Single-tooth structural unit with improved fastening of starting section and / or end section of winding wire, and method for production thereof

Abstract

The invention relates to a single-tooth unit for a stator or in a stator of a brushless DC motor, comprising:-stator teeth for stator coils,-at least one insulating cover which is inserted on the stator teeth at the end side; a stator coil comprising a winding wire wound onto the stator teeth provided to at least one insulating cover, the insulating cover having a flange region at its radially outer end in the stator, in which flange region a starting slot and / or an end slot extending substantially in the axial direction of the stator is provided, wherein a starting section of a winding wire of the stator coil is introduced into the starting slot or an end section of the winding wire is introduced into the end slot, and wherein the starting section of the winding wire introduced into the starting slot is fixed in its position in the starting slot by a subsequently applied winding and / or winding layer of the winding wire, or the end section introduced into the end slot is fixed in its position in the end slot by a previously applied winding and / or winding layer of the winding wire.

Description

TECHNICAL FIELD

[0001] The invention relates to a single-tooth structural unit for or in a stator of a brushless direct current motor. The invention furthermore relates to a stator for a brushless direct current motor and to a brushless direct current motor. Furthermore, the invention relates to a method for producing a single-tooth structural unit for a stator of a brushless direct current motor. BACKGROUND

[0002] Brushless direct current motors, also referred to as BLDC motors, are generally composed of a rotor and a stator, without depending on whether they are permanent magnet excited direct current motors or electrically excited direct current motors and without depending on whether they are inner rotor motors or outer rotor motors. Here, the part of the rotor and / or the stator that guides the magnetic flux is generally composed of a composite structure of electric steel sheets that are layered on top of one another.

[0003] The stator of a BLDC inner rotor motor is generally composed of a full-cut lamination stack or by means of a suitable division by separate loop-star-lamination stacks or T-shaped segment-lamination stacks. The T-shaped segments can be made in a conventional implementation. It is furthermore possible, for example, for the lamination stack to be provided as a quasi-full-cut structure with predefined target breaking points at which the stator lamination stack supplied as a full-cut structure is separated into individual T-shaped segments shortly before the winding process with Amperewindungen of wire with lacquer insulation. During the punching process at the supplier, the individual lamination sheets are separated at the predefined target breaking points in a first step and are pressed back into the original position in a second step, thereby achieving the joining into a quasi-full-cut structure and at the same time providing the target breaking points (separation points in the stator yoke).

[0004] The necessary insulation of the lamination stack with respect to the winding wire can be achieved by means of plugged-in insulation covers composed of plastic, injection encapsulation with plastic, powder coating or plugged-in paper insulation, if necessary in combination with other insulation methods. In the case of a stator with single teeth, single-tooth windings and wire clamping structures, plugged-in insulation covers composed of plastic are generally used.

[0005] It is an object of the invention to provide a single-tooth structural unit for a stator and a method for producing a single-tooth structural unit, which enables a defined arrangement of the start and / or end sections of the winding wire when winding the stator teeth. SUMMARY

[0006] The invention relates to a single-tooth structural unit for or in a stator of a brushless direct current motor, wherein the single-tooth structural unit has: - a stator tooth for a stator coil, - at least one insulation shield which is plugged on at the end side onto the stator tooth; - a stator coil which comprises a winding wire which is wound onto the stator tooth provided with the at least one insulation shield, - wherein the insulation shield has a flange region at its end which is placed radially outward in the stator, in which flange region a start slot and / or an end slot is provided which extends essentially in the axial direction of the stator, - wherein a start section of the winding wire of the stator coil is introduced into the start slot, or an end section of the winding wire of the stator coil is introduced into the end slot, and - wherein the start section of the winding wire introduced into the start slot is fixed in its position in the start slot by subsequently applied windings and / or winding layers of the winding wire, or the end section of the winding wire introduced into the end slot is fixed in its position in the end slot by previously applied windings and / or winding layers of the winding wire.

[0007] In the single-tooth structural unit according to the embodiment of the application it is possible to provide a start section and / or an end section of the winding wire at a prescribed position of the structural unit. To achieve this, the start section and / or the end section of the winding wire can be introduced into a prescribed start slot or end slot at the flange region of the insulation shield. Here, for example, the fixing of the start section and / or the end section in the respective recess can be achieved by means of subsequently applied windings and / or winding layers or by means of previously applied windings and / or winding layers. By this prescribed arrangement, for example, the subsequent joining process can be simplified. In particular, for example, measures for wire receiving and wire bending are simplified. A further advantage is that, because the start section and / or the end section is at least partially received in the start slot or the end slot, more free space is provided for the winding process.

[0008] The application furthermore relates to a stator for a brushless DC motor, comprising at least one single-tooth structural unit as described above.

[0009] Furthermore, the application relates to a brushless DC motor comprising a stator as described above and a rotor.

[0010] Furthermore, the application relates to a method for manufacturing a single-tooth structural unit for a stator of a brushless DC motor, which method is based on: - a stator tooth for a stator coil, - at least one insulation shield which is plugged on at the end side onto the stator tooth, - a winding wire for winding the stator tooth provided with the at least one insulation shield, - wherein the flange region has a starting slot and / or an end slot provided therein, which extends essentially in the axial direction of the stator, wherein the method has: - if a starting slot is provided in the flange region, a starting section of the winding wire is introduced into the starting slot, wherein the starting section of the winding wire introduced into the starting slot is fixed by subsequently applied winding and / or winding layers, - winding the stator tooth provided with at least one insulation cover with winding wire, - if an end slot is provided in the flange region, an end section of the winding wire is introduced into the end slot, wherein the end section of the winding wire introduced into the end slot is fixed by previously applied winding and / or winding layers.

[0011] Preferably, the starting section of the winding wire is positively locked or clamped in its position in the starting slot in the radial direction of the stator by subsequently applied winding and / or winding layers.

[0012] Further preferably, the end section of the winding wire is positively locked or clamped in its position in the end slot in the radial direction of the stator by previously applied winding and / or winding layers.

[0013] According to a preferred embodiment, the flange region laterally adjacent to the end slot has a clamping protrusion, which is elastically deformable configured and can then press away from the stator coil, so that the lateral access to the end slot is released and the end section of the winding wire can be pushed into the end slot.

[0014] Preferably, the end section of the winding wire can be fixed by the elastically springing back clamping protrusion after being pushed into the end slot.

[0015] Advantageously, the starting slot is arranged at a first spacing with respect to a center plane of the single-tooth structural unit extending in the radial direction of the stator, and the end slot is arranged at a second spacing greater than the first spacing with respect to the center plane.

[0016] According to a preferred embodiment, the flange region of the insulation cover has two starting slots and / or two end slots, - wherein the starting slots are arranged symmetrically with respect to each other on both sides of a center plane of the single-tooth structural unit extending in the radial direction of the stator, and - wherein the end slots are arranged symmetrically with respect to each other on both sides of a center plane of the single-tooth structural unit extending in the radial direction of the stator.

[0017] By means of the symmetrical configuration of the insulation shield, for example, the following possibility is implemented, namely to use the same insulation shield on all stator teeth independently of the different winding directions. Furthermore, for example, the following possibility is implemented, namely to use the same insulation shield on both end sides of a stator tooth.

[0018] According to a preferred embodiment, the flange region of the insulation shield has two start line slots and two end line slots, - wherein the start line slots are arranged symmetrically with respect to each other on both sides of a center plane of the single-tooth structure unit which extends in the radial direction of the stator, - wherein the end line slots are arranged symmetrically with respect to each other on both sides of a center plane of the single-tooth structure unit which extends in the radial direction of the stator, - wherein the two start line slots are each arranged at a first distance with respect to the center plane of the single-tooth structure unit, and wherein the two end line slots are each arranged at a second distance with respect to the center plane, the second distance being greater than the first distance.

[0019] The stator is preferably composed of a plurality of T-shaped segments, wherein each T-shaped segment comprises a single-tooth structure unit as described above. BRIEF DESCRIPTION OF DRAWINGS

[0020] Embodiments are explained in more detail below with reference to the drawings. Therein: Figure 1 A schematic view of a rotor and a stator of a brushless DC motor is shown; Figure 2 A single-tooth structure unit of a stator is shown, which is wound with winding wires, wherein a start section of the winding wires is introduced into a start line slot; Figure 3 A symmetrical arrangement of start line slots and end line slots in a flange region of an insulation shield is shown; Figure 4 A single-tooth structure unit is shown, which is wound with winding wires, wherein an end section of the winding wires is introduced into an end line slot; Figure 5 A flange region of an insulation shield is shown, which has a laterally next to an end line slot prescribed elastically deformable clamping protrusion, which can be elastically deformed for pushing in an end section of a winding wire; Figure 6 A flow chart of a method for manufacturing a single-tooth structure unit for a stator is shown. DETAILED DESCRIPTION

[0021] In Figure 1A rotor 2 and a stator 4 of a brushless DC motor are shown in a schematic view. The stator 4 is configured as a split stator, which in the example shown consists of twelve T-shaped segments 6-1 to 6-12. Each of the T-shaped segments 6-1 to 6-12 comprises stator teeth 8-1 to 8-12, which are shown in a simplified display without the associated stator coils. Each of the T-shaped segments 6-1 to 6-12 is configured in the form of a lamination stack, which comprises a plurality of lamination sheets layered on top of one another. Figure 1 The stator teeth 8-1 to 8-12 are shown in a simplified display without the associated stator coils. Each of the T-shaped segments 6-1 to 6-12 is configured in the form of a lamination stack, which comprises a plurality of lamination sheets layered on top of one another.

[0022] Figure 2 For the purpose of Figure 1 An associated single-tooth structure unit 10 is shown for the T-shaped segment 6-3 shown in. The lamination sheets 12 of the T-shaped segment 6-3 can be recognized well in. Furthermore, it can be recognized that the stator teeth 8-3 of the T-shaped segment 6-3 are wound with winding wire, so that the stator forms a coil. Figure 2

[0023] In order to provide the required electrical insulation between the winding wire of the stator coil and the lamination sheets 12 of the T-shaped segment 6-3, it is provided in the solution shown in that an insulation cover composed of plastic is plugged onto the T-shaped segment 6-3 on the end side, respectively. The insulation cover 14 can be recognized in, which is plugged onto the lamination sheets 12 of the T-shaped segment 6-3 in the axial direction. The insulation cover 14 has a flange region 16 at its end, which is placed radially outward in the stator 4. At the flange region 16, a start wire slot 18-1, 18-2 is provided not only on the left side, but also on the right side, which extends essentially in the axial direction of the stator 4. Furthermore, an end wire slot 20-1, 20-2 is provided not only on the left side, but also on the right side at the flange region 16, which likewise extends essentially in the axial direction of the stator 4. Figure 2 Figure 2 The start section 22 of the winding wire can be introduced into the start wire slot 18-1 in the winding process and guided in the start wire slot 18-1 towards the insulation cover 14. The start section 22 is fixed in the winding process by the subsequent windings, in particular by the first 24 and the second 26 subsequent winding of the first winding layer 28. Furthermore, the start section 22 of the winding wire can also be fixed in its position in the start wire slot 18-1 by the windings of the second winding layer 30 and, if necessary, further winding layers. Here, the start section 22 of the winding wire is positively locked or clamped, in particular in the radial direction of the stator 4. Thereby, it is achieved that the start section 22 of the winding wire cannot slide out of the start wire slot 18-1.

[0024] The start section 22 of the winding wire can be introduced into the start wire slot 18-1 in the winding process and guided in the start wire slot 18-1 towards the insulation cover 14. The start section 22 is fixed in the winding process by the subsequent windings, in particular by the first 24 and the second 26 subsequent winding of the first winding layer 28. Furthermore, the start section 22 of the winding wire can also be fixed in its position in the start wire slot 18-1 by the windings of the second winding layer 30 and, if necessary, further winding layers. Here, the start section 22 of the winding wire is positively locked or clamped, in particular in the radial direction of the stator 4. Thereby, it is achieved that the start section 22 of the winding wire cannot slide out of the start wire slot 18-1.

[0025] ​​There is usually space for realizing the starting wire groove 18 - 1 , and the wire layers produced thereby are very advantageous during the winding process, since the layer structure from the second winding layer 30 onwards is not negatively influenced by the partially sunken starting section 22 of the winding wire.

[0026] The spatial arrangement of the starting wire ducts 18-1, 18-2 and the end wire ducts 20-1, 20-2 is particularly Figure 3 can be well identified. Figure 3 The insulating cover 14 is shown in an unwound state. Figure 3 The two starting slots 18-1 and 18-2 are symmetrically arranged relative to each other on both sides of a center plane 32 of the single-tooth structural unit 10 extending in the radial direction of the stator 4 in the flange area 16 of the insulating cover 14. The two end slots 20-1 and 20-2 are also symmetrically arranged relative to each other on both sides of the center plane 32. Advantageously, the starting slots 18-1 and 18-2 are fully formed only at the axial ends, while the end slots 20-1 and 20-2 are formed over the entire axial length.

[0027] exist Figure 3 In the groove arrangement shown in FIG, the starting grooves 18-1, 18-2 are arranged internally and the two end grooves 20-1, 20-2 are arranged externally. That is, the two starting grooves 18-1, 18-2 are arranged at a first spacing relative to the center plane 32 of the single tooth structure unit 10, and the two end grooves 20-1, 20-2 are arranged at a second spacing relative to the center plane 32, wherein the second spacing is greater than the first spacing.

[0028] Grooved Figure 3 The arrangement shown in FIG results in a completely symmetrical design, which offers advantages in terms of manufacturability and, on the other hand, allows the use of the same insulating cover 14 on all stator teeth, independent of different requirements and winding directions. In particular, this allows the use of the same insulating cover 14 on both axial sides of each T-segment 6 - 1 to 6 - 12 . This reduces component diversity, costs, and the risk of component mix-ups.

[0029] exist Figure 4 A further view of the single tooth structural unit 10 is shown in FIG. Figure 4In FIG. 8 , a single tooth 8 - 3 has been wound using the first winding layer 28 and the second winding layer 30 of the stator coil. At the end of the winding process, the end section 34 of the winding wire is introduced into the end slot 20 - 2 and led out of the insulating cover 14 in the end slot 20 - 2 . Depending on the geometric constraints, tolerances, and wire diameter, there are two possible options for wire placement. According to the first option, the end section 34 of the winding wire is placed in the end slot 20 - 2 during winding.

[0030] The end section 34 of the winding wire is then fixed in its position in the end slot 20-2 by the previously applied winding and / or previously applied winding layer of the winding wire. In this case, the end section 34 of the winding wire is locked or clamped in a form-fitting manner, in particular in the radial direction of the stator 4, by the previously applied winding and / or winding layer. Figure 4 As shown in FIG, in order to securely fix the end section 34 in the end wire groove 20-2, at least one preceding winding 36 of the second winding layer 30, preferably two preceding windings 36, 38 of the second winding layer 30, are required. This can be useful, for example, to ensure that the end section 34 of the winding wire is subjected to sufficient holding force and does not slip out of the end wire groove 20-2 again. Furthermore, further previously applied windings and / or winding layers, for example, the first winding layer 28, can also contribute to fixing the end section 34 in the end wire groove 20-2.

[0031] exist Figure 4 In the example shown in , the end section 34 is secured in the end slot 20-2 by the preceding winding of the second winding layer 30. However, depending on the coil design and the number of winding layers used in the corresponding coil design, the end section can also be secured equally well by the windings of higher winding layers, for example, the third, fourth, fifth, or higher winding layers. In this case, the end section can, for example, be secured initially by the windings of the outermost winding layer, but further previously applied windings and / or winding layers can also contribute to securing the end section in this case. Generally, it is advantageous to use an even number of winding layers, but an odd number of winding layers can also be used equally well.

[0032] According to a second possible approach to wire placement, the end section 34 of the winding wire is pressed into the end wire groove 20-2 after winding. For this purpose, it is advantageous if the clamping projections 40 provided laterally adjacent to the end wire groove 20-2 in the flange region 16 of the insulating cover 14 are designed to be elastically deformable. Figure 5As shown in, the clamping protrusion 40 arranged next to the end slot 20-2 can be pressed away from the stator coil in the direction of the arrow 42, thereby releasing the lateral access to the end slot 20-2. Through this lateral access, the end section 34 of the winding wire can then be pushed into the end slot 20-2 from the side until the end section 34 of the winding wire is received in the end slot 20-2. After the push-in into the end slot 20-2, the end section 34 of the winding wire is fixed by the elastically springing back clamping protrusion 40.

[0033] Even in this second possibility of wire placement, the end section 34 of the winding wire introduced into the end slot 20-2 is fixed in its position in the end slot 20-2 by the previously applied windings and / or winding layers of the winding wire. In Figure 4 In the example shown in, the end section 34 is positively locked or clamped in its position in the end slot 20-2 by the previous winding 36 of the second winding layer 30, better still by the two previous windings 36, 38 of the second winding layer 30. In addition, further previously applied windings and / or winding layers, for example the first winding layer 28, can also contribute to fixing the end section 34 in the end slot 20-2. As a result, the end section 34 cannot be re-slipped out of the end slot 20-2.

[0034] Even in this second possibility of wire placement, the end section can likewise be fixed well by the windings of the higher winding layers, for example the third, fourth, fifth or higher winding layer, depending on the respective coil design and the number of winding layers used in the respective coil design. Here, the end section can for example be fixed first by the windings of the outermost winding layer, but further previously applied windings and / or winding layers can also contribute to fixing the end section in this case.

[0035] In the single-tooth structure unit 10 there is usually at least partially a structure space for implementing the end slots 20-1 and 20-2, that is to say a small adaptation of the design is necessary if necessary. For the winding process Figure 4 The wire layer shown in is advantageous in that the end section 34 of the winding wire is at least partially outside the winding space, that is to say there is more free space for the winding process.

[0036] In Figure 6A flow chart of a method for manufacturing a single tooth structure unit 10 for a stator 4 of a brushless DC motor is shown in Fig. 3. Here, in a step 44, a start section 22 of winding wire is introduced into one of the start wire slots 18-1, 18-2 provided in the flange region 16 of the insulating cover 14. The start section 22 introduced into the respective start wire slot 18-1, 18-2 is fixed by the subsequent winding 24, 26 and / or further winding layers. In a step 46, the stator tooth 8-3 provided with the insulating cover 14 is wound with winding wire in order to form a stator coil. In a step 48, an end section 34 of the winding wire is introduced into one of the end wire slots 20-1, 20-2. Here, the end section 34 of the winding wire introduced into the respective end wire slot 20-1, 20-2 is fixed by the previous winding 36, 38 and / or winding layers.

[0037] The features disclosed in the foregoing description, in the claims and in the accompanying drawings, may, both separately and in any combination thereof, be material for realizing the application in diverse its design embodiments.

Claims

1. A single tooth structure unit (10) for or in a stator (4) of a brushless DC motor, wherein The single-tooth structural unit (10) has: - stator teeth (8-1 to 8-12) for stator coils, - at least one insulation cover (14) which is plugged on at an end side onto the stator teeth (8-1 to 8-12); - the stator coils, which comprise winding wires which are wound onto the stator teeth (8-1 to 8-12) provided with the at least one insulation cover (14), - wherein the insulation cover (14) has a flange region (16) at its end which is placed radially externally in the stator (4), in which flange region a start slot (18-1, 18-2) and / or an end slot (20-1, 20-2) which extend essentially in the axial direction of the stator (4) are provided, - wherein a start section (22) of the winding wires of the stator coils is introduced into the start slot (18-1, 18-2) or an end section (34) of the winding wires of the stator coils is introduced into the end slot (20-1, 20-2), and - wherein the start section (22) of the winding wires introduced into the start slot (18-1, 18-2) is fixed in its position in the start slot (18-1, 18-2) by subsequently applied windings (24, 26) and / or winding layers (28, 30) of the winding wires or the end section (34) of the winding wires introduced into the end slot (20-1, 20-2) is fixed in its position in the end slot (20-1, 20-2) by previously applied windings (36, 38) and / or winding layers (28, 30) of the winding wires.

2. The monodentate structural unit (10) according to claim 1, characterized in that The start section (22) of the winding wires is positively locked or clamped in its position in the start slot (18-1, 18-2) in the radial direction of the stator (4) by subsequently applied windings (24, 26) and / or winding layers (28, 30).

3. The monodentia building block (10) according to claim 1 or claim 2, characterized in that The end section (34) of the winding wires is positively locked or clamped in its position in the end slot (20-1, 20-2) in the radial direction of the stator (4) by previously applied windings (36, 38) and / or winding layers (28, 30).

4. The monodentia building block (10) according to any one of claims 1 to 3, characterized in that The flange region (16) has a clamping projection (40) laterally adjacent to the end slot (20-1, 20-2), which is elastically deformable configured and can be pressed away from the stator coil such that a lateral inlet relative to the end slot (20-1, 20-2) is released and the end section (34) of the winding wires can be pushed into the end slot (20-1, 20-2).

5. The monodentia building block (10) according to claim 4, characterized in that The end section (34) of the winding wires can be fixed after being pushed into the end slot (20-1, 20-2) by the elastically springing back clamping projection (40).

6. The monodentia building block (10) according to any one of claims 1 to 5, characterized in that The start slots (18-1, 18-2) are arranged at a first spacing relative to a center plane (32) of the single-tooth structural unit (10) extending in a radial direction of the stator (4), and the end slots (20-1, 20-2) are arranged at a second spacing relative to the center plane (32) that is greater than the first spacing.

7. Single-tooth structural unit (10) according to any one of claims 1 to 6, characterized in that - the flange region (16) of the insulation cover (14) has two start slots (18-1, 18-2) and / or two end slots (20-1, 20-2), - wherein the start slots (18-1, 18-2) are arranged symmetrically relative to one another on both sides of a center plane (32) of the single-tooth structural unit (10) extending in a radial direction of the stator (4), and - wherein the end slots (20-1, 20-2) are arranged symmetrically relative to one another on both sides of the center plane (32) of the single-tooth structural unit (10) extending in a radial direction of the stator (4).

8. Single-tooth structural unit (10) according to any one of claims 1 to 7, characterized in that - the flange region (16) of the insulation cover (14) has two start slots (18-1, 18-2) and two end slots (20-1, 20-2), - wherein the start slots (18-1, 18-2) are arranged symmetrically relative to one another on both sides of a center plane (32) of the single-tooth structural unit (10) extending in a radial direction of the stator (4), - wherein the end slots (20-1, 20-2) are arranged symmetrically relative to one another on both sides of the center plane (32) of the single-tooth structural unit (10) extending in a radial direction of the stator (4), - wherein the two start slots (18-1, 18-2) are each arranged at a first spacing relative to the center plane (32) of the single-tooth structural unit (10), and wherein the two end slots (20-1, 20-2) are each arranged at a second spacing relative to the center plane (32) that is greater than the first spacing.

9. Stator (4) for a brushless DC motor, comprising at least one single-tooth structural unit (10) according to any one of claims 1 to 8.

10. Stator (4) according to claim 9, characterized in that The stator (4) is composed of a plurality of T-shaped segments (6-1 to 6-12), wherein each T-shaped segment (6-1 to 6-12) comprises a single-tooth structural unit (10) according to any one of claims 1 to 8.

11. Brushless DC motor comprising a stator (4) according to any one of claims 9 or 10 and a rotor (2).

12. Method for manufacturing a single-tooth structural unit (10) for a stator (4) of a brushless DC motor, based on - stator teeth (8-1 to 8-12) for stator coils, - at least one insulation cover (14) plugged onto the stator teeth (8-1 to 8-12) on the end side, - winding wire for winding a stator tooth (8-1 to 8-12) provided with the at least one insulation shield (14), - wherein, The insulation shield (14) has a flange region (16) at its end which is placed radially outward in the stator (4), in which a start slot (18-1, 18-2) and / or an end slot (20-1, 20-2) extending essentially in the axial direction of the stator (4) is provided, wherein the method has: - if a start slot (18-1, 18-2) is provided in the flange region (16), a start section (22) of the winding wire is introduced into the start slot (18-1, 18-2), wherein the start section (22) of the winding wire introduced into the start slot (18-1, 18-2) is fixed by subsequently applied windings (24, 26) and / or winding layers (28, 30), - winding a stator tooth (8-1 to 8-12) provided with the at least one insulation shield (14) with the winding wire, - if an end slot (20-1, 20-2) is provided in the flange region (16), an end section (34) of the winding wire is introduced into the end slot (20-1, 20-2), wherein the end section (34) of the winding wire introduced into the end slot (20-1, 20-2) is fixed by previously applied windings (36, 38) and / or winding layers (28, 30).

Images