STATOR FOR AN ELECTRICAL ROTATING MACHINE

Abstract

A stator for an electrical rotating machine, in particular for use in a pod drive, includes a laminated stator core having coils. Each coil has a groove portion, a winding overhang portion and a connecting portion. The winding overhang portion is configured as a stator winding overhang board arranged at an end face of the laminated stator core and having an insulating main body and conducting tracks integrated into the insulating main body. Each conducting track is formed by a number of partial conducting tracks that are electrically insulated from each other. Conductors extend in the groove portion, with each conductor formed by a number of partial conductors that are electrically insulated from each other, wherein each of the conductors and an associated one of the conducting tracks of the winding overhang portion are electrically conductively connected in the connecting portion.

Claims

1.-15. (canceled)

16. A stator for an electrical rotating machine, in particular for use in a pod drive, said stator comprising: a laminated stator core having coils, each coil having a groove portion, a winding overhang portion and a connecting portion, said winding overhang portion configured as a stator winding overhang board arranged at an end face of the laminated stator core and having an insulating main body and conducting tracks integrated into the insulating main body, each of the conducting tracks formed by a number of partial conducting tracks that are electrically insulated from each other; and conductors extending in the groove portion, with each of the conductors formed by a number of partial conductors that are electrically insulated from each other, wherein each of the conductors and an associated one of the conducting tracks of the winding overhang portion are electrically conductively connected in the connecting portion.

17. The stator of claim 16, wherein the number of partial conductors is different from the number of partial conducting tracks.

18. The stator of claim 16, wherein the partial conductors are twisted.

19. The stator of claim 16, wherein the partial conductors are twisted in a manner of a Roebel bar.

20. The stator of claim 16, wherein the conductors in the groove portion and the conducting tracks of the winding overhang portion are connected with a material bond in the connecting portion.

21. The stator of claim 20, wherein the material bond is established using nanoparticles.

22. The stator of claim 20, wherein the material bond is established using silver nanoparticles.

23. The stator of claim 16, further comprising metallic connecting elements arranged in the connecting portion between the conductors in the groove portion and the conducting tracks of the winding overhang portion.

24. The stator of claim 23, wherein the metallic connecting elements are wedge-shaped.

25. The stator of claim 16, wherein the coil has at least two windings, and further comprising a conductor insulation arranged in a meandering shape and electrically insulating the conductors of a respective one of the windings.

26. The stator of claim 16, wherein the coil has at least two windings, and further comprising a conductor insulation arranged in a meandering shape and electrically insulating the conductors of a respective one of the windings in the groove portion.

27. The stator of claim 16, further comprising cooling ducts arranged in the stator winding overhang board.

28. The stator of claim 27, wherein the partial conducting tracks are arranged around the cooling ducts.

29. The stator of claim 27, wherein the partial conducting tracks are arranged equidistantly around the cooling ducts.

30. The stator of claim 16, wherein the stator winding overhang board is at least partially produced using an additive manufacturing method.

31. An electrical rotating machine, comprising a stator, said stator comprising a laminated stator core having coils, each coil having a groove portion, a winding overhang portion and a connecting portion, said winding overhang portion configured as a stator winding overhang board arranged at an end face of the laminated stator core and having an insulating main body and conducting tracks integrated into the insulating main body, each of the conducting tracks formed by a number of partial conducting tracks that are electrically insulated from each other, and conductors extending in the groove portion, with each of the conductors formed by a number of partial conductors that are electrically insulated from each other, wherein each of the conductors and an associated one of the conducting tracks of the winding overhang portion are electrically conductively connected in the connecting portion.

32. A pod drive, comprising an electrical rotating machine, said electrical rotating machine comprising a stator, said stator comprising a laminated stator core having coils, each coil having a groove portion, a winding overhang portion and a connecting portion, said winding overhang portion configured as a stator winding overhang board arranged at an end face of the laminated stator core and having an insulating main body and conducting tracks integrated into the insulating main body, each of the conducting tracks formed by a number of partial conducting tracks that are electrically insulated from each other, and conductors extending in the groove portion, with each of the conductors formed by a number of partial conductors that are electrically insulated from each other, wherein each of the conductors and an associated one of the conducting tracks of the winding overhang portion are electrically conductively connected in the connecting portion.

33. A watercraft, in particular a ship, comprising a pod drive as set forth in claim 32.

34. A method for manufacturing a stator for an electrical rotating machine, said method comprising: placing a stator winding overhang board on an end face of a laminated stator core; and connecting conductors in a groove portion of a coil of the laminated stator core and conducting tracks of a winding overhang portion of the coil.

35. The method of claim 34, wherein the conductors in the groove portion and the conducting tracks of the winding overhang portion of the coil are connected with a material bond.

Description

[0036] The following describes and explains the invention in more detail with reference to the exemplary embodiments depicted in the figures, which show:

[0037] FIG. 1 a longitudinal section of an electrical rotating machine,

[0038] FIG. 2 an enlarged longitudinal section of a first embodiment of a stator in the region of a stator winding overhang board,

[0039] FIG. 3 an enlarged cross section of a second embodiment of a stator in the region of a stator winding overhang board,

[0040] FIG. 4 an enlarged section of a stator winding overhang board and

[0041] FIG. 5 a ship with a pod drive.

[0042] The same reference characters have the same meaning in the different figures.

[0043] FIG. 1 shows a longitudinal section of an electrical rotating machine 2 having a rotor 4 that can be rotated about an axis of rotation 6 and a stator 8 surrounding the rotor 4. A gap 10, preferably embodied as an air gap, is arranged between the rotor 4 and the stator 8. The axis of rotation 6 defines an axial direction, a radial direction and a circumferential direction. The electrical rotating machine 2 is embodied by way of example as a synchronous machine and has permanent magnets 12, which are at least partially integrated in at least one laminated stator core 14. The at least one laminated stator core 14 is connected in a rotationally fixed manner to a shaft 16, which is embodied by way of example as a hollow shaft and is supported by bearings 18 arranged on both sides.

[0044] The stator 8 has a laminated stator core 20 having coils 22, wherein the coils 22 extend in the axial direction through grooves 24 of the laminated stator core 20. Terminals of the coils 22, for example on a terminal box, are not shown for reasons of clarity. The coils 22, which are, for example, made of copper, have groove portions 26 and winding overhang portions 28, wherein a connecting portion 30 is arranged in each case between a groove portion 26 and a winding overhang portion 28. The winding overhang portions 28 of the coils 22 are arranged in stator winding overhang boards 32, which lie on the end faces 32 of the laminated stator core 16.

[0045] FIG. 2 shows an enlarged longitudinal section of a first embodiment of a stator 8 in the region of a stator winding overhang board 32. A coil 22 extending through a groove 24 of the laminated stator core 20 has by way of example two windings each having a conductor 34 embodied as a coil bar. The conductors 34 in the groove portion 26 each have a first number n1 of partial conductors 40 that are electrically insulated from each other, which are twisted, in particular in the manner of a Roebel bar. The first number n1 of partial conductors 40 is at least 2 per conductor 34. In the connecting portion, the partial conductors 40 that are electrically insulated from each other are short circuited by an electrically conductive connection 42. The electrically conductive connection 42 is in particular embodied as a material-bonded connection. A material-bonded connection is, for example, established by filling the connection gap with a metal, in particular copper, using a cold spray method. Alternatively, the material-bonded connection is established by a pressureless sintering process, in particular at a temperature in the range of 200 C. to 300 C.

[0046] In a pressureless sintering process of this kind, the partial conductors 40 are joined with the aid of a bonding material, which, upon being heated develops nanoparticles, in particular silver nanoparticles, wherein, when more energy is supplied, a molten phase forms which, on subsequent solidification, creates an irreversible joint between the partial conductors 40. The joint is called irreversible because its melting point is much higher than that of the molten phase. In particular, the melting point of the cured joining material is in the region of the melting point of the metal used for the nanoparticles, for example, in the case of silver in the range of 900 C. to 1000 C. Therefore, the preceding joint does not also melt on the establishment of a subsequent joint of this kind.

[0047] Alternatively, the material-bonded connection is established by soldering or welding. The conducting tracks 36 of the stator winding overhang board 32 in the connecting portion 30 are also connected to the conductors 34 of the groove portion 26 by a material-bonded connection. The conducting tracks 36 are integrated in an insulating main body 38, wherein the insulating main body 38 establishes a thermally conductive connection between conducting tracks 36 and the laminated stator core 20. Furthermore, the conducting tracks 36 are encapsulated by the insulating main body 38. The insulating main body 38 contains a ceramic material, for example aluminum oxide or aluminum nitrite, with a high thermal conductivity, in particular a thermal conductivity of more than 5 W/mK. Alternatively, the insulating main body 38 contains a plastic, having portions of at least one ceramic material. In particular when using a plastic, it is additionally necessary to cool the conducting tracks 36, for example via cooling ducts.

[0048] The stator winding overhang board 32, which has a thickness d in the centimeter range, in particular in the range between 3 centimeters and 10 centimeters, is completely or at least partially produced using an additive manufacturing method. For example, the insulating main body 38 is produced with a 3D printing method or a screen-printing method and then the conducting tracks 36 are cast, for example using a die-cast method. Alternatively, the conducting tracks 36 are produced with a 3D printing method or a screen-printing method. The insulating main body 38 is then attached, for example using a sintering method. A further possibility for producing the stator winding overhang board 32 is to produce both the conducting tracks 36 and the insulating main body 38, preferably simultaneously, with a 3D printing method or a screen-printing method. The further embodiment of the stator 8 in FIG. 2 corresponds to the embodiment in FIG. 1.

[0049] FIG. 3 shows an enlarged cross section of a second embodiment of a stator 8 in the region of a stator winding overhang board 32. A coil 22 extending through a groove 24 has by way of example five windings each having a conductor 34, wherein the windings are electrically insulated from each other by a conductor insulation 44 arranged in a meandering shape. Arranged between the conductors 34 and the respective conducting tracks 36 of the stator winding overhang board 32 are metallic connecting elements 46, which establish an electrically conductive connection in the connecting portion 30 between the conductors 34 and the respective conducting tracks 36. The metallic connecting elements 46 further bridge a thickness d of a main insulation 48. The metallic connecting elements 46 are embodied as individual parts. For the application of a preload force and/or to compensate tolerances, the metallic connecting elements 46 are designed as, in particular wedge-shaped, individual parts. Alternate connection of the conducting tracks 36 ensures an, in particular electrically, sufficient distance a between the connection points of the conducting tracks 36. In the winding overhang portion 28 within the stator winding overhang board 32, the conducting tracks 36 of a winding are each divided into a second number n2 of partial conducting tracks 50 in order to achieve improved mechanical properties and improved cooling of the partial conducting tracks 50 by enlarging a contact surface with the insulating main body 38. The second number n2 of partial conducting tracks 50 is at least 2 per conducting track 36. The further embodiment of the stator 8 in FIG. 3 corresponds to the embodiment in FIG. 2.

[0050] FIG. 4 shows an enlarged section of a stator winding overhang board 32 in which a cooling duct 52 is arranged. A coolant flows through the cooling duct 52. Partial conducting tracks 50, which by way of example have a ring-segment-shaped cross section, are arranged equidistantly around the cooling duct 52 and thus the partial conducting tracks 50 are cooled substantially uniformly by the coolant. The further embodiment of the stator winding overhang board 32 in FIG. 4 corresponds to the embodiment in FIG. 3.

[0051] FIG. 5 shows a watercraft 54 with a pod drive 56. The pod drive 56 is located under a water surface 58 and has an electrical rotating machine 2 and a propeller 60, wherein the propeller 60 is connected to the electrical rotating machine 2 via a shaft 16. The use of a stator winding overhang board 32, which is not shown in FIG. 5 for reasons of clarity, endows the pod drive 56 with a short axial length.

[0052] To summarize, the invention relates to a stator 8 for an electrical rotating machine 2, in particular for use in a pod drive 56 having a laminated stator core 20 with coils 22. In order to achieve improved electrical and mechanical properties in comparison with the prior art while achieving a low axial length, it is suggested that the coils 22 each have at least one groove portion 26, at least one winding overhang portion 28 and at least one connecting portion 30, wherein the winding overhang portion 28 is designed as a stator winding overhang board 32, which is arranged at an end face of the laminated stator core 20 and has conducting tracks 36 integrated in an insulating main body 38, wherein in each case a conductor 34 of the groove portion 26 and a conducting track 36 of the winding overhang portion 28 are connected in a connecting portion 30, wherein the conductors 34 of the groove portion 26 each have a first number n1 of partial conductors 40 that are electrically insulated from each other and/or the conducting tracks 36 of the winding overhang portion 28 each have a second number n2 of partial conducting tracks 50 that are electrically insulated from each other and wherein the partial conductors 40 of the groove portion 26 that are electrically insulated from each other and/or the partial conducting tracks 50 of the winding overhang portion 28 that are electrically insulated from each other are connected to each other in an electrically conductive manner in the connecting portion 30.