Method for manufacturing a winding for a stator in a rotary electric machine, stator, method for manufacturing the stator, and rotary electric machine

Abstract

The invention relates to a method for manufacturing a winding for a stator, the stator itself, a method for manufacturing the stator and a rotary electric machine. The method for manufacturing a winding (20) for a stator (10) of a rotary electric machine provides a first conductor (31) and a further conductor (41), wherein both conductors (31, 41) are bent in a Z-shaped form at least in a length portion, and the further conductor (32) is moved relative to the first conductor (31) in a combined movement, which has a translational movement component (210) along a longitudinal axis (200) of the further conductor (41) and a rotational movement component (211) around the longitudinal axis (200) of the further conductor (41), so that the further conductor (41) is wound around a pole axis of the first conductor (31), which extends through a region (120) of the first conductor (31) forming a pole extremum of the Z-shaped route. The method for manufacturing a winding for a stator and the stator itself, a method for manufacturing the stator and a rotary electric machine provide a solution which allows manufacturing the winding and thus also the stator comprising the winding and the rotary electric machine comprising the stator at low costs and with a smaller effort.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing windings for a stator of a rotating electric machine, the stator itself, a method for manufacturing the stator, and a rotating electric machine. Background Technology

[0002] Electric drive systems for motor vehicles are known from existing technology. These electric drive systems include components for energy storage, energy conversion, and energy transmission. The energy conversion components include radial flux machines and axial flux machines.

[0003] However, radial flux machines typically have only one operating point at which they achieve optimal efficiency. Therefore, radial flux machines are not designed to adjust the operating point according to varying demands placed upon them, and thus not to achieve maximum efficiency based on different operating parameters or different demands at different operating points.

[0004] To overcome this drawback, a rotary motor adapted to the demands arising in its operating range is typically used, or the aforementioned drawback is compensated for by connecting the rotary motor to a gear unit or by integrating the gear unit into the rotary motor, for example, using an electric shaft.

[0005] Various designs of axial throughput machines with one or more stators and one or more rotors are known from the prior art.

[0006] An electro-axial flux machine, also known as a transverse flux machine, is a motor or generator in which the magnetic flux between the rotor and stator is realized as a rotational axis parallel to the rotor. Other names for electro-axial flux machines include brushless DC motor, permanently excited synchronous motor, or disc motor.

[0007] Such axial flux machines can be designed with different arrangements of the rotor and / or stator, and when used, for example as traction motors for vehicles, different specific features and advantages can be achieved.

[0008] Axial flux machines have different winding configurations. A common configuration is the single-tooth winding. While single-tooth windings form a small winding head, they generate a magnetic field with a high proportion of harmonics—that is, a magnetic field with a frequency different from the rotor speed of the axial flux machine. This magnetic field adversely affects acoustics and efficiency. Axial flux machines with distributed windings offer the advantage that the aforementioned disadvantages do not occur, or only to a reduced extent. However, these distributed windings require a significant amount of space at the winding head in the axial and / or radial directions.

[0009] Large winding heads are undesirable, especially in axial flux machines, because they limit the maximum diameter of the active components under radial expansion, which reduces the maximum torque that can be obtained. The relatively large axial extension of the winding head also results in a large axial length of the entire rotary motor, which is also undesirable.

[0010] To illustrate the prior art, specific implementation methods are discussed below.

[0011] US 6,348,751 B1 discloses an electric motor having active hysteresis control of winding current and / or having an efficient stator winding arrangement and / or an adjustable air gap to form an axial flux machine. The stator of this electric motor includes multiple stator teeth in multiple sections, the stator teeth being wound in a serpentine manner with corresponding winding sections realized in multiple planes. Each phase occupies a corresponding peripheral area of ​​the stator.

[0012] US 2003 / 0189388 A1 discloses an assembly of an axial flux machine comprising a stator and a rotor. The stator has a plurality of axially aligned stator teeth separated from each other by grooves. A winding of a stator winding extends around the stator teeth. It can be seen that the winding head has a relatively large volume requirement in the axial and / or radial directions.

[0013] US 2019 / 0252930 A1 relates to a stator assembly for an axial throughput machine and an axial throughput machine having such a stator assembly. The stator assembly includes a stator having a plurality of stator teeth concentrically distributed in the circumferential direction and arranged axially separated from the rotor by an air gap. Each stator tooth includes two opposite end segments in the axial direction and a tooth core between the two end segments. Each tooth core has a core cross-sectional area and is wrapped with at least one coil winding. A corresponding single-tooth winding is provided therein.

[0014] When using windings, the individual windings are typically interwoven, making it extremely time-consuming and mechanically demanding to individually bend each conductor and then braid them together. This is particularly true for windings where the conductors are laid out in more than two planes. Summary of the Invention

[0015] Based on this, the present invention aims to provide a method for manufacturing a winding for a stator of a rotary electric machine, a stator itself, a method for manufacturing a stator, and a rotary electric machine that enables the winding to be manufactured at low cost and with minimal effort, and thus also enables the manufacture of a stator having the winding and a rotary electric machine including the stator at low cost and with minimal effort.

[0016] The features of the claims can be combined in any technically useful manner, wherein the following description and features from the accompanying drawings may also be consulted for this purpose, which include supplementary embodiments of the invention.

[0017] The present invention relates to a method for manufacturing a winding for a stator of a rotary electric machine, wherein a first conductor and another conductor are provided, each of the two conductors being bent into a zigzag shape at least in a longitudinal section, and the other conductor moves relative to the first conductor in a combined motion having a translational motion component along the longitudinal axis of the other conductor and a rotational motion component about the longitudinal axis of the other conductor, such that the other conductor is wound around an extreme axis of the first conductor that extends through the extreme region of the first conductor forming the zigzag path.

[0018] This forms a woven fabric with a grid, similar to a chain link fence. Specifically, this method is used to manufacture windings for the stator of an axial flux machine. In this case, the longitudinal axis of one conductor corresponds to an ideal axis extending along the longitudinal direction and approximately in the middle of the other conductor in a zigzag shape. If the zigzag path is equivalent to an oscillation, then the sharp corner regions of the zigzag form correspond to the minimum and maximum values ​​of the oscillation, and thus to extreme values. The corresponding conductors are arranged to connect to the phases. Thus, along approximately the winding direction, starting from the common connection region, one conductor can be arranged to connect to the first phase and the corresponding other conductor is arranged to connect to the other phase.

[0019] This process can be repeated with additional conductors to provide the conductor braid. When implementing a 3-phase winding, the conductors are arranged to connect to the phases in the following order: U+, V+, W+, U-, V-, W-. The first conductor is then arranged to connect to U+.

[0020] Any additional conductors are braided into the already connected braided conductors.

[0021] The method for manufacturing the winding can be made in such a way that: the Z-shaped shape is three-dimensional, wherein the Z-shaped shape is equivalent to a harmonic oscillation, and the linear conductor segments with positive slopes and the linear conductor segments with negative slopes of the conductor under discussion are arranged on both sides extending beyond the central plane through the extreme region.

[0022] Correspondingly, the conductors form a three-dimensional helical or threaded shape, with angular regions in the extreme values. These regions in the extreme values ​​can also be referred to as connecting conductor elements.

[0023] The linear segments are connected to each other by regions of the respective conductors that form extrema. These regions forming extrema are the regions of the conductors in question that surround the stator teeth on either their radially inner or radially outer side when the manufactured windings are subsequently arranged on the stator body and extend in the grooves between the stator teeth, and thus connect the linear conductor segments arranged in the grooves of the stator body together.

[0024] The linear section, together with the connecting conductor, forms a corresponding winding portion of at least one stator tooth.

[0025] An advantageous embodiment provides that the zigzag shape is implemented such that the linear conductor segments of the associated conductors are aligned parallel to each other. Alternatively or additionally, it is proposed to alternately form a first interval and a second interval between adjacent linear segments, wherein the first interval is larger than the second interval.

[0026] Therefore, it is possible for the connecting area, also known as the connecting conductor, located on one longitudinal side of the manufactured braid between corresponding adjacent linear segments to be longer than the connecting area or connecting conductor located on the opposite longitudinal side of the manufactured braid.

[0027] When the roughly strip-shaped braid is bent into a circular shape, the longer connecting areas or longer connecting conductors can be arranged on the radially outer side of the circular shape, while the shorter connecting areas or shorter connecting conductors are arranged on the radially inner side of the circular shape. This facilitates bending into a circular shape, and furthermore, it ensures that the linear portion of the winding is arranged to roughly correspond to the position of the groove in the stator body.

[0028] After the conductors are wound around each other, the braid made from them can be reduced in thickness perpendicular to the manufactured side-by-side grid. In other words, the manufactured braid is flattened to reduce its axial extent when arranged between the stator teeth of an axial flux machine. During this flattening, the forming extremities of the respective conductors, also known as the connecting conductor sections, are pressed together, resulting in a smaller thickness of the braid, particularly in these sections.

[0029] Furthermore, after the conductor is wound, the braid made from it can be bent so that the braid extends in a circular shape. This bending of the manufactured braid can be done before or after reducing its thickness.

[0030] According to another aspect, the present invention relates to a stator of a rotating electric machine, the stator comprising a stator body having a plurality of stator teeth arranged in a circumferential direction and grooves formed between the stator teeth, and conductor segments of windings manufactured according to the invention disposed in the grooves. The conductors of the windings are assigned to different electrical phases. At least one conductor segment of at least one conductor of only one corresponding phase is disposed in the corresponding groove.

[0031] This means that conductor segments of conductors of different phases do not share grooves. The parallel conductor segments are arranged alternately in the circumferential direction in each groove through which the conductor passes. In this case, the conductor bends in a direction that is substantially perpendicular to the circumferential direction or in the radial direction, deviating from the winding direction that extends substantially in the circumferential direction, and forms a corresponding winding portion, thereby winding a set of stator teeth.

[0032] The vertical direction can also be understood as a direction that is 60° to 120° relative to the ideal tangent in the circumferential direction. Additionally, the route in this direction can be curved or designed to have at least one slight kink.

[0033] The stator is particularly the stator of an axial flow machine. In some embodiments, the stator body may also be called the stator yoke, and multiple axially projecting stator teeth are arranged on the stator body.

[0034] Another aspect of the invention is a method for manufacturing a stator of a rotating electric machine according to the invention, wherein a stator body having a plurality of stator teeth arranged in a circumferential direction and grooves formed between the stator teeth, and a winding manufactured according to the method of the invention, is provided. The conductors of the winding are assigned to different electrical phases or are intended to be connected to different phases, such as three phases. At least one conductor segment of at least one conductor of only one corresponding phase is arranged in a groove, such that the conductor forms at least a portion of the winding of the stator. The parallel conductor segments are arranged alternately in the circumferential direction in each groove through which the conductor passes. The conductors are arranged such that, when deviating from a winding direction that extends substantially in the circumferential direction, the conductors bend in a direction substantially perpendicular to the circumferential direction or in a radial direction, and each conductor is wound with a set of stator teeth by a corresponding winding portion thus formed.

[0035] Here, the vertical direction can also be understood as a direction that is 60° to 120° relative to the ideal tangent in the circumferential direction. Additionally, the route in this direction can be curved or designed to have at least one slight kink.

[0036] Furthermore, the present invention provides a rotary motor having a rotor and at least one stator according to the present invention.

[0037] In particular, the rotary motor is designed as an axial flow machine.

[0038] Specifically, it can be configured that the conductors of each phase are connected in a star configuration to the corresponding contacts that carry the current of the relevant phase. Attached Figure Description

[0039] The invention described above will now be described in detail with reference to the accompanying drawings, which illustrate preferred embodiments, and in light of the relevant technical background. The invention is not limited in any way to the purely illustrative drawings, wherein it should be noted that the embodiments shown in the drawings are not limited to the dimensions shown. In the drawings:

[0040] Figure 1 The axial throughput machine, arranged in an I-shape, is shown in a three-dimensional cross-section.

[0041] Figure 2 An exploded view shows an axial flow machine arranged in an I-shape.

[0042] Figure 3 The stator core is shown in a 3D diagram;

[0043] Figure 4 This shows a stator core with windings;

[0044] Figure 5 The windings are shown in a 3D diagram;

[0045] Figure 6 The previous view showed the windings;

[0046] Figure 7 : A first side view of the winding is shown;

[0047] Figure 8 : A second side view of the winding is shown;

[0048] Figure 9 : This shows a third side view of the winding;

[0049] Figure 10 : Showing along Figure 6 A cross-sectional view of the section indicated in the middle;

[0050] Figure 11 : This illustrates a conductor element in a double layer;

[0051] Figure 12 The arrangement of the individual conductor elements in the winding is shown in partial illustrations a) to f).

[0052] Figure 13 This shows the arrangement of the positive and negative conductors;

[0053] Figure 14 This shows a stator core with windings and electrical connections;

[0054] Figure 15 The fins with several windings arranged on them are shown in a three-dimensional view;

[0055] Figure 16 The plan view shows the fins with several windings arranged on them.

[0056] Figure 17 The fin with only one winding is shown in a three-dimensional view.

[0057] Figure 18 The plan view shows a fin with only one winding arranged on it.

[0058] Figure 19 The manufactured windings are shown in a 3D diagram;

[0059] Figure 20 The manufactured windings are shown in a plan view.

[0060] Figure 21 The previous view shows fins with windings;

[0061] Figure 22 A side view shows fins with windings.

[0062] Figure 23 A plan view shows a fin with windings.

[0063] Figure 24 The manufactured winding is shown in a side view.

[0064] Figure 25 The manufactured windings are shown in a plan view.

[0065] Figure 26 The manufactured winding is shown.

[0066] Figure 27 The conductor element is shown in a three-dimensional diagram;

[0067] Figure 28 The conductor element is shown in a side view;

[0068] Figure 29 The conductor element is shown in a three-dimensional diagram;

[0069] Figure 30 The windings are shown in a 3D diagram;

[0070] Figure 31 The winding is shown in a side view;

[0071] Figure 32 The conductor element is shown in a side view;

[0072] Figure 33 The conductor element is shown in a planar diagram;

[0073] Figure 34 The side view shows two conductor elements connected to each other.

[0074] Figure 35 The diagram shows two conductor elements connected to each other.

[0075] Figure 36 The manufactured winding is shown.

[0076] Figure 37 A three-dimensional view shows a stator core with windings; and

[0077] Figure 38 The previous view shows the stator core with windings. Detailed Implementation

[0078] First, refer to Figure 1 and Figure 2 Explain the overall design of the stator according to the present invention.

[0079] Figure 1 A three-dimensional cross-section is shown of an axial flux machine with wave-shaped windings arranged in an I-shape, the axial flux machine having a stator 10 on each side of a rotor 2. The corresponding stator 10 includes a stator body 11, which includes or forms a stator yoke. The stator 10, derived from or also including the stator body 11, has a plurality of stator teeth 12 arranged along a circumferential direction 14, the plurality of stator teeth extending in an axial direction. The stator teeth 12 are separated from each other by grooves 15.

[0080] The stator 10 also includes one or more windings 20 of electrical conductors wound around the grooves 15 and stator teeth 12. These windings are placed on the stator teeth 12 along a general winding direction 21 that extends along a circumferential direction 14.

[0081] The winding 20 forms a winding head 22 on the radial inner side and the radial outer side of the stator teeth 12.

[0082] Figure 2 It shows the relationship with Figure 1 The same design, but shown in an exploded view. The rotor 2 is centrally arranged between the two stators 10, wherein each stator 10 has a winding 20 designed as a wave winding.

[0083] However, the present invention is not limited to the design of the axial flow machine illustrated, but can also be designed as an H-type or a single-sided axial flow machine with only one stator and one rotor.

[0084] Figure 3A perspective view of the stator core 11 is shown. The groove 15 and its depth 16 are clearly visible here.

[0085] like Figure 4 As clearly shown, the stator configuration according to the invention is such that at least one conductor pair 30 has a linear conductor segment 33 arranged in a groove 15, the linear conductor segment forming at least a portion of the stator winding 20, wherein the linear conductor segments 33 of the conductor pair 30 are arranged in the respective grooves 15 to be offset parallel to each other along the depth 16 of the groove 15, and the parallel conductor segments 33 are arranged in a sequence alternating along the circumferential direction 14 in each groove 15 through which the conductor extends.

[0086] exist Figure 4 The diagram illustrates a pair of conductors through the first conductor 31 and the second conductor 32.

[0087] Unlike the embodiment shown here, the linear conductor segment 33 can also be designed to be curved or knife-shaped. However, for the sake of conceptual illustration, conductor segments formed in this way are also included under the term "linear conductor segment".

[0088] Figure 4 As shown, the conductors of the illustrated waveform winding 30 are bent in a direction perpendicular to the circumferential direction 14 or in the radial direction, thus deviating from the winding direction 21 which extends substantially along the circumferential direction 14. The result of this is, as... Figure 5 As shown in the figure, the conductors of conductor pair 30 are wound with a set of stator teeth 12 by the winding part 34.

[0089] Current flows through conductors of conductor pair 30 in different circumferential directions. This is explained using the first pair of conductors 30.

[0090] For this purpose, the first conductor 31 of conductor pair 30 is referred to as the positive conductor. For this purpose, the second conductor 32 of conductor pair 30 is referred to as the negative conductor.

[0091] The first conductor 31 forms the first connection portion 36 of the positive conductor and the second connection portion 37 of the positive conductor.

[0092] The second conductor 32 forms the first connection portion 38 of the negative conductor and the second connection portion 39 of the negative conductor.

[0093] The conductors are organized to be connected to three phases respectively, wherein each phase has a positive winding and a negative winding.

[0094] The corresponding conductors 31 and 32 of the conductor pair 30 are wound with the set 13 of stator teeth 12 on different radial sides, such that the current in the corresponding common groove 15 occurs in the two conductors 31 and 32 in the same direction.

[0095] It can be seen from this that the stator 10 includes not only one pair of conductors, but also three pairs of conductors, wherein the third conductor 61 and the fourth conductor 62 form the second pair of conductors, and the fifth conductor 63 and the sixth conductor 64 form the third pair of conductors.

[0096] However, only the conductor segments of the conductor pairs are arranged in the corresponding grooves 15.

[0097] In addition, from Figure 4 It can be seen that the conductors of the conductor pair are arranged in an alternating axial sequence in the groove 15 relative to the conductor pair.

[0098] To better illustrate the conductor's path, Figure 5 The manufactured winding assembly without stator teeth is shown.

[0099] Here, all the conductors are clearly visible again in the 3D view.

[0100] Furthermore, it can be seen that a corresponding pair of conductors 30 are wound around a group 13 of stator teeth 12, each group comprising three stator teeth 12.

[0101] Because the conductors of the corresponding conductor pairs 30 are arranged alternately in the grooves 15, these conductors must cross. For this purpose, the conductors form connecting conductor segments 35, which connect the linear conductor segments 35 to each other and ensure that the corresponding conductors extend back and forth between the two arrangement planes between the grooves 15 to which the relevant conductors extend.

[0102] For the three phases shown, one phase occupies 15 of every three grooves.

[0103] The axial first conductor layer in the relevant groove 15 is alternately assigned as positive or negative phase. A layer may also include several discrete individual lines.

[0104] Figure 4 and Figure 5 A winding 20 with two so-called double layers 60 is shown. A double layer 60 represents the path of the conductor in two mutually parallel planes. Accordingly, the two double layers 60 comprise four planes.

[0105] In order for the conductors of conductor pair 30 to extend in four planes, each conductor forms a transition segment 70, as illustrated by way of example using the first conductor 31. This transition segment 70 allows the first conductor 31 to pass from the second plane to the third plane.

[0106] This transition section 70 is also known as a layer jump.

[0107] Figure 6 The implemented winding 20 is shown again in a side view. The common connection region 40 of the conductors implemented on the circumference is also clearly visible.

[0108] Figure 7 The arrangement of conductors 31, 61, 63, 32, 62, and 64 in different planes, namely the first plane 51, the second plane 52, the third plane 53, and the fourth plane 54, is clearly shown.

[0109] Furthermore, a connecting conductor section 35 can be seen here, which ensures that conductors 31, 61, 63, 32, 62, and 64 can switch between the first plane 51 and the second plane 52, and between the third plane 53 and the fourth plane 54.

[0110] Figure 8 With Figure 7 The same side view shows the same winding 20, except that the path of the plane is not illustrated.

[0111] Figure 9 It shows Figure 6 The top view of the winding 20 shown shows a transition section 70 that brings the first conductor 31 and the second conductor 32 from the second plane 52 to the third plane 53.

[0112] Figure 10 It shows that according to Figure 6 A cross-sectional diagram of the route indicated in the diagram. Connecting conductor segment 35, which is used to allow conductors to cross and simultaneously form part of the winding head 22, can also be seen in the cross-section.

[0113] It can also be seen that the winding head 22 can be designed such that the winding head is no wider than the width of the associated groove 15 or only slightly wider than the width of the associated groove, and thus has a small axial space requirement.

[0114] In addition, the winding head 22 is also designed to be radially flat, which allows for a larger radius to be achieved in the torque-effective region of the axial flux machine equipped with the winding head.

[0115] This principle, used for designing waveform windings, can also be applied to radial flux machines.

[0116] Therefore, a winding 20 with two double layers 60 is shown, which occupy a total of four layers or planes 51, 52, 53, and 54 in the axial direction. An even number of layers or planes are required for this. Since each of the two layers or planes represents a common structure, the two layers belonging to each other are referred to as double layers 60.

[0117] The planes 51, 52, 53, and 54 shown here need not be planar or flat. For example, these planes 51, 52, 53, and 54 may also be conical in order to follow a conical rotor.

[0118] To illustrate the corresponding conductor path Figure 11 A separate perspective view shows the first conductor 31 for one phase in a winding with two double layers. It can be seen that linear segments 33 are followed by connecting conductor segments 35, which guide the first conductor 31 back and forth between the respective arrangement planes. After completing one rotation, starting from the first connection 36, the first conductor 31 forms a transition segment 70, which axially carries the first conductor 31 behind the already completed winding. There, the first conductor undergoes another rotation until it terminates at its second connection 37. The first connection 36 and the second connection 37 are substantially within the same angular range.

[0119] Figure 12 The implementation of the entire winding is illustrated in six parts, a) through f).

[0120] Partial illustration a) shows the first conductor 31, as already referenced. Figure 11 As illustrated, partial diagram b) shows the first conductor 31 and the third conductor 61. Partial diagram c) shows the first conductor 31, the third conductor 61, and the fifth conductor 63. For example, these conductors all form the so-called positive conductors of the corresponding phase. In addition to the conductors shown in partial diagram c), partial diagram d) now shows the arrangement of the second conductor 32, which belongs to the same phase as the first conductor 31. As already described, it can also be seen here that the linear conductor segments 33 of the first conductor 31 and the second conductor 32 are arranged such that the linear conductor segments can be placed together in the groove.

[0121] Partial illustration e) shows all the conductors already shown in partial illustration d) and also shows a fourth conductor 62, which together with the third conductor 61 forms a second pair of conductors. Partial illustration f) shows all the conductors already shown in partial illustration e) and also shows a sixth conductor 64, which together with the fifth conductor 63 forms a third pair of conductors. Additionally, partial illustration f) shows that the winding head 22 is approximately as wide as the required axial length of the conductor in the groove.

[0122] exist Figures 7 to 10 Each figure shows a winding 20 with two double layers 60, but the winding 20 may also include only one double layer, or it may have more than two double layers. The second conductor 32, the fourth conductor 62, and the sixth conductor 64 each form a so-called negative conductor.

[0123] from Figures 6 to 10It can also be seen that the linear conductor segments 33 extending in the grooves 15 are connected to the connecting conductor segments 35. These connecting conductor segments—when the stator is designed in an I-shape arrangement—increase the radial distance to the stator core and simultaneously bridge a portion of the distance to the next groove 15 belonging to the same phase in the circumferential direction, and bridge the winding heads 22 radially inward and radially outward. Since the two layers of linear conductor segments 33 to be connected are located on different layers or planes, the connecting conductor segments 35 also undergo necessary positional changes.

[0124] To illustrate conductor pair 30, in Figure 13 The routes of the first conductor 31 and the second conductor 32 are shown again. It can be seen here that the linear conductor segments 33 overlap each other along the axial direction, so that these linear conductor segments can be shown together in the groove. Furthermore, it can be seen that each of the two conductors 31, 32 shown here forms a transition segment 70 or a layer jump.

[0125] Figure 14 A stator 10 with windings 20 and corresponding electrical interconnections is shown.

[0126] in this case, Figure 14 An advantageous connection between the positive and negative windings is shown, resulting in a star connection of the windings with three connection points for connection to power electronic devices. The power electronic devices are supplied with a phase via a first connection point, also referred to as the positive connection point 71, of the positive winding, or the first connection point is connected to the power electronic devices. Each of the second connection points of the positive winding is individually connected to the second connection point of the associated phase of the negative winding. The first connection points 73 of the negative windings are interconnected to form a star connection. This connection ensures that the positive and negative windings of the phases are connected such that the conductors in the recesses have the same current direction. Compared to hairpin windings, which require connections for the conductors in the recesses, wiring work is reduced to four connection points per phase.

[0127] Alternatively, the connection shown can be used for the series interconnection section 72. Unlike the exemplary embodiment shown here, the stator according to the invention can also be designed for more or fewer than three phases.

[0128] Figures 15 to 26 An implementation of an alternative method for manufacturing stator windings.

[0129] The process described here involves manufacturing two double-layered windings.

[0130] Therefore, such as Figures 15 to 18As shown, the first fin 80, the second fin 90, and the third fin 100 are aligned such that their longitudinal axes extend substantially parallel to each other. The first fin 80 is arranged to produce a first double layer of turns. The third fin 100 is arranged to produce a second double layer of turns.

[0131] Each fin has a geometry that facilitates the subsequent process steps of bending into a flat pad and bending into a circular shape.

[0132] like Figure 15 and Figure 16 As shown in different views, the first conductor 31, the second conductor 32, the third conductor 61, the fourth conductor 62, the fifth conductor 63, and the sixth conductor 64 are wound around the first fin 80 along a first winding direction 82, which is mathematically positive. It makes sense to rotate and move the first fin 80 about its longitudinal axis 81 so that subsequent windings reach the first fin 80 adjacent to existing windings.

[0133] Regarding the conductor pair comprising the first conductor 31 and the second conductor 32 forming the first phase, it should be mentioned that the third conductor 61 and the fifth conductor 63 are located between the first conductor 31 and the second conductor 32; however, the third conductor and the fifth conductor belong to the second phase and the third phase, respectively.

[0134] During the winding process onto the first fin 80, the second fin 90 is not yet in place, ensuring that it does not interfere with the winding process on the first fin 80. The second fin 90 is not positioned until the required number of turns has been formed on the first fin 80. After the required number of turns has been completed, the second fin 90 is positioned adjacent to the first fin 80, and the winding direction is reversed approximately half a turn. In this way, the conductor is guided on the second fin 90 along a second winding direction 91, which extends in the opposite direction to the first winding direction 82.

[0135] By reversing the winding direction, the conductor is pre-bent for layer skipping. The conductor is then wound again along the first winding direction 82 onto a third fin 100, which is positioned after the half-turn reverse rotation. If more double layers are required, the number of fins and the number of completed windings are increased accordingly. If there are more than two layer skips or transitions between double layers, additional second fins can be used. After the windings have been formed, the wound conductors can be pressed together to form a winding pad such that the winding pad has an axial extension approximately the same depth as the grooves in the stator body that accommodate one or more windings. This winding pad can still be bent into a circular loop shape to facilitate insertion into the grooves of the stator core.

[0136] The implementation of this method is not limited to the order of the above steps.

[0137] To achieve a winding pad with only one double layer, the second fin 90 and the third fin 100 can be omitted.

[0138] This method can also be used to manufacture windings for radial flux machines.

[0139] To simplify the explanation of the process sequence, Figure 17 and Figure 18 The winding process is illustrated using only two conductors out of 2*n conductors, namely the first conductor 31 and the third conductor 61, as an example.

[0140] It can also be clearly seen here that two transition sections 70 are formed by winding these conductors 31 and 61 around the second fin 90.

[0141] Figure 19 and Figure 20 The diagram shows the winding 20 formed after the fins have been removed. It can be seen that the winding structure has been retained, and the bridging section 70 has also been formed.

[0142] Figure 21 The previous view shows the three fins 80, 90, and 100 when the first conductor 31 is wound. It can be seen that the first conductor 31 completely wraps around the first fin 80 and the third fin 100. However, the second fin 90, located between the first fin 80 and the third fin 100, is only wound at a limited winding angle 92 on its upper side. Therefore, the winding portions surrounding the first fin 80 and the third fin 100 are formed on both the first winding side 110 and the second winding side 111 opposite to the first winding side 110. The first conductor 31 is guided substantially linearly on the flat lateral surfaces 112 of the fins 80 and 100.

[0143] It can be seen that when the generated winding is equated to harmonic oscillation, the first winding side 110 forms an extreme value range 120, and the second winding side 111 forms the opposite extreme value range 120.

[0144] In the extreme regions 120 arranged opposite to each other, the windings are designed to have different widths so that their shape is adapted to the fact that the distance between the grooves in the stator body on the radially outer side is greater than the distance on the radially inner side.

[0145] Figure 22 and Figure 23 The winding 20 surrounding the first fin 80 is shown again in a different view.

[0146] Figure 24 The formed winding 20 is shown in a side view, and Figure 25 The formed winding 20 is shown in plan view. Specifically, it can be seen that... Figure 24 The extreme range 120 formed by winding 20 can be seen very clearly. It can also be seen that each of the two conductors 31 and 61 forms a grid 140.

[0147] It can also be seen here that the distances between the linear conductor segments 33 within the axial segment are alternately spaced from each other by a first distance 230 and a second distance 231, wherein the second distance 231 is greater than the first distance 230. This takes into account the fact that the outer winding head requires a larger bridging distance in the circumferential direction compared to the inner winding head. If this method is used for the stator windings of a radial flux type machine, the distances between the two winding heads will be similar. The distances may vary with the radius of the winding layers because the fins used one after another are designed to have different widths for each double layer.

[0148] Figure 26 The windings, comprising all six conductors forming the three phases, are shown.

[0149] Figures 27 to 38 Embodiments relating to a method for manufacturing windings for a stator according to the invention.

[0150] Figure 27 The first conductor 31 in the double layer is shown as an example. The various segments of the first conductor 31, namely the linear conductor segment 33 and the connecting conductor segment 35, as well as the extreme range 120 in the radially innermost and radially outermost segments, can be seen again.

[0151] Figure 28 The side view clearly shows that the connecting conductor segment 35 ensures that the first conductor 31 extends alternately between the first plane 51 and the second plane 52.

[0152] Figure 29 A braid 130 formed by a first conductor 31 and a second conductor 32 is shown, such that they together produce positive and negative phases. The two conductors 31 and 32 form multiple grids 140. It can be seen that the two conductors 31 and 32 are alternately guided in two arrangement planes. This means that the linear conductor segments 33 of the two conductors 31 and 32 are alternately arranged at the axial front and axial rear portions.

[0153] Figure 30 Now shown is the braid 130, which has been constructed from a third conductor 61, a fourth conductor 62, a fifth conductor 63, and a sixth conductor 64. Figure 29 The aforementioned method is supplemented. These six conductors, arranged for three-phase connection, together form a complete double layer.

[0154] Figure 31 The woven fabric 130 is shown in a top view.

[0155] Reference Figures 32 to 35 The process of forming this woven fabric will now be explained.

[0156] like Figure 32 As shown, a first conductor 31 is first provided, which is in a zigzag or Z-shaped shape. It can be seen here that a first distance 230 and a second distance 231 are alternately implemented between adjacent linear conductor segments 33, wherein the second distance 231 is greater than the first distance 230. This results in a grid 140 with varying widths, which are open at the top and bottom.

[0157] Figure 33 It is clearly shown that the first conductor 31 shown here not only bends in a plane, but also bends in a plane extending perpendicular to that plane, thus forming a threaded shape or a three-dimensional helix. In a practical implementation, this three-dimensional helix can also be designed to be more... Figure 33 The three-dimensional spiral shown is much flatter. In extreme cases, Figure 33 The conductor in the middle is already as flat as it was after being inserted into the stator groove. The central plane 222 passes through the extreme range 120. The wavy or helical route of the conductor already has features that are advantageous for subsequent steps in forming the winding pad. The conductor piece for the subsequent inner winding head is shorter / smaller than the conductor piece for the subsequent outer winding head, such that the distances 230, 231 between the conductor pieces in the winding groove also have alternating different dimensions. The non-circular shape in the form of a three-dimensional helix is ​​formed so that in subsequent process steps, the braid is subsequently flattened to produce the desired profile for forming the linear conductor segments for the inner and outer winding heads, as well as the winding grooves.

[0158] This means that the Z-shaped shape is three-dimensional, wherein, by equating the Z-shaped shape with harmonic oscillation, the linear conductor segment 33 of the associated conductor with a positive slope 220 and the linear conductor segment of the associated conductor with a negative slope 221 are arranged on both sides outside the central plane 222 extending through the extreme region 120.

[0159] The braid is now formed by providing another conductor 41, which has been pre-formed in substantially the same manner as the first conductor 31. Figure 34 and Figure 35As shown, the other conductor 41 then moves relative to the first conductor 31 in a combined motion incorporating translational motion component 210 and rotational motion component 211, such that the other conductor 41 rotates about its longitudinal axis 200 and simultaneously moves forward along the longitudinal axis 200, such that the conductor tip 212 of the other conductor penetrates the axis of the first conductor 31 in each case. Thus, the other conductor 41 meanders through the grid 140 of the first conductor 31 in a manner similar to forming a wire mesh fence, such that the two conductors create multiple spatial spirals that twist together.

[0160] If it is possible Figure 34 As seen in the diagram, the linear conductor segments 33 also overlap with each other.

[0161] Figure 36 A braid 130 is shown, formed by a first conductor 31, a second conductor 32, a third conductor 61, a fourth conductor 62, a fifth conductor 63, and a sixth conductor 64, which have been joined together according to the steps described above. The fourth conductor 62 and the first conductor 31 have been twisted together in the manner described. This means that the fourth conductor 62 corresponds to another conductor 41.

[0162] The other conductors shown here, namely the second conductor 32, the third conductor 61, the fifth conductor 63 and the sixth conductor 64, have been connected to each other in the order shown according to this method.

[0163] Therefore, this provides three pairs of conductors for connecting to the intertwined three phases.

[0164] Unlike the implementation shown here, more or fewer conductor pairs can, of course, be intertwined to connect the phases.

[0165] After the braid 130 is formed, it still needs to be bent into a circular shape. In addition, the three-dimensional structure of the individual conductors of the braid can also be reduced in the axial range, so that when these conductors are coupled between the stator teeth, they produce a flat pad that requires less axial space.

[0166] However, this method is not limited to the order of the steps described above. Figure 37 and Figure 38 The stator 10 is shown, in which a linear conductor segment 33 of a braid made of the six conductors described above is arranged in a groove 15.

[0167] The stator 10 shown here has a special feature: it comprises six conductors arranged in two double layers; however, these conductors do not have the following characteristics: Figure 5 As shown, they are connected to each other through transition sections. For example, this is from... Figure 37 The indications of the two first conductors 31 in the middle are clearly visible.

[0168] By means of a method for manufacturing a winding for a stator of a rotating electric motor, and by means of the stator itself, the method for manufacturing the stator, and the rotating electric motor, a solution can be obtained that achieves the winding at low cost and with a small amount of work, and correspondingly also achieves a stator with the winding, and a rotating electric motor including the stator, especially for windings in which conductors are wired in more than two planes.

[0169] List of reference numerals

[0170] 1 Axial throughput type machine

[0171] 2 rotors

[0172] 10 stators

[0173] 11Stator body

[0174] 12 stator teeth

[0175] 13 stator teeth group

[0176] 14 circumferential direction

[0177] 15 grooves

[0178] 16. Depth of the groove

[0179] 20 windings

[0180] 21. Winding direction

[0181] 22 winding head

[0182] 30 conductor pairs

[0183] 31 First Conductor

[0184] 32 Second conductor

[0185] 33 Linear Conductor Section

[0186] 34 winding section

[0187] 35 Connecting conductor section

[0188] 36 First connection of positive conductor

[0189] 37. Second connection of positive conductor

[0190] 38 The first connection of the negative conductor

[0191] 39 Second connection of negative conductor

[0192] 40 Common Connecting Areas

[0193] 41 Another conductor

[0194] 51 First plane

[0195] 52 Second plane

[0196] 53 Third plane

[0197] 54 Fourth Plane

[0198] 60 Double Layer

[0199] 61 Third Conductor

[0200] 62 Fourth Conductor

[0201] 63 Fifth Conductor

[0202] 64 Sixth Conductor

[0203] 70 Transition Section

[0204] 71 Positive Connection Part

[0205] 72 Connecting part for series connection

[0206] 73 Connecting part for star connection

[0207] 80 First Fin

[0208] 81 Longitudinal axis

[0209] 82 First winding direction

[0210] 90 Second Fin

[0211] 91 Second roll winding direction

[0212] 92 winding angle

[0213] 100 Third Fin

[0214] 110 First winding side

[0215] 111 Second winding side

[0216] 112 Flat lateral surface

[0217] 120 extreme value range

[0218] 130 knitted fabric

[0219] 140 grid

[0220] 200 Longitudinal axis of the second conductor

[0221] 210 translational motion components

[0222] 211 Rotational Motion Components

[0223] 212 conductor tip

[0224] 220 positive slope section

[0225] 221 Negative Slope Section

[0226] 222 Central Plane

[0227] 230 First Distance

[0228] 231 Second distance.

Claims

1. A method for manufacturing a winding (20) for a stator (10) of a rotating electric machine, wherein a first conductor (31) and another conductor (41) are provided, wherein, Two conductors (31, 41) are each bent into a zigzag shape at least along their length, and the other conductor (41) moves relative to the first conductor (31) in a combined motion having a translational motion component (210) along the longitudinal axis (200) of the other conductor (41) and a rotational motion component (211) about the longitudinal axis (200) of the other conductor (41), such that the other conductor (41) is wound around the extreme axis of the first conductor (31). The extreme axis extends through the region (120) of the first conductor (31) that forms a zigzag path of extreme values. The zigzag shape is realized in three dimensions, wherein, by equating the zigzag shape with harmonic oscillations, linear conductor segments (33) with positive slopes (220) and linear conductor segments (33) with negative slopes (221) of the first conductor (31) and the other conductor (41) are respectively arranged on both sides outside the central plane (222) extending through the region (120) of extreme values.

2. The method for manufacturing the windings of the stator (10) of a rotating electric machine according to claim 1, characterized in that, The Z-shaped shape is designed such that a first distance (230) and a second distance (231) are alternately achieved between adjacent linear conductor segments (33), wherein the second distance (231) is greater than the first distance (230).

3. The method for manufacturing the windings of the stator (10) of a rotating electric machine according to any one of the preceding claims, characterized in that, After the conductor of the winding has been wound, the braid (130) made from the conductor of the winding decreases in thickness in the direction perpendicular to the side-by-side grid (140) of the braid.

4. The method for manufacturing the windings of the stator (10) of a rotating electric machine according to any one of claims 1-2, characterized in that, After the conductor of the winding has been wound, the braid (130) made from the conductor of the winding is bent so that the braid extends in a circular shape.

5. A stator (10) of a rotary electric motor, said stator comprising: A stator body (11) having a plurality of stator teeth (12) arranged along a circumferential direction (14) and grooves (15) formed between the stator teeth (12); and conductor segments of a winding (20) manufactured according to any one of claims 1 to 4, the conductor segments being arranged in the grooves (15), wherein the conductors of the winding (20) are assigned to different electrical phases, and wherein at least one conductor segment of at least one conductor of only one corresponding phase is arranged in a corresponding groove (15), and the parallel conductor segments are arranged alternately along the circumferential direction (14) in each groove (15) through which the conductors (31, 41) pass, and wherein the conductors of the winding are deviated from a winding direction (21) extending substantially along the circumferential direction (14) to a direction extending substantially perpendicular to the circumferential direction (14), and wherein the corresponding winding portion formed therefrom winds a group (13) of the corresponding stator teeth (12).

6. A method for manufacturing the stator (10) of the rotary electric machine according to claim 5, wherein, A stator body (11) and a winding (20) are available. The stator body has a plurality of stator teeth (12) arranged in a circumferential direction and grooves (15) formed between the stator teeth (12). The winding is manufactured by the method according to any one of claims 1 to 4, and conductor segments of the winding (20) are arranged in the grooves (15) such that the conductors of the winding form at least a portion of the winding (20) of the stator (10), wherein the conductors of the winding (20) are assigned to different electrical phases, and wherein only one corresponding phase is assigned to the other phase. At least one conductor segment of at least one conductor of a phase is arranged in a corresponding groove (15), wherein the parallel conductor segments are arranged alternately in each groove (15) through which the conductors (31, 41) pass, along the circumferential direction (14), and wherein the conductors of the winding are arranged such that the conductors of the winding are bent in the radial direction, thereby deviating from the winding direction (21) which extends substantially along the circumferential direction (14) to a direction that extends substantially perpendicular to the circumferential direction (14), and wherein the corresponding winding portion formed thereby winds around a group (13) of the corresponding stator teeth (12).

7. A rotary electric motor, comprising a rotor (2) and at least one stator (10) according to claim 5.

8. The rotary electric motor according to claim 7, characterized in that, The conductors of the winding of the phase are connected in a star configuration to the corresponding contacts that carry the current of the relevant phase.

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