Stator for an electric drive machine of a motor vehicle with a temperature sensor, electric drive machine with the stator, and motor vehicle

Abstract

The invention relates to a stator (10) for an electric drive machine (100) of a motor vehicle (K), having a stator base body (20), at least one winding assembly (30) having a plurality of single-winding regions (32, 34) arranged in corresponding slots of the stator base body (20), at least one busbar (60) which is electrically connected to at least one single-winding region end (36) of at least one of the single-winding regions (32, 34), and at least one temperature sensor (90) which is connected at least indirectly and thermally to the at least one busbar (60). The at least one busbar (60) and the at least one single-winding region end (36) are connected to one another by a connection region (40). The busbar (60) has a holding region (70) on which the at least one temperature sensor (90) is arranged and which projects from a winding head (50) of the winding assembly (30) comprising a corresponding single-winding region bend (42, 44) of the single-winding regions (32, 34). Further aspects of the invention relate to an electric drive machine (100) having at least one stator (10) and to a motor vehicle (K) having at least one electric drive machine (100).

Description

Technical Field

[0001] This invention relates to a stator for an electric drive machine for a motor vehicle, the stator having a stator body, at least one winding assembly, at least one busbar, and at least one temperature sensor. The winding assembly has a plurality of single winding regions arranged in corresponding slots in the stator body. The busbar is electrically connected to at least one end of at least one of the single winding regions. The temperature sensor is at least indirectly and thermally connected to the at least one busbar. Another aspect of the invention relates to an electric drive machine having a stator and a motor vehicle. The winding assembly can generally also be constructed as a continuous winding or a continuous wave winding and is thus referred to. Alternatively, the winding assembly can generally be constructed as a hairpin winding, i.e., a so-called U-shaped pin winding and is thus referred to. Background Technology

[0002] Temperature sensors may be required in the stator of an electrically driven machine to detect the current temperature of current-carrying conductor sections on the stator. These conductor sections may, for example, be single-winding regions of continuous-wave windings. For this purpose, a stator for an electric motor, particularly for a drive machine configured for an electrically driven motor vehicle, is known, for example, from WO2022 / 002295A1. This stator includes a stator body having multiple stator windings and a temperature sensor for detecting the temperature of at least one section of the stator windings. The temperature sensor is arranged together with the conductor section in a slotted receiving portion of an accessory and fixed therein by means of potting compound. The conductor section is either in thermal contact with the temperature sensor as part of the stator winding or configured as a section thermally connected to the stator winding. Summary of the Invention

[0003] The objective of this invention is to provide a stator, electric drive machine, and motor vehicle of the type described at the beginning, in which improved maintenance can be achieved.

[0004] This task is accomplished by a stator having the features of claim 1, an electric drive machine having the features of claim 10, and a motor vehicle having the features of claim 11. Advantageous embodiments with suitable extensions of the invention are given in the dependent claims.

[0005] A first aspect of the invention relates to a stator for an electric drive mechanism in a motor vehicle, the stator having a stator body, at least one winding assembly, at least one busbar, and at least one temperature sensor. The winding assembly has a plurality of single-winding regions arranged in corresponding slots of the stator body. The busbar is electrically connected to at least one end of at least one of the single-winding regions. The temperature sensor is connected at least indirectly and thermally to the at least one busbar. The winding assembly may also be referred to as a continuous winding and thus constructed. Alternatively, the winding assembly may also be referred to as a hairpin winding (U-shaped pin winding) and thus constructed. The single-winding regions may be arranged at least locally in corresponding slots of the stator body.

[0006] According to the present invention, the at least one busbar and the at least one single winding region end are interconnected by a connection region, and the busbar has a holding region on which the at least one temperature sensor is disposed and the holding region protrudes from the winding head of the winding assembly, which includes a bend in a corresponding single winding region of the single winding region.

[0007] This is advantageous because arranging the temperature sensor on the retaining area protruding from the winding head improves its accessibility during potential maintenance of the electric drive machine or stator. In other words, arranging the temperature sensor on the retaining area protruding from the winding head allows for particularly low-cost replacement of the temperature sensor, for example, with a lower risk of tool collision with the winding head. Another advantage is that by arranging the temperature sensor on the retaining area, it is possible to at least qualitatively measure the temperature of particularly hot points (also known as "hot spots") during the operation of the electric drive machine, or at least allow for the inference of temperature variation curves or temperature average variation curves of the winding temperature of a single winding area. Another advantage is that the retaining area constitutes an interface on the winding head for the temperature sensor, i.e., a mounting portion, also known as a measurement interface, which can be provided without significantly interfering with the stator manufacturing process. Preferably, the temperature sensor is arranged here on the uninsulated, i.e., the uninsulated area of ​​the retaining area. Temperature sensors can be inserted into or fixed to the holding area via so-called clip connections, thereby achieving reversible and therefore non-destructive fixation of the temperature sensor in the holding area. The holding area here constitutes the measurement interface, i.e., the attachment point for fixing the temperature sensor, which enables the temperature sensor to be held securely in an exposed and easily accessible location for maintenance, allowing for simple replacement of the temperature sensor in case of failure. During maintenance, not only is potential damage to the insulation of the single-winding area and therefore the winding head avoided, but also undesirable deformation of the single-winding area beyond process safety limits is prevented. The bus can also be referred to and / or constructed as a busbar, a phase-connecting busbar, or a star-point busbar. Unlike the connection area that electrically connects the at least one busbar to the end of the at least one single-winding area, the holding area can be constructed solely for holding the at least one temperature sensor. In other words, it can be specified that current does not flow through the holding area.

[0008] This invention is based on the understanding that temperature sensors may be required in the stator of an electrically driven machine to detect the current temperature of conductors (e.g., buses) or on the stator. It has proven particularly advantageous to mount the temperature sensor as close as possible to the so-called hot spot of the electrically driven machine, but in any case, to a local area or component area that qualitatively has a temperature change curve of the hot spot or a curve showing the change of the average winding temperature appearing at the winding head or throughout the winding assembly, especially in continuous wave windings or continuous windings, or at least has a temperature change curve proportional to the temperature change curve of the hot spot or the change of the average temperature. With the arrangement of the temperature sensor according to the invention, for example in applications using continuous wave windings, it is possible to achieve corresponding temperature measurements at locations without insulation material, thus eliminating the need to remove and therefore damage the insulation of a single winding area, such as at the winding head, to determine the temperature.

[0009] In an advantageous extension of the invention, the retaining region protrudes from at least a majority of the single-winding region bend in the axial and / or radial extension direction of the stator. This is advantageous because it improves the accessibility of the retaining region and therefore the at least one temperature sensor for maintenance operations. The retaining region may protrude from the majority of the single-winding region bend in the axial extension direction and therefore parallel to the rotational axis of the motor's rotor and the longitudinal axis of the motor's rotor and stator. Alternatively, the retaining region may protrude from the majority of the single-winding region bend in the radial extension direction and therefore perpendicular to the rotational axis of the motor's rotor and the longitudinal axis of the motor's rotor and stator. Furthermore, the retaining region may protrude diagonally and therefore both in the axial and radial extension directions from the majority of the single-winding region bend.

[0010] In another advantageous extension of the invention, the holding region protrudes beyond the planar intermediate region in the axial extension direction, wherein the planar intermediate region is defined in the axial extension direction by two planes parallel to each other and oriented perpendicular to the axial extension direction, and at least a majority of the single-winding region bends are arranged in the planar intermediate region, wherein a first plane of the two parallel planes is tangent to the end face of the stator base facing the busbar, and a second plane of the two parallel planes is tangent to or at a distance from most of the single-winding region bends, the distance being at most equal to the average winding diameter of the conductor elements disposed on the winding assembly. This is advantageous because it allows for maintenance and, if necessary, replacement of the temperature sensor without causing possible collisions between the tools used for maintenance or replacement and the single-winding region bends. The winding diameter here can be the total diameter of the conductor elements forming the winding assembly, i.e., the total diameter of the current-carrying core wire of the conductor element together with the insulation layer surrounding the core wire of the conductor element.

[0011] In another advantageous extension of the invention, the retaining region protrudes beyond the stator base in the radial extension direction of the stator. This is advantageous because the retaining region is therefore particularly easily accessible and the temperature sensor can thus be maintained with particularly low cost. The retaining region can protrude outward or inward from the stator base in the radial extension direction. If the retaining region protrudes inward from the stator base in the radial extension direction, it can result in the retaining region overlapping with the internal space of the stator base in the axial extension direction. In other words, when the stator is viewed in the axial extension direction, the retaining region can overlap with the internal space of the stator base in which the rotor and rotor shaft of the electrically driven machine can be arranged.

[0012] In another advantageous extension of the invention, the retaining region is spaced apart from the connecting region. This is advantageous because the spacing simplifies the assembly or disassembly of the temperature sensor without causing collision with the connecting region. The retaining region is preferably spaced apart from the connecting region in the radial extension direction of the stator. Therefore, the retaining region is preferably positioned further outward in the radial extension direction of the stator than the connecting region. In other words, since the rotor of the electrically driven machine can rotate about its axis of rotation during operation, the distance between the retaining region and the axis of rotation in the radial extension direction can be greater than the distance between the connecting region and the axis of rotation.

[0013] In another advantageous extension of the invention, the connection area is at least partially formed by an overhanging region of the busbar protruding from the winding head. This is advantageous because particularly undisturbed heat conduction can occur between the temperature sensor arranged in the holding area and the busbar through this overhanging region.

[0014] In another advantageous extension of the invention, the connection area is formed by a material-locked connection between the end of a single winding region and the busbar. This material-locked connection can be achieved directly, i.e., by direct material locking between the busbar and the end of the single winding region, or indirectly, i.e., by intervening in other elements, such as conductor segments, especially conductor segments of the winding assembly. The material-locked connection is preferably a welded connection, which ensures particularly undisturbed heat conduction between the winding head and the busbar.

[0015] In another advantageous extension of the invention, the temperature sensor is arranged spaced apart from the end of the single winding region on the holding region. This allows the temperature sensor to be particularly well-accessible for maintenance work.

[0016] In another advantageous extension of the invention, the temperature sensor is arranged at the end of the holding region, which corresponds to the holding region segment furthest from the winding head. By arranging the temperature sensor at the end of the holding region, particularly good accessibility for possible maintenance operations is ensured.

[0017] A second aspect of the invention relates to an electrically driven machine having at least one stator according to a first aspect of the invention. In this electrically driven machine, temperature measurement can be performed in an improved manner, and temperature sensors can be maintained in an improved manner.

[0018] A third aspect of the invention relates to a motor vehicle having at least one electrically driven mechanism according to a second aspect of the invention. Improved temperature monitoring and maintenance can be achieved in the electrically driven mechanism of the motor vehicle.

[0019] The preferred embodiments and advantages described with respect to one of the aforementioned aspects are respectively applicable to other aspects of the invention and vice versa.

[0020] The features and combinations of features mentioned above in the specification, as well as the features and combinations of features mentioned below in the description of the drawings and / or shown separately in the drawings, can be used not only in the combinations given separately, but also in other combinations or individually, without departing from the scope of the invention.

[0021] Further advantages, features and details of the invention will become apparent from the claims, the following description of preferred embodiments and with reference to the accompanying drawings. Attached Figure Description

[0022] The invention will now be described again with reference to specific embodiments. The accompanying drawings are as follows:

[0023] Figure 1 A schematic perspective view showing a partial area of ​​the stator is provided, in which a busbar is interconnected with the ends of a single winding region via a connecting region. The busbar has a retaining region that protrudes from the winding head of the winding assembly, which includes a bend in the corresponding single winding region.

[0024] Figure 2 An abstract view of a motor vehicle and an electric drive machine including a stator is shown, with temperature sensors arranged in the holding area. Detailed Implementation

[0025] Figure 1 A partial area of ​​the stator 10 is shown in a schematic perspective view, the stator being provided with Figure 2 An electric drive machine 100 is abstractly illustrated. The electric drive machine 100 is used to drive... Figure 2 The same highly abstract representation of the motor vehicle K is shown in the image.

[0026] The stator 10 has a stator base 20 having at least one winding assembly 30 having a plurality of single-winding regions 32, 34. These single-winding regions 32, 34 are arranged on the stator base 20 and are at least sectionally guided through corresponding slots of the stator base 20. In other words, the single-winding regions 32, 34 are arranged in corresponding slots of the stator base 20. A bus 60 of the stator 10 is electrically connected to the end 36 of one of the single-winding regions 32, 34. The bus 60 can generally be designed as a star bus, a point-to-point bus, a phase bus, or a phase-connected bus. Currently, the end 36 of the single-winding region is exemplarily disposed to the single-winding region 32. A temperature sensor 90 is connected to the bus 60 at least indirectly and thermally.

[0027] With the help of Figure 1 As can be seen, the busbar 60 and the single-winding region end 36 are interconnected via a common connection region 40. In order to keep the temperature sensor 90 spaced apart from the connection region 40 and thus from the single-winding region end 36, the busbar 60 has a holding region 70 on which the at least one temperature sensor 90 is arranged. Figure 1 and Figure 2 The retaining region 70 is shown to protrude from the winding head 50 of the winding assembly 30, which includes the respective single winding region bends 42, 44 of the single winding regions 32, 34.

[0028] Despite Figure 1 and Figure 2 Only the retaining region 70 is shown protruding from the winding head 50 in the axial extension direction A of the stator 10, but the retaining region 70 may also additionally or alternatively protrude from the winding head 50 in the radial extension direction R of the stator 10, however, this is not shown further here. In general, the retaining region 70 can therefore protrude from at least most of the single winding region bends 42, 44 in the axial extension direction A of the stator 10 and additionally or alternatively in the radial extension direction R of the stator.

[0029] In addition Figure 1 As can be seen, the retaining region 70 and the connecting region 40 exemplarily protrude beyond the planar intermediate region EZB in the axial extension direction A. The planar intermediate region EZB is currently defined in the axial extension direction A by two planes that are parallel to each other and oriented perpendicular to the axial extension direction A, namely, a first plane E1 and a second plane E2. At least most of the single-winding region bends 42, 44 are arranged in the planar intermediate region EZB, wherein the first plane E1 of the two parallel planes E1, E2 is tangent to the end face 22 of the stator base 20 facing the busbar 60, i.e., it can extend, for example, along the end face 22. The second plane E2 of the two parallel planes E1, E2 is tangent to most of the single-winding region bends 42, 44 or as Figure 1It can be seen that the bends 42 and 44 in most of the corresponding single winding regions have a distance A1. The value of the distance A1, which is currently measured in the axial extension direction A, can be exemplarily equal to the value of the average winding diameter D_W of the conductor element 31 provided to the winding assembly 30.

[0030] The retaining region 70, which is spaced apart from the connecting region 40, especially in the radial extension direction R and / or in the axial extension direction A, may, in principle and also advantageously, protrude inward (i.e. toward the internal space of the stator base) or outward from the stator base 20 in the radial extension direction R of the stator.

[0031] Similarly, by means of Figure 1 As can be seen, bus 60 includes a protruding region 64 that partially forms the connection region 40 and protrudes from the winding head 50, and a main bus section 63 integrally connected to the protruding region 64. The main bus section 63 may extend along the stator base 20 in the circumferential direction U, for example, parallel to the end face 22 of the stator base 20. The main bus section 63 may lead to and be electrically connected to the stator windings of the stator 10 (not shown further here). Figure 1 It can be seen that both the extending region 64 and the retaining region 70 branch off from the main busbar section 63. The main busbar section 63 has a longer length than both the retaining region 70 and the extending region 64. Furthermore, the retaining region 70 is longer than the extending region 64, and the retaining region 70 protrudes beyond the extending region 64 in the axial extension direction A.

[0032] The retaining region 70 and the main bus section 63 can form an angle α between them, which is advantageously greater than 45°, preferably greater than 70°, and particularly preferably greater than 80°. Currently, the angle α is 90°, i.e., angle α is designed as a right angle, thereby allowing the main bus section 63 to extend along the stator base 20 with particularly economical structural space, and enabling the retaining region 70 to achieve particularly good accessibility for possible maintenance of the temperature sensor 90. In other words, the retaining region 70 protrudes from the winding head 50 vertically and therefore axially in the direction A.

[0033] In addition to being formed by the overhang region 64 protruding from the winding head 50 of the busbar 60, the connection region 40 is also formed by the overhang portion 37 protruding from the winding head 50 of the end of the single winding region 36.

[0034] The extended portion 37 extends largely parallel to the extended region 64, thereby achieving a space-saving arrangement. Within the scope of this disclosure, the phrase "largely parallel" should be understood as meaning that the extended portion 37 and the extended region 64 form an angle of less than 20°, preferably less than 10°, between them. Figure 1 and Figure 2 As can be seen, the overhanging part 37 and the overhanging region 64 are currently oriented parallel to each other. The intermediate angle can therefore be constructed as a zero-degree angle.

[0035] In general, the busbar 60 and the single-winding region 32 are material-locked, i.e., currently connected by welding, to each other on the connection region 40 protruding from the winding head 50 along the axial extension direction A and additionally or alternatively along the radial extension direction R of the stator 10. In other words, the connection region 40 is formed by the material-locked connection between the single-winding region end 36 and the busbar 60, and in particular by the material-locked connection between the protrusion 37 and the protrusion region 64.

[0036] By arranging the temperature sensor 90 on the holding region end 72 of the holding region 70, which corresponds to the holding region segment of the holding region 70 that is furthest from the winding head 50 in the axial extension direction A and additionally or alternatively in the radial extension direction R, the temperature sensor 90 is arranged spaced apart from the single winding region end 36 on the holding region 70.

[0037] exist Figure 2 The temperature sensor 90, as shown in the schematic diagram, is in direct thermal contact with the busbar 60 only through the holding region 70—which is constructed as an integral part of the busbar 60—that is, a direct thermally conductive connection. Heat conduction from the single-winding region 32 of the winding assembly 30 to the temperature sensor 90 can also be achieved through a material-locked connection between the extended region 64 of the busbar 60 and the single-winding region end 36, or extended portion 37, thereby allowing at least one temperature value representing the temperature of the winding assembly 30 to be measured on the temperature sensor 90. In this case, the single-winding region end 36 is constructed as an integral part of the single-winding region 32.

[0038] In summary, the holding region 70, and especially the holding region end 72 of the holding region 70, constitutes the measuring tap of the temperature sensor 90. The basic idea in this case is to arrange the measuring tap at the beginning or end of the winding assembly 30 without damaging, for example, the insulation material in the region of the winding head 50, i.e., in the region of the winding assembly 30 spaced apart from the holding region 70, or without interrupting the winding assembly 30 specifically to make the measuring tap possible and thus weakening the winding assembly, for example, by adding solder joints.

[0039] The retaining region 70 and therefore the retaining region end 72 can, in principle, be arranged at any position along the busbar 60 in the circumferential direction U. Figure 1 and Figure 2In this invention, although the retaining region 70 is offset relative to the connecting region 40 only in the radial extension direction R, a key advantage is that the retaining region 70 can also be additionally or alternatively constructed as a branch of the busbar 60 offset relative to the connecting region 40 in the circumferential direction U, i.e., it can protrude from the main busbar section 63. In other words, between the retaining region 70 and the connecting region 40, there can generally be an intermediate region 66 of the busbar 60 extending circumferentially along the main busbar section 63 of the busbar in the busbar direction U. This intermediate region can, for example, be a few centimeters long, i.e., 1cm, 2cm, 3cm, 4cm, 5cm, 6cm, 7cm, 8cm, 9cm, 10cm, 11cm, 12cm, 13cm, 14cm, 15cm, 16cm, 17cm, 18cm, 19cm, or 20cm (only to list some possible length values ​​for the intermediate region 66). These length values ​​allow for particularly good accessibility to the temperature sensor 90 for maintenance work without the risk of collision with the connecting region 40.

[0040] Therefore, the holding region 70 generally allows temperature measurements to be performed at a certain distance from the stator substrate 20, which may include laminations not shown here.

[0041] To form the connection region 40, the single-winding region end 36 of the single-winding region 32 of the winding assembly 30 is truncated further away from the lamination group and therefore further away from the stator base 20. The bus 60 (phase-connecting bus, star bus) extends (redirects) by the same dimension through the extension region 64 in the axial extension direction A and additionally or alternatively in the radial extension direction R, wherein the single-winding region end 36 is connected to the extension region 64 at its extension portion (especially by welding) to form the connection region 40. This method can be applied to one or more phases or conductors as required.

[0042] Clearly, the stator 10 may also have multiple holding regions 70 with corresponding temperature sensors 90, which may be arranged offset from each other in the circumferential direction U on the busbar 60. This allows the temperature gradient to be determined advantageously, from which the temperature level at the winding head 50 can be inferred with low cost, for example.

[0043] List of reference numerals

[0044] 10 stators

[0045] 20 stator substrate

[0046] 22 end face

[0047] 30 winding assembly

[0048] 31 wire components

[0049] 32 Single Winding Region

[0050] 34 Single-winding region

[0051] 36 Single-winding region end

[0052] 37 Exceeding the limit

[0053] 40 connection areas

[0054] 42 Single-winding region bend

[0055] 44 Single-winding region bend

[0056] 50 winding head

[0057] 60 bus

[0058] 63 Busbar Main Section

[0059] 64 Beyond the area

[0060] 66 Middle Area

[0061] 70 Maintain Area

[0062] 72. Maintain the end of the region

[0063] 90 temperature sensor

[0064] 100 electric drive machine

[0065] A-axis extension direction

[0066] A1 Distance

[0067] D_W winding diameter

[0068] EZB Plane Middle Area

[0069] E1 First Plane

[0070] E2 Second Plane

[0071] R radial extension direction

[0072] K Motor Vehicle

[0073] U-shaped direction

Claims

1. A stator (10) for an electric drive machine (100) of a motor vehicle (K), the stator having a stator body (20), at least one winding assembly (30), at least one busbar (60), and at least one temperature sensor (90), the winding assembly having a plurality of single winding regions (32, 34) arranged in corresponding slots of the stator body (20), the busbar being electrically connected to at least one end (36) of at least one single winding region (32, 34), the temperature sensor being connected at least indirectly and thermally to the at least one busbar (60), characterized in that, The at least one busbar (60) and the at least one single winding region end (36) are interconnected via a connection region (40), and the busbar (60) has a holding region (70) on which the at least one temperature sensor (90) is disposed, and the holding region protrudes from the winding head (50) of the winding assembly (30) which includes the respective single winding region bends (42, 44) of the single winding regions (32, 34).

2. The stator (10) according to claim 1, characterized in that, The retaining region (70) protrudes from at least most of the single-winding region bends (42, 44) in the axial extension direction (A) and / or radial extension direction (R) of the stator (10).

3. The stator (10) according to claim 2, characterized in that, The holding region (70) protrudes from the intermediate planar region (EZB) in the axial extension direction (A); the intermediate planar region (EZB) is defined in the axial extension direction (A) by two planes (E1, E2) that are parallel to each other and oriented perpendicular to the axial extension direction (A), and at least the majority of the single-winding region bends (42, 44) are arranged in the intermediate planar region (EZB); the first plane (E1) of the two parallel planes (E1, E2) is tangent to the end face (22) of the stator base (20) facing the busbar (60), and the second plane (E2) of the two parallel planes (E1, E2) is tangent to the majority of the single-winding region bends (42, 44) or has a distance (A1) from the corresponding majority of the single-winding region bends (42, 44), the distance being at most equal to the average winding diameter (D_W) of the conductor element (31) provided to the winding assembly (30).

4. The stator (10) according to any one of the preceding claims, characterized in that, The retaining region (70) protrudes from the stator base (20) in the radial extension direction (R) of the stator (10).

5. The stator (10) according to any one of the preceding claims, characterized in that, The holding region (70) is spaced apart from the connecting region (40).

6. The stator (10) according to any one of the preceding claims, characterized in that, The connection area (40) is formed at least in part by the overhang area (64) of the busbar (60) protruding from the winding head (50).

7. The stator (10) according to any one of the preceding claims, characterized in that, The connection area (40) is formed by the material locking connection between the end (36) of the single winding area and the busbar (60).

8. The stator (10) according to any one of the preceding claims, characterized in that, The temperature sensor (90) is arranged on the holding region (70) at a distance from the end (36) of the single winding region.

9. The stator (10) according to any one of the preceding claims, characterized in that, The temperature sensor (90) is arranged on the end of the holding region (72), which corresponds to the holding region segment of the holding region (70) that is farthest from the winding head (50).

10. An electrically driven machine (100) having at least one stator (10) according to any one of claims 1 to 9.

11. A motor vehicle (K) having at least one electrically driven machine (100) according to claim 10.

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