Folded wave winding formed by shingling

Abstract

The present invention relates to a winding pad device (21) configured as a stator winding for a stator, wherein the winding pad device (21) has at least two winding pads (17, 18, 19, 20) that intersect each other. The present invention also relates to a method for manufacturing a stator.

Description

Technical Field

[0001] The present invention relates to a winding pad device configured as a stator winding for use in a stator, and to a method for manufacturing a stator. Background Technology

[0002] Methods for manufacturing stator windings for electric motors, particularly those used in motor vehicles, are known in the prior art.

[0003] US 8966742 B2 discloses a method for manufacturing stator windings for use in motors, particularly motors for motor vehicles, wherein at least one phase of the stator winding is positioned in a horizontal plane, and wherein regions of the phase are bent toward each other along at least one fold line, thereby creating a toroidal winding.

[0004] US 2019 / 0260249 A1 discloses a coil for a rotating electric machine, wherein the coil is mounted in a plurality of slots in a stator core, and wherein the slots extend in a circumferential direction. The overlapping shaft winding coil is composed of coil wire having: a plurality of slots receiving portions within the slots; and a plurality of coil end portions that connect the slot receiving portions in a herringbone pattern along the axial direction of the stator core outside the slots, thereby forming the coil. At least two layers of coil wire are connected by continuous wire-based connecting sections, folded backward, and stacked within the connecting sections.

[0005] However, the drawback of existing technologies is that the manufacturing process is always laborious. Summary of the Invention

[0006] Therefore, the object of this invention is to avoid or at least mitigate the disadvantages of the prior art. In particular, the manufacturing process will be changed.

[0007] This objective is achieved according to the invention in a general apparatus in which a winding pad device configured for use as a stator winding is provided. This winding pad device can then be attached to or mounted on the stator body, for example, a laminated stator core. The winding pad device has at least two winding pads. The winding pads intersect each other.

[0008] Therefore, the manufacturing process can be parallelized by providing winding pads, which is more time-consuming than assembling the winding pads in a final step before applying them to the stator body. In this case, the crossover can be understood as such that a first portion of one winding pad is above / below another winding pad, and a second portion is below / above another winding pad.

[0009] Specifically, at least two winding pads can be joined together. This can be a simple folding process to join at least two winding pads together.

[0010] At least two winding pads can be arranged in an X-shape in the horizontal cross-section. In this case, the horizontal cross-section can be longitudinal, relative to the winding direction used to wind the winding pad assembly onto the stator. This principle can also be used for more than two winding pads.

[0011] Furthermore, each of the at least two winding pads can have a wire wave winding. The number of wire wave windings in each winding pad can be the same. Therefore, a simple configuration of the wave winding pad assembly for winding onto the stator body can be made from multiple wave winding pads.

[0012] Furthermore, the connection portions of at least two winding pads can be arranged adjacent to each other. When the wave winding pad assembly is located on a shelf, the connection portions of the corresponding wave winding pads can be arranged at a certain distance from each other / above each other. In this case, the connection portions can form a matrix that allows the use of a phase distribution diagram.

[0013] The above-described objectives are achieved according to the present invention in a general method, in which a method for manufacturing a stator is provided. The method includes: providing a plurality of winding pads. The method further includes: crossing the respective winding pads into a winding pad assembly. The method further includes: winding or introducing the winding pad assembly onto or into a stator body, thereby forming a stator.

[0014] Therefore, the manufacturing process can be improved.

[0015] Advantageous embodiments are claimed in the dependent claims and are described below.

[0016] Individual winding pads can be combined to form a winding pad assembly.

[0017] Furthermore, each of the different winding pads can have a different unfolded horizontal plane. The method may further include nesting the different winding pads. Additionally, the method may include folding the horizontal planes relative to each other such that a common horizontal plane of the winding pad assembly is substantially formed. When the individual pads are in the unfolded state, they can be nested such that the outer portion associated with the horizontal plane of one winding pad connects to the inner portion associated with the horizontal plane of another winding pad. Similarly, the inner portion of another horizontal plane belonging to one winding pad can connect to or contact the outer portions of other horizontal planes belonging to other winding pads. Thereafter, the horizontal planes can be aligned as a whole by folding them.

[0018] The horizontal plane of various winding pads can have different dimensions.

[0019] The unfolded horizontal planes can be unfolded at an angle to each other before folding. The wire mesh or wires contained in the horizontal planes or in the individual winding pads can be folded in a meandering or serpentine manner. In this case, adjacent wires can be designed as a whole in a serpentine manner to the corresponding winding pads.

[0020] For example, in a folded state, at least the first strand segment is parallel to the second strand segment. A strand segment can be understood as a segment along the extension of a strand. This definition of a strand segment can be purely hypothetical, meaning it is not associated with any specific physical characteristic or even with any interruption in the strand. However, typically, the beginning or end of a strand segment will be associated with the path of directional change experienced by the strand in the horizontal plane, such as with the formation of a kink.

[0021] In its unfolded state, the strand segments can form a stepped integral structure.

[0022] Multiple strands can be used to make stator windings. These strands can mostly be made in parallel. For this purpose, several strands can be simply manufactured and stored in a library before the windings are folded. Once the required number of strands has been reached in the library, the strands are then folded into a winding pad.

[0023] Preferably, the strands are positioned as distributed windings. By winding in opposite directions, the intersections of the individual strands are spatially equal, making these intersections easier to handle.

[0024] For example, continuous wire can be used for strands. This can be applied to all strands. However, strands can also be formed from multiple elements that are then electrically connected to each other.

[0025] Rectangular wires are advantageous for use with strands. Other conductor shapes can also be envisioned.

[0026] The diameter of the conductor forming the strands can be substantially corresponding to or smaller than the slot width in the stator core.

[0027] Another aspect of this article can be an electric motor, particularly an electric motor for motor vehicles, having a stator winding, particularly the winding pad arrangement described above. This can be a toroidal winding with at least two layers.

[0028] In other words, the present invention relates to a folded wave winding formed by folding. Specifically, the present invention relates to manufacturing the stator as an unwound toothed chain and incorporating the distributed windings into the flat toothed chain. In particular, this is an adaptation of the distributed winding topology, wherein the resulting pads are as compact as possible and can be incorporated into the toothed chain. Here, the winding pads should be able to be incorporated into the toothed chain (unwound stator) as much as possible.

[0029] In the case of wave windings, the challenge is to connect parallel winding branches in the end windings so that even continuous winding schemes do not generate circulating current. Parallel winding branches per phase are necessary because, especially in the case of wave windings, the conductor height used (compared to so-called hairpin windings) is smaller, and therefore the number of conductors in the slots increases. Therefore, to keep the voltage generated per phase the same, the number of parallel winding branches must be increased.

[0030] In conventional winding variations, the conductor can be continuously wound in a circle with optional layer offset. This is not possible for windings to be coupled in a flat and inverted toothed chain. Therefore, the winding direction must be reversed, creating reversal points. Due to geometric boundary conditions, the conductor occupies these reversal points only every other horizontal plane. These reversal points are then interposed with each other as the winding is wound up. The manufacturing process for such wave windings is very complex.

[0031] In summary, the following problems will be solved by new windings: optimal interconnection of parallel winding branches minimizes circulating current and enables flat / compact windings with reversal points, as well as simplifying manufacturing concepts.

[0032] According to one embodiment, pads are manufactured in a first step, and then these pads are inserted into each other in an X-shape for use in a flat winding. The pads can be manufactured by bending a flat preliminary design (bending individually for each phase), stacking the individual flat preliminary designs, folding the stacked preliminary designs of the phases to form a pad at the bend line, thereby producing the end winding.

[0033] At the jump point on the horizontal plane, the conductor is not initially bent to its final state so that the pad can be inserted in an X-shape. Only after the pad has been inserted is the conductor bent to its final state.

[0034] Although some of the aspects described above pertain to winding pad devices, these aspects can also be applied to stators and motors. Similarly, the aspects described above concerning stators or motors can be applied to winding pad devices in a corresponding manner.

[0035] If it means that a component is "connected" to another component, this could mean that the component is directly connected to the other component or that the component is directly close to the other component. However, it should be noted that the other component can be located between the two components. On the other hand, when a component is "directly connected" to another component, it means that there are no other components between this component and the other component. Attached Figure Description

[0036] The invention will now be described with reference to the accompanying drawings. In the drawings:

[0037] Figure 1 A schematic diagram of the preliminary plan is shown;

[0038] Figure 2 A schematic diagram of the conductor arrangement in the preliminary scheme is shown;

[0039] Figure 3 A schematic diagram of a preliminary stacking scheme is shown;

[0040] Figure 4 A schematic diagram of the folding process is shown;

[0041] Figure 5 A schematic diagram of a single pad before folding is shown;

[0042] Figure 6 A schematic diagram of nested pads is shown;

[0043] Figure 7 A schematic diagram of nested pads is shown;

[0044] Figure 8 A schematic diagram of a nested pad and a finished winding pad assembly is shown;

[0045] Figure 9 A schematic diagram of the winding pad device is shown;

[0046] Figure 10 A schematic diagram of a bent and inserted winding pad device is shown;

[0047] Figure 11 A schematic diagram of the allocation diagram is shown; and

[0048] Figure 12 A schematic diagram of the winding assembly is shown. Detailed Implementation

[0049] The accompanying drawings are merely illustrative in nature and are used only for understanding the invention. The same elements are given the same reference numerals. Features of the various embodiments are interchangeable.

[0050] Furthermore, spatial relative terms, such as "below," "under," "lower," "above," "upper," "left," "right," etc., may be used to describe only the relationship between one element or structure depicted in the figures and one or more other elements or structures. In addition to the orientations depicted in the figures, spatial relative terms are intended to cover other orientations of the device during use or operation. Components may be oriented in different ways (rotated 90 degrees or in other orientations), and the spatial relative descriptive terms used herein may be interpreted accordingly.

[0051] The winding pad device and the method for manufacturing a stator will now be described with reference to the embodiments.

[0052] To prevent circulating current, the conductor along the winding path must see each slot in the slot block of each conductor horizontal plane. A slot block refers to the superposition of the individual poles of each phase. Therefore, it is irrelevant whether the conductor passes through the horizontal plane 1 of the first slot of each pole in the first or second pole circumferentially. In this case, the conductor changes horizontal plane upwards in each end winding. If the conductor has reached the top horizontal plane, the horizontal plane then jumps to the bottom horizontal plane.

[0053] This illustrates the following horizontal plane sequence (3, 4, 5, 6, 7, 8, 1, 2), where there are z_n = 8 conductor horizontal planes in the slots. In the regions of reversal points 8 and 11, the conductors are interchanged for different slots of each pole, allowing the rules described above to be satisfied. Due to the continuous horizontal plane transitions, all conductors in each winding pad satisfy the rules.

[0054] For the z_n / 2 winding pad, different numbers of parallel conductors a_mat are possible. The following conditions must be met: mod(q / a_mat) = 0 for the connection at the same reversal points 8 and 11, or mod(q / a_mat) = 0.5 for the connection at two reversal points. In the case of connections at the same reversal points 8 and 11, the parallel winding arm connections are located in adjacent regions.

[0055] The following description pertains to a machine with q=4 holes, a=8 parallel conductors, p=4 pole pairs, z_n=8 pole pairs, and N=96 slots: the preliminary design is for one phase (for the arrangement of a_mat=2 parallel conductors per winding pad).

[0056] This implementation requires four pads (z_n / 2). Here, the horizontal jump 10 occurs once on each odd-numbered bend line. The bend lines can be different for each pad. For example, the bend lines can be different for the first pad 7, the second pad 5, the third pad 3, and the fourth pad 1. Figure 1 The arrows in the diagram show the orientation of the bend. In the case of horizontal jump 10, the bend direction is outside this configuration, for example, only half-folded, or at least not fully folded, so that the pad can be interlocked later. In the case of horizontal jump 10, a larger offset is required between the vertical slots 9 due to the larger end winding length.

[0057] Other details and aspects are mentioned in conjunction with the above or the following embodiments. Figure 1 The embodiments shown may have one or more optional additional features, which correspond to the following regarding Figures 2 to 12 The description refers to one or more aspects of the proposed concept or implementation method.

[0058] Figure 2Schematic conductor arrangements are shown in preliminary schemes 12, 13, and 14 for a_mat = 2 and q = 3. Connections may be required at the two reversal points. Typically, due to the folding, the conductors on the left and right loop sides are located in the horizontal plane of each slot. On each loop side, for each pole, the conductor is always located in the same slot. By interchanging reversal points 8 and 11, the conductors can thus see all the slots in each slot block. In the simple arrangement for a_mat = 1, the conductor arrangement in the preliminary schemes follows concentric loops.

[0059] Figure 3 The diagram shows the stacking of the various flat preliminary schemes 12, 13, and 14. Stacking of the preliminary schemes 12, 13, and 14 is possible due to the shape of the end windings in the regions of reversal points 8 and 11. The preliminary schemes 12, 13, and 14 are layered in the same order at reversal points 8 and 11. Conductor bending may require additional offset of the conductor height (in region a).

[0060] Other details and aspects are mentioned in conjunction with the above or the following embodiments. Figure 2 , Figure 3 The embodiments shown may have one or more optional additional features, which correspond to the combination of the above (e.g.) Figure 1 ) or below (e.g.) Figures 4 to 12 The concept or one or more aspects of one or more implementations described herein.

[0061] The folding process with a horizontal jump of 10 at bend line 5 is shown as an example. Figure 4 The diagram schematically illustrates the folded state during the folding process of the pad itself, see folded sections 15, 16. In the area of ​​the horizontal jump 10, the bending occurs on the outside of the directional scheme (see...). Figure 5 The bend does not initially follow the final state. Here, a 90-degree bend is schematically shown, but 0-degree and 150-degree bends can also be envisioned to allow for insertion. The final state of bending to 180 degrees only occurs after insertion.

[0062] according to Figures 6 to 8 Pads 17, 18, 19, and 20 are inserted or nested inside each other in an X-shape. In this case, in Figures 6 to 8 In the upper right corner of the image, the first local regions 17a, 18a, 19a, and 20a (also referred to as the first horizontal plane) of pads 17, 18, 19, and 20 are arranged adjacent to each other. In this case, in Figures 6 to 8 At the top, the second local regions 17b, 18b, 19b, and 20b are also arranged adjacent to each other. According to... Figures 6 to 8At the bottom, in the intermediate region between the first partial regions 17a, 18a, 19a, 20a and the second partial regions 17b, 18b, 19b, 20b, pads 17, 18, 19, 20 are arranged adjacent to each other. When all pads 17, 18, 19, 20 are arranged adjacent to each other, the inserted pads are then bent to the final state for the winding pad assembly 21 (see...). Figure 8 (See Figure 2).

[0063] Figure 9 The diagram shows the reversal points of finished pads 17, 18, 19, 20 and connecting areas U, V, W, X, Y, Z. Preferably, the connecting portions can be configured as star-shaped connecting portions (XYZ to star) or triangular connecting portions. At reversal points 8 and 11, the conductor occupies only every other horizontal plane (see [reference]). Figure 11 (Phase-specific distribution diagrams). Figure 10 The diagram shows a bent and inserted winding, also referred to herein as the rolled-up winding pad device 21.

[0064] Other details and aspects are mentioned in conjunction with the above or the following embodiments. Figures 4 to 10 The embodiments shown may have one or more optional additional features, which correspond to the combination of the above (e.g.) Figures 1 to 3 ) or below (e.g.) Figures 11 to 12 The proposed concept or one or more aspects of one or more implementations described herein.

[0065] Figure 11 A phase-specific distribution diagram is shown as an example. If the winding step is shortened at one end and extended at the opposite end, a chord is obtained (similar to a two-layer winding). In multi-layer windings, the displacement of the winding layers is called a chord. This displacement smooths the excitation curve and thus reduces harmonics in the induced voltage. Due to the chord, the amplitude of the induced voltage is reduced. The insertion region increases the shortening / extending length. Aside from bending variations, the manufacturing concept is unaffected by this (see [link]). Figure 12 The dashed groove was occupied once, and the solid groove was occupied twice.

[0066] Explanation of reference numerals in the attached figures

[0067] 1-7 Bend Points

[0068] 8 Reversal Point

[0069] 9 Grooved parts

[0070] 10 Horizontal Jump

[0071] 11 Reversal Point

[0072] 12 First Preliminary Plan

[0073] 13 Second Preliminary Plan

[0074] 14 Third Preliminary Plan

[0075] 15 Folding Section

[0076] 16 Folding Sections

[0077] 17a First horizontal plane - First pad

[0078] 17b Second horizontal plane - First pad

[0079] 18a First horizontal plane - Second pad

[0080] 18b Second horizontal plane - second pad

[0081] 19a First horizontal plane - third pad

[0082] 19b Second Horizontal Plane - Third Pad

[0083] 20a First horizontal plane - fourth pad

[0084] 20b Second Horizontal Plane - Fourth Pad

[0085] 17 First Pad

[0086] 18 Second Pad

[0087] 19 Third Pad

[0088] 20 Fourth Pad

[0089] 21 Winding pad assembly

[0090] U connection area

[0091] N connection area

[0092] V Connection Area.

Claims

1. A method for manufacturing a stator, the method comprising: By bending flat preliminary schemes (12, 13, 14) and stacking each flat preliminary scheme (12, 13, 14), the stacked preliminary schemes (12, 13, 14) are folded at the bending line to set the winding pads (17, 18, 19, 20). The characteristic feature is that the different winding pads (17, 18, 19, 20) are crossed such that the first part of one winding pad is above another winding pad and the second part is below another winding pad, or the first part of one winding pad is below another winding pad. The second part is positioned below the first winding pad and above the second winding pad, and each of the different winding pads (17, 18, 19, 20) has a different unfolded horizontal plane. When the individual pads are in the unfolded state, the outer side of the horizontal plane of at least one winding pad is connected to the inner side of the corresponding horizontal plane of the other winding pad. The horizontal planes are aligned as a whole by folding them to form a winding pad assembly (21), and the winding pad assembly (21) is incorporated into the stator body.

2. The method for manufacturing a stator according to claim 1, characterized in that, The horizontal planes of each of the winding pads (17, 18, 19, 20) have different dimensions.

3. The method for manufacturing a stator according to claim 1, characterized in that, Each of the unfolded horizontal planes unfolds at a certain angle to each other before folding.

4. A winding pad device (21), characterized in that, The winding pad device (21) is configured as a stator winding for a stator manufactured according to the method of claim 1, and the winding pad device (21) has at least two winding pads (17, 18, 19, 20) that intersect each other.

5. The winding pad device (21) according to claim 4, characterized in that, The at least two winding pads (17, 18, 19, 20) are joined together and form an X-shape in the horizontal cross-section.

6. The winding pad device (21) according to claim 5, characterized in that, The horizontal plane of the cross section is in the longitudinal direction relative to the winding direction used to wind the winding pad device (21) onto the stator.

7. The winding pad device (21) according to claim 6, characterized in that, Each of the at least two winding pads (17, 18, 19, 20) has a wire wave winding.

8. The winding pad device (21) according to claim 7, characterized in that, The number of wire wave windings in each of the winding pads is the same.

9. The winding pad device (21) according to any one of claims 5 to 8, characterized in that, The connection portions of the at least two winding pads (17, 18, 19, 20) are arranged adjacent to each other and form a matrix that realizes the phase distribution diagram.

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