FOLDED WAVE WINDING WITH COVER

Abstract

A winding mat arrangment which is provided as a stator winding for a stator, has at least two winding mats which cross one another. A method for producing a stator is also provided.

Claims

1. A winding mat arrangment for a stator, comprising: at least two winding mats which cross one another.

2. The winding mat arrangement according to claim 1, wherein the at least two winding mats are joined together and represent an X-shape in a sectional level.

3. The winding mat arrangement according to claim 2, wherein the sectional level is a longitudinal direction in relation to a winding direction for winding mat arrangement onto the stator.

4. The winding mat arrangement according to claim 1, wherein each of the at least two winding mats has wire wave windings.

5. The winding mat arrangement according to claim 4, wherein a number of wire wave windings of each winding mat is the same.

6. The winding mat arrangements according to claim 1, wherein connections of the at least two winding mats are arranged next to one another and form a matrix which enables a phase assignment diagram

7. A method for producing a stator, the method comprising: providing a plurality of winding mats that are each different from one another; crossing the winding mats into a winding mat arrangement; and incorporating the winding mat arrangements into a stator body.

8. The method for producing a stator according to claim 7, wherein the winding mats are joined to form the winding mat arrangement, wherein each winding mat is produced by folding stacked phase preliminary schemes on bending lines.

9. The method for producing a stator according to claim 7, wherein each of the winding mats has different opened levels, and in that the method further comprises: nesting the winding mats and folding over the levels to one another, so that a common level of the winding mat arrangement is formed.

10. The method for producing a stator according to claim 9, wherein the levels of the winding mats have different dimensions.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0037] The disclosure is explained below with the aid of drawings. In the figures:

[0038] FIG. 1 shows a schematic representation of a preliminary scheme;

[0039] FIG. 2 shows a schematic representation of a conductor arrangement in the preliminary scheme;

[0040] FIG. 3 shows a schematic representation of a stack of preliminary schemes;

[0041] FIG. 4 shows a schematic representation of a folding process;

[0042] FIG. 5 shows a schematic representation of a single mat prior to being folded over;

[0043] FIG. 6 shows a schematic representation of nested mats;

[0044] FIG. 7 shows a schematic representation of nested mats;

[0045] FIG. 8 shows a schematic representation of nested mats and a finished winding mat arrangement;

[0046] FIG. 9 shows a schematic representation of a winding mat arrangement;

[0047] FIG. 10 shows a schematic representation of a bent and inserted winding mat arrangement;

[0048] FIG. 11 shows a schematic representation of an assignment diagram; and

[0049] FIG. 12 shows a schematic representation of a winding arrangement.

DETAILED DESCRIPTION

[0050] The figures are only schematic in nature and serve only for understanding the disclosure. The same elements are provided with the same reference signs. The features of the individual embodiments can be interchanged.

[0051] In addition, spatially relative terms such as “located below”, “under”, “lower”, “located above”, “upper”, “left”, “right”, and the like, may be used to simply describe the relationship of one element or structure to one or more other elements or structures depicted in the figures. The spatially relative terms are intended to encompass other orientations of the device in use or operation in addition to the orientation depicted in the figures. The component can be oriented differently (rotated 90 degrees or in a different orientation) and the spatially relative descriptors used herein interpreted accordingly as well.

[0052] The winding mat arrangement and the method for producing the stator will now be described with reference to embodiments.

[0053] To prevent circulating currents, a conductor along a winding path must see every slot in the slot block in every conductor level. The slot block means the superimposition of the individual poles per phase. Thus, it doesn't matter whether the conductor crosses level 1 in the first slot per pole in the first or in the second pole along the circumference. In the present case, a conductor changes one level up in each end winding. If the conductor has reached the top level, a level jump follows to the bottom level.

[0054] This shows the following level sequence (3,4,5,6,7,8,1,2) where z_n=8 conductor levels in the slot. In the area of the reversal points 8, 11, a conductor is exchanged for a different slot per pole, so that the rule mentioned above can be fulfilled. Due to the continuous level shifting, all conductors of each winding mat thus fulfill the rule.

[0055] Different numbers of parallel conductors a_mat are possible for the z_n/2 winding mats. The following condition must be met: mod(q/a_mat)=0 for connections at the same reversal point 8, 11 or mod(q/a_mat)=0.5 for connections at both reversal points. In the case of connections at the same reversal point 8, 11, the parallel winding arm connections are in zones next to one another.

[0056] The following explanations refer to a machine with a number of holes q=4, number of parallel conductors a=8, number of pole pairs p=4, z_n=8 and a number of slots N=96: Preliminary scheme for one phase (arrangement for a_mat=2 parallel conductors per winding mat).

[0057] The embodiment requires four mats (z_n/2). The level jump 10 takes place here once on each odd bending line. The bending lines can be different for each mat. For example, for the first mat 7, the second mat 5, the third mat 3 and the fourth mat 1. The orientation of the bend can be seen from the arrows in FIG. 1. In the case of a level jump 10, the bending direction is outside of the scheme, for example folded only in half, at least not completely folded, so that the mats can later be interlocked. In the case of a level jump 10, a larger offset between the vertical slot pieces 9 is required due to the larger end winding length.

[0058] Further details and aspects are mentioned in connection with the embodiments described above or below. The embodiment shown in FIG. 1 may have one or more optional additional features corresponding to one or more aspects mentioned in connection with the proposed concept or embodiments described below in relation to FIGS. 2 to 12.

[0059] FIG. 2 shows a schematic conductor arrangement in a preliminary scheme 12, 13, 14 for a_mat=2 and q=3. Connections may be necessary at both reversal points. In general, conductors on the right and left loop sides lie in each slot level due to the folding. On each loop side, the conductors are always in the same slot for each pole. By interchanging the reversal points 8, 11, a conductor thus sees all the slots in each slot block. In the case of a trivial arrangement for a_mat=1, the arrangement of the conductors in the preliminary scheme follows a concentric loop.

[0060] The stacking of the individual flat preliminary schemes 12, 13, 14 is shown in FIG. 3. A stacking of the individual preliminary schemes 12, 13, 14 is possible due to the shape of the end winding in the area of the reversal points 8, 11. The individual preliminary schemes 12, 13, 14 are layered in the same order at the reversal points 8, 11. Conductor bending can require an additional offset by the conductor height (in area a).

[0061] Further details and aspects are mentioned in connection with the embodiments described above or below. The embodiment shown in FIGS. 2, 3 may have one or more optional additional features corresponding to one or more aspects described in connection with the proposed concept or one or more embodiments described above (e.g., FIG. 1) or below (e.g., FIGS. 4 to 12).

[0062] The folding process with a level jump 10 at the bending line 5 is shown as an example. A folding state during the folding process of the mat itself is shown schematically in FIG. 4, see folding sections 15, 16. In the area of the level jump 10, the bending takes place outside of the directional scheme (see FIG. 5); it does not initially follow the final state. The bending is shown here schematically at 90 degrees, but 0 degrees and 150 degrees are also conceivable in order to enable plugging in. The bending to the final state of 180 degrees only takes place after plugging in.

[0063] According to FIGS. 6 to 8, the mats 17, 18, 19, 20 are plugged or nested one inside the other in an X-shape. In this case, first partial areas 17a, 18a, 19a, 20a (also referred to as first levels) of the mats 17, 18, 19, 20 are arranged next to one another, at the top right in FIGS. 6 to 8. In this case, second partial areas 17b, 18b, 19b, 20b are also arranged next to one another, at the top in FIGS. 6 to 8. In an intermediate area between the first partial area 17a, 18a, 19a, 20a and the second partial area 17b, 18b, 19b, 20b, the mats 17, 18, 19, 20 are arranged next to one another, at the bottom according to FIGS. 6 to 8. When all mats 17, 18, 19, 20 are arranged relative to one another, the plugged in mats are then bent to the final state for the winding mat arrangement 21 (see FIG. 8, second illustration).

[0064] The reversal points of the finished mats 17, 18, 19, 20 and the connection zones U, V, W, X, Y, Z are shown in FIG. 9. A connection can preferably be provided as a star connection (X-Y-Z to star) or as a delta connection. In the reversal points 8, 11, only every second level is occupied by a conductor (see the assignment diagram for a phase in FIG. 11). In FIG. 10, the bent and plugged in winding, which is also referred to herein as the rolled up winding mat arrangement 21, is shown.

[0065] Further details and aspects are mentioned in connection with the embodiments described above or below. The embodiment shown in FIGS. 4 to 10 may have one or more optional additional features corresponding to one or more aspects described in connection with the proposed concept or one or more embodiments described above (e.g., FIGS. 1 to 3) or below (e.g., FIGS. 11 and 12).

[0066] FIG. 11 shows an assignment diagram for a phase as an example. If the winding step is shortened on one end and if the winding step Is lengthened on the opposite end, a chord is obtained (analogous to two-layer winding). In a multi-layer winding, the shifting of the winding layers is referred to as a chord. This shifting smooths the excitation curve and thus reduces the harmonics of the induced voltage. Due to the chord, the induced voltage amplitude decreases. The plug-in zone increases by the length of the shortening/lengthening. The production concept is not affected by this, except for the bending variation (see FIG. 12, dashed slot occupied once, solid slot occupied twice).

LIST OF REFERENCE SYMBOLS

[0067] 1-7 Bending points

[0068] 8 Reversal point

[0069] 9 Groove piece

[0070] 10 Level jump

[0071] 11 Reversal point

[0072] 12 First preliminary scheme

[0073] 13 Second preliminary scheme

[0074] 14 Third preliminary scheme

[0075] 15 Folding section

[0076] 16 Folding section

[0077] 17a First level—first mat

[0078] 17b Second level—first mat

[0079] 18a First level—second mat

[0080] 18b Second level—second mat

[0081] 19a First level—third mat

[0082] 19b Second level—third mat

[0083] 20a First level—fourth mat

[0084] 20b Second level—fourth mat

[0085] 17 First mat

[0086] 18 Second mat

[0087] 19 Third mat

[0088] 20 Fourth mat

[0089] 21 Winding mat arrangement

[0090] U Connection zones

[0091] N Connection zones

[0092] V Connection zones