Modular system for manufacturing stator for electric machine and method for manufacturing stator for electric machine by means of modular system

Abstract

The invention relates to a modular system for manufacturing a stator for an electric machine, comprising:-a stator assembly having a stator core and a stator winding with a plurality of winding connections; and-a plurality of bus bar devices for the production of stators, in which the interconnection of the stator windings differs, the bus bar devices each have a plurality of stator winding connection points for connection to winding connections of the stator windings, a plurality of phase connection points, and a plurality of connection lines for connecting the stator winding connection points to the phase connection points, the stator winding connection points and the phase connection points of the plurality of bus bar arrangements are each arranged geometrically identically with respect to one another, and wherein the stator winding connection points and the phase connection points of the plurality of bus bar arrangements are each connected to one another in a different manner via connecting lines.

Description

Technical Field

[0001] The invention relates to a modular system for manufacturing a stator for an electric machine. The invention also relates to a method for manufacturing a stator for an electric machine using such a modular system. Background Art

[0002] The use of electric motors in mobile, stationary and industrial applications is widespread and is replacing the use of conventional drives, such as internal combustion engines. In order to meet the various different technical requirements, electric motors are manufactured for specific applications using different manufacturing processes and the motors are interconnected in different ways. For example, the motors can be interconnected in a star or delta configuration, the motors comprising different numbers of parallel or series connections, in order to provide different powers, for example, depending on the application. Since different applications each require a different electric motor and therefore a different manufacturing process, the number of manufacturing processes and therefore the manufacturing effort can be very high.

[0003] In this context, the goal is to reduce the costs of manufacturing electric machines of different configurations. Summary of the invention

[0004] This object is achieved by a modular system for producing a stator for an electric machine, the modular system comprising:

[0005] a stator assembly having a stator core and a stator winding having a plurality of winding connections, and

[0006] - a plurality of busbar arrangements for manufacturing stators in which the stator windings are interconnected in different ways,

[0007] wherein each busbar device has a plurality of stator winding connection points for connection with winding connection portions of the stator winding, a plurality of phase connection points, and a plurality of connection lines for connecting the stator winding connection points to the phase connection points,

[0008] wherein the stator winding connection points and the phase connection points of the plurality of busbar arrangements are each arranged geometrically identically relative to one another, and

[0009] Therein, the stator winding connection points and the phase connection points of the plurality of busbar arrangements are each connected to one another via connection lines in different ways.

[0010] The modular system according to the invention for manufacturing a stator for an electric machine has a stator assembly, which includes a stator core and a stator winding with a plurality of winding connections. The stator core can contain a magnetizable electrical sheet. The stator winding can be one or more parts. In addition, the stator winding has a plurality of winding connections, by means of which the electric machine can be electrically contacted in different ways.

[0011] The modular system also includes a plurality of busbar devices. These busbar devices can be configured differently for manufacturing stators in which the interconnection modes of the stator windings are different. Busbar devices suitable for the respective applications can be electrically connected to the stator. The busbar devices according to the present invention can each include a plurality of tracks made of a conductive material. The busbar devices can preferably be arranged on the end face of the motor, in particular the winding head of the stator. They can be connected to the winding connection of the stator winding and can realize different interconnections of the stator winding. The busbar device can be arranged flush with the winding head, the stator assembly or the motor in terms of its external dimensions. They can be annular, hollow cylindrical or have other rotationally symmetrical geometries, and each have an inner diameter and an outer diameter. The busbar device can also have a uniform outer contour with a constant outer diameter. Therefore, they can at least partially surround the stator or the stator winding. They can have a section extending in the radial direction of the motor, such as a protrusion for electrical contact.

[0012] The busbar devices each have a plurality of stator winding connection points for connecting to the winding connection parts of the stator winding. By means of the electrical connection between the busbar device and the winding connection parts of the stator winding at the stator winding connection points, the motor can be supplied with energy, for example, in motor mode, or can be provided with energy by the motor, for example, in generator mode. In addition, the busbar device has a plurality of phase connection points, by means of which the motor can be supplied with multi-channel current, in particular phase-shifted current. In addition, the busbar device includes a plurality of connecting wires for connecting the stator winding connection points to the phase connection points. In other words, the busbar device can be designed as an adapter between the power grid and the stator assembly. The connecting wires can be arranged inside or outside the corresponding busbar device. The connecting wires can also be arranged partially inside the busbar device and partially outside the busbar device.

[0013] According to the invention, the stator winding connection points and phase connection points of a plurality of busbar arrangements are each arranged geometrically identically relative to one another. The stator winding connection points and phase connection points of a busbar arrangement can be arranged to align with the stator winding connection points and phase connection points of another busbar arrangement relative to the rotor axis of the electric machine. In other words, the corresponding connection lines of the respective stator winding connection points and phase connection points of different busbar arrangements can each be arranged parallel to the rotor axis.

[0014] In addition, the stator winding connection points and the phase connection points of multiple busbar devices are connected to each other in different ways via connecting lines. Due to the different connections of the stator winding connection points and the phase connection points, different interconnections of the stator of the motor can be formed. This has the advantage that a single stator assembly can in principle be used to manufacture stators interconnected in different ways in each case by selecting a suitable busbar device from the available multiple busbar devices. Since only one suitable busbar device needs to be selected and connected, and the interfaces of the busbar devices are the same, a common manufacturing process can be used. With the modular system according to the present invention, stators with different technical specifications can be manufactured using a single manufacturing process. This reduces the workload for manufacturing motors of different configurations.

[0015] A preferred embodiment of the invention provides that a plurality of busbar arrangements each have twelve stator winding connection points and / or three phase connections. The three phase connections can be used to supply a three-phase current to the electric machine. Thus, the electric machine can be operated, for example, as a synchronous motor or an asynchronous motor. All twelve stator winding connection points of the busbar arrangement can be used for contacting the winding connections.

[0016] In a preferred embodiment of the present invention, it is provided that a plurality of busbar devices each have at least three phase tracks, a cover track and a base track. The three phase tracks can form a connecting line between the stator winding connection point and the phase connection point of the busbar device. The phase tracks can be arranged at least partially parallel to each other. In order to electrically contact the phase track, recesses and / or elements, in particular circular recesses and / or elements, for inserting, clamping or latching contacts, etc. can be formed in the phase track. The phase track can be partially or completely covered by the cover track and / or the base track on one or more sides. A section for electrically grounding the busbar device can be formed in the cover track or the base track of each busbar device. Pins, bolts, etc. and corresponding recesses can be formed in the phase track, the cover track and the base track so that all tracks can be accurately positioned relative to each other. In addition, the phase track, the cover track and the base track can be connected to each other or to other components using pins or bolts, for example, by means of a transition fit or a press fit.

[0017] In a preferred embodiment of the present invention, it is provided that the phase track, the cover track and the base track are arc-shaped, in particular circular arc-shaped, and can be arranged in the circumferential direction of the stator assembly. Due to the curved phase track, the cover track and the base track, the busbar device can have a curved shape. This provides the advantage of low volume and installation space requirements. In particular, the phase track, the cover track and the base track can be designed in the shape of a circular arc. Therefore, they can be arranged on the outer contour of the stator assembly of the motor in an optimized geometry. Preferably, the phase track, the cover track and the base track are arranged in a direction parallel to the rotor axis. The circular arc shape can preferably extend in the circumferential direction of the stator assembly.

[0018] A preferred embodiment of the invention provides that the plurality of phase rails of the busbar arrangement each have a different arc length. By using different arc lengths, the material stress on the busbar arrangement can be optimized and costs can be saved, because all phase rails can be made to the specific length required for the respective application.

[0019] In a preferred embodiment of the present invention, it is provided that each phase track has at least one stator winding connection pin, wherein all stator winding connection pins extend substantially perpendicularly to the base body of the corresponding associated phase track. The stator winding connection pins form electrical contacts of the busbar arrangement. They are arranged in the stator winding connection points. In addition, they can have a polygonal, circular or elliptical cross-section. In addition, the stator winding connection pins can be at least partially hollow. The stator winding connection pins preferably extend perpendicularly to the base body of the associated phase track and preferably extend parallel to the rotor axis. The stator winding connection pins can be arranged along the circumferential direction of the corresponding phase track. In the case of an arc-shaped phase track, the stator winding connection pins can be formed on the smaller diameter of the phase track, i.e., on the side of the phase track facing the stator assembly, or on the larger diameter of the phase track, i.e., on the side of the phase track facing away from the stator assembly.

[0020] A preferred embodiment of the invention provides that the stator winding connection points are formed at least in the periphery of the cover rail. The stator winding connection points can be designed as recesses in the periphery or on the outer contour of the cover rail. This can make the assembly of the busbar arrangement easier. Furthermore, since small stator winding connection points can be produced, for example by drilling or milling, their manufacture can be made more flexible.

[0021] In a particularly preferred embodiment of the invention, it is provided that the stator winding connection pins protrude through the stator winding connection points. The stator winding connection pins can each extend from the bottom to the top of the cover rail. If the stator winding connection points are designed as through-holes, they can be inserted; if the stator winding connection points are peripheral, they can be inserted or pushed into the stator winding connection points.

[0022] In a preferred embodiment of the present invention, it is provided that each phase track has a stepped section in which a phase connection point is formed. The section can be produced by making two right-angle bends in the phase track. In other words, the phase track can each include a web extending perpendicularly to the base body of the phase track and a section extending parallel to the base body of the phase track. Preferably, a phase connection point is formed at each section. The phase track, the cover track and the base track can be aligned so that a plurality of phase connection points of the busbar device formed on different tracks can be arranged in an overlapping manner. In particular, the first phase connection point / the second phase connection point / the third phase connection point of the cover track can be arranged to overlap with the phase connection points of the first phase track / the second phase track / the third phase track. In order to save space, the webs of different phase tracks can also have different lengths. In addition, the sections of different phase tracks can have different lengths.

[0023] Another object of the present invention is to provide a method for manufacturing a stator for an electric machine by means of a modular system.

[0024] wherein a modular system as described above is provided,

[0025] wherein one of the plurality of busbar arrangements is selected according to a desired interconnection of the stator windings, and

[0026] Therein, the selected busbar arrangement is connected to the stator assembly.

[0027] The method achieves the same advantages and technical effects as those mentioned in the context of the aforementioned system and its preferred embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Further details and advantages of the invention will be described below with reference to the exemplary embodiments shown in the accompanying drawings. In the drawings:

[0029] Figure 1a A first exemplary embodiment of a busbar arrangement according to the invention is shown in a schematic plan view, a schematic side view and a further schematic side view, respectively, wherein the busbar arrangement is mounted on an electric machine;

[0030] Figure 1b Three schematic diagrams are shown according to Figure 1a a first phase track of a bus bar arrangement;

[0031] Figure 1c Three schematic diagrams are shown according to Figure 1a a second phase track of a bus bar arrangement;

[0032] Figure 1d Three schematic diagrams are shown according to Figure 1a The third phase track of the busbar device;

[0033] Figure 1e The schematic top view and side view respectively show the Figure 1a A cover rail of a busbar device;

[0034] Figure 1f The schematic top view and side view respectively show the Figure 1a A base rail of a bus bar assembly;

[0035] Figure 2 A second exemplary embodiment of a busbar arrangement according to the invention is shown in a schematic plan view, a schematic side view and a further schematic side view, respectively, wherein the busbar arrangement is mounted on an electric machine; and

[0036] Figure 3 A third exemplary embodiment of a busbar arrangement according to the invention is shown in a schematic top view. DETAILED DESCRIPTION

[0037] Figure 1 to Figure 3 The busbar arrangements 20 of different configurations shown in the figure can be used as part of a modular system 1 for manufacturing a stator 3 for an electric machine 5 according to the present invention. Since the busbar arrangements 20 of different configurations each have a stator winding connection point L 1 To L 12 and phase connection points U, V, W, the stator winding connection points and the phase connection points are each arranged geometrically identically relative to one another in all different busbar arrangements 20 , so that depending on the desired interconnection of the stator windings 14 of the stator assembly 10 , one of the multiple busbar arrangements 20 can be selected as part of the manufacturing process and connected to the stator assembly 10 .

[0038] Figure 1a A busbar arrangement 20 of a modular system 1 according to the invention for producing a stator 3 for an electric machine 5 is shown. Figure 1a It consists of three parts. Figure 1a , the busbar arrangement 20 is shown in plan view. Figure 1a In the middle, the same busbar arrangement 20 can be seen in a side view. Figure 1a Below, the same busbar arrangement 20 is shown in another side view, wherein the busbar arrangement 20 is arranged on the stator assembly 10 of the electric machine 5 .

[0039] The stator assembly 10 has a stator core 12 and is arranged according to Figure 1aIn the exemplary embodiment of the present invention, there is a stator winding 14 with twelve winding connections. The stator core 12 forms the base body of the stator 3 and comprises a magnetizable stator lamination stack. The twelve winding connections of the stator winding 14 are connected to the busbar arrangement 20, in particular welded to the busbar arrangement, so that a delta connection is achieved.

[0040] The busbar arrangement 20 is arc-shaped and has twelve stator winding connection points L 1 To L 12 . Connect point L via stator winding 1 To L 12 The stator winding 14 of the stator 3 is connected to the busbar arrangement 20 by means of its winding connection. In addition, the busbar arrangement 20 has three phase connection points U, V and W, via which the busbar arrangement 20 is connected to the power supply network, so that the electric machine 5 can be operated as a motor with three-phase current. In addition, the busbar arrangement 20 has a phase track 22 formed 1 ,twenty two 2 ,twenty two 3 The first phase track 22 1 、Second phase track 22 2 and the third phase track 22 3 Connect the stator winding to point L 1 To L 12 Connect to the phase connection points U, V, and W.

[0041] The busbar device 20 has three phase rails 22 1 ,twenty two 2 ,twenty two 3 In addition, there is a cover rail 24 and a base rail 26. Three phase connection points U, V, and W are formed in the cover rail 24, and the three phase connection points are arranged at a certain distance from each other in the circumferential direction. In addition, the phase connection point U is formed in the first phase rail 22 1 In the embodiment, the phase connection point V is formed in the second phase track 22 2 and the phase connection point W is formed on the third phase track 22 3 The phase connection points U are arranged in an overlapping manner. Similarly, the phase connection points V are arranged in an overlapping manner. The phase connection points W are also arranged in an overlapping manner. The motor 5 can be connected to the phase track 22 1 ,twenty two 2 ,twenty two 3 By inserting electrical contacts into the phase connection points U, V, W, they are supplied with energy.

[0042] The busbar arrangement 20 has twelve stator winding connection pins 22', via which the stator 3 is electrically connected to the busbar arrangement 20. The three phase rails 22 1 ,twenty two 2 ,twenty two3 Each includes four stator winding connection pins 22' having a rectangular cross section. The stator winding connection pins 22' protrude from the lower side of the cover rail 24 through the stator winding connection point L 1 To L 12 to the upper side of the cover rail 24. They are arranged parallel to each other and Figure 1a The rotor axes of the motor 5 indicated by the circles are arranged in parallel, wherein the circles refer to Figure 1a , that is, a top view of the upper part of the busbar device 20.

[0043] exist Figure 1b In, according to Figure 1a The first phase track 22 1 Shown in three views. First phase track 22 1 It has an arc-shaped base body and four stator winding connection pins 22'. At a free end of the base body, the first phase track 22 1 The first phase track 22 is bent twice. 1 There is a web 23 formed perpendicularly to the base body and a segment 22" formed parallel to the base body, and a phase connection point U is formed in the segment 22".

[0044] exist Figure 1c In, according to Figure 1a The second phase orbital 22 2 It is shown in three views. Like the first phase track 22 1 Same, the second phase track 22 2 It also has an arc-shaped base body and four stator winding connecting pins 22'. 1 Similarly, the second phase track 22 2 The second phase track 22 is bent twice at one free end of the base body. 2 There is a web 23 formed perpendicularly to the base body and a segment 22" formed parallel to the base body, and a connection point V is formed in the segment 22".

[0045] exist Figure 1d In, according to Figure 1a The third phase orbital 22 3 It is shown in three views. Like the first phase track 22 1 and the second phase track 22 2 Same, the third phase track 22 3 It also has an arc-shaped base body and four stator winding connecting pins 22'. 1 and the second phase track 22 2 Similarly, the third phase track 22 3 The third phase track 22 is bent twice at one free end of the base body.3 The first phase track 22 has a web 23 formed perpendicular to the base body and a segment 22" formed parallel to the base body. The phase connection point W is formed in the segment 22". 1 、Second phase track 22 2 and the third phase track 22 3 The web 23 and the segments 22 ″ have different lengths to save space and material.

[0046] exist Figure 1e In, according to Figure 1a The cover rail 24 is shown in a top view and a side view. The cover rail 24 is arc-shaped and has twelve stator winding connection points L 1 To L 12 , where only the stator winding connection point L 1 , L 5 and L 12 exist Figure 1e Reference numerals are provided in the top view of the upper cover rail 24. All stator winding connection points L 1 To L 12 On one side, the stator winding connection pins 22' are formed in the periphery of the cover rail 24. In addition, the stator winding connection pins 22' are each arranged at the stator winding connection point L 1 To L 12 In which the stator winding connecting pin 22' is only Figure 1e The cover rail 24 is shown in a top view. The stator winding connection pin 22' extends from the bottom of the cover rail 24 to the top of the cover rail 24. In order to simplify the assembly of the busbar 20, the cover rail 24 also has two bolts 24'. For this purpose, a tip is formed at each free end of the bolt 24' to facilitate the assembly of the cover rail 24 with, for example, the base rail 26.

[0047] exist Figure 1f In, according to Figure 1a The base rail 26 is shown in top view and side view. The base rail 26 is arc-shaped and has twelve stator winding connection points L 1 To L 12 , where only the stator winding connection point L 2 , L 7 and L 10 exist Figure 1f Reference numerals are provided in the top view of the base rail 26 above. In addition, two recesses 26' are formed in the base body of the base rail 26, the recesses being arranged relative to, for example, Figure 1e The position of the bolt 24 ′ is arranged accordingly. The bolt 24 ′ can be inserted into the recess 26 ′ and the busbar arrangement 20 can be closed at the same time.

[0048] Figure 2A second exemplary embodiment of a busbar arrangement 20 of a modular system 1 according to the invention for producing a stator 3 for an electric machine 5 is shown. Figure 1a A first exemplary embodiment according to Figure 2 The key difference between the second exemplary embodiment and the second exemplary embodiment is the interconnection method. Figure 1a When the busbar device 20 is implemented as a triangle connection, Figure 1a The busbar arrangement 20 is also realized as a star connection. Therefore, the second exemplary embodiment has an additional fourth phase rail 22 4 , the fourth phase rail can be used as a neutral conductor, especially in three-phase operation.

[0049] exist Figure 3 In FIG. 2 , a third exemplary embodiment of a busbar arrangement 20 according to the invention is also shown in a top view. In addition to the stator winding connection points L on the side facing the stator 3 , 1 To L 12 In addition, Figure 2 The busbar arrangement 20 shown in FIG. 1 has further stator winding connection points L on the side facing away from the stator 3 . 1 'To L 12 '.

[0050] Reference numerals

[0051] 1 Modular system

[0052] 3. Stator

[0053] 5 Motor

[0054] 10 Stator assembly

[0055] 12 stator core

[0056] 14 Stator winding

[0057] 20 Busbar assembly

[0058] L i Stator winding connection point

[0059] L i 'Other stator winding connection points 22 1 First phase track

[0060] twenty two 2 Second phase orbit

[0061] twenty two 3 The third phase track

[0062] twenty two 4 Fourth phase orbit

[0063] 22' stator winding connection pin

[0064] 22” section

[0065] 23 belly plate

[0066] 24 Cover rail

[0067] 24' bolt

[0068] 26 base track

[0069] 26' recess

[0070] 27 wire connection points

[0071] U phase connection point

[0072] V phase connection point

[0073] W phase connection point

Claims

1. A modular system (1) for manufacturing a stator (3) for an electric machine (5), the modular system comprising: - a stator assembly (10) having a stator core (12) and a stator winding (14) with a plurality of winding connections, and - a plurality of busbar arrangements (20) for manufacturing stators (3) in which the stator windings (14) are interconnected in different ways, The busbar devices (20) each have a plurality of stator winding connection points (L1 to L2) for connecting to the winding connection portion of the stator winding (14). 12 ), a plurality of phase connection points (U, V, W) and a stator winding connection point (L1 to L2) 12 ) are connected to a plurality of connection lines of the phase connection points (U, V, W), wherein the stator winding connection points (L1 to L2) of the plurality of busbar devices (20) 12 ) and the phase connection points (U, V, W) are each arranged geometrically identically relative to one another, and wherein the stator winding connection points (L1 to L2) of the plurality of busbar devices (20) 12 ) and the phase connection points (U, V, W) are each connected to each other in different ways via the connecting lines.

2. The modular system (1) according to claim 1, characterized in that Each of the plurality of busbar devices (20) has twelve stator winding connection points (L1 to L2). 12 ) and / or three phase connections (U, V, W).

3. The modular system (1) according to claim 1 or 2, characterized in that Each of the plurality of busbar devices (20) has at least three phase rails (22 i ), a cover track (24) and a base track (26).

4. The modular system (1) according to claim 3, characterized in that The phase orbit (22 i ), the cover rail (24) and the base rail (26) are arc-shaped, in particular circular arc-shaped, and can be arranged in the circumferential direction of the stator assembly (10).

5. The modular system (1) according to claim 4, characterized in that The plurality of phase rails (22) of the busbar device (20) i ) each have a different arc length.

6. Modular system (1) according to claim 3, 4 or 5, characterized in that Each phase orbital (22 i ) has at least one stator winding connection pin (22'), wherein all stator winding connection pins (22') are connected to the corresponding phase track (22 i )'s base body extends substantially vertically.

7. The modular system (1) according to claim 6, characterized in that The stator winding connection points (L1 to L 12 ) is formed at least in one peripheral edge of the cover rail (24).

8. Modular system (1) according to claim 7, characterized in that The stator winding connection pin (22') protrudes through the stator winding connection point (L1 to L 12 ).

9. Modular system (1) according to one of claims 3 to 8, characterized in that The phase orbit (22 i ) each have a stepped section (22") in which a phase connection point (U, V, W) is formed.

10. A method for manufacturing a stator (3) for an electric machine (5) by means of a modular system, in, A modular system (1) according to one of the preceding claims is provided, wherein one of the plurality of busbar arrangements (20) is selected based on a desired interconnection of the stator windings (14), and The selected busbar device (20) is connected to the stator assembly (10).

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