Set, stator unit for a set and method for manufacturing said stator unit

Abstract

The invention relates to a kit comprising: a first stator unit having a first connection device for connecting stator windings into a triangular circuit, the first connection device having three connection bus bars for contacting respective phase branches U, V, W of the stator windings and an insulating housing with a receiving structure for receiving the connection bus bars; and a second stator unit having a second wiring device for wiring the stator windings into a star-shaped circuit, the second connection device has three connection bus bars for contacting the respective phase branches U, V, W of the stator winding, a star-shaped junction bus bar for contacting all the phase branches U, V, W of the stator winding, and an insulating housing with a receiving structure for receiving the connection bus bars and the star-shaped junction bus bar; wherein the accommodating structures of the two wiring devices are configured to have the same structure and / or the insulating shells of the two wiring devices are configured to have the same component.

Description

TECHNICAL FIELD

[0001] The invention relates to a kit having the features of the preamble of claim 1. The invention further relates to a stator unit, in particular for a kit, and to a method for producing the stator unit. BACKGROUND

[0002] It is known with respect to electric machines that the stator winding of a stator is contacted by means of a wiring assembly with high-voltage terminals, for example power electronics, in order to apply a voltage to the individual phases of the stator winding. The stator winding usually has three phases, which can be wired in a star circuit or a delta circuit.

[0003] For example, document DE 10 2022 210 667 A1 discloses a motor stator for a motor. The motor stator comprises a stator body and a plurality of windings. The stator body comprises a welding end, a crown end and a plurality of slots arranged in a circumferential direction and extending axially between the welding end and the crown end. Each winding comprises a phase lead, a neutral lead and a plurality of coils. The plurality of coils comprises lead coils of the same layer, which comprise two legs extending across several slots of the plurality of slots and are inserted into the respective slots at the same layer thereof. The lead coils of the same layer position the phase lead at the welding end. The neutral lead and the welds connecting the plurality of coils are each positioned at the welding end. The motor stator further comprises a busbar arranged at the welding end, wherein, for each winding of the plurality of windings, the welds of the phase lead and the neutral lead are configured at the welding end, such that all welds of the motor stator are configured at the welding end. SUMMARY

[0004] It is an object of the invention to provide a stator unit of the type initially described, which is characterized by a simple and cost-effective assembly.

[0005] This object is achieved by a kit having the features of claim 1, a stator unit having the features of claim 13 and a method having the features of claim 14. Further design options and advantages according to the invention result from the respective subclaims and the following description and the drawings.

[0006] The subject of the invention is a kit having a first stator unit and a second stator unit. In particular, the first stator unit and the second stator unit are configured for and / or suitable for an electric machine. Preferably, in order to form an electric machine, the first stator unit or the second stator unit can be selected from the kit and combined with further components, for example a rotor, a housing, etc. Specifically, a first electric machine is formed by using the first stator unit and a second electric machine is formed by using the second stator unit.

[0007] The first stator unit has a first connection device which is configured and / or adapted for connecting the stator winding as a delta circuit. The first connection device for this purpose has three connection conductors for contacting the respective phase branches of the stator winding and an insulating housing with accommodation structures for accommodating the connection conductors. In particular, the stator winding of the first stator unit has exactly three phase branches (U, V, W), wherein the three phase branches are connected as a delta circuit by means of the three connection conductors. The connection conductors are in particular used for contacting the phase branches to the power electronics.

[0008] The second stator unit has a second connection device which is configured and / or adapted for connecting the stator winding as a star circuit. The second connection device for this purpose has three connection conductors for contacting the respective phase branches of the stator winding, a star junction conductor for contacting all phase branches of the stator winding and an insulating housing with accommodation structures for accommodating the connection conductors and the star junction conductor. In particular, the stator winding of the second stator unit has exactly three phase branches (U, V, W), wherein the three phase branches are connected as a star circuit by means of the three connection conductors and the star junction conductor. Preferably, the star junction conductor forms the star junction of the star circuit. The connection conductors are in particular used for contacting the phase branches to the power electronics.

[0009] It is proposed in the context of the application that the accommodation structures of the first connection device and of the second connection device are configured identically. Alternatively or additionally, the insulating housings of the first connection device and of the second connection device are configured as identical components. In other words, two different connection devices are proposed which have identical accommodation structures and / or identical insulating housings. This means that the same insulating housing can be used to form the first connection device and the second connection device, wherein the change between the delta circuit and the star circuit is achieved by adding the optional star junction conductor. In particular, the accommodation structures are used for accommodating the connection conductors and the optional star junction conductor in a form-fitting connection. Preferably, the connection conductors and, if necessary, the star junction conductor are arranged in the respectively associated accommodation structure in an electrically insulated manner from one another. The insulating housing can be made of any electrically insulating material, for example of plastic or ceramic. In particular, the accommodation structures are configured such that at least the star junction conductor can be removed to form the first connection device and added to form the second connection device, without having to change the insulating housing, more precisely the accommodation structures.

[0010] The invention is based on the insight that delta circuits and star circuits are produced by always inserting the stator winding in the same way and by adjusting the connection device and bending the winding end. For this, a large axial available length of the winding end to the connection device is required and additional support members are required to support the long winding end in order to ensure the fatigue strength during the service life. The invention has the advantage that by using a structurally identical accommodation structure, more precisely an insulation housing, the manufacturing costs for manufacturing the stator unit in delta connection and star connection can be reduced. Furthermore, the assembly can be significantly simplified, since for the change from the delta circuit to the star circuit only the star junction conductor bar has to be assembled into the predetermined accommodation structure.

[0011] In a specific design proposal, it is proposed that the accommodation structure has on the upper side of the insulation housing accommodation sections for the three connection conductor bars respectively and on the lower side of the insulation housing an additional accommodation section for the star junction conductor bar, wherein the additional accommodation section of the first connection device is not occupied and the additional accommodation section of the second connection device is occupied by the star junction conductor bar. In other words, the star junction conductor bar is arranged below the connection conductor bars. Preferably, at least the additional accommodation section is open in the assembly direction, in particular in the axial direction with respect to the stator axis, so that the star junction conductor bar can be axially inserted or assembled into the additional accommodation section, if required. Thereby, the subsequent assembly of the star junction conductor bar for the realization of the star circuit can be particularly expedient.

[0012] In an embodiment, it is proposed that the first stator unit and the second stator unit each comprise a stator body and a stator winding, wherein the stator body and / or the stator winding of the first stator unit and the second stator unit are configured as identical components. The stator winding is preferably arranged on the stator body of the stator, wherein the stator body for this purpose has a plurality of stator grooves each extending along the stator axis, into which the stator winding is partially inserted. Preferably, the stator winding is formed by a plurality of plug-in coils. Preferably, each plug-in coil passes through at least one, preferably exactly two stator grooves spaced apart in the circumferential direction. The stator winding can be configured as a hairpin winding or a wave winding. For this purpose, the plug-in coils can be configured in the form of hairpins, I-pins or D-pins. The stator winding has three phase branches, wherein each phase branch can be formed by at least or exactly two sub-branches. In particular, each phase branch or each sub-branch has at least one or exactly one winding end. The winding end preferably extends in the axial direction with respect to the stator axis, preferably parallel and / or identically oriented to the stator axis. In particular, the winding end protrudes in the axial direction from a winding head of the stator winding at least at the axial end side. Particularly preferably, the winding end extends in the axial direction on the radially inner diameter of the stator winding. Thus, a kit is proposed, wherein the stator units can be formed from a large number of identical components, so that the manufacturing costs can be further reduced.

[0013] In a specific embodiment, it is proposed that the three connection conductive strips of the first and the second connection device each have a set of terminal tabs for connecting to the at least one or exactly one winding end of the respective phase branch, and each have a conductive strip section for connecting to the power electronics, wherein at least a portion of the conductive strip sections and the terminal tabs of the first and the second connection device form identical sections. In other words, the connection conductive strips of the first and the second connection device are configured as identical components in sections. Preferably, the conductive strip sections are designed as structurally identical or completely identical, and the terminal tabs are configured as locally structurally identical or locally completely identical. Preferably, each connection conductive strip has a plurality of terminal tabs by means of which a plurality of winding ends of a phase branch can be contacted. In particular, a change between a delta circuit and a star circuit can be achieved by adapting the terminal tabs, while the conductive strip sections remain identical. Thereby, the same connection conductive strips can be manufactured for the delta circuit and the star circuit in the manufacturing process, and can be subsequently changed or adapted, in particular to form the second connection device. Particularly preferably, the first stator unit and the second stator unit can be manufactured from identical components only. Thereby, the manufacturing costs are further reduced.

[0014] It is proposed according to one specific implementation that the first and second terminal arrangement can be arranged and / or arranged in a fixed angular position relative to the respective associated stator body in the mounted condition. In other words, the first and second terminal arrangement are arranged in the same position relative to the respective associated stator body. In short, the first and second terminal arrangement, preferably at least the respective insulating housing, can be arranged coincidentally with each other on the respective stator body. This further simplifies the assembly, since the first and second terminal arrangement can be positioned in the same position relative to the stator body and thus arranged or held in place in the same assembly tool.

[0015] It is proposed according to one specific implementation that the terminal lugs of the three connecting conductive strips of the first terminal arrangement are arranged in a connection region of n stator slots. In particular, the connection region corresponds to an angular range defined by a fixed number of stator slots. For example, the connection region extends over 10, preferably more than 15, in particular more than 20 stator slots in the circumferential direction. Alternatively or additionally, the connection region extends over less than 25, preferably less than 20, in particular less than 15 stator slots in the circumferential direction. Particularly preferably, the terminal lugs of the three connecting conductive strips of the first terminal arrangement are arranged in a connection region of exactly n = 18 stator slots.

[0016] In one refinement, it is proposed that the star point conductor bar of the second connection device has, for each phase branch, a set of terminal lugs for connection to the at least one winding end of each phase branch and a connection section for connecting the terminal lugs. In other words, the star point conductor bar has three sets of terminal lugs, which are connected to one another by connection sections, preferably to form a star point. According to this refinement, it is proposed that the terminal lugs of the three connection conductor bars of the second connection device and the terminal lugs of the star point conductor bar of the second connection device are arranged in the connection region of n stator slots. In short, the first connection region defined by the connection conductor bars of the first connection device is identical to the second connection region defined by the connection conductor bars and the star point conductor bar of the second connection device. Here, "identical" means that the two connection regions have the same angular extent, although they can be arranged offset to one another in the circumferential direction. Preferably, the terminal lugs of the three connection conductor bars and the terminal lugs of the star point conductor bar are arranged in n / 2 stator slot connection regions, respectively. In other words, the terminal lugs of the connection conductor bars and the terminal lugs of the star point conductor bar extend into half of the connection regions, respectively. In particular, this means that the terminal lugs of the second connection device must be shortened by half, more precisely by the angular extent of n / 2 stator slots, in order to free up the connection regions for the terminal lugs of the star point conductor bar. This achieves a particularly compact design of the connection device, in which the delta circuit and the star circuit can be implemented conveniently by cutting off the unnecessary terminal lugs.

[0017] In another specific implementation, it is proposed that the connection regions of the first connection region and the second connection region extend over an angular extent of greater than 90 degrees and / or less than 180 degrees. In particular, the connection regions extend over an angular extent of at least or exactly 120 degrees. Thus, a first connection device and a second connection device are proposed, which provide a plurality of connection locations over a large angular extent in order to contact a plurality of sub-branches to the respective connection device by means of the terminal lugs.

[0018] In another specific implementation it is proposed that the angular distance between the terminal tabs corresponds to the angular distance between the stator slots. In other words, the number of stator slots in the connection region corresponds to the number of terminal tabs. For example, the first and second connection devices each have a number n = 18 of terminal tabs, wherein the connection conductor bars of the first connection device each provide six terminal tabs for each phase branch and the connection conductor bars of the second connection device and the star point conductor bar each provide three terminal tabs for each phase branch. In other words, for each phase branch, the second connection device has only three terminal tabs for each connection conductor bar instead of six terminal tabs for each connection conductor bar, wherein the missing terminal tabs are provided by the terminal tabs of the star point conductor bar. Thus, a stator winding having a maximum of six winding ends per phase branch can form a delta circuit or a star circuit by contacting the winding ends with the terminal tabs, respectively.

[0019] In another embodiment it is proposed that all terminal tabs of the first and second connection devices are located on a pitch circle, wherein the terminal tabs of the three connection conductor bars of the first connection unit are arranged in groups in succession in the circumferential direction and the terminal tabs of the three connection conductor bars of the second connection unit are arranged in groups alternatingly with respect to the terminal tabs of the star point conductor bar. In particular, especially in the initial state of the first and / or second connection device, all terminal tabs are arranged within the respective connection region at the same angular distance, in particular corresponding to the slot distribution of the stator body. Thereby, the winding ends can be led directly from the insertion region, more precisely the stator slots, and directly into contact with the respective terminal tabs. Furthermore, the connection can be made directly by the winding head, so that additional support of the winding ends can be dispensed with, since they can be led directly from the insertion region of the stator slots, more precisely of the stator winding. Thus, a stator unit is proposed which has a reduced axial construction length.

[0020] In a preferred embodiment it is proposed that the conductor bar sections of the three connection conductor bars of the first connection device are connected at a central location of the respectively associated group of terminal tabs and / or the connection sections of the star point conductor bar of the second connection device are connected at a central location of the respectively associated group of terminal tabs. By connecting the conductor bar sections or connection sections at a central location, the vibration behavior of the terminal tabs including the connected winding ends can be optimized.

[0021] In another specific implementation it is proposed that the terminal lugs of the first connection device and the winding ends of the stator winding of the first stator unit are arranged relative to the terminal lugs of the second connection device and the winding ends of the stator winding of the second stator unit in a manner that is offset in the circumferential direction by at least or exactly one stator slot. Alternatively or additionally, the connection regions of the first connection device are arranged relative to the connection regions of the second connection device in a manner that is offset in the circumferential direction by at least or exactly one stator slot. In other words, the first winding ends of one stator unit are led out at stator slot nl and the first winding ends of the other stator unit are led out at stator slot n2. In other words, in the case of an arrangement in connection regions of n = 18 stator slots, one connection device provides a terminal lug for each stator slot nl to n18 and the other connection device provides a terminal lug for each stator slot n2 to n19. An offset of exactly one stator slot in the circumferential direction is thereby formed. Likewise, an offset of exactly two or more stator slots in the circumferential direction can be formed, as shown in the following table. If the terminal lugs are shortened to form a star circuit or to form a usable area for the terminal lugs of the star junction, the connection of the conductor strips of the connection conductor strip paths of the second connection device to the conductor strip sections at the center or at least almost at the center is also made possible by the offset in the circumferential direction.

[0022] According to the following table, for an exemplary stator body with a total of 54 slots and n = 18 stator slots or n = 18 terminal lugs in the connection region, the following connection configurations Y-Varl, Y-Var2 or Y-Var3 (phases U, V, W; star junction S) can be used for a star circuit:

[0023]

[0024]

[0025] Angular distance (°) 66.67 73.33 80.00 86.67 93.33 100.00 106.67 113.33 120.00 126.67 Position 11 12 13 14 15 16 17 18 19 20 Y-Var1 V V S S S W W W Y-Var3 V S S W W Y-Var3 S W

[0026] According to the following table, for an exemplary stator body, in the case of an offset of exactly two stator slots or two connection positions (position 1, position 2) by the stator winding, the following connection configurations Δ-Varl, Δ-Var2 or Δ-Var3 (phases U, V, W) can be used for a delta circuit:

[0027] Angular distance (°) 0 6.67 13.33 20.00 26.67 33.33 40 46.67 53.33 60 Position 1 2 3 4 5 6 7 8 9 10 Δ-Var1 U U U U U U V V Δ-Var3 U U U U V V Δ-Var3 U U V

[0028] Angular distance (°) 66.67 73.33 80.00 86.67 93.33 100.00 106.67 113.33 120.00 126.67 Position 11 12 13 14 15 16 17 18 19 20 Δ-Var1 V V V V W W W W W W Δ-Var3 V V W W W W Δ-Var3 V W W

[0029] A further subject of the application relates to a stator unit, in particular for a kit as described above. The stator unit has a terminal device with an insulating housing having an accommodation structure for optionally accommodating three connection conductive strips to configure the terminal device as a delta circuit, more precisely the stator unit as a first stator unit, or three connection conductive strips and a star point conductive strip to configure the terminal device as a star circuit, more precisely the stator unit as a second stator unit.

[0030] A further subject of the application relates to a method for manufacturing a stator unit as described above, in particular a first stator unit and a second stator unit. To this end, a stator body, a stator winding and a terminal device for wiring the stator winding as a delta circuit or as a star circuit are provided, wherein the stator winding has one or more winding ends for each phase branch. If a delta circuit is to be established, the stator winding is inserted into the stator body in a predetermined first angular position and the terminal device is arranged in an angular position fixed relative to the stator body, wherein at least one winding end of a phase branch is brought into contact with a respective connection conductive strip of the terminal device. In other words, the respective at least one winding end of a phase branch is in contact with a respective terminal tab of the associated connection conductive strip. Thus, in order to form a delta circuit, at least one winding end of the stator winding is connected to each connection conductive strip. If a star circuit is to be established, the stator winding is inserted into the stator body in a predetermined second angular position, the terminal device is supplemented with a star point conductive strip and the terminal device is arranged in an angular position fixed identically relative to the stator, wherein the respective at least one winding end of a phase branch is brought into contact with a respective connection conductive strip of the terminal device and the respective at least one winding end of each phase branch is brought into contact with the star point conductive strip. In other words, the respective winding end of a phase branch is in contact with a respective terminal tab of the associated connection conductive strip and the respective winding end of each phase branch is in contact with a respective terminal tab of the star point conductive strip. Thus, in order to form a star circuit, at least one winding end of the stator winding is connected to each connection conductive strip and the respective winding end of each phase branch is connected to the star point conductive strip.

[0031] In an improved embodiment, the connection conductive strips of the second terminal device are shortened to form a usable area for the star point conductive strip. In particular, the connection conductive strips are shortened symmetrically or at least almost symmetrically in order to continue to ensure the central connection of the conductive strip sections. Alternatively or additionally, the connection conductive strips can also be shortened after the winding end connection by an unused or surplus number of terminal tabs.

[0032] In another specific implementation it is proposed that the stator winding is inserted into a first angular position which is shifted in the circumferential direction by one or more, preferably exactly two stator slots, relative to the second angular position. For example, for a star circuit the stator winding is inserted with the first winding end into the stator slot nl and for a delta circuit with the first winding end into the stator slot n2 or n3. By inserting the stator winding in such a way that it is inserted into a shifted slot, a centered or almost centered connection of the terminal tabs can be achieved after shortening, more precisely after cutting off the terminal tabs. BRIEF DESCRIPTION OF DRAWINGS

[0033] The application is further explained below with reference to the drawings. The drawings show:

[0034] Figure 1 An axial top view of a first connection device for a delta circuit of a first stator unit is shown as an embodiment of the application;

[0035] Figure 2 A detailed perspective view of a first stator unit wired into a delta circuit with the first connection device is shown;

[0036] Figure 3 An axial top view of a second connection device for a star circuit of a second stator unit is shown as another embodiment of the application;

[0037] Figure 4 A detailed perspective view of a second stator unit wired into a star circuit with the second connection device is shown. DETAILED DESCRIPTION

[0038] Figure 1 A first connection device 1 for wiring a stator winding 11 into a delta circuit is shown as Figure 2 is shown. The first connection device 1 has an insulating housing 3 and three connecting conductive strips 4a, 4b, 4c, also referred to as U conductive strip, V conductive strip, W conductive strip, which are accommodated in an accommodating structure 5 of the insulating housing 3 in a form-fitting connection and electrically insulated from one another.

[0039] The insulating housing 3 is manufactured, for example, from plastic, preferably by plastic injection molding, wherein the accommodation structure 5 is formed by recesses, for example, a negative contour, which correspond to the connecting conductive bars 4a, 4b, 4c. The accommodation structure 5 has a first accommodation section 6a for accommodating the first connecting conductive bar 4a, a second accommodation section 6b for accommodating the second connecting conductive bar 4b, and a third accommodation section 6c for accommodating the third connecting conductive bar 4c, wherein the accommodation sections 6a, 6b, 6c are spatially separated from one another or electrically insulated by means of partitions, ribs, thin walls, or the like. For example, the accommodation sections 6a, 6b, 6c are open in the axial direction with respect to the stator axis 100, so that the individual connecting conductive bars 4a, 4b, 4c can be inserted or fitted into the respective accommodation section 6a, 6b, 6c in the axial direction, more precisely from above. The connecting conductive bars 4a, 4b, 4c can be fixed in the respective accommodation section 6a, 6b, 6c, for example, by means of thermal caulking.

[0040] The connecting conductive bars 4a, 4b, 4c each have a conductive bar section 7a, 7b, 7c and a set of terminal lugs 8a, 8b, 8c, which are each integrally connected to one another or made from a common material section. Here, the conductive bar sections 7a, 7b, 7c are for connecting the power electronics and the terminal lugs 8a, 8b, 8c are for connecting the stator winding 2. The terminal lugs 8a, 8b, 8c are arranged on a common reference circle 101 (only partially shown) around the stator axis 100, wherein the terminal lugs 8a, 8b, 8c are arranged in groups in succession in the circumferential direction. Here, the conductive bar sections 7a, 7b, 7c are each connected at the center of the respective group of terminal lugs 8a, 8b, 8c in order to optimize the vibration behavior of the terminal lugs 8a, 8b, 8c in the installed condition.

[0041] Figure 2 A first stator unit 10 for a first electric machine is shown, which is used, for example, for generating an electric drive torque, in particular a traction torque for an electric axle of a vehicle. The electric machine is an internal rotor electric machine and for this can have a not shown rotor arranged radially inside the first stator unit 10. The stator axis 100 can be defined, for example, by the axis of rotation of the rotor.

[0042] The first stator unit 10 comprises a stator body 11 and a multiphase stator winding 12, wherein the stator body 11 carries the stator winding 12. For this, the stator body 11 has a plurality of stator grooves 13 distributed in the circumferential direction and extending in the axial direction with respect to the stator axis 100.

[0043] The stator winding 12 is formed, for example, from a plurality of plug-in coils, for example in the form of hairpins or I-shaped pins, which are wired to one another in a specific pattern. The stator winding 12 is inserted here into the stator slots 13, wherein a plurality of plug-in coils can be arranged per stator slot 13. The stator winding 12 has exactly three phase branches U, V, W here, wherein each phase branch U, V, W comprises two sub-branches 15a, 15b, respectively, each formed from a plurality of plug-in coils among the plug-in coils. The sub-branches 15a, 15b each have two winding ends 14 which extend parallel to one another and / or identically oriented on the inner diameter of the stator winding 12 in the axial direction about the stator axis 100.

[0044] The phase branches U, V, W are wired into a delta circuit by the first wiring device 1, wherein the winding ends 14 of the two sub-branches 15a, 15b of the first phase branch U are in contact with the terminal lugs 8a of the first connecting conductor bar 4a, the winding ends 14 of the two sub-branches 15a, 15b of the second phase branch V are in contact with the terminal lugs 8b of the second connecting conductor bar 4b, and the winding ends 14 of the two sub-branches 15a, 15b of the third phase branch W are in contact with the terminal lugs 8c of the third connecting conductor bar 4c.

[0045] To this end, the wiring device 1 is arranged in an angular position fixed relative to the stator body 11, wherein the terminal lugs 8a, 8b, 8c of the three connecting conductor bars 4a, 4b, 4c of the first wiring device 1 are arranged in a fixed first connection region 102 of n = 18 stator slots 13. Here, each connecting conductor bar 4a, 4b, 4c has six terminal lugs 8a, 8b, 8c, respectively, wherein each terminal lug 8a, 8b, 8c is associated with one stator slot 13. Here, the angular distance between the individual terminal lugs 8a, 8b, 8c corresponds to the angular distance between the stator slots 13, respectively. For example, the stator body 11 has a total of 54 stator slots 13, wherein the terminal lugs 8a, 8b, 8c are associated with the stator slots n3 to n20 as shown, for example. The first connection region 102 thus extends over an angular range of 120° when the number of stator slots 13 is n = 18. Figure 1

[0046] In the embodiment shown, the winding ends 14 of the first phase branch U occur at the stator slots n3, n4, n6, n7, the winding ends 14 of the second phase branch V occur at the stator slots n9, n10, n12, n13, and the winding ends 14 of the third phase branch W occur directly at the stator slots n15, n16, n18, n19. In other words, the terminal lugs 8a, 8b, 8c associated with the stator slots n5, n8, n11, n14, n17, n20 are not occupied. ​

[0047] Figure 3 A second connection device 2 is shown, which is used to connect the stator winding 11 into a star circuit as shown in Figure 4 The second connection device 2 has an insulating housing 3, three connection conductor bars 4a, 4b, 4c, in particular also referred to as U conductor bar, V conductor bar, W conductor bar, and a star point conductor bar 9, which are accommodated in an accommodating structure 5 of the insulating housing 3 in a form-fitting connection and electrically insulated from one another.

[0048] For the connection into a delta circuit and a star circuit by means of the respective connection device 1, 2, always the same insulating housing 3 with the connection conductor bars 4a, 4b, 4c should be used, wherein the change between the delta circuit and the star circuit is achieved by the optional star point conductor bar 9 and the not required pin positions of the terminal lugs 8a, 8b, 8c. For this reason, the insulating housings 3 of at least two connection devices 1, 2 are constructed as identical components.

[0049] For this purpose, the accommodating structure 5 of the insulating housing 3 of both connection devices 1, 2 has, in addition to the three accommodating sections 6a, 6b, 6c for accommodating the respective connection conductor bars 4a, 4b, 4c, an additional accommodating section 6d as shown in Figure 1 and Figure 3 for accommodating the star point conductor bar 9. This additional accommodating section 6d is not occupied when forming the first connection device 1, whereas the star point conductor bar 9 is fitted into this additional accommodating section 6d when forming the second connection device 2. This additional accommodating section 6d is arranged here on the lower side of the insulating housing 3, which faces away from the accommodating sections 6a, 6b, 6c, so that the star point conductor bar 9 can be arranged below the connection conductor bars 4a, 4b, 4c. For example, the additional accommodating section 6d is open in the axial opposite direction with respect to the stator axis 100, so that the star point conductor bar 9 can be inserted or fitted into the additional accommodating section 6d in the axial direction, more precisely from below. The star point conductor bar 9 can be fixed in the additional accommodating section 6d, for example, by means of a hot caulk.

[0050] The star point conductor bar 9 has three groups of terminal lugs 16a, 16b, 16c and a connection section 17, which is partially obscured here by the insulating housing 3, which are connected to one another in one piece or are made of a common material section. Here, the connection section 17 serves for connecting the terminal lugs 16a, 16b, 16c, more precisely for forming the star point of the star circuit.

[0051] The terminal lugs 16a, 16b, 16c of the star point conductor bar 9 are arranged together with the terminal lugs 8a, 8b, 8c of the connection conductor bars 4a, 4b, 4c distributed around the stator axis 100 on a common pitch circle 101 (only partly shown), wherein the terminal lugs 8a, 8b, 8c of the connection conductor bars 4a, 4b, 4c and the terminal lugs 16a, 16b, 16c of the star point conductor bar 9 are arranged in groups alternatingly one after the other in circumferential direction. In other words, the terminal lugs 8a, 8b, 8c of the connection conductor bars 4a, 4b, 4c and the terminal lugs 16a, 16b, 16c of the star point conductor bar 9 are arranged alternatingly one after the other in circumferential direction. Here, the connection sections 17 are connected at a central position of the respective group of terminal lugs 16a, 16b, 16c, and the conductor bar sections 7a, 7b, 7c are connected at at least approximately central positions of the respective group of terminal lugs 8a, 8b, 8c, in order to optimize the vibration behavior of the terminal lugs 16a, 16b, 16c and the terminal lugs 8a, 8b, 8c in the mounted state. In order to ensure this, the positions of the terminal lugs 8a, 8b, 8c, 16a, 16b, 16c of the second connection device 2 must be different, more precisely offset in circumferential direction, relative to the positions of the terminal lugs 8a, 8b, 8c of the first connection device 1, which is achieved by inserting the stator winding 12 into the offset grooves of the stator body 11.

[0052] Figure 4 A second stator unit 20 for a second electric machine is shown, which likewise comprises a stator body 11 and a multiphase stator winding 12. The stator body 11 and the stator winding 12 of the second stator unit 20 are configured identically, more precisely identically in structure, to the stator body 11 and the stator winding 12 of the first stator unit 10, wherein the stator winding 12 of the second stator unit 20 is inserted into the stator body 11 offset by two stator grooves 13 relative to the stator winding 12 of the first stator unit 10. Thereby, the mounting positions of the stator body 11 and the connection devices 1, 2 remain identical, while the positions of the terminal lugs 8a, 8b, 8c and the winding end portions 14, more precisely the connection regions 102, are not identical, in order to achieve an advantageous design of the busbar.

[0053] The phase branches U, V, W are wired into a star circuit by the second wiring device 2, wherein the winding ends 14 of the first sub-branches 15b of the first phase branch U are in contact with the terminal lugs 8a of the first connecting conductor bar 4a, the winding ends 14 of the first sub-branches 15b of the second phase branch V are in contact with the terminal lugs 8b of the second connecting conductor bar 4b, and the winding ends 14 of the first sub-branches 15b of the third phase branch W are in contact with the terminal lugs 8c of the third connecting conductor bar 4c. Furthermore, the winding ends 14 of the second sub-branches 15a of the first phase branch U are in contact with the terminal lugs 16a of the star junction conductor bar 9, the winding ends 14 of the second sub-branches 15a of the second phase branch V are in contact with the terminal lugs 16b of the star junction conductor bar 9, and the winding ends 14 of the second sub-branches 15a of the third phase branch W are in contact with the terminal lugs 16c of the star junction conductor bar 9.

[0054] To this end, the second wiring device 2, more precisely the insulating housing 3, is arranged in the same angular position relative to the stator body 11 as the first wiring device 1, more precisely the insulating housing 3, wherein the terminal lugs 8a, 8b, 8c of the three connecting conductor bars 4a, 4b, 4c and the terminal lugs 16a, 16b, 16c of the star junction conductor bar 9 of the second wiring device 2 are arranged in the connection region 103 of the n = 18 stator grooves 13, which is different from the connection region 102. The two connection regions 102, 103, for example, cover the same angular range, but are arranged offset to each other in the circumferential direction.

[0055] In particular, each connecting conductor bar 4a, 4b, 4c has three terminal lugs 8a, 8b, 8c, respectively, and the star junction conductor bar 9 has nine terminal lugs 16a, 16b, 16c, wherein the respective three terminal lugs 16a, 16b, 16c of the star junction conductor bar 9 replace the respective three terminal lugs 8a, 8b, 8c of the first wiring device 1. To this end, the respective three terminal lugs 8a, 8b, 8c are truncated in order to provide a respective available area for the terminal lugs 16a, 16b, 16c of the star junction conductor bar 9. Thus, the connecting conductor bars 4a, 4b, 4c of the first wiring device 1 and the second wiring device 2 have the same segments, which are formed by the conductor bar segments 7a, 7b, 7c and by the partial terminal lugs 8a, 8b, 8c. In short, the same connecting conductor bars 4a, 4b, 4c can be used for the first wiring device 1 and the second wiring device 2, wherein the connecting conductor bars 4a, 4b, 4c of the second wiring device 2 are shortened to form the available areas for the terminal lugs 16a, 16b, 16c of the star junction conductor bar 9.

[0056] In the embodiment shown, the terminal tabs 8a are truncated at positions n3, n7 and n8, the terminal tabs 8b are truncated at positions n9, n13 and n14 and the terminal tabs 8c are truncated at positions n15, n19 and n20. Thus, as shown, the terminal tabs 8a, 8b, 8c are associated with the stator slots n4 to n6, n10 to n12 and n16 to n18, while the terminal tabs 16a, 16b, 16c are associated with the stator slots n1 to n3, n7 to n9 and n13 to n15. In other words, the connection region 103 of the second connection device 2 is arranged with a two-stator-slot offset with respect to the connection region 103 of the first connection device 1 in order to provide connection positions corresponding to the stator windings 12 inserted into the offset slots. Figure 3

[0057] In the embodiment shown, the winding ends 14 of the first phase branch U occur at the stator slots n1, n2, n4, n5, the winding ends 14 of the second phase branch V occur at the stator slots n7, n8, n10, n11 and the winding ends 14 of the third phase branch W occur at the stator slots n13, n14, n16, n17. In other words, the terminal tabs 8a, 8b, 8c and 16a, 16b, 16c associated with the stator slots n3, n6, n9, n12, n15 and n18 are not occupied.

[0058] Thus, a stator unit 10, 20 is proposed which can be wired alternatively into a delta circuit or a star circuit with the maximum number of identical components by inserting the stator windings 12 into offset slots and by adding or removing the star junction conductive strips 9 and by truncating the terminal tabs 8a, 8b, 8c which are not required, in order to adjust the connection devices 1, 2.

[0059] List of reference signs:

[0060] 1 first connection device

[0061] 2 second connection device

[0062] 3 insulating housing

[0063] 4a-4c connection conductive strip

[0064] 5 accommodation structure

[0065] 6a-6c accommodation section

[0066] 7a-7c conductive strip section

[0067] 8a-8c terminal tab

[0068] 9 star junction conductive strip

[0069] ​11 stator body

[0070] 12 stator winding

[0071] 13 stator slot

[0072] 14 winding end

[0073] 15a, 15b sub-branch

[0074] 16a-16c terminal lug

[0075] 17 connection section

[0076] 10 first stator unit

[0077] 20 second stator unit

[0078] 100 stator axis

[0079] 101 reference circle

[0080] 102 first connection area

[0081] 103 second connection area

[0082] U, V, W phase branch

Claims

1. Kit, having a first stator unit (10) with first wiring means (1) for wiring a stator winding (11) into a delta circuit, wherein, The first connection device (1) has three connection conductive strips (4a, 4b, 4c) for contacting the respective phase branch (U, V, W) of the stator winding (11) and an insulating housing (3) with a receiving structure (5) for receiving the connection conductive strips (4a, 4b, 4c); the kit also has a second stator unit (20) with a second connection device (2) for connecting the stator winding (11) into a star circuit, wherein the second connection device (2) has three connection conductive strips (4a, 4b, 4c) for contacting the respective phase branch (U, V, W) of the stator winding (11), a star junction conductive strip (9) for contacting all phase branches (U, V, W) of the stator winding (11) and an insulating housing (3) with a receiving structure (5) for receiving the connection conductive strips (4a, 4b, 4c) and the star junction conductive strip (9); characterized in that the receiving structures (5) of the first connection device (1) and the second connection device (2) are configured identically and / or the insulating housings (3) of the first connection device (1) and the second connection device (2) are configured as identical components.

2. The kit of claim 1, wherein, The receiving structure (5) has three receiving sections (6a, 6b, 6c) for the three connection conductive strips (4a, 4b, 4c) on the upper side of the insulating housing (3) and an additional receiving section (6d) for the star junction conductive strip (9) on the lower side of the insulating housing (3), wherein the additional receiving section (6d) of the first connection device (1) is not occupied and the additional receiving section (6d) of the second connection device (2) is occupied by the star junction conductive strip (9).

3. The kit of claim 1 or 2, wherein The first stator unit (10) and the second stator unit (20) each comprise a stator body (11) and a stator winding (12), wherein the stator bodies (11) and / or the stator windings (12) of the first stator unit (10) and the second stator unit (20) are configured as identical components.

4. The kit of any of the preceding claims, characterized in that, The three connection conductive strips (4a, 4b, 4c) of the first connection device (1) and the second connection device (2) each have a set of terminal lugs (8a, 8b, 8c) for connecting to at least one winding end (14) of the respective phase branch (U, V, W) and each have a conductive strip section (7a, 7b, 7c) for connecting to a power electronics, wherein the conductive strip sections (7a, 7b, 7c) and at least a portion of the terminal lugs (8a, 8b, 8c) of the first connection device (1) and the second connection device (2) form identical sections.

5. The kit of claim 4, wherein, The first connection device (1) and the second connection device (2) can be arranged and / or are arranged in a fixed angular position in the installed condition, wherein the terminal lugs (8a, 8b, 8c) of the three connection conductors (4a, 4b, 4c) of the first connection device (1) are arranged in the first connection region (102) of the n stator grooves (13).

6. The kit of claim 5, wherein, The star point conductor (9) of the second connection device (2) has for each phase branch (U, V, W) a set of terminal lugs (16a, 16b, 16c) for connecting to the respectively at least one winding end (14) of each phase branch (U, V, W) and a connection section (17) for connecting the associated terminal lugs (16a, 16b, 16c) to the star point, wherein the terminal lugs (8a, 8b, 8c) of the three connection conductors (4a, 4b, 4c) of the second connection device (2) and the terminal lugs (16a, 16b, 16c) of the star point conductor (9) of the second connection device (2) are arranged in the second connection region (103) of the n stator grooves (13).

7. The kit of claim 5 or 6, wherein, The first connection region (102) and / or the second connection region (103) extend in an angular range greater than 90 degrees and / or less than 180 degrees.

8. The kit of any one of claims 5 to 7, wherein, The angular distance between the terminal lugs (8a, 8b, 8c, 16a, 16b, 16c) corresponds to the angular distance between the stator grooves (13).

9. The kit of any one of claims 4 to 8, wherein, All terminal lugs (8a, 8b, 8c, 16a, 16b, 16c) of the first connection device (1) and the second connection device (2) lie on a division circle (101), wherein the terminal lugs (8a, 8b, 8c) of the three connection conductors (4a, 4b, 4c) of the first connection device (1) are arranged in groups in succession in a circumferential direction and the terminal lugs (8a, 8b, 8c) of the three connection conductors (4a, 4b, 4c) of the second connection device (2) are arranged in groups alternately with respect to the terminal lugs (16a, 16b, 16c) of the star point conductor (9).

10. The kit of any one of claims 4 to 9, wherein, The conductor sections (7a, 7b, 7c) of the three connection conductors (4a, 4b, 4c) of the first connection device (1) are respectively connected at a central location of the respectively associated group of terminal lugs (8a, 8b, 8c) and / or the connection sections (17) of the star point conductor (9) of the second connection device (2) are respectively connected at a central location of the respectively associated group of terminal lugs (16a, 16b, 16c).

11. The kit of any one of claims 4 to 10, wherein, The terminal lugs (8a, 8b, 8c) of the first connection device (1) and the winding ends (14) of the stator windings (11) of the first stator unit (10) are arranged relative to the terminal lugs (8a, 8b, 8c, 16a, 16b, 16c) of the second connection device (2) and the winding ends (14) of the stator windings (11) of the second stator unit (12) in such a way that they are offset in the circumferential direction by at least one stator slot (13), and / or the first connection region (102) and the second connection region (103) are offset in the circumferential direction by at least one stator slot (13).

12. Stator unit (10, 20), in particular for a kit according to any one of the preceding claims, having a wiring device (1, 2), wherein The connection device (1, 2) has an insulating housing (3) with a receiving structure (5) for optionally receiving three connection conductive strips (4a, 4b, 4c) to configure the connection device (1) as a delta circuit or three connection conductive strips (4a, 4b, 4c) and a star point conductive strip (9) to configure the connection device (2) as a star circuit.

13. Method for manufacturing a stator unit (10, 20) according to claim 12, in which method: - a stator body (11), a stator winding (12) and a connection device (1, 2) for wiring the stator winding (12) into a delta circuit or a star circuit are provided; - if a delta circuit is to be established, the stator winding (12) is inserted into the stator body (11) in a predetermined first angular position, and the connection device (1) is arranged in an angular position fixed relative to the stator body (11), wherein - in order to form a first stator unit (10), at least one winding end (14) of a phase branch (U, V, W) is brought into contact with a respective connection conductive strip (4a, 4b, 4c) of the connection device (1); and - if a star circuit is to be established, the stator winding (12) is inserted into the stator body (11) in a predetermined second angular position, the connection device (2) is supplemented with a star point conductive strip (9) and the connection device (2) is arranged in an angular position that is fixed relative to the stator body (11), wherein, in order to form a second stator unit (20), at least one winding end (14) of a phase branch (U, V, W) is brought into contact with a respective connection conductive strip (4a, 4b, 4c) of the connection device (2) and at least one winding end (14) of each phase branch (U, V, W) is brought into contact with the star point conductive strip (9).

14. The method of claim 13, wherein, The connection conductive strips (4a, 4b, 4c) are shortened to form a usable area for the star point conductive strip (9).

15. The method according to claim 13 or 14, characterized in that, The stator winding (11) is inserted into the first angular position, which is offset in the circumferential direction by at least one stator slot (13) relative to the second angular position. The terminal lugs (8a, 8b, 8c) of the first connection device (1) and the winding ends (14) of the stator windings (11) of the first stator unit (10) are arranged relative to the terminal lugs (8a, 8b, 8c, 16a, 16b, 16c) of the second connection device (2) and the winding ends (14) of the stator windings (11) of the second stator unit (12) in such a way that they are offset in the circumferential direction by at least one stator slot (13), and / or the first connection region (102) and the second connection region (103) are offset in the circumferential direction by at least one stator slot (13).

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