Winding mat for an electric machine

Abstract

The invention relates to an electric motor generator stator (1) which is easy to assemble, comprising a stator body (2) with stator grooves (16) and at least one winding mat (3) with groove sections (7) and head sections (8), the groove sections being arranged in the stator grooves (16) and located one after the other in different radial positions, the head sections connecting the groove sections, wherein • each wave winding conductor (6) changes position by exactly one radial position in the stator groove (16) in the middle of the wave winding conductor's extension in the winding direction, and • the winding mat comprises a first sub-winding mat (11) which comprises exactly one first group (4, 5, 13) of wave winding conductors (6) for each branch, the first group (4, 5, 13) being joined together in the area of a layer change in an X-shaped manner, so that at the intersection between the wave winding conductor (6) of a first branch and the wave winding conductor of a second branch, on one side of the layer change the wave winding conductor (6) of the first branch is constantly located above the wave winding conductor of the second branch, and on the other side the wave winding conductor (6) of the second branch is constantly located above the wave winding conductor of the first branch.

Description

Technical Field

[0001] This invention relates to a stator for an electric generator, the stator comprising a stator body having stator grooves and at least one winding pad disposed in the stator grooves. Furthermore, this invention relates to a method for producing such a winding pad. Background Technology

[0002] It is known that such winding pads are formed as so-called wave windings. Such wave windings include multiple wave winding conductors, wherein grooved sections extending in grooves in the stator are connected to head sections arranged in a region at the head of the winding. In a radial flux machine having grooves extending along the axial direction of the stator, when viewed in the circumferential direction, these grooved sections are alternately positioned on the two end faces of the stator carrier for each wave winding conductor. In this context, the stator carrier is understood as the non-electromagnetically active part of the stator, such as the stator body of a coil that does not generate a field. In particular, the stator body can be designed as a laminated stator core formed by stator laminations stacked one on top of the other and electrically insulated from each other.

[0003] An electric generator is known from US 6,894,414 B1, in which the stator is manufactured as a so-called unfolded toothed chain. Winding pads forming distributed windings are first placed in stator recesses of this flat toothed chain. The extension of the winding pads along the winding direction corresponds to the extension of the flat toothed chain and thus to the circumference of the resulting cylindrical stator. After the winding pads are inserted, the toothed chain is bent into a cylindrical shape. The ends of the toothed chain are then welded together.

[0004] An electric generator with wave windings is known from EP 259 77 54 A1, wherein the distance between two recessed segments connected to each other via a head segment varies at least partially. Summary of the Invention

[0005] The present invention is based on the following objective: to specify a stator for an electric generator that is easy to manufacture and has a continuous winding scheme.

[0006] First, the stator may specifically include axially oriented stator recesses. However, the stator recesses may also have a slope to reduce torque pulsation and cogging effects. At least one winding pad is arranged in the stator recess. This winding pad is designed as a distributed winding. The distributed winding comprises two sets of continuous wave-shaped winding conductors for each branch of the machine. Each wave-shaped winding conductor includes recessed sections that can be positioned at different radial locations within the stator recess. Furthermore, each wave-shaped winding conductor includes head sections, each head section connecting two recessed sections in the region of the winding head on the outside of the stator recess. In the case of so-called wave-shaped windings, for each wave-shaped winding conductor, these head sections are alternately arranged on two end faces of the stator.

[0007] In motors with wave-shaped windings, parallel winding branches for each phase are necessary because, especially in the case of wave-shaped windings, a smaller conductor height is used (particularly compared to so-called hairpin windings), and therefore the number of conductors in the slots increases. To limit the induced phase voltage, several winding branches are connected in parallel.

[0008] The so-called gap number q defines the number of recesses in each pole and each branch of the electric generator. Each group can have q consecutive wave-shaped winding conductors, and the recessed segments of the q consecutive wave-shaped winding conductors are distributed above the recessed blocks of q adjacent stator recesses in each pole. Therefore, the segments of the wave-shaped winding conductors can occupy different recesses within the recessed blocks and different positions in the radial direction within the recesses, because according to the invention, multiple conductors are arranged one after another in the stator recesses.

[0009] To prevent circulating current from forming when wave winding conductors in specific sections are connected in parallel, the order of the groove segments of the individual wave winding conductors in the group can be interchanged between the groove blocks, such that each winding conductor occupies each of the q possible peripheral positions in the groove block the same number of times. Furthermore, it can be configured such that the position of each wave winding conductor in the stator groove at the center of its extension along the winding direction changes exactly by one radial position.

[0010] The result of these two measures is that each wave winding conductor employs each possible radial position combined with each possible position within the recessed block at least once and at the same frequency. The possible combinations of circumferential and radial positions within the recessed block are uniformly distributed throughout the wave winding conductor. In this way, circulating currents are effectively avoided when the winding conductors are connected in parallel. This also applies when the stator is designed to have multiple winding pads of this structure, for example, to increase the number of parallel connections. In this embodiment, each equivalent radial layer recess combination is used in each winding pad. For each conductor in each branch, this rule is satisfied by continuously interchanging the conductor order of segments in the winding head and by changing the radial position of the center of the extension, and therefore specifically according to the p poles of the wave winding conductor in the winding direction. Here, p represents the number of pole pairs of the stator.

[0011] The stator body can have a toothed chain bent into a cylindrical shape, the toothed chain having at least one axially extending joint where the ends of the bent toothed chain are connected to each other. The advantage of this configuration is that, when the toothed chain is in the unfolded state, the stator groove can be easily fitted with the winding pad. In contrast, introducing the winding pad into a cylindrical stator body can represent a complex process.

[0012] In particular, when the stator body is designed as a toothed chain, it is especially advantageous that the extension of the winding pad along the winding direction corresponds to the inner circumference of the stator.

[0013] The number of pole pairs p of the stator can be an integer multiple of q. If the number of pole pairs p is a multiple of the number of gaps q, then each possible position within the groove block in each of the two possible radial positions within the stator groove is occupied multiple times by the wave winding conductors in the group.

[0014] A set of wave-wound conductors in a linearly extended state can be axially symmetrical with respect to the cross scheme of the head section and have an axis of symmetry oriented parallel to the groove section. This ensures that each groove position within the groove block in each of the two radial layers is occupied at least once by the wave-wound conductors in the set, and that these positions, or the occupancy of the radial layers, are uniformly distributed among a set of different wave-wound conductors.

[0015] The stator includes a first sub-winding pad that comprises exactly one set of wave-shaped winding conductors for each branch. These sets are joined in an X-shape in regions of layer variation, such that at the intersection between the wave-shaped winding conductors of the first branch and the second branch, on one side of the layer variation, the wave-shaped winding conductor of the first branch is consistently positioned above the wave-shaped winding conductor of the second branch, and on the other side, the wave-shaped winding conductor of the second branch is consistently positioned above the wave-shaped winding conductor of the first branch. Therefore, sets of wave-shaped winding conductors from different segments can be readily pre-constructed and then added to the first sub-winding pad.

[0016] The second sub-winding pad can be used in a similar manner. This means that the stator includes a second sub-winding pad that includes exactly a second set of wave winding conductors for each branch, the second set being joined together in an X-shape in the layer-change region such that at the intersection between the wave winding conductors of the first branch and the wave winding conductors of the second branch, on the layer-change side, the wave winding conductors of the first branch are constantly positioned above the wave winding conductors of the second branch, and on the other side, the wave winding conductors of the second branch are constantly positioned above the wave winding conductors of the first branch.

[0017] A complete winding pad can now be formed from the first sub-winding pad and the second sub-winding pad. In this case, the second part of the winding pad can now be rotated 180 degrees relative to the first part of the winding pad about an axis oriented along the winding direction in a linearly unfolded state. The sub-winding pads can be joined together in an X-shape in the region of layer change, such that the wave-shaped winding conductor of the first sub-winding pad is constantly above the wave-shaped winding conductor of the second sub-winding pad on one side of the layer change and constantly below the wave-shaped winding conductor of the second sub-winding pad on the other side of the layer change.

[0018] If at least some regions of the head section of each wave winding conductor are offset from the corresponding connected groove section in the direction of the groove opening by more than the positional change on one side and from the corresponding connected groove section in the direction of the groove base by more than the positional change on the other side, then this forms a particularly compact winding head.

[0019] When viewed in the radial direction, the maximum offset of the head segment can correspond to half of the maximum offset of the radial position in each case, and therefore to half of the extension of the conductor.

[0020] If the first sub-winding pad and the second sub-winding pad are fitted together, a particularly compact design is achieved by offsetting the head section. The offset of the first sub-winding pad is always in the opposite direction to the offset of the second sub-winding pad. When viewed along the winding direction, these conditions are reversed at the layer changes.

[0021] An electric generator having a stator according to one embodiment of the above-described embodiments is particularly suitable as a traction drive for electric or hybrid vehicles. It is easy to manufacture and therefore suitable for mass production. Its electromagnetic characteristics are highly advantageous due to the elimination of circulating current.

[0022] Another subject of the invention is a method for producing a winding pad for the stator of an electric generator. In this method, a first sub-winding pad is first produced. For this purpose, in a first step, a first set of q wave-shaped winding conductors is provided for each branch of the stator. Each of these wave-shaped winding conductors includes a recessed section and a head section, the recessed section being arranged in a stator recess in the stator body of the electric generator, and the head section connecting two recessed sections of the wave-shaped winding conductor in the region of the winding head of the machine in each case.

[0023] The q wave winding conductors are arranged such that, in each case, the q adjacent groove segments of the corresponding wave winding conductor follow each other at a distance of two stator grooves. It is particularly advantageous here that the order of the groove segments of the individual wave winding conductors is reversed within the group, such that each wave winding conductor occupies each of the q possible positions within the groove block an equal number of times. If, for example, the groove block includes four possible positions, then therefore the number of gaps in the stator is four, and thus the groove segments of the wave winding conductors involved in this group can be evenly distributed above positions 1, 2, 3, and 4.

[0024] Then, all the first sets of wave winding conductors formed in this way are assembled or combined to form the first sub-winding pad.

[0025] The second sub-winding pad can be produced in the same manner as the first sub-winding pad.

[0026] The two sub-winding pads produced in this way can eventually be joined together. When the sub-winding pads are joined together, the grooved sections of the involved wave-shaped winding conductors change position. This is accomplished in the following manner: the wave-shaped winding conductor of the first sub-winding pad is positioned below the wave-shaped winding conductor of the second sub-winding pad before and after the layer change. After the sub-winding pads have been joined together, on the side of the layer change, the grooved section of the wave-shaped winding conductor of the first sub-winding pad is positioned above the grooved section of the wave-shaped winding conductor of the second sub-winding pad, and vice versa on the other side. When the resulting winding pads are subsequently arranged in the stator body of the generator, the winding pads have occupied two radial positions, wherein each wave-shaped winding conductor can occupy each of the two radial positions an equal number of times in each of the q possible positions within the groove block. Attached Figure Description

[0027] The invention will now be explained in more detail using exemplary embodiments illustrated in the accompanying drawings. In the drawings: Figure 1 A schematic diagram of the first group of wave-shaped winding conductors is shown. Figure 2 The structural implementation of the first group of wave-shaped winding conductors is shown. Figure 3 The diagram shows the three first groups of wave-shaped winding conductors combined together. Figure 4 This illustrates the first sub-winding pad formed by the three first groups of wave-shaped winding conductors coming together. Figure 5 This illustrates two sub-winding pads joined together to form a winding pad. Figure 6 A stack of multiple winding pads is shown. Figure 7 The stator body is shown, wherein a winding stack is disposed in a stator recess within the stator body. Figure 8 A first circuit diagram for a winding according to an embodiment of the present invention is shown. Figure 9 A second circuit diagram of the winding for use according to an embodiment of the present invention is shown. Figure 10 A first embodiment of a toothed chain for forming a cylindrical stator body is shown. Figure 11 A second embodiment of the toothed chain for forming the cylindrical stator body is shown. Figure 12 A third embodiment of the toothed chain for forming the cylindrical stator body is shown. Figure 13 A fourth embodiment of the toothed chain for forming the cylindrical stator body is shown. Figure 14 A fifth embodiment of a toothed chain for forming a cylindrical stator body is shown, and Figure 15 A sixth embodiment of a toothed chain for forming a cylindrical stator body is shown. Detailed Implementation

[0028] Figure 1A schematic diagram of the first group 4 of wave-shaped winding conductors according to an embodiment of the present invention is shown. Each wave-shaped winding conductor 6 includes a grooved section 7, which are connected to each other via a head section 8. After the wave-shaped winding conductor 6 has been laid in the stator groove of the stator body of the generator, the head section 8 forms a winding head that protrudes axially beyond the stator body, while the grooved section 7 is disposed in the stator groove of the stator body.

[0029] The first group 4 shown is precisely assigned to a section of the machine and comprises four wave-shaped winding conductors 6. These four wave-shaped winding conductors 6 are each arranged side-by-side in the recess blocks of four grooves in the stator body. Therefore, the so-called gap number q in the stator, and the number of grooves per pole and per branch, is q=4. The number of pole pairs of the stator including the group shown in the figure in its stator windings is p=4.

[0030] This machine is a three-phase machine. Since a set of wave-shaped winding conductors 6 occupies four slots in each slot block and exactly one slot block is assigned to each of the eight poles of the stator, there are 32 stator slots in each branch of the machine. This results in a total number of slots for the three phases of the stator of N=96.

[0031] Since each groove block includes four grooves, the grooved section 7 of the wave winding conductor 6 can occupy four different positions in each groove block. As shown in the schematic diagram of the first group 4 of the wave winding conductor 7, each wave winding conductor 7 continuously changes its position from groove block to groove block.

[0032] It is assumed that the positions within the recessed blocks are numbered consecutively from left to right, increasing sequentially from position one to position four. The wave-shaped winding conductor 6, located at position one in the first recessed block from the left, is in position four in the subsequent second recessed block. This wave-shaped winding conductor 6 is arranged in position three in the third recessed block from the left. In the fourth recessed block, the wave-shaped winding conductor is in position two. This wave-shaped winding conductor 6 changes to position three in the fifth recessed block and returns to position two in the sixth recessed block. In the seventh recessed block, the wave-shaped winding conductor 6 is again in position one. Then, the wave-shaped winding conductor occupies position four in the eighth recessed block.

[0033] The arrangement formed by the first group 4 of the wave-shaped winding conductors 6 is axially symmetrical with respect to the axis of symmetry 9, which, when viewed along the winding direction, divides the first group 4 into two equal halves in the middle. This axial symmetry is itself reflected in the design of the winding heads. At the poles located exactly above the axis of symmetry 9, the head segments 8 do not cross. The crossing arrangements of the other head segments 8 are symmetrical with respect to the axis of symmetry 9.

[0034] The groove positions are occupied in a similar manner by the other wave-shaped winding conductors 6 involved in the first group 4. Therefore, the wave-shaped winding conductors 6 do not follow a constant pitch. Instead, the distance between the two groove segments 7 of the wave-shaped winding conductors varies continuously.

[0035] The head segment 8, arranged in the winding head, defines positively correlated and negatively correlated head segment conductor layers. The head segment conductor layer is offset by half the conductor height in the positive z-direction or negative z-direction. Figure 1 The dashed lines in the diagram are intended to illustrate the offset in the conductor layer of the positively correlated head segment, while the solid lines illustrate the offset in the conductor layer of the negatively correlated segment.

[0036] Viewed from the left, the head segment 8, located to the left of the axis of symmetry 9, is initially oriented along the negative z-axis. Upon reaching the winding head tip 10, the orientation reverses, such that the grooved segments 7 connected via the head segment 8 are ultimately arranged in the same z-axis position. After the illustrated wave winding conductor 6 is installed in the stator body, this means that these grooved segments 7 are arranged in the same radial position.

[0037] In the region to the right of the axis of symmetry 9, the orientation of the head segment 8 is exactly the opposite. That is, when viewed from left to right, the head segment 8 first extends in the positive z-direction to the winding head tip 10 and then extends in the negative z-direction after reaching the winding head tip, such that the groove segment 7 connected via the head segment 8 is again in the same z-position and therefore in the same radial position during installation.

[0038] The positional change in the z-direction occurs along the axis of symmetry 9 and therefore at the center of the first group 4 of the wave winding conductors 6 of the machine segment. The head segment 8 extends along the negative z-direction on both sides of the winding head tip 10 arranged here. Here, when viewed in the radial direction, the offset on the left and right sides of the winding head tip 10 is also half the conductor width in each case. However, due to the same orientation of this offset in the z-direction, this results in the layer of the groove segment 7 connected via the head segment 8 being offset by exactly one conductor width. Therefore, the groove segment 7 located on the right side of the axis of symmetry in the groove of the machine is positioned radially closer to the groove base than the groove segment 7 on the left side of the axis of symmetry 9.

[0039] Therefore, the illustrated distribution of the groove segments 7 within the first group 4, with respect to the possible positions within the groove blocks involved and to the radial positions occupied by the wave-wound conductors 8, means that each wave-wound conductor 8 occupies every possible position within the groove block and generally occupies every possible radial position in the same way. In this way, a foundation has been created within a group of wave-wound conductors 8, such that the formation of circulating currents can be prevented by the consistent continuation of this scheme for all groups of wave-wound conductors involved in the winding pads of the stator, even though they are parallel-connected conductor loops.

[0040] Importantly for understanding, the positive head segment conductor layer of the first sub-pad conductor layer corresponds to the negative winding head conductor layer of the second sub-pad conductor layer, which is offset in the positive z-direction. Along the segment, according to... Figure 1 The wave direction in the positive x-direction, after leaving the groove in the first sub-pad conductor layer, exhibits an offset to the associated negative winding head conductor layer. Conversely, in the second conductor layer, after leaving the groove, there is an offset to the associated positive winding head conductor layer. This difference arises from the change in position. Along the described positive wave direction, after leaving the groove, when changing layers, the conductor initially offsets to the negative winding head conductor layer associated with the first sub-pad conductor layer. In the winding head tip, the conductor changes to the winding head conductor layer, which is positive for the first sub-pad conductor layer. Therefore, at the subsequent groove inlet, there is an offset in the positive z-direction in the second sub-pad conductor layer. In the case of the winding head structure design, it is obvious that if the groove inlet is along the positive wave direction, there must also be an offset in the positive z-direction in the second sub-pad conductor layer. Therefore, as described above, there must be an offset in the positive direction at the groove outlet.

[0041] Figure 2 The structural implementation of the first group 4 of the wave winding conductor 6 is shown.

[0042] The conductors are bent above the short edge in the tip 10 of the winding head. The q parallel conductors of the segment can be prefabricated separately from each other. This allows the conductors to be bent in the xy plane first, and then, in a second step, the necessary conductor offset is punched into the winding head using a punch. The order in which these conductors will be inserted into each other is different for each winding scheme with different parameters, and must be checked individually in each case.

[0043] This insertion process will refer to Figure 2As an example, upon closer inspection, it can be seen that the second wave winding conductor 6 in the left connecting section is arranged in front of the other conductors in the first and seventh winding head sections, following the positive wave direction from the left. Conversely, this conductor is arranged behind the remaining wave winding conductors 6 in the third and fifth winding head sections. In the remaining winding head sections, this conductor does not cross with other wave winding conductors 6, resulting in a wave winding conductor 6 neither being arranged in front of nor behind another wave winding conductor 6. Therefore, this conductor must be the last of the already arranged conductors inserted into the section along the positive y-direction. In this case, the described arrangement must be implemented in the winding head section. The remaining wave winding conductors 6 are arranged in the same order in the corresponding winding head sections, one below the other. The second conductor from the right in the left connecting section is always located in front of the first conductor from the right in the left connecting section. Therefore, the insertion of the remaining conductors is not necessary. Therefore, the remaining conductors can be arranged in such a way that one is inside the other, depending on their order.

[0044] Figure 3 The diagram illustrates the combination of three first groups 4, 5, and 13 of the wave-wound conductor 6 to form a first sub-winding pad, which correspondingly includes the first groups 4, 5, and 13 of the wave-wound conductor 6 for each branch of the machine. The first groups 4, 5, and 13 shown have been manufactured in the same manner, particularly in combination. Figure 2 Insert according to the description.

[0045] Then, the associated groups 4, 5, 13 of these segmental or wave-shaped winding conductors 6 must be inserted into each other to form the first sub-pad. The process described below is the same for each winding scheme with different parameters. Figure 3 As schematically illustrated, the joining is carried out with the aid of the x-shaped insertions of the respective first groups 4, 5, and 13. Since the arrangement of the head segment 8 between the corresponding segments on the left and right sides of the stratum change is different, the individual segments must be pushed into each other in an x-shape in the y-direction and then rotated relative to each other, wherein this process can be performed sequentially.

[0046] According to this principle, the first group 5 of the second branch is first coupled to the first group 4 of the first branch. Then, the first group 13 of the third branch is inserted into the already formed sub-pad, and subsequently, the completed first sub-winding pad is obtained. Figure 4 The diagram shows this first sub-winding pad 11, generated by three insertion groups 4, 5, and 13 of the wave-shaped winding conductor 6. The sequential assembly is similar for the alternative number of segments. The different arrangement of the head segment 8 relative to the left and right sides of the layer variation is due to the different designs of the winding heads in the two segments.

[0047] Then, the second sub-winding pad 12 is produced in a completely similar manner. Finally, the first sub-winding pad 11 and the second sub-winding pad 12 are combined to form the winding pad 3. This process can be completed in [timeframe missing]. Figure 5 I saw it in the middle.

[0048] As described above, each sub-winding pad 11, 12 is divided into two regions, in which the conductor is located in different radial positions. Therefore, when the first sub-winding pad 11 and the second sub-winding pad 12 are inserted together, the unoccupied layer recess positions in the first sub-winding pad must be occupied by the second sub-winding pad. If Figure 4 If the first sub-winding pad 11 shown is rotated 180 degrees along the R-axis, then in the structural embodiment, it can be seen that the rotated first sub-winding pad 11 (here referred to as the second sub-winding pad 12) forms a counterpart to the original first sub-winding pad 11 in both the region of the groove section 7 and the region of the head section 8. Therefore, the second sub-winding pad 12 corresponds to the first sub-winding pad 11 rotated 180 degrees along the R-axis.

[0049] Therefore, only one type of sub-winding pads 11 and 12 is required in the process, which significantly reduces the production workload. Similar to the combination of groups 4, 5, and 13 of each section, the two opposing sub-winding pads 11 and 12 must be fitted into each other in an x-shape in the y-direction and then rotated relative to each other. When viewed from the y-direction, the two sub-winding pads 11 and 12 intersect here along the layer change of the sub-winding pads 11 and 12.

[0050] Figure 6 A winding stack 13 consisting of several winding pads 3 is shown. In the illustrated embodiment, this forms a flat winding with a conductor layer having a zn=8. Since each winding pad in the stacked winding pads 3 contains two conductor layers, four winding pads 3 are stacked.

[0051] The winding pads 3 can be directly stacked in the stator recesses of the stator body. This is achieved in a particularly simple way if the stator body, for example, is manufactured in the form of a laminated stator core, is designed as a toothed chain.

[0052] The number of stacked winding pads 3 can be flexibly selected. Due to the structure of the winding pads consisting of two sub-pads 11 and 12, and thus forming two conductor layers, the number of conductor layers in the entire winding stack 13 is even.

[0053] You can also Figure 6 As can be seen, the connecting conductors 14 protrude from the winding stack 13 at both ends of the winding stack 13. If the windings are placed in a toothed chain, these connecting conductors must be interwoven with the toothed chain due to the windings being wound up.

[0054] Figure 7 A stator body is shown, wherein a winding is disposed in a stator recess of the stator body 2. A winding having a stator body 2 in a wound state and interlaced connecting conductors 14 is shown. A winding with the aforementioned parameters is schematically shown without interchanging the order of the conductors in the winding head.

[0055] Figure 8 A first circuit diagram for a winding stack 13 according to an embodiment of the present invention is shown, and Figure 9 A second circuit diagram is shown for a winding stack 13 according to an embodiment of the present invention.

[0056] Then, the stacked and rolled-up winding pads 3 must be connected to each other. Interconnections are similarly performed on both end faces. Furthermore, the interconnections are the same for all sections, which is why only one section is used for explanation below. In principle, it can be said that the maximum number of parallel winding branches corresponds to the number of gaps q on each end face. Therefore, for the entire winding stack 13, each branch can have a maximum of a=2q parallel winding branches. For any number of gaps, the interconnections must be checked individually. A connection with q=4 is used as an example to illustrate the necessary considerations. After interleaving, the connecting conductors 14 are arranged in a matrix when viewed from the axial direction. The connecting conductors 14 at different ends of the winding pads 3 are always one on top of the other in the matrix arrangement, where, when viewing the end faces, only the sub-pads 11 and 12 of the winding pads 3 are connected here.

[0057] Figure 8 The wiring for the four parallel branches for each end face is schematically shown, and Figure 9 The wiring for the two parallel branches for each end face is shown. Different profiles are intended to clearly identify the different conductors of the winding stack 13. Furthermore, the associated lateral deviations in the winding heads are shown for each connecting conductor level in the matrix, and alternate continuously as desired. The reversal of the conductor arrangement when the layers are changed has the effect that the conductor arrangement in the two connecting conductor planes of the winding pad 3 is also reversed in the connected region. In the case of four parallel branches, the connection contact is made in the top connecting conductor level and the bottom connecting conductor level. Between the top and bottom connecting conductor levels, the corresponding overlapping connectors of the different winding pads 3 are connected in series with each other. This connection concept can be applied to any other number of gaps, wherein the number of parallel branches for each end face must correspond to the number of gaps.

[0058] exist Figures 10 to 15The diagram shows a total of six different embodiments of a stator body formed as a chain referred to as a toothed chain 15. What all these types are similar in is that the stator body initially has two axially oriented end faces 18 on the circumference, which, after being fitted with the winding stack 13, can be joined to each other, for example by welding, so that the stator body is given a cylindrical shape.

[0059] According to Figure 10 In the first embodiment, each stator tooth 17 and stator groove 16 is also provided with reference numerals in the toothed chain.

[0060] According to Figure 10 In the first embodiment, the toothed chain 15 is in a fully linearly extended form, allowing for assembly with the winding stack 13 in a manner similar to that in the case of a linear motor. Each individual stator tooth 17 has a clearance at a certain angle that is substantially the same for all teeth. This clearance is sized such that it is fully utilized when the linear silent chain 15 is bent into the closed cylindrical shape of the linear silent chain.

[0061] According to Figure 11 In the second embodiment, this flexibility in the circumferential direction is provided only in the linearly extending region of the laminated stator core. This region is adjacent to the rigid section of the stator body that has been formed into a semi-circular arc.

[0062] According to Figure 12 In the third embodiment, on the other hand, two rigid stator body halves with semi-circular cross sections are hinged to each other at a point opposite to the joint of the two end faces 18.

[0063] According to Figure 13 In the fourth embodiment, the hinge point is realized by means of the area of ​​the four hinged stator teeth 17 opposite to the joint portion.

[0064] and Figure 13 In comparison, in the fifth and sixth embodiments ( Figure 14 and Figure 15 The area of ​​the articulated stator teeth 17 is expanded at the expense of the extension of the rigid, arcuate stator area.

[0065] List of reference numerals 1. Stator 2 Stator body 3 Winding pads Group 1: 4, 5, 13 6-wave winding conductor 7. Groove section 8. Head segment 9. Axis of symmetry 10. Head tip of winding 11 First Sub-winding Pad 12 Second Sub-winding Pad 13 Winding stack 14 Connecting conductors 15. Toothed chain 16 Stator Grooves 17. Stator teeth 18. End face.

Claims

1. A stator (1) of an electric generator, the stator comprising a stator body (2) having a stator groove (16) and at least one winding pad (3) having a grooved section (7) and a head section (8), the grooved section being arranged in the stator groove (16) and located one after another in different radial positions, the head section being connected to the grooved section, wherein, • Each wave winding conductor (6) undergoes a radial positional shift in the center of its extension along the winding direction within the stator recess (16). At least some regions of the head segment (8) of each wave winding conductor (6) extend offset relative to the corresponding connected recess segment (7) along the direction of the recess opening on one side of the positional shift and offset relative to the corresponding connected recess segment (7) along the direction of the recess base on the other side of the positional shift. Each time, the maximum offset of the head segment (8) corresponds to half the radial extension of the recess segment along the stator recess. • The winding pad includes a first sub-winding pad (11) which includes a first group (4, 5, 13) of wave winding conductors (6) for each branch, the first group (4, 5, 13) being joined together in an X-shape in the layer-change region such that at the intersection between the wave winding conductor (6) of the first branch and the wave winding conductor of the second branch, on one side of the layer-change, the wave winding conductor (6) of the first branch is constantly positioned above the wave winding conductor of the second branch, and on the other side, the wave winding conductor (6) of the second branch is constantly positioned above the wave winding conductor of the first branch.

2. The stator (1) according to claim 1, wherein, Each group (4, 5, 13) has q consecutive wave winding conductors (6), the consecutive wave winding conductors having grooved sections (7) distributed above the grooved blocks of q adjacent stator grooves (16) of each pole.

3. The stator (1) according to claim 2, wherein, The order of the grooved segments (7) of the different wave winding conductors (6) in the group is interchanged between the groove blocks such that each winding conductor (6) occupies each of the q optional circumferential positions in the groove block the same number of times.

4. The stator (1) according to any one of claims 3, wherein, The number of pole pairs p of the stator is an integer multiple of q.

5. The stator (1) according to claim 1, comprising a second sub-winding pad (12), the second sub-winding pad comprising a second set of wave winding conductors for each branch, wherein, The second group is combined in an X-shape in the region of the layer change, such that at the intersection between the wave winding conductor (6) of the first branch and the wave winding conductor of the second branch, on one side of the layer change, the wave winding conductor (6) of the first branch is always above the wave winding conductor of the second branch, and on the other side, the wave winding conductor (6) of the second branch is always above the wave winding conductor of the first branch.

6. The stator (1) according to claim 5, wherein, The second sub-winding pad (12) is rotated 180 degrees relative to the first sub-winding pad (11) about an axis oriented along the winding direction in a linearly deployed state, wherein the first sub-winding pad (11) and the second sub-winding pad (12) are joined together in an X-shape in the region of layer change, such that the wave winding conductor (6) of the first sub-winding pad (11) is constantly located above the wave winding conductor (6) of the second sub-winding pad (12) on one side of the layer change and constantly located below the wave winding conductor (6) of the second sub-winding pad (12) on the other side of the layer change.

7. The stator (1) according to claim 1, wherein, The extension of the winding pad along the winding direction corresponds to the inner circumference of the stator.

8. The stator (1) according to claim 1, wherein, The wave winding conductor (6) of the group (4, 5, 13) in the linear extension state has axial symmetry with respect to the cross scheme of the head section (8) and has a symmetry axis (9) parallel to the orientation of the groove section.

9. The stator (1) according to any one of the preceding claims, wherein, The stator body (2) has a toothed chain (15) bent into a cylindrical shape, the toothed chain having at least one axially extending joint where the ends of the bent toothed chain are connected to each other.

10. An electric generator comprising a stator (1) according to any one of the preceding claims.

11. A method for producing winding pads (3) for the stator (1) of an electric generator, wherein, The first sub-winding pad (11) is produced by the following steps: • A first group (4, 5, 13) of q wave-shaped winding conductors (6) is provided for each branch of the stator (1), wherein each wave-shaped winding conductor (6) has a grooved section (7) and a head section (8) connecting the grooved section (7), each wave-shaped winding conductor (6) undergoes a radial positional shift in the center of its extension along the winding direction in the stator groove (16), at least one region of the head section (8) of each wave-shaped winding conductor (6) extends offset relative to the connected grooved section (7) along the direction of the groove opening on one side of the positional shift, and extends offset relative to the connected grooved section (7) along the direction of the groove base on the other side of the positional shift, wherein each offset corresponds to half the radial extension of the grooved section along the stator groove. • Arrange the q wave winding conductors (6) such that the groove segments (7) of the corresponding wave winding conductors (6) follow each other at a distance of two stator grooves (16), and • All the first groups (4, 5, 13) are combined in an X-shape to form the first sub-winding pad (11), such that when viewed along the winding direction, the wave winding conductor (6) changes position in the central region of the extension of the wave winding conductor, such that at the intersection of the wave winding conductor (6) of the first branch and the wave winding conductor of the second branch, on the side of the layer change, the wave winding conductor (6) of the first branch is constantly above the wave winding conductor of the second branch, and on the other side, the wave winding conductor (6) of the second branch is constantly above the wave winding conductor of the first branch.

12. The method of claim 11, further comprising the following additional method steps: • Produce the second sub-winding pad (12) in the same manner as the first sub-winding pad (11). • The first sub-winding pad (11) and the second sub-winding pad (12) are joined together, wherein, The wave winding conductor (6) of the first sub-winding pad (11) is positioned below the wave winding conductor of the second sub-winding pad (12) before the layer change and above the wave winding conductor of the second sub-winding pad after the layer change.

13. The method according to claim 12, wherein, The second sub-winding pad (12) is rotated 180 degrees relative to the first sub-winding pad (11) about an axis oriented along the winding direction, and wherein the first sub-winding pad (11) and the second sub-winding pad (12) are joined together in an X-shape in the region of the layer change.

14. The method according to any one of claims 11 to 13, wherein, The order of the grooved segments (7) of the different wave winding conductors (6) in the group is interchanged between the head segments (8) such that each winding conductor (6) occupies each of the q optional positions the same number of times.

15. The method according to claim 14, wherein, The stator body (2) is manufactured as a linearly extended toothed chain, which is bent into a cylindrical shape after being fitted with the winding pad (3).

16. The method according to claim 11, wherein, The extension of the winding pad (3) along the winding direction corresponds to the inner circumference of the stator (1).

17. The method according to claim 11, wherein, The wave winding conductors (6) in groups (4, 5, 13) are arranged relative to each other such that the cross scheme of the wave winding conductors relative to the head section (8) is axially symmetrical and has an axis of symmetry (9) parallel to the orientation of the groove section.

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