ROTATING ELECTRICAL MACHINE AND SPECIALLY ADAPTED METHOD FOR PRODUCING SAID ROTATING ELECTRICAL MACHINE

Abstract

A rotating electrical machine includes a rotor iron, a stator iron and conductor bars. An air gap separates the rotor iron from the stator iron. The stator iron has a slot and the conductor bars run in the slot. The conductor bars have a first profile in a first segment, the conductor bars have a second profile in a second segment and the first profile differs from the second profile. Also described is a method which is adapted for producing an electrical machine.

Claims

1. A rotating electrical machine comprising: a rotor iron, a stator iron having a slot, conductor bars running in the slot, the conductor bars having a first profile in a first segment, and a second profile in a second segment, wherein the first profile differs from the second profile; and an air gap separating the rotor iron from the stator iron.

2. The rotating electrical machine as claimed in claim 1, wherein the conductor bars have a curved surface such that, when a magnetic alternating field passes through the slot, the alternating field has a uniform flux density at the curved surface.

3. The rotating electrical machine as claimed in claim 1, wherein the first segment and the second segment are at a corresponding distance from the rotor iron.

4. The rotating electrical machine as claimed in claim 1, wherein: the slot has a slot gap which faces the rotor iron and a slot base which is averted from the rotor iron, the conductor bars at the slot gap have a first cross-sectional area, the conductor bars at the slot base have a second cross-sectional area, and wherein the second cross-sectional area is greater than the first cross-sectional area.

5. The rotating electrical machine as claimed in claim 4, wherein the first and second cross-sectional areas are selected such that the conductor bars at the slot gap and the conductor bars at the slot base have a corresponding effective resistance when the alternating field passes through the slot at a given frequency.

6. The rotating electrical machine as claimed in claim 4, wherein the first and second cross-sectional areas are selected such that a corresponding power loss is implemented in the conductor bars at the slot gap and in the conductor bars at the slot base when the alternating field passes through the slot at a given frequency.

7. The rotating electrical machine as claimed in claim 4, wherein the cross-sectional areas are selected such that the conductor bars at the slot gap and the conductor bars at the slot base have a corresponding power loss density when the alternating field passes through the slot at a given frequency.

8. A method for producing an electrical machine, said method comprising: winding conductor bars to form a conductor loop, establishing an electrically conductive connection between segments of the conductor bars, inserting the conductor loop into at least one slot of a stator iron, and mechanically connecting the stator iron coaxially to a rotor iron, such that an air gap exists between the rotor iron and the stator iron.

9. The method as claimed in claim 8, wherein the mechanical connection is established in a force-fitting manner by clamping.

10. The method as claimed in claim 8, wherein the mechanical connection is established in a cohesive manner by arc fusion welding or resistance pressure welding.

11. The method as claimed in claim 8, wherein a profile of at least one conductor bar is formed by mathematicophysical calculation of a vectorial magnetic flux in such a way that a projection of the vectorial magnetic flux onto at least one surface of the conductor bar is approximately minimal.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Exemplary embodiments of the invention are illustrated in the drawings and will be described in greater detail in the text which follows.

[0033] FIG. 1 shows a first electrical machine comprising a stator iron (12) and a rotor iron (11).

[0034] FIG. 2 shows a section through the machine.

[0035] FIG. 3 shows the, in regions, longitudinal section through a second electrical machine without stator windings.

[0036] FIG. 4 shows a corresponding longitudinal section through the machine with stator windings.

[0037] FIG. 5 shows the, in regions, longitudinal section through a third electrical machine without stator windings.

[0038] FIG. 6 shows a corresponding longitudinal section through the machine with stator windings.

[0039] FIG. 7 shows the extended longitudinal section through a fourth electrical machine.

[0040] FIG. 8 shows the enlarged view of a plurality of segments of a first conductor bar in the region of a connecting point.

[0041] FIG. 9 shows the perspectively corresponding view of a plurality of segments of a second conductor bar.

[0042] FIG. 10 shows the perspective view of a conductor loop.

DETAILED DESCRIPTION OF THE INVENTION

[0043] FIG. 1 shows the mechanical design of an electrical machine (10) having a rotor iron (11), a stator iron (12) and a stator winding comprising a plurality of conductor bars (17).

[0044] FIG. 2 illustrates a section through the machine. The slots (14), illustrated on an enlarged scale, include conductor bars (17) of different cross sections and/or different curvatures. By way of example, the cross section of the conductor bars (17) decreases toward the air gap (13).

[0045] FIG. 3 illustrates the magnetic alternating field profile (15) in a slot (14) of the stator iron (12) of a rotating electrical machine (10).

[0046] In this case, the stator iron (12) is separated from the rotor iron (11) of the machine (10) in an initially conventional manner by an air gap (13). In this context, the term air gap is to be understood, in accordance with the terminology customary in electrical engineering, in the sense of an intermediate space which is distinguished only by the absence of ferromagnetic material but not necessarily by its possible air content. Therefore, non-ferromagnetic rivets, foils or powder metallurgical composite materials of which the intermediate spaces are sometimes called distributed air gap in technical circles can equally be used.

[0047] FIG. 4 shows, on the basis of this alternating field profile (15) by which the magnetic flux close to the slot gap is increasingly deflected toward the rotor iron (11) (reference symbol 16), the forming according to aspects of the invention of the conductor bars (17) with surfaces parallel to the profile of the alternating field component. Here, the cross-sectional area content of individual conductor bars (17) is inversely related to the field strength at their site of installation. Specifically, the conductor bars (17) are designed, for example, for the same energy loss at an identical current.

[0048] Looking at FIGS. 5 and 6 together explains the structural principle according to aspects of the invention when it is transferred to a second electrical machine (10) of which the alternating field which is injected by the rotor iron (11) is impressed by a convex profile of its field lines. In this case too, the content of the cross-sectional area of individual conductor bars (17) is substantially inversely related to the field strength at their site of installation.

[0049] FIG. 7 illustrates, by way of example, segmentation in the horizontal direction, in accordance with the figure, for reducing the vertical components of a rotating field. Rotating fields of this kind have the disadvantage that they do not have a temporally fixed profile which varies only in its amplitude. However, rotating fields of this kind can be subdivided into two to three alternating field components. In this case, two alternating field components, specifically a, in accordance with the figure, horizontal and a vertical alternating field in the interior of the slot (14) are typically sufficient for modeling the alternating field components of the rotating field. The above-described method can be used not only for segmenting the, in accordance with the figure, vertical alternating field component but rather also can be transferred to the horizontal alternating field component. This produces a second segmentation direction which should be observed at the same time and generally runs approximately perpendicular to the other segmentation direction. Rotating fields of the described type can be produced, for example for the stator field given a highly varying reluctance depending on the rotor position, by strong rotor stray fields which periodically occur during operation or by superimposition of non-phase-identical rotor and stator fields in the slot (14).

[0050] Exemplary design criteria for cross sections of the individual paths in a group of parallel paths can be found in the following list:

1. Identical effective resistance at frequency ;
2. identical power loss at frequency ;
3. Identical power loss density at frequency ;
4. limiting the percentage deviation in the resistance of the paths within a prespecified frequency band;
5. achieving a similar increase in resistance dR/d or increase in loss dW.sub.loss/d at frequency ;
6. division in such a way that displacement of the current into one of the two paths at frequency is suppressed;
7. reducing the losses at relatively high rotation speeds, slight increase at low rotation speeds; and
8. minimizing the system losses for a given load spectrum or a given drive cycle.

[0051] According to aspects of the invention, the profile of at least one conductor bar (17) in at least one slot (14) can be matched to the vectorial magnetic field profile or the vectorial magnetic flux profile of the magnetic alternating field (15) flowing through the slot in such a way that currents induced by the magnetic alternating field (15) can be effectively reduced in the at least one conductor bar (17). The profile of the at least one conductor bar (17) is preferably formed such that the vectorial magnetic flux density which is projected onto the respective local surface normal of at least one of the surfaces (20) of the at least one conductor bar is minimal, so that consequently the at least one surface (20) runs substantially tangentially to the local direction of the vectorial magnetic flux. At least 50% of the at least one surface (20), particularly advantageously more than 75%, preferably run tangentially to the local direction of the vectorial magnetic flux.

[0052] Furthermore, according to aspects of the invention, at least two surfaces (20), which are situated approximately opposite one another, of at least one conductor bar (17) can follow the vectorial magnetic flux density in such a way that the at least two surfaces (20), which are situated approximately opposite, run largely tangentially to the local direction of the vectorial magnetic flux. Since, according to Faraday's law of induction, electrical fields which are induced by the magnetic field and are ultimately responsible for eddy currents and current displacement effects always run perpendicular to the temporal change in the vectorial magnetic flux, a surface which runs along the local vectorial magnetic flux ensures, at least in the case of magnetic alternating fields, that the induced electrical field runs perpendicular to the surface and therefore there is no closed current path for a by the induced electrical field on the surface and these therefore do not occur locally.

[0053] FIGS. 8 and 9 illustrate a connection technique according to aspects of the invention for the transition of segments with unequal cross sections and of individual paths into parallel paths. A connection (18) can accordingly be made, for example, by welding, primarily tungsten inert gas welding (gas tungsten arc welding, GTAW; tungsten inert gas, TIG) and resistance welding. Furthermore, hard-soldering or clamping are feasible, without departing from the scope of the invention. In this way, an electrically conductive connection (18) can be established between more than two segments of different cross sections or between all subdivisions of the segments.

[0054] Even though the above embodiments relate primarily to wave windings, the operating principle of the invention can be transferred to lap windings. FIG. 10 illustrates the use according to aspects of the invention of pre-segmented coil elements for lap windings. Relatively long conductor segments with more than two slot sections allow more complex connections of the subdivisions of the segment in virtually any desired combinations of series and parallel connections here. In particular, it is possible to connect in parallel a plurality of thin subdivisions which are situated close to the air gap (13) and, in turn, form a series connection with large sub-segments which are further seated on the slot base.

[0055] This configuration provides the advantage that, in spite of different cross sections of the individual subdivisions of the segment, similar effective cross sections are produced by the parallel and series connection, and therefore optimal resistance ratios can be created with the available copper.