Electric motor and winding process

Abstract

Electric motor, comprising stator and its coil windings (42), wherein the connection of the coil windings (42) can be carried out on an end plate, in particular of the stator laminated core, wherein the interconnection of a first phase is carried out in a first spatial area, the connection of a second phase is carried out in a second room area, the connection of a third phase is carried out in a third room area, where the first spatial region is larger in the radial direction than the second and this in turn than the third, whereby the first has larger radii than the second and this than the third, wherein, when connecting a phase to deflect winding wire (41), the latter is guided around deflection posts (13, 14) which are provided on a larger radius than the radii of the spatial areas, wherein the three spatial areas are provided at the same axial position, characterized in that the coil windings (42) are connected in a star connection, where each phase is assigned a series circuit of three or more individual windings connected in series and the series circuits are brought together at the star point, wherein contact hooks (21, 22, 23, 24) are positively connected to the end plate (10), wherein the winding wire (41) is placed on contact hooks (21, 22, 23, 24), wherein the end plate (10) is formed in one piece as a plastic injection-molded part, wherein the end plate (10) has deflection posts, support posts (11) and / or angles for wire guidance and deflection wherein the support posts (11) serve to guide the wire and provide recesses into which the winding wire (41) is inserted and thus guided, wherein the recesses for wire guidance are located on radii (31, 32, 33), whereby the interconnection is carried out on the respective radii.

Description

[0001] The invention relates to an electric motor and a winding method.

[0002] From JP2003102152A a stator is known which is connected in a delta circuit.

[0003] From EP 1 467 466 A2, a stator is known which is wound by a winding machine. However, according to Fig. 9a at the upper and lower axial end grippers are necessary, which - as in Fig. As shown in Figure 9a, the winding wire must be pulled out radially to allow the stator to rotate further. The wire is placed on the outer circumference.

[0004] From US 5 717 273 A, an insulating end cap of a stator is known as the closest prior art.

[0005] EP 1 420 505 A1 discloses a method for applying a wire along a path on an element of a dynamoelectric machine.

[0006] The invention is therefore based on the object of developing a manufacturing method and an electric motor, wherein a manufacturing machine as simple as possible can be used and few parts are necessary.

[0007] According to the invention, the object is achieved in the electric motor according to the features specified in claim 1 or 6 and in the winding method according to the features specified in claim 5.

[0008] Important features of the invention in the electric motor are that it comprises a stator and its coil windings, wherein the entire wiring of the coil windings can be carried out on an end plate.

[0009] The advantage here is that no pivoting needle is required for winding. The needle only needs to be movable in radial and axial directions and can always remain in the same orientation. It is thus only moved in parallel, so to speak. However, the stator must be mounted so that it can rotate. A lead frame or circuit board is not necessary; instead, the needle performs the wiring by placing the winding wire on the contact hooks on the end plate. This eliminates many connection points and the associated quality risks compared to the state of the art.

[0010] Since no needle folding is necessary, corresponding winding times are eliminated and the overall winding time is shortened.

[0011] The distance to the housing is uncritical due to the wire routing within the winding head. Therefore, no additional surface insulation is required, which would be necessary due to the wire routing.

[0012] Another advantage is the presence of a central component, namely the end plate, which not only determines the tolerances but also provides positive connection interfaces to the laminated core and to electrical connection devices, such as contact hooks. The end plate is connected to the axial end of the stator laminated core, thus serving as the last plate of the laminated core, so to speak.

[0013] In an advantageous embodiment, the end plate is provided at one axial end of the stator core. The advantage here is that the end plate can be arranged as the last plate, thus making the production of the stator very simple and cost-effective.

[0014] In an advantageous embodiment, the end plate is positively connected to the stator laminated core, particularly in the circumferential direction. This has the advantage that elevations on the end plate only need to be arranged in such a way that they engage in recesses in the stator laminated core, particularly on its inner side.

[0015] According to the invention, contact hooks are positively connected to the end plate. This is advantageous because the mechanical connection is easy to establish. The contact hooks are made of metal, and the end plate is made of plastic, particularly with high insulation strength.

[0016] According to the invention, the winding wire is deposited on contact hooks. The advantage of this is that no tilting is required, but only a parallel displacement of the needle.

[0017] According to the invention, the interconnection of a first phase is carried out in a first spatial region, the interconnection of a second phase is carried out in a second spatial region, the first spatial region being larger in the radial direction than the second, in particular having larger radii than the second. In particular, the interconnection of a first phase is carried out in a first spatial region, the interconnection of a second phase is carried out in a second spatial region, the interconnection of a third phase is carried out in a third spatial region, the first spatial region being larger in the radial direction than the second and this in turn than the third, in particular the first has larger radii than the second and this than the third. The advantage here is that the needle deposits the interconnection of the outer region and then creates the interconnection further inward.This means that no wires get in each other’s way and the space is used efficiently.

[0018] Preferably, the spatial areas are arranged inside each imaginary torus. The dimensions, i.e., the maximum diameters of the tori, decrease from the first to the third phase. Ideally, the tori are as thin as possible. This increases the distance between the interconnections and improves the insulation strength.

[0019] In an advantageous embodiment, when connecting a phase, the winding wire is routed around deflection posts that are provided with a larger radius than the radii of the spatial areas. This deflection is therefore not counted as part of the spatial areas of the connection.

[0020] According to the invention, the three spatial areas are arranged at the same axial position. This is advantageous because the motor has the smallest possible axial dimension and is therefore compact.

[0021] According to the invention, the end plate has deflection posts, support posts, and / or angles for wire guidance and deflection. Advantageously, the end plate is formed in one piece, eliminating the need for additional manufacturing effort for the aforementioned functional areas of the end plate, i.e., deflection posts, support posts, and / or angles.

[0022] In an advantageous embodiment, the end plate is formed as a single-piece plastic injection-molded part. This is advantageous because the end plate's production is very simple and cost-effective.

[0023] In an advantageous embodiment, the end plate is held axially to the stator's laminated core by the coil windings. The advantage here is that no retaining devices are required.

[0024] In an advantageous embodiment, the coil windings are connected in a star configuration. This is advantageous because the star configuration can be implemented without a circuit board or other interconnection devices. With the invention, only the last disc of the laminated core needs to be made of plastic and shaped accordingly, so that the interconnection can then be implemented on this insulating part.

[0025] In an advantageous embodiment, each phase is assigned a series circuit of three or more individual windings connected in series, and the series circuits are joined at the star point. The advantage here is that a winding pattern has been found that allows this type of connection to be created in a single winding process without flipping the needle.

[0026] Important features of the winding method are that it is suitable for producing a stator of an electric motor, wherein the stator comprises coil windings belonging to respective phases, wherein the connection of the windings belonging to the first phase is carried out in a first spatial region, then the connection of the windings belonging to a second phase is carried out in a second spatial region, wherein the first spatial region is larger in the radial direction than the second, in particular has larger radii than the second.

[0027] The advantage here is that the spatial areas of the interconnection are arranged from the outside in and are used successively. This allows the needle to move through the spatial areas by simply sliding them parallel to create the interconnections. There is no disruption to the wire during winding.

[0028] In particular, the connection of the windings belonging to the first phase is carried out in a first spatial area, then the connection of the windings belonging to a second phase is carried out in a second spatial area, then the connection of the windings belonging to a third phase is carried out in a third spatial area.

[0029] The advantage here is that the method can be carried out with a three-phase motor, especially even with a synchronous motor.

[0030] In an advantageous embodiment, the winding and connection of all stator windings is achieved by simply moving the needle within a plane, The needle always remains oriented in the same direction, and the stator core is rotated intermittently. The advantage of this machine is that it is mechanically robust, simple, and cost-effective. It only requires one rotary axis and two linear axes. Angular movements or self-rotation of the needle are not required.

[0031] In an advantageous embodiment, the stator windings and the interconnection are manufactured using a winding process as described, with the interconnection being implemented on an end plate. The advantage here is that only one end plate, i.e., one axial area, is required in which the interconnection is implemented.

[0032] The wiring includes not only the electrical connection of coils connected in series, but also the connection with the contact hooks, which can be carried out by welding after winding to create a welded connection.

[0033] Further advantages arise from the subclaims.

[0034] The invention will now be explained in more detail with the aid of illustrations: In winding machines for producing stator windings, the winding wire exits from a so-called needle. Advantageously, with the invention, this needle only needs to be moved parallel in one plane.

[0035] In the Fig. 1 shows an end plate 10 according to the invention, which is attached to an axial end of the stator laminated core. It is positively connected to the stator laminated core. For this purpose, lugs 15 are provided, which engage in a respective axially extending intermediate groove of the stator laminated core. The positive connection thus prevents the end plate from rotating relative to the stator laminated core about the stator axis. In the axial direction, the end plate is pressed on and held by the windings. This means that the end plate is only secured after the stator winding has been wound.

[0036] The main advantage of the invention lies in the fact that a very simple winding device can be used. The winding needle only needs to be movable in the axial and radial directions, i.e., it has two axes. For this purpose, the stator core is rotatable about its axis. Therefore, no grippers are required, and the needle does not need to be designed to be foldable.

[0037] The winding pattern is in Fig. 5. Starting from the contact hook 23, the needle first connects the three serially wound partial windings of the W phase. The deflection takes place at deflection posts and is carried out on the large radius. Thus, the serial connection is also carried out there, namely by winding the windings one after the other in the Fig. 5, i.e., after number 3, number 6, and then number 9. Finally, the wire is placed on the contact hook 24 of the star point. The winding of the three serially connected partial windings of the V phase is then carried out on the middle radius. After that, the corresponding winding of the U phase is carried out.

[0038] Thus, the U-phase can be connected to contact hook 21, the V-phase to contact hook 22, and the W-phase to contact hook 23. The star point can be connected to contact hook 24.

[0039] In Fig. 1 shows the end plate 10, which is constructed in one piece with support post 11, angle bracket 12, and deflection post 13 and deflection post 14. It is preferably manufactured as an injection-molded plastic part.

[0040] The contact hooks 21, 22, 23, 24 are connected to the end plate 10 in a form-fitting manner. In further embodiments according to the invention, a snap-on connection is carried out.

[0041] The deflection posts 13 serve for the essentially straight deflection of the wire. The deflection posts 14 serve for the angular deflection of the winding wire 41, as in the Fig. 4 shown in large detail. The support posts 11 serve as wire guides and provide recesses into which the wire can be inserted and thus guided. This is also evident from Fig. 4, where the winding wire 41 is shown as an example.

[0042] A welded connection is made to the contact hooks. Additionally, stranded wire is inserted and welded to electrically connect the phases.

[0043] In Fig. 4 also shows the coil 42, although the individual winding wires are not shown.

[0044] The end plate is designed to create tolerances for the position of the contact hooks. As a central element, it determines geometric deviations. This allows the end plate to be manufactured as a single part with high precision, resulting in high accuracy in the wire routing and positioning of the contact hooks.

[0045] Each additional part increases the tolerance deviations of the final product.

[0046] The invention therefore only requires two linear axes and one rotational axis.

[0047] In the Fig. 2 shows a top view of the end plate.

[0048] In the Fig. 3 is in addition to the Fig. 2 shows the spatial area of the conductor tracks for interconnection. The first spatial area of interconnection is provided on the large radius 31. The second spatial area of interconnection is provided on the medium radius 32, and the third on the smallest radius 33.

[0049] Fig. Figure 4 is intended to explain the winding pattern in more detail and is therefore only symbolically indicated and shown in a linearized manner. The circumference is therefore the abscissa of the diagram. Wire guide recesses located at radii 31, 32, and 33 are marked with these reference symbols. This indicates that the wiring is carried out at the respective radii.

[0050] Only for the deflection of winding wire is the deflection posts 14 used, which are located on a very large radius that is larger than the radii 31, 32, 33 of the wiring areas.

[0051] An important aspect of the invention is that the introduction of a separate additional space for winding the circuitry, which is spatially separated from the space used for winding the stator coil windings, enables the wiring to be carried out using the winding machine. It is very important that winding wire sections assigned to phases with different potentials do not cross each other and are not routed in parallel, touching each other.

[0052] In further embodiments according to the invention, instead of the three individual windings connected in series in each phase u, v, w shown, more individual windings connected in series are provided. List of reference symbols 10 End plate 11 support posts 12 angles 13 deflection posts, straight 14 deflection posts, angled 15 noses 21 contact hooks 22 contact hooks 23 contact hooks 24 contact hooks 31 large radius 32 medium radius 33 small radius 41 winding wire 42 coil winding U, V, W phase

Claims

[1] Electric motor, comprising stator and its coil windings (42), wherein the connection of the coil windings (42) can be carried out on an end plate, in particular of the stator laminated core, wherein the interconnection of a first phase is carried out in a first spatial area, the connection of a second phase is carried out in a second room area, the connection of a third phase is carried out in a third room area, where the first spatial region is larger in the radial direction than the second and this in turn than the third, whereby the first has larger radii than the second and this than the third, wherein, when connecting a phase to deflect winding wire (41), the latter is guided around deflection posts (13, 14) which are provided on a larger radius than the radii of the spatial areas, wherein the three spatial areas are provided at the same axial position, characterized by , that the coil windings (42) are connected in a star connection, where each phase is assigned a series circuit of three or more individual windings connected in series and the series circuits are brought together at the star point, wherein contact hooks (21, 22, 23, 24) are positively connected to the end plate (10), wherein the winding wire (41) is placed on contact hooks (21, 22, 23, 24), wherein the end plate (10) is formed in one piece as a plastic injection-molded part, wherein the end plate (10) has deflection posts, support posts (11) and / or angles for wire guidance and deflection wherein the support posts (11) serve to guide the wire and provide recesses into which the winding wire (41) is inserted and thus guided, wherein the recesses for wire guidance are located on radii (31, 32, 33), whereby the interconnection is carried out on the respective radii. [2] Electric motor according to claim 1, characterized by that the end plate (10) is provided at one axial end of the stator laminated core. [3] Electric motor according to at least one of the preceding claims, characterized by that the end plate (10) is positively connected to the stator laminated core, in particular in the circumferential direction. [4] Electric motor according to at least one of the preceding claims, characterized by that the end plate (10) is held in the axial direction on the laminated core of the stator by the coil windings (42). [5] Winding method for producing a stator of an electric motor, wherein the stator comprises coil windings (42) belonging to respective phases, wherein the coil windings (42) are connected in a star connection, wherein the connection of the windings belonging to the first phase is carried out in a first spatial area, then the connection of the windings belonging to a second phase is carried out in a second spatial area, then the connection of the windings belonging to a third phase is carried out in a third spatial area, where the first spatial region is larger in the radial direction than the second and this in turn than the third, whereby the first has larger radii than the second and this than the third, wherein the first spatial region is arranged on a large radius (31), the second spatial region is arranged on a medium radius (32), the third spatial region is arranged on a smallest radius (33), wherein the spatial area of the interconnection is spatially separated from the spatial area of the winding of the stator coil windings (42), wherein only for the deflection of winding wire (41) is relied upon deflection posts (13, 14) which are located on a radius which is larger than the large, medium and smallest radius (31, 32, 33), characterized by , that the winding and connection of all stator windings is achieved by simply moving the needle within one plane, where the needle always remains in the same orientation and the stator core is rotated intermittently, wherein the support posts (11) serve to guide the wire and provide recesses into which the winding wire (41) is inserted and thus guided, wherein the recesses for wire guidance are located on radii (31, 32, 33), whereby the interconnection is carried out on the respective radii. [6] Electric motor with stator, characterized bythat the stator windings and the interconnection are produced using a winding method according to the preceding claim, in particular wherein the interconnection is carried out on an end plate (10).

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