Power generation assembly of electric machine

Abstract

The invention relates to a power generation assembly of an electric machine. The invention relates to a winding coil comprising an annular laminated core having a plurality of radially arranged slots N1,..., N36, and a wave winding having at least a first and a second continuous conductor U1, U2, which are each guided by a plurality of turns through adjacent slots, which are connected in parallel or in series and form a conductor composite. The conductor composite has a slot step in which the first conductor U1 and the second conductor U2 each span the same number of slots N1,..., N36, and in which there is a layer change. The conductor composite further has at least one slot step change, in which the first conductor U1 and the second conductor U2 span a different number of slots from each other, such that the first conductor U1 and the second conductor U2 exchange their arrangement with each other after the slot step change. In order to improve the efficiency and operational stability of the electric machine, at least one slot step change is made within each turn of the conductor composite.

Description

Technical Field

[0001] The invention relates to a power generation component of an electric machine, such as a rotor or a stator of the electric machine. The power generation component comprises an annular lamination stack having a plurality of radially arranged slots and a wave winding having at least one first conductor and a second conductor in series, which conductors are respectively guided through adjacent slots for a plurality of turns, and which are connected in parallel or in series and form a conductor complex. The conductor complex has a slot step, wherein the first conductor and the second conductor respectively span the same number of slots, and wherein there is a layer change. In addition, the conductor complex has at least one slot step change section, in which the first conductor and the second conductor span a different number of slots from each other, so that the first conductor and the second conductor are interchanged in their arrangement after passing through the slot step change section. Background Art

[0002] Electric motors for vehicles consist of a stator and a rotor as power generating components. Both components consist of mutually insulated laminated sheets stacked on top of each other, which form a laminated sheet stack and are each designed as a ring with surrounding slots. These slots are surrounded by conductors (usually copper wires or conductor bundles) to form the windings of the coils.

[0003] One method of winding these laminated cores is wave winding. For this purpose, a winding mat is usually prepared, which is inserted into the slots and then contacted. Alternatively, the laminated core can also be directly wrapped. It is important here to isolate all elements of the motor from one another, for example using films or paper. Finally, the slots are closed with a cover sheet and cast with a casting medium to improve durability and insulation.

[0004] In the case of wave winding, the conductor is guided through a slot, across a fixed number of slots and through another slot. The area of ​​the conductor that spans multiple slots is called the winding head. The power-generating components of the motor are completely wrapped around by multiple conductors in multiple layers. Here, the layer of the conductor is the radial position of the conductor in the respective slot. For the highest efficiency, high running smoothness and high robustness, the course of the individual conductors relative to each other needs to be adjusted in a targeted manner. In addition, it is necessary to change the layer of the individual conductors in the slot step.

[0005] DE 10 2014 223 202 A1 discloses a wave winding for a stator, wherein the wave winding has at least two conductors connected in parallel and / or in series for each phase of the machine, which conductors can be arranged in a predetermined winding step in a predetermined sequence for each phase and each pole along the circumference of the machine in (a plurality of) at least two successive stator slots for each pole and each phase of the machine. The predetermined sequence of the connected conductors is exchanged at at least one position along the circumference of the machine by at least one slot step change, which is defined as a slot step in DE 10 2014 223 202 A1. The winding head of the conductor is designed in this case in an arc shape and twisted once around its own axis. The problem is that the conductor with a rectangular cross section bulges at this location due to this twisting. As a result, in particular in the case of slot step changes, the conductor can no longer be guided smoothly and the motor loses efficiency and running smoothness. Summary of the invention

[0006] The object of the present invention is to provide a power generation assembly for an electric machine which has improved efficiency and greater running smoothness.

[0007] According to the invention, for the power generating component of the electric machine described at the outset, this object is achieved in that at least one slot step change is present in each turn of the conductor assembly. This greater number of slot step changes allows a greater running smoothness and improved efficiency compared to the prior art, since a high level of electromagnetic symmetry is achieved in this way.

[0008] In an advantageous embodiment, the slot step is designed in an arcuate manner and has a vertex with an S-shaped stop. In order to achieve the highest possible packing density in the individual slots, conductors with a rectangular cross section are usually used. In this way, the conductor twisting previously known in the prior art, which leads to a greater space requirement and makes a closer arrangement in the region of the slot step more difficult, is avoided.

[0009] It is also advantageous if the slot steps of the first and second conductors are arranged parallel to one another. This also makes it possible to arrange the conductors particularly closely in the region of the slot steps.

[0010] In a further advantageous embodiment, the slot step changes are arranged radially next to one another on the laminated core. This allows the conductors to be arranged as closely as possible next to one another even in the region of the slot step change. It is particularly advantageous here that, in the case of a first slot step change, the first conductor spans one slot less than the slot step and the second conductor spans one slot more than the slot step, and in the case of a second slot step change, the first conductor spans one slot more than the slot step and the second conductor spans one slot less than the slot step, wherein the second slot step change occurs exactly one turn before or after the first slot step change.

[0011] It is also particularly advantageous if the first conductor spans two more slots than the slot step and the second conductor spans the same number of slots than the slot step; or if the first conductor spans the same number of slots than the slot step and the second conductor spans two fewer slots than the slot step. Together with the change in the number of slots spanned by the slot step, a shift (pitch) of the winding layers of the first conductor is then achieved and the motor is acoustically optimized. It is particularly advantageous here if the third slot step change occurs after the first and / or second slot step change. Such a winding pattern has been shown to be particularly advantageous with regard to running smoothness, acoustic optimization and efficiency.

[0012] It is also advantageous if the wave winding has a plurality of phases, each of which consists of one or more conductor composites. This increases the efficiency of the electric machine by allowing the individual phases to be connected in succession. The slot step changes present in the individual phases are ideally arranged next to one another, since this is beneficial to the smooth operation and efficiency of the electric machine.

[0013] The object is also achieved by the previously described wave winding for incorporation into a power generation component of an electric machine. The wave winding can be directly incorporated into a rotor or stator in the form of a winding mat.

[0014] It goes without saying that the features mentioned above and the features still to be explained below can be used not only in the combination specified but also in other combinations or alone, without departing from the scope of the present invention.

[0015] The present invention will be explained in more detail below with reference to the accompanying drawings by means of embodiments, and the accompanying drawings also disclose important features of the present invention. These embodiments are only for illustration and should not be interpreted in a limiting sense. For example, the description of the embodiment with multiple elements or assemblies should not be interpreted as meaning that all these elements or assemblies are necessary for implementation. On the contrary, other embodiments may also include alternative elements and assemblies, fewer elements or assemblies, or additional elements or assemblies. Unless otherwise indicated, the elements or assemblies of different embodiments may be combined with each other. The modifications and variations described for one of the embodiments may also be applied to other embodiments. In order to avoid repetition, the same or corresponding elements in different drawings are represented by the same reference numerals and are not explained again for many times. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 A stator with conductors is shown;

[0017] Figure 2 is a schematic diagram of the winding scheme. DETAILED DESCRIPTION

[0018] Figure 1 A lamination stack 1 as a stator of a power generation component is shown, which has a plurality of slots 2 through which conductors 3 extend. The conductor is guided through a first slot 2, transitions into a winding head 4, which spans a first number of slots 2 and is guided through a second slot 2 to the opposite side of the lamination stack 1, where another winding head 4 is present. In this way, the conductor 3 is guided around the stator multiple times. The winding head 4 is arc-shaped and in this design spans exactly six slots 2. At its apex there is an S-shaped stop 5, so that the adjacent conductor 3, not shown here, can be arranged close to the conductor 3. In particular, the conductor 3 with a rectangular cross section does not twist around its own axis in the region of the winding head 4. In addition, there is a layer change on the winding head 4, which corresponds to a change in the radial position of the conductor 3 in the slot 2. This is achieved here by the S-shaped stop 5.

[0019] Figure 2 Schematic diagram of the winding scheme of the wave winding of the laminated core 1, which has exactly thirty-six slots N1, ..., N36. Here, the first row gives the number for exactly naming the slots N1, ..., N36. The first column gives the layers L1, ..., L10 within the slots N1, ..., N36. The layer L1 is here the position at the bottom of the corresponding slot N1, ..., N36, and the distance from the bottom increases with increasing number. It is thus possible to accurately trace the route of each conductor 3 through the slots N1, ..., N36 of the laminated core 1, wherein the conductor always has a winding head 4 that spans a plurality of slots N1, ..., N36 alternately on the first side and the second side of the laminated core 1.

[0020] All conductors 3 for one phase are introduced into the winding layout, and the winding of the first conductor U1, the second conductor U2, the third conductor U3 and the fourth conductor U4 is described. The first conductor U1 and the second conductor U2 form a first conductor complex, and the third conductor U3 and the fourth conductor U4 form a second conductor complex, wherein all conductors U1, U2, U3, U4 are connected in series or in parallel, thus forming a common phase. For ease of understanding, the slots N1, ..., N36 spanned by the four conductors U1, U2, U3, U4 do not specify the introduction part. Conductors 3 that can be assigned to one or more other phases individually or in one or more conductor complexes are also guided in these slots. Their arrangement can correspond to the arrangement of the first and second conductor complexes, or it can also be different from it.

[0021] The first conductor U1 and the second conductor U2 start on the first side of the laminated core 1 and are guided through the first two adjacent slots N1 or N2. They extend out on the second side of the laminated core 1 and cross six slots N2 to N7 in a slot step, respectively, so that they are guided through the adjacent slots N7 or N8 to the first side of the laminated core 1. In the slot step, the winding heads 4 of the first and second conductors U1, U2 extend in parallel. At the slot step, a layer change from layer L1 to layer L2 is also performed. Then, another slot step is performed on the first side and another layer change occurs. This operation is continued until all thirty-six slots N1, ..., N36 are passed through or crossed in this way, thus completing a turn, and the pattern continues in the next layer (here L3 and L4) starting from the first two slots N1 and N2. The power generating component thus has five turns in ten layers L1, ..., L10, but usually this number is freely selectable and depends on the size of the component, so that there are multiple turns.

[0022] Between the thirteenth slot N13 and the twenty-first slot N21, a first slot step change is performed in the first turn, wherein the first conductor U1 and the second conductor U2 span different numbers of slots N1, ..., N36. The first conductor U1 spans one more slot N1, ..., N36 than the slot step, i.e., seven slots, and the second conductor U2 spans one less slot N1, ..., N36 than the slot step, i.e., five slots, so that their positions in the conductor complex are exchanged. Exactly one turn later, a second slot step change occurs, wherein the first conductor U1 spans one less slot N1, ..., N36 than the slot step and the second conductor U2 spans one more slot N1, ..., N36 than the slot step. Thus, the first and second conductors U1, U2 swap their positions in the conductor complex for the second time and are again in their initial positions.

[0023] In the third turn, the first and second conductors U1, U2 are offset relative to one another in such a way that the first slot step of the third turn spans seven slots N1, ..., N36 and the second slot step of this turn spans five slots N1, ..., N36. A third slot step change then occurs, in which the first conductor U1 spans eight slots N1, ..., N36 and the second conductor U2 regularly spans six slots N1, ..., N36. This is followed by another second slot step and then the first slot step. This causes the winding layer in which the conductor complex is located to be shifted to the right by one slot N1, ..., N36. This so-called pitch optimizes the acoustic properties of an electric machine provided with such a power generating assembly. The fourth and fifth turns each occur with a slot step spanning six slots N1, ..., N36, in which a second slot step change occurs in the fourth turn or a first slot step change occurs in the fifth turn.

[0024] In addition to the first conductor complex, the power generation assembly also includes a second conductor complex consisting of a third conductor U3 and a fourth conductor U4. These conductors extend in the opposite direction to the second conductor complex: when a slot step of the first conductor complex occurs on a first side of the lamination stack 1, a slot step of the second conductor complex occurs on the opposite second side. The layers L1, ..., L10 are also always in opposite directions. In order to maintain the guiding symmetry outside the third turn, the third turn of the second conductor complex is constructed as follows: first a slot step across six slots N1, ..., N36 is performed, and then a slot step across seven slots. This is followed by a third slot step change, in which the third conductor U3 spans six slots N1, ..., N36, while the fourth conductor U4 spans only four slots. This is followed by two slot steps again, in which seven or six slots N1, ..., N36 are spanned in the slot step. The subsequent turns correspond to the turns of the first conductor complex, only in the opposite direction. Thus, in this exemplary embodiment, the power generation component wound with two conductor composites has two slot step changes in each turn, which are located at the same or at least adjacent slots N1, ..., N36. On the laminated core 1, all slot step changes are thus arranged radially next to each other. This can also include phases that are not introduced.

[0025] List of Reference Numerals

[0026] 1 lamination pack

[0027] 2 slots

[0028] 3 Conductors

[0029] 4 Winding head

[0030] 5S shaped stop

[0031] N1, ..., N36 slots

[0032] L1, ..., L10

[0033] U1 First conductor

[0034] U2 Second conductor

[0035] U3 Third conductor

[0036] U4 fourth conductor.

Claims

1. A power generation component of an electric machine, comprising an annular lamination stack (1) and a wave winding, wherein the lamination stack has a plurality of radially arranged slots (N1, ..., N36), the wave winding has at least a first conductor (U1) and a second conductor (U2) which are continuous, wherein the conductors are respectively guided through adjacent slots (N1, ..., N36) for a plurality of turns, the conductors being connected in parallel or in series to form a conductor complex, wherein: The conductor composite has a slot step, the first conductor (U1) and the second conductor (U2) respectively span the same number of slots (N1, ..., N36) in the slot step, and there is a layer change in the slot step, and the conductor composite has at least one slot step change portion, the first conductor (U1) and the second conductor (U2) span different numbers of slots (N1, ..., N36) in the slot step change portion, so that the first conductor (U1) and the second conductor (U2) exchange their mutual arrangement after the slot step change portion, characterized in that At least one slot step change is present within each turn of the conductor composite.

2. The power generation assembly according to claim 1, characterized in that: The first conductor (U1) and the second conductor (U2) both comprise an arc-shaped winding head (4), wherein the winding head has a vertex with an S-shaped stopper (5).

3. The power generation assembly according to claim 2, characterized in that: In the slot step, the winding heads (4) of the first conductor (U1) and the second conductor (U2) are arranged parallel to each other.

4. The power generation assembly according to any one of claims 1 to 3, characterized in that: The groove transitions are arranged radially next to one another on the laminated core (1).

5. The power generation assembly according to any one of claims 1 to 4, characterized in that: During a first slot step change, the first conductor (U1) spans one more slot (N1, ..., N36) than the slot step, and the second conductor (U2) spans one less slot (N1, ..., N36) than the slot step, and during a second slot step change, the first conductor (U1) spans one less slot (N1, ..., N36) than the slot step, and the second conductor (U2) spans one more slot (N1, ..., N36) than the slot step, wherein the second slot step change occurs exactly one turn before or after the first slot step change.

6. The power generation assembly according to claim 5, characterized in that: During the third slot step change, the first conductor (U1) spans two more slots (N1, ..., N36) compared with the slot step, while the second conductor (U2) spans the same number of slots (N1, ..., N36) compared with the slot step; or, the first conductor (U1) spans the same number of slots (N1, ..., N36) compared with the slot step, while the second conductor (U2) spans two fewer slots (N1, ..., N36) compared with the slot step.

7. The power generation assembly according to claim 6, characterized in that: The third groove step change occurs one turn after the first groove step change and / or the second groove step change.

8. The power generation assembly according to any one of claims 1 to 7, characterized in that: The wave winding has a plurality of phases, each of which is composed of one or more conductor composites.

9. A wave winding for use in a power generation component of an electric machine according to any one of claims 1 to 8.

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