Stator for a radial flux double rotor machine and radial flux double rotor machine

Abstract

The invention relates to a stator for a radial flux double rotor machine, having a stator core with a stator lamination stack, windings which are placed in the stator core and formed with conductor bars having opposite inclination angles, wherein the stator lamination stack has stator slots which correspond to the winding paths of the windings and extend in the stator core, the stator slots being designed to receive one individual conductor bar of the windings respectively, and at least one support device which is arranged axially offset from the stator core and is designed for torque support of the windings at the axial end, wherein between the inner contour of the respective stator slot and the conductor bar placed in the respective stator slot an additional reinforcement element is provided for structurally connecting the stator lamination stack and the conductor bar. The invention further relates to a radial flux double rotor machine having such a stator.

Description

Technical Field

[0001] This invention relates to a stator for a radial flux dual-rotor machine. The invention further relates to a radial flux dual-rotor machine having such a stator. Background Technology

[0002] Compared to conventional motors with only one rotor, motors with one stator and two rotors connected to each other in a rotating-fixed manner—so-called dual-rotor machines (also known as multi-rotor, double-rotor, etc.)—can increase both the torque density and efficiency of the electric drive. This is due, particularly in so-called "yokeless" designs, the absence of a magnetic return path in the stator, thus significantly reducing core losses. Additionally, the two rotors typically provide more space for field-excitation magnets (in permanent magnet synchronous machines (PSMs)) or conductor materials (in induction machines (IMs) or electrically excited synchronous machines (ESMs). Depending on the orientation of the magnetic field lines in the air gap, such machines can be divided into two groups: axial flux-carrying (field lines parallel to the axis of rotation, so-called axial flux machines) and radial flux-carrying (field lines radially in the air gap, so-called radial flux machines).

[0003] For example, radial flux twin-rotor machines are disclosed in DE 10 2021 003 942 A1. These radial flux twin-rotor machines are characterized by high torque and high power density. These radial flux twin-rotor machines typically use mature manufacturing methods suitable for the mass production of windings and laminated cores, and enable the torque generated in the stator core to be supported. For example, disclosure DE 10 2023 101 990 B3, based on this, describes a particularly advantageous manufacturing of winding heads with bent conductors.

[0004] The stator, a key component of radial flux twin-rotor machines, essentially consists of a stator core, windings housed within the core, and supports to withstand the generated torque. The structural integrity of the stator is crucial, as relative displacement between components can lead to efficiency losses or short circuits. Summary of the Invention

[0005] In this context, the object of the present invention is to provide a stator for a radial flux dual-rotor machine that has high structural integrity, particularly high strength and stiffness.

[0006] According to the invention, this objective is achieved by a stator having the features of claim 1 and / or by a radial flux dual-rotor machine having the features of claim 17.

[0007] Accordingly, the following content is provided: - A stator for a radial flux dual-rotor machine, the stator comprising: a stator core having a stator lamination stack; windings disposed in the stator core and formed with conductor bars having opposite inclination angles, wherein the stator lamination stack has stator slots corresponding to the winding path of the windings and extending in the stator core, the stator slots being designed to receive a single conductor bar of the winding; and at least one support device arranged axially offset from the stator core, the at least one support device being designed to provide torque support for the windings at axial ends; wherein additional reinforcing elements are provided between the inner contour of the respective stator slot and the conductor bars disposed in the respective stator slots for structurally connecting the stator lamination stack and the conductor bars.

[0008] - A radial flux dual rotor machine, particularly a radial flux dual rotor machine for hub drives, the radial flux dual rotor machine having: a mechanically fixed base; a stator according to the invention, wherein a support device is supported on the base for torque support of the windings; a first rotor radially arranged within the stator core; and a second rotor radially arranged outside the stator core.

[0009] The basic principle of this invention is that the torque supported on the conductor bar may cause local deformation and / or stress peaks within the stator lamination stack, which requires additional reinforcement to increase the structural integrity within the stator lamination stack and the conductor bar.

[0010] The concept of this invention is to provide additional structurally effective reinforcing elements within the stator slots, between the conductors and the slot interior, particularly in addition to the insulation of the conductor bars. In this way, the stator lamination stack is distributed with reinforcing elements that extend directly along the conductor bars at opposite angles of inclination, and thus along the load path used for torque support. In this manner, continuous stator reinforcement is achieved, enabling support for increased torque on the one hand, and stress dispersion along the reinforcing elements on the other, thus effectively avoiding stress peaks.

[0011] The stator lamination stack should be understood in particular as a stack of insulating electrical sheets designed and configured for magnetic flux guiding. Therefore, the stator lamination stack can be an electrical lamination. However, in other embodiments, the stator lamination stack can also be a non-laminated core, such as an additive manufacturing version of multiple insulating flux guiding layers as the stator lamination stack. Therefore, the stator lamination stack is a functional name and does not necessarily have to be formed from actual sheets.

[0012] Conductor bars with opposite tilt angles should be understood as a bar arrangement with opposite tilt angle orientations. For this purpose, conductor bars can be arranged in at least two layers. The first layer has a first tilt orientation, while the second layer tilts in the opposite direction. The winding can be specifically designed as a bar frame made of individual conductor bars.

[0013] The support device can be designed to engage with the winding shape, for example, by engaging with a conductor rod. The support device can be a separate component or a functional device integrated with other components. For example, integration with a housing or end plate is conceivable. However, the support device can also be a support device that is material-fitted to the winding, such as a casting designed as the winding head.

[0014] The reinforcing element is specifically designed to structurally connect the stacked metal sheets and further serves to restrict the degrees of freedom between the conductor rod and the stator slot. The reinforcing element also allows the conductor to be inserted into the stator slot by external force without damaging the insulation layer of the conductor rod in the process.

[0015] Advantageous embodiments and further developments are derived from the additional dependent claims and the description with reference to the accompanying drawings.

[0016] According to one embodiment, the reinforcing element at least partially surrounds the conductor bar in the corresponding stator slot. In this way, the conductor bar can be supported on the reinforcing element on multiple sides, and particularly on opposite sides. Therefore, a press fit is preferably formed between the conductor bar and the inner surface of the slot.

[0017] According to one embodiment, the reinforcing element comprises an expandable material that can expand by at least 5% by volume in a pre-assembled or assembled state for structurally connecting a stator lamination stack and a conductor rod within a stator slot. The conductor rod is inserted into the stator slot for manufacture after or together with the reinforcing element. Depending on the fit, a smaller expansion is required in the case of a transition fit provided before expansion, and a larger expansion is required in the case of a clearance fit, particularly a press fit and / or form fit, to create a structural assembly. The expansion is preferably irreversible, resulting in a robust structural assembly. For example, the reinforcing element can be designed to expand in the range of at least 5% to no more than 150% to create a structural assembly within the stator slot in a stable manner. In particular, the expansion is at least 10% by volume. In other embodiments, the expansion is at least 50% by volume. In the case of free expansion, the expansion of the material can exhibit even larger proportions, such as up to 500%.

[0018] According to one embodiment, the reinforcing element is made of plastic, which has irreversible expansion properties that can be activated by heat. Alternatively or additionally, the reinforcing element has an adhesive material, particularly plastic. These are preferably adhesive materials with irreversible expansion properties that can be activated by heat. The expansion properties advantageously produce tolerance compensation as well as a combination of material fit connections and press fit connections. Form fit connections can also be produced by expansion beyond the inside of the groove at the groove end.

[0019] According to one embodiment, the reinforcing elements comprise an electrically insulating material. In this way, these reinforcing elements further contribute to electrical safety and short-circuit protection.

[0020] According to one embodiment, the reinforcing element is designed as a single-piece element. Multi-piece, particularly two-piece, embodiments are also possible. The reinforcing element further has a profile that joins the radially inner and outer surfaces of the conductor rod. The corresponding conductor rod is thus enclosed by the corresponding reinforcing element.

[0021] According to one embodiment, the winding protrudes beyond the stator core at a first axial end and a second axial end opposite to the first axial end, wherein the reinforcing element has a protruding portion at either the first axial end or the second axial end, or at both axial ends. In this way, the reinforcing element can also provide axial reinforcement by further restricting axial degrees of freedom.

[0022] According to one embodiment, at least one reinforcing element is arranged in each stator slot and located between the conductor bar and the inner contour of the stator slot, and between the conductor bar and the support device. Specifically, the reinforcing element extends as a protrusion between the conductor bar and the support device. Therefore, the connection between the conductor bar and the support device is also strengthened and structurally connected to the reinforcing element.

[0023] According to one embodiment, the support device is designed to have an opening for supporting the winding at a first axial end. A protruding portion of a reinforcing element is arranged between the respective conductor rod and the corresponding opening of the support device, and is configured to structurally connect the support device and the conductor rod. In this way, the connection between the conductor rod and the support device is also advantageously reinforced by means of the reinforcing element. The reinforcing element is designed, particularly in expandable embodiments, to compensate for tolerances in the opening. Alternatively or additionally, expansion of the reinforcing element creates a step or undercut on the corresponding opening, and thus ensures that the conductor rod is axially fixed in the opening or at least ensures that the reinforcing element is axially fixed. The opening may, in particular, be wedge-shaped or conical to enhance axial fixation.

[0024] According to one embodiment, the reinforcing element each has at least one longitudinal, particularly slot-shaped or elongated hole-shaped recess extending longitudinally along the conductor rod within the stator slot. Multiple longitudinal recesses are also possible. In one embodiment, these longitudinal recesses may extend parallel to each other. In other embodiments, these longitudinal recesses may also extend segmentally, one after another, or in a straight line.

[0025] According to one embodiment, the reinforcing element comprises a foldable material. The reinforcing element is designed to fold around the conductor rod within the stator slot. In the joint region of the folded material, the reinforcing element may have an overlap or a free region. The corresponding folded connection region of the reinforcing element disposed in the respective stator slot extends around the edge of the corresponding conductor rod disposed in the stator slot. Alternatively or additionally, the folded connection region extends along the inner edge of the corresponding inner contour of the stator slot. In this way, the reinforcing element can advantageously fold to a greater extent for insertion into the stator slot and unfold in the inserted state, thereby preventing friction during insertion and any resulting damage. Furthermore, the position of the reinforcing element on the conductor rod or within the slot is predetermined by the folded connection region and is adjusted independently or in a self-adjusting manner, particularly by elastic deformation.

[0026] According to one embodiment, the foldable material is designed as a multilayer composite material having at least one centrally arranged support layer, particularly a membrane. Alternatively or additionally, the multilayer composite material contains an expansion layer and / or an adhesive layer. In this way, multiple functions can be integrated into the reinforcing element, particularly in addition to reinforcement, connection functions, insulation functions, and / or tolerance compensation functions.

[0027] According to another embodiment, the foldable material comprises a laminate. According to another embodiment, the foldable material comprises a flat product, particularly a flat product made of plastic. According to another embodiment, the foldable material comprises a thin-layer molded part. According to another embodiment, the foldable material comprises a profile. According to other embodiments, the foldable material comprises a film. A common feature of all these embodiments is that the stator is reinforced by providing and arranging corresponding reinforcing elements in the stator slots between the inner surface of the slots and the outer surface of the conductors, and optionally also between the inner surface of the opening of the support device and the outer surface of the conductors.

[0028] According to one embodiment, the reinforcing element comprises a sealing material, and the corresponding stator slot is fluidly sealed by the reinforcing element arranged in the stator slot. This advantageously prevents unwanted ingress or escape of liquid or even gas, and achieves directional fluid guidance.

[0029] According to one embodiment, the longitudinal recess is designed and arranged as a conduit defined by stator slots and conductor bars for axial coolant flow from one of the first and second axial ends of the stator to the other. In this way, further functional integration is advantageously achieved by simultaneously using reinforcing elements to form the coolant conduit.

[0030] According to one embodiment, the axial end of the reinforcing element is folded to form a fold. In this way, an integral axial stop is advantageously provided when the reinforcing element is inserted into the stator slot. In the case of an expandable reinforcing element, this folded fold also has twice the expansion capacity due to its double layer. In particular, due to the expansion, an undercut can be formed behind the support, which can be used, for example, for axial fixation. In an advantageous embodiment, one end of the longitudinal recess is also recessed into the folded fold, for example, having a corresponding recess. Therefore, if configured as a coolant conduit, this recess can advantageously serve as an inlet or outlet.

[0031] According to one embodiment, the winding has an inner conductor layer and an outer conductor layer, wherein the folds of the inner and outer conductor layers are located at opposite axial ends of the stator. In this way, opposite insertion directions of the reinforcing elements can be achieved, these opposite insertion directions specifically coinciding with the insertion directions of conductor rods bent at opposite ends. This is particularly provided in windings formed of interconnected conductor rods having radially inner helically arranged conductor rods and radially outer oppositely helically arranged conductor rods, wherein the conductor rods are bent at first conductor rod ends but not at second conductor rod ends. The first conductor rod ends of the radially outer conductor rods are arranged such that the bent portions are respectively oriented radially inward. The first conductor rod ends of the radially inner conductor rods are arranged such that the bent portions are respectively oriented radially outward.

[0032] According to one embodiment, the free region of the reinforcing element, formed because its circumference is shorter than that of the conductor rod, is designed and arranged as a conduit defined by the stator slots and the conductor rod for the axial flow of coolant from one end of the stator to the other. The reinforcing element naturally contains sealing material, and the corresponding stator slot is fluidly sealed by the reinforcing element arranged within it. In this way, functional integration is advantageously achieved by simultaneously using the reinforcing element to form the coolant conduit, without requiring additional materials.

[0033] The above embodiments and further developments can be combined with each other in any meaningful way. Other potential embodiments, further developments, and implementations of the invention include combinations of features of the invention not explicitly mentioned above or below with reference to exemplary embodiments. In particular, those skilled in the art will also add various aspects as improvements or additions to the corresponding basic form of the invention. Attached Figure Description

[0034] The invention will now be explained in more detail based on exemplary embodiments specified in the accompanying drawings. In the drawings: Figure 1 This is a schematic diagram of the longitudinal section of the stator used in a radial flux dual-rotor machine; Figure 2 This is a schematic diagram of the longitudinal section of a radial flux dual-rotor machine; Figure 3 This is a perspective view of the stator for a radial flux dual-rotor machine according to one embodiment; Figure 4A , Figure 4B This is a detailed 3D view of the stator in the winding head region; Figure 5A , Figure 5B This is a detailed perspective view of the stator in the area of ​​the support device; Figure 6 This is a front view of a reinforcing element according to one embodiment; Figure 7 This is a perspective view of a reinforcing element according to one embodiment; Figure 8 It is based on Figure 7 Detailed view of the cross-section of the stator, which is a reinforcing element; Figure 9 This is a schematic longitudinal section of the stator for a radial flux dual-rotor machine according to another embodiment; Figure 10 This is a perspective view of a reinforcing element according to one embodiment; Figure 11 It is based on Figure 10 Detailed view of the cross-section of the stator, which is a reinforcing element; Figure 12A , Figure 12B It is based on Figure 10 Detailed perspective view of the stator with reinforcing elements in the winding head region; Figure 13 This is a perspective view of the reinforcing element according to another embodiment; Figure 14 It is based on Figure 13 Detailed perspective view of the stator with reinforcing elements in the winding head region; Figure 15 It is based on Figure 14 Detailed view of the cross-section of the stator, which is a reinforcing element; Figure 16 This is a perspective view of the reinforcing element according to yet another embodiment; Figure 17 It is based on Figure 16Detailed perspective view of the stator with reinforcing elements in the winding head region; Figure 18 This is a perspective view of a support device according to one embodiment; and Figure 19A , Figure 19B This is a perspective view of a two-part support device according to one embodiment.

[0035] The accompanying drawings are intended to provide a further understanding of embodiments of the invention. These drawings illustrate embodiments and are used to explain the principles and concepts of the invention in conjunction with the description. Other embodiments and numerous advantages mentioned are derived from the drawings. Elements in the drawings are not necessarily shown to scale.

[0036] Unless otherwise stated, identical, functional, and operational elements, features, and parts shall have the same reference numerals in the accompanying drawings. Detailed Implementation

[0037] Figure 1 A schematic longitudinal section of stator 1 for a radial flux dual-rotor machine is shown.

[0038] Stator 1 is designed for use in radial flux dual rotor machine 10 ( Figure 2 This allows the stator to be used only on one side (in this case, the first axial end 4, for example, at...) Figure 1 (As shown on the right) The support rests against the base. On the other side (in this case, the second axial end 6), the stator is designed to be surrounded by two rotors.

[0039] The stator has a stator core 3, which comprises a stator lamination stack 30. Windings 4 are placed within the stator core 3 and formed with conductor bars 8 having opposite angles of inclination. For clarity, the angle of inclination of the conductor bars 8 is not shown here; that is, the figures should be understood as schematic in this respect.

[0040] The stator lamination stack 30 has stator slots 7 extending through or within the stator core 3, which receive conductor bars 8. Each of these stator slots is designed to receive a single conductor bar 8 of the winding 4. The stator slots 7 correspond in their path to the winding path of the winding 4. For simplicity, the inclination is not shown here; in this respect, the figures should be understood as schematic.

[0041] Additional reinforcing elements 2 are provided between the inner contour of the corresponding stator slot 7 and the conductor rod 8 placed in the corresponding stator slot 7. These additional reinforcing elements are designed to structurally connect the stator lamination stack 30 and the conductor rod 8. These additional reinforcing elements extend along the conductor rod 8 and axially through the stator core within the stator slot 7.

[0042] The support device 14 is arranged axially offset from the stator core 3 and is designed to provide torque support for the winding 4 at its axial end 5. The reinforcing element may optionally extend further axially, and in particular, as schematically shown here, extend further axially from the stator core into the support device 14.

[0043] Stator 1 is designed to be substantially rotationally symmetric about the central axis M of the schematic diagram, which will be obvious to those skilled in the art.

[0044] Figure 2 A schematic longitudinal cross-section of a radial flux dual-rotor machine 10 is shown.

[0045] The radial flux dual-rotor machine 10 is specifically designed for hub drives in vehicles. However, this radial flux dual-rotor machine can also be used as a central drive for vehicles, particularly motor vehicles. Furthermore, different types of applications beyond vehicle technology are also conceivable, such as robotics.

[0046] Radial flux dual rotor machine 10 has according to Figure 1 The stator and a mechanically fixed base 11, which can be part of the machine housing. For example, the base can be designed as an end plate or otherwise attached to the machine housing for torque support. Figure 1 Stator 1 is only mentioned by example. Figure 2 The winding 4 is schematically shown on the right side supported on the base 11 by a support device 14 for torque support.

[0047] The dual rotors 24 are arranged in Figure 2 On the left side. The dual rotor has a first rotor 25 radially arranged within the stator core 3 and a second rotor 26 radially arranged outside the stator core 3, in which case the first and second rotors are mounted, for example, on a common rotor head of the dual rotor 24. The dual rotor 24 is designed to be driven by current in the windings to rotate about the central axis M.

[0048] Figure 3 A perspective view of a stator 1 for a radial flux dual-rotor machine 10 according to one embodiment is shown.

[0049] The figure shows the conductor bars 8 at opposite inclinations within the stator lamination stack 30. The winding 4 comprises a radially outer layer of conductor bars 8a that extend at an angle, particularly spirally, within the radially outer stator slots 7a. Furthermore, the winding 4 comprises a radially inner layer with conductor bars 8 extending at opposite angles, particularly spirally.

[0050] Support device 14 is arranged in Figure 3The bottom is shown at the first axial end 5. The support device 14 is designed here to have openings 9 in the dimension of the conductor cross-section, such that the conductor rod extends through these openings, and such that the torque generated during operation is supported on the support device 14 via the winding 4. The support device 14 can then be attached to the machine housing, in this case for example by means of a plurality of fastening devices that can be provided at fastening points 34.

[0051] The second winding head 13 is formed here. Figure 3 The second axial end is shown at the top. The conductor rods are designed to be bent at one axial end and fused or welded to each other. For embodiments of winding heads with bent conductor rods and their production, refer to DE 10 2023 101 990 B3, the disclosure of which is incorporated herein by reference in its entirety.

[0052] Unlike the disclosure in document DE 10 2023 101 990 B3, in the illustrated embodiment, the additional reinforcing element 2 is disposed between the inner contour of the corresponding stator slot 7 and the conductor rod placed in the corresponding stator slot 7. For example, in the illustrated embodiment, the reinforcing element 2 at least partially surrounds the conductor rod 8 in the corresponding stator slot 7. The reinforcing element preferably extends along the entire stator slot, particularly continuously.

[0053] The reinforcing element 2 may comprise an expandable material that irreversibly expands by at least 5% by volume in a pre-assembled or assembled state to structurally connect the stator lamination stack 30 and the conductor rods 8 within the stator slots 7. In other embodiments, the expandable material may expand by 10% or more by volume, depending on the fit of the conductor rods in the stator slots. In other embodiments, expansion by volume up to 150% is conceivable. For example, the expandable material may be a plastic with irreversible expansion properties that can be activated by heat, and alternatively or additionally, may contain an adhesive substance. In this way, the stator is structurally reinforced and strengthened as a whole by expanding or activating all reinforcing elements. Thus, conventional casting materials can be advantageously omitted. The structural integrity of the entire stator is established after the expansion or activation of the reinforcing elements in the assembled state of the individual parts.

[0054] Electrical connection pins 35 and 36 are also shown, which are designed to connect winding 4 to power electronic devices, particularly inverters.

[0055] Figure 4A , Figure 4B A detailed perspective view of stator 1 in the winding head region is shown.

[0056] Independent second winding head 13 (in) Figure 3(Seen at the top) Located on the second axial end 6 of the stator 1. In the illustrated embodiment, at this end, the conductor rod 8 of the outer conductor rod 8a is bent, and the conductor rod 8 of the inner conductor rod 8b is straight. At the ends of the conductor rods, these conductor rods form a joint 37, which is electrically and firmly connected, specifically by laser beam welding. Other conductive connection techniques (such as welding) are also conceivable.

[0057] The winding 4 protrudes beyond the stator core at the second axial end shown, wherein the reinforcing element also protrudes as such that the protruding portion extends beyond the stator core 3 at the first axial end 5 and the second axial end 6 opposite to the first axial end 5.

[0058] The reinforcing element 2 received in the stator slot 7 can be a single-piece or multi-piece element. The reinforcing element surrounds multiple surfaces, particularly the radially inner and outer surfaces of the conductor rod 8, and is engaged around these surfaces with corresponding engagement profiles. In the embodiment shown here, these reinforcing elements are designed as single-piece elements and are provided with recesses 19. However, in other embodiments, other designs are conceivable, particularly those without recesses, recesses at different locations, and multi-piece designs.

[0059] In the illustrated embodiment, by way of example only, the stator lamination stack 30 is designed as a two-piece stack, having an inner sub-stack 31 and an outer sub-stack 32, with an inner stator slot 7b formed in the inner sub-stack and an outer stator slot 7a formed in the outer sub-stack. Other structures for the stator lamination stack 30 are conceivable in other embodiments, such as single-piece, additive manufacturing, etc.

[0060] The radially outer stator slots each have a grooved slot 23 on the radially outward-facing side, which interrupts magnetic flux, thus largely blocking magnetic flux in the circumferential direction, and the radial magnetic flux dominates during operation. The stator lamination stack 30 preferably comprises a soft magnetic material.

[0061] Figure 5A , Figure 5B A detailed perspective view of the stator 1 in the region of the support device 14 is shown.

[0062] This is the first axial end 5 with the first winding head 12.

[0063] The reinforcing element 2 also has a protruding portion on the first axial end 5. At least one reinforcing element 2 is arranged in each stator slot 7 and located between the conductor rod 8 and the inner contour of the stator slot 7. Furthermore, the protruding portion of the reinforcing element on the first end 5 is additionally located between the conductor rod 8 and the support device 14. The support device 14 is designed to have an opening 9 for supporting the winding 4 at the first axial end 5. The protruding portion also extends between the corresponding conductor rod 8 and the corresponding opening 9 of the support device 14, and is provided and designed to structurally connect the support device 14 and the conductor rod 8.

[0064] Figure 6 A front view of the reinforcing element 2 according to one embodiment is shown.

[0065] In the illustrated configuration, the reinforcing element is a foldable reinforcing element 2. The foldable reinforcing element 2 comprises a foldable material and is designed to fold around the conductor rod 8 within the stator slot 7. This foldable material is, for example, designed as a multilayer composite material having at least one expansion layer. Alternatively or additionally, it may comprise a centrally located support layer (particularly a membrane), or an expansion layer or adhesive layer, or a combination thereof. Other embodiments of the foldable material may comprise a laminate. Flat products or thin-layer molded parts, profiles, or films made of plastic are also conceivable.

[0066] According to the embodiment shown here, the reinforcing element 2 includes at least one longitudinal (in this case, a slot-shaped or elongated hole-shaped) recess 19. In the assembled state, the recess 19 extends longitudinally along the conductor rod 8 within the stator slot 7.

[0067] The axial end of the reinforcing element 2 is also prepared to form the fold 17. For example, the fold has a fold preparation portion 21 at a predetermined position and a continuation of the recess 19. In the illustrated embodiment, for example, the recess 38 corresponds to the recess in the folded state.

[0068] Figure 7 A perspective view of the reinforcing element 2 according to one embodiment is shown.

[0069] A folded portion 17 is provided here, which also has a continuation of the recess 19 at the folded end. The folded portion 17 also forms a stop for restricting the insertion of the reinforcing element 2 into the stator slot 7, and thus ensures the predetermined positioning within the stator core.

[0070] Furthermore, the reinforcing element 2 also has a free region 18, which can be formed because the reinforcing element 2 is shorter than the circumference of the conductor rod 8 to be surrounded. The side of the reinforcing element 2 is connected to the connecting region 20, which in this case is, for example, in the form of rounded corners.

[0071] In this embodiment, the cross-section of the reinforcing element is constant in length. However, variable cross-sections are conceivable in other embodiments, particularly variable cross-sections with cross-sectional variations that adapt to the conductor rod profile or the inner profile of the stator slot in length.

[0072] Figure 8 It shows that it has the following characteristics: Figure 7 Detailed view of the cross section of the stator 1 of the reinforcing element 2.

[0073] The reinforcing element 2 is arranged within the stator slot 7 between the outer contour of the conductor rod 8 and the inner contour of the stator slot 7. The connection region 20 of the reinforcing element 2 arranged in the respective stator slot 7 (folded at approximately 90°, for example) surrounds the edge 28 of the respective conductor rod 8 arranged in the stator slot 7 and extends along the inner edge 27 of the respective inner contour of the stator slot 7. The contour of the stator slot and the corresponding folding angle are not fixed, but can be adapted to the contour of the conductor rod, which can be designed differently depending on the application.

[0074] In one embodiment, the reinforcing element 2 comprises an electrically insulating material. Thus, in addition to the insulating layer 39 of the conductor bar, another insulator and additional short-circuit protection are integrated. In one embodiment, the reinforcing element 2 also comprises a sealing material. The insulating and sealing materials can also be the same material. The corresponding stator slot 7 is therefore fluidly sealed by the reinforcing element 2 arranged within the stator slot 7. The sealing allows the recess 19 or free region 18 of the reinforcing element 2 to be designed and arranged as a conduit 22 defined by the stator slot and the conductor bar for axial coolant flow from one of the axial ends 5, 6 of the stator to the other.

[0075] Figure 9 Another longitudinal cross-sectional schematic diagram of the stator 1 for a radial flux dual-rotor machine 10 according to one embodiment is shown.

[0076] This diagram is based on Figure 1 Furthermore, the possible arrangement of the fold 17 of the reinforcing element 2 and the possible path of the longitudinal recess 19 are also illustrated. For simplicity, these are not shown here. Figure 1 The tilt of the conductor shown.

[0077] The longitudinal recess 19 serves as a conduit 22 defined by the stator slot 7 and conductor rod 8 for axial coolant flow from one of the first axial end 5 and the second axial end 6 of the stator to the other. The reinforcing element contains sealing material, as per [reference needed]. Figure 8 The explanation given.

[0078] Furthermore, the folded portions 17 of the radial inner conductor layer and the radial outer conductor layer are located at opposite axial ends 5 and 6 of the stator 1. The folded portions are preferably located at the bent ends or angled ends of the conductor rod 8.

[0079] Figure 10 A perspective view of the reinforcing element 2 according to one embodiment is shown. Figure 11 It shows that it has the following characteristics: Figure 10 Detailed view of the cross section of stator 1, which is a reinforcing element. Figure 12A , Figure 12B It shows that it has the following characteristics: Figure 10 A detailed perspective view of the stator 1 in the winding head region, showing the reinforcing element.

[0080] In this further exemplary embodiment, no recess is provided in the material, and only a relatively small free area 18 is provided on one of the long sides of the reinforcing element. However, the free area can form a conduit 22.

[0081] Figure 13 A perspective view of a reinforcing element according to yet another embodiment is shown.

[0082] In this further exemplary embodiment, no recess is provided in the material, but it is consistent with... Figure 10 Unlike other components, the free region 18 is not located on one of the long sides of the reinforcing element 2, but rather on one of the short sides. The free region can also form the conduit 22.

[0083] Figure 14 It shows that it has the following characteristics: Figure 13 A detailed perspective view of the stator with reinforcing elements in the winding head region.

[0084] For clarity, the conductor rod 8 of the radial inner conductor layer and the associated reinforcing element 2 are not shown here, so that the free region 18 of the radial outer reinforcing element 2 facing radially inward can be seen. Therefore, the cooling conduit 22 can be provided in the central region of the stator core, which is particularly susceptible to thermal stress due to heat accumulation.

[0085] Figure 15 It shows that it has the following characteristics: Figure 14 Detailed view of the cross section of stator 1, which is a reinforcing element.

[0086] The figure also shows the positioning of the free region 18 and the resulting conduit 22 on the radially inner side of the outer reinforcing element 2.

[0087] Figure 16 A perspective view of the reinforcing element 2 according to yet another embodiment is shown.

[0088] In this further exemplary embodiment, no recess is provided in the material, and it is consistent with... Figure 11 or Figure 14Unlike other features, there is no free area 18. Instead, an overlapping portion 33 of a reinforcing element extending along the longitudinal short side is provided here. This is specifically provided in addition to the fold portion 17.

[0089] In other embodiments, the overlapping portion 33 may also be located on the long side.

[0090] Figure 17 It shows that it has the following characteristics: Figure 16 A detailed perspective view of the stator with reinforcing elements in the winding head region.

[0091] For clarity, the conductor rod 8 of the radial inner conductor layer and the associated reinforcing element 2 are not shown here, so that the overlapping portion 33 of the radial outer reinforcing element 2 facing the radial inner side can be seen.

[0092] Figure 18 A perspective view of a support device 14 according to one embodiment is shown.

[0093] The support device 14 is designed to be annular and has multiple openings 9 arranged in two concentric rings for the conductor rod to pass through.

[0094] In the embodiment shown here, the path of opening 9 is inclined and corresponds to the intended inclination of conductor rod 8. Therefore, the inclination of the radially inner opening is opposite to that of the radially outer opening. Consequently, the inner surface of the opening is designed such that it continues the inner surface of the corresponding stator slot at the axial end.

[0095] The support device 14 is designed to be attached to a base, such as a machine housing. For this purpose, a plurality of fastening points 34 are provided (seven in this example only), and these fastening points are used for attachment to fastening devices. In other embodiments, various other numbers of fastening points 34 are of course possible.

[0096] Figure 19A and Figure 19B A perspective view of the support device 14, which is designed in two parts, is shown.

[0097] Figure 19A An external support portion 16 with fastening point 34 and radial external opening 9 is shown. Figure 19B An internal support portion 15 with a radial internal opening 9 is shown.

[0098] Furthermore, a centering feature 29 is radially disposed within the opening 9. In the illustrated embodiment, this centering feature is a step designed for centering. In this way, a profile protruding from the support surface on the stator stack is provided, and this profile allows the support device 14 to be aligned centered with the stator core 3.

[0099] Although the invention has been described above entirely based on preferred exemplary embodiments, the invention is not limited thereto and can be modified in various ways.

[0100] List of reference numerals 1. Stator 2. Reinforcing elements 3. Stator core 4. Windings 5. First axial end 6. Second axial end 7. Stator slots 7a. Radial outer stator slot 7b. Radial internal stator slots 8. Conductor rod 8a. Conductor rod in the radial outer layer 8b. Conductor rods in the radial inner layer 9. Opening 10. Radial flux twin-rotor machine 11. Base 12. Winding head 13. Winding head 14. Support device 15. Internal support components 16. External support components 17. Folding section 18. Free Zone 19. Concave 20. Connecting Area 21. Folding part preparation section 22. Catheter 23. A groove with a notch 24. Dual rotor: 25. First Rotor 26. Second rotor 27. Inner edge 28. Edge 29. Characteristics of a calm mind 30. Stator laminate stack 31. Sub-stacks 32. Sub-stacks 33. Overlapping parts 34. Fastening points 35, 36. Connecting pins 37. Connector 38. Concave 39. Insulation layer

Claims

1. A stator (1) for a radial flux dual-rotor machine (10), said stator having: Stator core (3), the stator core having stator lamination stack (30); The winding (4) is placed in the stator core (3) and formed with conductor rods (8) having opposite tilt angles, wherein, The stator lamination stack (30) has stator slots (7) that correspond to the winding path of the winding (4) and extend in the stator core (3), each stator slot being designed to receive a separate conductor bar (8) of the winding (4). as well as At least one support device (14) is arranged to be axially offset from the stator core (3) and the at least one support device is designed to provide torque support for the winding (4) at the axial end (5). Its features are, An additional reinforcing element (2) is provided between the inner contour of the corresponding stator slot (7) and the conductor rod (8) placed in the corresponding stator slot (7) for structurally connecting the stator lamination stack (30) and the conductor rod (8), and The reinforcing element (2) has at least one longitudinal recess (19) that extends longitudinally along the conductor rod (8) within the stator slot (7).

2. The stator (1) according to claim 1, Its features are, The reinforcing element (2) at least partially surrounds the conductor rod (8) in the corresponding stator slot (7).

3. The stator (1) according to claim 1 or 2. Its features are, The reinforcing element (2) comprises an expandable material that is capable of expanding, particularly irreversibly, in a pre-assembled or assembled state, by at least 5% by volume, particularly at least 10% by volume, and preferably at least 50% by volume, for structural connection of the stator lamination stack and the conductor rods within the stator slot (7).

4. The stator (1) according to any one of the preceding claims. Its features are, The reinforcing element (2) has a plastic and / or adhesive material, the plastic having irreversible expansion properties that can be activated by heat.

5. The stator (1) according to any one of the preceding claims. Its features are, The reinforcing element (2) comprises an electrically insulating material.

6. The stator (1) according to any one of the preceding claims. Its features are, The reinforcing element (2) is designed as a single or multiple element, particularly a two-piece element, and has a profile that joins the radial inner and outer surfaces around the conductor rod (8).

7. The stator (1) according to any one of the preceding claims. Its features are, The winding (4) protrudes beyond the stator core (3) at a first axial end (5) and a second axial end (6) opposite to the first axial end (5), wherein the reinforcing element (2) has a protruding portion at the first axial end and / or the second axial end (5, 6), respectively.

8. The stator (1) according to any one of the preceding claims. Its features are, At least one reinforcing element (2) is arranged in each stator slot (7) and located between the conductor rod (8) and the inner contour of the stator slot (7), and in particular the protrusion is located between the conductor rod (8) and the support device (14).

9. The stator (1) according to claim 7 or 8. Its features are, The support device (14) is designed to have an opening (9) for supporting the winding (4) at the first axial end (5), and the protrusion is arranged between the corresponding conductor rod (8) and the corresponding opening (9) of the support device (14) and is configured to structurally connect the support device (14) and the conductor rod (8).

10. The stator (1) according to any one of the preceding claims. Its features are, The at least one longitudinal recess is configured as a groove-shaped or elongated hole-shaped recess (19).

11. The stator (1) according to any one of the preceding claims. Its features are, The reinforcing element (2) comprises a foldable material and is designed to fold around the conductor rod (8) within the stator slot (7), particularly having an overlap (33) or a free region (18), wherein a corresponding folded connecting region (20) of the reinforcing element (2) arranged in the corresponding stator slot (7) extends around the edge (28) of the corresponding conductor rod (8) arranged in the stator slot (7) and / or along the inner edge (27) of the corresponding inner contour of the stator slot (7).

12. The stator (1) according to claim 11, Its features are, The foldable material is designed as a multilayer composite material having at least one insulating layer and / or an expansion layer and / or an adhesive layer, or the foldable material comprises paper, laminates or, in particular, flat products made of plastic, or thin-layer molded parts, profiles or films.

13. The stator (1) according to any one of claims 10 to 12. Its features are, The reinforcing element (2) contains sealing material, and the corresponding stator slot (7) is fluidly sealed by the reinforcing element (2) arranged in the stator slot (7).

14. The stator (1) according to claims 10 and 13. Its features are, The longitudinal recess (19) is designed and arranged as a conduit (22) defined by the stator slot (7) and the conductor bar (8) for axial coolant flow from one of the first axial end and the second axial end (5, 6) of the stator to the other.

15. The stator (1) according to claim 14. Its features are, The axial end of the reinforcing element is folded to form a fold (17), which in particular forms a stop for inserting the reinforcing element (2) into the stator slot, wherein one end of the longitudinal recess (19) is preferably also recessed into the fold (17), particularly in the form of a corresponding recess (38).

16. The stator (1) according to claim 15, Its features are, The winding has an inner conductor layer and an outer conductor layer, wherein the folds (17) of the inner conductor layer and the outer conductor layer are located at opposite axial ends (5, 6) of the stator.

17. The stator (1) according to any one of claims 13 to 15. Its features are, The free region (18) of the reinforcing element (2) formed because the reinforcing element (2) is shorter than the circumference of the conductor rod (8) is designed and arranged as a conduit (22) defined by the stator slot and the conductor rod for axial coolant flow from one of the axial ends (5, 6) of the stator to the other.

18. A radial flux dual-rotor machine (10), particularly a radial flux dual-rotor machine for hub drives, said radial flux dual-rotor machine having: Mechanically fixed base (11); The stator (1) according to any one of the preceding claims, wherein, The support device (14) is supported on the base (11) for torque support of the winding (4); The first rotor (25) is radially arranged within the stator core (3); as well as The second rotor (26) is arranged radially outside the stator core (3).

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