Abstract
A filter for an electric machine is disclosed. The filter has an inductor, which is a coil, and a capacitor. The coil has multiple windings, and each turn of the windings includes at least one conductor which is designed to be flat. By virtue of the flat conductor of the coil, the capacitance of the filter is thus formed in the coil itself In the process, the surface of one conductor is arranged opposite the surface of an adjacent conductor.
Claims
1. A filter for an electric machine, the filter comprising an inductor, which is a coil, and a capacitor, wherein: the coil has multiple windings and turns of the windings comprise at least one conductor which is designed to be flat and the coil itself forms the capacitor of the filter, wherein a surface of one conductor is located opposite the surface of an adjacent conductor.
2. The filter according to claim 1, wherein the coil comprises a first winding and a second winding, and the turns of the first winding and of the second winding comprise a single conductor.
3. The filter according to claim 1, wherein the coil comprises a first winding and a second winding, and the turns of the first winding and of the second winding comprise multiple separate conductors which together form the surface in each turn.
4. The filter according to claim 1, wherein the coil comprises a first winding, a second winding, a third winding, and a fourth winding, which each comprises multiple separate conductors, which together form the surface in each turn.
5. The filter according to claim 1, wherein the turns of the windings for the coil of the filter are wound around a core and the conductor of each winding is separated from other conductors by an insulation material.
6. A filter element for an electric machine, comprising at least one filter having an inductor, which is a coil, and a capacitor, wherein the coil has multiple windings and turns of the windings comprise at least one conductor which is designed to be flat and the coil itself forms the capacitor of the filter, wherein a surface of one conductor is located opposite the surface of an adjacent conductor, wherein the turns of the windings are wound around a core and the conductor of each winding is separated from other conductors by an insulation material, wherein the filter is attached to a stator ring via the core in such a way that the filter is oriented towards an interior of the stator ring or that the filter is inserted into the stator ring and is aligned in a direction of an axis of the stator ring.
7. The filter element according to claim 6, wherein the stator ring defines the interior in which a power electronics is installed.
8. The filter element according to claim 6, wherein the stator ring is mounted together with the at least one filter on the stator of the electric machine.
9. The filter according to claim 1, wherein the coil comprises flat and wide conductors on an end face of a stator of the electric machine in multiple layers or comprises flat and wide conductors which are wound onto a lateral surface of the stator of the electric machine in multiple layers.
10. A filter element for an electric machine comprising at least one filter including an inductor, which is a coil, and a capacitor, wherein the coil has multiple windings and turns of the windings comprise at least one conductor which is designed to be flat and the coil itself forms the capacitor of the filter, wherein a surface of one conductor is located opposite the surface of an adjacent conductor, wherein the coil comprises flat and wide conductors on an end face of a stator of the electric machine in multiple layers or comprises flat and wide conductors which are wound onto a lateral surface of the stator of the electric machine in multiple layers, wherein the at least one filter and the stator of the electric machine form the filter element.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] With reference to the accompanying drawings, the disclosure and its advantages will now be explained in more detail by means of exemplary embodiments, without thereby limiting the disclosure to the exemplary embodiment shown. The proportions in the figures do not always correspond to the real proportions, since some shapes are simplified and other shapes are shown enlarged in relation to other elements for better illustration.
[0026] FIG. 1 shows a schematic arrangement from the prior art of the power electronics, filter and electric machine.
[0027] FIG. 2 schematically shows an exemplary embodiment according to the disclosure of the arrangement of the power electronics, filter and electric machine.
[0028] FIG. 3 shows a cross-section of a coil (inductor) used in the filter according to the disclosure.
[0029] FIG. 4 shows a sectional view of the coil along the section line A-A shown in FIG. 3.
[0030] FIG. 5 schematically shows the cross-section of a conductor with which the coil of the filter is wound.
[0031] FIG. 6 shows a three-phase implementation variant of the filter according to the disclosure, which is attached directly to the stator of the electric machine.
[0032] FIG. 7 shows another possible embodiment variant of the filter element.
[0033] FIG. 8 additionally shows a possible variant of the filter element for an electric machine.
[0034] FIG. 9 shows a plan view in the axial direction of a possible embodiment for the winding of the coil of the filter of the filter element.
[0035] FIG. 10 shows a side view of the embodiment shown in FIG. 9 in partial section.
[0036] FIG. 11 shows the plan view in the axial direction of a further possible embodiment for the winding of the coil of the filter of the filter element.
[0037] FIG. 12 shows a side view of the embodiment shown in FIG. 11 in partial section.
[0038] FIG. 13 shows the embodiment of a multi-layer winding for forming the coil of the filter.
[0039] FIG. 14 shows the embodiment of a multi-layer winding for forming the coil of the filter, wherein multiple windings are connected in parallel.
[0040] FIG. 15 shows the further embodiment of a multi-layer winding for forming the coil of the filter, wherein multiple windings are connected in parallel but wound in an offset manner.
DETAILED DESCRIPTION
[0041] Identical reference symbols are used for elements of the disclosure that are the same or have the same effect. Furthermore, for the sake of clarity, only those reference symbols that are necessary for the description of the respective figure are shown in the individual figures. The figures merely represent exemplary embodiments of the disclosure without, however, restricting the disclosure to the exemplary embodiments shown. The figures shown do not claim the completeness of the structure of an electric machine (electric motor).
[0042] FIG. 1 shows a schematic arrangement from the prior art of the power electronics 2 and electric machine 1. The power electronics 2 is connected to the electric machine 1 via a cable 4. A filter (not shown here) can be interposed between the electric machine 1 and the power electronics 2. The filter 3 (see FIG. 2) includes at least one inductor 5 and one capacitor 6, which, as separate components, require additional installation space and generate corresponding costs.
[0043] FIG. 2 shows a schematic arrangement of a possible embodiment of the arrangement of the power electronics 2, filter 3 and electric machine 1 according to the disclosure. The power electronics 2 is connected to the electric machine 1 via a cable 4. According to the disclosure, the filter 3 is assigned to the electric machine 1. The filter 3 is designed in such a way that it forms an inductor 5 and a capacitor 6. The arrangement according to the disclosure of the filter 3 according to the disclosure on the electric machine 1 has the advantage that no additional installation space is required.
[0044] FIG. 3 shows a cross-section through a coil 10 (inductor) as is used in the filter 3 according to the disclosure. The coil 10 has a core 11 around which a first winding 12.sub.1 and a second winding 12.sub.2 (see FIG. 4) are wound.
[0045] As can be seen in the embodiment shown in FIG. 4 (sectional view of the coil 10 along the section line A-A shown in FIG. 3), the coil 10 is made up of a first winding 12.sub.1 and a second winding 12.sub.2, which alternate along the core 11. An insulating layer 13 surrounds the conductor 20 of the turns 9 of the first winding 12.sub.1 and of the second winding 12.sub.2 and thus insulates them from one another. In this embodiment, the insulation material 13 is a layer of lacquer which surrounds the conductor 20. Both windings 12.sub.1 and 12.sub.2 are energized 180° out-of-phase in order to compensate for the magnetic flux in the core 11 (iron core) and to avoid saturation effects in the material of the core 11. This means that a compact material can be used in the core 11.
[0046] FIG. 5 schematically shows the cross-section of a conductor 20 with which the coil 10 of the filter 3 is wound. In this embodiment, the conductor 20 is constructed analogously to the enameled wire of an electric machine and is surrounded by an insulation material 13, which is, for example, a layer of enamel. It is also conceivable that the insulation material 13 is not necessarily closed around the conductor 20. The representation of the conductor 20 with the insulating layer shown in FIG. 5 should not be construed as a limitation of the disclosure. The conductor 20 for the filter 3 is designed to be flat. This means that the conductor 20 has a width B to height H ratio such that the width B is greater than the height H of the conductor 20. The ratio between the width B and the height H results in opposite, parallel surfaces F, which extend along the length (not shown) of the conductor 20. As shown in FIG. 4, in the wound coil 10—the surfaces F of two successive conductors 20 in the coil 10—are opposite each other. As a result, a capacitor forms within the coil 10. The inductor 5 and capacitor 6 are thus combined in the coil 10.
[0047] FIG. 6 shows a three-phase implementation variant of the filter 3 according to the disclosure, which is attached directly to the stator (not shown) of the electric machine 1. The representation of FIG. 6 is a side view of the structure consisting of electric machine 1 (not shown) and stator ring 32.
[0048] In addition to the rotationally symmetrical geometry shown, the filter 3 can have any configuration. The number of windings can also vary and can also be multi-layered (see FIGS. 13-15). The structure of the filter 3 already described in FIG. 5 results in advantages with regard to integration into the electric machine 1 (not shown). Similar to the electric machine 1 (not shown), a multi-phase filter element 30 can be constructed similarly to the stator 102 (see FIG. 9 or 11) of the electric machine 1 (not shown).
[0049] The filter element 30 has three phases in the embodiment shown here.
[0050] Consequently, three filters 3 are attached to a stator ring 32, which forms an interior 34 in such a way that the filters 3 protrude into the interior 34. Each filter 3 is thus connected to the stator ring 32 via the core 11 of the coil 10. The stator ring 32 is applied directly to the geometry of the stator (not shown) of the electric machine 1. The stator ring 32 is shown in FIG. 6 as an open magnetic circuit to ensure the necessary leakage flux. The stator ring 32 can also be implemented with multiple phases or with a closed magnetic circuit. Depending on the geometry of the electric machine 1 and depending on the application, multiples of these filter elements 30 can also be connected in parallel to form one phase. Due to the direct connection to the iron of the stator, the filter elements 30 are cooled directly by the existing cooling (not shown) of the electric machine 1.
[0051] FIG. 7 shows another possible embodiment of the filter element 30. Here, the interior 34 provided in the design of the filter element 30 is provided with the power electronics 2. The interior 34 is ideal for installing the power electronics 2 since the ends 10E of the coil 10 that are already present point to the interior 34. The ends 10E of the coil 10 can thus be easily connected to the power electronics 2. Installing the power electronics 2 in the interior 34 results in a compact ring which can also be attached directly to the stator of the electric machine 1. An integration of the power electronics 2 only makes sense if the magnetic circuits are closed in order to avoid the EMC problem.
[0052] FIG. 8 shows an additional possible variant of the filter element 30 for an electric machine 1. Due to the geometry of the conductor 20 shown in FIG. 5, a filter 3 that is short in the direction of the axis A of the stator ring 32 or of the electric machine 1 can be implemented by the flat winding of the conductor 20. The length of the filter 3 corresponds approximately to the thickness of the stator ring 32 and can therefore also be arranged to be parallel to the axis A, i.e., perpendicular to the iron of the stator 102 of the electric machine 1. In this case, FIG. 8 shows a possible geometry for a three-phase radial flux machine with two parallel filters 3 each (indicated by a dashed line). The interior 34 in turn offers the installation space for the power electronics (not shown here). Due to the direct connection of the filter element 30 to the stator of the electric machine 1, busbars that connect the electric machine 1 to the power electronics 2 can be replaced.
[0053] In addition to the implementation described in FIG. 8 for a radial flux machine, this disclosure can also be used for any variants, such as axial flux transverse flux machines or combinations with any interconnections, such as star/delta. In addition to the application for the integration of filter elements 30, the described embodiments are also conceivable for the integration of the inductors of a DC/DC converter.
[0054] FIG. 9 shows a possible embodiment for the winding of the coil 10 of the filter 3 of the filter element 20 for the electric machine 1. The electric machine 1 comprises a rotor 101 and a stator 102. The winding heads 103 are formed in the stator 102. Flat and wide conductors 20, preferably made of copper, are used for winding the coil 10 of the filter 3 of the embodiments in FIGS. 9 and 11. In the embodiment shown in FIG. 9, these are attached directly to an end face 104 of the stator 102 and are wound around the stator 102. For a multi-phase electric machine 1, these filters 3 must be placed on top of one another several times.
[0055] FIG. 10 shows a side view of the embodiment shown in FIG. 9 in partial section. It can be seen that multiple layers 8.sub.1, 8.sub.2, . . . , 8.sub.N of conductors 20 are placed on top of one other on the stator 102. These two implementation options make it possible to implement a large surface and compact coil element with a comparatively larger capacity.
[0056] FIG. 11 shows a plan view in the axial direction of a further possible embodiment for the winding of the coil 10 of the filter 3 of the filter element 20.
[0057] FIG. 12 shows a side view of the embodiment shown in FIG. 11 in partial section. As already mentioned in the description of FIG. 9, flat and wide conductors 20 (conductive strips which can also consist of multiple sections), preferably made of copper, are used for winding the coil 10 of the filter 3. In the embodiment shown in FIG. 11, these are wound around the lateral surface 106 of the stator 102 of the electric machine 1 in multiple layers 8.sub.1, 8.sub.2, . . . 8.sub.N. For a multi-phase electric machine 1, these filters 3 must also be placed on top of one another multiple times. FIG. 11 shows a side view of the embodiment shown in FIG. 12 in partial section. It can be seen that multiple layers 8.sub.1, 8.sub.2, . . . , 8.sub.N of conductors 20 are wound on the outer surface 106 of the stator 102 of the electric machine 1.
[0058] These two implementation options possibilities, shown in FIGS. 9-12, facilitate filters 3 comprising a large surface and compact coil 10 for the filter 3 or the filter element 30. In addition, the filter 3 or the filter element 30 can be implemented with a larger capacity than is the case with the filters 3 or filter elements 30 of the embodiments of FIGS. 5 and 13-15. A further advantage of the embodiments of FIGS. 9 and 11 is that the filter elements 30 are thermally very well connected to the electric machine 1.
[0059] FIG. 13 shows the embodiment of a multi-layer winding, which is constructed from multiple windings 12.sub.1, 12.sub.2, . . . , 12.sub.N. Here, the coil 3 consists of a first winding 12.sub.1 and a second winding 12.sub.2.
[0060] FIG. 14 shows the embodiment of a multi-layer winding, which according to the embodiment described here consists of a first winding 12.sub.1, a second winding 12.sub.2, a third winding 12.sub.3 and a fourth winding 12.sub.4. For the formation of the coil 10 of the filter 3, the first winding 12.sub.1 and the second winding 12.sub.2 are connected in parallel. Likewise, the third winding 12.sub.3 and the fourth winding 12.sub.4 are connected in parallel. The embodiment described in FIG. 14 with the first winding 12.sub.1, the second winding 12.sub.2, the third winding 12.sub.3 and the fourth winding 12.sub.4, is only used for description. More than four windings 12.sub.1, 12.sub.2, . . . , 12.sub.N are also possible. The windings 12.sub.1, 12.sub.2, . . . , 12.sub.N can either be connected in parallel, which requires an even multiple, or can be controlled in a phase-shifted mariner, such as 5-phase then 72 degrees out-of-phase or 12-phase, then 30 degrees out-of-phase, etc.
[0061] FIG. 15 shows a further embodiment of a multi-layer winding which, according to the embodiment described here, consists of a first winding 12.sub.1, a second winding 12.sub.2, a third winding 12.sub.3 and a fourth winding 12.sub.4. For the formation of the coil 10 of the filter 3, the first winding 12.sub.1 and the third winding 12.sub.3 are connected in parallel. Likewise, the second winding 12.sub.2 and the fourth winding 12.sub.4 are connected in parallel. According to this embodiment, the first winding 12.sub.1 and the third winding 12.sub.3 (half-bridge) and the second winding 12.sub.2 and the fourth winding 12.sub.4 (half-bridge) are connected in parallel and are energized 180° out-of-phase.
[0062] According to a further embodiment, four phases are each supplied with current phase-shifted by 90° (in each case via a half-bridge) and the first winding 12.sub.1 and the third winding 12.sub.3 are shifted by 180° with respect to one another.
[0063] As can be seen from FIGS. 13-15, multiple large-surface, thin and wide conductors 20 are provided for the formation of the coil 10 of the filter 3 in one of the multiple windings 12.sub.1, 12.sub.2, . . . , 12.sub.N of the coil 10 can be connected according to the above-mentioned embodiments. As already described in FIG. 5, the ratio between the width B and the height H of the D conductor 20 is that the width B is greater than the height H (thickness) of the conductor 20. Consequently, flat conductors 20 are used for winding the coil 10. According to the disclosure, the capacitor formed as a result is relevant for the function of the filter 3 or filter element 30.
[0064] It should be mentioned at this point that the number of windings 12.sub.1, 12.sub.2, . . . , 12.sub.N mentioned in the above description is for descriptive purposes only and should not be construed as a limitation of the disclosure.
[0065] It is believed that the present disclosure and many of the advantages noted therein will be understandable from the preceding description. It will be apparent that various changes in the shape, construction and arrangement of the components can be made without departing from the disclosed subject matter. The form described is illustrative only and it is the intent of the appended claims to comprise and incorporate such changes. Accordingly, the scope of the disclosure should be limited only by the appended claims.
LIST OF REFERENCE SYMBOLS
[0066] 1 Electric machine
[0067] 2 Power electronics
[0068] 3 Filter
[0069] 4 Cable
[0070] 5 Inductor
[0071] 6 Capacitor
[0072] 8.sub.1, 8.sub.2, . . . 8.sub.N Layer
[0073] 9 Turn
[0074] 10 Coil
[0075] 10E End
[0076] 11 Core
[0077] 12.sub.1, 12.sub.2, . . . 12.sub.N Winding
[0078] 13 Insulation material
[0079] 20 Conductor
[0080] 30 Filter element
[0081] 32 Stator ring
[0082] 34 Interior
[0083] 101 Rotor
[0084] 102 Stator
[0085] 103 Winding heads
[0086] 104 End face
[0087] 106 Lateral surface
[0088] A Axis
[0089] A-A Section line
[0090] B Width
[0091] F Surface
[0092] H Height
