ACTIVE PART FOR AN ELECTRICAL MACHINE COMPRISING A COIL WITH PREFABRICATED PUSH-ON ELEMENTS AND CONNECTING ELEMENTS, ELECTRICAL MACHINE, AND METHOD OF PRODUCTION

Abstract

The disclosure relates to an active part for an electrical machine, wherein the active part includes: a plurality of teeth and a plurality of coils, wherein a coil of the plurality of coils is arranged on each of the teeth, wherein each of the coils has a plurality of prefabricated push-on elements arranged adjacent to one another on the tooth and enclose the tooth in parts, and wherein each of the coils has a plurality of prefabricated connecting elements each for electrically connecting two adjacent push-on elements.

Claims

1. An active part (1) for an electrical machine, comprising: a plurality of teeth; and a plurality of coils arranged on the respective teeth, wherein the respective coils have a plurality of prefabricated plug-on elements arranged next to one another on a respective tooth and surround the tooth in regions, wherein the respective coils have a plurality of prefabricated connecting elements for electrically connecting, in each case, two plug-on elements arranged next to one another, wherein the respective plug-on elements are of U-shaped design and have a central region and two limb regions, wherein the central region bears against a transverse side of the tooth and the two limb regions bear against respective longitudinal sides of the tooth at least in regions, and wherein at least one limb region of the respective plug-on elements runs obliquely in relation to a base surface of the tooth, wherein the tooth has guide elements by which the oblique direction of the plug-on elements is prespecified.

2. The active part of claim 1, wherein each plug-on element of the plurality of plug-on elements and each connecting element of the plurality of connecting elements has a rectangular cross section.

3. The active part, of claim 1, wherein the plurality of plug-on elements and the plurality of connecting elements are prefabricated in such a way that the plurality of plug-on elements and the plurality of connecting elements bear against an outer contour of the tooth at least in regions.

4. The active part of claim 1, wherein the respective connecting elements are of U-shaped design and have a central region and two limb regions, wherein the central region bears against a transverse side of the tooth and the two limb regions bear against respective longitudinal sides of the tooth at least in regions.

5. The active part of claim 1, wherein the respective connecting elements have a straight design and bear against a transverse side of the tooth.

6. The active part of claim 1, wherein the plurality of connecting elements is arranged on a board, and wherein at least one electronic component is arranged on the board.

7. The active part of claim 1, wherein the plurality of plug-on elements and the plurality of connecting elements are coated with an insulation at least in regions.

8. The active part of claim 1, wherein the respective connecting elements are connected to the associated plug-on elements by a weld or solder.

9. The active part of claim 8, wherein each tooth of the plurality of teeth has, on a top side, at least one opening for the weld or solder.

10. An electrical machine comprising: a stator or rotor having: a plurality of teeth, and a plurality of coils arranged on the respective teeth, wherein the respective coils have a plurality of prefabricated plug-on elements arranged next to one another on a respective tooth and surround the tooth in regions, wherein the respective coils have a plurality of prefabricated connecting elements for electrically connecting, in each case, two plug-on elements arranged next to one another, wherein the respective plug-on elements are of U-shaped design and have a central region and two limb regions, wherein the central region bears against a transverse side of the tooth and the two limb regions bear against respective longitudinal sides of the tooth at least in regions, and wherein at least one limb region of the respective plug-on elements runs obliquely in relation to a base surface of the tooth, wherein the tooth has guide elements by which the oblique direction of the plug-on elements is prespecified.

11. The active part of claim 2, wherein the plurality of plug-on elements and the plurality of connecting elements are prefabricated in such a way that the plurality of plug-on elements and the plurality of connecting elements bear against an outer contour of the tooth at least in regions.

12. The active part of claim 11, wherein the respective connecting elements are of U-shaped design and have a central region and two limb regions, wherein the central region bears against a transverse side of the tooth and the two limb regions bear against respective longitudinal sides of the tooth at least in regions.

13. The active part of claim 11, wherein the respective connecting elements have a straight design and bear against a transverse side of the tooth.

14. The active part of claim 2, wherein the plurality of connecting elements is arranged on a board, and wherein at least one electronic component is arranged on the board.

15. The active part of claim 2, wherein the plurality of plug-on elements and the plurality of connecting elements are coated with an insulation at least in regions.

16. The active part of claim 3, wherein the plurality of connecting elements is arranged on a board, and wherein at least one electronic component is arranged on the board.

17. The active part of claim 3, wherein the plurality of plug-on elements and the plurality of connecting elements are coated with an insulation at least in regions.

18. The active part of claim 6, wherein the plurality of plug-on elements and the plurality of connecting elements are coated with an insulation at least in regions.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Further features of the disclosure may be found in the claims, the figures, and the description of the figures. The features and combinations of features cited above in the description and the features and combinations of features cited below in the description of the figures and/or shown in the figures alone may be used not only in the respectively indicated combination but also in other combinations, without departing from the scope of the disclosure.

[0027] The disclosure will now be explained in more detail on the basis of exemplary embodiments and with reference to the appended drawings, in which:

[0028] FIG. 1 shows a tooth and a coil of an active part of an electrical machine according to the prior art.

[0029] FIG. 2 shows a tooth and a coil according to one embodiment.

[0030] FIG. 3 shows a side view of the tooth with the coil according to FIG. 2.

[0031] FIG. 4 shows a sectional illustration of the tooth and the coil according to FIG. 3.

[0032] FIG. 5 shows a tooth and a coil of an active part of an electrical machine according to a further embodiment.

[0033] FIG. 6 shows a side view of the tooth and the coil according to FIG. 5.

[0034] FIG. 7 shows a sectional illustration of the tooth and the coil according to FIG. 6.

[0035] FIG. 8 shows a plug-on element and a connecting element according to one embodiment, wherein a turn of the coil is formed by the plug-on element and the connecting element.

[0036] FIG. 9 shows a limiting element on a top side of the coil according to an embodiment, which limiting element has corresponding openings for inserting a tool.

[0037] FIG. 10 shows a plug-on element and a connecting element according to a further embodiment.

[0038] FIG. 11 shows a limiting element of a coil according to a further embodiment.

[0039] FIG. 12 shows a plug-on element and connecting elements which are arranged on a common board, according to an embodiment.

[0040] Identical or functionally identical elements are provided with the same reference symbols in the figures.

DETAILED DESCRIPTION

[0041] FIG. 1 shows a schematic perspective view of a tooth 2 and a coil 3 arranged on the tooth 2. The tooth 2 and the coil 3 are part of an active part 1 of an electrical machine. The active part may be a stator or a rotor of the electrical machine. The tooth 2 has a cuboidal shape in the region in which the coil 3 is arranged, and has opposite longitudinal sides 4a, 4b and opposite transverse sides 5a, 5b. Only the longitudinal side 4a may be seen in the present illustration. The tooth 2 has a lower limiting element 8a on a bottom side 6, and the tooth has an upper limiting element 8b on a top side 7. The coil 3 is fitted onto the tooth 3 between the limiting elements 8a, 8b. In the present example, the coil 3 is formed by a continuous wire 9 which is wound onto the tooth 2.

[0042] FIG. 2 shows a perspective view of a tooth 2 with a coil 3 according to one embodiment. Here, the coil 3 is designed as a straight armature winding. The coil 3 includes a plurality of plug-on elements 10 which are plugged onto the coil 2. These plug-on elements 10 are prefabricated and matched to the profile of the tooth 2 or the outer contour of the tooth 2. Furthermore, the coil 3 includes a plurality of connecting elements 11 by way of which in each case two plug-on elements 10 which are arranged one above the other are electrically connected to one another.

[0043] In addition, FIG. 3 shows a side view of the tooth 2 and the coil 3 according to FIG. 2. It may be seen here that the respective plug-on elements 10 run parallel in relation to a base surface 12 or parallel in relation to the limiting element 8a. The respective plug-on elements 10 are of substantially U-shaped design and are pushed onto the tooth 2 along the direction of the arrow 13. In this example, the respective plug-on elements 10 bear against the transverse side 5a completely and against the respective longitudinal sides 8a, 8b at least in regions.

[0044] FIG. 4 shows the tooth 2 and the coil 3 according to FIG. 3 along section IV-IV. It may be seen here that the respective plug-on elements 10 are arranged parallel in relation to one another and parallel in relation to the base surface 12. In addition, it may be gathered from FIG. 4 that the respective plug-on elements 10 have a rectangular cross section. In other words, the respective plug-on elements 10 are designed in the form of a flat wire. As may be seen in FIG. 2, the respective connecting elements 11 are located in the region of the transverse side 5b or the end side of the tooth 2. Here, the respective connecting elements 11 run parallel in relation to one another and in each case obliquely in relation to the base surface 12 of the tooth 2. As a result, the plug-on elements 10 which are arranged one above the other may be electrically connected to one another in order to realize the coil 3.

[0045] FIG. 5 shows a perspective view of a tooth 2 and a coil 3 according to a further embodiment. FIG. 6 shows the side view of the tooth 2 and the coil 3 according to FIG. 5. It may be seen here that the respective plug-on elements 10 run obliquely or diagonally in relation to the base surface 12. Additional guide elements 14 are arranged on the tooth 2, the diagonal direction of the plug-on elements 10 being prespecified by the additional guide elements. As may be gathered from FIG. 7, which shows the tooth 2 and the coil 3 according to section VII-VII from FIG. 6, the plug-on elements 10 run obliquely or diagonally in relation to the base surface 12 on the longitudinal side 4a. The plug-on elements run parallel in relation to the base surface 12 on the opposite longitudinal side 4b. As may be gathered from FIG. 5, the connecting elements 11 also run parallel in relation to the base surface 12 on the transverse side 5b. A diagonal armature winding may be provided in this way.

[0046] FIG. 8 shows a schematic illustration of a plug-on element 10 and a connecting element 11 according to one embodiment. It may be seen here that the plug-on element 10 is of U-shaped design and has a central region 15 and two limb regions 16. In this example, the limb regions 16 are arranged perpendicularly in relation to the central region 15. When the plug-on element 10 is arranged on the tooth 2, the central region 15 bears against the transverse side 5a of the tooth 2 completely. The respective limb regions 16 bear against the opposite longitudinal sides 4a and 4b completely. In this example, the connecting element 11 is of straight design and bears against the transverse side 5b completely when it is arranged on the tooth 2.

[0047] In order to produce the respective plug-on elements 10 and the connecting elements 11, the plug-on elements and connecting elements may be punched out of a main body, for example a metal sheet. Subsequently, a corresponding insulation may be applied to the plug-on elements 10 and the connecting elements 11. Thereafter, the plug-on elements 10 may be pushed onto the tooth 2 and then may be connected to the respective connecting elements 11 to form the coil 3. The respective plug-on elements 10 have contact regions 17 at the free ends of the limb regions 16. The connecting elements 11 also have corresponding contact regions 18 at their free ends. The plug-on elements 10 may be connected to the connecting elements 11 at the contact regions 17, 18. A welding process and/or a soldering process may be used in order to electrically connect the plug-on elements 10 and the connecting elements 11. In order to simplify this welding process, the limiting element 8b has corresponding passage openings 19 on the top side 7 of the tooth 2, wherein it is possible for a tool for welding and/or soldering to be inserted through the passage openings.

[0048] FIG. 10 shows a plug-on element 10 and a connecting element 11 according to a further embodiment. The plug-on element 10 is of substantially U-shaped design in this example too. After the plug-on element 10 is pushed onto the tooth 2, the central region 15 bears against the transverse side 5a completely. The respective limb regions 16 bear only against a region of the respective longitudinal sides 4a, 4b. In the present example, the connecting element 11 is also of U-shaped design and has a central region 20. This central region 20 bears against the transverse side 5b completely when the connecting element 11 is arranged on the tooth 2. Furthermore, the connecting element 11 includes, analogously to the plug-on element 10, corresponding limb regions 21 which bear against the longitudinal sides 4a, 4b in regions when the connecting element 11 is arranged on the tooth 2. Corresponding passage openings 19 for the tool may be provided on the limiting element 8b in a refinement of this kind of the plug-on elements 10 and the connecting elements 11 too. This is schematically illustrated in FIG. 11. As may be seen in combination with FIG. 9, the passage openings 19 are located in the region of the contact regions 17, 18 of the plug-on elements 10 and the connecting elements 11.

[0049] FIG. 12 shows a plug-on element 10 and connecting elements 11 according to a further embodiment. Here, the plug-on element 10 is of U-shaped design once again. The respective connecting elements 11, of which only two are illustrated in the present example for reasons of clarity, are arranged on a common board 22. This board 22 has corresponding openings 23 into which contact regions 17 or the free ends of the respective plug-on elements 10 may be inserted. In addition, at least one electronic component may be mounted on this board 20. The electronic component is, in particular, one or more semiconductor components. In particular, a converter circuit may be provided by these semiconductor components.

[0050] Several advantages result from the coil 3 of the active part 1 being formed by the prefabricated plug-on elements 10 and the connecting elements 11. One result is, for example, increased speed during manufacture of the coil 3 or the active part 1. A particular result is the option of pushing the respective coils 3 onto the tooth 2 in a prefabricated manner as a stack, as a result of which a considerable advantage in respect of speed is produced over single-tooth windings. In addition, fitting of the plug-on elements 10 and the connecting elements 11 may be automated. This results in lower costs owing to the simpler manufacturing method in comparison to automated methods in which a complete wire is wound onto the tooth 2.

[0051] Furthermore, the effectiveness is increased, e.g., the individual turns may be manufactured so as to exactly match the required size and shape. This allows a considerable reduction in the electromagnetically disadvantageous distance between the tooth 2 and the respective turns. A further result is long-term prevention of damage which may occur in a winding process. In addition, potential use of tooth geometries which cannot be achieved at present is rendered possible. The individual plug-on elements 10 and connecting elements 11 result in the option of interconnection of the individual coils as desired, with the prospect of increased safety during use. In addition, individual test processes on each coil 3 or the entire winding after the push-on operation may be rendered possible, this resulting in additional proof of quality. Furthermore, there is also the option of creating flat wire windings in sizes which cannot be achieved at present. In addition, the option of repairing individual turns is provided or rendered possible by this manner of interconnection. Owing to this flexible manner of connection, electrical testing is still possible even after electrical interconnection of the individual coil and furthermore the individual turns may still be tested. For example, a resistance may be measured or a surge voltage test may be carried out. In addition, the use of a board 20 provides the advantage of rapid manufacture, interconnection as desired and direct mounting of individual converters, either for each tooth 2 or for each turn.

[0052] Although the disclosure has been illustrated and described in greater detail by the exemplary embodiments, the disclosure is not restricted by these exemplary embodiments. Other variations may be derived herefrom by the person skilled in the art, without departing from the scope of protection of the disclosure. It is therefore intended that the foregoing description be regarded as illustrative rather than limiting, and that it be understood that all equivalents and/or combinations of embodiments are intended to be included in this description.

[0053] It is to be understood that the elements and features recited in the appended claims may be combined in different ways to produce new claims that likewise fall within the scope of the present disclosure. Thus, whereas the dependent claims appended below depend from only a single independent or dependent claim, it is to be understood that these dependent claims may, alternatively, be made to depend in the alternative from any preceding or following claim, whether independent or dependent, and that such new combinations are to be understood as forming a part of the present specification.