Stator, stator arrangement, method for manufacturing a stator arrangement, and electrical drive device of a vehicle

Abstract

The invention relates to a stator, a stator device, a method of manufacturing the stator device and an electric drive device of a vehicle. The stator comprises a stator iron core and a stator winding with a phase winding; each phase winding comprises a first and a second coil, each coil being formed by conductors connected into a series connection having a first and a third conductor and a second conductor, the first and the third conductor each having a leg section and a connection section having an end section, the connecting section of the first conductor of the second coil and the connecting section of the third conductor of the corresponding coil are respectively provided with an inclined section which extends away from the axial direction and the circumferential direction of the stator iron core; the inclined section of the third conductor of the first coil is longer than the inclined section of the third conductor of the second coil to form a first gap; the inclined section of the first conductor of the second coil is shorter than the inclined section of the third conductor of the second coil to form a second gap; the connection section of the first conductor is bent at least radially outward to form a third gap.

Description

Technical Field

[0001] The present invention relates to a stator, comprising a stator core and a stator winding having a phase winding; wherein the stator core has an axial face side and slots distributed in the circumferential direction, each slot is divided into a first layer to an Lth layer in the radial direction, wherein L≥4, and the layers are indexed in their order from the outside to the inside; wherein each phase winding comprises a first coil and a second coil, each coil is formed by a plurality of conductors connected into a series connection body, the series connection body having a first conductor and a third conductor among the conductors as their opposite outer conductors and a second conductor among the conductors as one of its inner conductors, the second conductor having a first leg section and a second leg section extending through two different slots in the slot and a head section connecting the leg sections at the face side, the first leg section and the second leg section extending through two different slots in the slot The first conductor and the third conductor each have a leg section extending through one of the slots and a connecting section located at the face side, the connecting section having an end section, the end section including a free end of the conductor and extending axially farther than the head section, the connecting section of the first conductor of the second coil and the connecting section of the third conductor of the corresponding coil each have an inclined section extending away from the stator core axially and circumferentially between the leg section and the end section; wherein, in the first coil, the leg section of the first conductor is arranged in the first layer, and the leg section of the third conductor is arranged in the (L-1)th layer, and in the second coil, the leg section of the first conductor is arranged in the second layer, and the leg section of the third conductor is arranged in the Lth layer.

[0002] Furthermore, the invention relates to a stator arrangement, a method for producing a stator arrangement, and an electric drive for a vehicle. Background Art

[0003] US2021 / 0159749 A1 discloses a stator for a motor, the stator comprising:

[0004] A plurality of pins are arranged in slots of the stator on concentric circles at different distances from the center of the stator. Each concentric circle forms a layer. In each case, four pins in different layers are connected in series with each other and form a winding. The stator has a first end face and a second end face opposite to each other. The input and output of the partial coil are arranged on the first end face.

[0005] A stator with two coils per phase winding provides the possibility to connect the coils in parallel or in series. Typically, this is achieved by terminal means, which connect the connection sections of the outer conductor of each coil in the desired manner. In order to allow the terminal means to correctly connect the connection sections, the geometry of the connection sections is typically adapted to the desired type of connection achieved by the terminal means. Summary of the invention

[0006] The object of the present invention is to improve the connectivity of a stator to a terminal arrangement.

[0007] This object is achieved by the stator described at the beginning, wherein the inclined section of the third conductor of the first coil is longer than the inclined section of the third conductor of the second coil, so as to form a circumferential and radial first gap between the end sections of the third conductors of the first coil and the second coil; wherein the inclined section of the first conductor of the second coil is shorter than the inclined section of the third conductor of the second coil, so as to form a circumferential and radial second gap between the end section of the third conductor of the first coil and the end section of the first conductor of the second coil; wherein the connecting section of the first conductor is bent at least radially outward, so as to form a circumferential and radial third gap between the end section of the first conductor of the second coil and the end section of the first conductor of the first coil.

[0008] The stator according to the present invention comprises a stator core and a stator winding. The stator winding has a phase winding. The stator core has an axial face side and slots. The slots are distributed in the circumferential direction. Each slot is divided into a first layer to an Lth layer in the radial direction, where L≥4. The layers are indexed in their order from outside to inside. Each phase winding comprises a first coil and a second coil. Each coil is formed by a plurality of conductors. A plurality of conductors are connected into a series connection body. The series connection body has a first conductor and a third conductor in the conductor as its opposite outer conductors. The series connection body has a second conductor in the conductor as one of its inner conductors. The second conductor has a first leg section and a second leg section. The leg section of the second conductor extends through two different slots in the slot. The second conductor has a head section. The head section connects the leg section at the face side. The first conductor and the third conductor each have a leg section and a connecting section. The leg section of each of the first conductor and the third conductor extends through one of the slots. The connecting section is located at the face side. The connecting section has an end section. The end section includes a free end of the conductor and extends further in the axial direction than the head section. The connecting section of the first conductor of the second coil and the connecting section of the third conductor of the corresponding coil each have an inclined section between the leg section and the end section. The inclined section extends away from the stator core axially and circumferentially. In the first coil, the leg section of the first conductor is arranged in the first layer, and the leg section of the third conductor is arranged in the (L-1)th layer. In the second coil, the leg section of the first conductor is arranged in the second layer, and the leg section of the third conductor is arranged in the Lth layer. The inclined section of the third conductor of the first coil is longer than the inclined section of the third conductor of the second coil to form a circumferential and radial first gap between the end section of the third conductor of the first coil and the second coil. The inclined section of the first conductor of the second coil is shorter than the inclined section of the third conductor of the second coil to form a circumferential and radial second gap between the end section of the third conductor of the first coil and the end section of the first conductor of the second coil. The connecting section of the first conductor is bent at least radially outward to form a third gap in the circumferential direction and in the radial direction between the end section of the first conductor of the second coil and the end section of the first conductor of the first coil.

[0009] The proposed geometry of the connecting section forms a first gap to a third gap, which provides sufficient space to connect the connecting sections in parallel or in series by selecting the external terminal means. Therefore, only one type of stator is required, and the connection of the coils can be achieved by a specific design of the terminal means. Since the coils connected in series can be connected to a voltage source with a voltage twice that of the coils connected in parallel, the present invention provides a stator that can be used for various different levels of operating voltage. In particular, different designs of the stator conductors in terms of diameter and shape in stators for different operating voltages can be omitted.

[0010] The stator core may include a plurality of axially stacked and / or mutually insulated metal laminations.Each layer of slots may be configured to accommodate exactly one leg segment.

[0011] The conductor may be formed from a single metal rod, in particular a copper rod. The conductor may have a rectangular or rounded rectangular cross section. The stator winding may be considered a hairpin winding. The first conductor and the third conductor may be considered an I-shaped pin. The second conductor may be considered a U-shaped pin. Of course, each coil may be provided with a plurality of second conductors connected in series.

[0012] The terms "outer conductor" and "inner conductor" refer to the series connection of the conductors of the respective coils, such that each coil comprises two outer conductors and one or more inner conductors formed by a second conductor located between the outer conductors. In other words, the outer conductors form two opposite ends of the series connection, with the inner conductors interconnected between them.

[0013] The first gap to the third gap are respectively the free spaces between the respective end sections in a plane parallel to the face side or perpendicular to the longitudinal axis of the stator core.

[0014] For each leg section thereof, the corresponding conductor may further include a joining section as an extension of the leg section at an axial second face side opposite to the axial first face side. In order to achieve a series connection of the conductors, the joining sections of different conductors may be joined in pairs in an electrically conductive and mechanical manner (e.g., by welding).

[0015] Each phase winding may have a number of poles, P. Further, the number of phase windings may be N, and the number of slots may be S.

[0016] In more detail, the space between the end segments may be implemented in the following manner: the end segment of the third conductor of the second coil may be arranged at a circumferential position that is S / (P·N) slots away from the slot in which the leg segment is arranged. Alternatively or additionally, the end segment of the third conductor of the first coil may be arranged at a circumferential position that is [S / (P·N)]+1 slots away from the slot in which the leg segment is arranged. Alternatively or additionally, the end segment of the first conductor of the second coil may be arranged at a circumferential position between a circumferential position that is [S / (P·N)]−1 slots away from the slot in which the leg segment is arranged and a circumferential position that is S / (P·N) slots away from the slot in which the leg segment is arranged.

[0017] In order to allow the end section of the third conductor of the first coil to be sufficiently spaced apart from the third conductor of the second coil, the end section of the third conductor of the first coil is preferably bent radially outward so that the free end of the conductor is displaced radially outward more than the inclined section. In particular, the end section of the third conductor of the first coil is displaced by a radial range of one layer.

[0018] Preferably, the connection section of the first conductor of the second coil includes a displacement section configured to displace the end section radially outward more than the inclined section. Such a displacement section allows the position of the end section of the first conductor of the second coil to be defined to form the second gap and the third gap. In particular, the displacement section is configured to displace the end section outside the radial range of each slot.

[0019] Advantageously, the connection section of the first conductor of the first coil comprises a displacement section extending radially outwardly between the leg section and the end section. Such a displacement section allows defining the position of the end section of the first conductor of the first coil to form a third gap and provide a phase connection for powering the phase winding.

[0020] Preferably, a first phase winding to a third phase winding are provided. The leg section of the first conductor of the second phase winding can be arranged circumferentially between the leg sections of the first conductor of the first phase winding and the third phase winding. Alternatively or additionally, the leg section of the third conductor of the second phase winding can be arranged circumferentially between the leg sections of the third conductor of the first phase winding and the third phase winding.

[0021] In a preferred design, the connecting sections of the first conductors of the first coils of the first phase winding and the third phase winding each include a displacement section that is bent toward the connecting section of the first conductor of the first coil of the second phase winding. Thus, an appropriate space can be achieved between the first conductors of the first coils.

[0022] According to an advantageous embodiment, the end sections of the first conductors of the respective first coils of the first to third phase windings are arranged in one plane. In particular, the plane extends tangentially with respect to the circumferential position at which the leg sections of the first conductors of the first coils of the second phase winding are arranged. The arrangement of the end sections in one plane allows for a simple connection via busbars arranged in parallel in the terminal arrangement.

[0023] In a further detail of the stator according to the invention, the third conductors of the second coils of each phase winding have the same shape. Alternatively or additionally, the third conductors of the first coils of each phase winding may have the same shape. Alternatively or additionally, the first conductors of the second coils of each phase winding have the same shape. Using corresponding conductors of the same shape reduces the number of individual conductor types and reduces the manufacturing effort.

[0024] Preferably, connecting sections of the first conductors of the first coils of the first phase winding and the third phase winding are mirror-symmetrical.

[0025] The above-mentioned object is further solved by a stator device for an electric machine, which comprises a terminal device and a stator according to the present invention; wherein the terminal device comprises a phase connector busbar, a neutral connector busbar, a coil connector busbar, and an isolator; wherein the phase connector busbars each comprise an attachment section, which is electrically and mechanically connected to an end section of a connection section of a first conductor of a first coil of one of the phase windings; wherein each of the neutral connector busbar and the coil connector busbar comprises a main section and at least two attachment sections connected by the main section; wherein the main section of the neutral connector busbar extends between circumferentially adjacent pairs of end sections of a third conductor of a second coil of the phase winding, and the attachment section of the neutral connector busbar is electrically and mechanically connected to the paired end sections; wherein, for the corresponding phase winding,

[0026] The attachment section of the coil connector busbar is electrically and mechanically connected to the end sections of the first conductor of the first coil and the second coil, wherein the third gap is bridged for forming a parallel connection of the coils of the respective phase windings, or

[0027] an attachment section of the coil connector bus bar electrically and mechanically connected to an end section of the third conductor of the first coil and to an end section of the first conductor of the second coil, wherein the second gap is bridged for forming a series connection of the coils of the respective phase windings;

[0028] The position of the bus bars relative to each other is fixed by the spacers.

[0029] Preferably, the isolator comprises a cutout and / or a through hole through which the end section is guided towards the attachment section. In particular, an end section of the first conductor of the first coil and an end section of the first conductor of one of the second coils are guided through the through hole. Furthermore, the attachment section of the phase connector busbar can be guided through the through hole. The isolator can be formed in one piece or comprise a plurality of, in particular two, isolating members.

[0030] When the coil connector busbar bridges the third gap, the terminal device may include another busbar having two attachment sections and a main section located between the two attachment sections, the attachment section being electrically and mechanically connected to an end section of the third conductor of the first coil of one of the phase windings, in particular the third phase winding, and an end section of the third conductor of the second coil, wherein the first gap of one of the phase windings is bridged.

[0031] When the coil connector busbar bridges the third gap, each neutral connector busbar may include another attachment section and an extension section connecting the other attachment section with the main section and extending radially outward away from the main section, the extension section extending partially across the second gap.

[0032] The above-mentioned attachment sections of the respective busbars may extend perpendicularly with respect to the main section and / or parallel to the end sections to which they are connected.

[0033] When the coil connector bus bars bridge the second gap, the coil connector bus bars may be arranged circumferentially and / or have the same shape.

[0034] The above-mentioned object is further solved by a method for manufacturing a stator device, which method comprises the following steps: providing a stator according to the present invention; providing a first terminal device and a second terminal device, each terminal device comprising a phase connector busbar, a neutral connector busbar, a coil connector busbar, and an isolator, the phase connector busbars each comprising an attachment section, which is configured to be electrically and mechanically connected to an end section of a connection section of a first conductor of a first coil of one of the phase windings, each of the neutral connector busbar and the coil connector busbar comprising a main section and at least two attachment sections connected by the main section, the main section of the neutral connector busbar extending between circumferentially adjacent pairs of end sections of the third conductor of the second coil of the phase winding, the attachment section of the neutral connector busbar being configured to be electrically and mechanically connected to the paired end sections, the busbar phase The positions of the coils with respect to each other are fixed by an isolator, wherein, in a first terminal device, for a corresponding phase winding, an attachment section of a coil connector busbar is configured to be electrically and mechanically connected to an end section of a first conductor of a first coil and a second coil, wherein a third gap is bridged, wherein, in a second terminal device, for a corresponding phase winding, an attachment section of a coil connector busbar is configured to be electrically and mechanically connected to an end section of a third conductor of the first coil and an end section of a first conductor of the second coil, wherein a second gap is bridged; one of the terminal devices is selected according to manufacturing information; and the attachment section of the selected terminal device is electrically and mechanically connected to a corresponding end section of the stator, wherein if the first terminal device is selected, a parallel connection of the coils of the corresponding phase winding is formed, and if the second terminal device is selected, a series connection of the coils of the corresponding phase winding is formed.

[0035] All statements regarding the stator according to the invention and the stator arrangement according to the invention apply analogously to the method according to the invention, so that all the above-mentioned advantages can also be achieved.

[0036] The above objects are further solved by an electric drive device for a vehicle, the electric drive device comprising an electric machine having a stator device according to the invention or a stator device obtained by a method according to the invention, the electric machine further comprising a rotor rotatably arranged relative to the stator, the electric machine being configured to propel the vehicle. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] Further details and advantages of the present invention are disclosed below. Among them, reference is made to schematic diagrams showing:

[0038] Figure 1 A perspective view of a first embodiment of a stator arrangement according to the invention with an embodiment of a stator according to the invention;

[0039] Figure 2 A schematic diagram of the connection of the stator winding according to the first embodiment;

[0040] Figure 3 A detailed view of an embodiment of a stator;

[0041] Figure 4 Schematic diagram of the second conductor;

[0042] Figure 5 a perspective view of a first conductor of a first coil of each phase winding;

[0043] Figure 6 a perspective view of a first conductor of a second coil;

[0044] Figure 7 a perspective view of a third conductor of the first coil;

[0045] Figure 8 a perspective view of a third conductor of the second coil;

[0046] Fig. 9 a detailed top view of the stator showing the stator core and the first and third conductors;

[0047] Fig.10 A top view of a terminal device of a stator device according to a first embodiment of the stator device;

[0048] Fig.11 A perspective view of a second embodiment of a stator device according to the present invention;

[0049] Fig.12 A schematic diagram of the connection of the stator winding according to the second embodiment;

[0050] Fig.13 A top view of a terminal device of a stator device according to a second embodiment;

[0051] Fig.14 A flow chart of an embodiment of a manufacturing method according to the present invention; and

[0052] Fig.15 Schematic diagram of an exemplary embodiment of a vehicle according to the invention, which has an exemplary embodiment of an electric drive according to the invention. DETAILED DESCRIPTION

[0053] Figure 1is a perspective view of a first embodiment of a stator arrangement 100, which comprises an embodiment of a stator 1. Below the stator 1, the stator arrangement 100 comprises a terminal arrangement 101', which will be described in detail below.

[0054] The stator 1 comprises a stator core 2 and a stator winding 3 having phase windings 3u, 3v, 3w (see Figure 2 ). In the present embodiment, the number of phase windings is exemplarily N=3. Also exemplarily, each phase winding 3u, 3v, 3w has a pole number of P=8. The stator core 2 has a first axial face side 4, a second axial face side 5 opposite to the first axial face side 4, and circumferentially distributed slots 6, of which only three are provided with reference numerals for the sake of simplicity. Also exemplarily, in the present embodiment, S=48 slots 6 are provided. Each slot 6 is radially divided into a first layer to an Lth layer, and the layers are indexed in their order from the outside to the inside. In the present embodiment, L is selected to be four, so that a first layer 7a to a fourth layer 7d are provided (see also Fig. 9 ). Therefore, the first layer 7a is an outer layer, the fourth layer 7d is an inner layer, and the second layer 7b and the third layer 7c are located therebetween.

[0055] Figure 2 is a schematic diagram of the connection of the stator winding 3 according to the first embodiment.

[0056] Each phase winding 3u, 3v, 3w includes a first coil 8 and a second coil 9, and each coil 8, 9 is formed by a plurality of conductors 10u', 10v', 10w', 10", 11, 12', 12" connected in series. Among them, each coil in the coils 8, 9 is formed by a first conductor 10u', 10v', 10w', 10", a plurality of second conductors 11 and a third conductor 12', 12". The first conductor 10u', 10v', 10w', 10" and the third conductor 12', 12" of each coil 8, 9 are the opposite outer conductors of the coil 8, 9 relative to the series connection. The second conductor 11 of each coil 8, 9 is the inner conductor of the coil relative to the series connection.

[0057] The interconnection of the first coil 8 and the second coil 9 with respect to each other (ie whether they are connected in series or in parallel) and with the neutral point 13 is achieved by means of a terminal device 101' (see Figure 1 ). In the present embodiment, the first coil 8 and the second coil 9 of each phase winding 3u, 3v, 3w are connected in parallel by connecting their first conductors 10u', 10v', 10w', 10" on the one hand and their third conductors 12', 12" on the other hand. Also in the present embodiment, the third conductors 12', 12" are connected to form a neutral point 13.

[0058] Internally, the second conductors 11 of each coil 8, 9 are interconnected in a suitable manner to form a suitable winding scheme for the stator 1. In particular, the second conductors 11 can be interconnected to form a lap winding, a wave winding, or a combination thereof. Possible implementations of the winding scheme are disclosed in patent application publication US2021 / 0159749 A1.

[0059] Figure 3 is a detailed view of stator 1, Figure 4 is a schematic diagram of a second conductor in the second conductor 11, Figure 5 A perspective view of a first conductor 10u', 10v', 10w' of a first coil 8 of each phase winding 3u, 3v, 3w is shown, Figure 6 is a three-dimensional diagram of the first conductor 10″ of the second coil 9, Figure 7 is a perspective view of the third conductor 12' of the first coil 8, and Figure 8 It is a perspective view of the third conductor 12 ″ of the second coil 9 .

[0060] As from Figure 4 As can be best seen in FIG. 1 , the second conductor 11 has a first leg section 14 and a second leg section 15 extending through two different slots in the slot 6, and a head section 16 connecting the leg sections 14 and 15 at the first face side 4. The head section 16 of the second conductor 11 of the coils 8 and 9 forms an annular winding head 17 extending circumferentially along the first face side 4 and having a certain axial extent.

[0061] As from Figures 5 to 8 As can be best seen in FIG. 4 , the first conductors 10u′, 10v′, 10w′, 10″ and the third conductors 12′, 12″ each include a leg section 18 extending through one of the slots 6 and a connecting section 19 at the face side 4 .

[0062] Each connecting section 19 has an end section 20, which includes the free end 21 of the corresponding conductor 10u', 10v', 10w', 10", 12', 12". Figure 3 As can be best seen in FIG. 1 , the end section 20 of the connecting section 19 of each first conductor 10u′, 10v′, 10w′, 10″ and the third conductor 12′, 12″ respectively extends further in the axial direction than the head section 16 of each second conductor 11 or than the winding head 17. Referring again to Figures 6 to 8 The connecting section 19 of the first conductor 10 ″ of the second coil 9 and the connecting sections of the third conductors 12 ′, 12 ″ of the respective coils 8 , 9 each have an inclined section 22 extending axially and circumferentially away from the stator core 2 between the leg section 18 and the end section 20 .

[0063] In a specific implementation of the present embodiment according to the stator 1, the third conductor 12" of the second coil 9 of each phase winding 3u, 3v, 3w has the same shape. Further, the third conductor 12' of the first coil 8 of each phase winding 3u, 3v, 3w has the same shape. The first conductor 10" of the second coil 9 of each phase winding 3u, 3v, 3w has the same shape.

[0064] Fig. 9 1 is a detailed top view of the stator 1, showing the stator core 2 and the first conductors 10u', 10v', 10w', 10" and the third conductors 12', 12". That is, for the sake of clarity, Fig. 9 The second conductor 11 is not shown.

[0065] In the first coil 8, the leg sections 18 of the first conductors 10u', 10v', 10w', 10" are arranged in the first layer 7a, and the leg sections 18 of the third conductor 12' are arranged in the (L-1)th layer, i.e., the third layer 7c. In the second coil 9, the leg sections 18 of the first conductor 10" are arranged in the second layer 7b, and the leg sections 18 of the third conductor 12" are arranged in the Lth layer, i.e., the fourth layer 7d. According to the above winding scheme, the leg sections 14, 15 of the second conductor 11 are arranged in the corresponding layers 7a to 7d.

[0066] For each phase winding 3u, 3v, 3w, the inclined section 22 of the third conductor 12' of the first coil 8 is longer than the inclined section 22 of the third conductor 12" of the second coil 9 to form a circumferential and radial first gap 23 between the end sections 20 of the third conductors 12', 12" of the first coil 8 and the second coil 9. Further, the inclined section 22 of the first conductor 10″ of the second coil 9 is shorter than the inclined section 22 of the third conductor 12″ of the second coil 9 to form a circumferential and radial second gap 24 between the end section 20 of the third conductor 12′ of the first coil 8 and the end section 20 of the first conductor 10″ of the second coil 9. In addition, the connecting section 19 of each first conductor 10u′, 10v′, 10w′, 10″ is bent at least radially outward to form a circumferential and radial third gap 25 between the end section 20 of the first conductor 10″ of the second coil 9 and the end section of the first conductor 10u′, 10v′, 10w′ of the first coil 8. It should be noted that the gaps 23, 24, 25 respectively refer to the free space between the corresponding end sections 20 in a plane parallel to the face side 4 or perpendicular to the longitudinal axis of the stator core 2.

[0067] In further detail, the end segment 20 of the third conductor 12″ of the second coil 9 is arranged at a circumferential position that is S / (P·N)=2 slots away from the slot 6 in which the leg segment 18 is arranged. The end segment 20 of the third conductor 12′ of the first coil 8 is arranged at a circumferential position that is [S / (P·N)]+1=3 slots away from the slot 6 in which its leg segment 18 is arranged. Further, the end segment 20 of the first conductor 10″ of the second coil 9 is arranged at a circumferential position between a circumferential position that is [S / (P·N)]–1=1 slot away from the slot 6 in which the leg 18 is arranged and a circumferential position that is S / (P·N)=2 slots away from the slot 6 in which the leg segment 18 is arranged.

[0068] The end section 20 of the third conductor 12' of the first coil 8 is bent radially outward so that the free end 21 of the conductor 12' is shifted radially outward more than the inclined section 22. In this embodiment, the free end 21 is shifted relative to the inclined section 22 by a radial range of one layer 7a to 7d.

[0069] As from Fig. 9 and Figure 5 As can be seen in FIG. 1 , the connecting section 19 of the first conductor 10u', 10v', 10w' of the first coil 8 includes a displacement section 26 extending radially outward between the leg section 18 and the end section 20. In the first phase winding 3u and the third phase winding 3w, the displacement section 26 is shorter than in the second phase winding 3v.

[0070] Further, the leg sections 18 of the first conductors 10v', 10"' of the second phase winding 3v are arranged in the circumferential direction between the leg sections 18 of the first conductors 10u', 10w', 10" of the first phase winding 3u and the third phase winding 3w. In addition, the leg sections 18 of the third conductors 12', 12"' of the second phase winding 9v are arranged in the circumferential direction between the leg sections 18 of the third conductors 12', 12" of the first phase winding 3u and the third phase winding 3w. The connecting sections 19 of the first conductors 10u', 10w" of the first coils 8 of the first phase winding 3u and the third phase winding 3w each include a displacement section 27 that is bent toward the connecting section 19 of the first conductor 10v' of the first coil 8 of the second phase winding 3v, so that the end sections 20 of the first conductors 10u', 10v', 10w' of the respective first coils 8 of the first to third phase windings 3u, 3v, 3w are arranged in a plane 28. The plane 28 extends tangentially with respect to the circumferential position at which the leg section 18 of the first conductor 10v' of the first coil 8 of the second phase winding 3v is arranged. Fig. 9 In FIG. 2 , the plane 28 is perpendicular to the drawing plane. Furthermore, the connecting sections 19 of the first conductors 10u', 10w' of the first coils 8 of the first phase winding 3u and the third phase winding 3w are mirror-symmetrical.

[0071] Furthermore, the connecting section 19 of the first conductor 10″ of the second coil 9 of the respective phase winding 3u, 3v, 3w includes a displacement section 31 configured to displace the end section 20 radially outwardly more than the inclined section 22. As can be seen, by the displacement section 31, the end section 20 is arranged outside the radial range of each slot 6.

[0072] Again, reference Figures 4 to 8 , each of the first and third conductors 10u', 10v', 10w', 12', 12" further comprises a joining section 29 as an extension of the leg section 18 at the second side 5. Correspondingly, each second conductor 11 further comprises two joining sections as extensions of the corresponding leg sections 14, 15. In order to achieve the series connection of the conductors 10u', 10v', 10w', 11, 12', 12", the joining sections 29 are connected in pairs in an electrically conductive and mechanical manner (for example, by welding). As shown from Figure 1 As can be seen in the figure, the free ends of each pair of joined joining segments 29 are covered by an electrically insulating cover 30. It should be noted that the circumferential direction in which the joining segments 29 point depends on the selected winding scheme. In particular, the corresponding joining segments 29 of the second conductor 11 can point in the same direction, away from each other or towards each other.

[0073] Fig.10 is a top view of the terminal device 101' of the stator device 100 according to the first embodiment. Fig.10 The positions of the free ends 21 of the first conductors 10u', 10v', 10w' and the third conductors 12', 12" are also marked.

[0074] The terminal device 101' includes N=3 phase connector busbars 102u, 102v, 102w, N-1=2 neutral connector busbars 103a, 103b, coil connector busbars 104a, 104b, 104c, and an isolator 105, which fixes the positions of the busbars 102u, 102v, 102w, 103a, 103b, 104a, 104b, 104c relative to each other.

[0075] The phase connector busbars 102u, 102v, 102w each include an attachment section 106 which is electrically and mechanically connected to an end section 20 of a connection section 19 of a first conductor 10u', 10v', 10w' of a first coil 8 of one of the phase windings 3u, 3v, 3w. Further, each phase connector busbar 102u, 102v, 102w includes a main section 107. Each of the neutral connector busbars 103a, 103b and the coil connector busbars 104a, 104b, 104c includes a main section 108 and at least two attachment sections 109 connected by the main section 108.

[0076] The attachment section 106, 109 of each bus bar 102u, 102v, 102w, 103a, 103b, 104a, 104b, 104c is bent away from the main section 107, 108 in the axial direction so as to be aligned parallel to the end section 20. In other words, the main section 107, 108 extends perpendicularly relative to the attachment section 106, 109 and the end section 20.

[0077] The main section 108 of the neutral connector busbars 103a, 103b extends between circumferentially adjacent pairs of end sections 20 of the third conductor 12" of the second coil 9 of the phase windings 3u, 3v, 3w. Two of the attachment sections 109 of the neutral connector busbars 103a, 103b are electrically and mechanically connected to the pairs of end sections 20, and the two attachment sections extend between the pair of end sections. The other attachment section 109 of the respective neutral connector busbars 103a, 103b is connected to the main section 108 via an extension section 110 extending in the same plane as the main section 108. The other attachment sections 109 of the neutral connector busbars 103a, 103b are electrically and mechanically connected to the end sections 20 of the third conductor 12' of the first coil 8 of two of the phase windings 3u, 3v, and partially extend through the second gap 24.

[0078] For the respective phase winding 3u, 3v, 3w, the attachment sections 109 of the coil connector busbars 104a, 104b, 104c are electrically and mechanically connected to the end sections 20 of the first conductors 10u', 10v', 10w', 10" of the first and second coils 8, 9, wherein the third gap 25 is bridged.

[0079] Furthermore, a further busbar 111 of the terminal device 101' is provided, which busbar is provided with a main section 108 and two attachment sections 109. The attachment section 109 is electrically and mechanically connected to the end section 20 of the third conductor 12' of the first coil 8 and the end section 12" of the third conductor 12" of the second coil 9 of the phase winding 3w (i.e. the phase winding whose third conductors 12', 12" are not connected via the neutral connector busbars 103a, 103b). The main section 108 of the further busbar 111 bridges the first gap 23 of the phase winding 3w. The isolator 105 also fixes the relative position of the further busbar 111 with respect to the other busbars 102u, 102v, 102w, 103a, 103b, 104a, 104b, 104c.

[0080] In particular detail, the isolator 105 includes a first isolating member 105a and a second isolating member. The first isolating member 105a partially covers the phase connector busbars 102u, 102v, 102w and provides phase terminals, which are located on the opposite side of the main section relative to the connection section 106 for supplying AC voltage to the stator 1. The second isolating member 105b covers a portion of the main section 106 of the phase connection busbars 102u, 102v, 102w and the main section 108 of the neutral connector busbars 103a, 103b, the coil connector busbars 104a, 104b, 104c and the other busbar 111 to fix their relative positions. Nevertheless, in an alternative embodiment, the isolator 105 can be formed in an integral manner.

[0081] Fig.11 is a perspective view of a second embodiment of a stator arrangement 100. The second embodiment corresponds to the first embodiment except for the differences described below. In the following, the same reference numerals are used for identical or equivalent components.

[0082] The stator 1 of the stator device 100 according to the second embodiment is the same as the stator 1 according to the first embodiment except for the outer shape of the stator core 2 .

[0083] Fig.12 is a schematic diagram of the connection of the stator winding 3 according to the second embodiment of the stator device 100 .

[0084] The stator device 100 differs from the first embodiment in that the terminal device 101" realizes the series connection of the coils 8 and 9 of the corresponding phase windings 3u, 3v, 3w. Therefore, the third conductor 12' of the first coil 8 is connected to the first conductor 10". of the second coil 9 of the corresponding phase winding 3u, 3v, 3w. The third conductor 12" of the second coil 9 of the corresponding phase winding 3u, 3v, 3v is connected to form a neutral point 13.

[0085] Fig.13is a top view of a terminal device 101″ according to a second embodiment of a stator device 100. Fig.10 Correspondingly, Fig.13 The positions of the free ends 21 of the first conductors 10u', 10v', 10w' and the third conductors 12', 12'' are marked.

[0086] As in the first embodiment, the terminal device 101" includes N=3 phase connector busbars 102u, 102v, 102w, N-1=2 neutral connector busbars 103a, 103b, coil connector busbars 104a, 104b, 104c, and an isolator 105. It should be noted that another busbar 111 is omitted in the second embodiment. In addition, the neutral connector busbars 103a, 103b are not provided with an extension section 110, and therefore, each busbar has two attachment sections 109 connected by a main section 108.

[0087] Compared to the first embodiment, the attachment section 109 of the coil connector busbars 104a, 104b, 104c is electrically and mechanically connected to the end section of the third conductor 12' of the first coil 8 and the first conductor 10" of the second coil 9, wherein the second gap 24 is bridged to form a series connection of the coils 8, 9 of the corresponding phase windings 3u, 3v, 3w. In more detail, the coil connector busbars 104a, 104b, 104c are arranged in the circumferential direction and have the same shape.

[0088] By comparing the first embodiment and the second embodiment of the stator device 100, it can be seen that the stator 1 allows the coils 8, 9 of the phase windings 3u, 3v, 3w to be connected in parallel or in series by selecting appropriate terminal devices 101', 101". Therefore, compared with applying the terminal device 101' according to the first embodiment, when the terminal device 101" according to the second embodiment is applied, the stator device 100 can operate at twice the voltage at the stator winding 3. As an example, the stator device 100 according to the first embodiment is suitable for an operating voltage of 400 volts, while the stator device 100 according to the second embodiment is suitable for an operating voltage of 800 volts.

[0089] In the following, an embodiment of a method for producing a stator arrangement 100 according to any of the above-described embodiments is described. Therein, reference is made to the above-described embodiments.

[0090] Fig.14 is a flow chart of an embodiment of a manufacturing method.

[0091] The method comprises: step S1: providing a stator 1; step S2: providing a first terminal device 101 ′ according to a first embodiment of the stator device 100 and a second terminal device 101 ″ according to a second embodiment of the stator device 100 .

[0092] Subsequently, the method comprises step S3: selecting one of the terminal devices according to the manufacturing information, wherein the manufacturing information may describe whether the coils 8, 9 of each phase winding 3u, 3v, 3w of the stator 1 should be connected in parallel or in series.

[0093] In a further step S4, the attachment section 109 of the selected terminal device 101', 101" is electrically and mechanically connected to the corresponding end section 20 of the stator 1, wherein if the first terminal device 101' is selected, a parallel connection of the coils 8, 9 of the corresponding phase windings 3u, 3v, 3w is formed, and if the second terminal device 101" is selected, a series connection of the coils 8, 9 of the corresponding phase windings 3, 3v, 3w is formed.

[0094] Fig.15 is a schematic diagram of an exemplary embodiment of a vehicle 200 having an exemplary embodiment of an electric drive 201 .

[0095] The vehicle 200 comprises an electric drive device 201, which comprises an electric machine 202, such as a permanent magnet or electrically excited synchronous machine or an induction machine. The electric machine 202 comprises a stator device 100 obtained according to any one of the above embodiments or by performing an embodiment of the method. Further, the electric machine 202 comprises a rotor 203. The rotor 203 is rotatably mounted in the stator core 2 around a longitudinal axis.

[0096] In addition, the vehicle 200 includes wheels 204. The motor 202 is configured to drive at least one of the wheels 204 indirectly (e.g., via a gearbox (not shown)) or directly (e.g., as a hub motor). The vehicle 200 may further include an axle (not shown) coupled to the wheel 204, the axle being driven directly or indirectly by the motor 202.

[0097] The vehicle 200 is a pure electric vehicle (BEV), a vehicle powered via a fuel cell, or a hybrid vehicle further including an internal combustion engine (not shown).

Claims

1. A stator (1), comprising a stator core (2) and a stator winding (3) having phase windings (3u-w); wherein: The stator core (2) has an axial face side (4) and slots (6) distributed along the circumferential direction, each slot is divided into a first layer to an Lth layer (7a-d) along the radial direction, where L≥4, and the layers (7a-d) are indexed in order from the outside to the inside; wherein, Each phase winding (3u-w) comprises a first coil and a second coil (8, 9), each coil (8, 9) being formed by a plurality of conductors (10u-w', 10", 11, 12', 12") connected in series, the series connection body having a first conductor and a third conductor (10u-w', 10", 12', 12") of the conductors as opposite outer conductors thereof and a second conductor (11) of the conductors as one of its inner conductors, the second conductor (11) having first and second leg sections (14, 15) extending through two different slots of the slots (6) and a head section (16) connecting the leg sections (14, 15) at the face side (4), the first conductor and the third conductor (10u-w', 10", 11, 12', 12") of the conductors being connected in series, , 10", 12', 12") each having a leg section (18) extending through one of the slots (6) and a connecting section (19) located at the face side (4), the connecting section (19) having an end section (20), the end section including a free end (21) of the conductor (10u-w', 10", 12', 12") and extending axially further than the head section (16), the connecting section (19) of the first conductor (10") of the second coil (9) and the connecting section of the third conductor (12', 12") of the corresponding coil (8, 9) each having an inclined section (22) extending axially and circumferentially away from the stator core (2) between the leg section (18) and the end section (20); wherein, In the first coil (8), the leg section (18) of the first conductor (10u-w') is arranged in a first layer (7a), and the leg section (18) of the third conductor (12') is arranged in an (L-1)th layer (7c), and in the second coil (9), the leg section (18) of the first conductor (10") is arranged in a second layer (7b), and the leg section (18) of the third conductor (12") is arranged in an Lth layer (7d); It is characterized in that The inclined section (22) of the third conductor (12') of the first coil (8) is longer than the inclined section (22) of the third conductor (12") of the second coil (9) to form a first gap (23) in the circumferential and radial directions between the end sections (20) of the third conductors (12', 12") of the first coil and the second coil (8, 9); wherein, The inclined section (22) of the first conductor (10") of the second coil (9) is shorter than the inclined section (22) of the third conductor (12") of the second coil (9) to form a circumferential and radial second gap (24) between the end section (20) of the third conductor (12') of the first coil (8) and the end section (20) of the first conductor (10") of the second coil (9); wherein, The connecting section (9) of the first conductor (10u-w', 10") is bent at least radially outward to form a circumferential and radial third gap (25) between the end section (20) of the first conductor (10") of the second coil (9) and the end section of the first conductor (10u-w') of the first coil (8).

2. The stator according to claim 1, wherein: Each phase winding (3u-w) has a number of poles P, the number of phase windings (3u-w) is N, and the number of slots (6) is S, wherein: The end section (20) of the third conductor (12") of the second coil (9) is arranged at a circumferential position S / (P·N) slots away from the slot (6) in which the leg section (18) is arranged, and / or The end section (20) of the third conductor (12') of the first coil (8) is arranged at a circumferential position which is [S / (P·N)]+1 slots away from the slot (6) in which the leg section (18) thereof is arranged, and / or The end section (20) of the first conductor (10") of the second coil (9) is arranged at a circumferential position between a circumferential position that is [S / (P·N)]-1 slots (6) away from the slot (6) in which the leg section (18) is arranged and a circumferential position that is S / (P·N) slots away from the slot (6) in which the leg section (18) is arranged.

3. The stator according to claim 1 or 2, wherein: The end section (20) of the third conductor (12') of the first coil (8) is bent radially outward so that the free end (21) of the conductor (12') is displaced radially outward more than the inclined section (22), in particular by the radial extent of one layer (7a-d).

4. A stator according to any one of the preceding claims, wherein: The connecting section (19) of the first conductor (10") of the second coil (9) comprises a displacement section (31) configured to displace the end section (20) radially outwards more than the inclined section (22), in particular, to outside the radial range of each slot (6).

5. A stator according to any one of the preceding claims, wherein: The connecting section (19) of the first conductor (10u-w') of the first coil (8) comprises a displacement section (26) extending radially outward between the leg section (18) and the end section (20).

6. A stator according to any one of the preceding claims, wherein: A first phase winding to a third phase winding (3u-w) are provided, a leg section (18) of a first conductor (10u-w', 10") of the second phase winding (3v) is circumferentially arranged between leg sections (18) of first conductors (10u-w', 10") of the first phase winding and the third phase winding (3u, 3w), and / or a leg section (18) of a third conductor (12', 12") of the second phase winding (3v) is circumferentially arranged between leg sections (18) of third conductors (12', 12") of the first phase winding and the third phase winding (3u, 3w).

7. The stator according to claim 6, wherein: The connecting sections (19) of the first conductors (10u', 10w') of the first coils (8) of the first phase winding and the third phase winding (3u, 3w) each include a displacement section (27) which is bent toward the connecting section (19) of the first conductor (10v') of the first coil (8) of the second phase winding (3v).

8. The stator according to claim 6 or 7, wherein: The end sections (20) of the first conductors (10u-w') of the respective first coils (8) of the first phase winding to the third phase winding (3u-w) are arranged in a plane (28), the plane (28) particularly extending tangentially with respect to a circumferential position at which the leg sections (18) of the first conductors (10v') of the first coils (8) of the second phase winding (3v) are arranged.

9. A stator according to any one of the preceding claims, wherein: The third conductor (12") of the second coil (9) of each phase winding (3u-w) has the same shape, and / or The third conductor (12') of the first coil (8) of each phase winding (3u-w) has the same shape, and / or The first conductor (10") of the second coil (9) of each phase winding (3u-w) has the same shape, and / or The connecting sections (19) of the first conductors (10u', 10w') of the first coils (8) of the first phase winding and the third phase winding (3u, 3w) are mirror-symmetrical.

10. A stator device (100) for an electric machine (202), the stator device (100) comprising a terminal device (101', 101") and a stator (1) according to any one of claims 1 to 9; wherein: The terminal device (101', 101") comprises a phase connector busbar (102u-w), a neutral connector busbar (103a, 103b), a coil connector busbar (104a-c), and an isolator (105); wherein, The phase connector busbars (102u-w) each include an attachment section (106) electrically and mechanically connected to an end section (20) of a connection section (19) of a first conductor (10u-w') of a first coil (8) of one of the phase windings (3u-w); wherein, Each of the neutral connector busbar (103a, 103b) and the coil connector busbar (104a-c) includes a main section (108) and at least two attachment sections (109) connected by the main section (108); wherein, The main section (108) of the neutral connector busbar (103a, 103b) extends between circumferentially adjacent pairs of end sections (20) of the third conductor (12") of the second coil (9) of the phase winding (3u-w), and the attachment section (109) of the neutral connector busbar (103a, 103b) is electrically and mechanically connected to the pairs of end sections (20); wherein, For the corresponding phase winding (3u-w), The attachment section (109) of the coil connector busbar (104a-c) is electrically and mechanically connected to the end section (20) of the first conductor (10u-w', 10") of the first and second coils (8, 9), wherein the third gap (25) is bridged for forming a parallel connection of the coils (8, 9) of the respective phase windings (3u-w), or The attachment section (109) of the coil connector busbar (104a-c) is electrically and mechanically connected to the end section (20) of the third conductor (12') of the first coil (8) and the end section (12") of the first conductor (12") of the second coil (9), wherein the second gap (24) is bridged for forming a series connection of the coils (8, 9) of the respective phase windings (3u-w); wherein, The positions of the bus bars (102u-w, 103a, 103b, 104a-c) relative to each other are fixed by the separator (105).

11. The stator arrangement of claim 10, when the coil connector busbar (104a-c) bridges the third gap (25), wherein: The terminal device (101') comprises a further busbar (111) having two attachment sections (109) and a main section (108) located between the two attachment sections, the attachment section (109) being electrically and mechanically connected to an end section (20) of a third conductor (12') of a first coil (8) of one of the phase windings (3u-w), in particular a third phase winding (3w), and an end section (12") of a third conductor (12") of a second coil (9), wherein a first gap (23) of one of the phase windings (3w) is bridged.

12. The stator arrangement according to claim 10, when the coil connector busbar (104a-c) bridges the third gap (23), or the stator arrangement according to claim 11, wherein: Each neutral connector bus bar (103a, 103b) includes another attachment section (109) and an extension section (110), wherein the extension section connects the other attachment section (109) with the main section (108) and extends radially outward away from the main section (108), and the extension section (110) partially extends through the second gap (24).

13. The stator arrangement of claim 10, when the coil connector busbar (104a-c) bridges the second gap (24), wherein: The coil connector bus bars (104a-c) are arranged circumferentially and / or have the same shape.

14. A method for manufacturing a stator device (100), the method comprising the following steps: Providing a stator (1) according to any one of claims 1 to 9; A first terminal device (101') and a second terminal device (101") are provided, each terminal device (101', 101") comprising a phase connector busbar (102u-w), a neutral connector busbar (103a, 103b), a coil connector busbar (104a-c), and an isolator (105), wherein the phase connector busbar (102u-w) each comprises an attachment section (106) configured to be electrically and mechanically connected to an end section (20) of a connection section (19) of a first conductor (10u-w') of a first coil (8) of one of the phase windings (3u-w), the neutral connector busbar (103a, 103b) and the coil connector busbar (104a-c), and an isolator (105). Each of the busbars (104a-c) comprises a main section (108) and at least two attachment sections (109) connected by the main section (108), the main section (108) of the neutral connector busbar (103a, 103b) extending between circumferentially adjacent pairs of end sections (20) of the third conductor (12") of the second coil (9) of the phase winding (3u-w), the attachment sections (109) of the neutral connector busbar (103a, 103b) being configured to be electrically and mechanically connected to the pairs of end sections (20), the positions of the busbars (102u-w, 103a, 103b, 104a-c) relative to each other being fixed by the isolator (105), wherein, In the first terminal device (101'), for the respective phase winding (3u-w), the attachment section (109) of the coil connector busbar (104a-c) is configured to be electrically and mechanically connected to the end section (20) of the first conductor (10u-w', 10") of the first coil and the second coil (8, 9), wherein the third gap (25) is bridged, wherein, In the second terminal arrangement (101"), for the respective phase winding (3u-w), the attachment section (109) of the coil connector busbar (104a-c) is configured to be electrically and mechanically connected to an end section (20) of the third conductor (12') of the first coil (8) and to an end section (10") of the first conductor (10") of the second coil (9), wherein the second gap (24) is bridged; Selecting one of the terminal devices (101', 101") according to manufacturing information; and The attachment section (109) of the selected terminal device (101', 101") is electrically and mechanically connected to the corresponding end section (20) of the stator (1), wherein if the first terminal device (101') is selected, a parallel connection of the coils (8, 9) of the corresponding phase winding (3u-w) is formed, and if the second terminal device (101") is selected, a series connection of the coils (8, 9) of the corresponding phase winding (3u-w) is formed.

15. An electric drive device (201) for a vehicle (200), the electric drive device comprising an electric motor (202), the electric motor having a stator device (100) according to any one of claims 10 to 13 or obtained by the method according to claim 14, the electric motor (202) further comprising a rotor (203) rotatably arranged relative to the stator (1), the electric motor (202) being configured to propel the vehicle (200).

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