Stator with pins for an electric machine

Abstract

A stator (1) for an electric machine (100), comprising a plurality of pins (22, 23, 24, 25) arranged in slots (51-58, 71-78, 91-98) in the stator (1) on concentric circles at different distances from a stator center (M) and each forming a layer (L1, L2, L3, L4), wherein each four pins (22, 23, 24, 25) in different layers (L1, L2, L3, L4) are connected in series with each other and form a winding turn (41), a first pin (25) of the winding turn (41) is located in a first slot (53) in the 4n-3 layer (L1), wherein n is a natural number, a second pin (24) of the winding turn (41) is located in a second slot (94) in the 4n-2 layer (L2), wherein the second slot (94) is at a first radial distance (13) from the first slot (53) in a first circumferential direction of the stator (1), a third pin (23) of the winding turn (41) is located in the first slot (53) in the 4n layer (L4), and a fourth pin (22) of the winding turn (41) is located in the second slot (94) in the 4n-1 layer (L3).

Description

Technical Field

[0001] This invention relates to a stator with pins for use in electric motors, particularly for electric motors. Background Art

[0002] Electric motors are well-known and increasingly used to drive vehicles. An electric motor consists of a stator and a rotor.

[0003] The stator includes multiple slots in which the wire turns are guided. The wire turns may be formed from insulated copper rods as so-called pins. The rotor is located in the stator and connected to the rotor shaft.

[0004] Such pin motors, U-pin motors, or hairpin motors are known, for example, from US 9,136,738 B2. Summary of the Invention

[0005] The objective of this invention is to provide a stator that is easy to manufacture and has coils consisting of pins.

[0006] According to the present invention, the stator for an electric motor includes a plurality of pins arranged in slots in the stator on concentric circles with different distances from the center of the stator, and each concentric circle forms a layer, wherein four pins in each different layer are connected in series with each other to form a coil, the first pin of the coil is located in the first slot in the 4n-3 layer, where n is a natural number, the second pin of the coil is located in the second slot in the 4n-2 layer, wherein the second slot is a first radial distance from the first slot in the first circumferential direction of the stator, the third pin of the coil is located in the first slot in the 4n layer, and the fourth pin of the coil is located in the second slot in the 4n-1 layer.

[0007] Layers can be numbered in ascending order from the outside inwards towards the center of the stator. Natural numbers do not include zero.

[0008] A stator with windings according to the invention can be easily manufactured and produces an effective electromagnetic field with less iron loss or hysteresis loss and better utilization of the laminated core. The connection type establishes a conductive connection between pins in the slot. The connection type can be welding from the conductor to the pin, or the pin can be constructed as a double pin, i.e., a so-called U-pin, thus establishing a connection upon introduction into the stator. Furthermore, welding the pin end sections bent towards each other is also a connection type.

[0009] Preferably, the stator may have a first end side and a second end side, and the first pin and the second pin may be connected to each other on the second end side by a first type of connection, the second pin and the third pin may be connected to each other on the first end side by a second type of connection, and the third pin and the fourth pin may be connected to each other on the second end side by a third type of connection, wherein the first, second and third type of connections are different from each other.

[0010] Different connection types enable improved manufacturing. Alternating positions of connection types on different end sides allow for efficient formation of wire turns around the stator teeth located between slots. Different connection types enable improved manufacturing.

[0011] Because the bending direction of the pins relative to the inside or outside of the stator may differ, even the connection type on the same end side of the stator may be different.

[0012] Combinations of the aforementioned connection types on different or the same end sides of the stator are also feasible. Due to the identical connection types on the same end sides of the stator and the different connection types on different end sides, simple and rapid production can be achieved. For example, a connection can be established on one end side using a pre-bent pin type, namely a double pin or U-pin, and on the other end side of the stator, the pin is welded individually or one side of each double pin is welded. The welding point can be on the foot of the pin or double pin.

[0013] Preferably, the pin at the beginning of the coil can be a first end pin, wherein the first end pin is designed as a single pin. A single pin is, for example, an I-pin.

[0014] In one design of the present invention, the stator may have at least two turns, and at least the fourth pin in the second slot may be connected to the fifth pin in the 4n-3 layer in the third slot via a fourth type of connection.

[0015] The rotating magnetic field generated by this type of coil has fewer interfering harmonics, resulting in less torque ripple, smaller torque fluctuations, and better NVH performance.

[0016] Preferably, a second gap greater than the first gap may exist between the second and third grooves.

[0017] Stator with windings distributed on slots with different spacing has lower ohmic AC losses and lower magnetic saturation.

[0018] In another embodiment of the invention, the stator may have multiple turns that extend over the entire circumference of the stator and thereby form sub-coils.

[0019] As a result, the winding has symmetry, which generates a uniform rotating field.

[0020] More preferably, one pin of each of the two sub-coils can be connected to each other by a fifth type connection or a sixth type connection to form a coil.

[0021] These pins can be called end pins because they mark the ends of the sub-coil.

[0022] In one design of the present invention, the end pin at the beginning or end of the coil can be designed as a single pin.

[0023] Preferably, the four pins of the coil can completely occupy the four slots.

[0024] More preferably, the sub-coils can form six coils and be assigned to three phases, such that two coils assigned to the same phase are located in three adjacent slots, and thus the two outer slots are occupied by pins of other phases.

[0025] In a preferred embodiment of the invention, at least one input and one output terminal of each of the two coils can be connected to each other, and the two coils are thus connected in parallel and particularly belong to a phase.

[0026] More preferably, the input terminals of at least two coils can be connected to each other via a type 7 connection.

[0027] The seventh type of connection can be established by a conductor mounted on a pin or by a conductive ring.

[0028] These two coils can be connected in parallel and, additionally, can be powered by the same phase. The parallel connection can be achieved by pairing the first and fifth end pins or the fourth and eighth end pins.

[0029] Furthermore, the two phases can each have nearly identical current and voltage curves, allowing the six-phase inverter to drive only a three-phase motor. This arrangement enables the current to be distributed among the switching elements within the inverter.

[0030] Therefore, two coils in three adjacent slots can be connected in parallel to be powered by one phase, thus creating a stator with windings for a three-phase motor.

[0031] According to the present invention, the vehicle is equipped with a motor having a stator according to one of the preferred designs. (See attached drawings.)

[0032] Figure 1 The stator is shown;

[0033] Figure 2 A stator with eight slots and four layers is shown;

[0034] Figure 3 A schematic diagram of the winding of the first sub-coil is shown;

[0035] Figure 4 A schematic diagram of the winding of the second sub-coil is shown;

[0036] Figure 5 A stator with first and second sub-coils is shown, as well as their connection to each other, and thus the first coil is shown;

[0037] Figure 6 A schematic diagram of the winding of another sub-coil is shown;

[0038] Figure 7 A schematic diagram of the winding of another sub-coil is shown;

[0039] Figure 8 The stator with two additional sub-coils is shown, as well as their connection to each other, and thus it is a second coil;

[0040] Figure 9 A stator with two coils is shown, each coil consisting of two sub-coils;

[0041] Figure 10 A stator with two additional coils is shown;

[0042] Figure 11 A stator with two additional coils is shown;

[0043] Figure 12 A stator with six coils is shown;

[0044] Figure 13 A schematic diagram of the wire turns of the first and second coils is shown;

[0045] Figure 14 A vehicle with a motor, particularly an electric motor, is shown, which has a stator equipped with an inverter. Detailed Description

[0046] Figure 1 A stator 1 with multiple slots 5 is shown, in which pins 2 and 3 are guided. The stator 1 has a first end side 7 and an opposite second end side 9. Input terminals 81, 87, 101, 107, 111, and 117 and output terminals 83, 85, 103, 105, 113, and 115 of sub-coils are shown on the first end side 7. These sub-coils are used to connect the pins to an energy source for operating the motor. Clearly, a rotor is also required to operate the motor. The pins for connection are placed close to each other, allowing for short connection lines.

[0047] Figure 2 Stator 1 is shown, having slots and pins in four layers, of which only eight slots 51, 52, 53, 54, 55, 56, 57, and 58 are shown. Pins 21 and 23 are arranged in slots 51, 52, 53, 54, 55, 56, 57, and 58. Pins 21 and 23 are located side-by-side in the slots. Figure 2 In the example, there are four pins arranged side by side in the slot. Therefore, the four pins within the slot lie on different concentric circles L1, L2, L3, and L4 around the center M of the stator, thus forming a single layer. A standard spacing 11 is located between each pair of slots. This standard spacing 11 is present in all... Figure 2 The slots shown are identical.

[0048] Figure 3 It shows Figure 2 Stator 1. In addition, the pins are arranged on concentric circles, that is, on layers, wherein the concentric circles are not drawn for better illustration. Figure 3 The diagram shows which pins are connected in series with each other. Pin 21, which is also the first end pin and has an input end 81, is located in slot 51 in layer L4. The first end pin is, for example, a single pin designed as an I-shaped pin.

[0049] Pin 21 is connected to pin 27 in slot 92 via third type connection 63 (shown in solid line). Pin 27 is located in layer L3. Pin 22 is connected to first pin 25 in first slot 53 via fourth type connection 64 (shown in short dashed line). First pin 25 is located in layer L1.

[0050] The first pin 25 is connected to the second pin 24 via a first type connection 61 (shown as a dotted line). The second pin 24 is located in the second groove 94. A first gap 13 exists between the first groove 53 and the second groove 94, the first gap being more than... Figure 2 The standard spacing 11 is shorter than one slot. The second pin 24 is located in layer L2.

[0051] The second pin 24 is connected to the third pin 23 in the first slot 53 via a second type connection 62 (shown in dashed lines). The third pin 23 is located in layer L4. Therefore, there is still space in the first slot 53 between the first pin 25 and the third pin 23 for two additional pins.

[0052] The third pin 23 is connected to the fourth pin 22 in the second slot 94 via a third type connection 63 (shown in solid line). The fourth pin 22 is located in layer L3. The second pin 24 and the fourth pin 22 are located in the middle of the slot, so that there is still space for two additional pins on the inner layer L4 and the outer layer L1 of the stator.

[0053] The connection of the first, second, third and fourth pins forms the first wire turn 41.

[0054] The fourth pin 22 is connected to the fifth pin 26 in the third slot 55 via a fourth type connection 64. A second spacing 19 exists between the second slot 94 and the third slot 55, which is one slot longer than the standard spacing 11. The fifth pin 26 is in layer L1. The series connection of subsequent pins in the stator described above begins again with the fifth pin 26, which is similar to the first pin 25 but offset by 90 degrees in terms of slot.

[0055] The fifth pin 26 is connected in series with another pin in the other slot 96 to form the second wire turn 42. The first, second and third type connections 61, 62, 63 between these pins are the same as the respective first, second and third type connections 61, 62, 63 of the pins of the first wire turn 41.

[0056] Two wire turns 41 and 42 are connected by a fourth type connection 64. A third wire turn 43 is formed in two additional slots 57 and 98 by continuing the series connection. Wire turns 41, 42, and 43 are each connected using a fourth type connection 64. Therefore, the fourth type connections 64 between the respective wire turns are identical. The first, second, and third type connections 61, 62, and 63 between the pins of wire turn 43 are also identical to the first, second, and third type connections 61, 62, and 63 between the first and second wire turns 41 and 42.

[0057] The fourth coil 44 is also connected to the third coil 43 via a fourth type connection 64, but the fourth coil does not have a second type connection. Pin 28 is the second end pin, and coil 44 is based on... Figure 5 To be produced and described there.

[0058] Four turns 41, 42, 43, and 44 form a first sub-coil by winding clockwise around the stator 1. A first end pin 21 has an input terminal 81 for connecting to an energy source. The sub-coil terminates with a second end pin 28 of the turn 44.

[0059] Figure 4 Stator 1 is shown, where eight slots 71, 73, 75, 77, 92, 94, 96, and 98 are shown.

[0060] Sales numbers 31, 32, 33, 34, 35, and 38 are related to... Figure 3 Pins 22, 23, 24, 25, 26, and 28 are connected in the same way. Even the connection type is the same. Figure 3 They are identical, and clearly have the same reference numerals. (The last two sentences appear to be fragments and don't translate directly.) Figure 3 In the same manner described, turns 45, 46, 47, and 48 are formed and they are connected to each other by a fourth type of connection 64.

[0061] Four coils 45, 46, 47, and 48 are wound counterclockwise around stator 1 to form a second sub-coil. The sub-coil begins with pin 31, which is the third end pin. The sub-coil ends with pin 38 of coil 48. Therefore, the last pin 38 of coil 48 is the fourth end pin. The fourth end pin 38 also has an output terminal 83 for connecting to an energy source. Of course, the input and output terminals can be interchanged.

[0062] Figure 5 It shows Figure 3 and Figure 4The pin assignments of the first and second sub-coils are indicated by black squares. The same reference numerals in the figures denote the same pins, slots, and connections. The second end pin 28 of the fourth turn 44 of the first sub-coil in layer L2, slot 92, and the third end pin 31 of the first turn 45 of the second sub-coil in layer L3, slot 71, are connected to a fifth-type connection 65. This connection is formed in… Figure 3 The description refers to the fourth type of connection, 44. The fifth type of connection, 65, bridges the second spacing, 19.

[0063] Therefore, the two sub-coils form the first coil 201, which has an input terminal 81 and an output terminal 83 formed after twice radially wrapping around the stator in different directions. The third spacing 17 shown in the figure is a slot length.

[0064] In the four slots 92, 94, 96, and 98, the pins of coil 201 occupy all layers. These four slots 92, 94, 96, and 98 are each twisted by 90 degrees and have twice the standard spacing, which is the sum of the first spacing 13 and the second spacing 19.

[0065] Figure 6 Stator 1 is shown. Pins are also arranged in concentric circles, i.e., layers, which are not drawn for better illustration. Pins shown as black squares on a white background are connected in series to form the first sub-coil of the second coil 202. The fifth end pin 21a is located in slot 91 in layer L4. The fifth end pin 21a is connected to pin 27a in slot 72 via a third type connection 63 (shown in solid lines). Pin 27a is located in layer L3. Pin 26a is connected to the first pin 25a in layer L1 in first slot 93 via a fourth type connection 64 (shown in short dashed lines).

[0066] The first pin 25a is connected to the second pin 24a via a first type connection 61 (shown as a dotted line). The second pin 24a is located in the second groove 74. A first gap 13 exists between the first groove 93 and the second groove 74, the first gap being more than... Figure 2 The standard spacing 11 is shorter than one slot. The second pin 24a is located in layer L2.

[0067] The second pin 24a is connected to the third pin 23a in the first slot 93 via a second type connection 62 (shown in dashed lines). The third pin 23a is located in layer L4. Therefore, there is still space in the first slot 93 between the first pin 25a and the third pin 23a for two additional pins.

[0068] The third pin 23a is connected to the fourth pin 22a in the second slot 74 via a third type connection 63 (shown in solid line). The fourth pin 22a is located in layer L3. The second pin 24a and the fourth pin 22a are located in the middle of the second slot 74, so that there is still space for two additional pins in the inner layer L4 and the outer layer L1 of the stator.

[0069] The connection of the first, second, third and fourth pins forms the first wire turn 41.

[0070] The fourth pin 22a is connected to the fifth pin 26a in the third slot 95 via a fourth type connection 64. A second spacing 19 exists between the second slot 74 and the third slot 95, which is one slot longer than the standard spacing 11. The fifth pin 26a is in layer L1. The series connection of subsequent pins in the stator described above begins again with the fifth pin 26a, which is similar to the first pin 25a but offset by 90 degrees in terms of slot.

[0071] The fifth pin 26a is connected in series with another pin in the other slot 76 to form the second wire turn 42. The first, second and third type connections 61, 62, 63 between these pins are the same as the respective first, second and third type connections 61, 62, 63 of the pins of the first wire turn 41.

[0072] Two wire turns 41 and 42 are connected by a fourth type connection 64. A third wire turn 43 is formed in two additional slots 97 and 78 by continuing the series connection. Wire turns 41, 42, and 43 are each connected using a fourth type connection 64. Therefore, the fourth type connections 64 between the respective wire turns are identical. The first, second, and third type connections 61, 62, and 63 between the pins of wire turn 43 are also identical to the first, second, and third type connections 61, 62, and 63 between the first and second wire turns 41 and 42.

[0073] The fourth coil 44 is also connected to the third coil 43 via a fourth type connection 64, but the fourth coil does not have a second type connection. Pin 28a is the sixth end pin, and coil 44 is based on... Figure 8 To be produced and described there.

[0074] Four turns 41, 42, 43, and 44 form a first sub-coil by winding clockwise around the stator 1. A fifth end pin 21a has an input terminal 87 for connecting to an energy source. The sub-coil terminates with a sixth end pin 28a of the turn 44.

[0075] Figure 7 Stator 1 is shown, in which eight slots 52, 54, 56, 58, 91, 93, 95, and 97 are shown.

[0076] The pins are still arranged in concentric circles, i.e., on the layers, so the concentric circles are not shown for better illustration. Pins shown as black squares on a white background are connected in series with each other to form the second sub-coil of the second coil 202.

[0077] Sales of models 31a, 32a, 33a, 34a, 35a, and 38a are compatible with... Figure 6 The pins 22a, 23a, 24a, 25a, 26a, and 28a are connected in the same way. Even the connection type is the same. Figure 6 They are identical, and clearly have the same reference numerals. (The last two sentences appear to be fragments and don't translate directly.) Figure 6 In the same manner described, turns 45, 46, 47, and 48 are formed and they are connected to each other by a fourth type of connection 64.

[0078] Four coils 45, 46, 47, and 48 are wound counterclockwise around stator 1 to form a second sub-coil. The sub-coil begins with pin 31a, which is the seventh end pin. The sub-coil ends with pin 38a of coil 48. Therefore, the last pin 38a of coil 48 is the eighth end pin. The eighth end pin 38a also has an output terminal 85 for connecting to an energy source. Of course, the input and output terminals can be interchanged.

[0079] Figure 8 It shows Figure 6 and Figure 7 The pin assignments for the two sub-coils are indicated by black squares on a white background. The same reference numerals in the accompanying drawings denote the same pins, slots, and connections.

[0080] The sixth end pin 28a of the fourth turn 44 of the first sub-coil in layer L2, slot 72, and the seventh end pin 31a of the first turn 45 of the second sub-coil in layer L3, slot 91, are connected to a sixth-type connection 66. This connection is formed in... Figure 6 The description refers to the fourth line turn 44. The sixth type connection 66 bridges the first spacing 13.

[0081] Therefore, the two sub-coils form a second coil 202, which has an input terminal 87 and an output terminal 85 formed after twice radially wrapping around the stator in different directions. The third spacing 17 shown in the figure is a slot length.

[0082] In the four slots 91, 93, 95, and 97, the pins of coil 202 occupy all layers. These four slots are each twisted by 90 degrees and have twice the standard spacing, which is the sum of the first spacing 13 and the second spacing 19.

[0083] Figure 9 It shows Figure 5 The pin assignments for the first coil 201 are indicated by black squares. The same reference numerals in the figures denote the same pins, slots, and connections. Furthermore, Figure 8 The second coil is shown as a black square on a white background. The sub-coils of both coils are connected to either a fifth-type connection 65 (first coil) or a sixth-type connection 66 (second coil). The fifth-type connection 65 bridges the second gap 19. The sixth-type connection 66 bridges the first gap 13. The pins of both coils are located in three adjacent slots each. Between the outermost slots of each of the three adjacent slots is a third gap 15, which is two slots shorter than the standard gap 11.

[0084] Therefore, two parallel coils are shown, each comprising two sub-coils. The inputs and outputs of the coils are also shown. The input terminal 81 of the first coil is located in slot 51, and the output terminal 83 is located in slot 52. The input terminal 87 of the second coil is located in slot 91, and the output terminal 85 is located in slot 52. Thus, the input and output terminals of the two coils are in adjacent slots.

[0085] Figure 10 The pin assignments for the third and fourth coils are shown, represented by black squares with white dots and white squares with black dots, respectively. This is achieved by... Figure 3 , 4 The known winding diagrams 5, 6, 7, and 8 are created, and these winding diagrams are offset by eight slots counterclockwise compared to the pins and connections of the sub-coils shown therein. The input terminal 101 and output terminal 103 of the third coil and the input terminal 107 and output terminal 105 of the fourth coil are also shown. Therefore, the input and output terminals of the two coils are in adjacent slots.

[0086] Figure 11 The pin assignments for the fifth and sixth coils are shown, represented by a black square with a white cross and a white square with a black cross, respectively. This is achieved by... Figure 3 , 4 The known winding diagrams for coils 5, 6, 7, and 8 are created, and these diagrams are offset by four slots counterclockwise from the pins and connections of the sub-coils shown therein. The input terminal 111 and output terminal 113 of the fifth coil and the input terminal 117 and output terminal 115 of the sixth coil are also shown. Therefore, the input and output terminals of both coils are in the same slot.

[0087] Figure 12 It was shown as Figure 9 , 10The pin assignment of the six coils in combination with 11. Specifically, from the positions of the input terminals 81, 87, 101, 107, 111, 117 and the output terminals 83, 85, 103, 105, 113, 115, it can be seen that the coils can be interconnected within 16 slots. Therefore, in the stator with forty-eight slots shown in the example, the input and output terminals can be interconnected within one-third of the stator circumference. Individual wiring can be achieved purely with respect to the input or output terminals within ten slots.

[0088] Figure 13 A schematic diagram of the winding of the two sub-coils, first coil 201 and second coil 202, is shown. Consecutive "slot numbers" are not reference numerals. Reference numerals with arrows over the slots are the same as in the previous figures and can be referenced therein.

[0089] Figure 14 A schematic diagram of an embodiment of vehicle 403 is shown, which is, for example, a hybrid vehicle or an electric vehicle, and includes a motor 401, particularly an electric motor, having an embodiment of a stator 1 for driving vehicle 403. Furthermore, vehicle 403 may have an inverter 405 that supplies alternating current from a direct current source to motor 401.

[0090] List of reference numerals

[0091]

Claims

1. A stator (1) for an electric motor (100), the stator comprising - Multiple pins (22, 23, 24, 25) are arranged in slots (51-58, 71-78, 91-98) in the stator (1) on concentric circles with different distances from the stator center (M), and each concentric circle forms a layer (L1, L2, L3, L4). -in, The four pins (22, 23, 24, 25) in each of the different layers (L1, L2, L3, L4) are connected in series to form a wire turn (41). - The first pin (25) of the coil (41) is located in the first slot (53) in the 4n-3rd layer (L1), where n is a natural number. - The second pin (24) of the coil (41) is located in the second groove (94) in the 4n-2th layer (L2), wherein the second groove (94) is a first distance (13) from the first groove (53) in the first circumferential direction of the stator (1), - The third pin (23) of the coil (41) is located in the first groove (53) in the 4nth layer (L4), - The fourth pin (22) of the coil (41) is located in the second groove (94) in the 4n-1th layer (L3), characterized in that the stator (1) has a first end side (7) and a second end side (9); and - The first pin (25) and the second pin (24) are connected to each other on the second end side (9) by a first type connection (61); - The second pin (24) and the third pin (23) are connected to each other on the first end side (7) by a second type of connection (62); - The third pin (23) and the fourth pin (22) are connected to each other on the second end side (9) by a third type of connection (63); Among them, the first, second and third types of connections are different from each other.

2. The stator (1) according to claim 1, wherein, The stator (1) has at least two turns (41, 42, 43), and the fourth pin (22) in at least the fourth slot (94) is connected to the fifth pin (26) in the 4n-3 layer (L3) in the third slot (55) via a fourth type connection (64).

3. The stator (1) according to claim 2, wherein, There is a second gap (19) between the second groove (94) and the third groove (55) that is greater than the first gap (13).

4. The stator (1) according to claim 2 or 3, wherein, The stator (1) has a plurality of turns (41, 42) extending over the entire circumference of the stator (1) and thereby forming sub-coils.

5. The stator (1) according to claim 4, wherein, One pin (28, 28a, 31, 31a) of each of the two sub-coils are connected to each other by a fifth type connection (65) or a sixth type connection (66) to form a coil (201, 202).

6. The stator (1) according to claim 5, wherein, The four pins of the coil completely occupy the four slots (92, 94, 96, 98).

7. The stator (1) according to claim 6, wherein, The sub-coils form six coils and are assigned to three phases, such that two coils assigned to the same phase are located in three adjacent slots (51-58, 71-78, 91-98), and two different layers of the two outer slots (71-78, 91-98) are occupied by pins of other phases.

8. The stator (1) according to claim 7, wherein, At least two coils (201, 202) have one input terminal (81, 87, 101, 107, 111, 117) and one output terminal (83, 103, 113, 85, 105, 115) connected to each other, and thus the two coils (201, 202) are connected in parallel and belong to one phase.

9. A vehicle (403) comprising an electric motor (401) having a stator (1) according to any one of claims 1 to 8.

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