Power-generating component of an electric machine

Abstract

Power-generating component of an electric machine, comprising a ring-shaped laminated core (1) with a plurality of radially arranged slots (N1, ..., N36) and a wave winding with at least one first and one second continuous conductor (U1, U2) each guided in a plurality of turns through adjacent slots (N1, ..., N36), which are connected in parallel or series and form a conductor assembly, wherein the conductor assembly has a slot step in which the first conductor (U1) and the second conductor (U2) each span the same number of slots (N1, ..., N36) and in which a change of position is present, and wherein the conductor assembly has at least one slot step change in which the first conductor (U1) and the second conductor (U2) span a different number of slots (N1, ..., N36) span, such that the first conductor (U1) and the second conductor (U2) are interchanged in their arrangement after the slot change, characterized in that . within each circuit of the conductor assembly, at least one groove change is present, that, in the case of a first slot change, the first conductor (U1) spans one more slot (N1, ..., N36) and the second conductor (U2) spans one fewer slot (N1, ..., N36) compared to the slot change, and in the case of a second slot change, the first conductor (U1) spans one fewer slot (N1, ..., N36) compared to the slot change and the second conductor (U2) spans one more slot (N1, ..., N36) compared to the slot change, wherein the second slot change occurs exactly one revolution before or after the first slot change. and that, in the case of a third slot change, the first conductor (U1) skips two more slots (N1, ..., N36) compared to the slot change and the second conductor (U2) skips the same number of slots (N1, ..., N36) compared to the slot change, or the first conductor (U1) skips the same number of slots (N1, ..., N36) compared to the slot change and the second conductor (U2) skips two fewer slots (N1, ..., N36) compared to the slot change.

Description

[0001] The invention relates to a power-generating component of an electric machine, such as a rotor or stator of an electric motor. The power-generating component comprises a ring-shaped laminated core with a plurality of radially arranged slots and a wave winding with at least one first and one second continuous conductor, each guided through adjacent slots in a plurality of turns, which are connected in parallel or series and form a conductor assembly. The conductor assembly has a slot step in which the first conductor and the second conductor each span the same number of slots and in which a change of position occurs. Furthermore, the conductor assembly has at least one slot step change in which the first conductor and the second conductor span a different number of slots, so that the arrangement of the first conductor and the second conductor is reversed after the slot step change.

[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 laminated core, each with a ring of circumferential slots. Conductors, usually copper wires or bundles of conductors, are wound around these slots to form the windings of a coil.

[0003] One way to wind these lamination stacks is wave winding. This typically involves preparing winding mats, inserting them into the slots, and then connecting them. Alternatively, a lamination stack can be wound directly. It is important to insulate all components of the electric motor from each other, for example, with foil or paper. Finally, the slots are closed with cover plates and potted with a casting compound for improved durability and insulation.

[0004] In wave winding, a conductor is guided through a slot, spans a defined number of slots, and is guided through another slot. The section of the conductor spanning multiple slots is called the winding head. The power-generating component of the electric machine or motor is thus completely wrapped with multiple conductors in several layers. The conductor's position 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 at a slot transition.

[0005] DE 10 2014 223 202 A1 discloses a wave winding for a stator, wherein the wave winding for each phase of the machine comprises at least two conductors connected to each other in parallel and / or series, which can be arranged with a predetermined winding pitch in a sequence predetermined for each phase and for each magnetic pole along the circumference of the machine in a number of at least two successive stator slots of each magnetic pole and each phase of the machine. The predetermined sequence of the connected conductors is reversed at at least one position along the circumference of the machine by at least one slot step change, which in DE 10 2014 223 202 A1 is defined as a slot step. The winding heads of the conductors are arcuate and twisted once around their own axis. The problem here is that the conductors, which have a rectangular cross-section, protrude at this point due to this twist.This is particularly noticeable during groove transitions, where the conductors are no longer guided cleanly, and the electric motor loses efficiency and smooth running.

[0006] Further examples from the prior art in this regard can be US 2020 / 0280231A1 or DE 10 2021 204 303 A1, where the winding is formed from so-called hairpins.

[0007] The object of the invention is to provide a power-generating component for an electric motor with a comparatively better efficiency and smoother running.

[0008] The invention achieves the problem for the power-generating component of an electric machine described above by providing at least one slot transition within each revolution of the conductor assembly. This higher number of slot transitions compared to the prior art allows for smoother operation and improved efficiency, as a high degree of electromagnetic symmetry is achieved in this way.

[0009] In an advantageous embodiment, the slot transition is arc-shaped and has a vertex with an S-shaped bend. To achieve the highest possible packing density within the individual slots, conductors with a rectangular cross-section are generally used. This avoids the twisting of the conductor known from the prior art, which leads to a greater space requirement and makes a denser arrangement in the area of ​​the slot transitions more difficult.

[0010] Furthermore, it is advantageous if the groove transitions of the first and second conductors are arranged parallel to each other. This also allows for a particularly dense arrangement of the conductors in the area of ​​the groove transitions.

[0011] In another advantageous embodiment, the slot transitions on the lamination stack are arranged radially adjacent to one another. This makes it possible to arrange the conductors as close together as possible, even in the area of ​​the slot transitions.

[0012] It is an advantage of the invention that, in the case of a first slot change, the first conductor spans one slot less and the second conductor spans one slot more compared to the slot change, and in the case of a second slot change, the first conductor spans one slot more and the second conductor spans one slot less compared to the slot change, wherein the second slot change occurs exactly one revolution before or after the first slot change.

[0013] Furthermore, according to the invention, the first conductor skips two more slots compared to the slot step, and the second conductor skips the same number of slots compared to the slot step, or the first conductor skips the same number of slots compared to the slot step, and the second conductor skips two fewer slots compared to the slot step. Thus, together with a variation in the number of slots spanned by a slot step, a shift in the winding position of the first conductor is achieved (tensification), and the electric motor is acoustically optimized.

[0014] It is particularly advantageous if the third groove transition occurs after the first and / or second groove transition. This winding pattern has proven especially beneficial with regard to smooth running, acoustic optimization, and efficiency.

[0015] Furthermore, it is advantageous if the wave winding has several phases, each composed of one or more conductor bundles. This improves the efficiency of the electric motor by allowing the phases to be switched sequentially. Ideally, the slot transitions within the individual phases are arranged adjacent to each other, as this benefits the smooth running and efficiency of the electric motor.

[0016] The problem is also solved by a previously described wave winding for insertion into a power-generating component of an electric machine. In the form of a winding mat, this can be inserted directly into the rotor or the stator.

[0017] 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.

[0018] 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. They show: Fig. 1 a stator with a conductor and Fig. 2 a schematic representation of a winding scheme.

[0019] The Fig. Figure 1 shows a stator core 1 as a power-generating component with a plurality of slots 2 through which a conductor 3 runs. This conductor is guided through a first slot 2, transitions into a winding head 4 which spans a first number of slots 2, and is guided through a second slot 2 to the opposite side of the core 1, where another winding head 4 is located. In this way, the conductor 3 is guided around the stator in a plurality of turns. The winding head 4 is arc-shaped and, in this embodiment, spans exactly six slots 2. At its apex, it has an S-shaped bend 5, so that adjacent conductors 3 (not shown here) can be arranged close to the conductor 3. In particular, the conductor 3, which has a rectangular cross-section, is not even twisted about its own axis in the region of the winding head 4.Furthermore, a layer change is present at the winding head 4, which corresponds to a change in the radial position of the conductor 3 within the grooves 2. This is effected here by the S-shaped bend 5.

[0020] The Fig.Figure 2 shows a schematic representation of a winding diagram for a wave winding of the laminated core 1, which has exactly thirty-six slots N1, ..., N36. The first row indicates the numbering for the exact designation of the slots N1, ..., N36. The first column specifies a layer L1, ..., L10 within a slot N1, ..., N36. Layer L1 is a position at the bottom of the respective slot N1, ..., N36, and the distance to the bottom increases with increasing reference number. Thus, the path of each conductor 3 through the slots N1, ..., N36 of the laminated core 1 can be precisely traced, with each conductor having a winding head 4 alternately on a first side and a second side of the laminated core 1, spanning a number of slots N1, ..., N36.

[0021] All conductors for a phase are shown in the winding diagram, and the winding of a first conductor U1, a second conductor U2, a third conductor U3, and a fourth conductor U4 is described. The first conductor U1 and the second conductor U2 form a first conductor group, and the third conductor U3 and the fourth conductor U4 form a second conductor group, with all conductors U1, U2, U3, and U4 connected in series or parallel to form a common phase. For clarity, the slots N1, ..., N36 spanned by the four conductors U1, U2, U3, and U4 are not labeled. These slots also contain conductors 3, which can be assigned individually or in one or more conductor groups to one or more other phases. Their arrangement can correspond to or differ from that of the first and second conductor groups.

[0022] The first conductor U1 and the second conductor U2 begin at the first side of the lamination stack 1 and are guided through the first two adjacent slots N1 and N2, respectively. They exit at a second side of the lamination stack 1 and, in a slot jump where the winding heads 4 of the first and second conductors U1 and U2 run parallel, span the six slots N2 to N7 each, so that they are guided through the adjacent slots N7 and N8 to the first side of the lamination stack 1. During this slot jump, a layer change from layer L1 to layer L2 also occurs. On the first side, another slot jump with another layer change then takes place. This continues until all thirty-six slots N1, ..., N36 have been traversed or spanned in this way, so that one revolution has been completed and the pattern continues from the first two slots N1 and N2 into the next layers, here L3 and L4. The power-generating component has ten layers L1, ..., L10 thus performs five cycles, but in general this number is freely selectable and depends on the size of the component, so that a large number of cycles are available.

[0023] Between the thirteenth slot N13 and the twenty-first slot N21, a first slot change occurs during the first circuit, in which the first conductor U1 and the second conductor U2 span a different number of slots N1, ..., N36. The first conductor U1 spans one more slot N1, ..., N36 compared to the initial slot change, i.e., seven, and the second conductor U2 spans one fewer slot N1, ..., N36 compared to the initial slot change, i.e., five, thus exchanging their positions within the conductor assembly. Exactly one circuit later, a second slot change occurs, in which the first conductor U1 spans one fewer slot N1, ..., N36 compared to the initial slot change, and the second conductor U2 spans one more slot N1, ..., N36 compared to the initial slot change. Thus, the first and second conductors U1, U2 exchange their positions within the conductor assembly a second time and return to their original positions.

[0024] In a third rotation, the first and second conductors U1, U2 are offset relative to each other. The first slot change of this third rotation spans seven slots N1, ..., N36, and the second slot change spans five slots N1, ..., N36. A third slot change then occurs, in which the first conductor U1 spans eight slots N1, ..., N36, and the second conductor U2 spans six slots N1, ..., N36 as usual. This is followed by another second slot change and then a first slot change. This shifts the winding layer containing the conductor assembly one slot N1, ..., N36 to the right. This so-called skewing optimizes the acoustic properties of the electric motor equipped with such a power-generating component. The fourth and fifth rotations each involve slot changes spanning six slots N1, ..., N36, with a second slot change occurring in the fourth rotation and a first slot change in the fifth.

[0025] In addition to the first conductor assembly, the power-generating component comprises the second conductor assembly, consisting of the third conductor U3 and the fourth conductor U4. These run in the opposite direction to the second conductor assembly: While the slot transition of the first conductor assembly occurs on the first side of the lamination stack 1, the slot transition of the second conductor assembly is on the opposite second side. The layers L1, ..., L10 also always run in the opposite direction. To maintain the symmetry of the guide outside the third circuit, the third circuit of the second conductor assembly is structured as follows: First, there is a slot transition across six slots N1, ..., N36 and then across seven. This is followed by a third slot transition, in which the third conductor U3 spans six slots N1, ..., N36, while the fourth conductor U4 spans only four slots. Subsequently, there are two more slot transitions, spanning seven and six slots N1, ..., N36, respectively.The following turns correspond to those of the first conductor assembly and are simply reversed. In this embodiment, the power-generating component, wound with both conductor assemblies, thus has two slot transitions in each turn, located at the same or at least adjacent slots N1, ..., N36. Therefore, all slot transitions on the lamination stack 1 are arranged radially adjacent to one another. This can also include the phases not shown. Reference sign 1 sheet metal package 2 Nut 3 conductors 4 winding head 5 S-shaped stroke N1, ..., N36 grooves L1, ... , L10 Location U1 first conductor U2 second conductor U3 third conductor U4 fourth conductor

Claims

[1] Power-generating component of an electric machine, comprising a ring-shaped laminated core (1) with a plurality of radially arranged slots (N1, ..., N36) and a wave winding with at least one first and one second continuous conductor (U1, U2) each guided in a plurality of turns through adjacent slots (N1, ..., N36), which are connected in parallel or series and form a conductor assembly, wherein the conductor assembly has a slot step in which the first conductor (U1) and the second conductor (U2) each span the same number of slots (N1, ..., N36) and in which a change of position is present, and the conductor assembly has at least one slot step change in which the first conductor (U1) and the second conductor (U2) span a different number of slots (N1, ..., N36) so that the first conductor (U1) and the second conductor (U2) are interchanged in their arrangement after the slot step change,characterized by , that within each circuit of the conductor assembly, at least one groove change is present, that, in the case of a first slot change, the first conductor (U1) spans one more slot (N1, ..., N36) and the second conductor (U2) spans one fewer slot (N1, ..., N36) compared to the slot change, and in the case of a second slot change, the first conductor (U1) spans one fewer slot (N1, ..., N36) compared to the slot change and the second conductor (U2) spans one more slot (N1, ..., N36) compared to the slot change, wherein the second slot change occurs exactly one revolution before or after the first slot change. and that, in the case of a third slot change, the first conductor (U1) skips two more slots (N1, ..., N36) compared to the slot change and the second conductor (U2) skips the same number of slots (N1, ..., N36) compared to the slot change, or the first conductor (U1) skips the same number of slots (N1, ..., N36) compared to the slot change and the second conductor (U2) skips two fewer slots (N1, ..., N36) compared to the slot change. [2] Power-generating component according to claim 1, characterized by , that the first conductor (U1) and the second conductor (U2) each comprise an arc-shaped winding head (4) which has a vertex with an S-shaped bend (5). [3] Power-generating component according to claim 2, characterized by , that in a slot step the winding heads (4) of the first and second conductors (U1, U2) are arranged parallel to each other. [4] Power-generating component according to any one of claims 1 to 3, characterized by, that the groove transitions on the sheet metal stack (1) are arranged radially next to each other. [5] Power-generating component according to any one of claims 1 to 4, characterized by that the third groove change occurs one revolution after the first and / or the second groove change. [6] Power-generating component according to any one of claims 1 to 5, characterized by , that the wave winding has several phases, each composed of one or more conductor bundles. [7] Wave winding according to any one of claims 1 to 6 for insertion into a power-generating component of an electric machine.

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