Stator arrangement for an electric machine with a simplified assembly of the stator in

Abstract

The invention relates to a stator arrangement (8a, 8g) for an electric machine (1, 1a, 1f), comprising a stator housing (2a, 2g), end plates (3a, 3g) arranged on the axial side of the stator housing (2a, 2g), and a stator lamination core which is arranged in the stator housing (2a, 2g) and has a plurality of stator laminations (6) stacked axially. The stator lamination core (5) is fitted into the end plates (3a, 3g). The invention also relates to an electric machine (1, 1a, 1f) having a stator arrangement (8a, 8 g) of this type, to a vehicle (24) having an electric machine (1, 1a, 1f) of this type, and to a method for producing a stator arrangement (8a, 8 g) of this type.

Description

Technical Field

[0001] This invention relates to a stator assembly for an electric motor, the stator assembly comprising a stator housing, an end cover disposed on an axial side of the stator housing, and a stator lamination core disposed within the stator housing, the stator lamination core having a plurality of axially stacked stator laminations. Furthermore, this invention relates to an electric motor having a stator assembly of the above type and a vehicle having such an electric motor. Finally, this invention also relates to a method for manufacturing a stator assembly of the aforementioned type. Background Technology

[0002] The types of stator assemblies, motors, vehicles, and manufacturing methods mentioned are known in principle from the prior art. Stator laminations are stacked one on top of the other to form a stator lamination core, and then the stator lamination core or the manufactured stator is assembled into a stator housing.

[0003] The installation of the stator or stator lamination core within the stator housing is problematic, especially if the inner contour of the stator housing is not smooth and cylindrical, but rather has features such as channels or notches. The stator laminations may easily become stuck during insertion into the stator housing, potentially damaging both the housing and the lamination core. It is also conceivable that metal debris may be drawn in during the insertion of the stator lamination core into the stator housing. This debris could unknowingly enter the motor's interior, where it could subsequently cause damage during operation and may even lead to motor malfunction.

[0004] To avoid debris formation, the stator housing can be expanded by heating (a thermal bonding process) before the stator lamination core is inserted into the stator housing. Then, the two components are assembled as the stator housing contracts through cooling. However, this process is time-consuming and costly. Furthermore, due to the risk of torsion, this process cannot be used for complex stator housings that also house gears and inverters in addition to the motor. Summary of the Invention

[0005] Therefore, the object of the present invention is to provide an improved stator assembly, an improved electric motor, an improved vehicle, and an improved method for manufacturing a stator assembly for an electric motor. In particular, the mounting of the stator or stator lamination core in the stator housing is simplified, thereby avoiding heating of the stator housing.

[0006] The object of the present invention is achieved by a stator assembly of the type described at the beginning, wherein the stator lamination core is assembled into an end cover. Specifically, the stator lamination core can be press-fitted into the end cover or screwed onto the end cover. Alternatively, the stator lamination core can be assembled into the end cover by thermal bonding. For this purpose, the stator lamination core can be inserted into a heated end cover, after which the end cover retracts onto the stator lamination core upon cooling. The end cover may in particular include a bearing housing for a rotor shaft of a motor or a bearing for a bearing of a rotor shaft.

[0007] Furthermore, the object of the present invention is achieved by an electric motor having a stator arrangement of the type described above. In particular, the stator lamination core may have a plurality of stator windings arranged therein. The electric motor may also particularly include a rotor arranged in the stator and rotatably mounted in a housing about a rotor axis, the rotor having rotor windings or rotor magnets.

[0008] Furthermore, the object of the present invention is achieved by a vehicle having a motor of the type described above configured to drive the vehicle.

[0009] The object of the present invention is also achieved by a method for manufacturing a stator device, the method comprising the following steps:

[0010] - Provides a stator housing, end caps, and a stator lamination core having multiple axially stacked stator laminations.

[0011] - Assemble the stator lamination core into the end cover, and (subsequently)

[0012] - An end cover with assembled stator lamination core is arranged on the axial side of the stator housing, wherein the stator lamination core is inserted into the stator housing.

[0013] The proposed measures, particularly the pre-assembly of the stator lamination core in the end cover and subsequent installation into the stator housing, significantly simplify the installation of the stator or stator lamination core within the stator housing. This is not a problem even when the inner contour of the stator housing is not a smooth cylinder but has features such as channels or recesses. Therefore, the stator laminations no longer jam when inserted into the stator housing, thus preventing damage to the stator housing and stator lamination core, and also preventing the intake of metal debris. Consequently, damage to the motor during operation is avoided, and motor failure is also prevented. Furthermore, this invention eliminates the need to heat the stator housing during the thermal bonding process.

[0014] Further advantageous embodiments and developments of the invention will become clear from the dependent claims and description when considered in conjunction with the accompanying drawings.

[0015] In one embodiment, the end cover may be screwed onto the stator housing. In particular, the end cover may have a flange in which screws for screwing the end cover onto the stator housing are arranged.

[0016] Advantageously, the end cover has a can-shaped or cylindrical section surrounding the stator lamination core. In this way, the stator lamination core can be held particularly well in the end cover and centered, and can also be particularly well inserted into the stator housing.

[0017] Typically, one can imagine that the cylindrical portion extends:

[0018] - Until the axial position between the axial sides of the stator lamination core.

[0019] - Up to the relative axial side of the stator lamination core, or

[0020] - Beyond the relative axial side of the stator lamination core.

[0021] In particular, in the last two variations, the stator lamination core is held along its entire length and is therefore held particularly effectively. Furthermore, the insertion of the stator lamination core into the stator housing is also particularly successful. However, for the first variation, only a small amount of material is required.

[0022] Another advantage is that the stator housing has a central cooling channel for the cooling medium, which extends along the circumference of the stator housing. In this way, the stator can be cooled effectively. Liquids, such as water-based or oil-based liquids, are particularly suitable as cooling media, although the use of gaseous cooling media is also conceivable.

[0023] The central cooling channel can extend within the cylindrical section and be defined by the stator housing or the stator lamination core. Alternatively, the central cooling channel can be defined by the axial side of the cylindrical section, the stator housing, and the stator lamination core. These measures enable particularly effective cooling of the stator, especially if the cooling channel is directly adjacent to the stator laminations.

[0024] In another advantageous embodiment, the cooling channel can be hydraulically connected to an axially extending channel leading into the interior of the motor, or hydraulically connected to an outlet opening facing the stator axis and leading into the interior of the motor. This also allows for cooling of other parts of the motor. For example, coolant jets can be directed to the winding heads of the stator and / or rotor.

[0025] Advantageously, the axial side of the cylindrical portion abuts against the stop of the stator housing. This allows the cylindrical portion to be efficiently positioned within the stator housing.

[0026] Finally, it is particularly advantageous that the end cover is formed as a single piece. In this way, very few parts are required for the construction of the motor. However, it is also conceivable in principle that the end cover could be constructed from multiple parts. Attached Figure Description

[0027] An exemplary embodiment of the invention is illustrated in the accompanying schematic diagram, wherein:

[0028] Figure 1 An example of a motor is shown schematically in half-section;

[0029] Figure 2 An example of an electric motor is shown, having an end cap spirally connected thereto and a cooling channel defined by a stator housing;

[0030] Figure 3 An example of a motor with cooling channels defined by stator lamination cores is shown;

[0031] Figure 4 An example of an electric motor is shown, in which the stator lamination core is helically connected to an end cover;

[0032] Figure 5 An example of a motor with an axial cooling channel is shown;

[0033] Figure 6 An example of a motor with cooling channels defined by a stator housing, end caps, and stator lamination core is shown;

[0034] Figure 7 An exploded view of an example of a stator assembly is shown, and

[0035] Figure 8 An example of a vehicle with the proposed type of motor is shown. Detailed Implementation

[0036] As a matter of introduction, it should be noted that the same parts in different embodiments are given the same reference numerals or the same part names, and have different indexes where appropriate. The disclosure of a part in the specification can be similarly transferred to another part having the same reference numerals or the same part name. Furthermore, positional terms selected in the specification, such as "top," "bottom," "rear," "front," "side," etc., refer to the drawings that are directly described and shown, and should be similarly transferred to the new position if the position changes.

[0037] Figure 1A half-sectional view through a schematically shown motor 1a is shown. Motor 1a includes a stator housing 2a, a (front) end cover 3a disposed on the (front) axial side of the stator housing 2a, and a stator 4a including a stator lamination core 5 having a plurality of axially stacked stator laminations 6 and optionally stator windings 7 disposed in the stator lamination core 5. The stator housing 2a, end cover 3a, and stator lamination core 5 form a stator assembly 8a or at least a portion of a stator assembly.

[0038] The stator lamination core 5 is assembled into the end cover 3a, wherein the end cover 3a in this example has a cylindrical portion 9a surrounding the stator lamination core 5.

[0039] In this example, end cover 3a is also a single piece. However, in principle, it can also be constructed as multiple parts. In addition, motor 1a includes another (rear) end cover 10a, which is connected to stator housing 2a. End cover 3a, stator housing 2a and end cover 10a together form machine housing 11a.

[0040] The motor 1a also includes a rotor shaft 12 and a rotor lamination core 13 mounted thereon, the rotor lamination core 13 having a plurality of rotor laminations (not shown in detail) as part of a rotor 14, wherein the rotor shaft 12 is rotatably mounted about a rotor axis or a stator axis A by means of (roller) bearings 15a, 15b. Specifically, the first bearing 15a is disposed in the (front) end cover 3a, and the second bearing 15b is disposed in the other (rear) end cover 10a.

[0041] Figure 2 Another example of motor 1b is shown, which is similar to Figure 1 The motor 1a shown is an example. In contrast, the cylindrical portion 9b of the end cover 3b has two separate mounting seats 16a and 16b, through which the end cover 3b or its cylindrical portion 9b is fitted into the stator housing 2b. Specifically, mounting seat 16a is arranged in the region of the first axial side or end side B1 of the stator lamination core 5, and mounting seat 16b is arranged in the region of the second axial side or end side B2 of the stator lamination core 5. Alternatively, the end cover 3b may have a gap relative to the stator housing 2b in this region.

[0042] The cylindrical portion 9b is left empty between the mounting bases 16a and 16b, thereby forming a central cooling channel 17 extending in the cylindrical portion 9b for a heat transfer medium (liquid or gas). In this example, the central cooling channel 17 is defined by the stator housing 2b and extends along the circumference of the stator housing 2b.

[0043] To avoid debris generation when inserting the cylindrical portion 9b into the stator housing 2b, the inner diameter of the cylindrical portion 9b in the region of mounting 16a can be larger than the inner diameter of the cylindrical portion 9b in the region of mounting 16b. Depending on the required precision, interference fit, clearance fit, or transition fit can be used for each mounting 16a, 16b. Sealing elements, such as O-rings, can also be used.

[0044] For axial positioning of the end cover 3b, the axial side of the cylindrical portion 9b abuts against the stop portion 18 of the stator housing 2b. Conversely, on the opposing axial sides, the end cover 3b has a gap relative to the stator housing 2b, such that... Figure 2 The right-hand axial side of the cylindrical portion 9b can press against the stop portion 18. For this purpose, a screw 19 is provided, which is used to screw the end cover 3b onto the stator housing 2b. Alternatively, the axial side of the cylindrical portion 9b can be slightly spaced from the stop portion 18 and have clearance.

[0045] In this example, the end cover 3b also has a stop 20, on which the stator lamination core 5 abuts with its first axial side B1 and is positioned in the end cover 3b in this manner.

[0046] Figure 3 Another motor 1c is shown, which is... Figure 2 The motor 1b shown is very similar. In contrast, the cooling channel 17 in this example is defined by the stator lamination core 5, resulting in particularly good cooling of the stator lamination core 5. Another difference is that the other end cover 10c is integrally molded onto the stator housing 2c. A gap may exist between the end cover 3c and the stator housing 2c, except for a small centering area.

[0047] Figure 4 Another example of motor 1d is shown, which is similar to Figure 3 The motor 1c shown is very similar. In contrast, the stator lamination core 5 is screwed onto the end cover 3d by means of screws 21.

[0048] Figure 5 An example of motor 1e is now shown, which has Figure 1 Motor 1a and Figure 2 The characteristics of motor 1b in the motor are as follows. Specifically, the cylindrical portion 9e again has a central cooling channel 17; however, in this example, the central cooling channel 17 is connected to an axially extending axial channel 22, which can lead to the interior of motor 1e, or as... Figure 5As shown, an outlet opening 23 can be hydraulically connected to the direction facing the stator axis A, which leads to the interior of the motor 1e. In this way, other parts of the motor 1e can also be cooled. For example, a coolant jet can be directed to the winding heads of the stator 4e and / or the rotor 14.

[0049] exist Figure 1 and Figure 4 In the example shown, the cylindrical portions 9a and 9d extend to the axial side B2 of the stator lamination core 5. Alternatively, the cylindrical portions 9a and 9d may be shorter or longer.

[0050] exist Figure 2 , Figure 3 and Figure 5 In the example shown, the cylindrical portions 9b, 9c, and 9e extend beyond the axial side B2 of the stator lamination core 5.

[0051] exist Figure 6 In the example shown, the cylindrical portion 9f extends to an axial position between the axial sides B1 and B2 of the stator lamination core 5. Another difference from the embodiments shown so far is that, here, in addition to the stator housing 2f and the stator lamination core 5, the central cooling channel 17 is also defined by the axial sides of the cylindrical portion 9f.

[0052] exist Figures 1 to 6 In each example shown, the stator lamination core 5 can be force-fitted into the cylindrical portions 9a, 9b, 9c, 9d, 9e, and 9f, particularly through thermal bonding. For this purpose, the stator lamination core 5 can be inserted into the heated end covers 3a, 3b, 3c, 3d, 3e, and 3f, which subsequently retract onto the stator lamination core 5 upon cooling.

[0053] Figure 7 An exploded view of a stator assembly 8g having a stator housing 2g, an end cover 3g, and a stator 4g (and its stator lamination core 5) is also shown.

[0054] A method for manufacturing a stator assembly 8a..8g for an electric motor 1a..1f typically includes the following steps:

[0055] - Provides a stator housing 2a..2g, an end cover 3a..3g, and a stator lamination core 5 having multiple axially stacked stator laminations 6.

[0056] - Assemble the stator lamination core 5 into the end cover 3a..3g, and (subsequently)

[0057] - An end cover 3a..3g with assembled stator lamination core 5 is arranged on the axial side of stator housing 2a..2g, wherein the stator lamination core 5 is inserted into stator housing 2a..2g.

[0058] at last, Figure 8 An electric motor 1 is shown installed in vehicle 24. Vehicle 24 has two axles, one of which is driven. Specifically, motor 1 is connected to a half-shaft 26 of either the rear or front axle via an optional transmission 25. Finally, a driven wheel 27 is mounted on the half-shaft 26. Motor 1, transmission 25, and half-shaft 26 are part of the drivetrain of vehicle 24. Vehicle 24 is driven at least partially or temporarily by electric motor 1. That is, motor 1 can be used alone to drive vehicle 24, or it can be provided, for example, in combination with an internal combustion engine (hybrid drive).

[0059] In summary, it is important to emphasize that the scope of protection is determined by the claims. However, the specification and drawings should be used to interpret the claims. Features included in the drawings may be interchanged and combined as needed. In particular, it should be emphasized that the illustrated description may actually include even more or even fewer components than shown. In some cases, the illustrated devices or their components may also be shown out of scale and / or at an enlarged and / or reduced scale.

[0060] List of reference numerals

[0061] 1. 1a..1f motor

[0062] 2a..2g stator housing

[0063] 3a..3g (front) end cover

[0064] 4a..4g stator

[0065] 5 stator lamination core

[0066] 6 stator laminations

[0067] 7 stator windings

[0068] 8a..8g stator assembly

[0069] 9a..9f Cylindrical section

[0070] 10a..10f Additional (rear) end cap

[0071] 11a..11f Machine casing

[0072] 12 rotor shafts

[0073] 13 rotor lamination core

[0074] 14 rotors

[0075] 15a and 15b (roller) bearings

[0076] 16a, 16b mounting brackets

[0077] 17 cooling channels

[0078] 18 Stop section

[0079] 19 screws

[0080] 20 Stop Sections

[0081] 21 screws

[0082] 22-axis channel

[0083] 23 Exit opening

[0084] 24 vehicles

[0085] 25 Transmission device

[0086] 26 half-shaft

[0087] 27 wheels

[0088] Stator axis

[0089] B1, B2 Axial / End Side

Claims

1. A stator assembly (8a.8g) for an electric motor (1, 1a..1f), comprising: - Stator housing (2a..2g). - End caps (3a..3g), said end caps being arranged on the axial side of the stator housing (2a..2g), and - Stator lamination core (5), which is arranged in the stator housing (2a..2g) and has a plurality of axially stacked stator laminations (6). Its features are, - The stator lamination core (5) is assembled into the end cover (3a..3g).

2. The stator device (8a..8g) according to claim 1, characterized in that, The stator lamination core (5) is pressed into the end cover (3a..3g) or is screwed onto the end cover (3a..3g).

3. The stator device (8a..8g) according to claim 1 or 2, characterized in that, The end cap (3a..3g) is spirally connected to the stator housing (2a..2g).

4. The stator device (8a..8g) according to any one of the preceding claims, characterized in that, The end cover (3a..3g) has a cylindrical portion (9a..9f) surrounding the stator lamination core (5).

5. The stator device (8a..8g) according to claim 4, characterized in that, The cylindrical portion (9a..9f) extends to an axial position between the axial sides (B1, B2) of the stator lamination core (5), extends to the opposite axial side (B2) of the stator lamination core (5), or extends beyond the opposite axial side (B2) of the stator lamination core (5).

6. The stator assembly (8a..8g) according to any one of claims 4 and 5, having a central cooling channel (17) extending circumferentially along the stator housing (2a..2g).

7. The stator device (8a..8g) according to claim 6, characterized in that, The central cooling channel (17) extends in the cylindrical portion (9a..9f) and is defined by the stator housing (2a..2g) or the stator lamination core (5).

8. The stator device (8a..8g) according to claim 6, characterized in that, The central cooling channel (17) is defined by the axial side of the cylindrical portion (9a..9f), the stator housing (2a..2g) and the stator lamination core (5).

9. The stator device (8a..8g) according to any one of claims 4 to 8, characterized in that, The axial side of the cylindrical portion (9a..9f) abuts against the stop portion (18) of the stator housing (2a..2g).

10. The stator device (8a..8g) according to any one of the preceding claims, characterized in that, The end cap (3a..3g) is formed as a single piece.

11. An electric motor (1, 1a..1f) having a stator assembly (8a..8g) according to any one of the preceding claims.

12. A vehicle (24) having an electric motor (1, 1a, 1f) according to claim 11, the electric motor being configured to drive the vehicle (24).

13. A method for manufacturing a stator assembly (8a.8g) for an electric motor (1, 1a..1f), comprising the following steps: - Provides a stator housing (2a..2g), an end cap (3a..3g), and a stator lamination core (5) having multiple axially stacked stator laminations (6). - The stator lamination core (5) is assembled into the end cover (3a..3g), and - The end cap (3a..3g) and the assembled stator lamination core (5) are arranged on the axial side of the stator housing (2a..2g), wherein the stator lamination core (5) is inserted into the stator housing (2a..2g).

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