Method for producing a winding for a stator in an electric rotating machine, stator, method for producing the stator and electric rotating machine
12562628 ยท 2026-02-24
Assignee
Inventors
Cpc classification
H02K21/24
ELECTRICITY
International classification
H02K15/08
ELECTRICITY
Abstract
A method for producing a winding for a stator, the stator itself, a method for producing the stator and an electric rotating machine. The method for producing a winding for a stator of an electric rotating machine provides a first conductor and a further conductor, wherein the two conductors are bent into a zigzag form, at least in length portions, and the further conductor is moved with respect to the first conductor in a combination movement, which has a translatory movement component along the longitudinal axis of the further conductor and a rotary movement component about the longitudinal axis of the further conductor, such that the further conductor winds around an extreme value axis of the first conductor, which runs through regions f the first conductor, said regions forming extreme values of the zigzag course. The method for producing a winding for the stator, and the stator itself, the method for producing the stator and the electric rotating machine provide solutions that permit the winding, and accordingly also the stator comprising the winding and the electric rotating machine comprising the stator, to be produced at low cost and with little effort.
Claims
1. A stator of an electric rotating machine, comprising: a stator body having a plurality of stator teeth arranged along a circumferential direction and grooves formed between the stator teeth; and conductor sections of conductors of a winding, arranged in the grooves wherein the conductors of the winding are assigned to different electrical phases, and wherein only one respective phase is arranged for at least one conductor section of at least one conductor in a respective groove, and the sequence of arrangement of parallel conductor sections in each groove through which the conductors pass alternates along the circumferential direction, and wherein the conductors deviate from a winding direction running basically in the circumferential direction to meander in a first plane in a radial direction in a direction running substantially perpendicular to the circumferential direction and in a second plane perpendicular to the first plane, and with a respective enlacing formed thereby enlacing a respective group of stator teeth; wherein the conductors include a first conductor and a further conductor, and the further conductor is wound around an extreme value axis of the first conductor, which runs through regions of the first conductor, which regions form extreme values.
2. An electric rotating machine, comprising a rotor and at least one stator according to claim 1.
3. The electric rotating machine according to claim 2, wherein the conductors of each of the phases are connected in a star connection to corresponding contacts carrying current of the relevant phase.
4. The stator of claim 1, wherein the conductors have a zigzag shape at least in length portions, wherein the zigzag shape is three-dimensional, and corresponds to a harmonic oscillation, and wherein linear conductor sections of the conductors having a positive slope and linear conductor sections of the conductors having a negative slope are each arranged on both sides outside of a central plane running through regions of the extreme values.
5. The stator of claim 4, wherein the zigzag shape is configured between adjacent linear conductor sections alternately a first distance and a second distance, wherein the first distance is greater than the second distance.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The disclosure described above is explained in detail below against the relevant technical background with reference to the accompanying drawings, which show preferred embodiments. The disclosure is not limited in any way by the purely schematic drawings, wherein it should be noted that the embodiments shown in the drawings are not limited to the dimensions shown. In the drawings:
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DETAILED DESCRIPTION
(40) First, the general design of a stator according to the disclosure is explained with reference to
(41)
(42) The stator 10 also includes one or more windings 20 of electrical conductors enlacing the grooves 15 and stator teeth 12. These windings are placed on the stator teeth 12 along a general winding direction 21 that runs along the circumferential direction 14.
(43) The windings 20 form winding heads 22 on the radial inside of the stator teeth 12 and on their radial outside.
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(45) However, the present disclosure is not limited to the illustrated design of an axial flow machine, but can also be designed as an H-type, or one-sided axial flow machine having only one stator and only one rotor.
(46)
(47) As
(48) A pair of conductors is illustrated in
(49) Deviating from the embodiment shown here, the linear conductor sections 33 can also be designed to be curved or saber-shaped. For conceptual clarification, however, conductor sections shaped in this way are also subsumed below under the term linear conductor sections.
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(51) Current flows through the conductors of the conductor pair 30 in different circumferential directions. This is explained using the first pair of conductors 30.
(52) A first conductor 31 of the conductor pair 30 is referred to as the positive conductor for this purpose. A second conductor 32 of the conductor pair 30 is referred to as the negative conductor for this purpose.
(53) The first conductor 31 forms a first connection 36 of the positive conductor and a second connection 37 of the positive conductor.
(54) The second conductor 32 forms a first connection 38 of the negative conductor and a second connection 39 of the negative conductor.
(55) Said conductors are organized to be correspondingly connected to three phases, with one positive winding and one negative winding per phase.
(56) A respective conductor 31, 32 of the conductor pair 30 enlaces a group 13 of stator teeth 12 on different radial sides, so that the current flow in a respective common groove 15 takes place in both conductors 31, 32 along the same direction.
(57) It can be seen here that the stator 10 includes not only one pair of conductors, but three pairs of conductors, wherein a third conductor 61 and a fourth conductor 62 form the second pair of conductors, and a fifth conductor 63 and a sixth conductor 64 form the third pair of conductors.
(58) However, only sections of conductors of a conductor pair are arranged in a respective groove 15.
(59) In addition, it can be seen from
(60) For better clarification of the course of the conductors,
(61) All conductors are once again clearly visible here in a perspective view.
(62) Furthermore, it can be seen that a respective pair of conductors 30 enlaces a group 13 of stator teeth 12 which respectively includes three stator teeth 12.
(63) Due to the alternating arrangement of the conductors of a respective conductor pair 30 in the grooves 15, it is necessary for these conductors to cross. For this purpose, the conductors form connecting conductor sections 35 which connect the linear conductor sections 35 to one another and ensure that the respective conductor runs back and forth between two arrangement planes between the grooves 15 in which the relevant conductor runs.
(64) For the three phases shown, one phase occupies every third groove 15.
(65) The axially first conductor layer in a relevant groove 15 is alternately assigned a positive or a negative phase. A layer can also consist of several discrete individual wires.
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(67) To enable the conductors of the conductor pair 30 to run in the four planes, the conductors each form a transition section 70, as is shown by way of example using the first conductor 31. This transition section 70 allows the first conductor 31 to pass from a second plane to a third plane.
(68) Such a transition section 70 is also referred to as a layer jump.
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(71) Furthermore, the connecting conductor sections 35 can be seen here, which ensure that the conductors 31, 61, 63, 32, 62, 64 can switch between the first plane 51 and the second plane 52, and between the third plane 53 and the fourth plane 54.
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(75) It can additionally be seen here that the winding heads 22 can be designed in such a way that they are not, or are only slightly, wider than the width of a relevant groove 15, and accordingly have a small axial space requirement.
(76) In addition, the winding heads 22 are also designed to be radially flat, so that a larger radius can be realized in the torque-active region of axial flux machines equipped therewith.
(77) This principle for designing a wave winding can also be used for radial flux machines.
(78) A winding 20 with two double layers 60 is thus shown, which occupy a total of four layers or planes 51, 52, 53, 54 in the axial direction. An even number of layers or planes is required for this. Since two layers or planes each represent a common structure, two layers that belong together are referred to as a double layer 60.
(79) The planes 51, 52, 53, 54 shown here do not necessarily need to be planar or even. For example, to follow a conical rotor, these planes 51, 52, 53, 54 could also be conical.
(80) To clarify a respective conductor course,
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(82) Partial illustration a) shows the first conductor 31, as has already been explained with reference to
(83) Partial representation e) shows all the conductors already shown in partial representation d) and also a fourth conductor 62 which, together with the third conductor 61, forms a second pair of conductors. Partial representation f) shows all the conductors already shown in partial representation e) and additionally a sixth conductor 64 which, together with the fifth conductor 63, forms a third pair of conductors. In addition, partial representation f) shows that the winding heads 22 are approximately as wide as the axial length required for the conductors in the grooves.
(84) A winding 20 with two double layers 60 is shown in each of
(85) It can also be seen in
(86) To illustrate a pair of conductors 30, the course of the first conductor 31 and of the second conductor 32 is shown once again in
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(88) In this case,
(89) Alternatively, the connection shown can also be used for a series connection 72. Deviating from the exemplary embodiments presented here, the stator designed according to the disclosure can also be designed for more or fewer than 3 phases.
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(91) The process described here relates to the production of windings in two double layers.
(92) For this purpose, as shown in
(93) The fins each have a geometry that favors the later process steps of bending into a flattened mat and bending into a circular shape.
(94) As
(95) With regard to the conductor pair, which includes the first conductor 31 and the second conductor 32 and forms the first phase, it should be mentioned that the third conductor 61 and the fifth conductor 63 are located between the first conductor 31 and the second conductor 32, while they belong to the second phase and the third phase.
(96) During the winding onto the first fin 80, the second fin 90 has not yet been brought into position, so that it does not interfere with the winding process on the first fin 80. The second fin 90 is not positioned until the required turns on the first fin 80 have been created. After completing the necessary number of turns, the second fin 90 is positioned to be adjacent to the first fin 80 and the winding direction is reversed for approximately half a rotation. In this way, the conductors are guided over the second fin 90 in a second winding direction 91 which runs in the opposite direction to the first winding direction 82.
(97) By reversing the winding direction, the conductors are pre-bent for the layer jump. After that, said conductors are again wound up along the first winding direction 82 on the third fin 100, which is positioned after said half reverse rotation. If more double layers are required, the number of fins and the number of windings carried out is increased accordingly. If there are more than two layer jumps or transitions between double layers, additional second fins can be used. After the windings have been produced, the wound conductors can be pressed together to form a winding mat, so that this winding mat has approximately the same axial extent as the depth of the grooves in the stator body in which the winding or windings are to be accommodated. This winding mat can still be bent into an annular shape to facilitate insertion into the grooves of the stator core.
(98) The implementation of the method is not necessarily restricted to the sequence of the steps mentioned above.
(99) The use of the second fin 90 and the third fin 100 can be dispensed with to implement a winding mat with only one double layer.
(100) The present method can also be used to produce windings for radial flux machines.
(101) For a simplified explanation of the process sequence, the winding processes are illustrated by way of example in
(102) It is also clearly visible here that the two transition sections 70 are formed by enlacing the second fin 90 with these conductors 31, 61.
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(105) It can be seen that, when the generated winding is equated with a harmonic oscillation, the first enlacing side 110 forms an extreme value range 120 and the second enlacing side 111 forms an opposite extreme value range 120.
(106) In the extreme value regions 120 lying opposite one another, the winding is designed with a different width to adapt the shape thereof to the fact that the distance between the grooves in the stator body is greater on the radial outside than on the radial inside.
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(109) It can also be seen here that the distance between the linear conductor sections 33 within a shaft section is spaced apart from one another in an alternating manner by a first distance 230 and a second distance 231, wherein the second distance 231 is greater than the first distance 230. This takes account of the fact that the outer winding heads must bridge greater distances in the circumferential direction than the inner winding heads. If this method is used for the stator windings of a radial flux machine, the distances for the two winding heads are similar. These may change with the radius on which the winding layer lies, in that the fins used one after the other are designed with different widths for the individual double layers.
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(113) In a side view,
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(117) The procedure for producing such a braid will now be explained with reference to
(118) First, as shown in
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(120) This means that the zigzag shape is three-dimensional, wherein by equating the zigzag shape with a harmonic oscillation, linear conductor sections 33 of the relevant conductor which have a positive slope 220, and linear conductor sections of the relevant conductor which have a negative slope 221, are arranged in the middle on both sides outside of a central plane 222 running through regions of the extreme values 120.
(121) The braid is now created by providing a further conductor 41 which has been pre-formed in essentially the same way as the first conductor 31. As indicated in
(122) As can be seen from
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(124) The other conductors shown here, i.e., the second conductor 32, the third conductor 61, the fifth conductor 63 and the sixth conductor 64 have in turn been connected to one another according to the present method in the sequence shown.
(125) Accordingly, this provides three pairs of conductors for connection to three phases that are intertwined.
(126) Deviating from the embodiment shown here, of course, more or fewer pairs of conductors can be intertwined to connect the phases.
(127) After the production of this braid 130, this braid 130 still must be bent into a circular shape. In addition, the three-dimensional structures of the individual conductors of this braid can also be reduced in the axial extent, so that they result in a flat mat that requires less axial space when integrated between the stator teeth.
(128) However, the method is not limited to the sequence of the individual steps described above.
(129) The stator 10 shown here has the special feature that it comprises the six conductors in two double layers, which, however, are not connected to one another by transition sections, as shown in
(130) With the method for producing a winding for a stator of an electric rotating machine, and with the stator itself, the method for producing the stator, and with the electric rotating machine, solutions are made available that allow the winding and accordingly also the stator having the winding, and the electric rotating machine comprising the stator at low cost and with little effort, especially for windings in which a conductor is routed in more than two planes.
LIST OF REFERENCE SYMBOLS
(131) 1 Axial flux machine 2 Rotor 10 Stator 11 Stator body 12 Stator tooth 13 Group of stator teeth 14 Circumferential direction 15 Groove 16 Depth of groove 20 Winding 21 Winding direction 22 Winding head 30 Conductor pair 31 First conductor 32 Second conductor 33 Linear conductor section 34 Enlacing 35 Connecting conductor section 36 First connection of the positive conductor 37 Second connection of the positive conductor 38 First connection of the negative conductor 39 Second connection of the negative conductor 40 Common connection region 41 Further conductor 51 First plane 52 Second plane 53 Third plane 54 Fourth plane 60 Double layer 61 Third conductor 62 Fourth conductor 63 Fifth conductor 64 Sixth conductor 70 Transition section 71 Positive connections 72 Connection for series connection 73 Connection for star connection 80 First fin 81 Longitudinal axis 82 First winding direction 90 Second fin 91 Second winding direction 92 Enlacing angle 100 Third fin 110 First enlacing side 111 Second enlacing side 112 Flat side surface 120 Extreme value range 130 Braid 140 Mesh 200 Longitudinal axis of the second conductor 210 Translatory movement component 211 Rotary movement component 212 Conductor tips 220 Positive slope section 221 Negative slope section 222 Center plane 230 First distance 231 Second distance