Method for producing stator of rotating electrical machine, rotating electrical machine stator produced by said method, and rotating electrical machine

Abstract

The present invention relates to a method for producing a stator of a rotating electrical machine, a rotating electrical machine stator produced by the method, and a rotating electrical machine comprising the stator. In a method for producing a stator of a rotary electric machine, a stator body (10) having grooves (12) for receiving portions of conductor elements of a winding is provided, at least one first conductor element winding (21) of a first phase (20) is provided on the outside of the stator body (10) and the first conductor element winding has a plurality of first bays (30) of bundled first conductor elements (22), the first insulating element (50) is fixed to the at least one first bay (30) by means of an adhesive connection (40), each first bay (30) being assigned with at least one first insulating element (50), and the first conductor element winding (21) is inserted into the first groove (12) of the stator body (10), the adhesive connection (40) has the effect that the first insulating element (50) is driven along with the movement of the first conductor element winding (21) and positioned relative to the stator body (10). The method proposed herein for producing a stator of a rotating electrical machine can be used to electrically insulate conductors of different phases of the stator from one another more easily, cheaply and reliably in the winding head.

Description

Technical Field

[0001] The present invention relates to a method for producing a stator of a rotating electric machine, a stator of a rotating electric machine produced by the method, and a rotating electric machine having the stator. Background Art

[0002] The stator of the rotating electric machine has a plurality of phases, which are realized by windings extending in different directions in the stator body.

[0003] Figure 1 An example of a first conductor element winding 21 is shown, which is intended to form the first phase of the stator to be produced of a rotating electrical machine. The individual conductor elements are arranged in bundles 22, which form first bays 30 on their radially outer sides. These first bays 30 rest on the coil plate. It must be ensured that the first phase or the conductor elements of the first phase are insulated from the conductor elements of other phases or other phases. Phase separators are usually used for this purpose, which must be placed manually in the original automated production process. Depending on the product design, separation of the potential within the phase may also be necessary, for example in the case where the start and end points of the phase are adjacent in the stator. This is particularly important in the case of a phase star connection, because a higher potential difference will be formed in the winding head section. For simplicity, these insulation tasks are also referred to as phase separators below, even if the actual insulation occurs within the electrical phase. In the prior art, the winding heads of the produced retractable windings must be separated with a special tool, such as a sizing iron, so that the phase separator can be arranged at the desired position by manual insertion.

[0004] In the automated method, a robotic handling device must be used specifically to form the retracted coils. The phase separator can be used automatically after each coil has been inserted, although this operation must be performed in a separate processing station. In addition, the phase separator needs to be made into a three-dimensional shape, for example by folding the phase separator.

[0005] Continuous phase separators in the form of cap-shaped insulating elements for the grooves and winding heads of the stator are known, as disclosed, for example, in document CN203984116U, which can be installed accordingly and according to the method according to document US Pat. No. 4,831,715.

[0006] For this purpose, US4831715A discloses a coil positioning machine for positioning a coil separator in a groove. Before arranging the electrical conductor in the groove, the insulator is positioned radially outward in the groove.

[0007] In an alternative embodiment, end plates are arranged on the stator, which provide different chambers for the individual phases and thus achieve phase separation.

[0008] For the automation of the assembly of phase separators, gripper systems such as those disclosed in document DE 10 2019 105 308 B4 are known, which enable the coils to be individually shaped and assembled after they have been retracted. However, the accessibility of the assembly is then reduced, especially in the case of multi-phase retraction.

[0009] Furthermore, it is known to position an insulating element relative to the winding before retracting the conductor elements of the winding, said insulating element being carried along with the retracting movement of the winding and achieving an insulating effect between the windings or between the phases formed thereby. Such an insulating element is designed, for example, as a ring which, when positioned, is arranged along the circumference of the groove of the stator.

[0010] These rings are used for mixed phase retraction when several phases or windings of several phases are retracted into the stator body by one retraction. These rings are placed on the retraction mandrel after the winding of the first phase. After the winding of another phase or another phase is wound, the ring is fixed and the ring is also retracted when the winding is retracted.

[0011] However, this means that only continuous insulation can be achieved in the winding head.Due to the continuous annular shape, the circumferential phase separator takes up more space in the installation space of the winding head than a separately installed insulating element used in a location with a critical potential difference. Summary of the invention

[0012] Based on this, the basic object of the present invention is to provide a method for producing a stator for a rotating electrical machine, a rotating electrical machine stator produced by said method and a rotating electrical machine, by which the conductors of different phases of the stator can be electrically insulated from each other more easily, more cheaply and more reliably in the winding heads.

[0013] This object is achieved by a method for producing a stator for a rotating electrical machine according to claim 1, by a stator for a rotating electrical machine produced by said method according to claim 9, and by a rotating electrical machine according to claim 10. Advantageous embodiments of the method for producing a stator are set forth in dependent claims 2 to 8.

[0014] The features of the claims can be combined in any technically meaningful way, and for this purpose reference is also made to the explanations from the following description including additional embodiments of the invention and to the features from the drawings.

[0015] The invention relates to a method for producing a stator for a rotating electrical machine, in which a stator body is provided with recesses for receiving portions of conductor elements of the winding, at least one first conductor element winding of a first phase is provided on the outside of the stator body, the first conductor element winding having a plurality of first bays of bundled first conductor elements, and a first insulating element is fixed to at least one first bay by means of an adhesive connection, wherein each first bay portion is provided with at least one first insulating element. The first conductor element winding is inserted into a first recess of the stator body, wherein the adhesive connection has the effect that the first insulating element is carried along with the movement of the first conductor element winding and is positioned relative to the stator body.

[0016] Thus, it can be provided that the insulation element is arranged on one side of the stator body, for example on the side of the electrical connection of the stator, the so-called A side, before retraction, and that the insulation element is positioned in the winding head during retraction. The arrangement of the first conductor element winding of the first phase on the outside of the stator body optionally takes place on a positioning element, which can also be referred to as a retraction mandrel. Here, the first conductor element winding extends through the gap or through the radial opening slot.

[0017] The bay is formed by a number of bundled arched conductor sections.The first insulating element is fixed to the first bay by adhering the first insulating element to at least one conductor element of the bay by means of an adhesive connection.

[0018] Approved and standardized surface insulation materials can be used as the material of the insulation element, which are provided with an adhesive for forming the adhesive connection. In an advantageous embodiment, the selected surface insulation material can be adapted as easily as possible to the final shape of the bay in the stator during the assembly process. The selected insulation material must meet appropriate product requirements in terms of temperature resistance and dielectric strength.

[0019] The insulating element provides a separation between adjacent conductors of different phases of the stator or within a phase. In other words, by covering the bays of the conductor elements with the insulating element, these bays are isolated from other conductor elements of other windings of the stator by mechanical separation.

[0020] The insulating elements also secure the conductor elements relative to each other in the respective bays, thereby maintaining the individual conductor elements in a relatively ordered state and facilitating retraction of the conductor elements into the recesses of the stator body.

[0021] One embodiment of the described method provides that only one first insulation element is assigned to each first bay.

[0022] Furthermore, at least one further conductor element winding of another phase may be provided on the outside of the stator body, the further conductor element winding comprising a plurality of further bays in a bundle of further conductor elements, wherein a further insulating element is fixed to at least one further bay by means of an adhesive connection, and each further bay portion is provided with at least one further insulating element. Depending on the process characteristics, the insulating element may also be used during the assembly process of the coil retraction of different phases instead of the coil retraction of a single phase.

[0023] A further conductor element winding can be inserted into a further groove of the stator body, wherein the adhesive connection has the effect that the further insulation element is entrained with the movement of the further conductor element winding and positioned relative to the stator body such that the insulation element is arranged between overlapping parts of the conductor element winding.

[0024] At least one insulating element is provided for each bundle of conductor elements present in the bay. Thus, when the phase is retracted, a plurality of insulating elements will move and position.

[0025] In this way, the bundle of conductor elements can be retracted into the grooves of the stator, whereby the bay remains axially outside the stator and can be insulated by the insulating element axially outside the stator.

[0026] Before arranging the insulating element, the conductor elements may be positioned on a positioning element, such as a retracted mandrel, such that the conductor elements in the winding can extend through radially open slots of the positioning element and thereby can meander between the radial inside and outside of the substantially hollow cylindrical positioning element.

[0027] The retraction tool can retract the conductor elements into the grooves of the stator, wherein the positioning element can have the function of the retraction tool or an additional tool can be used which transfers the bundle of conductor elements from the positioning element into the grooves of the stator.

[0028] This technology can be applied to the production of windings for stators of inner rotor motors, in which the stator surrounds the rotor radially outside the rotor. However, this should not exclude the production of windings for stators of outer rotor motors, in which the rotor surrounds the stator radially outside the stator.

[0029] The application of the method in the production of windings for axial flux machines should also not be excluded, wherein insulation elements can be arranged radially outside and / or radially inside the winding, being assigned to the individual bays of the bundle of conductor elements at the bays realized radially outside and / or radially inside the winding.

[0030] Furthermore, if the surface insulation elements are shaped to match the transition profile of the winding, at least one of the insulation elements can be partially retracted into the grooves of the stator body. In this embodiment of the method, the insulation effect by means of the insulation elements extends not only to the area outside the grooves of the stator, but also to partial areas of the grooves. In one embodiment, the contour of the insulation element has the inverse shape of the installation space, so that when the insulation element is installed in the adjacent groove area, a strip must be provided on the end contour of the insulation element.

[0031] The respective first insulating element may be substantially two-dimensional and have a surface on one side which is at most 18% of the size of a surface covering the first bay outside the first bay in the plane of the course of the associated first bay before the first conductor element winding belonging to the first bay is inserted into the groove. The radially extending symmetry axis of the insulating element may be positioned substantially centrally with respect to the center of the first bay.

[0032] In a preferred embodiment of the insulating element, there is a two-dimensional profile of the insulating element which corresponds to the vertical projection of the bay onto the plane in which the bay extends. Typically, this results in a surface insulating element which presents a simple U-shape or V-shape and which presents a butterfly profile when adjusting the details.

[0033] Each insulating element can be designed to be self-adhesive. After positioning the insulating element at the relevant bay and contacting the relevant bay, the element is properly fixed in place and no further efforts are required for the final position of the insulating element, because the insulating element is carried along with the movement of the conductor element and thus automatically enters its final position.

[0034] The first insulating element can be placed on the coil plate before assembly of the winding in the stator and before realization of the adhesive connection, and the adhesive connection can then be produced by pressing the first bay of the conductor element onto the first insulating element.

[0035] The adhesive connection is thus automatically achieved when the insulating element is in contact with the conductor element of the bay, regardless of whether the insulating element has been previously placed on the coil plate.

[0036] The insulation element can be introduced from the side of the bay facing away from the stator body into the process of producing the adhesive connection.

[0037] In this case, the first insulating element can be arranged in one or more boxes, which are open or can be opened on the side facing the stator body, for example by means of a sliding closure, so that the first insulating element can be conveyed from the one or more boxes towards the bay in order to be fixed to the bay by means of an adhesive connection. The first insulating element can be provided with an index for unambiguously assigning the first insulating element to the respective bay or phase.

[0038] For example, such a box can be arranged in the coil plate so that the first insulating element is delivered to the bay in the vertical direction from the bottom to the top.

[0039] In an alternative embodiment, the first insulating element may be automatically positioned by a gripper that guides the first insulating element between the bay and the coil plate.

[0040] Such a gripper can be combined with a conveying device that conveys the insulation elements to the vicinity of the stator body and then distributes the individual insulation elements from the vicinity of the stator body to the individual bays with the aid of the gripper. Such a gripper can also be used to position the start and end sections of the conductor element and / or to shape the produced coil.

[0041] Before producing the adhesive connection, the respective insulation element can have a shape having a longer extension on a first radial side in the circumferential direction than on a second radial side in the circumferential direction.

[0042] For example, the first radial side may be the radial inner side and the second radial side may be the radial outer side.The circumferential direction or radial direction is a circular cross-section of a given sub-body.

[0043] The insulating element may be designed to be axially symmetrical about a radially extending axis, so that the insulating element substantially overall resembles a butterfly shape. The method for producing a stator for a rotating electrical machine may be implemented on a retracting mandrel or on a positioning element for positioning the individual windings, or as an intermediate station between a winding station and a retracting station.

[0044] The advantage of the method is that only the bays in the bundled conductor elements are insulated by means of the insulating unit, whereby the use of insulating material is relatively low. The adhesive connection prevents any unintentional displacement of the insulating element. The fact that the insulating element can be positioned immediately before the process of retracting the conductor element or the coil into the groove of the stator further counteracts unintentional displacement. The insulating element can still be positioned very accurately, because there is still a relatively large amount of available space between the individual bays before retraction. By means of the space-saving assembly of the insulating element, the mechanical stress on the winding and the wiring harness is reduced.

[0045] The insulating element may be designed such that the insulating element insulates not only the bays of the bundled conductor elements but also the connection regions of the conductor elements used.

[0046] The conductor elements can be retracted until there is mechanical contact between the respective insulation element and other insulation elements of the stator body or winding, such as groove insulation. The automated arrangement of the insulation elements enables consistent quality and low production costs.

[0047] After the first retraction or the second retraction, it is not necessary to fix the insulation element with a further adhesive connection.

[0048] Furthermore, there is no need to re-form or fold the insulating elements, since the retraction of the subsequent coil ensures that the previously arranged insulating elements are positioned, fixed and formed so that the shape of the insulating elements is complementary to the adjacent coil or conductor element, or this is achieved by a free-forming or final-forming process step that is already present after the retraction of the coil or phase.

[0049] Another aspect of the invention is a stator for a rotating electrical machine, the stator comprising a stator body having a groove and portions of conductor elements of a winding received in the groove, the portions of conductor elements of the winding forming bays outside the groove, wherein insulating elements are fixed to the bays by means of an adhesive connection and each respective bay portion is provided with one insulating element.

[0050] According to the method, a stator is produced if the stator is designed such that at least one further insulating element is fixed to at least one bay by means of an adhesive connection, wherein each further bay is assigned only one further insulating element, and further conductor element windings are inserted into further grooves of the stator, the insulating elements being arranged between overlapping parts of the conductor element windings.

[0051] A rotating electric machine is also provided, which has the described stator or has a stator produced according to the described method. BRIEF DESCRIPTION OF THE DRAWINGS

[0052] The invention described above will be described in detail below with reference to the accompanying drawings showing preferred embodiments according to the relevant technical background. The invention is in no way limited by the purely schematic drawings, and it should be noted that the exemplary embodiments shown in the drawings are not limited to the dimensions shown. In the drawings:

[0053] Figure 1 : A conventional arrangement of conductor elements of the first phase is depicted in a three-dimensional diagram,

[0054] Figure 2 : A perspective view depicts the arrangement of the conductor elements and the insulating elements of the first phase according to the method,

[0055] Figure 3 : The enlarged image depicts Figure 2 Details in A.

[0056] Figure 4 : depicts in perspective a stator body equipped with an insulating element according to the method, and

[0057] Figure 5 : depicts an insulating element used according to the present method. DETAILED DESCRIPTION

[0058] It has been discussed in detail Figure 1 To explain the prior art.

[0059] Figure 2 A stage during the implementation of the method for producing a stator for a rotating electrical machine is shown, wherein a first conductor element winding 21 is provided with a first insulating element 50 .

[0060] It can be seen that the first conductor element winding 21 as a bundle of first conductor elements 22 is guided through radially open slots 62 between retractable discs 61 of a positioning element 60, also referred to as a retracting mandrel. This first conductor element winding 21 thus forms the first phase 20 of the entire winding package to be produced of the stator to be produced.

[0061] Here, too, the individual conductor elements of the first conductor element winding 21 are realized in the first bay. Figure 1 The embodiment shown in FIG. 7 differs in that a first insulating element 50 is present between the first bay 30 and the coil plate 70 , wherein a first insulating element 50 is assigned to each first bay 30 .

[0062] like Figure 3 As shown in FIG. 1 , the first insulating element 50 is adhered to the first bay 30 or the individual conductor elements of the bundle 22 by means of an adhesive connection 40 . Figure 3 It is also apparent that the center 31 of the respective first bay 30 is substantially located on the radially extending symmetry axis of the respective first insulating element 50. Figure 5 This radially extending axis of symmetry of the first insulation element 50 is explained.

[0063] from Figure 2 and Figure 3 It can also be seen that the first insulating element 50 not only covers the respective first bay 30 but also partially covers the connection region 23 of the conductor element for electrically connecting the winding.

[0064] Figure 4A stator body 10 is shown, which is provided according to the method on the A side 11 of the stator body, i.e., on the side on which the connection region 23 of the conductor elements is implemented. In the state shown here, the conductor elements of the first phase (not visible here) have been retracted into the respective grooves 12 of the stator body 10. In addition, groove insulation 13 is present in the grooves 12.

[0065] It can be seen that the first insulating elements 50 previously arranged by means of adhesive connections have also been moved upwards to the stator body 10 due to the winding retraction and are now positioned and fixed in the axial end region of the stator body 10. Furthermore, it can be seen that the first insulating elements 50 overlap each other in some regions in order to reliably ensure the insulation of the bundle 22 of first conductor elements positioned below.

[0066] Here, after the first phase has been retracted, the bundles of conductor elements of the other phases or other phases can be retracted into the grooves 12 of the stator body 10. The already arranged first insulating element ensures that the conductor elements of the other phases do not contact the conductor elements of the first phase. The further conductor element windings can also be equipped with further insulating elements in order to also achieve an insulating effect between the further conductor element windings.

[0067] Figure 5 The first insulating element 50 is shown in plan view. The first insulating element is designed essentially two-dimensionally and has a slightly butterfly shape 52. This means that the first insulating element 50 has a longer extension 51 on one radial side than on the radially opposite side. The first insulating element 50 is designed essentially symmetrically about a radially extending axis of symmetry 53.

[0068] To explain the radial direction of the symmetry axis 53, refer to Figure 3 It can be seen that the symmetry axis 53 extends radially relative to the shape of the first conductor element winding 21 .

[0069] The method proposed here for producing a stator for a rotating electrical machine can be used to electrically insulate conductors of different phases of the stator from one another more easily, more cheaply and more reliably in a winding head.

[0070] Reference numerals list

[0071] 10 Stator body

[0072] 11 Side A

[0073] 12 grooves

[0074] 13 Groove insulation

[0075] 20 First Phase

[0076] 21 First conductor element winding

[0077] 22 Bundle of first conductor element

[0078] 23 Connection area

[0079] 30 First Bay

[0080] 31 The center of the first bay

[0081] 40 Bonding joint

[0082] 50 first insulating element

[0083] 51 Longer reach

[0084] 52 Butterfly Shape

[0085] 53 Radially extending axis of symmetry

[0086] 60 Positioning elements

[0087] 61 Retractable tray

[0088] 62 radial opening slots

[0089] 70 Coil Plate

Claims

1. A method for producing a stator for a rotating electrical machine, in which method: - a stator body (10) provided with recesses (12) for receiving parts of conductor elements of a winding, - at least one first conductor element winding (21) of a first phase (20) is arranged on the outer side of the stator body (10), the first conductor element winding having a plurality of first bends (30) of bundled first conductor elements (22), - fixing the first insulating element (50) to the at least one first bay (30) by means of an adhesive connection (40), wherein: Each first bay (30) is assigned at least one first insulating element (50), and - Inserting the first conductor element winding (21) into the first groove (12) of the stator body (10), wherein the adhesive connection (40) has the following effect: the first insulating element (50) is entrained with the movement of the first conductor element winding (21) and is positioned relative to the stator body (10).

2. The method for producing a stator for a rotating electrical machine according to claim 1, characterized in that At least one further conductor element winding of another phase is arranged outside the stator body (10), the further conductor element winding comprising a plurality of further bays in a bundle of further conductor elements. - fixing the further insulation element to the at least one further bay portion by means of an adhesive connection, wherein each further bay portion is provided with at least one further insulation element, - inserting the further conductor element winding into a further groove of the stator body (10), wherein the adhesive connection has the effect that the further insulating element is entrained with the movement of the further conductor element winding and positioned relative to the stator body (10) such that the insulating element is arranged between overlapping parts of the conductor element winding.

3. A method for producing a stator for a rotating electrical machine according to any one of the preceding claims, characterised in that At least one of the insulation elements (50) is pulled into a groove (12) of the stator body (10) in a specific area.

4. A method for producing a stator for a rotating electrical machine according to any one of the preceding claims, characterised in that The first insulating element (50) is essentially two-dimensional and has a surface on one side that is at most 18% of the size of the surface covering the first bay (30) on the outside of the first bay in the plane of the course of the associated first bay (30) before the first conductor element winding (21) belonging to the first bay (30) is inserted into the groove (12).

5. Method for producing a stator for a rotating electrical machine according to any one of the preceding claims, characterized in that The insulating element (50) is designed to be self-adhesive.

6. Method for producing a stator for a rotating electrical machine according to any one of the preceding claims, characterised in that The first insulating element (50) is placed on the coil plate (70) before the realization of the adhesive connection (40), and the adhesive connection (40) is then formed by pressing the first bay (30) of the conductor element onto the first insulating element (50).

7. The method for producing a stator for a rotating electrical machine according to claim 6, characterized in that The insulating element (50) is introduced from the side of the bay facing away from the stator body (10) into the process of producing the adhesive connection (40).

8. Method for producing a stator for a rotating electrical machine according to any one of the preceding claims, characterised in that Before producing the adhesive connection (40), the respective insulation element (50) has a shape having a longer extension (51) on a first radial side in the circumferential direction than on a second radial side in the circumferential direction.

9. A stator for a rotating electric machine, the stator comprising a stator body (10), the stator body having a groove (12) and portions of conductor elements of a winding received in the groove, the portions of conductor elements of the winding forming a bay (30) outside the groove, wherein: Insulation elements (50) are fixed to the bays (30) by means of adhesive connections (40), and each respective bay (30) is assigned at least one insulation element (50).

10. A rotating electric machine comprising a stator according to claim 9 and / or a stator produced according to any one of claims 1 to 8.

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