Winding with hairpin coils and method for manufacturing the winding

Abstract

The present application relates to a winding having a distributed coil formed by a plurality of hairpin-shaped sections (2), wherein the hairpin-shaped sections (2) each have two straight conductor sections which are arranged in different slots of a winding frame (1), wherein a contact region is coupled to the conductor sections at one axial end, which is shaped in the circumferential direction, and the conductor sections are connected by a turn region at the other axial end, wherein an even number of conductor sections are arranged in layers (3, 3.1, 3.2) in the radial direction in the slots of the winding frame (1), wherein the contact region has a connection section at its end facing away from the winding frame (1), and the connection section is oriented in a row running in the radial direction, wherein the contact regions of the layers (3, 3.1, 3.2) are shaped in the same circumferential direction, wherein a portion of the contact regions of the outer layers (3.1, 3.2) is deformed in the radial direction in order to form additional layers (4, 4.1, 4.2), and the contact regions are shaped in the circumferential direction opposite to the contact regions of the outer layers. The present application also relates to an electric machine having such a winding and to a method for producing such a winding.

Description

Technical Field

[0001] This application relates to a design scheme for one side of the contact area to be connected in a hairpin coil. Background Technology

[0002] Pre-formed hairpin-shaped portions are known from existing technology; however, this makes assembly very complex. Alternatively, U-shaped hairpin-shaped portions are known, and then shaped. Hairpin-type coils are known, for example, from DE 10 2017 201 533 A1.

[0003] To connect the various endpoints of the sub-windings, additional bridging conductors are required, thereby creating sub-circuits of the coil. Due to the bridging conductors, the number of components increases, and their positioning and conductive connection to the corresponding contact ends require high manufacturing costs. Summary of the Invention

[0004] The purpose of this invention is to provide a winding with a hairpin coil and a method for manufacturing the winding, wherein sub-circuits can be easily and quickly constructed.

[0005] This objective is achieved by a winding having a distributed coil formed by multiple hairpin-shaped portions, each hairpin-shaped portion having two straight conductor segments arranged in different slots of the winding frame, wherein a contact area is connected to the conductor segment at one axial end, the contact area being shaped in the circumferential direction, and the conductor segment being connected at the other axial end by a turning area, wherein an even number of conductor segments are arranged in layers in the slots of the winding frame in the radial direction, wherein the contact area has a connecting section at its end opposite to the winding frame, and the connecting section is oriented in a radially extending row, wherein the contact areas of the layers are shaped in the same circumferential direction, characterized in that a portion of the contact area of ​​the outer layer is deformed in the radial direction to form an additional layer, and these contact areas are shaped in the opposite circumferential direction to the contact areas of the outer layer.

[0006] For the basic construction of hairpin coils, refer to DE 10 2017 201 533 A1, paragraphs

[0005] to

[0012] of which are included in this specification.

[0007] To connect the contact areas of different sub-windings to each other, a portion of the contact area of ​​the outer layer, particularly the contact area at the ends of the sub-windings, is radially deformed, thereby forming an additional layer. Therefore, regarding layers, the winding according to the invention has more layers than the conductor segments disposed in the slots. Here, the outer layer can be a radially outer layer or a radially inner layer. Thus, the additional layer is radially inside or radially outside of other layers.

[0008] The additional layer and the directly adjacent outer layer have correspondingly less contact area.

[0009] The contact area of ​​the additional layer is shaped in the opposite circumferential direction to the directly adjacent outer layer. Therefore, the contact areas that were originally arranged in the same layer can then be directly connected to each other.

[0010] In the additional layer, the amount of molding along the circumferential direction can be the same as or different from that of the directly adjacent outer layer. Therefore, the coil pitch between the contact areas to be connected can be adjusted accordingly as needed.

[0011] One implementation of the winding is characterized in that, at both outer layers, a portion of the contact area is deformed radially to form an additional layer. Therefore, it is also possible to implement an embodiment in which additional layers are formed radially inner and radially outer. This embodiment is particularly advantageous for windings having multiple coaxial hairpin coils and / or contact areas for connecting interconnects or power electronics in the intermediate layer.

[0012] The winding according to the embodiment is characterized in that, through the contact areas in the additional layers, a portion of the rows has an odd number of layers, and in these rows, the contact areas are arranged to connect with interconnects, while other contact areas are electrically connected to form contact pairs with their connecting sections. Depending on the shaped coil pitch and the position of the contact areas at the periphery, the connecting sections of the contact areas in the additional layers are advantageously arranged in rows, in which contact areas are also arranged for connecting interconnects or power electronic devices. Thus, sufficient contact areas are again provided in the rows so that all other contact areas, except those to be connected to interconnects, are connected to form contact pairs with their connecting sections.

[0013] Accordingly, gaps exist in the outer layer at the locations of the contact areas introduced into the additional layer, so that an odd number of contact areas are also provided in these rows after molding. Contact areas for connection to interconnects or power electronic devices are also preferably present in these rows.

[0014] In a row with an odd number of contact areas, the contact pairs that exist in addition to the contact areas provided for connection with the interconnection section are preferably used as transition sections to connect between the sub-lines of adjacent double layers or to the sub-lines of the same double layer in an additional layer.

[0015] For implementations with additional layers at two radial outer layers, such as multiple coaxial hairpin coils, the odd number corresponds to one of the hairpin coils.

[0016] The winding implementation is characterized in that the hairpin coil comprises multiple sub-circuits, such as different phases and / or parallel circuits, and for each sub-circuit, contact areas are arranged in an additional layer. Here, such a sub-region is understood as a sub-circuit corresponding to a distributed coil formed by conductor segments connecting bends and contact pairs, situated between contact areas for connection to power electronics, and crossing the layer twice in the radial direction, i.e., once from the inside out and once from the outside in. If the distributed coil crosses the layer more than twice, for example when the contact areas for connection to power electronics are in different layers or when the distributed coil crosses the layer multiple times in two radial directions, they are respectively considered as multiple sub-circuits. To connect the sub-circuits in the opposite direction of radial crossing, more precisely, to connect their conductor segments in the outer or double layer, contact areas are introduced into the additional layer for each sub-circuit. Thus, the connecting segments of the contact areas in the additional layer can be electrically connected to the connecting segments of the contact areas in the outer layer to form contact pairs.

[0017] The winding implementation is characterized in that the contact area of ​​the additional layer is shaped with the same pitch distance as the other contact areas. This maintains a uniform pitch distance for the coil.

[0018] Other embodiments of the winding are characterized in that the contact areas of the additional layer are shaped with a pitch distance different from that of the other contact areas. Therefore, depending on the construction of the hairpin coil, for example, the slot and / or coil pitch variation coefficient (Sehnung) of the poles can be easily changed.

[0019] Another aspect of this application relates to an electric motor, characterized in that it is provided with windings according to an embodiment of the invention.

[0020] Similarly, one aspect of this application relates to a method for manufacturing a winding according to the invention, comprising the steps of:

[0021] a) Introduce the hairpin-shaped portion into the winding frame, wherein the contact area is aligned with the conductor section;

[0022] b) Shape a portion of the contact area of ​​the outer layer radially so that it can be arranged in the additional layer;

[0023] c) The contact area of ​​the layer is shaped in the circumferential direction, wherein the connecting sections are arranged in a radially extending row.

[0024] Advantageously, the hairpin portion is formed as two parallel extending conductor segments before being installed into the slot of the winding frame. These segments are connected to each other by a turning area, and the contact area is correspondingly aligned with the conductor segments. The name "hairpin portion" also derives from this basic shape. The aligned contact areas have the advantage that the hairpin portion can be installed into the slot more easily and compactly.

[0025] After the hairpin-shaped portion is installed into the winding frame, a portion of the contact area of ​​the outer layer is shaped radially away from the other layers in order to introduce them into the additional layer.

[0026] The contact areas protruding axially from the winding frame are shaped in different circumferential directions so that the connecting sections of the contact areas of adjacent layers are oriented relative to each other.

[0027] The method is characterized by performing steps b) and c) simultaneously. In addition to performing the method steps sequentially, at least the outer layer and the additional layer can be formed simultaneously. By accordingly constructing a torsion tool for producing circumferential forming, a portion of the contact area of ​​the outer layer can be deflected radially rather than circumferentially by a portion of the tool and received by another portion of the tool. Preferably, the other portion of the tool performs a circumferential movement opposite to that of the mold portion for the outer layer, so that the contact area of ​​the additional layer is formed circumferentially.

[0028] The method according to the embodiment is characterized in that, in the subsequent step d), the connecting segments of adjacent contact areas are welded in a row to form contact pairs. The shaped contact areas protruding from the winding frame on the axial side are oriented relative to each other, such that the connecting segments of the contact areas of adjacent layers are electrically connected to form contact pairs, provided that they are not configured for connection to interconnects or power electronic devices.

[0029] In addition to the implementation plan for the method, other instructions regarding the windings and the motor also apply. Attached Figure Description

[0030] The invention is further illustrated below with reference to the accompanying drawings. Identical or similar components are indicated by uniform reference numerals. Wherein:

[0031] Figure 1 A schematic view of the embodiment is shown in detail from the axial direction.

[0032] Figure 2 A portion of the embodiment is shown in detail.

[0033] Figure 3 A perspective view of another embodiment is shown in detail. Detailed Implementation

[0034] exist Figure 1The diagram shows a schematic embodiment of the winding in the axial direction. The winding has a winding frame 1, which is preferably formed of a stacked plate. Multiple axially extending slots are provided in the winding frame 1, and the conductor sections of the hairpin-shaped portions 2 are arranged in these slots in multiple radially layered layers 3, 3.1, 3.2. In the illustrated example, six layers 3, 3.1, 3.2 of the hairpin-shaped portions 2 are provided, although other even numbers of layers 3, 3.1, 3.2 can also be implemented. An even number of layers 3, 3.1, 3.2 is always provided because the hairpin-shaped portions 2 are typically electrically connected to each other within the double layers. If sub-windings formed by interconnected hairpin-shaped portions 2 pass through multiple double layers, they correspondingly have transmission contacts with each other. The sub-windings typically pass through layers 3, 3.1, 3.2 multiple times in the radial direction, for example, from one outer layer 3.1, 3.2 to another outer layer 3.1, 3.2 and back. In this case, the hairpin-shaped part 2 of the reverse line in the outer double layer must be connected.

[0035] Therefore, according to an embodiment of the present invention, a portion of the contact area 2.1 of the hairpin-shaped portion 2 of the corresponding outer layers 3.1, 3.2 is introduced into the additional layers 4, 4.1, 4.2. Figure 1 The locations of the feasible additional layers 4, 4.1, and 4.2 are correspondingly indicated by the shaded torus. The radially inward additional layer 4.1 accordingly accommodates a portion of the contact area 2.1 initially in the radially inward outer layer 3.1, or the radially outward additional layer 4.2 accommodates the contact area 2.1 of the radially outer layer 3.2.

[0036] After the contact area 2.1 in the additional layers 4, 4.1, and 4.2 is formed in the circumferential direction, it is electrically connected to the contact area of ​​the hairpin portion 2 of the corresponding outer layers 3.1 and 3.2, which is also formed in the circumferential direction.

[0037] Figure 2 A perspective view of a sub-region of the winding in one embodiment is shown. Here, similarly, the six layers 3, 3.1, 3.2 of the hairpin-shaped portion 2 are disposed in the slots of the winding frame 1.

[0038] An additional layer 4.1 is provided adjacent to the radially built-in layer 3.1. A portion of the contact area 2.1 is shaped to allow entry from the outer layer 3.1 into the additional layer 4.1.

[0039] In the additional layer 4.1, the contact area 2.1 is shaped circumferentially, just like the contact areas of other layers 3, 3.1, and 3.2, so as to form contact pairs with other contact areas. Here, the direction of circumferential shaping is opposite to that of the outer layer 3.1, thereby realizing the coil pitch.

[0040] Contact areas 2.1, which are formed into the additional layer 4.1 due to molding, and radial rows of formed contact areas appearing through reverse intersections formed in the circumferential direction, have a number of contact areas different from the number of layers. In the illustrated embodiment, in addition to radial rows having six contact areas (correspondingly connected to form three contact pairs) corresponding to the number of layers, there are also rows with five and seven contact areas. In rows with an odd number of rows, in addition to contact pairs, contact areas 2.2 for connection with the interconnection unit 5 are also provided.

[0041] The interconnection section 5 enables the contact areas 2.2 of the sub-windings to be connected to each other and to power electronic devices when necessary.

[0042] exist Figure 3 In the embodiment shown, the additional layer 4.2 is arranged adjacent to the radially outer layer 3.2. Therefore, the contact area 2.1 formed in the additional layer 4.2 extends along the outer periphery.

[0043] In this embodiment, the contact area 2.2 is configured to interact with the radially inner layer 3.1, where... Figure 3 The interconnection section 5, not shown in the diagram, is connected.

[0044] In addition, Figure 3 The embodiments shown are largely similar to those in Figure 2 The embodiments shown are similar, so please refer to the description above.

[0045] Depending on the available installation space and structure, as well as the winding design, the additional layers 4.1 and 4.2 may, if necessary, differ from the illustrated embodiment, with the additional layers 4.1 and 4.2 disposed on two radial sides, such as... Figure 1 As exemplarily shown.

[0046] The invention is not limited to the illustrated embodiments. As mentioned above, it is also possible to provide only individual advantageous features or to combine features from different examples with each other.

[0047] List of reference numerals

[0048] 1 Winding frame

[0049] 2. Hairpin-shaped part

[0050] 2.1 Contact area in the additional layer

[0051] 2.2 Contact area for connecting interconnect parts

[0052] 3. Layers of the hairpin portion

[0053] 3.1 Radially Built-in Outer Layer

[0054] 3.2 Outer layer placed radially outward

[0055] 4 Additional Layers

[0056] 4.1 Radially Built-in Additional Layer

[0057] 4.2 Radially Outer Additional Layer

[0058] 5. Internet Department.

Claims

1. A winding having a distributed coil formed by a plurality of hairpin-shaped sections (2), wherein the hairpin-shaped sections (2) each having two straight conductor sections which are arranged in different slots of a winding support (1), wherein, at an axial end, the conductor sections are coupled with a contact region which is shaped in a circumferential direction and, at the other axial end, the conductor sections are connected by a turn region, wherein an even number of conductor sections is arranged in layers (3, 3.1, 3.2) in the slots of the winding support (1) in each case in a radial direction, wherein the contact regions have a connection section at their end facing away from the winding support (1) and the connection sections are oriented in a row extending in a radial direction, wherein the contact regions of the layers (3, 3.1, 3.2) are shaped in the same circumferential direction, characterized in that a part of the contact regions (2.1) of the outer layers (3.1, 3.2) is deformed in a radial direction in order to form additional layers (4, 4.1, 4.2), whereby the contact regions are arranged in more than one layer of conductor sections in the slots and the contact regions (2.1) are shaped in a circumferential direction opposite to the contact regions of the outer layers, whereby the contact regions (2.1) of the additional layers are arranged in the same row as the contact regions of the outer layers in order to be directly connected thereto.

2. The winding of claim 1, wherein At two outer layers (3.1, 3.2), a part of the contact regions (2.1) is deformed in a radial direction and forms additional layers (4, 4.1, 4.2).

3. The winding of claim 1, wherein, Due to the contact regions (2.1) in the additional layers (4, 4.1, 4.2), a part of the rows has an uneven number of layers and, in these rows, contact regions (2.2) are provided for connection to interconnections and the other contact ends are electrically connected with their connection sections into contact pairs.

4. The winding of claim 2, wherein, Due to the contact regions (2.1) in the additional layers (4, 4.1, 4.2), a part of the rows has an uneven number of layers and, in these rows, contact regions (2.2) are provided for connection to interconnections and the other contact ends are electrically connected with their connection sections into contact pairs.

5. Winding according to any of the preceding claims 1 to 4, characterized in that The winding comprises a plurality of sub-circuits and, for each sub-circuit, a contact region (2.1) is arranged in the additional layers.

6. The winding of claim 5, wherein, The winding comprises different phases and / or parallel circuits.

7. Winding according to any of the preceding claims 1 to 4, characterized in that The contact regions (2.1) of the additional layers (4, 4.1, 4.2) are shaped at the same pitch distance as the other contact regions.

8. The winding of any one of claims 1 to 4, characterized in that, The contact regions (2.1) of the additional layers (4, 4.1, 4.2) are shaped at a different pitch distance than the other contact regions.

9. An electric machine characterized by A winding according to any one of claims 1 to 8 is provided.

10. A method for manufacturing a winding according to any one of claims 1 to 8, comprising the steps of: a) introducing a hairpin (2) into the winding frame (1), wherein aligning the contact regions with the conductor sections; b) shaping a part of the contact regions (2.1) of the outer layers (3.1, 3.2) in a radial direction in order to arrange the contact regions in additional layers (4, 4.1, 4.2); c) shaping the contact areas of the layers in a circumferential direction, wherein the connecting sections are arranged in a row extending in a radial direction.

11. The method of claim 10, wherein, Steps b) and c) are carried out simultaneously.

12. The method according to claim 10 or 11, characterized in that, In a following step d), the connecting sections of adjacent contact areas in a row are welded into a contact pair.

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