Stator for an electric machine and electric machine

Abstract

A stator (1) for an electrical machine (101), wherein - the stator (1) has N ≥ 3 phases (U, V, W), P ≥ 2 pole pairs, and q ≥ 1 slots, - the stator (1) comprises a stator core (3) having at least 2NPq slots (4) and a number of 2NPqL shaped conductors (5) arranged in an even number of L ≥ 4 layers (6a-h) radially stacked in the slots (4), - the shaped conductors (5) form 2q paths (7a-d) for each phase and are arranged in 2P winding sections (8), each winding section extending radially across L layers (6a-h) and extending across at least q directly adjacent slots (4) in a circumferential direction, - the shaped conductors (5) of each path are connected in a series circuit provided by connectors (9a-e, 10a-f, 11a-g) arranged at both end faces (2a, 2b) of the stator core, - each path comprises L / 2 groups (12a-d) of shaped conductors (5) connected in series in turn, - each group (12a-d) is formed by at least one arrangement (13a, 13b) of at least four shaped conductors (5) arranged alternately in two immediately adjacent layers (6a-g) and connected in series by a first connector (9a-e) providing an offset of qN slots (4) and an offset of one layer, and - pairs of groups (12a-d) adjacent with respect to the series connection are each connected by a second connector (10a-f) providing an offset of a number of slots (4) and an offset of two layers.

Description

Technical Field

[0001] This invention relates to a stator for an electric motor. Furthermore, this invention relates to an electric motor. Background Technology

[0002] Document US 2015 / 0244227 A1 discloses a stator having a stator core and stator windings. The stator core has a plurality of circumferentially arranged slots. The stator windings are formed by a plurality of phase windings inserted into the slots and wound around the stator core. The stator core has n (n is a natural number greater than or equal to 2) in-phase slots arranged sequentially in the circumferential direction to correspond to the magnetic poles of the rotor. In-phase phase windings are installed in each in-phase slot. Each phase winding is divided into 2n parts from one end in the extension direction to the other, such that each phase winding is formed by a first part winding, a second part winding, up to a 2n part winding, which are connected in series from one end in the extension direction. The first part winding and the 2n part winding are arranged in different in-phase slots of the stator core.

[0003] In the case of stators with stator windings formed of shaped conductors, the challenges, particularly for automotive applications, are: providing the required number of winding paths that can be connected in parallel or series while meeting symmetry requirements; providing the minimum possible winding overhang in the axial direction; offering simple connection options for the phases; and enabling high process reliability for automated manufacturing processes. Furthermore, it is desirable to have a large number of layers per slot (with the shaped conductors arranged in radial layers) to allow for the use of flat conductors, which enables low losses at high frequencies. Summary of the Invention

[0004] The purpose of this invention is to provide a stator suitable for automotive applications, which has multiple paths and a relatively high number of layers per slot.

[0005] According to the invention, this objective is achieved by a stator for an electric motor, wherein the stator has N phases, P pole pairs, and q holes, where N ≥ 3, P ≥ 2, and q ≥ 1; wherein the stator comprises a stator core having at least 2·N·P·q slots and 2·N·P·q·L shaped conductors, these shaped conductors being arranged in L layers radially stacked in the slots, where L ≥ 4 and is an even number; wherein the shaped conductors form 2·q paths per phase, these paths may be connected in series or in parallel, and are arranged as 2P winding regions, each winding region extending radially across L layers and circumferentially across at least q adjacent slots; wherein the shaped conductors of each path form… The conductors are connected in a series circuit provided by connectors arranged at two end faces of the stator core, wherein each path comprises L / 2 groups of continuously connected shaped conductors, wherein each group is formed by at least one arrangement of at least four shaped conductors and by a first connector, the at least four shaped conductors being alternately arranged in two adjacent layers, the first connector providing an offset of q·N slots in each case and an offset of one layer in the radial direction, wherein each of the pairs of adjacent groups connected in series is connected by a second connector providing an offset of multiple slots in the circumferential direction and an offset of two layers in the radial direction.

[0006] The stator according to the invention is characterized in that the forming conductors of each group are alternately arranged in two directly adjacent layers and connected in series, thereby providing shaft windings for each path of the phase. A particularly advantageous symmetry arises from the fact that each pair of adjacent groups connected in series is connected by a second connector, which provides an offset of multiple slots in the circumferential direction and an offset of two layers in the radial direction. This offset of two layers causes the forming conductors of the two groups adjacent to the series connection to alternate in opposite directions within the layers. For example, if the first forming conductor of the first group connected in series is arranged radially outward than the next forming conductor of that group, then the first forming conductor of the next group connected in series is arranged radially inward than the next forming conductor of that group, since the last forming conductor of the first group and the first forming conductor of the next group are connected by the second connector, and so on.

[0007] This results in a particularly advantageous symmetrical arrangement of the groups. It is especially beneficial for automated production because only a smaller number of different types of second connectors are needed to provide the stator winding structure according to the invention.

[0008] The shaped conductor is typically a rod-shaped conductor, especially made of copper. The shaped conductor is typically not flexible. Typically, the L-shaped conductor of the L-layer occupies at least 60%, preferably at least 80%, of the cross-sectional area of ​​the slot. The shaped conductor typically has a rectangular cross-section, which may be rounded. Typically, each winding region provides one pole of the stator. The number of holes q specifically corresponds to the number of directly adjacent slots allocated to a phase of the stator in one layer.

[0009] Typically, N≤12 is true, preferably N≤9, and particularly preferably N≤6. P≤20 can be specified, preferably P≤16, and particularly preferably P≤12. Typically, q≤6 is true, preferably q≤4, and particularly preferably q≤3. More appropriately, L≤16 is specified, preferably L≤12, and particularly preferably L≤8. The number of slots is preferably less than 200, and particularly preferably less than 120.

[0010] In principle, it is advantageous if the forming conductor of each group occupies each winding region once, so that a group forms a complete circumferential circuit. Preferably, with regard to series connection, the first forming conductor in a group is arranged in the same winding region, and the last forming conductor is arranged in the same winding region.

[0011] Although the stator according to the invention can certainly have a number of holes q = 1, it is preferred that q ≥ 2, especially q = 2. In this case, each winding region typically has a first to a qth partial winding region, wherein each partial winding region extends across L layers. The partial winding regions of the winding region are typically directly adjacent to each other in the circumferential direction.

[0012] According to the first preferred variant, each partial winding region extends across exactly one slot. This allows for the provision of straight or full-pitch stators.

[0013] Advantageously, it can be specified that the second connector of the connecting path group provides the same offset for multiple slots. This can improve the symmetry characteristics with respect to the path.

[0014] In a preferred embodiment, it may be specified that the second connector of at least one of the paths, particularly the second connectors of q paths, provides an offset of N·q-1 slots. Alternatively or additionally, the second connector of at least one of the paths, particularly the second connectors of q paths, provides an offset of N·q+1 slots. Thus, the second connectors provide alternation of partial winding regions to improve symmetry characteristics.

[0015] According to an alternative embodiment, advantageously, a stator with string-like windings can be provided, wherein each partial winding region extends across at least two directly adjacent slots and has a number of protrusions V in the radial direction, one protrusion per slot, where V ≥ 1. Typically, V ≤ 6, preferably V ≤ 3, and particularly preferably V ≤ 2. Preferably, in each case, the offset has the same orientation in the circumferential direction and / or appears after the L / [V+1] layer.

[0016] To provide a change in the local winding region via a second connector in a stator with chord windings (which improves symmetry), it can be specified that the second connectors in at least one of the paths provide an offset of N·q-1 slots and / or N·q-1 slots when they do not cover the radial offset. To provide variation in the case of a left-chord stator, it is preferable that the second connectors in at least one of the paths provide an offset of N·q-2 slots and / or N·q slots when they cover the radial offset. To provide variation in a right-chord stator, it is preferable that the second connectors in at least one of the paths provide an offset of N·q+2 slots and / or N·q slots when they cover the radial offset.

[0017] Particularly advantageously, when the stator has q ≥ 2 holes, each group can be specified to include q arrangements, each arrangement being placed in a different partial winding region within a partial winding region. Particularly preferred is that, relative to a series connection, directly adjacent arrangements within a group are connected by a third connector, which provides an offset of slots in the circumferential direction not equal to N·q, and an offset of one layer in the radial direction. In this way, the variation in the partial arrangement regions of adjacent arrangements is provided along with the simultaneous continuation of the shaft winding.

[0018] For reasons of symmetry, it is preferable that the third connector of the path provides the same offset in the circumferential direction.

[0019] In addition, it can be specified that at least one of the third connectors in the path provides an offset of N·q+1 slots, and / or at least one of the third connectors in the path provides an offset of N·q-1 slots.

[0020] If the third connectors of different paths connecting the same winding regions of the shaped conductors in the same layer are arranged in such a way that the third connector that provides a smaller offset of the plurality of slots than the other third connector is arranged more axially inward than the other third connector, a particularly low winding overhang can be achieved.

[0021] In the stator according to the invention, if the second connectors of different paths (the second connectors connecting the shaped conductors between the same winding regions and in the same layer) are arranged in such a way that the second connectors providing an offset of less than the other second connector of the plurality of slots are arranged to be axially more inward than the other second connector, a particularly small winding overhang can preferably be achieved.

[0022] In other words, two second or third connectors are arranged so that one is inside the other, so that the axially available installation space is effectively utilized. The second and third connectors may extend parallel and / or equidistantly relative to their positions in the radial and / or circumferential directions.

[0023] If the paths of q sets of the same size relative to the series connection have the same connector sequence, and the paths of each set are offset from each other by N·q slots, then the reduction in winding overhang is also beneficial. In this way, it is possible to ensure that the second or third connector of one set of paths is not arranged in the same position in the circumferential direction as the second or third connector of other sets of paths.

[0024] Advantageously, the stator according to the invention can also be specified such that each connector arranged at one end face of the stator core is integrally formed with a shaped conductor connected therethrough, and the connector arranged at the other end face of the stator core is formed by the connection of the free ends of connecting elements, preferably integrally formed with and adjacent to the shaped conductor. In this way, hairpin windings can be provided, which is particularly advantageous from a manufacturing point of view. The corresponding arrangement including connectors, two shaped conductors and connecting elements is also referred to as "U-shaped pins". Alternatively, it is conceivable that the connectors and / or connecting elements are not integrally formed with the shaped conductor, but are fastened to the shaped conductor, for example, by fastening devices such as screws or rivets.

[0025] Preferably, the first connectors of one arrangement are alternately formed integrally with the shaped conductors connected therethrough on one hand, and formed through the connection of connecting elements on the other hand. Preferably, all the second and / or all the third connectors are formed integrally with the shaped conductors connected therethrough.

[0026] In this configuration, each connector located at the first end face preferably has two protrusions extending in both the axial and circumferential directions, particularly at an obtuse angle. Preferably, each protrusion extends along a predetermined radial position. The protrusions may be connected by a transition portion that creates a radial offset.

[0027] Each connecting element preferably includes a protrusion extending in both the axial and circumferential directions. The protrusions may be abutted by a connecting portion extending in the axial direction, at which a connecting element is provided with another connecting element, thereby forming a first connector at another end face.

[0028] In an advantageous embodiment of the stator according to the invention, each outer shaped conductor of the path may also be provided, relative to a series connection, to have a free end protruding at one of the end faces of the stator core, and a connecting element abutting the shaped conductor at the other end face, the free end of which is provided with a connecting element abutting a second outer shaped conductor of the path. Thus, the connecting element can be used to connect the paths particularly conveniently.

[0029] According to a preferred embodiment of the stator of the invention, the path of each phase is connected to the star point of the phase. Alternatively, the path of each phase may be connected to multiple star points of the phase, particularly two star points.

[0030] Advantageously, the stator also includes a connection device that is connected to the outer shaped conductor relative to the series connection and forms a phase connection and / or one or more star point connectors.

[0031] According to a preferred embodiment, the following conditions apply: N = 3, P = 4, q = 2, and L = 8. Preferably, V = 1. Thus, typically, the number of slots is 48.

[0032] According to the invention, the objective forming the basis of the invention is also achieved by an electric motor comprising a stator according to the invention and a rotor rotatably arranged within the stator. The motor is preferably an electric motor. The motor is preferably a rotary motor. The motor is typically classified as a rotating magnetic field motor. In advantageous embodiments, the motor is a synchronous motor, particularly a permanently excited synchronous motor, or an asynchronous motor.

[0033] The objective that forms the basis of this invention can also be achieved by a vehicle comprising an electric motor according to the invention, the motor being configured to drive the vehicle. The vehicle is preferably a partially or fully electric vehicle, such as a hybrid vehicle or a battery electric vehicle (BEV). Attached Figure Description

[0034] Further features and details of the invention will become apparent from the embodiments described below and from the accompanying drawings. These are illustrative and shown:

[0035] Figure 1 This is a perspective view of a first exemplary embodiment of the stator according to the present invention;

[0036] Figure 2 yes Figure 1 A detailed view of the stator in the region of the first end face of the stator;

[0037] Figure 3a and 3b yes Figure 1 A schematic diagram of the winding of one phase of the stator shown;

[0038] Figure 4-7 They are respectively by Figure 1 The first connector of the stator shown connects two shaped conductors;

[0039] Figure 8-13 They are respectively by Figure 1 The second connector of the stator shown connects two shaped conductors;

[0040] Figure 14 It is by Figure 1 The first and third connectors of the stator shown connect multiple shaped conductors;

[0041] Figures 15 to 22 They are connected via a third connector. Figure 1 The stator shown has two shaped conductors;

[0042] Figure 23 This is a front view of the first end face of the first exemplary embodiment;

[0043] Figure 24a and 24b This is a schematic diagram of the winding of a second exemplary embodiment of the stator according to the present invention;

[0044] Figure 25 This is a front view of the first end face of the second exemplary embodiment;

[0045] Figure 26a and 26b This is a schematic diagram of the winding of a third exemplary embodiment of the stator according to the present invention;

[0046] Figure 27 This is a front view of the first end face of the third exemplary embodiment;

[0047] Figure 28 and 29 These are circuit diagrams of the stator paths according to the first to third exemplary embodiments; and

[0048] Figure 30 This is a schematic diagram of an exemplary embodiment of an electric motor for driving a vehicle according to the present invention. Detailed Implementation

[0049] Figure 1 and Figure 2 Each shows a first exemplary embodiment of stator 1, wherein Figure 1 It is a partial perspective view. Figure 2This is a detailed view of the area of ​​the first end face 2a of stator 1.

[0050] The stator 1 has three phases U, V, W (N=3), four pole pairs (P=4), and a quantity of two (q=2). The stator includes a stator core 3 with 48 slots 4 and 384 shaped conductors 5, which are arranged in eight radially stacked layers 6a to 6h (L=8) in the slots 4. Here, the first layer 6a is the outermost radial layer, the eighth layer 6h is the innermost radial layer, and the second to seventh layers 6b to 6g are indicated by their index from the outside to the inside.

[0051] The shaped conductor 5 forms four paths 7a to 7d for each phase U, V, W, which can be connected in series or in parallel. The shaped conductor 5 is also arranged into 16 winding regions 8, each extending radially across layers 6a to 6h and circumferentially across two directly adjacent slots 4. Here, the number of winding regions corresponds to twice the number of pole pairs, i.e., the number of poles, and the number of adjacent slots 4 to which the winding region 8 extends corresponds to the number of holes q. Each winding region 8 is further subdivided into multiple partial winding regions 8a, 8b corresponding to the number of holes q, which extend across all layers 6a to 6h and are adjacent in the circumferential direction. In this exemplary embodiment, the stator 1 is formed as a non-chorded stator, so each partial winding region 8a, 8b includes exactly one slot 4.

[0052] The shaped conductors 5 of each path 7a to 7d are connected in series, which is provided by connectors arranged at the two end faces 2a and 2b of the stator core 3. Here, first connectors 9a to 9e, second connectors 10a to 10f, and third connectors 11a to 11h are provided.

[0053] Figure 3a and Figure 3b A schematic diagram of the windings of stator 1 according to a first exemplary embodiment is shown.

[0054] exist Figure 3a and Figure 3b In the top row, the numbers "1" to "48" for slot 4 are indicated in a clockwise direction relative to end face 2a, where... Figure 3a and Figure 3bThe division is between the numbers "22" and "23" in slot 4. Referring to slot 4 and layers 6a to 6h, the table above shows the starting and ending points of paths 7a to 7d for phases U, V, and W, respectively. U+, V+, and W+ represent winding regions 8 through which the forming conductor 5 passes along the first current direction, and U-, V-, and W- represent winding regions 8 through which the forming conductor 5 passes along a second current direction opposite to the first current direction. Below the table, for each of the paths 7a to 7d for phase U, the position of the forming conductor 5 in the winding region 8 is shown in each case. Here, the first connectors 9a to 9d, the second connectors 10a to 10f, and the third connectors 11a to 11h at the first end 2a are indicated by dashed arrows, and the first connector 9e at the second end 2b is indicated by a solid arrow. From Figure 3a and Figure 3b As can be seen, each path 7a to 7d includes multiple groups 12a to 12d of continuously connected shaped conductors 5, corresponding to half the number of layers 6a to 6g. Here, the symbol "x" indicates the ends of paths 7a to 7d, i.e., relative to the outer shaped conductors 5 connected in series, and these ends can be connected to the connecting portion. The symbol "o" indicates the corresponding ends of paths 7a to 7d, which are connected to form a star point. The remaining shaped conductors 5 are marked with the symbol "+".

[0055] Each pair of adjacent groups 12a to 12d connected in series is connected via one of the second connectors 10a to 10f. Each of the second connectors 10a to 10f provides an offset of two layers 6a to 6h in the radial direction. The second connectors 10a, 10e, and 10e in paths 7a and 7c provide an offset of five (N·q-1) slots 4 in the circumferential direction, while the second connectors 10b, 10d, and 10f in paths 7b and 7d provide an offset of seven (N·q+1) slots 4 in the circumferential direction. Therefore, in specific paths 7a to 7d, the first group 12a is located in the eighth layer 6h and the seventh layer 6g, the second group 12b is located in the sixth layer 6f and the fifth layer 6e, the third group 12c is located in the fourth layer 6d and the third layer 6c, and the fourth group 12d is located in the second layer 6b and the first layer 6a. Thus, in each winding region 8 of phases U, V, and W, there is exactly one shaped conductor 5 of one group 12a to 12d. In other words, the shaped conductors 5 of group 12a to 12d form a circumferential circuit.

[0056] Each group 12a to 12d is formed by two arrangements 13a, 13b of four shaped conductors 5, which are alternately arranged in two adjacent layers 6a to 6h and connected in series by first connectors 9a to 9e. For example, the first arrangement 13a of the first path 7a thus includes shaped conductors 5 arranged in the eighth layer 6h and the seventh layer 6g, as well as in slots numbered "19", "25", "31", and "47". Correspondingly, the second arrangement 13b of the first path 7a includes shaped conductors 5 arranged in the eighth layer 6h and the seventh layer 6g, as well as in slots numbered "44", "2", "8", and "14". Each first connector 9a to 9e between two directly adjacent shaped conductors relative to the series connection of arrangements 13a, 13b provides an offset of six slots 4 in the circumferential direction and an offset of one layer 6a to 6h in the radial direction.

[0057] Arrangements 13a and 13b are located in different sections of the two partial winding regions 8a and 8b of the winding region 8, respectively. Here, the first arrangement 13a of the first path 7a and the fourth path 7d is located in the first partial winding region 8a of the winding region 8, and the first arrangement 13b of the second path 7b and the third path 7c is located in the second partial winding region 8b of the winding region 8. Correspondingly, the second arrangement 13b of the first path 7a and the fourth path 7d is located in the second partial winding region 8b of the winding region 8, and the second arrangement 13b of the second path 7b and the third path 7c is located in the first partial winding region 8b of the winding region 8.

[0058] Arrangements 13a and 13b of groups 12a to 12d are connected via one of the third connectors 11a to 11g. The third connectors 11a, 11c, 11e, and 11g provide an offset of seven (N·q+1) slots 4, while the third connectors 11b, 11d, 11f, and 11h provide an offset of five (N·q-1) slots 4. Therefore, the third connectors 11a, 11c, 11e, and 11g are configured to connect arrangements 13a and 13b arranged in the first partial winding region 8a to arrangements 13a and 13b arranged in the second partial winding region 8b, while the third connectors 11b, 11d, 11f, and 11h are configured to connect arrangements 13a and 13b arranged in the second partial winding region 8b to arrangements 13a and 13b arranged in the first partial winding region 8a. To ensure continuous variation between adjacent layers 6a to 6h, only third connectors 11a, 11c, 11e, and 11g providing offsets of seven slots 4 are provided in the first path 7a and the third path 3c, and only third connectors 11b, 11d, 11f, and 11h providing offsets of five slots 4 are provided in the second path 7b and the fourth path 7d.

[0059] like Figure 3a and Figure 3bAs further shown, paths 7a to 7d are subdivided into multiple sets 14a, 14b corresponding to the number of holes q, i.e., two sets 14a, 14b in this example, wherein the first set 14a includes the first path 7a and the second path 7b, and the second set 14b includes the third path 7c and the fourth path 7d. The two sets 14a, 14b have the same connectors 9a to 9e, 10a to 10f, 11a to 11g in the same order, but are separated by a winding zone 8 or by six (N·q) slots 4 offset from each other in the circumferential direction.

[0060] Therefore, from the overall view of paths 7a to 7c, the winding region 8 of phase U is completely occupied by the shaped conductor 5. This means that in each partial winding region 8a, 8b of the winding region, all layers 6a to 6h are occupied by the shaped conductor 5. The winding regions 8 of the other phases V and W are similarly occupied by the shaped conductor 5, which is connected by corresponding connectors 9a to 9e, 10a to 10f, and 11a to 11g.

[0061] Figures 4 to 13 and Figures 15 to 22 Two shaped conductors 5 are shown, each connected by connectors 9a to 9d, 10a to 10f, and 11a to 11g.

[0062] Figure 4 Two shaped conductors 5 are shown, arranged parallel to each other, and formed as a single piece with a first connector 9a. The first connector 9a includes two protrusions 15a and 15b projecting from the associated shaped conductor 5 at an obtuse angle. The protrusions 15a and 15b extend circumferentially and axially at their radial positions from which they project from the shaped conductor 5. Figure 2 It can also be seen that the protruding parts 15a and 15b therefore have an arc shape.

[0063] The protruding portions 15a and 15b are connected to each other via a transition portion 16 at their ends facing away from the formed conductor 5. The transition portion 16 provides an offset in the radial direction. Therefore, the transition portion 16 extends substantially in both the circumferential and radial directions.

[0064] A connecting element 17, integrally formed with the forming conductor 5, is connected to the forming conductor 5 at the end opposite to the first connector 9a. The connecting element 17 includes a protrusion 18 that protrudes from the forming conductor 5 at an obtuse angle. The protrusion 18 extends from its protruding radial position on the forming conductor 5 and bends radially outward in both the circumferential and axial directions. Figure 1 As can be seen, the protruding portion 18 therefore has an arc shape. Adjacent to the protruding portion 18 is the connecting portion 19, which extends essentially only in the axial direction.

[0065] The first connector 9e, located at the second end face 2b, is formed by integrally joining the connecting portions 19 of the connecting element 17, for example by welding, which, relative to a series connection, brings two consecutive shaped conductors 5 abutting each other. In this case, the connecting portions 19 are arranged such that their flat sides are parallel to each other. The fact that the protruding portion 18 of the connecting element 17 bends outward ensures a sufficient insulating distance between the two radially adjacent first connectors 9e.

[0066] Figures 5 to 13 and Figures 15 to 22 The other components of the stator 1 shown correspond in their structure to Figure 4 The component shown, the structure includes two shaped conductors 5, connectors 9b to 9d, 10a to 10f, 11a to 11g, and two connecting elements 17. Connectors 9b to 9d, 10a to 10f, 11a to 11g have protrusions 15a, 15b and transition portions 16. Each connecting element 17 includes a protrusion 18 and a connecting portion 19, wherein different offsets in the radial and / or circumferential directions are provided in each case. Although the protrusions 15a, 15b, 18 are shown obliquely here, i.e., with a constant spacing in the axial direction, the protrusions 15a, 15b, 18 may have different forms, individually or separately, for example, they may be bent along the axial direction.

[0067] Figures 4 to 7 The first connectors 9a to 9d shown each have six slots 4 offsets and one layer 6a to 9h offsets in the circumferential direction. Figure 4 The first connector 9a shown provides an offset from the eighth layer 6h to the seventh layer 7g. Figure 5 The first connector 9b shown provides an offset from the fifth layer 6e to the sixth layer 6f. Figure 6 The first connector 9c shown provides an offset from the fourth layer 6d to the third layer 6d. Figure 7 The first connector 9d shown provides an offset from the first layer 6a to the second layer 6b.

[0068] Figures 8 to 12 The shaped conductors 5 connected by the second connectors 10a to 10f are shown respectively.

[0069] Figure 8 The second connector 10a is shown. Figure 9 The second connector 10b is shown. Both connectors 10a and 10b provide a radial offset from the eighth layer 6h to the sixth layer 6f. The second connector 10a provides an offset of five slots 4 in the circumferential direction, while the second connector 10b provides an offset of seven slots 4. From Figure 8 and Figure 9The comparison shows that the second connector 10a is shorter in the axial direction than the second connector 10b. As a result, the second connector 10a in the first path 7a can be arranged further inward in the axial direction at the same radial position than the second connector 10b in the second path 7b. This similarly applies to the second connector 10a in the third path 7c and the second connector 10b in the fourth path 7d.

[0070] Figure 10 The second connector 10c is shown. Figure 11 The second connector 10d is shown. The two second connectors 10e and 10d provide an offset in the radial direction from the fifth layer 6e to the third layer 6c. Figure 12 The second connector 10e is shown. Figure 13 The second connector 10f is shown. Both second connectors 10e and 10f provide a radial offset from the fourth layer 6d to the second layer 6b. Similar to second connectors 10a and 10b, second connectors 10c and 10e provide an offset of five slots 4 in the circumferential direction, and second connectors 10d and 10f provide an offset of seven slots 4 in the circumferential direction. Similarly, second connectors 10c and 10e are shorter in the axial direction than second connectors 10d and 10f, such that second connectors 10c and 10e in the first path 7a and third path 7c are arranged further inward in the axial direction at the same radial position than second connectors 10d and 10f in the second path 7b and fourth path 7d.

[0071] Figure 14 The connection between the first connectors 9a to 9d and the third connectors 11a to 11c, 11e, and 11g is shown. Figure 1 The stator phase W shown has multiple shaped conductors 5, wherein the third connectors 11d, 11f, and 11h are in Figure 14 It is hidden in the view shown.

[0072] It can be clearly seen that the third connector 11b is arranged further inward axially than the third connector 11a to reduce the outward extension of the winding. Like the third connector 11b, the third connector 11a also connects to the shaped conductors 5 arranged in the seventh layer 6g and the eighth layer 6h. This correspondingly applies to the arrangement of the third connectors 11c and 11d connecting the shaped conductors 5 arranged in the fifth layer 6e and the sixth layer 6f, to the arrangement of the third connectors 11e and 11f connecting the shaped conductors 5 arranged in the third layer 6c and the fourth layer 6d, and to the arrangement of the third connectors 11g and 11h connecting the shaped conductors 5 arranged in the first layer 11a and the second layer 11b.

[0073] Regarding the generally U-shaped structure of the paired shaped conductors 5 connected by the third connectors 11a to 11h, this axial arrangement of the paired shaped conductors 5 can also be referred to as a "conductor in U-in-U" or a "pin with U-inside-U". Based on Figure 14 The explanation regarding the third connectors 11a to 11h can also be applied to the arrangement of the second connectors 10a to 10f.

[0074] Figures 15 to 22 The shaped conductors 5 connected by the third connectors 11a to 11h are shown respectively.

[0075] Figure 15 The third connector 11a is shown. Figure 16 The third connector 11b is shown. Both connectors 11a and 11b provide an offset in the radial direction from the eighth layer 6h to the seventh layer 6g. The third connector 11a provides an offset of seven slots 4 in the circumferential direction, while the third connector 11b provides an offset of five slots 4. From Figure 15 and Figure 16 As can be seen from the comparison, the third connector 11a is shorter in the axial direction than the third connector 11b, so that the third connectors 11a and 11b are arranged in the same radial position as described above, one inside the other in the axial direction.

[0076] Figure 17 The third connector 11c is shown. Figure 18 The third connector 11d is shown. The two third connectors 11c and 11d provide an offset in the radial direction from the fifth layer 6e to the sixth layer 6f. Figure 19 The third connector 11e is shown. Figure 20 The third connector 11f is shown. Both the third connectors 11e and 11f provide an offset in the radial direction from the fourth layer 6d to the third layer 6c. Figure 21 The third connector 11g is shown. Figure 22 The third connector 11h is shown. Both third connectors 11g and 11h provide an offset in the radial direction from the first layer 6a to the second layer 6b. Similar to third connectors 11a and 11b, third connectors 11c, 11e, and 11g provide an offset of seven slots 4 in the circumferential direction, and third connectors 11d, 11f, and 11h provide an offset of five slots 4 in the circumferential direction.

[0077] Therefore, the multi-path winding structure of stator 1 can be provided with only four types of first connectors 9a to 9d, six types of second connectors 10a to 10f, and eight types of third connectors 11a to 11h. Since the shaped conductors 5 connected by the aforementioned connectors 9a to 9d, 10a to 10f, and 11a to 11h can be the same, the relatively small number of conductors of only 18 types makes it easy and highly automated to manufacture stator 1. Furthermore, the shaped conductors 5 outside the series-connected paths 7a to 7d are located in a smaller connection window (see...). Figure 3a and Figure 3b The slots 4 (numbered 13 to 34) in the middle mean that space-saving connection devices can be used. It is also advantageous that... Figure 3a and Figure 3b The outer formed conductor 5 marked with "o" (which can be used to connect to the star point connector) has only one intersection point with the formed conductor 5 marked with "x" (which can be used as a phase connection to the inverter), which simplifies the design structure of the connection device.

[0078] Refer again Figure 2 It can be seen that some of the shaped conductors 5 in the first layer 6a and the seventh layer 6g of some grooves 4 at the first end face 2a are not connected by the first connectors 9a to 9d, the second connectors 10a to 10f, or the third connectors 11a to 11h. In these areas, shaped conductors 5 are positioned outside the paths 7a to 7d relative to the series connections. These outer shaped conductors... Figure 3a and Figure 3b The symbols “o” and “x” are used to mark them.

[0079] These shaped conductors 5 protrude from the stator core 3 at their free ends at the first end face 2a, extending beyond the transition portion 16 (see...). Figure 4 The free end of the outer shaped conductor 5 has an obtuse-angled protrusion 20a extending in both the axial and circumferential directions, and a straight portion 20b adjacent to the protrusion 20a and extending further in the axial direction than the transition portion 16. The straight portion 20b is used for electrical connection to the connecting device.

[0080] like Figure 4 As shown, a connecting element 17 having a protruding portion 18 and a connecting portion 19 is connected to the second end face 2b of the outer shaped conductor 5. The connecting portion 19 is integrally connected to the connecting portion 19 of the second outer shaped conductor 5 of the corresponding paths 7a to 9d.

[0081] at last, Figure 1 and Figure 2Also shown is a slot box 20c extending through the slot 4, which surrounds the shaped conductor 5 and lines the slot 4. The slot box is used to electrically insulate the shaped conductor 5 from the stator core 3. Generally, the slot box 20c is made of insulating paper.

[0082] Figure 23 This is a front view of the first end face 2a of the stator 1. Specifically, the first connectors 9a to 9d, the second connectors 10a to 10f, and the third connectors 11a to 11h can be seen here.

[0083] Figure 24a and Figure 24b A schematic diagram of the windings of a second exemplary embodiment of the stator 1 is shown. The representation corresponds to... Figure 3a and Figure 3b The interpretation of the first exemplary embodiment can be transferred to the second exemplary embodiment, provided that the following description does not deviate from this. Components that function the same or similarly herein have the same reference numerals.

[0084] According to the second exemplary embodiment, the stator 1 is a left-chorded stator 1. Therefore, each partial winding region 8a, 8b extends across at least two directly adjacent slots 4, wherein each partial winding region has an offset of one slot 4 (V = 1) in the radial direction. Viewed radially inward to radially outward, the offset in the winding region 8 has a leftward or counterclockwise orientation when viewed from the first end face 2a in each case, and appears after the four layers 6e to 6h (L / 2).

[0085] To provide this left-hand stator 1, first connectors 9a to 9d and third connectors 11a to 11h, as described in the first exemplary embodiment, are used, and they are arranged to be circumferentially offset by a slot 4, only beyond the offset in the first layer 6a to the fourth layer 6d.

[0086] Regarding the second connectors 10a to 10f, the following deviations occur: Second connectors 10a and 10e, which do not cover the offset in the first path 7a and the third path 7c, provide an offset of five slots 4 (N·q-1), while second connectors 10b and 10f, which do not cover the offset in the second path 7b and the fourth path 7d, provide an offset of seven slots 4 (N·q+1). Second connector 10c, which covers the offset in the first path 7a and the third path 7c, provides an offset of four slots 4 (N·q-2), while second connector 10d, which covers the offset in the second path 7b and the fourth path 7d, provides an offset of six slots 4 (N·q). Therefore, in the second exemplary embodiment, second connectors 10a and 10b, second connectors 10c and 10d, and second connectors 10e and 10f can also be axially arranged one inside the other.

[0087] Figure 25This is a front view of the first end face 2a of the stator 1 according to the second exemplary embodiment. In particular, the first connectors 9a to 9d, the second connectors 10a to 10f, and the third connectors 11a to 11h can be seen.

[0088] Figure 26a and Figure 26b A schematic diagram of the windings of a third exemplary embodiment of stator 1 is shown. The representation corresponds to... Figure 3a and Figure 3b The interpretation of the first exemplary embodiment can be transferred to the third exemplary embodiment, provided that the following description does not deviate from this. Here, components with the same or similar functions have the same reference numerals.

[0089] The stator 1 according to the third exemplary embodiment is a right-chord stator 1. Therefore, each partial winding region 8a, 8b extends across at least two directly adjacent slots 4, wherein each partial winding region has an offset of one slot 4 (V = 1) in the radial direction. From radial inward to radial outward, the offset in the winding region 8 has a rightward or clockwise orientation when viewed from the first end face 2a in each case, and appears after four layers 6e to 6h (L / 2).

[0090] To provide this right-chord stator 1, first connectors 9a to 9d and third connectors 11a to 11h, as described in the first exemplary embodiment, are used. They are arranged to be offset by a slot 4 in the circumferential direction, only beyond the offset in the first layer 6a to the fourth layer 6d.

[0091] Regarding the second connectors 10a to 10f, the following deviations occur: Second connectors 10a and 10e, which do not cover the offset in the first path 7a and the third path 7c, provide an offset of five slots 4 (N·q-1), while second connectors 10b and 10f, which do not cover the offset in the second path 7b and the fourth path 7d, provide an offset of seven slots 4 (N·q+1). Second connector 10c, which covers the offset in the first path 7a and the third path 7c, provides an offset of four slots 4 (N·q), while second connector 10d, which covers the offset in the second path 7b and the fourth path 7d, provides an offset of eight slots 4 (N·q+2). Therefore, in the third exemplary embodiment, the second connectors 10a and 10b, the second connectors 10c and 10d, and the second connectors 10e and 10f can also be arranged axially, one inside the other.

[0092] Figure 27 This is a front view of the first end face 2a of the stator 1 according to the third exemplary embodiment. In particular, the first connectors 9a to 9d, the second connectors 10a to 10f, and the third connectors 11a to 11h can be seen.

[0093] Figure 28 and Figure 29 These are circuit diagrams of paths 7a to 7d of stator 1 according to one of the aforementioned exemplary embodiments.

[0094] Figure 28 As shown, for each phase U, V, W, their paths 7a to 7d are connected in parallel and connected via star point connector 21 to form a star point. Phase connection 22 is disposed on the side opposite to the star point connector 21 of each parallel connection.

[0095] Figure 29 As shown, for each phase U, V, W, their paths 7a to 7d are connected in parallel at one of their ends and connected to phase connector 22. The other ends of paths 7a to 7d are connected in parallel only in pairs, thus forming two star points through two star point connectors 21a and 21b. Here, star point connector 21a connects the first path 7a and the second path 7b of each phase U, V, W, and star point connector 21b connects the third path 7c and the fourth path 7d of each phase U, V, W.

[0096] Figure 28 and 29 The star-shaped connectors 21a, 21b and phase connection 22 shown can be provided by the aforementioned connection device in all the foregoing embodiments, which is disposed at the first end face 2a. Of course, according to alternative embodiments, it is also possible to connect the paths 7a to 7d of phases U, V, W in series and / or provide a delta connection instead of a star connection.

[0097] According to another exemplary embodiment, the stator may also have a number of holes q = 1, whereby the third connector is omitted. Such a stator then has at least P = 4 pole pairs and at least 12 slots. Thus, typically, two paths are provided for each phase.

[0098] According to another exemplary embodiment, the stator may also have a number of holes q = 3. Thus, typically, at least P = 12 pole pairs and at least 108 slots are provided. Thus, typically, six paths are provided for each phase. In each group, three arrangements and two third connectors are provided for the number of holes q = 3, such that each group occupies all three partial winding regions. In each case, the three second and third connectors arranged in the same winding region at the same radial location can then be axially arranged one inside the other, thereby forming a conductor of the shape "U in U, U in U (U-in-U-in-U)".

[0099] Figure 30 This is a schematic diagram of a vehicle 100 having an exemplary embodiment of an electric motor 101.

[0100] The motor 101 includes a stator 1 according to one of the foregoing exemplary embodiments and a rotor 102 rotatably arranged within the stator 1. The motor 101 is a rotating magnetic field motor, such as a permanent magnet synchronous motor or an asynchronous motor. The motor 101 is configured as an electric motor.

[0101] Vehicle 100 is a partially or fully electric vehicle, such as a battery electric vehicle (BEV) or a hybrid vehicle, wherein motor 101 is configured to drive vehicle 100.

[0102] from Figure 3a and Figure 3b It can be seen that groups 12a-d extend in opposite radial directions after the loops around the stator and connectors 10a-10e. As a result, each of the shaped conductors 5 in the latter group 12b-12d, relative to the former group 12a-12c, is alternately located in directly adjacent slots of the same partial winding regions 8a, b, or in slots of the same partial winding regions 8a, b separated by 3 layers.

[0103] For example, the shaped conductor 5 of group 12a is arranged in slot numbered "2" in the eighth layer 6h. The shaped conductor 5 of the next group 12b, also arranged in slot numbered "2", is arranged in the fifth layer 6e. Subsequently, another shaped conductor 5 of group 12a is arranged in slot numbered "8" in the seventh layer 6g. The shaped conductor 5 of the next group 12b, also arranged in slot numbered "8", is arranged in the sixth layer 6f, that is, in the layer directly adjacent to the shaped conductor 5 of group 12a.

Claims

1. A stator (1) for an electrical machine (101), wherein - the stator (1) has a number N of phases (U, V, W), a number P of pole pairs, and a number q of slots, with N > 3 and P > 2 and q > 1, wherein - the stator (1) comprises a stator core (3) having at least 2-N-P-q slots (4) and a number 2-N-P-q-L of shaped conductors (5) arranged in a number L of layers (6a-h) radially stacked in the slots (4), with L > 4 and being even, wherein - the shaped conductors (5) form 2-q paths (7a-d) per phase, which can be connected in series or parallel to each other, and the shaped conductors are arranged in 2P winding sections (8) each extending radially across L layers (6a-h) and in a circumferential direction across at least q directly adjacent slots (4), wherein - the shaped conductors (5) of each path are connected in a series circuit provided by connectors (9a-e, 10a-f, 11a-g) arranged at both end faces (2a, 2b) of the stator core, wherein - each path comprises L / 2 groups (12a-d) of shaped conductors (5) connected in series in turn, wherein - each group (12a-d) is formed by at least one arrangement (13a, 13b) of at least four shaped conductors (5) arranged in two immediately adjacent layers (6a-g) alternately and connected in series by first connectors (9a-e) each providing an offset of q-N slots (4) in the circumferential direction and an offset of one layer in the radial direction, wherein - pairs of groups (12a-d) adjacent with respect to the series connection are each connected by second connectors (10a-f) providing an offset of a number of slots (4) in the circumferential direction and an offset of two layers in the radial direction.

2. The stator of claim 1, wherein - q > 2 and each winding section (8) has a first to a q-th partial winding section (8a, 8b), wherein - each partial winding section (8a, 8b) extends across L layers (6a-g), wherein - the partial winding sections (8a, 8b) of each winding section (8) are immediately adjacent in the circumferential direction.

3. The stator of claim 2, wherein each partial winding section (8a, 8b) extends exactly across one slot (4).

4. The stator of claim 3, wherein the second connectors (10a-f) connecting the groups (12a-d) of a respective path (7a-d) provide the same offset of a number of slots (4).

5. The stator of claim 3 or 4, wherein - the second connectors (10a, 10c, 10e) of at least one (7a, 7c) of the paths provide an offset of N-q-l slots (4), and / or - the second connectors (10a, 10c, 10e) of at least one (7b, 7d) of the paths provide an offset of N-q slots (4). - the second connectors (10b, 10d, 10f) of at least one of the paths (7b, 7d) provide an offset of N-q+l slots (4).

6. Stator according to claim 2, wherein Each partial winding zone (8a, 8b) extends across at least two directly adjacent slots (4) and has an offset in the radial direction of a number V of slots (4), one slot (4) per offset, wherein V > 1.

7. The stator of claim 6, wherein, The offset - has the same orientation in the circumferential direction, and / or - occurs after L / [V+1] layers (6a-d).

8. Stator according to claim 6 or 7, wherein The second connectors (10a, 10b, 10e, 10f) of at least one of the paths (7a-d) provide, when they do not cover an offset in the radial direction, N-q-l slots (4) and / or an offset of N-q-l slots (4).

9. Stator according to claim 6 or 7, wherein The second connectors (10e, 10d) of at least one of the paths (7a-d) provide, when they cover an offset in the radial direction, - N-q-2 slots and / or an offset of N-q slots (4) or - N-q+2 slots and / or an offset of N-q slots (4).

10. Stator according to any one of claims 2 to 4, wherein - each group (12a-d) comprises q arrangements (13a, 13b), each arrangement being located in a different one of the partial winding zones (8a, 8b), wherein - with regard to the series connection, directly adjacent arrangements (13a, 13b) of a group (12a-d) are connected by a third connector (11a-g) which, in the circumferential direction, provides an offset of a number of slots (4) which is not equal to N-q and, in the radial direction, provides an offset of one layer (6a-g).

11. Stator according to claim 10, wherein The third connectors (11a-g) of each path (7a-d) provide the same offset in the circumferential direction.

12. Stator according to claim 10, wherein - the third connectors (11a, 11c, 11e, 11g) of at least one of the paths (7a, 7c) provide an offset of N-q+l slots (4), and / or - the third connectors (11b, 11d, 11f, 11h) of at least one of the paths (7b, 7d) provide an offset of N-q-l slots (4).

13. Stator according to claim 10, wherein The third connectors (11a-g) of different paths (7a-d) which connect shaped conductors (5) in the same layer (6a-g) between the same winding zones (8) are arranged such that one third connector (11b, 11d, 11f, 11h) is arranged axially more inwardly than another third connector (11a, 11c, 11e, 11g), the one third connector (11b, 11d, 11f, 11h) providing an offset of the number of slots (4) which is smaller than the other third connector (11a, 11c, 11e, 11g).

14. Stator according to any of claims 1 to 4, wherein the second connectors (10a-f) of different paths (7a-d) connecting shaped conductors (5) in the same layer (6a-g) between the same winding zone (8) are arranged such that one second connector (10a, 10c, 10e) is arranged axially more inwardly than the other second connector (10b, 10d, 10f), the one second connector (10a, 10c, 10e) providing a smaller offset of the number of slots (4) than the other second connector (10b, 10d, 10f).

15. Stator according to any of claims 1 to 4, wherein q equal numbers (14a, 14b) of paths (7a-d) each have the same sequence of connectors (9a-e, 10a-f, 11a-h) connected in series, each offset from one another by N-q slots (4).

16. Stator according to any of claims 1 to 4, wherein the connectors (9a-d, 10a-f, 11a-h) arranged at one of the end faces (2a) of the stator core (3) are each formed integrally with the shaped conductors (5) connected by them, and the connectors (9e) arranged at the other end face (2b) of the stator core (3) are formed in one piece by the joining of the free ends of connecting elements (17) formed integrally with the shaped conductors (5) and adjoining the shaped conductors (5).

17. Stator according to any of claims 1 to 4, wherein each outer shaped conductor (5) of a path (7a-d) has a free end protruding at one of the end faces (2a) of the stator core (3) with respect to the series connection, and a connecting element (17) adjoins the shaped conductor (5) at the other end face (2b), the free end of the connecting element (17) being provided with the connecting element (17) or connecting element (17) adjoining the second outer shaped conductor (5) of the path (7a-7d).

18. Stator according to any of claims 1 to 4, wherein the paths of each phase are connected to one or more star points of the phase (U, V, W).

19. The stator of claim 16, wherein, the connectors (9e) arranged at the other end face (2b) of the stator core (3) are formed in one piece by the joining of the free ends of connecting elements (17) in an integral bond.

20. An electric machine (101) comprising a stator (1) according to any of the preceding claims and a rotor (102) rotatably arranged within the stator (1).

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