Electric motor device, electric motor, double coil for an electric motor and method for manufacturing the double coil

Abstract

The invention relates to an electric motor device (10a; 10b), in particular for an axial flux motor (14a; 14b), with at least one stator (16a; 16b) which comprises more than two magnetic coils (36a, 38a; 36b, 38b). It is proposed that two of the magnet coils (36a, 38a; 36b, 38b) are wound from a common coil wire (40a; 40b) and thereby form a double coil (30a, 32a, 34a; 30b, 32b, 34b) connected via a connecting section (50a; 50b) of the coil wire (40a; 40b).

Description

State of the art

[0001] An EC motor with an axial flux topology has already been proposed, which has a stator with magnetic coils, wherein the magnetic coils are individually contacted with a circuit board.

[0002] Furthermore, a method for manufacturing magnetic coils for an electric motor with axial flux topology, which includes a sequential 3D forming process with wire feeding and bending forming, has already been proposed. Disclosure of the invention

[0003] The invention relates to an electric motor device, in particular for an (EC) axial flux motor, with at least one stator which comprises more than two magnetic coils.

[0004] It is proposed that two of the magnetic coils are wound from a common coil wire and thereby form a double coil connected via a connecting section of the coil wire.

[0005] The inventive design of the electric motor device advantageously allows for a direct connection of the magnetic coils, which leads to simplified wiring within the stator. This advantageously reduces the number of contact points between the magnetic coils and a controller. Furthermore, the limited space in the stator can be used more efficiently. Furthermore, connecting the magnetic coils advantageously distributes heat generation more evenly. Furthermore, the use of double coils advantageously reduces costs in the manufacture of the magnetic coils. Furthermore, the logistics in the manufacture of the double coils can advantageously be simplified.

[0006] The axial flux motor is preferably an EC axial flux motor. However, use with a brushed axial flux motor is also conceivable. The electric motor device, in particular the axial flux motor, is part of an electric motor for driving an electrical machine and / or in a generator mode for generating electrical energy. Particularly preferably, the electric motor device, in particular the electric motor, is intended for a pump, preferably a recirculation pump, or for other axial flux motors with a large coil wire diameter.Alternatively, the electric motor device, in particular the electric motor, can be used for industrial high-performance applications, such as in pumps, compressors, or rolling mills, and / or in fuel cell vehicles, hybrid vehicles, and / or electric vehicles, in particular commercial vehicles and / or high-performance vehicles, and / or in renewable energy systems, in particular in wind turbines, and / or in marine technology, in particular in electric propulsion systems for ships, and / or in another field of application that particularly requires high power. A motor concept that can be manufactured in large series is conceivable, particularly for use in vehicles.

[0007] The electric motor device is particularly designed to generate mechanical energy from electrical energy. In particular, the electric motor device, in particular the electric motor, has a rotor. The rotor or the stator is connected to a shaft which is driven by the electric drive, in particular when operated as an electric machine, or which transmits a rotary movement to the electric motor, in particular when operated as a generator. Preferably, the rotor and the stator, in particular in a configuration for an axial flux motor, are arranged next to one another, preferably one behind the other, along an axial direction of the electric motor device, in particular along a central axis of the stator, wherein a main extension plane of the stator is preferably parallel to a main extension plane of the rotor.In particular, the main extension plane of the stator and / or the rotor is defined by a plane having the central axis of the stator, in particular a rotational axis of the rotor, as its normal. A "central axis of the stator" is understood to mean an axis that is preferably orthogonal to a base area of ​​a minimal cylinder around the stator and extends longitudinally along a symmetrical central axis of the cylinder, wherein the central axis is preferably equidistant from a radial inner edge of coil windings of the magnetic coils, and wherein the central axis of the stator is preferably at least approximately equal to the rotational axis of the rotor.

[0008] In particular, the magnetic coils of the stator are arranged according to an axial flux topology, wherein the magnetic coils are arranged next to one another along a circumferential direction on a common diameter. Preferably, a winding axis of the magnetic coils, in particular defined by a central axis around which the coil wire is wound, is in each case parallel to the central axis of the stator, in particular the axis of rotation. Preferably, the stator has a plurality of cores which are arranged next to one another along a circumferential direction on a common diameter and each have one of the magnetic coils wound around them. Preferably, the rotor has a plurality of magnets, in particular permanent magnets, which are preferably arranged along a circumferential direction of the rotor. Preferably, the magnets, in particular permanent magnets, of the rotor are arranged spaced apart from one another at the same angle in the circumferential direction.Preferably, but not limited to, the number of windings per solenoid coil is between 4 and 100, advantageously between 6 and 50, and particularly advantageously between 8 and 12. Due to the small number of windings, a coil wire with a large coil wire diameter can be used to save space.

[0009] Preferably, the magnetic coils of the stator are connected to a control and / or regulating unit that is configured to regulate and / or control an electric current in the magnetic coils. Preferably, the electric motor device, particularly preferably the electric motor, has the control and / or regulating unit. In particular, the control and / or regulating unit is provided for regulating the current in the magnetic coils to vary a magnetic field generated by the magnetic coils. Preferably, generated magnetic field lines of the magnetic coils, particularly in a configuration for an axial flux motor, run substantially parallel to a rotational axis of the rotor in the axial direction, in particular parallel to the center axis of the stator. “Configured” or “provided” should be understood to mean, in particular, specially programmed, designed, and / or equipped.The fact that an object is intended or configured for a specific function should be understood in particular to mean that the object fulfils and / or executes this specific function in at least one application and / or operating state.

[0010] The present electric motor device, in particular the electric motor, may optionally comprise further components such as cooling mechanisms, sensors for detecting operating parameters and / or interfaces for communication with external devices.

[0011] Preferably, the common coil wire of the two magnetic coils is uninterrupted, so that the double coil is preferably formed from a single wire. Preferably, the double coil comprises at least the two magnetic coils and the connecting section. The connecting section of the coil wire is provided at least to electrically connect the two magnetic coils to one another, in particular directly. Preferably, the connecting section is part of the common coil wire and can be distinguished from the magnetic coils only by its connecting function. Preferably, the connecting section comprises all of the wire arranged between the two magnetic coils of the double coil and, in particular, is provided only for electrically connecting the two magnetic coils of the double coil and preferably does not generate a magnetic field intended to drive the rotor and, in particular, does not form a winding of a magnetic coil.

[0012] It is further proposed that the connecting section of the coil wire runs through a central region of the stator. This advantageously provides the most space-saving wiring of the coils. Furthermore, the available space between the magnetic coils can be used as efficiently as possible. The fact that the connecting section of the double coil runs through a central region of the stator is to be understood in particular to mean that the connecting section runs in a radial inner region between the magnetic coils, in particular spanned by a radial inner edge of the magnetic coils, particularly preferably at least approximately through the central axis of the stator, in particular through the rotational axis of the rotor.

[0013] Furthermore, it is proposed that the connecting section of the coil wire transitions only on an axial upper side of the stator or only on an axial lower side of the stator into a first winding section of the coil wire forming a first magnetic coil of the two magnetic coils and into a second winding section of the coil wire forming a second magnetic coil of the two magnetic coils. This advantageously allows a connection of the magnetic coils, in particular the winding sections of the first magnetic coil and the second magnetic coil, to be realized in the most space-saving and / or simple way possible. Furthermore, access to the connecting section, in particular during maintenance and / or during production, can advantageously be provided as simply as possible. The coil wire preferably has at least the connecting section and the winding section which forms the magnetic coil.Preferably, the axial top side of the stator is the side facing away from the rotor and the axial bottom side of the stator is the side facing the rotor. Preferably, the connecting section runs in particular in a plane at the axial height of the magnetic coils, wherein preferably the top or bottom side of the stator is the same as a top or bottom side of the magnetic coils. Preferably, the connecting section is in a range of a maximum of 50%, preferably at most 40%, advantageously a maximum of 30% and particularly advantageously 20% of the vertical longitudinal extent of the magnetic coils, in particular starting from the top side or the bottom side of the stator, preferably of the magnetic coils, preferably starting from a first or last winding of the winding section of the coil wire of the respective magnetic coils.

[0014] It is also proposed that the coil wire have at least one contact section, which is arranged on a side of the double coil axially opposite the connecting section. This advantageously makes wiring of the contact sections as simple as possible. Furthermore, access to the contact section can advantageously be simplified as much as possible. Preferably, the contact section of the coil wire is provided to connect the magnetic coil, in particular the double coil, to the control and / or regulating unit. Preferably, the coil wire has at least two contact sections, each of which merges into one of the winding sections of the coil wire of the two magnetic coils. Preferably, the contact section of the coil wire is provided to supply power to the magnetic coils.Preferably, the contact portion of the coil wire is on the axial top side of the stator and the connecting portion of the coil wire is on the axial bottom side of the stator.

[0015] Furthermore, it is proposed that the magnetic coils of the double coil be arranged opposite one another in the stator, in particular with regard to a central axis of the stator. This advantageously ensures that a uniform magnetic field is generated. Preferably, the magnetic coils of the double coil are arranged opposite one another such that the winding axes of the magnetic coils of the double coil and the central axis of the stator, in particular the rotational axis of the rotor, lie at least approximately on a straight line. In particular, the connecting section of the coil wire connects the opposite magnetic coils. Preferably, the magnetic coils of the double coil are wound in opposite directions, wherein the connecting section merges into the winding section of a right-aligned winding direction of the magnetic coil and, in the case of the opposite magnetic coil, merges into the winding section of a left-aligned winding direction of the magnetic coil.

[0016] It is further proposed that the coil wire, at least in the connecting section between the magnetic coils of the double coil, in particular the entire coil wire, is designed at least in such a way, in particular a coil wire diameter and / or a material property is selected such that the coil wire can support the dead weight of a magnetic coil. As a result, an axial flux motor which can reliably handle large electrical loads can advantageously be provided, in particular by the designed double coil. The fact that the connecting section, in particular the entire coil wire, can support the dead weight of the magnetic coil should be understood in particular to mean that during production of the double coil, the connecting section, in particular the entire coil wire, remains dimensionally stable without any further support structure.Preferably, at least the connecting section, particularly preferably the entire coil wire of the double coil, is designed to be at least approximately rigid, wherein in particular the cross-section and / or the material properties of the coil wire are selected such that the original shape of the coil wire is retained under external forces typical for handling and / or use and preferably does not allow any significant deformation. Preferably, at least the connecting section, particularly preferably the entire coil wire, is dimensionally stable. In particular, the coil wire has a coil wire diameter between 0.5 mm and 10 mm, preferably between 1 mm and 5 mm, and particularly preferably between 1.5 mm and 3 mm, wherein, for example, power outputs between 5 kW and 500 kW are conceivable.

[0017] It is also proposed that the stator comprise at least two further magnetic coils formed from a further coil wire, in particular one different from the coil wire, which form a further double coil. This can advantageously further ensure that a uniform magnetic field is generated. Preferably, the magnetic coils of the further double coil are arranged opposite one another in the stator, in particular with regard to a central axis of the stator. Preferably, the coil wire of the further double coil has further contact sections, which are in particular connected to the control and / or regulating unit, wherein the control and / or regulating unit is provided for a phase-shifted control of the double coil and the further double coil. Preferably, the double coil and the further double coil are operated out of phase with respect to one another, in particular controlled by the control and / or regulating unit.In particular, the double coil and the further double coil are arranged on the same plane in the circumferential direction, in particular next to one another. Preferably, the connecting section of the coil wire of the further double coil runs through the central region of the stator. Preferably, the connecting section of the coil wire of the further double coil transitions only on an axial upper side of the stator or only on an axial lower side of the stator, in particular on the same side as the connecting section of the double coil, into a first winding section of the coil wire forming a first magnetic coil of the two magnetic coils of the further double coil, and into a second winding section of the coil wire forming a second magnetic coil of the two magnetic coils of the further double coil.

[0018] It is further proposed that the coil wires of the double coils form at least substantially identically shaped connecting sections. This advantageously makes it possible to reduce the manufacturing costs of the stator, since only one shape of the connecting section, in particular of the entire double coil, is produced for the stator. Furthermore, the logistics during production and / or assembly of the stator can advantageously be simplified. Preferably, the connecting section is designed such that, when the double coils are arranged next to one another in the circumferential direction, the connecting sections run past one another, in particular in the central region of the stator, preferably on the axial underside or top side of the stator, particularly preferably on the axially opposite side of the contact sections. Particularly preferably, the coil wire of the entire double coil is identically shaped.Preferably, the connecting section of the coil wire of the double coil is guided at least partially at least approximately parallel to the central axis of the stator along a coil winding of one of the magnetic coils of the double coil and merges in the central region of the stator, in particular along an elliptical path, into the winding section of the further magnetic coil of the double coil, in particular tangentially with an input section of the winding section.

[0019] Furthermore, it is proposed that the stator comprise at least three double coils, each formed in particular by separate coil wires, which are arranged rotated relative to one another at an angle of 360° divided by a total number of double coils of the stator, preferably at an angle of 120°, about the central axis of the stator. This advantageously allows three identically shaped coil wires of the double coils to be arranged in the stator. Preferably, with three double coils, the angle of 360° divided by the total number of double coils of the stator, preferably at an angle of 120°, about the central axis of the stator is between identically rotated double coils. In particular, the at least three double coils have a coil wire that is preferably identical in each case, but at least has a respective identically shaped connecting section.Preferably, viewed in the circumferential direction around the center axis of the stator, each adjacent double coil of one of the double coils, in particular every second double coil, is rotated identically. Preferably, viewed in the circumferential direction, each directly adjacent double coil of one of the double coils is rotated by 180° around the center axis. Preferably, the double coils are twisted into one another, in particular during assembly and / or disassembly of the double coils. Preferably, the connecting section is shaped such that, when the double coils, in particular the connecting sections of the coil wires of the double coils, are twisted into one another, the axial flux topology of the stator is provided.

[0020] It is also proposed that the stator comprise at least three double coils, each formed in particular by separate coil wires, which are arranged rotated relative to one another at an angle of 360° divided by a total number of magnetic coils of the stator, preferably at an angle of 60°, about a central axis of the stator. This advantageously allows three identically shaped coil wires of the double coils to be arranged in the stator. Furthermore, assembly and / or disassembly of the double coils can advantageously be simplified. In particular, the at least three double coils have a coil wire that is preferably identical in each case, but at least have a respective identically shaped connecting section. Preferably, viewed in the circumferential direction, each directly adjacent double coil of one of the double coils is rotated identically.

[0021] It is further proposed that the three double coils are arranged in the stator so that they can be separated from one another by a movement in the direction of the central axis, in particular during assembly and / or disassembly. This advantageously simplifies assembly and / or disassembly of the double coils, at least during manufacture and / or maintenance of the electric motor device. This advantageously enables assembly and / or disassembly of the double coils from one direction. Preferably, the connecting sections of the coil wires of the double coil are arranged axially one above the other, wherein in particular the connecting sections are arranged at least substantially independently of one another, preferably such that during assembly and / or disassembly the connecting sections can be separated from one another while the double coils are guided axially.

[0022] Furthermore, the electric motor according to the invention, in particular an (EC) axial flux motor, with the electric motor device is proposed. The inventive design of the electric motor, in particular the (EC) axial flux motor, advantageously allows a direct connection of the magnetic coils to be realized, which leads to simplified wiring within the stator. This advantageously reduces the number of contact points between the magnetic coils and a controller. Furthermore, the limited space in the stator can advantageously be used more efficiently, which increases the compactness of the electric motor. Furthermore, by connecting the magnetic coils, an electric motor with more uniform heat development can advantageously be provided. Furthermore, the costs of the electric motor can advantageously be reduced due to the use of double coils in the manufacture of the magnetic coils.Furthermore, the logistics in the production of the double coils and thus the electric motor can be simplified.

[0023] Furthermore, the inventive double coil is proposed for the electric motor. The inventive design of the double coil advantageously allows for a reduction in the number of contact points of the magnetic coils to a controller. Furthermore, the limited space in the stator can be used more efficiently, increasing the compactness of the electric motor device and / or the electric motor. Furthermore, an electric motor with more uniform heat development can advantageously be provided. Furthermore, costs in the production of the magnetic coils can advantageously be reduced.

[0024] Furthermore, a method according to the invention for producing the double coil, in particular the electric motor device, is proposed, wherein in at least one method step, two magnetic coils of the double coil are wound from a single coil wire. The method according to the invention advantageously makes it possible to produce a double coil, which leads to simplified wiring within the stator. Furthermore, the logistics during the production of the double coils and thus of the electric motor can be advantageously simplified. Furthermore, costs during the production of the double coils can be advantageously reduced and profitability increased, since only one identical double coil is produced for the stator. Furthermore, a process speed can advantageously be increased.

[0025] In particular, the coil winding of the double coil is produced in one strand. Preferably, the connecting section of the coil wire is bent in at least one further method step. Preferably, the stator is assembled in at least one further method step, wherein the double coil, in particular the at least three double coils, are guided onto a magnet coil support unit. In particular, the three double coils are twisted into one another in this method step and / or guided axially onto the magnet coil support unit separately.

[0026] It is further proposed that in the method step at least the two magnetic coils of the double coil are wound onto two mutually movable partial sections of a common foldable winding mandrel, that in a further method step the mutually movable partial sections of the winding mandrel are folded open and that in a further method step the two magnetic coils are each stripped separately from the movable partial sections of the winding mandrel. This advantageously makes it possible to produce a continuous winding in one strand without connection points. Furthermore, an efficient method with a short process time can advantageously be provided. Preferably in the method step at least the two or more magnetic coils are wound together onto the foldable winding mandrel, wherein the winding mandrel preferably rotates and a wire feed is stationary.Alternatively, the winding mandrel is stationary, and the wire is wound around the winding mandrel using the wire feed. The winding mandrel preferably has at least one folding mechanism, with which the mutually movable sections of the winding mandrel are unfolded in the subsequent process step. Alternatively, the winding mandrel is designed to be separable, so that in the process step of unfolding the sections of the winding mandrel, the sections are separated from one another. Preferably, the double coil is separated from the winding mandrel using a stripper in the subsequent process step.

[0027] The electric motor device according to the invention, the electric motor according to the invention, the double coil according to the invention, and the method according to the invention are not intended to be limited to the application and embodiment described above. In particular, the electric motor device according to the invention, the electric motor according to the invention, the double coil according to the invention, and the method according to the invention can have a number of individual elements, components, units, and method steps that differs from the number stated herein to fulfill a function described herein. Furthermore, in the value ranges specified in this disclosure, values ​​within the stated limits are also to be considered disclosed and can be used arbitrarily. drawing

[0028] Further advantages will become apparent from the following description of the drawings. The drawings illustrate two exemplary embodiments of the invention. The drawings, the description, and the claims contain numerous features in combination. Those skilled in the art will also expediently consider the features individually and combine them into useful further combinations.

[0029] They show: Fig. 1 A part of an electric motor with an electric motor device which has at least one stator, Fig. 2 a part of the electric motor device with a magnetic coil support unit and with magnetic coils consisting of a coil wire, Fig. 3 a part of the electric motor device with the magnetic coils, wherein two of the magnetic coils form a double coil connected via a connecting section of the coil wire, Fig. 4 a method for producing the double coil, Fig. 5 a process step of the process in which the double coil is wound onto a winding mandrel, Fig. 6 a further process step in which mutually movable sections of the winding mandrel are unfolded and Fig. 7 a part of an alternative embodiment of an electric motor device, with magnetic coils, wherein two of the magnetic coils each form a double coil connected via a connecting section of a coil wire. Description of the embodiments

[0030] In the Fig. 1 schematically shows part of an electric motor 12a with an electric motor device 10a. The electric motor 12a is an (EC) axial flux motor 14a. The electric motor device 10a is for the axial flux motor 14a. The electric motor 12a is configured to generate mechanical energy from electrical energy. The electric motor 12a has a stator 16a. The electric motor device 10a has the stator 16a. The electric motor 12a has a rotor (not shown). The rotor is connected to a shaft that is driven by the electric drive, in particular when operated as an electric machine, or transmits a rotary motion to the electric motor 12a, in particular when operated as a generator. The rotor and the stator 16a are arranged side by side along an axial direction of the electric motor device 10a. The rotor and the stator 16a are arranged one behind the other along a central axis 26a of the stator 16a.A main extension plane of the stator 16a is parallel to a main extension plane of the rotor. The rotor has a plurality of magnets, in particular permanent magnets. The magnets are arranged in the rotor at equal angular spacing along a circumferential direction of the rotor.

[0031] The electric motor 12a has a housing 18a that at least partially encloses the stator 16a. The electric motor 12a has at least one heat sink. The electric motor 12a comprises at least one contact plate, which is connected to a control and / or regulating unit. The electric motor 12a has at least one insulation for the stator 16a. The electric motor device 10a has a plurality of magnetic coils 36a, 38a consisting of a coil wire 40a. The stator 16a has more than two magnetic coils 36a, 38a. The stator 16a has six magnetic coils 36a, 38a. The magnetic coils 36a, 38a are each formed by a winding section 42a, 44a of the coil wire 40a. The winding sections 42a, 44a comprise a plurality of coil windings. The electric motor 12a, in particular the electric motor device 10a, has at least one magnetic coil support unit 20a. The magnetic coil support unit 20a is provided for supporting the magnetic coils 36a, 38a.

[0032] The Fig. Figure 2 schematically shows a portion of the electric motor device 10a with the magnet coil support unit 20a. The magnet coils 36a, 38a of the electric motor device 10a are arranged according to an axial flux topology. The magnet coils 36a, 38a of the electric motor device 12a are arranged according to an axial flux topology on the magnet coil support unit 20a. The magnet coils 36a, 38a, in particular the coil wire 40a of the magnet coils 36a, 38a, are wound around support elements of the magnet coil support unit 20a. The magnet coils 36a, 38a are arranged side by side along a circumferential direction on a common diameter. A winding axis of the magnet coils 36a, 38a is parallel to the center axis 26a of the stator 16a. The central axis 26a of the stator 16a is at least substantially parallel to a rotational axis 28a of the rotor. The central axis 26a of the stator 16a is at least approximately equal to the rotational axis 28a of the rotor.

[0033] The magnetic coils 36a, 38a of the stator 16a are connected to the control and / or regulating unit. The magnetic coils 36a, 38a are directly connected to the contact plate. The coil wire 40a of the magnetic coils 36a, 38a is connected to the contact plate. The coil wire 40a has a contact section 46a, 48a that is directly connected to the contact plate. The coil wire 40a is connected to the control and / or regulating unit via the contact section 46a, 48a. The contact section 46a, 48a of the coil wire 40a is provided for connecting the magnetic coils 36a, 38a to the control and / or regulating unit. The contact section 46a, 48a of the coil wire 40a is provided for supplying power to the magnetic coils 36a, 38a. The control and / or regulating unit is configured to control and / or regulate an electrical current in the magnetic coils 36a, 38a.The control and / or regulating unit is provided for regulating the current in the magnetic coils 36a, 38a to vary a magnetic field generated by the magnetic coils 36a, 38a. Magnetic field lines of the magnetic field generated by the magnetic coils 36a, 38a run essentially parallel to a rotational axis of the rotor in the axial direction.

[0034] In the Fig. Figure 3 schematically shows a portion of the electric motor device 10a with the magnetic coils 36a, 38a. Two of the magnetic coils 36a, 38a are wound from a common coil wire 40a. The two magnetic coils 36a, 38a wound from a common coil wire 40a form a double coil 30a, 32a, 34a connected via a connecting section 50a of the coil wire 40a. The double coil 30a, 32a, 34a is for the electric motor 12a. The common coil wire 40a of the two magnetic coils 36a, 38a has no interruption. The double coil 30a, 32a, 34a is formed from a single wire. The connecting section 50a of the coil wire 40a is intended at least to electrically connect the two magnetic coils 36a, 38a directly to one another. The connecting section 50a is part of the common coil wire 40a of the two magnetic coils 36a, 38a and can be distinguished from the magnetic coils 36a, 38a only by its connecting function.The connecting section 50a comprises all the wire arranged between the two magnetic coils 36a, 38a of the double coil 30a, 32a, 34a. The connecting section 50a does not generate a magnetic field intended to drive the rotor.

[0035] The magnetic coils 36a, 38a of the double coil 30a, 32a, 34a in the stator 16a are arranged opposite one another. The magnetic coils 36a, 38a of the double coil 30a, 32a, 34a in the stator 16a are arranged opposite one another with respect to a central axis 26a of the stator 16a. The winding axes of the magnetic coils 36a, 38a of the double coil 30a, 32a, 34a and the central axis 26a of the stator 16a lie at least approximately on a straight line. The connecting section 50a of the coil wire 40a connects the opposite magnetic coils 36a, 38a. The magnetic coils 36a, 38a of the double coil 30a, 32a, 34a are wound in opposite directions. The connecting section 50a transitions into the winding section 42a of the coil wire 40a of a right-aligned winding direction of the magnetic coil 36a. The connecting section 50a transitions from the right-aligned magnetic coil 36a into the winding section 44a of the coil wire 40a of a left-aligned winding direction of the magnetic coil 38a.

[0036] The coil wire 40a is designed, at least in the connecting section 50a between the magnetic coils 36a, 38a of the double coil 30a, 32a, 34a, at least in such a way that the coil wire 40a can support the dead weight of a magnetic coil 36a, 38a. A coil wire diameter and / or a material property of the coil wire 40a is selected, at least in the connecting section 50a, such that the coil wire 40a can support the dead weight of a magnetic coil 36a, 38a. The entire coil wire 40a of the double coil 30a, 32a, 34a is designed such that the coil wire 40a can support the dead weight of a magnetic coil 36a, 38a. The connecting section 50a, particularly preferably the entire coil wire 40a of the double coil 30a, 32a, 34a, is designed to be at least approximately rigid. When subjected to external forces typical of handling and / or use on the double coil 30a, 32a, 34a, the coil wire 40a retains its original shape.At least the connecting section 50a is dimensionally stable. The entire coil wire 40a is dimensionally stable. The coil wire 40a has a relatively large coil wire diameter. The coil wire 40a has a coil wire diameter of approximately 2 mm.

[0037] The connecting section 50a of the coil wire 40a runs through a central region 60a of the stator 16a. The connecting section 50a is in a radial inner region between the magnetic coils 36a, 38a of the stator 16a. The central region 60a, in particular the radial inner region, is a region spanned by a radial inner edge of the magnetic coils 36a, 38a of the stator 16a. The connecting section 50a runs at least approximately through the central axis 26a of the stator 16a. The connecting section 50a runs at least approximately through the rotational axis 28a of the rotor.

[0038] The connecting section 50a of the coil wire 40a merely merges on an axial underside 24a of the stator 16a into the first winding section 42a of the coil wire 40a, forming the first magnetic coil 36a of the two magnetic coils 36a, 38a, and into the second winding section 44a of the coil wire 40a, forming the second magnetic coil 38a of the two magnetic coils 36a, 38a. The coil wire 40a has at least the connecting section 50a and the winding sections 42a, 44a. The axial underside 24a is the side of the stator 16a arranged opposite an axial top side 22a. The axial top side 22a of the stator 16a is the side facing away from the rotor. The axial underside 24a of the stator 16a is the side facing the rotor. The connecting section 50a is in a plane at the axial height of the magnetic coils 36a, 38a. A top side 22a of the stator 16a is equal to a top side 22a of the magnetic coils 36a, 38a.A bottom side 24a of the stator 16a is equal to a bottom side 24a of the magnetic coils 36a, 38a. The connecting section 50a is in a region of a maximum of 50% of the vertical longitudinal extent of the magnetic coils 36a, 38a, starting from the bottom side 24a of the stator 16a. The connecting section 50a is in a region of a maximum of 50% of the vertical longitudinal extent of the magnetic coils 36a, 38a, starting from a last winding of the winding sections 42a, 44a of the coil wire 40a of the magnetic coils 36a, 38a.

[0039] The contact section 46a, 48a of the coil wire 40a is arranged on a side of the double coil 30a, 32a, 34a axially opposite the connecting section 50a. The contact section 46a, 48a of the coil wire 40a is intended to connect the double coil 30a, 32a, 34a to the control and / or regulating unit. The coil wire 40a has at least two contact sections 46a, 48a, each of which merges into one of the winding sections 42a, 44a of the coil wire 40a of the two magnetic coils 36a, 38a. The contact section 46a, 48a of the coil wire 40a is located on the axial upper side 22a of the stator 16a. The contact portion 46a, 48a is opposite the bottom side 24a of the stator 16a with the connecting portion 50a of the coil wire 40a.

[0040] In an alternative embodiment according to the invention, the connecting section 50a of the coil wire 40a transitions only on an axial upper side 22a of the stator 16a into the first winding section 42a of the coil wire 40a, which forms the first magnetic coil 36a of the two magnetic coils 36a, 38a, and into the second winding section 44a of the coil wire 40a, which forms the second magnetic coil 38a of the two magnetic coils 36a, 38a. The connecting section 50a extends in a region of a maximum of 50% of the vertical longitudinal extent of the magnetic coils 36a, 38a, starting from the upper side 22a of the stator 16a. The connecting section 50a is in a range of a maximum of 50% of the vertical longitudinal extent of the magnetic coils 36a, 38a starting from a first winding of the winding sections 42a, 44a of the coil wire 40a of the respective magnetic coils 36a, 38a.

[0041] The stator 16a comprises at least two additional magnetic coils formed from a further coil wire 40a, which form a further double coil 30a, 32a, 34a. The stator 16a comprises at least three double coils 30a, 32a, 34a, each formed by separate coil wires 40a. For clarity, only the double coil 30a is provided with additional reference numerals. The magnetic coils 36a, 38a of the double coils 30a, 32a, 34a are arranged opposite one another in the stator 16a with respect to a central axis 26a of the stator 16a. The coil wires of the additional double coils 32a, 34a each have two additional contact sections, which are connected to the control and / or regulating unit. The control and / or regulating unit is designed for phase-shifted control of the double coils 30a, 32a, 34a. The double coils 30a, 32a, 34a are arranged side by side on the same plane in the circumferential direction.The connecting sections 50a of the coil wires 40a of the double coils 30a, 32a, 34a run through the central region 60a of the stator 16a. The connecting sections 50a of the coil wires 40a of the double coils 30a, 32a, 34a each merge only on an axial underside 24a of the stator 16a into the first winding section 42a of the coil wire 40a forming the first magnetic coil 36a of the two magnetic coils 36a, 38a of the respective double coils 30a, 32a, 34a and into the second winding section 44a of the coil wire 40a forming the second magnetic coil 38a of the two magnetic coils 36a, 38a of the respective double coils 30a, 32a, 34a.

[0042] The coil wires 40a of the double coils 30a, 32a, 34a form at least substantially identically shaped connecting sections 50a. The coil wire 40a of the double coils 30a, 32a, 34a is identically shaped. The connecting sections 50a of the coil wires 40a of the double coils 30a, 32a, 34a are shaped such that, when the double coils 30a, 32a, 34a are arranged in the circumferential direction, the connecting sections 50a of the coil wires 40a of the double coils 30a, 32a, 34a run past one another. The connecting sections 50a of the coil wires 40a of the double coils 30a, 32a, 34a are shaped such that, when the double coils 30a, 32a, 34a are arranged in the circumferential direction, the connecting sections 50a of the coil wires 40a of the double coils 30a, 32a, 34a pass one another in the central region 60a of the stator 16a on the axial underside 24a of the stator 16a and on the axially opposite side of the contact sections 46a, 48a.

[0043] The connecting section 50a of the coil wire 40a of the double coil 30a has a plurality of connecting sections 52a, 54a, 56a, 58a. The winding section 42a of the coil wire 40a of the magnetic coil 36a merges directly into the connecting section 52a. The connecting section 52a is at least substantially parallel to the central axis 26a of the stator 16a. The connecting section 52a runs along a coil winding of the magnetic coil 36a. The connecting section 52a runs along the inner edge of the coil winding of the magnetic coil 36a. The connecting section 52a has a continuous contact with the winding section 42a of the coil wire 40a of the magnetic coil 36a.

[0044] Connecting section 52a transitions directly into connecting section 54a. Connecting section 54a is at least substantially linear. Connecting section 54a extends in an extension, in particular along a straight line, to a lateral edge of magnetic coil 36a. Connecting section 54a extends approximately in the direction of magnetic coil 38a. Connecting section 54a extends past the central axis 26a of stator 16a.

[0045] Connecting section 54a transitions directly into connecting section 56a. Connecting section 56a extends along an elliptical path around the central axis 26a of stator 16a, at least approximately to a height of the last winding of winding section 44a of coil wire 40a of magnetic coil 38a.

[0046] The connecting section 56a transitions directly into the connecting section 58a. The connecting section 58a transitions tangentially into the winding section 44a of the coil wire 40a of the magnetic coil 38a. The coil wire 40a extends linearly from the winding section 44a of the coil wire 40a of the magnetic coil 38a into the connecting section 58a and into the central region 60a of the stator 16a.

[0047] The three double coils 30a, 32a, 34a, each formed by separate coil wires 40a, are arranged at an angle of 360° divided by a total number of double coils 30a, 32a, 34a of the stator 16a, preferably at an angle of 120°, relative to one another about a central axis 26a of the stator 16a. The three double coils 30a, 32a, 34a, each formed by separate coil wires 40a, are arranged at an angle of 120° relative to one another about a central axis 26a of the stator 16a. In a stator 16a with a 6 / 4 topology of the stator 16a, the angle between the identical double coils 30a, 32a, 34a is 120°. With three double coils 30a, 32a, 34a, the angle between the identically rotated double coils 30a, 32a, 34a is 120°. Viewed in the circumferential direction around the central axis 26a of the stator 16a, each adjacent double coil 30a, 32a, 34a of one of the double coils 30a, 32a, 34a is rotated identically.Viewed in the circumferential direction around the central axis 26a of the stator 16a, every second double coil 30a, 32a, 34a is rotated identically. Viewed in the circumferential direction, each directly adjacent double coil 30a, 32a, 34a of one of the double coils 30a, 32a, 34a is rotated 180° around the central axis 26a. The double coils 30a, 32a, 34a are twisted into one another. The connecting sections 50a of the double coils 30a, 32a, 34a are twisted into one another. The double coils 30a, 32a, 34a are twisted into one another during assembly and / or disassembly of the double coils 30a, 32a, 34a. The connecting section 50a is shaped such that, when the double coils 30a, 32a, 34a are arranged in a twisted configuration, the axial flux topology of the stator 16a is provided. The connecting section 50a is shaped such that, when the connecting sections 50a of the coil wires 40a of the double coils 30a, 32a, 34a are arranged in a twisted configuration, the axial flux topology of the stator 16a is provided.

[0048] In the Fig. Figure 4 schematically illustrates a method for manufacturing the double coil 30a. In this method, the double coil 30a of the electric motor device 10a is manufactured. The coil winding of the double coil 30a is manufactured in one strand. The winding sections 42a, 44a, contact sections 46a, 48a, and the connecting section 50a of the coil wire 40a are manufactured in one strand. The manufacture of the at least three double coils 30a, 32a, 34a is identical. The three double coils 30a, 32a, 34a are shaped identically to one another after manufacture.

[0049] In at least one method step 80a, two magnetic coils 36a, 38a of the double coil 30a are wound from a single coil wire 40a. In method step 80a, the two magnetic coils 36a, 38a of the double coil 30a are wound onto two mutually movable sections 102a, 104a of a common foldable winding mandrel 100a. Fig. 5 schematically illustrates method step 80a of the method, in which the double coil 30a is wound onto the winding mandrel 100a. The magnetic coils 36a, 38a are wound by rotating the winding mandrel 100a and a wire feed 106a dispensing the coil wire 40a in a stationary manner. Alternatively, the winding mandrel 100a is stationary, and the coil wire 40a is wound around the winding mandrel 100a using the wire feed 106a. The winding mandrel 100a is at least approximately linear in design. The subsections 102a, 104a are arranged linearly one behind the other. The two magnetic coils 36a, 38a of the double coil 30a are wound one behind the other onto the winding mandrel 100a. In method step 80a, the coil wire 40a is applied to the winding mandrel 100a. The application of coil wire 40a takes approximately half a second. In process step 80a, coil wire 40a is wound around winding mandrel 100a for approximately 10 seconds.Sixteen windings are wound with the connecting section 50a of the coil wire 40a. The coil wire 40a is wound at approximately 100 rpm. In process step 80a, the coil wire 40a is cut. Cutting the coil wire 40a takes approximately half a second. Cutting the coil wire 40a is performed in parallel at the end of the winding. Cutting the coil wire 40a takes approximately half a second. Process step 80a takes approximately 10.5 seconds.

[0050] In a further process step 82a, the mutually movable sections 102a, 104a of the winding mandrel 100a are opened. Fig. 6 illustrates the further method step 82a, in which the mutually movable sections 102a, 104a of the winding mandrel 100a are unfolded. The winding mandrel 100a has at least one folding mechanism. Alternatively, the winding mandrel 100a is designed to be separable, so that in the further method step 82a for unfolding the sections 102a, 104a of the winding mandrel 100a, the sections 102a, 104a are separated from one another. In the further method step 82a, the sections 102a, 104a are folded into a parallel arrangement. With the unfolding of the sections 102a, 104a, the winding axes of the respective magnetic coils 36a, 38a of the double coil 30a are folded parallel to one another. In the further method step 82a, a required magnetic coil arrangement of the magnetic coils 36a, 38a is produced. In the further method step 82a, a stripper 108a is guided onto the partial sections 102a, 104a.The unfolding of the partial sections 102a, 104a is carried out by the stripper 108a. The unfolding of the mutually movable partial sections 102a, 104a in the further method step 82a takes approximately one second.

[0051] In a further method step 84a, the two magnetic coils 36a, 38a are each stripped separately from the movable sections 102a, 104a of the winding mandrel 100a. In the further method step 84a, the double coil 30a is separated from the winding mandrel 100a by the stripper 108a. The magnetic coils 36a, 38a are stripped from the sections 102a, 104a in the direction of the connecting section 50a, starting from the winding sections 42a, 44a of the coil wire 40a of the magnetic coils 36a, 38a. The stripping of the magnetic coils 36a, 38a in the further method step 84a takes approximately one second.

[0052] In at least one further method step 86a, the sections 102a, 104a of the winding mandrel 100a are folded back. The sections 102a, 104a are folded back to wind another double coil 30a, 32a, 34a. Folding back the sections 102a, 104a in the further method step 86a takes approximately one second.

[0053] Process steps 80a, 82a, 84a, and 86a are performed on one spindle. Performing process steps 80a, 82a, 84a, and 86a on a single spindle enables a high cycle time. On a single spindle, process steps 80a, 82a, 84a, and 86a take approximately between 12 and 15 seconds. The use of a multiple spindle is conceivable, with several double coils 30a, 32a, and 34a being produced simultaneously. This could advantageously further accelerate the manufacturing process.

[0054] In at least one further method step 88a, the connecting section 50a of the coil wire 40a of the double coil 30a is bent.

[0055] In at least one further method step 90a, the stator 16a of the electric motor device 10a is assembled. In the further method step 90a, the double coil 30a is guided onto the solenoid support unit 20a. In the further method step 90a, the three double coils 30a, 32a, 34a are guided onto the solenoid support unit 20a. The three double coils 30a, 32a, 34a are screwed into one another in the further method step 90a. The three double coils 30a, 32a, 34a are screwed into one another and guided axially onto the solenoid support unit 20a.

[0056] In the Fig. 7 shows a further embodiment of the invention. The following descriptions and the drawings are essentially limited to the differences between the embodiments, whereby with regard to components with the same designation, in particular with regard to components with the same reference numerals, reference is also made to the drawings and / or the description of the other embodiments, in particular to the Fig. 1 to 6. To distinguish the embodiments, the letter a is added to the reference numerals of the embodiment in the Fig. 1 to 6. In the example of the Fig. 7, the letter a is replaced by the letter b.

[0057] In the Fig.Figure 7 schematically shows part of an alternative embodiment of an electric motor device 10b. The electric motor device 10b has a stator 16b. The stator 16b comprises at least three double coils 30b, 32b, 34b, each formed by separate coil wires 40b. Two magnetic coils 36b, 38b wound from a common coil wire 40b each form a double coil 30b, 32b, 34b connected via a connecting section 50b of the coil wire 40b.

[0058] The three double coils 30b, 32b, 34b, each formed by separate coil wires 40b, are arranged at an angle of 360° to each other, divided by the total number of magnetic coils 36b, 38b of the stator 16b, and are rotated about a central axis 26b of the stator 16b. The three double coils 30b, 32b, 34b, each formed by separate coil wires 40b, are arranged at an angle of 60° to each other, rotated about a central axis 26b of the stator 16b. For a stator 16b with a 6 / 4 topology, the angle between the identical double coils 30b, 32b, 34b is 60°. Viewed in the circumferential direction around the central axis 26b of the stator 16b, each directly adjacent double coil 30b, 32b, 34b of one of the double coils 30b, 32b, 34b is rotated identically.

[0059] The three double coils 30b, 32b, 34b are arranged in the stator 16b such that they can be separated from one another by a movement in the direction of the central axis 26b, particularly during assembly and / or disassembly. The connecting sections 50b of the coil wires 40b of the double coils 30b, 32b, 34b are arranged axially one above the other. The connecting sections 50b of the coil wires 40b of the double coils 30b, 32b, 34b are arranged at least substantially independently of one another. The connecting sections 50b of the coil wires 40b of the double coils 30b, 32b, 34b can be separated from one another during assembly and / or disassembly, with the double coils 30b, 32b, 34b being guided axially along or parallel to the central axis 26b of the stator 16b.

Claims

[1] Electric motor device (10a; 10b), in particular for an (EC) axial flux motor (14a; 14b), with at least one stator (16a; 16b) which comprises more than two magnetic coils (36a, 38a; 36b, 38b), characterized by in that two of the magnetic coils (36a, 38a; 36b, 38b) are wound from a common coil wire (40a; 40b) and thereby form a double coil (30a, 32a, 34a; 30b, 32b, 34b) connected via a connecting section (50a; 50b) of the coil wire (40a; 40b). [2] Electric motor device (10a; 10b) according to claim 1, characterized by that the connecting section (50a; 50b) of the coil wire (40a; 40b) runs through a central region (60a; 60b) of the stator (16a; 16b). [3] Electric motor device (10a; 10b) according to claim 1 or 2, characterized byin that the connecting section (50a; 50b) of the coil wire (40a; 40b) merges only on an axial upper side (22a; 22b) of the stator (16a; 16b) or only on an axial lower side (24a; 24b) of the stator (16a; 16b) into a first winding section (42a; 42b) of the coil wire (40a; 40b) forming a first magnetic coil (36a; 36b) of the two magnetic coils (36a, 38a; 36b, 38b) and into a second winding section (44a; 44b) of the coil wire (40a; 40b) forming a second magnetic coil (38a; 38b) of the two magnetic coils (36a, 38a; 36b, 38b). [4] Electric motor device (10a; 10b) according to one of the preceding claims, characterized by that the coil wire (40a; 40b) has at least one contact section (46a, 48a; 46b, 48b) which is arranged on a side of the double coil (30a, 32a, 34a; 30b, 32b, 34b) axially opposite the connecting section (50a; 50b). [5] Electric motor device (10a; 10b) according to one of the preceding claims, characterized by that the magnetic coils (36a, 38a; 36b, 38b) of the double coil (30a, 32a, 34a; 30b, 32b, 34b) are arranged opposite one another in the stator (16a; 16b), in particular with regard to a central axis (26a; 26b) of the stator (16a; 16b). [6] Electric motor device (10a; 10b) according to one of the preceding claims, characterized by that the coil wire (40a; 40b) at least in the connecting section (50a; 50b) between the magnetic coils (36a, 38a; 36b, 38b) of the double coil (30a, 32a, 34a; 30b, 32b, 34b), in particular the entire coil wire (40a; 40b), is at least designed in such a way, in particular a coil wire diameter and / or a material property is selected such that the coil wire (40a; 40b) can bear a dead weight of a magnetic coil (36a, 38a; 36b, 38b). [7] Electric motor device (10a; 10b) according to one of the preceding claims, characterized bythat the stator (16a; 16b) comprises at least two further magnetic coils formed from a further coil wire, which form a further double coil (30a, 32a, 34a; 30b, 32b, 34b). [8] Electric motor device (10a; 10b) according to claim 7, characterized by that the coil wires (40a; 40b) of the double coils (30a, 32a, 34a; 30b, 32b, 34b) form at least substantially identically shaped connecting sections (50a; 50b). [9] Electric motor device (10a) according to one of the preceding claims, characterized by that the stator (16a) comprises at least three double coils (30a, 32a, 34a), each formed in particular by separate coil wires (40a), which are arranged rotated relative to one another at an angle of 360° divided by a total number of double coils (30a, 32a, 34a) of the stator (16a), preferably at an angle of 120°, about a central axis (26a) of the stator (16a). [10] Electric motor device (10b) according to one of the preceding claims, characterized by that the stator (16b) comprises at least three double coils (30b, 32b, 34b), each formed in particular by separate coil wires (40b), which are arranged rotated relative to one another at an angle of 360° divided by a total number of magnetic coils (36b, 38b) of the stator (16b), preferably at an angle of 60°, about a central axis (26b) of the stator (16b). [11] Electric motor device (10a; 10b) according to claim 9 or 10, characterized by that the three double coils (30a, 32a, 34a; 30b, 32b, 34b), in particular during assembly and / or disassembly, are arranged in the stator (16a; 16b) in a manner that is separable from one another by a movement in the direction of the central axis (26a; 26b). [12] Electric motor (12a; 12b), in particular (EC) axial flux motor (14a; 14b), with an electric motor device (10a; 10b) according to one of the preceding claims. [13] Double coil (30a, 32a, 34a; 30b, 32b, 34b) for an electric motor (12a; 12b) according to claim 12. [14] Method for producing a double coil (30a, 32a, 34a; 30b, 32b, 34b) of an electric motor device (10a; 10b) according to one of claims 1 to 11, in particular a double coil (30a, 32a, 34a; 30b, 32b, 34b) according to claim 13, wherein in at least one method step (80a; 80b) two magnetic coils (36a, 38a; 36b, 38b) of the double coil (30a, 32a, 34a; 30b, 32b, 34b) are wound from a single coil wire (40a; 40b). [15] Method according to claim 14, characterized bythat in the method step (80a; 80b) at least the two magnetic coils (36a, 38a; 36b, 38b) of the double coil (30a; 32a; 34a; 30b; 32b; 34b) are wound onto two mutually movable partial sections (102a, 104a; 102b, 104b) of a common foldable winding mandrel (100a; 100b), that in a further method step (82a; 82b) the mutually movable partial sections (102a, 104a; 102b, 104b) of the winding mandrel (100a; 100b) are folded out, and that in a further method step (84a; 84b) the two magnetic coils (36a, 38a; 36b, 38b) are each separately are stripped off the movable sections (102a, 104a; 102b, 104b) of the winding mandrel (100a; 100b).

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