Power-dependent component with double-layer wave winding mat

Abstract

Power-dependent component for an electric motor, comprising a cylindrical laminated core with a plurality of radially extending slots and a double-layered wave winding mat inserted into the slots, wherein the double-layered wave winding mat comprises a first mat (1) and an identical second mat (2), each having at least one conductor strand comprising at least one conductor formed into parallel webs (3) and winding heads (4) connecting these, wherein the webs (3) of the first mat (1) and the webs (3) of the second mat (2) are arranged alternately in a first and a second mat plane (E1, E2), wherein the first mat (1) and the second mat (2) are arranged offset from each other in a longitudinal direction (R) perpendicular to the webs (3),that a single-layer starting region (5) is formed only by the first mat (1) and a single-layer ending region (6) is formed only by the second mat (2), and that between the starting region (5) and the ending region (6) the webs (3) of the first mat (1) and the webs (3) of the second mat (2) are arranged in pairs overlapping each other, and that the double-layer winding mat forms a plurality of concentric winding layers (L1 - L5), characterized in that the starting region (5) is arranged in the first of the winding layers (L1) and the ending region (6) is arranged in the last of the winding layers (L5), and that the starting region (5) and the ending region (6) together have a length corresponding to the length of a section of the wave winding mat arranged in one of the winding layers (L1 - L5), and that the starting region (5) in the first of the winding layers (L1) has a first half and the ending region (6) in the last of the winding layers (L5) has a second half covers.

Description

[0001] The invention relates to a double-layered wave winding mat for a stator or rotor, hereinafter referred to as a power-dependent component of an electric motor, a power-dependent component with such a winding mat, an electric motor with such a power-dependent component and a vehicle with such an electric motor.

[0002] Electric motors for vehicles consist of a stator and a rotor as power-generating components. Both of these components are assembled from stacked, insulated laminations, forming a cylindrical core and each core with circumferential slots. These slots are wound with individual conductors, typically flat copper wires or strands of parallel-connected individual conductors, forming the winding of a coil.

[0003] One way to wind these coils is using wave winding technology. This typically involves preparing wave winding mats, which are inserted into the slots and then connected. It is important to insulate all elements of the power-generating component from each other, for example, using foil or paper. Finally, the slots are closed with cover plates and potted with a casting compound for improved durability and insulation.

[0004] Wave winding is advantageous because this type of winding is particularly cost-effective and can be automated. Furthermore, wave winding results in better motor performance compared to a conventional concentrated winding.

[0005] In wave winding, a conductor is repeatedly guided through a slot, spanning a defined number of slots before passing through another slot. The section of the conductor spanning multiple slots is called the winding head, while the section within a single slot is called a conductor segment. The power-generating component of the electric machine or motor is thus completely wrapped with multiple conductors in several winding layers. The winding position of the conductor is its radial position within the respective slot. To maximize efficiency, smooth running, and robustness, it is necessary to precisely adjust the arrangement of the individual conductors relative to each other. This also necessitates, among other things, that individual conductors change their position within a winding layer at a slot transition.

[0006] For wave winding, examples from the prior art include DE 10 2021 130 257 A1 or EP4 213 353 A1.

[0007] To meet specific torque and power requirements with an electric machine, it is necessary to design the machine with a number of turns adapted to its overall length. For a wave-wound mat, the number of turns is determined by the number of conductor sections (webs) within each slot of the machine, as well as the number of conductors connected in parallel within the wave-wound mat, according to the formula w = p * q * z / a, where w is the efficient number of turns of the machine, n is the number of conductor sections per slot, a is the number of conductors connected in parallel within the wave-wound mat, p is the number of pool pairs, and q is the number of slots per magnetic pool and phase (number of holes). Thus, n = 2 * p * q * r, where n is the total number of slots and r is the number of phases of the machine.

[0008] In most known methods for manufacturing a wave winding mat, the individual conductors or conductor strands are wound offset from one another in the same winding direction, interwoven by changing layers. Fitted into slots of the stator or rotor, the conductor sections then all lie in a single winding layer and are therefore considered single-layer wave winding mats.

[0009] Meanwhile, processes have been developed in which two single-layer wave winding mats are simultaneously integrated into one another to create double-layer wave winding mats. This is achieved by winding the conductors or conductor strands in opposite directions and interweaving them via layer changes. Ultimately, this allows the production of wave winding mats that, at only half the length, have the same effective number of turns as a single-layer wave winding mat with the same winding pattern. This results in a significant time saving and thus a reduction in manufacturing costs. The disadvantage is that the number of conductor sections per slot (number of winding layers) is no longer freely selectable, but must always be an even number. Furthermore, the possible combinations of layer count, number of conductors connected in parallel within a wave winding, and number of holes are severely limited.This means that the power and torque requirements for the electric machine usually have to be significantly exceeded, resulting in a higher weight and installation space requirement.

[0010] The object of the invention is to modify a double-layer wave winding mat such that it can be used to realize an odd number of winding layers for a single winding. It is also an object of the invention to provide a power-dependent component with such a wave winding mat, an electric motor with such a power-dependent component, and a vehicle with such an electric motor.

[0011] The problem is solved for a double-layered wave-wound mat, formed from a first mat and an identical second mat, each having at least one conductor strand comprising at least one conductor formed in a repeating winding pattern into parallel webs and connecting winding heads, wherein the webs of the first mat and the webs of the second mat are arranged alternately in a first and a second mat plane, by arranging the first mat and the second mat offset from each other in a longitudinal direction perpendicular to the webs such that a single-layer starting area is formed only by the first mat and a single-layer ending area only by the second mat of the wave-wound mat, and between the starting area and the ending area the webs of the first mat and the webs of the second mat are arranged in pairs overlapping each other.

[0012] Advantageously, the beginning and end sections have the same length.

[0013] Furthermore, the problem for a power-dependent component for an electric motor, comprising a laminated core with a plurality of radially extending slots and a double-layered wave winding mat according to the invention inserted into the slots, forming a plurality of concentric winding layers, is solved by the fact that the starting region is arranged in the first of the winding layers and the end region in the last of the winding layers and the starting region and the end region together have a length that corresponds to the length of a section of the wave winding mat arranged in one of the winding layers.

[0014] According to the invention, the initial area in the first of the winding layers covers a first half and the final area in the last of the winding layers covers a second half.

[0015] It is advantageous that the inputs of at least one conductor of the first mat and of at least one conductor of the second mat are arranged opposite each other in the last of the winding layers, and that the outputs of at least one conductor of the first mat and of at least one conductor of the second mat are arranged opposite each other in the first of the winding layers.

[0016] For an electric motor, the problem is solved by including a power-dependent component according to the invention.

[0017] For a vehicle, the problem is solved by including an electric motor with a power-dependent component according to the invention.

[0018] It is understood that the features mentioned above and those to be explained below can be used not only in the combinations given, but also in other combinations or on their own, without leaving the scope of the present invention.

[0019] The invention is explained in more detail below with reference to exemplary embodiments and the accompanying drawings, which also disclose essential features of the invention. These exemplary embodiments serve only for illustration and are not to be interpreted as limiting. For example, a description of an exemplary embodiment with a plurality of elements or components is not to be interpreted as meaning that all of these elements or components are necessary for implementation. Rather, other exemplary embodiments may also contain alternative elements and components, fewer elements or components, or additional elements or components. Elements or components from different exemplary embodiments may be combined with one another unless otherwise specified. Modifications and variations described for one of the exemplary embodiments may also be applicable to other exemplary embodiments.To avoid repetition, identical or corresponding elements in different figures are designated with the same reference symbols and are not explained multiple times.

[0020] They show: Fig. 1 a wave winding mat with two conductors Fig. 2 Winding diagram for an embodiment of a wave winding mat, Fig. 3. Winding scheme for the wave winding mat according to Fig. 2, inserted into the grooves of the power-dependent component of a and Fig. 4 A schematic representation of the inserted wave winding mat in top view.

[0021] In Fig. Figure 1 shows a double-layered wave winding mat according to the invention, reduced to the representation of only one conductor per mat. The double-layered wave winding mat is formed from a first mat 1 and a second mat 2, which are arranged offset from each other in a longitudinal direction R. The single conductor shown for the first mat 1 is formed by a plurality of webs 3 and the winding heads 4 connecting them and is shown here as a dashed line. The single conductor shown for the second mat 2 is formed by an equal plurality of webs 3 and the winding heads 4 connecting them and is shown here as a solid line. All webs 3 run parallel to each other, with webs adjacent in the longitudinal direction R having a predetermined distance from each other, which corresponds to a multiple of a slot spacing of a power-dependent component of an electric motor for which this wave winding mat was specifically designed.

[0022] The bridges 3 of the first mat 1 represent ladder sections of the ladder U 1, U2, W1, W2, V1, or V2 of the in Fig. 2 shown winding diagrams.

[0023] The bridges 3 of the second mat 1 represent ladder sections U3, U4, W3, W4, V3, or V4 of the ladder in Fig. 2 shown winding diagrams.

[0024] If one imagines the depicted conductor of the first mat 1 as the U1 conductor, then the conductor is inserted into every 6th groove starting from the first groove. The predetermined distance between the adjacent webs 3 of the conductor therefore corresponds to 6 times the groove spacing.

[0025] The ladders have a layer jump in the winding heads 4, so that the webs 3 are alternately arranged in a first mat layer E1 and a second mat layer E2, as in Fig. 2. This is clearly recognizable, for example, from the initial section, which extends over bridge positions 1-24. In the double-layered area between the initial section 5 and the final section 6, where the first mat 1 and the second mat are interwoven, the bridges 3 lie on top of each other in the first mat layer E1 and the second mat layer E2. It was in the Fig. 1, each of which is the bridge 3 located on the top side, i.e., the one lying in the second mat level E2, is shown.

[0026] An advantageous embodiment of a wave-winding mat is shown in Fig. Figure 2 shows a winding diagram. It has 3 x 48 = 144 parallel webs in the beginning and end sections, or pairs of webs in the double-layered section in between. Each of the parallel webs (3) or web pairs is located at a numbered web position. The beginning section (5) and the end section (6) each comprise 48 / 2 = 24 webs (3), making the beginning section (5) and the end section (6) the same length and each one-quarter the length of the double-layered section. They could also be of different lengths, as long as the sum of the webs (3) in the beginning section (5) and the end section (6) equals 48. The wave winding mat shown here has a phase count r = 3, which are designated U, V, and W. It has a hole count q = 2, meaning that two adjacent web positions are occupied for each phase and magnetic pole.

[0027] In Fig. 3 is a winding scheme for the wave winding mat according to Fig. Figure 2 shows the shaft winding mat inserted into the slots of the power-dependent component of an electric motor. The power-dependent component has 48 slots, which accommodate the shaft winding mat with 144 ribs or rib pairs in three complete turns. Due to the radial compression of the shaft winding mat, the ribs 3 of rib positions 1 to 24 are located in the first winding layer L1, the rib pairs of rib positions 25 to 48 are located in the first and second winding layers L2, L3, while the subsequent rib positions are stacked on top of these until, finally, five ribs are inserted into each of the 48 slots, forming a five-layer winding.

[0028] In Fig.Figure 4 shows a schematic top view of the inserted wave-winding mat. The single-layer start section 5, the double-layer section, and the single-layer end section 6 are identifiable by their varying radial thicknesses. The outputs 8 of the conductors of the first mat 1, which alone forms the start section 5, and the outputs 8 of the second mat 2, at the transition to the double-layer section of the wave-winding mat, are arranged radially outwards opposite each other. The inputs 7 of the conductors of the second mat 2, which alone forms the end section 6, and the inputs 7 of the first mat, at the transition to the double-layer section of the wave-winding mat, are arranged radially inwards opposite each other. Reference sign 1 first mat 2 second mat 2 Bridge 4 winding head 5 Initial area 6 End area 7 Entrance of a conductor 8 Exit of a conductor E1 first mat level E2 second mat level L1-L5 first to fifth layer of diapering w effective number of turns z Number of conductor sections per slot = number of winding layers a number of conductors connected in parallel p number of pole pairs number of holes n Total number of slots r number of phases R Longitudinal direction

Claims

[1] Power-dependent component for an electric motor, comprising a cylindrical laminated core with a plurality of radially extending slots and a double-layered wave winding mat inserted into the slots, wherein the double-layered wave winding mat comprises a first mat (1) and an identical second mat (2), each having at least one conductor strand comprising at least one conductor formed into parallel webs (3) and winding heads (4) connecting these, wherein the webs (3) of the first mat (1) and the webs (3) of the second mat (2) are arranged alternately in a first and a second mat plane (E1, E2), wherein the first mat (1) and the second mat (2) are arranged offset from each other in a longitudinal direction (R) perpendicular to the webs (3),that a single-layer starting area (5) is formed only by the first mat (1) and a single-layer ending area (6) is formed only by the second mat (2), and between the starting area (5) and the ending area (6) the webs (3) of the first mat (1) and the webs (3) of the second mat (2) are arranged in pairs overlapping each other, and the double-layer winding mat forming a plurality of concentric winding layers (L1 - L5), , characterized by , that the starting area (5) is located in the first of the winding layers (L1) and the ending area (6) is located in the last of the winding layers (L5) and that the starting area (5) and the ending area (6) together have a length corresponding to the length of a section of the wave winding mat located in one of the winding layers (L1 - L5), and that the starting area (5) covers a first half in the first of the winding layers (L1) and the ending area (6) covers a second half in the last of the winding layers (L5). [2] Performance-dependent component according to claim 1, characterized by , that the inlets (7) of the at least one conductor of the first mat (1) and of the at least one conductor of the second mat (2) are arranged opposite each other in the last of the winding layers (L5) and the outlets (8) of the least one conductor of the first mat (1) and of the at least one conductor of the second mat (2) are arranged opposite each other in the first of the winding layers (L1). [3] Electric motor with a power-dependent component according to one of claims 1 or 2. [4] Vehicle with an electric motor according to claim 3.

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