STATOR WITH PINS AND AN INTERNAL CONNECTION FOR AN ELECTRIC MACHINE

Abstract

A stator for an electric machine has a plurality of pins, which are arranged on concentric circles at different distances from a stator center point in slots and each concentric circle forms a layer, wherein four pins in different layers are respectively connected to one another in series and form a winding, a first pin of the winding is located in a first slot in the 4n−3 layer, wherein n is a natural number, a second pin of the winding is located in a second slot in the 4n−2 layer, wherein the second slot is at a first radial distance from the first slot in a first circumferential direction of the stator, a third pin of the winding is located in the first slot in the 4n layer, a fourth pin of the winding is located in the second slot in the 4n−1 layer.

Claims

1. A stator for an electric machine, comprising: a plurality of pins, which are arranged on concentric circles at different distances from a stator center point in slots and each concentric circle forms a layer, wherein four pins of the plurality of pins in different layers are respectively connected to one another in series and form a winding, wherein a first pin of the four pins of the winding is located in a first slot in the 4n−3 layer, wherein n is a natural number, wherein a second pin of the four pins of the winding is located in a second slot in the 4n−2 layer, wherein the second slot is at a first radial distance from the first slot in a first circumferential direction of the stator, wherein a third pin of the four pins of the winding is located in the first slot in the 4n layer, and wherein a fourth pin of the four pins of the winding is located in the second slot in the 4n−1 layer.

2. The stator according to claim 1, further comprising: a first end face and a second end face, wherein the first pin and the second pin are connected to one another on the second end face by a first type of connection, wherein the second pin and the third pin are connected to one another on the first end face by a second type of connection, wherein the third pin and the fourth pin (24) are connected to one another on the second end face (9) by means of a third type of connection, wherein the first, second and third types of connection differ from one another.

3. The stator according to claim 1, wherein the stator has at least two windings and at least the fourth pin in the second slot is connected to a fifth pin in the 4n−3 layer in a third slot by a fourth type of connection.

4. The stator according to claim 3, wherein the stator has a multiplicity of windings, which extend over the entire circumference of the stator and thereby form a part-coil.

5. The stator according to claim 4, wherein respective pins of two part-coils are connected to one another by means of a fifth type of connection and form a coil.

6. The stator according to claim 5, wherein the part-coils form six coils and six phases are assigned to them in such a way that two coils, which are assigned to different phases, are respectively located in adjacent slots.

7. The stator according to claim 5, wherein respective inputs of a pin of two coils are connected to one another by means of a sixth type of connection.

8. The stator according to claim 7, wherein respective outputs of a pin of the two coils are connected to one another and the two coils as a result are connected in parallel and assigned to one phase.

9. The stator according to claim 1, wherein the second type of connection comprises a first double pin, which is formed from the second pin and the third pin, wherein the first double pin has two inwardly bent pin feet with a respective weld point and bridges a first radial distance.

10. The stator according to claim 1, wherein the fourth type of connection comprises a second double pin, which is formed from the fourth pin and the fifth pin, wherein the second double pin has two outwardly bent pin feet with a respective weld point and bridges a first radial distance.

11. The stator according to claim 1, wherein the fifth type of connection comprises a third double pin, which is formed from a second end pin and a third end pin, wherein the third double pin has two pin feet, which are bent anticlockwise, with a respective weld point and bridges a third radial distance.

12. The stator according to claim 1, wherein a seventh type of connection comprises a fourth double pin, which is formed from a sixth end pin and a seventh end pin, wherein the fourth double pin has two pin feet which are bent anticlockwise and bridges a second radial distance.

13. The stator according to claim 1, wherein a single pin comprises a first end pin or a fourth end pin or a fifth end pin or an eighth end pin and has a pin foot which is bent clockwise and has a weld point.

14. The stator according to claim 1, wherein the first type of connection is formed by a welded connection between a first weld point at the pin foot of the first double pin or of the third double pin or of the fourth double pin and a second weld point at the pin foot of the second double pin or of the single pin.

15. The stator according to claim 1, wherein the third type of connection is formed by a welded connection between a third weld point at the pin foot of the first double pin or of the single pin and a second weld point at the pin foot of the second double pin or of the third double pin or of the fourth double pin.

16. A vehicle having an electric machine with a stator according to claim 1.

Description

DESCRIPTION OF THE FIGURES

[0040] FIG. 1 shows a stator.

[0041] FIG. 2 shows a stator having eight slots and four layers.

[0042] FIG. 3 shows a winding pattern of a first part-coil.

[0043] FIG. 4 shows a winding pattern of a second part-coil.

[0044] FIG. 5 shows a stator having two part-coils and the connection of said part-coils to one another, and thus a coil.

[0045] FIG. 6 shows a stator having two coils, consisting of two respective part-coils.

[0046] FIG. 7 shows a stator having two further coils.

[0047] FIG. 8 shows a stator having two further coils.

[0048] FIG. 9 shows a stator having six coils.

[0049] FIG. 10 shows a winding pattern of two coils.

[0050] FIG. 11 shows a single pin.

[0051] FIG. 12 shows a further single pin.

[0052] FIG. 13 shows a first double pin.

[0053] FIG. 14 shows a second double pin.

[0054] FIG. 15 shows a third double pin.

[0055] FIG. 16 shows a fourth double pin.

[0056] FIG. 17 shows a vehicle having an electric machine, in particular an electric motor, having a stator.

[0057] FIG. 1 shows a stator 1 having a multiplicity of slots 5 in which pins 2, 3 are guided. The stator has a first end face 7 and a second end face 9. On the first end face 7, inputs 81, 87, 101, 107, 111, 117 and outputs 83, 85, 103, 105, 113, 115 of part-coils for connecting the pin to an energy source for the operation of the electric machine are shown. The inputs and outputs are respectively located in the outermost or innermost layer of the stator. Of course, a rotor is also necessary for the operation of an electric machine. For connection purposes, the pins lie close to one another and make short connection lines possible.

[0058] FIG. 2 shows a stator 1 having slots 51, 52, 53, 54, 55, 56, 57, 58 and pins 21, 22, 23, 24, 26, 27 on four layers, only eight slots being illustrated. The pins are arranged in the slots. The pins lie next to one another in a slot; in the example of FIG. 2, four pins lie next to one another in a slot. The four pins within one slot therefore lie on different concentric circles around the center point M of the stator, which circles thus form individual layers L1, L2, L3, L4. There is a distance 71 between two respective slots. This distance 71 is identical between all of the slots shown in FIG. 2.

[0059] FIG. 3 shows the stator 1 from FIG. 2. The pins are still arranged on concentric circles, that is to say layers, the concentric circles not being depicted for the sake of better illustration. FIG. 3 illustrates which pins are connected to one another in series. A first pin 21 is located in a first slot 51 in the layer L1. This first pin 51 is connected to a second pin 22 in the slot 52 by means of a first type of connection 61, illustrated as a dotted line. The second pin 22 is located in the layer L2. The second pin 22 is connected to a third pin 23 in the slot 51 by means of a second type of connection 62, illustrated as a short-dashed line. The third pin 23 is located in turn in the first slot 51, that is to say in the same slot as the first pin 21. The third pin 23, however, lies in the layer L4. Consequently, there is still space in the slot 51 for two further pins between the third pin 23 and the first pin 21. The third pin 23 is connected to a fourth pin 24 via a third type of connection 63, illustrated as a solid line. The fourth pin 24 lies in the same slot 52 as the second pin 22. The fourth pin 24 lies in the layer L3 directly next to the first pin 21. Consequently, there is still space in the slot 52 for two further pins in layers L1 and L4 next to the two pins 22, 24. The serial connection of the first, second, third and fourth pins forms a first winding 41.

[0060] The fourth pin 24 is connected to a fifth pin 25 in the layer L1 in a third slot 53 via a fourth type of connection 64, illustrated as a dashed line. With the fifth pin 25, the above-described serial connection of the subsequent pins in the stator begins again, with the fifth pin 25 being similar to the first pin 21 but with the slot being offset by 90 degrees. The first pin 21 is connected to a pin 27, which is similar to a fourth pin, via a fourth type of connection 64. The pin 27 is in turn connected to a first end pin 26 via a third type of connection 63, which first end pin has an input 81, see FIG. 12.

[0061] The serial connection of the fifth pin 25 to further pins in the slots 53 and 54 forms a second winding 42. The first, second and third types of connection 61, 62, 63 between these pins are identical to the respective first, second and third types of connection 61, 62, 63 of the pins of the first winding 41.

[0062] The two windings 41, 42 are connected by the fourth type of connection 64. The continuation of the serial connection forms the third winding 43 in the slots 55, 56. The windings 41, 42, 43, 44 are respectively connected by means of the fourth type of connection 64. The fourth type of connection 64 between the respective windings is therefore identical. It is also the case that the first, second and third types of connection 61, 62, 63 between the pins of the winding 43 are identical to the first, second and third types of connection 61, 62, 63 of the first and second windings 41, 42.

[0063] The fourth winding 44 constitutes a special feature and is formed at the beginning and at the end of the serial connection of the three other coils. The first pin 21 of the first winding 41 is connected to a pin 28 in slot 58 via the fourth type of connection 64. This pin 27 is connected to the end pin 26 via a third type of connection 63. After the circuit and the connection of the windings 41, 42, 43, two further pins are connected according to the pattern shown in FIG. 3 and the last pin 28 is configured as a second end pin, which thus completes the part-coil. The slots are at an identical distance 71 from one another.

[0064] FIG. 4 shows the stator 1 from FIG. 3 and shows eight slots 91, 92, 93, 94, 95, 96, 97, 98, which are located in the direct vicinity of the slots of FIG. 3.

[0065] The pins 31, 32, 33, 34, 35 are connected in the same way as the pins 21, 22, 23, 24, 25 of FIG. 3. Even the type of connection is identical to FIG. 3 and is made clear by the same reference signs. In the same way as described for FIG. 3, the windings 45, 46, 47 and 48 are formed and connected to one another clockwise by the fourth type of connection 64. The first pin 31 is in turn a third end pin 31.

[0066] The fourth pin in the slot 98 on the layer L1 of the winding 48 is a fourth end pin 38 and has an output 83 for the connection of an energy source. The four windings 45, 46, 47, 48 form a second part-coil.

[0067] FIG. 5 shows a pin configuration through the first and the second part-coil from FIGS. 3 and 4, which is illustrated by black squares. The same reference signs denote the same pins, slots and connections in the figures. The second end pin 28 of the winding 44 of the first part-coil in slot 58, layer L2, and the third end pin 31 of the first winding 45 in slot 91, layer L3, are connected by means of a fifth type of connection 65. The two part-coils thus form a first coil with a first end pin 26 as input 81 and a fourth end pin 38 as output 83 after two radial circuits in different directions around the stator. It is therefore possible to see the end pins 26, 28, 31, 38 which respectively mark the beginning and the end of a part-coil.

[0068] FIG. 6 shows a pin configuration through the first and the second part-coil from FIGS. 3 and 4, which are illustrated by black squares. The same reference signs denote the same pins, slots and connections in the figures. Furthermore, two further part-coils according to the principle of FIGS. 3 and 4 are indicated as black squares on a white background, but they are respectively offset by 5 slots in comparison with the first coil and respectively form a second and a third part-coil. These two part-coils are connected by means of a seventh type of connection 67 between a sixth end pin 28a in slot 98, layer L2, and a seventh end pin 31a in slot 57, layer L3, and form a second coil.

[0069] FIG. 6 thus shows two parallel coils, each of which consists of two part-coils. The inputs and outputs of the coils are likewise shown. The input 81 of the first coil is located at the slot 57 and the output 83 at the slot 98. The input 87 of the second coil is located at the slot 91 and the output 85 at the slot 58. The inputs and outputs of the two coils are thus in adjacent slots on the outermost or innermost layer. The second radial distance 73 is for example one slot shorter than the first radial distance 71. Furthermore, the third radial distance 75 is one slot longer than the first radial distance.

[0070] FIG. 7 shows a pin configuration through a third and a fourth coil in the black squares with a white dot and the white squares with a black dot. This is produced by a winding pattern established in FIGS. 3, 4 and 5, which is offset clockwise by two slots in comparison with the pins and connections illustrated in the latter figures. The inputs 101 and outputs 103 of the third coil and inputs 107 and outputs 105 of the fourth coil are likewise shown. The inputs and outputs of the two coils are thus in adjacent slots on the outermost or innermost layer.

[0071] FIG. 8 shows a pin configuration through a fifth and a sixth coil. This is produced by a winding pattern established in FIGS. 3, 4 and 5, which is offset clockwise by four slots in comparison with the pins and connections illustrated in the latter figures.

[0072] The inputs 111 and outputs 113 of the fifth coil and inputs 117 and outputs 115 of the sixth coil are likewise shown. The inputs and outputs of the two coils are thus in adjacent slots on the outermost or innermost layer.

[0073] FIG. 9 shows a pin configuration through the six coils in the form of a combination of FIGS. 6, 7 and 8. It is clear in particular from the position of the inputs 81, 87, 101, 107, 111, 117 and outputs 83, 85, 103, 105, 113, 115 that all of the inputs can be interconnected within one eighth of the stator. Furthermore, all of the outputs can also be interconnected within one eighth of the stator.

[0074] FIG. 10 shows two coils 201, 202, each of which consists of two part-coils. The same reference signs establish the relationship with the other figures. The connection of the part-coils to the coil and the connection of the respective coil to an inverter, for example, can be seen in FIG. 10. Pin 26 of the first coil 201 constitutes a first end pin 26 and has an input 81. A serial connection of the pins, filled in in black, by means of the solid-line arrows almost completes a single radial circuit around the stator and forms the first circuit, which comprises the first part-coil. The first end pin 26 is at the beginning of the first part-coil and the second end pin 28 is at the end.

[0075] The second part-coil is formed by connecting the pins, shown as horizontal dashes, by means of the dashed-line arrows. The part-coil begins with the third end pin 31 and ends with the fourth end pin 38. The fourth end pin 38 is connected to an inverter, for example, by way of the output 83. The fifth type of connection 65 is located between the second end pin 28 of the first part-coil and the third end pin 31 of the second part coil. The two end pins 31, 28 and the fifth type of connection 65 are shown in FIG. 15. Both circuits of the first coil 201 take place in different directions, for example firstly clockwise and then anticlockwise.

[0076] The pin 26a of the second coil 202 constitutes a fifth end pin 26a and has an input 87. A serial connection of the pins, filled in in black, by means of the solid-line arrows almost completes a single radial circuit around the stator and forms the first circuit, which comprises the first part-coil of the second coil 202. The fifth end pin 26a is at the beginning of the second part-coil and the sixth end pin 28a is at the end.

[0077] The second part-coil is formed by connecting the pins, shown as horizontal dashes, by means of the dashed-line arrows. The part-coil begins with the seventh end pin 31a and ends with the eighth end pin 38a. The eighth end pin 38a is connected to an inverter, for example, by way of the output 85. The seventh type of connection 67 is located between the sixth end pin 28a of the first part-coil and the seventh end pin 38a of the second part-coil. The two end pins 28a, 38a and the seventh type of connection 67 are shown in FIG. 16.

[0078] The circulation directions of the two coils may be selected freely, but they are in the same circulation direction.

[0079] FIG. 11 shows a single pin 219 or I-pin. The actual pin 38, 38a which is arranged in the slot of the stator is located in the center. The reference signs are identical to the preceding figures. The pins are illustrated with the first end face 7 upward from the perspective of the stator center point. The output 83, 85, 103, 105, 113, 115 is located at the top end. The single pin 219 is used on layer 1 for the fourth or eighth end pin 38, 38a. At the bottom end, the end pin has a pin foot 61a with a second weld point 223.

[0080] FIG. 12 shows a single pin 220 or I-pin. The actual pin 26, 26a which is arranged in the slot of the stator is located in the center. The reference signs are identical to the preceding figures. The pins are illustrated with the first end face 7 upward from the perspective of the stator center point. The single pin 220 is used on layer 4 for the first and fifth end pin 26, 26a. At the bottom end, the end pin has a pin foot 63a with a third weld point 225. The input 81, 87, 101, 107, 111, 117 is located at the top end.

[0081] FIG. 13 shows a first double pin 211 or U-pin, which establishes the type of connection 62 between a second pin 22, 32 and a third pin 23, 33. The double pin may bridge the first distance 71 between the slots. At the bottom end, the double pin has two inwardly bent pin feet 63a, 61b with a weld point 225, 221.

[0082] FIG. 14 shows a second double pin 213 or U-pin, which establishes the type of connection 64 between a pin 24, 34, 27 and a pin 21, 25, 35. The double pin may bridge the first distance 71 between the slots. At the bottom end, the double pin has two outwardly bent pin feet 63b, 61a with a weld point 227, 223.

[0083] The first distance 71 is identical only with respect to the number of slots to be bridged. The actual spatial distance to be bridged is different, because the double pins connect different layers.

[0084] FIG. 15 shows a third double pin 214 or U-pin, which establishes the type of connection 65 between a second end pin 28 and a third end pin 31. The double pin may bridge the third distance 75, thus is one slot more than the distance 71. At the bottom end, the double pin has two bent pin feet 63b, 61b with a respective weld point 227, 221.

[0085] FIG. 16 shows a fourth double pin 215 or U-pin, which establishes the type of connection 67 between a sixth end pin 28a and a seventh end pin 31a. The double pin may bridge the second distance 73, thus is one slot less than the distance 71. At the bottom end, the double pin has two bent pin feet 61b, 63b with a respective weld point 221, 227.

[0086] The various single and double pins in FIGS. 11 to 16 have similar pin feet. The connection 61 is formed by welding together the weld points 221, 223 at the pin feet 61a, 61b according to the winding pattern of FIG. 10. The connection 63 is formed by welding together the weld points 225, 227 at the pin feet 63a, 63b according to the winding pattern of FIG. 10.

[0087] The first type of connection 61 is thus formed via the pin feet 61a, 61b and the weld points 221 and 223. The third type of connection 63 is thus formed via the pin feet 63a, 63b and the weld points 225 and 227.

[0088] FIG. 17 is a basic diagram of an exemplary embodiment of a vehicle 403, for example a hybrid vehicle or an electric vehicle, comprising an electric machine 401, in particular an electric motor, with an exemplary embodiment of the stator 1 for driving the vehicle 403. The vehicle 403 may also comprise an inverter 405, which supplies the electric machine 401 with an alternating current from a direct-current source.

LIST OF REFERENCE SIGNS

[0089] 1 Stator [0090] 2, 21, 22, 23, 24, 25 Pin [0091] 31, 32, 33, 34, 35 Pin [0092] 5, 51, 52, 53, 54, 55, 56, Slot [0093] 57, 58, 91, 92, 93, 94, 95, Slot [0094] 96, 97, 98 Slot [0095] 7 First end face [0096] 9 Second end face [0097] 26, 26a, 28, 28a, 31, 31a, 38, 38a End pin [0098] 41-48 Winding [0099] 61 First type of connection [0100] 62 Second type of connection [0101] 63 Third type of connection [0102] 64 Fourth type of connection [0103] 65 Fifth type of connection [0104] 66 Sixth type of connection [0105] 67 Seventh type of connection [0106] 61a, 61b, 63a, 63b Pin foot [0107] 71 First distance [0108] 73 Second distance [0109] 75 Third distance [0110] 401 Electric machine [0111] 81, 87, 101, 107, 111, 117 Input [0112] 83, 85, 103, 105, 113, 115 Output [0113] 201 First coil [0114] 202 Second coil [0115] 211, 213, 214, 215 Double pin [0116] 219, 220 Single pin [0117] 221, 223, 225, 227 Weld point [0118] 403 Vehicle [0119] 405 Inverter [0120] L1, L2, L3, L4 Layer [0121] M Stator center point