Electronically commutated motors

Abstract

An electronically commutated motor comprises a rotor having an assigned rotor axis and a stator (120) coaxially surrounding the rotor, the rotor having a plurality of stator teeth (Z) arranged in an annular manner on a stator core. 1,...,9 ), the stator teeth at least partially have slot insulation (160), the stator winding (150) of the motor has at least three phase windings, each phase winding has at least two individual windings (E) connected in parallel and wound with a wire (198) 1,2 ), the individual windings are respectively assigned to the stator teeth, and at least one hook-shaped guide element (F) assigned to the slot insulation is provided on the stator axial end (182) between the stator teeth directly adjacent on each two circumferential sides. 1‑9 ), at least one connecting wire section (190) extending at least partially circumferentially between two individual windings of different phases (u, v, w) has at least one additional turn (240, 242) in two stator teeth directly adjacent to each other on the circumferential side, and at least one hook-shaped guide element assigned to the slot insulation is provided between the two stator teeth.

Description

Technical Field

[0001] The invention relates to an electronically commutated electric motor, comprising a rotor with an associated rotor axis and a stator coaxially surrounding the rotor, the rotor having a plurality of stator teeth arranged in an annular manner on a stator core, wherein the stator teeth have slot insulation at least in sections, the stator winding of the electric motor having at least three phase windings, each phase winding having at least two individual windings connected in parallel and wound in a wire, wherein the at least two individual windings are respectively assigned to a stator tooth, wherein at least one hook-shaped guide element (Führungselement) assigned to the slot insulation is respectively provided at the axial ends of the stator between two stator teeth directly adjacent on the circumferential side. Background Art

[0002] Electronically commutated electric machines with a rotor and a stator are known from the prior art. Furthermore, three-phase electronically commutated electric motors or electrical machines are known, for example, in which the respective phase windings each have at least two individual windings connected in parallel. Metallic guide elements, which each have a hook and are fixed to the slot insulation, and guide aids on the slot insulation itself serve to position and electrically connect the assigned winding wires. Furthermore, electronically commutated electric machines with parallel windings are known from the prior art, in which the wires of the respective windings or winding wires are guided from the hook to the other slot or the stator tooth assigned to the slot. In this case, the assigned wires are each guided along the stator on the circumferential side of the guide aids of the slot insulation. Summary of the invention

[0003] The invention relates to an electronically commutated electric machine, comprising a rotor and a stator coaxially surrounding the rotor, the rotor having an associated rotor axis, the stator having a plurality of stator teeth arranged in an annular manner of a stator core, wherein the stator teeth at least partially have slot insulation, the stator winding of the electric machine having at least three phase windings, each phase winding having at least two individual windings wound in parallel, each of which is associated with a stator tooth, wherein at least one hook-shaped guide element associated with the slot insulation is provided at the axial ends of the stator between two stator teeth directly adjacent on the circumference. At least one connecting wire section extending at least partially on the circumference between two individual windings of different phases has at least one additional turn in two stator teeth directly adjacent on the circumference, between which at least one hook-shaped guide element associated with the slot insulation is provided.

[0004] This reliably prevents deformation of the hook-shaped guide element during the corresponding winding process of the stator winding of the electronically commutated motor. Such deformation can occur, for example, if the corresponding hook is axially displaced so far relative to the slot-insulated associated guide element that tensile forces generated when the wire is positioned in the hook or when the wire is passed around the hook lead to bending of the hook of the relevant guide element. In such a case, the correspondingly bent hook can no longer reliably fix and / or position the relevant wire and, if necessary, other wires of the winding in the provided position.

[0005] Preferably, the at least two additional turns are guided starting from an axial end of the stator in a meandering manner at least partially around two stator teeth directly adjacent on the circumference and the associated guide element, so that the line guidance of the connecting line section extending on the circumference between the parallel individual windings of the stator winding essentially corresponds to the line guidance of standard individual windings.

[0006] Preferably, each guide element has at least one hook, wherein the wires of the individual windings are fixed in position or electrically connected in the region of the first axial end by means of the hooks of the guide elements to form the stator winding. Thus, a reliable fixing of the wires of the individual windings in position in the stator winding of the electronically commutated motor is ensured. Furthermore, it is also possible to position a plurality of wires in one hook.

[0007] In a technically advantageous embodiment, a plurality of guide aids for fixing the position of at least one wire of an individual winding are formed in the region of the outer surface of the slot insulation. This ensures reliable guidance and / or fixing of the wire of the individual winding in the region of the slot insulation of the stator even under relatively high loads. Furthermore, the guide aids simplify the production process of the stator by means of a winding machine.

[0008] According to one embodiment, a first wire section of the wire of the at least two additional turns extends from a first axial end of the stator through a first stator slot, a second wire section surrounds a free end of a first stator tooth adjacent to the first stator slot in the circumferential direction, remote from the first axial end, a third wire section extends through a second stator slot directly adjacent to the first stator tooth on the circumferential side, a fourth wire section wraps around a hook-shaped guide element and extends from the hook-shaped guide element through the second stator slot in the opposite direction to the third wire section, a fifth wire section extends around a free end of a second stator tooth directly adjacent to the second stator slot in the circumferential direction, remote from the first axial end, and a sixth wire section extends along the second stator tooth back to the outer surface of the slot insulation. This results in the desired loop-shaped meandering course of the wire of the at least two additional turns. The additional turns are preferably introduced circumferentially centrally between two individual windings of the stator winding, which are between the hook-shaped guide elements in the stator core.

[0009] Preferably, each of the hook-shaped guide elements has a substantially quadrilateral base plate into which a U-shaped cutout is introduced for cutting out a tongue that can be bent out of the plane of the base plate to form an integral hook. This ensures that the hook-shaped guide elements can be manufactured in a simple and cost-effective manner.

[0010] Preferably, a receiving portion is formed between the hook and the base plate for fixing the position of at least one wire and making an electrical connection, thereby providing reliable guidance and electrical connection of the wire at the hook of the guiding element.

[0011] In an advantageous embodiment, each of the guide elements is made from sheet metal as a stamped and formed part. This provides for mass-produced and cost-effective production of the guide elements. Due to the electrically conductive sheet metal of the guide elements, the electrical connection of the wires and thus the connection of the entire stator winding or motor winding can be carried out simultaneously.

[0012] According to another embodiment, at least one individual winding has a correspondingly adapted, preferably reduced number of turns in order to compensate for the magnetic influence of the at least two additional turns. The original induced voltage in the corresponding individual winding connected in parallel is thereby restored.

[0013] The slot insulation is preferably formed with a plurality of insulators arranged on the circumference, wherein each stator tooth is preferably respectively assigned at least one insulator. As a result, the slot insulation of the stator can be realized with a plurality of plastic injection molded parts of relatively simple construction. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] In the following description, the invention is further explained based on the exemplary embodiments shown in the drawings. The drawings show:

[0015] Figure 1 shows a schematic cross-sectional view of an electronically commutated electric machine having a rotor and a stator;

[0016] Figure 2 Show Figure 1 A top view of a stator;

[0017] Figure 3 Shown in the drawing plane Figure 2 A schematic top view of the inner side of a stator;

[0018] Figure 4 Show Figure 3 A partial three-dimensional top view of a stator;

[0019] Figure 5 Show Figure 3 Circuit diagram of the stator;

[0020] Figure 6A perspective view of a guide element with a hook is shown. DETAILED DESCRIPTION

[0021] Figure 1 The inner rotor is shown here merely as an example. The electronically commutated electric machine 100 is provided. The electric machine 100 has a rotor 130 with a rotor axis 132 and a stator 120 with a stator core 140. The electronically commutated electric machine 100 is preferably designed rotationally symmetrically with respect to the rotor axis 132. The stator core 140 is illustratively provided at least in sections with slot insulation 160, which is preferably implemented with a plurality of insulators (not shown here). The stator winding 150 is illustratively arranged on the slot insulation 160.

[0022] It should be noted that the present invention is preferably configured for stators of electronically commutated motors with an outer diameter of less than 100 mm that are operated at relatively high speeds, but the present invention can also be used for any other outer diameter and relatively low speeds. Figure 1 It is only schematically shown in the figure, because the structural construction and detailed functions of such a motor are sufficiently familiar to those skilled in the art in the field of motors from the prior art, so that a more in-depth description of the electronically commutated motor 100 is omitted here for the sake of brevity and simplicity of description.

[0023] It should also be noted that the electronically commutated electric machine 100 is shown only as an example and does not limit the invention to an inner rotor. It should also be noted that the outer stator 122 shown here with the rotor 130 designed as an inner rotor 134 has only exemplary properties and that the invention can also be used, for example, in the case of an annular inner stator.

[0024] Figure 2 Show Figure 1 The stator 120, wherein Figure 1 The stator core 140 of the stator 120 of the electronically commutated electric machine 100 has here, merely by way of example, nine stator teeth Z pointing radially inwards. 1,...,9 , the stator teeth are arranged evenly spaced apart from each other in the circumferential direction U of the stator 120. Preferably, the stator 120 is configured to be axially spaced apart from each other with respect to the stator axis 126 or the rotor axis of the rotor (not shown here) (see Figure 1 , reference numerals 130, 132) are rotationally symmetrical. 1,...,9 Each of the two stator teeth Z adjacent to each other on the circumferential side 1,...,9 Between stator teeth Z 1,...,9 A single winding with an insulated winding wire (also not shown here) is wound, wherein the stator teeth Z of the stator 120 1,...,9 Slot insulation 160 is provided. Slot insulation 160 particularly reliably protects the individual windings from being applied to stator teeth Z. 1,...,9The electrical (paint) insulation of the wires on the machine is protected from mechanical damage.

[0025] The slot insulation 160 can be realized in one piece or in the form of a plurality of insulation bodies which can be arranged one behind the other in the circumferential direction U of the stator 120. 1,2 , which represent all other insulators that are identical in structure (preferably at least within predefined manufacturing tolerances), are provided with reference numerals 162, 164. 1,...,9 By way of example, an insulator is respectively assigned to each of them. The slot insulation 160 can be made of electrically insulating plastic, paper or another sufficiently electrically insulating material.

[0026] The stator 120 also has a generally cylindrical inner face 180 which is formed by nine radially inwardly directed stator teeth Z 1,...,9 Definition. In the stator internal space 124, the rotor ( Figure 1 130) about the stator axis 126 or the same rotor axis (see Figure 1 ; Figure numerals 130, 132) rotate.

[0027] Figure 3 Show Figure 1 Electronically commutated motor 100 Figure 2 stator 120, which is extended in the circumferential direction U in the drawing plane and has stator teeth Z 1,...,9 and the stator slots N located between two adjacent stator teeth 1,...,9 The stator axis 126 extends perpendicularly to the circumferential direction U. With respect to the stator axis 126, the stator 120 has a first axial end 182 and a second axial end 184. When rolled out from the plane of the drawing, the stator teeth Z 1,...,9 A substantially cylindrical inner face 180 of the stator 120 is again defined.

[0028] In the region of the axial ends 182 , 184 of the stator 120 , illustratively and preferably in the region of the first axial end 182 of the stator 120 , merely by way of example, in each case at the stator tooth Z 6,7 , Z 7,8 , Z 8,9 , Z 9,1 , Z 1,2 , Z 2,3 , Z 3,4 , Z 4,5 and Z 5,6 A hook-shaped guide element F is provided approximately centrally between or respectively with respect to the stator slots N7, N8, N9, N1, N2, N3, N4, N5 and N6. 1,2,3,4,5,6,7,8,9 . Hook-shaped guide element F1,2,3,4,5,6,7,8,9 For example, the guide element F is assigned to the slot insulation 160. 1,2,3,4,5,6,7,8,9 In particular, it is mechanically fixed to the slot insulation 160. However, the guide element F 1,2,3,4,5,6,7,8,9 It can also be arranged or fixed at any other position of the stator 120. Nine guide elements F 1,2,3,4,5,6,7,8,9 The index corresponds to the guide element in the stator slot N 1,...,9 In the region of or on the circumferential side directly adjacent to the stator tooth Z 1,...,9 The arrangement of the guide elements F in the circumferential direction U between the stator 120 and the stator 120 may differ from the arrangement on the circumferential side shown. In this exemplary embodiment, nine hook-shaped guide elements F 1,2,3,4,5,6,7,8,9 Structurally, they are each designed identically.

[0029] Furthermore, two individual windings E of different phases of a stator winding 150 of a stator 120 of an electronically commutated electric machine are shown. 1,2 Here, nine guide elements F 1,2,3,4,5,6,7,8,9 Each of the stator windings 150 illustratively has an integrally formed hook 230 for guiding and / or electrically connecting the wires of a single winding of the stator winding 150. 1,2,3,4,5,6,7,8,9 Preferably at least one hook 230 is provided. Guide element F 1,2,3,4,5,6,7,8,9 Each of the guide elements F is preferably constructed as a stamped and formed part from a metal sheet which can be soldered or welded and preferably has a relatively good electrical conductivity. 1,2,3 , on the nine stator teeth Z 1,...,9 In the case of the invention, up to nine guide elements F may also be provided. 1,...,9 , the other six missing guide elements F 4,5,6,7,8,9 Shown as dotted lines.

[0030] Illustratively, at least three guide elements, preferably five guide elements F are required. 1,2,5,6,7 , for a single winding E of a stator winding 150 having three phases u, v, w in this case 1,...,9 Preferably, each phase u, v, w is provided with a guiding element F 1,...,9 The single winding E of the stator 120 1,...,9 A preferably varnish-insulated (copper) wire 198 is wound around, which has suitable geometric and electrical properties, in particular in terms of diameter, electrical conductivity and current carrying capacity.

[0031] Two single windings with different phases E 1,2 The connecting wire section 190 extends at least partially in the circumferential direction U of the stator 120 and is designed as at least two additional turns 240, 242 according to the invention, which reliably prevent the guide element F from being damaged. 1-9The invention relates to a method for plastically deforming the stator 120 of an electronically commutated motor having at least one hook 230 during winding. The two additional turns 240, 242 preferably have at least one turn, which is respectively arranged at two adjacent stator teeth Z1, Z2, wherein a guide element is arranged between the two stator teeth Z1, Z2. The additional turns are in particular assigned a guide element. The first line section 200 of the connecting line section 190 starts from the outer surface 176 of the slot insulation 160 and is preferably guided through the stator slot N1 in the region of the first axial end 182 of the stator 120. Preferably, a second line section 202 follows, which surrounds the free end 186 of the first stator tooth Z1 remote from the first axial end 182, which is directly adjacent to the first stator slot N1 in the circumferential direction U. Preferably, the third wire section 204 is guided through a second stator slot N2 which is directly adjacent to the stator tooth Z1 in the circumferential direction U and is preferably wound around the hook 230 of the first guide element F1 . The wire sections 200 , 202 and 204 are thus formed as a first additional turn 240 .

[0032] Starting from at least one hook 230 of the guide element F1, the fourth line segment 206 is preferably guided through the second stator slot N2 in the opposite direction to the third line segment 204. The fifth line segment 208 preferably surrounds the free end 188 of the second stator tooth Z2, which is directly adjacent to the second stator slot N2 in the circumferential direction U. The sixth line segment 210 preferably extends along the second stator tooth Z2 back to the outer surface 176 of the slot insulation 160. The line segments 206, 208, 210 are jointly configured to form a second additional turn 242. The two additional turns 240, 242 are preferably formed at the stator tooth Z2. 1,2 There are twists and turns in between.

[0033] In order to compensate for the magnetic influence of the additional turns 240, 242, the allocated individual windings (ie, here two individual windings E 1,2 ) preferably has a correspondingly adapted number of turns, in particular a reduced number of turns or number of turns. In this case, the magnetic influence of the additional turns is preferably compensated by reducing the number of turns of the individual windings by an amount that is preferably exactly the same as the number of turns of the associated additional turns. In this case, the number of turns of E1 is reduced by the number of turns of the additional turns 240. Similarly, the number of turns of E2 is reduced by the number of turns of the additional turns 242. In this case, the individual windings E 1,2 are respectively assigned to the different phases v, w and w, u of the electronically commutated motor (see in particular Figure 5 ).

[0034] Figure 4 Show Figure 3 The stator 120 in FIG. 1 , wherein the stator teeth of the stator 120 and the stator slots of the stator core 140 are shown with the stator slots N only in the region of the first axial end 182 of the stator 120 .1,...,4 Stator tooth Z 1,2,3,4,9 In this case, the slot insulation 160 is only used as an example for the stator tooth Z 1,2 All other two insulators of the stator are provided with reference numerals 162, 164. 1,2,3,4,9 The approximately cylindrical inner surface 180 of the stator 120 is defined, wherein the stator axis is not shown here. 1,2 The stator winding 150 of the connecting conductor section 190 extending in between lies on the circumferential side on the slot insulation 160 of the stator teeth.

[0035] Guide elements F with hooks 230 respectively formed thereon 1,2 For stator winding 150 Figure 3 The copper wire 198 in the slot insulation 160 is guided and / or electrically connected. The individual insulators 162, 164 of the slot insulation 160 are similar to the stator teeth Z pointing radially inward. 1,2,3,4,9 The outer surface 176 is formed as an example and is approximately cylindrical, wherein in the region of the stator slots N1 and N4 a guide aid 250 of identical design is formed in each case and points radially outwards. 1,2 Furthermore, a guide aid 250 of the slot insulation 160 is provided in order to further optimize the guidance of the (copper) wires 198 of the individual windings (not shown here) of the stator winding 150 .

[0036] Figure 5 Shows the assignment Figure 3 Schematic diagram of a stator. The stator winding 150 is designed as a delta connection here by way of example, and therefore has three phase connections u, v, w and correspondingly has three lines 300, 302, 304 arranged clockwise. Each of the three lines 300, 302 and 304 preferably has a phase winding Pw 1,...,3 , the phase windings each have three individual windings, wherein for better illustration, only a single winding E is shown here. 1,2 The small Arabic numerals at the respective ends of the individual windings respectively indicate the stator slots of the stator (not shown here) in which the respective individual winding is introduced. Thus, the individual winding E1 is located here, for example, in the stator slot N. 7,8 or wound onto the insulator of the stator tooth Z7. Accordingly, a single winding E2 is located in the stator slot N 5,6 The points which are arranged axially on one side on the individual windings and which are likewise not shown for the sake of a better graphical overview represent the respective winding directions of the individual windings.

[0037] Figure 6 The hook 230 is shown Figure 1The guide element F1 in FIG. 1 is shown here, wherein the guide element F1 is shown here and represents all other guide elements F which are designed identically in structure. 1-9 (See Figure 3 ). The guide element F1 preferably has a substantially rectangular solid base plate 320, at a first end 322 of which an angle plate 324 is integrally formed. An angle α of approximately 90° is preferably present between the angle plate 324 and the base plate 320. A second end 326 of the base plate 320, axially remote from the first end 322 of the base plate 320, illustratively has an approximately semicircular outer contour 328. A preferably U-shaped cutout 330 is introduced into the base plate 320 in order to cut out a rectangular and initially flat tongue 334, initially located in a plane 332 of the base plate 320 of the guide element F1, from the base plate 320.

[0038] By bending the cut tongue 334 upward out of the plane 332 of the base plate 320, the hook 230 of the guide element F1, which preferably has a U-shaped spatial configuration, can be produced, which preferably forms a receptacle 340 of the guide element F1 for guiding and / or electrically contacting at least one (copper) wire 198 of the stator winding 150, which is shown here in dashed lines. Thus, all guide elements can be produced in a simple manner from a flat metal sheet as a stamped and formed part. In this case, the metal sheet has sufficient electrical conductivity and is solderable and / or weldable as well as possible in order to achieve the necessary electrical contact with the (copper) wire of the stator winding 150.

Claims

1. An electronically commutated electric machine (100) comprising a rotor (130) and a stator (120), the rotor having an assigned rotor axis (132), the stator coaxially surrounding the rotor and having a plurality of stator teeth (Z) arranged in an annular manner of a stator core (140). 1,...,9 ),in, The stator teeth (Z 1,...,9 ) has slot insulation (160) at least in sections, the stator winding (150) of the electric machine (100) having at least three phase windings (Pw 1,...,3 ), each phase winding (Pw 1,...,3 ) each having at least two individual windings (E) connected in parallel and wound with a wire (198) 1,...,9 ), the at least two individual windings are respectively assigned to a stator tooth (Z 1,...,9 ), wherein at an axial end (182) of the stator (120) two stator teeth (Z 1,...,9 ) are provided with at least one hook-shaped guide element (F 1-9 ), wherein the at least one hook-shaped guide element is assigned to the slot insulation (160), characterized in that two individual windings (E 1,...,9 ) between two stator teeth (Z 1,...,9 ) respectively have at least one additional turn (240, 242), at least one hook-shaped guide element (F 1-9 ), the stator teeth (Z 1,...,9 ) extends through the at least one hook-shaped guide element (F 1-9 ), the at least one hook-shaped guide element being associated with the slot insulation (160).

2. The electronically commutated motor according to claim 1, characterized in that: At least two additional turns (240, 242) are formed starting from an axial end (182) of the stator (120) and winding in a linear manner at least partially around two stator teeth (Z) that are directly adjacent to each other on the circumference. 1,...,9 ) and the assigned guide element (F 1-9 ) to guide.

3. The electronically commutated motor according to claim 1 or 2, characterized in that: Each guide element (F 1,2,5,6,7 ) has at least one hook (230), wherein the single winding (E 1,...,9 ) of the wire (198) by means of the guide element (F 1-9 ) is fixed in position and / or electrically connected in the region of the axial end (182) to form the stator winding (150).

4. The electronically commutated motor according to claim 1 or 2, characterized in that: In the region of the outer face (176) of the slot insulation (160) a plurality of guide aids (250) are formed for guiding the individual windings (E 1,...,9 ) has a fixed position of at least one line (198).

5. The electronically commutated motor according to claim 1, characterized in that: A first line section (200) of the line of at least two additional turns (240, 242) extends from a first axial end (182) of the stator (120) through a first stator slot (N1), and a second line section (202) surrounds a free end (186) of a first stator tooth (Z1) remote from the first axial end, the first stator tooth (Z1) being adjacent to the first stator slot (N1) in a circumferential direction (U), and a third line section (204) extends through a second stator slot (N2), the second stator slot (N2) being directly adjacent to the first stator tooth (Z1) in a circumferential direction (U) , and a fourth wire segment (206) is wound around the hook-shaped guide element (F1) and extends from the hook-shaped guide element in the opposite direction to the third wire segment (204) through the second stator slot (N2), and a fifth wire segment (208) surrounds a free end (188) of a second stator tooth (Z2) remote from the first axial end (182), the second stator tooth (Z2) being directly adjacent to the second stator slot (N2) in the circumferential direction (U), and a sixth wire segment (210) extends along the second stator tooth (Z2) back to the outer surface (176) of the slot insulation (160).

6. The electronically commutated motor according to claim 5, characterized in that: The hook-shaped guiding element (F 1-9 ) each having a substantially quadrilateral base (320) into which a U-shaped cutout (330) is introduced for cutting out a tongue (334) which can be bent out from a plane (332) of the base (320) to form an integral hook (230).

7. The electronically commutated motor according to claim 6, characterized in that: An accommodation portion (340) is formed between the at least one hook (230) and the base plate (320) for fixing the position of the at least one wire (198) and for electrical connection.

8. The electronically commutated motor according to claim 6 or 7, characterized in that: The guide element (F 1-9 ) are each constructed from sheet metal as stamped and formed parts.

9. The electronically commutated motor according to claim 1 or 2, characterized in that: At least one single winding (E 1,...,9 ) has a correspondingly matched number of turns to compensate for the magnetic influence of at least two additional turns (240, 242).

10. The electronically commutated motor according to claim 1 or 2, characterized in that: The slot insulation (160) is constructed with a plurality of insulating bodies (162, 164) arranged on the circumference.

11. The electronically commutated motor according to claim 9, characterized in that: At least one single winding (E 1,...,9 ) has a correspondingly reduced number of turns to compensate for the magnetic influence of the at least two additional turns (240, 242).

12. The electronically commutated motor according to claim 10, characterized in that: Each stator tooth (Z 1,...,9 ) are respectively assigned at least one insulator (162, 164).

Images