Conductor segment of a coil arrangement of a rotating electrical machine

Abstract

Method for producing a conductor segment (1) of a coil arrangement (3) of a rotating electrical machine, wherein - an electrically insulating base body (5) with through holes (7) is produced by a primary forming process and - electrical conductors (9) are manufactured which run through the through-holes (7) of the base body (5), the through-holes (7) being filled with an electrically conductive conductor material by electroplating.

Description

[0001] The invention relates to a method for producing a conductor segment of a coil assembly of a rotating electrical machine. Furthermore, the invention relates to a coil assembly of a rotating electrical machine.

[0002] Rotating electrical machines typically comprise an active component (stator or rotor) comprising a laminated core with slots and a coil assembly with coils whose windings run through the slots of the laminated core. Such a coil assembly is also referred to as a coil winding, even if the coil assembly is not always manufactured by winding in the true sense of the word. The coil assembly typically has a relatively complex three-dimensional geometry, making it a complex and time-consuming process to manufacture. Coil assemblies are made from wires and / or conductor bars, for example, which are drawn or inserted into the slots and interconnected after manufacture. Manufacturing involves various steps such as drawing, painting, insulating, fastening, thermal bonding, bending, and / or electrically contacting coil components.Due to the multitude and complexity of the manufacturing steps, a variety of problems and errors can occur during production, such as wire stretching and damage to the coil insulation, inadequate thermal connections between coil components and temperature sinks, or problems with the positioning and contacting of coil components. Furthermore, production facilities are limited in terms of the size and design of the machines that can be manufactured (e.g., their diameter, geometry, and number of teeth), and the manufacturing technology determines a lower limit for the size of the machines that can be manufactured.

[0003] Conductor segments of a coil arrangement from the prior art are known, for example, from DE 11 2015 001 569 T5, DE 10 2014 223 421 A1 and US 2007 / 0 236 090 A1.

[0004] The invention is based on the object of simplifying the manufacture of a coil arrangement of a rotating electrical machine.

[0005] The object is achieved according to the invention by a method having the features of claim 1 and a coil arrangement having the features of claim 14.

[0006] Advantageous embodiments of the invention are the subject of the subclaims.

[0007] In the method according to the invention for producing a conductor segment of a coil arrangement of a rotating electrical machine, an electrically insulating base body with through holes is produced by a primary forming process. Furthermore, electrical conductors extending through the through holes of the base body are manufactured, wherein the through holes are filled with an electrically conductive conductor material.

[0008] The method according to the invention enables a very good thermal connection of the electrical conductors to a thermal sink via the base body. The base body also insulates the conductors from one another, so that advantageously no additional insulation of the conductors from one another is required. The method also offers a high degree of flexibility in the production of the conductors, as the conductors are made from a formless conductor material. Furthermore, the method enables an increase in the fill factor of coils in the coil arrangement, as no cannulas are required for collision-free manipulation of conductors in slots of a laminated core, the through-holes can be completely filled with the conductor material, and the packing density of the conductors can be optimized by suitable cross-sections of the through-holes and their arrangement.Furthermore, the method enables an increase in the robustness of the coil assembly through the base body of a conductor segment and a shortening of the value chain in the manufacture of rotating electrical machines through simplified production of the coil assemblies. In particular, the invention enables the production of coil assemblies for very small motors (micromotors), for which conventional winding techniques are unsuitable due to their space requirements. Furthermore, the invention advantageously enables a flexible and modular construction of a coil assembly comprising multiple conductor segments.

[0009] In one embodiment of the invention, the base body is made of a ceramic material or a composite material containing a ceramic material. Alternatively, the base body is made of a plastic, for example, a polyamide, epoxy resin, or another plastic with high thermal conductivity, or with admixtures of components with high thermal conductivity. These materials are suitable for the production of a base body due to their good processability and their magnetic and thermal properties.

[0010] In a further embodiment of the invention, the base body is manufactured by injection molding, dry pressing, or powder metallurgy. These processes are suitable for manufacturing the base body because they enable simple and cost-effective production of a base body with a predeterminable external and internal geometric structure.

[0011] In a further embodiment of the invention, the conductors are made of copper, aluminum, or an alloy containing copper or aluminum. Due to their good electrical conductivity, these materials are suitable as conductor materials for manufacturing the conductors of a conductor segment.

[0012] In the embodiment according to the invention, the through holes are filled with the conductor material using electroplating. In electroplating, the walls of the through holes are first chemically seeded with an electrically conductive nucleation layer, for example, and then the through holes are electrochemically filled with the conductor material. All of the aforementioned methods advantageously enable the through holes to be completely filled with a conductor material.

[0013] In a further embodiment of the invention, the conductors on at least one side of the base body are manufactured with conductor ends protruding from the through holes and / or with recesses in the conductor ends. This advantageously facilitates interconnection of the conductors to form coils of the coil arrangement. Recesses in the conductor ends can, for example, facilitate contacting the conductors by pressing press-in tips into the recesses using so-called press-fit technology.

[0014] In a further embodiment of the invention, the through-holes run parallel to one another in an axial direction through the base body. For example, the base body has a cross-section that is constant along the axial direction and perpendicular to the axial direction. In particular, the cross-section of the base body can have a substantially polygonal outer contour. These embodiments of the invention take into account that conductors of a coil arrangement are usually guided through straight slots in a laminated core of a rotating electrical machine. The aforementioned embodiments of the invention make it possible to arrange a conductor segment according to the invention in a slot of a laminated core instead of inserting or pulling conductors into the slot in the conventional manner. A cross-section with a suitable outer contour can enable or facilitate a positive and correct insertion of the conductor segment.

[0015] In a further embodiment of the invention, the base body is formed in a ring shape around a ring axis extending in the axial direction. For example, the base body has a hollow cylindrical cylinder section extending around the ring axis, from which segment sections protrude axially. These segment sections are arranged spaced apart from one another along a circle around the ring axis, with each through-hole extending through a segment section and the cylinder section. This embodiment of the invention is aimed at producing a conductor segment that already comprises a large part of a coil arrangement of a rotating electrical machine, wherein, if necessary, only the conductor ends of the conductors need to be connected to form coils.In particular, conductor ends of the conductors of such a conductor segment can be electrically connected to one another at one axial end of the conductor segment, for example by means of connections between two conductor ends produced by primary forming, so that conductors only need to be connected at the other axial end of the conductor segment.

[0016] A coil arrangement according to the invention of a rotating electrical machine comprises at least one conductor segment which is produced by the method according to the invention.

[0017] The following describes exemplary embodiments of the invention, which are illustrated with the drawings. In the drawings: Fig. 1 is a flowchart of a method for producing a conductor segment of a coil arrangement of a rotating electrical machine, Fig. 2 a first embodiment of a base body of a conductor segment, Fig. 3 a first embodiment of a conductor segment, Fig. 4 an active part of a rotating electrical machine with a coil arrangement, Fig. 5 a second embodiment of a conductor segment, Fig. 6 a third embodiment of a conductor segment.

[0018] Corresponding parts are provided with the same reference numerals in the figures.

[0019] Fig. 1 ( Fig. 1) shows a flow chart 100 of the method according to the invention with method steps 101, 102 for producing a conductor segment 1 of a coil arrangement 3 of a rotating electrical machine.

[0020] In a first method step 101, an electrically insulating base body 5 of the conductor segment 1 with through holes 7 is produced.

[0021] The base body 5 is manufactured by a primary forming process. For example, the base body 5 is manufactured by injection molding, dry pressing, or powder metallurgy from a ceramic material, a composite material containing a ceramic material, or a plastic.

[0022] In a second method step 102, electrical conductors 9 are produced which run through the through-holes 7 of the base body 5, wherein the through-holes 7 are filled with an electrically conductive conductor material, for example with copper, aluminum or an alloy containing copper or aluminum.

[0023] The through holes 7 are filled with the conductor material by electroplating. For this purpose, the walls of the through holes 7 are first chemically nucleated with an electrically conductive nucleation layer, for example, and the through holes 7 are then electrochemically filled with the conductor material.

[0024] Fig. 2 ( Fig. 2) and Fig. 3 ( Fig. 3) show a first embodiment of a conductor segment 1 produced by the method according to the invention. Fig. 2 a perspective view of the base body 5 and Fig. 3 shows a perspective view of the complete conductor segment 1 with the conductors 9 running through the holes 7 of the base body 5.

[0025] The through-holes 7 run parallel to one another in an axial direction 11 through the base body 5. The base body 5 has a cross-section that is constant along the axial direction 11 and perpendicular to the axial direction 11, wherein the cross-section has a substantially trapezoidal outer contour 13 with rounded corners and a bulge 15 in a base side.

[0026] The conductors 9 have conductor ends 17 protruding from the through-holes 7 on both sides. The through-holes 7 and the conductors 9 each have a circular cross-section perpendicular to the axial direction 11.

[0027] The Fig. 2 and Fig. The exemplary embodiment of a conductor segment 1 shown in Figure 3 can be modified in several respects compared to other exemplary embodiments. For example, instead of a cross-section with a trapezoidal outer contour 13, the conductor segment 1 can have a cross-section with a different outer contour 13, for example with a rectangular outer contour 13. Alternatively or additionally, the bulge 15 can be omitted. The through-holes 7 and the conductors 9 can also have a different cross-section than in the Fig. 2 and Fig. 3, for example, a cross-section in the shape of a polygon. Furthermore, the conductor ends 17 do not need to protrude from the base body 5. Furthermore, the conductor ends 17 can have recesses 29, see Fig. 6.

[0028] Fig. 4 ( Fig. 4) shows an active part 50 of a rotating electrical machine. For example, the active part 50 is a stator of the machine, and the machine is a brushless DC motor. The active part 50 comprises a laminated core 30 and a coil arrangement 3 according to the invention.

[0029] The coil arrangement 3 comprises several conductor segments 1, each of which is arranged as shown in Fig. 3 shown conductor segment 1 are formed.

[0030] The laminated core 30 is formed in a ring shape around a ring axis 31. The laminated core 30 has a groove 33 for each conductor segment 1 of the coil arrangement 3. The grooves 33 each run parallel to the ring axis 31, are distributed equidistantly along a circle around the ring axis 31, and are each open toward the ring axis 31. Each groove 33 has a constant cross-section along the ring axis 31, perpendicular to the ring axis 31, with a contour corresponding to the outer contour 13 of a conductor segment 1, wherein the bulge 15 of the outer contour 13 corresponds to the opening of the groove 33.

[0031] A conductor segment 1 is positively inserted into each groove 33. The axial directions 11 of the conductor segments 1 are parallel to the ring axis 31, so that all conductors 9 of the conductor segments 1 also run parallel to the ring axis 31. The conductor ends 17 of the conductors 9 are interconnected to form coils of the coil arrangement 3 in a manner not shown here.

[0032] Fig. 5 ( Fig. 5) shows a perspective view of a second embodiment of a conductor segment 1 produced using the method according to the invention. The base body 5 of the conductor segment 1 is formed in a ring shape around a ring axis 31, which defines an axial direction 11. The base body 5 has a hollow cylindrical cylinder section 19 extending around the ring axis 31, from which segment sections 21 protrude axially on one side, which segment sections 21 are arranged equidistantly from one another along a circle around the ring axis 31. Each through-hole 7 through the base body 5 extends in the axial direction 11 through a segment section 21 and the cylinder section 19. The through-holes 7 and the conductors 9 each have a rectangular cross-section perpendicular to the axial direction 11. Apart from the shape and number of the through-holes 7, each segment section 21 is like the one in Fig. 2, i.e., each segment section 21 has a constant cross-section along the axial direction 11 perpendicular to the axial direction 11, wherein the cross-section has a substantially trapezoidal outer contour 13 with rounded corners and a bulge 15 in a base side. The bulges 15 of all segment sections 21 face the ring axis 31. Fig. 5 shown conductor segment 1 can be analogous to Fig. 4 with a corresponding laminated core 30 form an active part 50 of a rotating electrical machine, wherein the segment sections 21 are arranged in the grooves 33 of the laminated core 30 and conductor ends 17 of the conductors 9 are connected to form coils of a coil arrangement 3 of the active part 50.

[0033] Also in Fig. The exemplary embodiment of a conductor segment 1 shown in FIG. 5 can be modified in several respects compared to other exemplary embodiments. For example, instead of a cross-section with a trapezoidal outer contour 13, the segment sections 21 can each have a cross-section with a different outer contour 13, for example, with a rectangular outer contour 13.

[0034] Alternatively or additionally, the recesses 15 can be omitted. The through holes 7 and the conductors 9 can also have a different cross-section than in the Fig. 5 shown embodiment of a conductor segment 1. Furthermore, the conductor ends 17 do not need to protrude from the base body 5. In addition, the conductor ends 17 can have recesses 29, see Fig. 6.

[0035] Fig. 6 ( Fig. 6) shows a sectional view of a third embodiment of a conductor segment 1 in the region of a conductor 9. The conductor ends 17 of the conductors 9 of this embodiment do not protrude from the base body 5 and have recesses 29, for example, to facilitate contacting of the conductors 9 by pressing press-in tips into the recesses 29 using a so-called press-fit technology. Apart from that, the conductor segment 1 is like one of the Fig. 3 or Fig. 5 or one of the modifications of these conductor segments 1 described above. List of reference symbols 1 conductor segment 3 coil arrangement 5 basic bodies 7 through hole 9 ladders 11 axial direction 13 Outer contour 15 bulge 17 Ladder end 19 Cylinder section 21 Segment section 29 Deepening 30 sheet packages 31 Ring axis 33 grooves 50 active part 100 Flowchart 101, 102 Process step

Claims

[1] Method for producing a conductor segment (1) of a coil arrangement (3) of a rotating electrical machine, wherein - an electrically insulating base body (5) with through holes (7) is produced by a primary forming process and - electrical conductors (9) are manufactured which run through the through-holes (7) of the base body (5), the through-holes (7) being filled with an electrically conductive conductor material by electroplating. [2] Method according to claim 1, wherein the base body (5) is made of a ceramic material or a composite material containing a ceramic material. [3] Method according to claim 1, wherein the base body (5) is made of a plastic. [4] Method according to one of the preceding claims, wherein the base body (5) is produced by injection molding, dry pressing or powder metallurgy. [5] Method according to one of the preceding claims, wherein the conductors (9) are made of copper, aluminum or an alloy containing copper or aluminum. [6] Method according to one of the preceding claims, wherein the walls of the through-holes (7) are first chemically nucleated with an electrically conductive nucleation layer and the through-holes (7) are then electrochemically filled with the conductor material. [7] Method according to one of the preceding claims, wherein the conductors (9) are produced on at least one side of the base body (5) with conductor ends (17) projecting from the through-holes (7) and / or with recesses (29) in the conductor ends (17). [8] Conductor segment (1) of a coil arrangement (3) of a rotating electrical machine, wherein - an electrically insulating base body (5) with through holes (7) is produced by a primary forming process and - electrical conductors (9) run through the through-holes (7) of the base body (5), wherein the through-holes (7) are filled with an electrically conductive conductor material by electroplating. [9] Conductor segment according to claim 8, wherein the through-holes (7) run parallel to one another in an axial direction (11) through the base body (5). [10] Conductor segment according to claim 9, wherein the base body (5) has a constant cross-section along the axial direction (11) perpendicular to the axial direction (11). [11] Conductor segment according to claim 10, wherein the cross section of the base body (5) has a substantially polygonal outer contour (13). [12] Conductor segment according to claim 9, wherein the base body (5) is formed annularly around a ring axis (31) extending in the axial direction (11). [13] Conductor segment according to claim 12, wherein the base body (5) has a hollow cylindrical cylinder section (19) extending around the ring axis (31), from which axially projecting segment sections (21) are arranged spaced apart from one another along a circle around the ring axis (31), wherein each through-hole (7) extends through a segment section (21) and the cylinder section (19). [14] Coil arrangement (3) of a rotating electrical machine, the coil arrangement (3) comprising at least one conductor segment (1) which is produced by a method according to one of the preceding claims.

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