Stator segment, electric machine for a wind turbine and method for producing a stator segment

Abstract

A stator segment (26) for a stator of an electrical machine (20) of an industrial wind turbine (10) is provided, comprising at least two support segments (28) which extend at least partially in a circumferential direction and are spaced apart from one another in an axial direction for transmitting loads occurring during operation, a first connecting plate (32) which extends in the axial direction and is inserted into the support segments (28) at an angle to the radial direction, a second connecting plate (34) which extends in the axial direction and is inserted into the support segments (28) at an angle to the radial direction, wherein an intermediate space (36) remains free between the first connecting plate (32) and the second connecting plate (34), and a connecting element (38) which is inserted into the intermediate space (36) in the radial direction for connection to a laminated core (40) carrying stator windings, wherein the connecting element (38) is connected to the first connecting plate (32) by a first weld seam (46) and to the second connecting plate (34) by a second weld seam (48). As a result of the fastening of the laminated core (40) by the connecting element (38) and by the welding of the connecting element (38) in the intermediate space (36) between the connecting plates (32, 34), the stator of the electrical machine (20) can be produced cost-effectively and simply.

Description

Technical Field

[0001] The present invention relates to a stator segment of an electric machine by means thereof, which can be used to form the stator of an industrial wind turbine, and to a method for producing such a stator segment. Background Technology

[0002] EP 3 872 964 A1 discloses a segmented stator for an electric machine for a wind turbine, wherein support segments are provided that extend partially in the circumferential direction and are spaced apart from each other in the axial direction, and U-shaped connecting elements extending in the axial direction are inserted therein in the radial direction, wherein the connecting elements have openings for screwing dovetail guides to the connecting elements, the dovetail guides being connectable to a stack of laminations for receiving stator windings.

[0003] DE 10 2008 063 783 A1 discloses a method for producing a segmented stator of an electric machine for a wind turbine, wherein, during the duration of a production step in which laminations are adhesively bonded together, laminations intended to receive stator windings of a stator segment of the stator are screwed onto a clamping device, wherein the clamping device has plates welded in a zigzag shape between radially inner and radially outer tubes, and a screw connection is provided between the laminations and the clamping device in an intermediate space between the zigzag-oriented plates.

[0004] US 8,319,389 B2 discloses a segmented stator for an electric machine for a wind turbine, wherein a stack of stator windings intended to receive a form-fitting holding element is held on a support structure.

[0005] There has always been a need for a cost-effective and simple way to produce stators for electric machines. Summary of the Invention

[0006] The purpose of this invention is to demonstrate a method for producing the stator of an electric machine in a cost-effective and simple manner.

[0007] This objective is achieved by a stator segment having the features of claim 1, a stator having the features of claim 12, a method having the features of claim 13, and a data aggregate having the features of claim 15. Preferred embodiments are specified in the dependent claims and the description below, and in each case an aspect of the invention may be represented individually or in combination. If one feature is presented in combination with another feature, this is only for the purpose of simplifying the presentation of the invention and is in no way intended to imply that the feature cannot be developed in the absence of the other features.

[0008] One aspect of the invention relates to a stator segment of an electric stator for an industrial wind turbine, the stator segment having: at least two support segments extending at least partially in a circumferential direction and spaced apart from each other in an axial direction for transmitting loads occurring during operation; a first connecting plate extending in an axial direction and inserted into the support segments at an angle to a radial direction; a second connecting plate extending in an axial direction and inserted into the support segments at an angle to a radial direction, wherein an intermediate space remains free between the first and second connecting plates; and a connecting element inserted in the intermediate space in a radial direction for connection to a lamination stack carrying stator windings, wherein the connecting element is connected to the first connecting plate via a first weld and to the second connecting plate via a second weld.

[0009] When manufacturing stator segments, they can be assembled in a frame-like manner using support segments and connecting plates, resulting in a stable and rigid structure with a lightweight design. This allows for excellent support of forces occurring in the stator during stator segment operation, particularly the electromagnetic forces generated during the interaction between the stator and the rotor in the electric machine, while maintaining low production costs. Welding allows for fewer parts compared to screwing the lamination stacks onto the connecting plates. Furthermore, welding creates an inseparable connection that cannot be independently separated due to the electromagnetic forces acting during ongoing operation. Therefore, the operational safety and lifespan of the stator segment are improved. The insight used here is that, particularly in the welded state, the connecting elements can mechanically and immovably secure the lamination stacks, avoiding direct welding connections to the lamination stacks. Instead, the connecting elements can be welded to the connecting plates while the connecting elements are fastened and / or immovably secured to the lamination stacks. This allows for optimization of the mechanical properties and weldability of the connecting elements, while simultaneously optimizing the electromagnetic properties of the lamination stacks as part of the electromagnetic core, without considering the weldability of the lamination stacks. Directly welding the lamination stacks to the connecting plates and / or support sections (which can be difficult) is avoided, and instead, welding connections from the connecting elements to the connecting plates are used, which is easier to manufacture. By securing the lamination stacks with connecting elements and fixing the connecting elements in the intermediate space between the connecting plates by welding, cost-effective and simple production of the motor stator can be achieved.

[0010] By welding the connecting element to the connecting plate, a capture connection can be formed in the radial direction. With the simultaneous welding of the first and second connecting plates to the connecting element, the connecting element can be held on the support section via the connecting plate inserted into the support section. Simultaneously, the connecting element inserted into the intermediate space can actively / formally block the relative movement of the corresponding connecting plate in the receiving slot of the corresponding support section, thus holding the connecting plate also within the support section.

[0011] The intermediate space between the first connecting plate and the second connecting plate is large enough that the first connecting plate and the second connecting plate can be inserted into the receiving slots provided in the respective support sections without abutting each other. At the same time, the intermediate space is large enough that the radially extending protrusions of the connecting elements can be inserted into the intermediate space and welded to the connecting plate that defines the intermediate space.

[0012] The corresponding weld can be produced, for example, by electric welding or oxy-acetylene welding. Preferably, in particular, a consumable that may be part of the welding electrode is melted to form the corresponding weld, such that the material of the connecting element and the associated connecting plate is not required to form the corresponding weld. It is sufficient that the material of the connecting element and the associated connecting plate is melted sufficiently to produce a material bond to the corresponding weld on the surface.

[0013] The connecting plates can be stamped from flat metal sheets. Most connecting plates are preferably designed as identical components. In particular, the first connecting plate is arranged and oriented in a mirror-symmetric manner with respect to the second connecting plate.

[0014] The angle α of the corresponding connecting plate tilted relative to the radial direction can be, for example, 0° < α < 90°, especially 10° ≤ α ≤ 80°, preferably 30° ≤ α ≤ 60°, and particularly preferably α = 45° ± 10°.

[0015] On the one hand, the connecting element can be connected to a stack of plates; on the other hand, it can be welded to a connecting plate. The connecting element may have a protrusion located within an intermediate space between the connecting plates, wherein the protrusion preferably extends over most of the interval between consecutive adjacent support segments. The connecting element is preferably designed as a rod oriented in the axial direction. For example, the connecting element has a generally T-shaped cross-section.

[0016] The support sections can be stamped from flat metal sheets. Most or even all stator sections are preferably designed as identical components. A corresponding support section can form at least a portion of the stator's circumferential extent. The support sections preferably extend in a curve having a stator radius, and the stator will be assembled from multiple support sections. A corresponding support section can have at least one receiving slot into which a corresponding connecting plate can be inserted. A portion of the connecting plate can preferably be inserted into the receiving slot in the radial direction; however, it can also be inserted into the receiving slot by relative movement in the axial direction. A portion of the connecting plate preferably protrudes beyond the receiving slot in the region axially adjacent to the support section, thus forming an axial abutment between the connecting plate and the support section, which specifies the relative position of at least one connecting plate relative to at least one support section.

[0017] The stator, which can be assembled using at least one stator segment, is essentially annular, and its annular shape defines the axial, radial, and circumferential directions. The stator can be designed for either an inner or outer rotor. In each case, the individual stator segments can be individually fastened to corresponding support structures within the motor and / or connected to each other to form a closed loop, thus forming the stator of the electric machine. Because the weight of each stator segment is much less than the weight of the entire stator, stator assembly is considerably simplified and is possible in applications where, for example, in the case of offshore wind turbines, heavy assembly equipment such as cranes is not readily available.

[0018] The electric motor may have a stator assembled from stator segments and a rotor that interacts with the stator. The rotor may be coupled (particularly via a wind turbine drive) to a wind turbine rotor, so that the electric motor can generate electrical energy from wind energy impacting the wind turbine rotor in generator mode (particularly for use in the public power grid).

[0019] Industrial wind turbines are primarily designed to generate energy from wind power, where the electricity generated can be specifically fed into the public power grid to supply renewable energy to energy consumers. Wind turbine drives designed for industrial wind turbines are specifically designed for power outputs exceeding 1.0 MW, preferably exceeding 5.0 MW, and particularly preferably exceeding 7.5 MW, and feature a correspondingly robust and large-volume design.

[0020] Specifically, the lamination stack is fastened to the connecting element, wherein the lamination stack is pressed against the support section and / or the connecting plate by the connecting element with a pressing force, wherein the lamination stack is supported flatly against the support section and / or the connecting plate. The connecting element may have a shape that matches the lamination stack, for example, allowing the lamination stack to be pressed downwards with a pressing force when the connecting element is pushed into and / or pulled out of the intermediate space, in particular pressing the lamination stack immovably. The lamination stack can be precisely oriented during assembly and secured in the intended final position by the applied pressing force, wherein the pressing force is maintained after the connecting element has been welded to the connecting plate. As a result, precise and stable bonding of the stator segments is achieved cost-effectively.

[0021] Pressing force can be applied by pulling the protrusion of the connecting element into the intermediate space. For this purpose, a clamp can, for example, engage on the protrusion and be pulled with the desired force. Alternatively, a hook can be hooked onto the protrusion of the connecting element, and pressing force can be applied by pulling the hook. Internal or external threads can also be provided in the connecting element, through which tools for tightening the connecting element can sometimes be tightened. With the applied pressing force, the connecting element can press the laminations flat against the correspondingly extending surfaces of the support section and / or connecting plate, thus avoiding unnecessary gaps between the lamination stack and the rest of the stator section.

[0022] The connecting element is preferably centered tangentially within the intermediate space at the first and second connecting plates. The first and second connecting plates may have side surfaces facing each other, forming grooves extending radially and axially for the intermediate space. The grooves can be large enough that tilting of the connecting element within the grooved intermediate space can be avoided or limited to a tolerable amount. Preferably, a fit is formed between the connecting element and the grooved intermediate space defined by the connecting plates. If the connecting plates are oriented radially, the tangential spacing between the connecting plates can form a fit within the intermediate space for the protrusion into which the connecting element is to be inserted. If the connecting plates are oriented at an angle to the radial direction, for example, in a roof and / or arrow shape, the connecting plates can be tilted along the thickness of the plates, creating parallel ranges of facing side surfaces, and the intermediate space can be designed for the grooved fit of the connecting element. Proper orientation of the connecting element in the inserted intermediate space and in the welded state can be ensured by centering, and thus also ensures proper orientation of the stack of plates immovably positioned by means of the connecting element.

[0023] The connecting element preferably has a connecting profile, particularly a dovetail profile, for axial pushing on the lamination stack. The connecting profile may particularly have hooks engaging in the undercut, thus forming a capture fastening in the radial direction. The lamination stack can be oriented relative to the support section via axial displacement. When the lamination stack has reached its designated final position relative to the support section, the connecting element can be further moved and further radially into the intermediate space, such that the connecting profile can press the lamination stack downwards with pressure, thus securing the lamination stack at least frictionally in place within the stator section. In the radial direction, even a gapless form-fit fixation of the lamination stack in place can be achieved, configured as inseparable due to the welded connection between the connecting element and the connecting plate. The lamination stack may have a thicker area in the radial direction in the region of the connecting profile to enable the associated form fit. The support section and / or connecting plate preferably have corresponding recesses to avoid unwanted gaps between the lamination stack and the rest of the stator section.

[0024] Specifically, a welding area with a V-shaped cross-section is formed between the connecting element and the first connecting plate and / or between the connecting element and the second connecting plate. This welding area is used to form the first weld and / or the second weld as a fillet weld. One side of the connecting plate may extend at an angle relative to the connecting element, particularly outside the intermediate space into which the connecting element can be inserted, thereby creating a V-shaped free space between the connecting plate and the connecting element. This free space defines a welding area filled with the fillet weld after welding. The V-shaped orientation of the surfaces of the connecting plates facing each other and the connecting element make it easier to guide the welding electrode and / or weld in the axial direction along the direction of the fillet weld to be produced. Production is thus simplified and can occur particularly quickly.

[0025] The first and second welds are preferably formed at different, opposite side surfaces of the connecting elements. Therefore, the connecting elements can be secured with a material bond having a generally symmetrical retaining force applied via the welds. Any deformation that may occur when one weld is formed can be fully or partially compensated for when the other weld is formed.

[0026] The connecting elements, the first connecting plate, and the second connecting plate are particularly preferably made of a different material than the lamination stack, especially a material other than electrical steel sheet, wherein the connecting elements, the first connecting plate, and the second connecting plate are particularly made of weldable steel. In particular, the lamination stack may have laminations made of electrical steel sheet. The electrical steel sheet may conform to EN 10106 or EN 10107. Because the connecting elements, rather than the lamination stack, are welded to the connecting plates, welded connections with the lamination stack are avoided. Therefore, welded connections with materials composed of electrical steel sheet, which have low weldability, are avoided. Instead, the connecting elements and the connecting plates can be made of a material with better weldability than electrical steel sheet.

[0027] Specifically, at least the first connecting plate and / or at least the second connecting plate have a curved cross-section at the tangential end of the support section and a straight cross-section at all other points. Because the connecting plates extend in a curve, protrusion at the tangential end of the stator section can be avoided, especially when it extends obliquely in the radial direction. The curved connecting plates can be inserted, for example, into the receiving groove of the support section in the axial direction. The curved connecting plates can be made from flat stamped sheets that have been bent into a curve after stamping. The remaining connecting plates are preferably produced from flat stamped sheets, particularly as tooling components.

[0028] In one embodiment, the lamination stack and support segments and / or connecting plates are coated with enamel. The laminations of the lamination stack can be baked together well by enamel. Therefore, in principle, enamel can be applied only after the connecting elements have been welded to the connecting plates, thus resulting in better bonding and uniform surface protection of the stator segments. Damage to the enamel coating from heat during welding can thus be avoided. However, it is also possible to first enamel-coate the lamination stack and then bake it, thus achieving a particularly defined pre-tension in the receiving fingers, and finally connecting the lamination stack (preferably in a compressed state in the axial direction) to the support segments and / or connecting plates via the welded connecting elements. In this case, the support segments and / or connecting plates can be selectively enamel-coated or left uncoated.

[0029] Particularly preferably, the lamination stack has receiving fingers at at least one point in the circumferential direction, which are at least partially formed in the circumferential region shared with the connecting element and protrude in the radial direction to define a stator recess. In the radial direction, the receiving fingers may cover at least a portion of the connecting element. Because no threaded connection is provided for fastening the lamination stack, there is no need for an exceptionally wide stator recess in the region where the lamination stack is fastened in the stator segment to provide sufficient space for applying a screwdriver. Instead, the width of the stator recess in the tangential direction can be adapted to the requirements of receiving the stator windings, thus avoiding unnecessary gaps due to the absence of stator windings. In particular, the connecting element is only provided on the underside of the lamination stack facing the support segment, allowing the lamination stack to be designed in almost any shape on the opposite top side. This also allows for stator recesses offset in the circumferential direction relative to the intermediate space and / or receiving fingers formed in the radial extension of the intermediate space.

[0030] Specifically, the air gap directly abuts the axial ends of the lamination stack. Because the lamination stack can be easily and correctly positioned and secured by means of connecting elements, there is no need to provide a plate at the axial ends that acts as an axial abutment to specify the axial relative position of the lamination stack. Therefore, the structure of the stator section can be simplified to have a very small axial range and a small number of parts.

[0031] Another aspect of the invention relates to a stator for an electric motor used in an industrial wind turbine, the stator having a plurality of stator segments arranged one after another in the circumferential direction and each of which can be formed and designed as described above. The motor can be specifically designed as an external rotor or an internal rotor. In particular, the stator can be formed and developed as explained above with reference to the stator segments. Cost-effective and simple production of the motor stator can be achieved by fastening the laminations together with connecting elements and by fixing the connecting elements in the intermediate space between the connecting plates by welding.

[0032] Another aspect of the invention relates to a method for producing a stator segment, which can be formed and designed as described above, wherein a first connecting plate and a second connecting plate are first inserted into a support segment, and then connecting elements are inserted into an intermediate space, wherein laminations are already connected to or subsequently connected to the connecting elements, and then a pressing force for pressing the laminations against the support segment and / or the connecting plates is applied to the connecting elements, wherein the connecting elements are simultaneously welded to the first connecting plate and / or the second connecting plate. In particular, the method can be formed and developed as explained above with reference to the foregoing aspects. By securing the laminations with connecting elements and fixing the connecting elements in the intermediate space between the connecting plates by welding, cost-effective and simple production of the stator of the electric machine can be achieved.

[0033] The lamination stack is preferably oriented axially before being pressed down, with a boundary plate acting axially specifically for orientation, wherein the boundary plate is removed from the stator segment after pressing down or after welding. The lamination stack can be axially displaced along the connecting device, with or without aids (e.g., boundary plates), to position the lamination stack in a designated final position, and then secured by pressing down and welding the connecting elements. Axial abutments permanently fastened to the stator segment can be omitted.

[0034] Furthermore, one aspect of the invention relates to a data aggregate having data packets combined in a common file or distributed across different files for representing the three-dimensional design and / or interactions of all components disposed in a stator segment (which may be formed and developed as described above) or stator (which may be formed and developed as described above). The data packets are prepared to perform additive manufacturing of the stator segment or stator components, particularly by 3D printing, during processing by a data processing device for additive manufacturing of a machine tool for the device, and / or to perform simulation of the function of the stator segment or stator during processing by a data processing device for performing technical simulations, and to output the resulting simulation results for further use, particularly for the purpose of providing fatigue strength verification under variable loads and / or variable temperature loads, and optionally comparing them with measurement data determined on a device actually manufactured according to the invention and / or a prototype of the device according to the invention. The data packets of the data aggregate are particularly suitable for the configuration according to the invention of the corresponding device described above, so as to enable the interaction of the components of the device according to the invention to be fully represented during processing in the data processing device. Data packets can be stored, particularly in a spatially distributed manner, but can be adapted to each other in such a way that, when all data packets are placed together in a common data processing device, such a combined data aggregate provides all the necessary data for additive manufacturing and / or technical simulation using a data processing device for the device according to the invention. For example, each data packet is a separate part of a database, which is placed together to form a data aggregate and adapted to each other in a manner corresponding to the corresponding device according to the invention, relative to their relative dimensions and / or absolute dimensions and / or material properties. The data aggregate can represent a virtual embodiment of the corresponding device according to the invention in a manner referred to as a "digital twin," which allows for virtual investigation in the form of simulation or real objectification via additive manufacturing processes. Such a digital twin is illustrated, for example, in US 2017 / 286572 A1, the disclosure of which is herein incorporated herein by reference.

[0035] When the machine tool's data processing unit processes the data aggregate, the device according to the invention is produced, such that after processing the data aggregate in the data processing unit, the device according to the invention is obtained at least in the form of a prototype. Specifically, in each case, the data packets can represent components of a separately configured corresponding associated device according to the invention, such that the components can be readily assembled, practically and / or virtually, in their relative positions and / or relative mobility to achieve the interactions essential to the invention. In particular, by means of the corresponding data packets, different components of the corresponding device can be generated individually and optionally from different materials by additive manufacturing, and subsequently assembled to form a prototype of the corresponding device. Thus, dividing the data of the data aggregate into different data packets allows for the sequential additive manufacturing of the components of the device in question, which are movable relative to each other, in the form of component kits prepared only when appropriate, for the interactions of the components of the prototype according to the invention to solve the problem on which the invention is based.

[0036] Additionally or alternatively, during technical simulation, data packets from data aggregates used in a virtual environment can calculate and / or predict the individual components of the corresponding device, their interactions, physical states, and / or physical parameters, according to different boundary conditions and / or changes over time of the relevant device according to the invention, and continue to be used to check whether the device according to the invention is adequately suited for its intended use based on assumed configurations and considering the effects of assumed simulations. When the data aggregates are processed by a data processing device representing the simulation environment, the behavior of the device according to the invention can be investigated, taking into account, particularly changed boundary conditions. This allows, for example, the effect of centrifugal force on the individual components of the device according to the invention to be studied according to different static and / or dynamic loads and / or different operating temperatures, wherein such simulation results can be incorporated into the creation of fatigue strength verification. Preferably, the simulation results obtained after processing the data aggregates are stored in a data processing device for the simulation environment so as to compare them with measurement data determined on the actual production device according to the invention and / or on a prototype of the device according to the invention. This allows the quality of the simulation results obtained by means of the data aggregates to be evaluated and / or, particularly in the case of particularly significant deviations, measurement errors and / or erroneous measurements to be identified. This thus simplifies and improves the non-destructive quality control of the device according to the invention.

[0037] Data aggregators enable the cost-effective production of prototypes and / or computer-based simulations to study the functionality of rotating bodies and / or holding tools, identify problems in specific applications, and find improvements. Solutions to the problems upon which this invention is based can be easily and cost-effectively examined using data aggregators. Attached Figure Description

[0038] Figure 1 A schematic perspective view of a wind turbine is shown. Figure 2 A schematic perspective view of a portion of the stator section during production is shown. Figure 3 It shows the source when production is complete. Figure 2 A schematic front view of the stator segment. Figure 4 It shows Figure 3 A schematic detailed view of the stator segment. Figure 5 This shows the effect of coating stacks during the process of stacking. Figure 4 A schematic perspective view of the stator segment, and Figure 6 As shown below Figure 3 A schematic perspective view of the stator segment. Detailed Implementation

[0039] Figure 1 The wind turbine 10 shown can be used to generate electrical energy from wind power. For this purpose, the wind turbine 10 has a wind turbine rotor 12, which is configured to rotate by wind power. The wind turbine rotor 12 is coupled to a drivetrain 14. For this purpose, the wind turbine rotor 12 is connected to a rotor shaft 16, which is coupled within the drivetrain 14 to a transmission 18 to convert the torque introduced via the wind turbine rotor 12 and the rotor shaft 16. The torque converted in the transmission 18 is supplied to an electric motor 20 operating in generator mode. The electric motor 20 may have a rotor coupled to the output of the transmission 18 and interacting with a stator to generate electrical energy in generator mode. However, in a variant called "direct drive," the electric motor 20 may be directly coupled to the rotor shaft 16, omitting the transmission 18 connected therebetween. The electrical energy generated by the electric motor 20 can be supplied to a rechargeable battery and / or the power grid. In the exemplary embodiment shown, the drivetrain 14 is fully housed in the nacelle 22, which is attached to the upper free end of the column tower 24.

[0040] Figure 2The stator segment 26 shown in the middle portion can form part of the stator of the electric machine 20. The stator segment 26 has at least two support segments 28, which extend partially in the circumferential direction, are spaced apart from each other in the axial direction, and form receiving grooves 30 in the support segments 28. A first connecting plate 32 extending at an angle to the radial direction and a second connecting plate 34 arranged mirror-symmetrically with respect to the first connecting plate 32 can be provided in the receiving grooves 30. In particular, multiple pairs of first connecting plates 32 and second connecting plates 34 are provided. The connecting plates 32, 34 can be designed as tooled flat stamping parts of metal sheets, wherein the connecting plates 32, 34 can extend in a curve at the tangential ends of the stator segment 26 for structural space reasons. An intermediate space 36 is left at the ends of the first connecting plates 32 and the second connecting plates 34 that taper toward each other.

[0041] like Figure 3 As shown, a connecting element 38, having a generally T-shaped cross-section and extending axially in the form of a rod, can extend into the intermediate space 36, and the radially protruding protrusion 42 of the connecting element can even be centered at the first connecting plate 32 and the second connecting plate 34. With the aid of the connecting element 38, the stacked plates 40 can be pressed against the support section 28 and the connecting plates 32, 34 with the smallest possible gap and as flat as possible. For this purpose, the protrusion 42 of the connecting element 38 can be pulled, for example.

[0042] like Figure 4 As shown, the connecting element 38 may have a connecting profile 44 designed as a dovetail profile, through which a capture connection with the lamination stack 40 in the radial direction can be formed. The connecting profile 44 may have sufficient clearance to allow the lamination stack 40 to shift axially on the connecting element 38. However, once the connecting element 38 has been tightened, the lamination stack 40 can be immovably fixed. In this compressed state, the connecting element 38 can be welded to the first connecting plate 32 and the second connecting plate 34. Due to the generally radial orientation of the protrusion 42 of the connecting element 38 in the intermediate space 36 and the orientation of the associated connecting plates 32, 34 tilted relative to the radial direction, a V-shaped welding space is created between the connecting element 38 and the connecting plates 32, 34 in each case. In this welding space, a first weld 46, formed as a fillet weld, can be formed between the protrusion 42 of the connecting element 38 and the first connecting plate 32, and a second weld 48, formed as a fillet weld, can be formed between the protrusion 42 of the connecting element 38 and the second connecting plate 34. Since the lamination stack 40 does not need to be screwed into the area of ​​the intermediate space 36, it is possible that the receiving finger 50 (by means of which can define the stator groove 52 for the stator winding) is at least partially positioned in the connecting element 38 and / or particularly in the radial extension of the slotted intermediate space 36.

[0043] like Figure 5 As shown, the stack 40 can be displaced axially along the connecting element 38 until the desired final position is found, with or without additional tools. Then, as... Figure 6 As shown, the protrusion 42 of the connecting element 38 is tightened, thus the lamination stack 40 is immovably secured by pressure. In this position, the connecting element 38 can be welded to the connecting plates 32, 34 to obtain the stator segment 26.

Claims

1. A stator segment (26) of the stator of an electric motor (20) for an industrial wind turbine (10), comprising: At least two support segments (28), which extend at least partially in the circumferential direction and are spaced apart from each other in the axial direction, are used to transmit loads that occur during operation. A first connecting plate (32), which extends in the axial direction and is inserted into the support section (28) at an angle to the radial direction, A second connecting plate (34), which extends in the axial direction and is inserted into the support section (28) at an angle to the radial direction, The intermediate space (36) remains free between the first connecting plate (32) and the second connecting plate (34). A connecting element (38), which is inserted radially into the intermediate space (36), is used to connect to the lamination stack (40) carrying the stator winding. The connecting element (38) is connected to the first connecting plate (32) via a first weld (46) and to the second connecting plate (34) via a second weld (48).

2. The stator segment (26) according to claim 1, wherein, The stack of plates (40) is fastened to the connecting element (38), wherein the stack of plates (40) is pressed against the support section (28) and / or the connecting plate (32, 34) by pressure via the connecting element (38), wherein, in particular, the stack of plates (40) is flatly supported against the support section (28) and / or the connecting plate (32, 34).

3. The stator segment (26) according to claim 1 or 2, wherein, The connecting element (38) is centered tangentially within the intermediate space (36) between the first connecting plate (32) and the second connecting plate (34).

4. The stator segment (26) according to any one of claims 1 to 3, wherein, The connecting element (38) has a connecting profile (44), particularly a dovetail profile, for axial pushing on the stack of laminations (40).

5. The stator segment (26) according to any one of claims 1 to 4, wherein, A welding area with a V-shaped cross-section is formed between the connecting element (38) and the first connecting plate (32) and / or between the connecting element (38) and the second connecting plate (34) for forming the first weld (46) and / or the second weld (48) as fillet welds.

6. The stator segment (26) according to any one of claims 1 to 5, wherein, The first weld (46) and the second weld (48) are formed on different side surfaces of the connecting element (38) that are opposite to each other.

7. The stator segment (26) according to any one of claims 1 to 6, wherein, The connecting element (38), the first connecting plate (32), and the second connecting plate (34) are made of a material different from the laminated stack (40), in particular of a material other than electrical steel sheet, wherein, in particular, the connecting element (38), the first connecting plate (32), and the second connecting plate (34) are made of weldable steel.

8. The stator segment (26) according to any one of claims 1 to 7, wherein, At least the first connecting plate (32) and / or at least the second connecting plate (34) have a curved cross section at the tangential end of the support segment (28) and a straight cross section at all other points.

9. The stator segment (26) according to any one of claims 1 to 8, wherein, The stacked plates (40) and the support segments (28) and / or the connecting plates (32, 34) are coated with ceramic.

10. The stator segment (26) according to any one of claims 1 to 9, wherein, The lamination stack (40) has a receiving finger (50) at at least one point in the circumferential direction, the receiving finger (50) being formed at least partially in the circumferential region shared with the connecting element (38) and protruding in the radial direction for defining the stator slot (52).

11. The stator segment (26) according to any one of claims 1 to 10, wherein, The air gap is directly adjacent to the axial end of the stack of laminations (40).

12. A stator for an electrical machine (20) for an industrial wind turbine (10), having a plurality of stator segments (26) arranged one after another in a circumferential direction, each stator segment being a stator segment as claimed in any one of claims 1 to 11.

13. A method for producing a stator segment (26) according to any one of claims 1 to 12, wherein First, the first connecting plate (32) and the second connecting plate (34) are inserted into the support section (28). Then, the connecting element (38) is inserted into the intermediate space (36), wherein the stack of laminates (40) has been connected to the connecting element (38) or subsequently connected to the connecting element (38). Then, a pressing force is applied to the connecting element (38) to press the stacked pieces (40) against the support section (28) and / or the connecting plates (32, 34). The connecting element (38) is simultaneously welded to the first connecting plate (32) and / or the second connecting plate (34).

14. The method according to claim 13, wherein, The lamination stack (40) is oriented in the axial direction before being pressed down, wherein a boundary plate acting in the axial direction is used, particularly for orientation, wherein the boundary plate is removed from the stator segment (26) after the pressing down or after the welding.

15. A data aggregate having data packets, said data packets being combined in a common file or distributed across different files, for representing the three-dimensional design and / or interaction of all components provided in a stator segment (26) as claimed in any one of claims 1 to 11 or in a stator as claimed in claim 12, wherein, The data packet is prepared so that, When additive manufacturing for operating machine tools for equipment is processed by a data processing device, additive production of the stator segment (26) or the components of the stator is performed, particularly by 3D printing. And / or, When the data is processed by the data processing device to perform technical simulation, the simulation of the function of the stator segment (26) or the stator is performed, and the simulation results generated therefrom are output for further use, particularly for the purpose of providing fatigue strength verification based on variable loads and / or variable temperature loads.

Images