that correspond to a maximum value of a mean current density over time in the one or more windings and a price category, and to allocate one of the winding designs stored in the memory apparatus to said windings proceeding from a defined construction of the machine comprising a defined laminated core, the winding designs comprising a cast winding made of copper, a cast winding made of a copper alloy, a cast winding made of aluminum, a cast winding made of an aluminum alloy, a cast winding made of magnesium, a cast winding made of a conductive plastics material, an insulating system, a list from which a design of the insulating system is selected comprising insulating systems of a 180° C. thermal class, a 250° C. thermal class and a 300° C. thermal class, a cooling system, to which the one or more windings can be connected, selected from a group comprising an air cooling system, a direct water cooling system, an indirect water cooling system, or a subselection of these designs.

9. An electric machine comprising a laminated core and one or more windings, which each surround a tooth of the laminated core, wherein at least one of the teeth of the laminated core each comprise a retaining device for a slid-on winding, which, after sliding the winding onto the tooth, is movable into a blocking position and prevents at least one of displacement and movement of the winding on the tooth.

10. The electric machine according to claim 9, wherein the retaining device comprises a bar, which is at least one of slidable and foldable out of the contour of the respective tooth into a blocking position.

11. The electric machine according to claim 9, wherein each winding comprises cooling structures.

12. A group comprising two or more electric machines comprising identically constructed laminated cores, the electric machines comprising windings which each surround teeth of the laminated cores, wherein at least two of the electric machines differ in terms of a design of the windings.

13. The group of electric machines according to claim 12, wherein the differing windings are selected from a group of designs, or a subselection of the group of designs, comprising: a cast winding made of copper, a cast winding made of a first copper alloy, a cast winding made of a second copper alloy, a cast winding made of aluminum, a cast winding made of a first aluminum alloy, a cast winding made of a second aluminum alloy, a cast winding made of magnesium, a cast winding made of a conductive plastics material.

14. The group of electric machines according to claim 12, wherein the differing windings are selected from a group of designs comprising: a cast winding made of copper, a cast winding made of a first copper alloy, and a cast winding made of a second copper alloy.

15. The group of electric machines according to claim 12, wherein the differing windings are selected from a group of designs comprising: a cast winding made of aluminum, a cast winding made of a first aluminum alloy, and a cast winding made of a second aluminum alloy.

16. The group of electric machines according to claim 12, wherein the differing windings are selected from a group of designs comprising: a cast winding made of a copper alloy, and a cast winding made of an aluminum alloy.

17. The group of electric machines according to claim 13, wherein the differing windings comprise an insulating system, a list from which a design of the insulating system is selected comprising insulating systems of the following thermal classes: a 180° C. thermal class, a 250° C. thermal class and a 300° C. thermal class.

18. The group of electric machines according to claim 12, wherein the differing windings are connectable to a cooling system, the cooling system being selected from a group comprising: an air cooling system, a direct water cooling system, and an indirect water cooling system.

19. The electric machine according to claim 11, wherein the cooling structures comprise at least one of cooling ducts and cooling fins.

20. The electric machine according to claim 12, wherein the differing windings are selected from different cast windings.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0053] In the following, the invention will be shown and subsequently described on the basis of embodiments in figures of the drawings, in which:

[0054] FIG. 1 is a schematic cross section through a laminated core of an electric machine comprising a tooth and the contour of a winding that can be slid onto the tooth;

[0055] FIG. 2a is a schematic longitudinal section through an electrical winding;

[0056] FIG. 2b is a schematic longitudinal section through an electrical winding comprising a cooling duct'

[0057] FIG. 2c is a schematic side view of an electrical winding comprising cooling fins;

[0058] FIG. 3 is a longitudinal section through another electrical winding;

[0059] FIG. 4 schematically shows a method for producing an electric machine;

[0060] FIG. 5 shows an apparatus for producing an electric machine;

[0061] FIG. 6 is a cross section through three different electric machines; and

[0062] FIG. 7 shows a tooth of a laminated core comprising a retaining device for a winding.

DETAILED DESCRIPTION OF THE DRAWINGS

[0063] FIG. 1 is a cross section through a laminated core 1 of an electric machine, with a plurality of teeth 2, 3 being shown over the circumference of the laminated core 1. Between the individual teeth 2, 3 of the laminated core, there is space for electrical windings 4, which each surround an individual tooth 2, 3. The space around the tooth 3 available for a winding is defined by the dashed lines 5, 6, is shaded and is denoted by reference numeral 7. When there are high power requirements on the electric machine, this space 7 needs to be utilized as efficiently as possible, i.e. it must be possible to achieve the highest possible current density in this space. To do this, it is necessary to fill a particular high proportion of the space with a highly conductive electrical conductor. This requirement can be met by cast coils in particular. For electric machines with lower power requirements, a conventional coil may also be wound around the tooth 3 by means of a strand-shaped, flexible conductor.

[0064] FIG. 2a is an exemplary longitudinal section through a cast coil 4′, with the extension of the cross sections of the helical conductor 10 enlarging in the radial direction of the coil 4′ and reducing in the direction parallel to the axis 11 from the first end 8 of the coil 4′ towards the second end 9. This is an exemplary configuration of a conductor having a variable cross section, with the use of conductors having a constant cross section along the coil likewise being possible. In the arrangement shown in FIG. 2, a constant cross-sectional area of the conductor 10 results along the coil, such that the current-carrying capacity remains constant in the entire coil. Therefore, optimal heat distribution of the heat loss in the coil can be achieved.

[0065] The material of the conductor 10 of which the cast coil 4′ consists can be selected according to the electrical requirements on the machine and the price requirements and other requirements, for example mechanical requirements, on the electric machine. For example, pure copper or aluminum or copper alloys, aluminum alloys, magnesium or other metal alloys can be selected. Conductive plastics material also comes into consideration, in particular for special applications.

[0066] FIG. 2b shows the same section as in FIG. 1. The cast winding 4′ comprises cooling ducts 27 here, through which a coolant can flow. The cooling ducts 27 may be produced during casting or by finishing. In the example shown, they are implemented by recesses on the flat sides of adjacent windings and thus extend between the windings. The cooling ducts may, however, also be in the interior of the windings, for example.

[0067] FIG. 2c is a plan view of the cast winding 4′, with the same viewing direction being selected as in FIGS. 2a and 2b. An outer face of the cast winding 4′ can be seen, on which the superimposed windings are visible. On this outer face, cast-on cooling fins 28 are visible on the windings 4′. The outer face shown is particularly suitable for providing the cooling fins 28, since it typically does not face an adjacent winding 4′ and the additional installation space required by the cooling fins 28 does not come at the expense of the use of space between the adjacent teeth.

[0068] FIG. 3 is a longitudinal section through a coil 4″ wound from a wire-shaped conductor. It is clear that there are spaces between the individual windings of the coil due to the round cross section of the conductor, and these spaces limit the electrical performance of the coil. Nevertheless, this type of coil can also be optimized for certain power requirements in relation to the price.

[0069] FIG. 4 schematically shows a method for producing an electric machine, in which, in a first method step 12, the electrical requirements of the machine, and optionally mechanical requirements and price requirements, are ascertained and recorded in a data-processing apparatus. In a second step 13, from this information and from a fixed outer contour of the coils with a given design of the electric machine, the type of coil and the material of the conductor of the coil are determined with which the given requirements can be met. Subsequently, in another method step 14, a number of coils of the determined type are produced, and, in a method step 15, are applied to and brought into contact with the laminated core, optionally the teeth of the laminated core of the electric machine to be produced.

[0070] FIG. 5 schematically shows a device for producing electric machines, with reference numeral 16 denoting an input device by means of which the electrical, mechanical and price requirements can be recorded in the electric machine to be produced. The type of the electric machine can be specified in many details, down to the type of electrical coils to be used.

[0071] Reference numeral 17 denotes a data-processing apparatus which comprises a processor unit 18, which allocates the parameters of the coils to be produced to the input data from the input unit 16 by means of a database 19. In particular, the material of the conductors and optionally also a cross-sectional shape of the conductors and/or a cooling structure are allocated to the coils to be produced. The processor unit 18 then passes the data on the coils to be produced to an output unit 20. Said unit can display the parameters such that the production and assembly of the coils can then be ordered, or the output unit 20 may already be configured as part of an automatic production device for electric machines and may control either the selection of suitable coils from a warehouse or the production of suitable coils in an automatic manner.

[0072] FIG. 6 shows, by way of example, a group of three electric machines, in particular electric motors, of which a first machine 21 comprises windings made of drawn round copper wire, the second machine 22 comprises cast copper coils, and the third machine 23 comprises cast aluminum coils. The coils in all three machines have the same outer dimensions, and the same applies to the laminated cores.

[0073] The first machine 21 is particularly cost-effective, the second machine 22 achieves a particularly high current-carrying capacity and power, and the third machine 23 is particularly mechanically stable. The machines form a group of machines that can be produced cost-effectively and can be adapted to the requirements.

[0074] FIG. 7 shows a tooth 3 of a laminated core comprising two bars 24, 26, which can be slid into recesses 25 in the tooth 3 such that, in the fastened state, they project out of the tooth and retain a winding positioned on the tooth.

[0075] The invention makes it possible to produce different electric machines by means of one construction platform, with the type of the electric machine, including the laminated cores, being able to be configured such that the different requirements on the electrical and mechanical performance and on the service life and price can be met solely by designing the electrical coils by means of selecting suitable materials for the coil conductors.

[0076] The present disclosure includes the following aspects, inter alia: [0077] 1. A group comprising two or more rotating electric machines (21, 22, 23), in particular generators and/or motors, which are equipped with identically constructed laminated cores, the machines (21, 22, 23) being equipped with windings (4, 4′, 4″) which each surround teeth (2, 3) of the laminated cores, characterized in that at least two of the machines (21, 22, 23) differ in terms of the design of the windings, the differing windings (4, 4′, 4″) in particular being selected from different cast windings and windings wound from wire. [0078] 2. The group of electric machines (21, 22, 13) according to aspect 1, characterized in that the differing windings (4, 4′, 4″) are selected from the following designs or a subselection of the following designs: cast winding made of copper, cast winding made of a first copper alloy, cast winding made of a second copper alloy, cast winding made of aluminum, cast winding made of a first aluminum alloy, cast winding made of a second aluminum alloy, cast winding made of magnesium, cast winding made of a conductive plastics material, winding (4″) wound from a wire. [0079] 3. The group of electric machines (21, 22, 13) according to aspect 1, characterized in that the differing windings (4, 4′, 4″) are selected from the following designs: cast winding made of copper, cast winding made of a first copper alloy, cast winding made of a second copper alloy. [0080] 4. The group of electric machines according to aspect 1, characterized in that the differing windings (4, 4′, 4″) are selected from the following designs: cast winding made of aluminum, cast winding made of a first aluminum alloy, cast winding made of a second aluminum alloy. [0081] 5. The group of electric machines according to aspect 1, characterized in that the differing windings (4, 4′, 4″) are selected from the following designs: cast winding made of a copper alloy, cast winding made of an aluminum alloy, winding wound from a wire. [0082] 6. A method for producing a rotating electric machine (21, 22, 23) comprising a laminated core and one or more windings (4, 4′, 4″), which each surround a tooth (2, 3) of the laminated core, characterized in that, proceeding from a defined construction of the machine comprising a defined laminated core of the electric machine to be produced, a design of the winding (4, 4′, 4″) is allocated from a number of defined designs depending on one or more of the parameters of maximum torque, maximum power and price category, the designs in particular comprising a cast winding made of copper, a cast winding made of a copper alloy, a cast winding made of aluminum, a cast winding made of an aluminum alloy, a cast winding made of magnesium, a cast winding made of a conductive plastics material, and a winding wound from a wire, or a subselection of these designs. [0083] 7. The method according to aspect 6, characterized in that the defined designs of windings (4, 4′, 4″) available for selection in order to be allocated to the electric machine (21, 22, 13) each have the same geometric dimensions. [0084] 8. The method according to aspect 6 or 7, characterized in that a cast winding is equipped with cooling structures, preferably in the form of cooling ducts (27) or cooling fins (28). [0085] 9. An apparatus for producing a rotating electric machine (21, 22, 23) comprising a laminated core and one or more windings (4, 4′, 4″), which each surround a tooth (2, 3) of the laminated core, characterized in that the apparatus comprises a data-processing unit (17) having a memory apparatus (19) in which a plurality of different designs of the winding are stored which have the same outer dimensions, and the data-processing unit being configured to detect one or more of the parameters of maximum torque, maximum power and price category, and to allocate one of the designs stored in the memory apparatus (19) to said winding(s) proceeding from a defined construction of the machine comprising a defined laminated core, the designs in particular comprising a cast winding made of copper, a cast winding made of a copper alloy, a cast winding made of aluminum, a cast winding made of an aluminum alloy, a cast winding made of magnesium, a cast winding made of a conductive plastics material, a winding wound from a wire, or a subselection of these designs. [0086] 10. A rotating electric machine (21, 22, 23) comprising a laminated core and one or more windings (4, 4′, 4″), which each surround a tooth (2, 3) of the laminated core, characterized in that at least one, in particular a plurality of or all the teeth (2, 3) of the laminated core each comprise a retaining device for a slid-on winding, which, after sliding the winding onto the tooth, can be brought into a blocking position and prevents displacement and/or movement of the winding (4, 4′, 4″) on the tooth. [0087] 11. A rotating electric machine according to aspect 10, characterized in that the retaining device comprises a bar (24, 26), which can be slid or folded out of the contour of the relevant tooth (3) into a blocking position. [0088] 12. A rotating electric machine according to aspect 10 or 11, characterized in that a cast winding comprises cooling structures, preferably in the form of cooling ducts (27) or cooling fins (28).