Power generation assembly and waveform winding of electric machine

Abstract

The invention relates to a power generation assembly of an electric machine. The invention relates to a stator for a motor vehicle, comprising an annular laminated core having a plurality of radially arranged slots (N1,..., N72) and a wave winding having at least one continuous first, second and third conductor (U1, U2, U3), which is respectively guided through adjacent slots (N1,..., N72) for a plurality of turns, said conductor forming a composite conductor. The composite conductor has a slot step in which the first conductor (U1), the second conductor (U2) and the third conductor (U3) each span the same number of slots (N1,..., N72), and in which there is a layer change. The composite conductor further has at least one slot step change which causes the first conductor (U1), the second conductor (U2) and the third conductor (U3) to exchange their arrangement with each other in the composite conductor 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 composite conductor.

Description

Technical Field

[0001] The present invention relates to a power generation component of an electric machine (electrical machine), such as a rotor or stator of an electric motor. The power generation component comprises an annular lamination stack and a wave winding, wherein the annular lamination stack has a plurality of radially arranged slots, and the wave winding has at least one continuous first conductor, a second conductor and a third conductor, which are respectively guided through adjacent slots for a plurality of turns, and which are connected in parallel or in series and form a composite conductor. The composite conductor has a slot step, wherein the first conductor, the second conductor and the third conductor respectively span the same number of slots, and wherein there is a layer change. In addition, the composite conductor has at least one slot step change section, wherein the first conductor, the second conductor and the third conductor span a different number of slots from each other, so that the first conductor, the second conductor and the third conductor are exchanged with each other 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 slot 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 slot is 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 component of the motor or electric motor is completely wrapped around by multiple conductors in multiple layers. Here, the layer of the conductor is the radial position of the conductor in the corresponding 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. This is particularly problematic in electric machines with a hole number q=3, in which each phase has three conductors running directly in adjacent slots, since the conductors are wired particularly closely together here. Summary of the invention

[0006] The object of the present invention is to provide a power generation assembly for an electric motor with a bore number q=3, which has relatively better efficiency and higher running smoothness.

[0007] According to the invention, for the power generating assembly 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 composite conductor. This greater number of slot step changes allows a greater running smoothness and improved efficiency to be achieved compared to the prior art, since a high level of electromagnetic symmetry is achieved in this way.

[0008] In an advantageous embodiment, the first conductor, the second conductor and the third conductor each comprise an arc-shaped winding head having an apex 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 slot step region more difficult, is avoided.

[0009] For the closest possible arrangement of the conductors, it is advantageous if the winding heads of at least two of the first, second and third conductors are arranged parallel to one another above and below or side by side. The remaining conductor is then guided above or below the other two conductors. It is particularly advantageous if the winding heads of the first, second and third conductors are arranged parallel to one another above and below. This allows an electric machine with particularly advantageous properties to be produced. This is achieved primarily in that the S-shaped stop protrudes less than with a sword winding, so that a more compact conductor arrangement can be achieved.

[0010] In another advantageous embodiment, the slot step changes on the lamination stack are arranged radially next to one another, thereby making it possible to arrange the conductors as closely as possible next to one another even in the region of the slot step changes, and to optimize the performance and operating characteristics of an electric machine equipped with such a power generation component.

[0011] In another advantageous embodiment, the wave winding has a pitch, wherein the first conductor, the second conductor and the third conductor are arranged together offset by at least one slot compared to the previous layer. This is achieved by correspondingly designed slot steps and slot step changes, wherein the composite conductor is offset by at least one slot on average compared to the previous layer.

[0012] It is also advantageous if the wave winding has a plurality of phases, each of which consists of one or more composite conductors. This increases the efficiency of the electric motor 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 advantageous for smooth operation and efficiency of the electric motor.

[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;

[0018] Figure 3is a schematic diagram of another winding scheme. DETAILED DESCRIPTION

[0019] Figure 1 A lamination stack 1 is shown as a stator of a power generation component, 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 even 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.

[0020] Figure 2 Schematic diagram of the winding scheme of the wave winding of the laminated core 1, which has exactly seventy-two slots N1, ..., N72. Here, the first row gives the number for exactly naming the slots N1, ..., N72. The first column gives the layers L1, ..., L6 within the slots N1, ..., N72. The layer L1 is here the position at the bottom of the corresponding slot N1, ..., N72, and the distance from the bottom increases as the number increases. It is thus possible to accurately trace the route of each conductor 3 through the slots N1, ..., N72 of the laminated core 1, wherein the conductor always has a winding head 4 that spans a plurality of slots N1, ..., N72 alternately on the first side and the second side of the laminated core 1.

[0021] 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, fifth and sixth conductors U4, U5, U6 is described. The first conductor U1, the second conductor U2 and the third conductor U3 form a first composite conductor here, and the fourth, fifth and sixth conductors U4, U5, U6 form a second composite conductor, wherein all conductors U1, U2, U3, U4, U5, U6 are connected in series or in parallel, thus forming a common phase. For ease of understanding, the slots N1, ..., N72 spanned by the six conductors U1, U2, U3, U4, U5, U6 do not specify the introduction part. In these slots, conductors 3 are also guided, which can be assigned to one or more other phases individually or in one or more composite conductors. Their arrangement can correspond to the arrangement of the first and second composite conductors, or it can also be different from it. Since the winding of the lamination stack 1 should be carried out evenly, two further phases are inserted here, each with six conductors 3. This results in a winding with three phases, the number of holes of which is q=3 and the number of pole pairs of which is p=4 in this case.

[0022] The first conductor U1, the second conductor U2 and the third conductor U3 start on the first side of the laminated core 1 and are guided through the first three adjacent slots N1, N2 or N3. They extend out on the second side of the laminated core 1 and in a slot step (where the winding heads 4 of the first, second and third conductors U1, U2, U3 extend in parallel) cross eight slots in the slots N1, ..., N72 respectively, thereby guiding them through the adjacent slots N10, N11 or N12 to the first side of the laminated core 1. 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 seventy-two slots N1, ..., N72 are crossed or crossed in this way, thereby completing a circle, and the pattern continues from the first three slots N1, N2 and N3 in the next layer (here L3 and L4). The power generating component thus has three turns in the six layers L1 , . . . , L6 , but this number is generally freely selectable and depends on the size of the component, so that a plurality of turns are present.

[0023] Between the twenty-eighth slot N28 and the thirty-ninth slot N39, a first slot step change is performed in the first turn, wherein the first conductor U1, the second conductor U2 and the third conductor U3 span different numbers of slots N1, ..., N72. The winding head 4 of the first conductor U1 here extends from the twenty-eighth slot N28 to the thirty-ninth slot N39, the winding head of the second conductor U2 spans the same number of slots N1, ..., N72 compared to the slot step of the slots N1, ..., N72, namely here from the twenty-ninth slot 29 to the thirty-eighth slot N38, and the winding head 4 of the third conductor U3 extends from the thirtieth slot N30 to the thirty-seventh slot N37. The arrangement of the first, second and third conductors U1, U2, U3 in the composite conductor is thus exchanged. Exactly one turn later, a second slot step change is performed, so that the first, second and third conductors U1, U2, U3 again change their position in the composite conductor and are in the original arrangement again. The arrangement of the conductors U1, U2, U3 relative to one another in the composite conductor is generally adapted to the specific design and the desired characteristics of the electric machine. The conductors U1, U2, U3 can thus be exchanged periodically, in pairs or in another way. It is also possible that with the second slot step change, an arrangement of the conductors U1, U2, U3 different from the initial position is introduced and that the initial arrangement is restored only with the third slot step change, for example. Alternatively, another different arrangement can also be selected in the third slot step change.

[0024] exist Figure 2 In the present embodiment, it is advantageous to design the winding heads 4 of the first, second and third conductors U1, U2, U3 to be arranged parallel to one another, one above the other, especially in the region of the slot step change. This is achieved by means of an S-shaped stop 5, since, in contrast to a sword winding, the conductors U1, U2, U3 are not twisted and can therefore be placed closer to one another or stacked. As described, the winding scheme continues until the sixth layer L6 is completed.

[0025] Figure 3 Another winding scheme for wave winding is shown in FIG. Figure 2The same as in . However, the slot step change portion is designed in a different way: thus, in the first turn, a first slot step change is performed between the 28th slot N28 and the 39th slot N39, in which the first conductor U1, the second conductor U2 and the third conductor U3 span different numbers of slots N1, ..., N72. Here, the winding head 4 of the first conductor U1 extends from the 28th slot N28 to the 39th slot N39, the winding head of the second conductor U2 spans the slots N1, ..., N72 whose number is reduced by one slot compared to the slot step of the slots N1, ..., N72, that is, here it jumps from the 29th slot N29 to the 37th slot N37, and the winding head 4 of the third conductor U3 extends from the 30th slot N30 to the 38th slot N38. The arrangement of the first, second and third conductors U1, U2, U3 in the composite conductor is thus exchanged. Exactly one turn later, a second slot step change occurs, so that the first, second and third conductors U1, U2, U3 change their positions in the composite conductor again. After the third slot step change, which is performed one turn after the second slot step change, in this embodiment, the three conductors U1, U2, U3 are again in their initial positions in the composite conductor. Here, the first, second and third conductors U1, U2, U3 are periodically exchanged with each slot step change. The winding head 4 is ideally arranged here so that the conductor 3 arranged first in the composite conductor extends over the other two conductors 3 arranged parallel to each other. Taking the first slot step as an example, this means that the first conductor U1 extends over the second conductor U2 and the third conductor U3, while the second conductor U2 and the third conductor U3 are arranged parallel to each other.

[0026] In its second turn, the first, second and third conductors U1, U2, U3 are offset from one another in that the slot steps are constructed to alternately widen one slot N1, ..., N72 or shorten one slot N1, ..., N72. Thus, the composite conductor is arranged offset by one slot N1, ..., N72 between the third layer L3 and the fourth layer L4. Here too, a slot step change is made, now between the twenty-eighth slot N28 and the fortieth slot N40, since differences in the width of the slot steps must be taken into account here. Now the third turn is again made with slot steps spanning eight slots N1, ..., N72, wherein the first conductor U1, the second conductor U2 and the third conductor U3 are arranged offset together by one slot N1, ..., N72 compared to the first two layers L1, L2. This offset is referred to as a pitch and an offset of more than one slot N1 , . . . , N72 may also be provided, by which the acoustic properties of an electric machine equipped with a power generating component wound in this manner are improved.

[0027] In addition to the first composite conductor, the power generation assembly in both embodiments also includes a second composite conductor consisting of a fourth conductor U4, a fifth conductor U5 and a sixth conductor U6. These conductors extend in the opposite direction to the first composite conductor: when the slot step of the first composite conductor occurs on the first side of the laminated stack 1, the slot step of the second composite conductor occurs on the opposite second side. Therefore, in both embodiments, the power generation assembly wound with two composite conductors has two slot step changes in each turn, which are located at the same or at least adjacent slots N1, ..., N72. On the laminated stack 1, all slot step changes are therefore arranged radially side by side. This can also include phases that are not introduced, and the winding of these phases can be carried out similarly to the winding of the first to sixth conductors U1, ..., U6. It is also possible without any problem to apply the principles presented below to motors with different structures, phase numbers, number of holes, number of pole pairs, and therefore also different numbers of slots N1, ..., N72.

[0028] List of Reference Numerals

[0029] 1 lamination pack

[0030] 2 slots

[0031] 3 Conductors

[0032] 4 Winding head

[0033] 5S shaped stop

[0034] N1, ..., N72 slots

[0035] L1, ..., L6

[0036] U1 First conductor

[0037] U2 Second conductor

[0038] U3 Third conductor

[0039] U4 Fourth conductor

[0040] U5 Fifth conductor

[0041] U6 sixth conductor.

Claims

1. A power generation component of an electric machine, the power generation component comprising an annular lamination stack (1) and a wave winding, the lamination stack having a plurality of radially arranged slots (N1, ..., N72), the wave winding having at least one first conductor (U1), at least one second conductor (U2) and at least one third conductor (U3) in succession, the conductors being guided through adjacent slots (N1, ..., N72) for a plurality of turns, the conductors being connected in parallel or in series to form a composite conductor, wherein: The composite conductor has a plurality of slot steps, in which the first conductor (U1), the second conductor (U2) and the third conductor (U3) respectively span the same number of slots (N1, ..., N72), and there is a layer change therein, and the composite conductor has at least one slot step change portion, in which the first conductor (U1), the second conductor (U2) and the third conductor (U3) span different numbers of slots (N1, ..., N72), so that the first conductor (U1), the second conductor (U2) and the third conductor (U3) exchange their arrangements with each other after the slot step change portion, characterized in that: There is at least one slot step change within each turn of the composite conductor.

2. The power generation assembly according to claim 1, characterized in that: The first conductor (U1), the second conductor (U2) and the third conductor (U3) each 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: The winding heads (4) of at least two of the first conductor (U1), the second conductor (U2) and the third conductor (U3) are arranged parallel to each other up and down or side by side.

4. The power generation assembly according to claim 3, characterized in that: The winding heads (4) of the first conductor (U1), the second conductor (U2) and the third conductor (U3) are arranged one above the other in parallel.

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

6. The power generation assembly according to any one of claims 1 to 5, characterized in that: The wave winding has a pitch in which the first conductor (U1), the second conductor (U2) and the third conductor (U3) are arranged together offset by at least one slot (N1, . . . , N72) compared to a preceding layer.

7. The power generation assembly according to any one of claims 1 to 6, characterized in that: The wave winding has a plurality of phases, each of which is composed of one or more composite conductors.

8. A wave winding for being incorporated into a power generation component of an electric machine according to any one of claims 1 to 7.

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