Electric machine with a displacement body

Abstract

The invention relates to an electric machine (1) with a displacement body (6), wherein the electric machine (1) is designed in the form of a separately excited, directly cooled synchronous machine, comprising a housing in which a rotor (2), comprising winding carriers (3) arranged star-shaped to one another, each having a winding (4), is rotatably mounted, and which is encompassed by a stator, and wherein a winding gap (5) is formed between adjacent windings (4), in which the displacement body (6) with a cooling channel (7) is mounted. According to the invention, the displacer body (6) is designed in multiple parts, consisting of at least two individual parts (12, 21), wherein the individual parts (12, 21) comprise a first module (14) in the form of an intermediate element (11) of the displacer body (6), and / or a second module (15) in the form of a first end region (9) of the displacer body (6) and / or a third module (22) in the form of a second end region (13) of the displacer body (6).

Description

[0001] The invention relates to an electric machine with a displacement body according to the preamble of claim 1.

[0002] It is known to equip electrical machines in the form of separately excited, directly cooled synchronous machines with so-called displacement bodies that do not typically contribute to the machine's power output, but which are used for coolant conveyance. For reasons of achieving the desired power output of the synchronous machine, the displacement bodies are usually designed with a delicate structure, so that the integration, fabrication, and / or sealing of cooling channels is usually very complex or their design is limited. Furthermore, the space formed between the winding heads offers potential for integrating and optimizing additional functions. However, this space is not usable, for example, when inserting one-piece displacement bodies radially.

[0003] German patent application DE 19 62 591 A1 discloses a directly cooled, separately excited synchronous machine with a metal displacement body arranged between winding heads. Cooling channels are formed in the displacement body, which is axially bounded by an end cap. A cooling medium can be collected and discharged via the end caps. The multi-part displacement body comprises several identical components and is longitudinally splayed.

[0004] German patent application DE 10 2012 217 711 A1 describes a directly cooled, separately excited synchronous machine which has a displacement body between its winding heads, which also has cooling channels. A cooling medium can be collected and / or distributed via cooling zones.

[0005] From the patent application DE 10 2021 210 498 A1, a separately excited synchronous machine is known, with a displacement body arranged between winding heads, which has cooling channels.

[0006] The patent applications EP 2 985 885 A1 and EP 3 916 963 A1 each disclose a directly cooled, separately excited synchronous machine with a displacement body arranged between winding heads. The displacement body has cooling channels and is axially delimited by means of an end cap. A cooling medium can be conveyed radially via the end caps.

[0007] From German patent application WO 2010 / 099974 A2, a directly cooled, separately excited synchronous machine is known which has a displacement body comprising cooling channels between its winding heads. The displacement body is axially limited by an end cap. The displacement body is formed as an injection-molded component and injected directly between the winding heads.

[0008] German patent application DE 10 2019 212 391 A1 describes a directly cooled, separately excited synchronous machine which has a displacement body with cooling channels between its winding heads. The displacement body is longitudinally spread.

[0009] The object of the present invention is to provide an improved electric machine with a displacement body.

[0010] This problem is solved according to the invention with an electric machine having a displacement body with the features of claim 1. Advantageous embodiments with expedient and non-trivial further developments of the invention are specified in the respective dependent claims.

[0011] An electrical machine according to the invention with a displacement body, wherein the electrical machine is designed in the form of a separately excited directly cooled synchronous machine, comprises a housing in which a rotor, comprising winding carriers arranged star-shaped to each other, each having a winding, is rotatably received, and which is encompassed by a stator, and wherein a winding gap is formed between adjacent windings, in which the displacement body with a cooling channel is received.

[0012] According to the invention, the displacer body is formed in multiple parts, consisting of at least two individual components, wherein the components comprise a first module in the form of an intermediate element of the displacer body, and / or a second module in the form of a first end region of the displacer body, and / or a third module in the form of a second end region of the displacer body. The advantage of the displacer body formed separately in individual parts lies in the fact that complex geometries can be designed, particularly cost-effectively, such as a cooling channel with several cooling channel sections, or a collection volume for the supply and / or discharge of the coolant. Thus, not only can the cooling channel be technically optimized, but sealing surfaces at coolant transfer points of the end regions can also be improved.Another significant advantage is that windings adjacent to the end areas can also be securely fixed.

[0013] In one embodiment of the electrical machine according to the invention, the individual parts are connected to each other by means of a material-bonded and / or form-bonded and / or force-bonded connection.

[0014] In a further embodiment of the electric machine according to the invention, the cooling channel comprises at least a first cooling channel section and a second cooling channel section, which are separated from each other by means of a web. In other words, to improve the cooling of correspondingly stressed areas of the electric machine, the cooling channel has separately formed cooling channel sections, the geometries of which can be adapted to the cooling requirements. These cooling channel sections are stabilized by the web with respect to possible deformation caused by the forces of the windings acting on the displacer body. Or, put another way, the overall stiffness of the displacer body can be locally adjusted by means of the webs.

[0015] In a further embodiment of the electric machine according to the invention, the first module, which includes the cooling channel, comprises a first sub-module and a second sub-module. The advantage lies in the fact that the cooling channel or cooling channel sections can be manufactured cost-effectively, particularly by injection molding or a similar process.

[0016] In particular, the first and second sub-modules are manufactured as identical parts. To produce the first module, one of the two identical parts is turned over so that it is arranged opposite the other identical part in a mirror image. This reduces manufacturing costs, as only one mold is required to produce the identical part, and the manufacturing costs are further reduced due to the doubled number of identical parts.

[0017] In a further embodiment of the electrical machine according to the invention, the displacer body is spread along its longitudinal extent along a longitudinal axis of the electrical machine. This allows for secure fixation of the windings even at the end regions. If the displacer body were designed as a single-piece component, it could not be axially inserted or mounted into the winding gap due to the spreading at its end regions. Radial mounting would not allow for radial support of the displacer body against a sheet metal section of the electrical machine and would not achieve the necessary displacement effect for fixing the windings.

[0018] The second and / or third modules are advantageously designed to be spread along the longitudinal extent of the displacer body. This locally spread design, particularly at its ends, increases the sealing surface area, thus improving the sealing effect at the coolant transfer point located between the end sections and the cooling channel or its cooling channel sections. The second and third modules are designed to seal against the rotor.

[0019] In a further embodiment of the electrical machine according to the invention, the first module has a shoulder at its end facing the second or third module. This shoulder allows for the simple formation of a stop for the axial joining of the second or third module. Furthermore, the shoulder defines a joining contour for a sealing surface formed between the first module and the second or third module.

[0020] In a further embodiment of the electric machine according to the invention, the second module and / or the third module have a collection basin for conveying the coolant. This allows the cooling channel formed in the first module, or the cooling channel sections, to be supplied with coolant, preferably continuously.

[0021] In a further embodiment of the machine according to the invention, a reinforcement ring of the electric machine is designed to receive the second module, and / or a cover ring of the electric machine is designed to receive the third module. Thus, a cost-effective reinforcement ring and / or a cost-effective cover ring can be manufactured, since complex machining of the reinforcement ring and / or the cover ring is eliminated due to the provision of the necessary geometries in the second module and / or third module.

[0022] The reinforcement ring is generally designed for coolant inlet from the rotor. It can be designed as a second component, in which case it has the necessary channel structure to direct the coolant into the cooling channel. However, this is generally more expensive because different manufacturing processes are required. If it is designed to accommodate the second module, the collection basin, for example, can be manufactured simply and therefore cost-effectively.

[0023] In a further embodiment of the electric machine according to the invention, the third module is configured for coolant outlet, wherein an element surface facing the stator has at least one outlet opening. Thus, the third module, in the form of the second end region, can be manufactured cost-effectively and simply by incorporating the outlet opening and connecting it to the collection basin formed in the third module.

[0024] Further advantages, features, and details of the invention will become apparent from the following description of preferred embodiments and from the drawings. The features and combinations of features mentioned above in the description, as well as those mentioned below in the figure description and / or shown in the figures alone, can be used not only in the combinations specified, but also in other combinations or individually, without departing from the scope of the invention. Identical or functionally equivalent elements are assigned identical reference numerals. The figures show: Fig. 1 in a radial top view an electric machine 1 according to the prior art, Fig. 2 in an axial top view a section of the electrical machine 1 according to the prior art, Fig. 3 in a radial top view a section of an electric machine according to the invention on a second end face designed for coolant removal, Fig. 4 in an axial plan view the electrical machine according to the invention. Fig. 3, Fig. 5 in a radial top view a section of the electrical machine according to the invention. Fig. 3, Fig. 6 in a radial top view a section of the electrical machine according to the invention with a displacer body formed from two individual parts, Fig. 7 in a top view a third module of the displacement body, Fig. 8 in a perspective view, the third module, Fig. 9 in a further perspective view the third module, Fig. 10 in an axial plan view a section of the electrical machine acc. Fig. 6, Fig. 11 in a top view a section of a reinforcement ring of the electrical machine according to the invention, Fig. 12 in a section a section of the reinforcement ring of the electrical machine according to the invention, Fig. 13 in one cut the reinforcing ring in one variant, Fig. 14 in one cut the reinforcing ring acc. Fig. 13 in conjunction with the rotor shaft, Fig. 15 in one cut the reinforcing ring acc. Fig. 13 in conjunction with the rotor shaft and a second module of the displacement body, Fig. 16 in one cut the reinforcing ring acc. Fig. 13 in conjunction with the rotor shaft, a first module and the second module of the displacement body, Fig. 17 in a perspective view the second module of the displacement body, Fig. 18 in a perspective view a section of the first module of the displacement body in one variant, Fig. 19 in an axial plan view a section of the electric machine in a further embodiment with the displacer body in a variant, and Fig. 20 in a front view the displacement body in the further variant.

[0025] An electrical machine 1 according to the prior art, which is designed in the form of a separately excited, directly cooled synchronous machine, has a cylindrical rotor 2 which has windings 4 on its star-shaped winding carriers 3. The winding carriers 3 are enclosed by separately formed laminations 10. The electrical machine 1 is designed according to Fig. 1. The rotor 2 is housed in a casing of the electric machine 1 (not shown in detail) and is enclosed by a stator (also not shown in detail).

[0026] A winding gap 5 is formed between adjacent windings 4, which is filled with the help of a displacer body 6 to fix the windings 4 and to prevent deformation of the windings 4 due to, for example, centrifugal forces.

[0027] Between the windings 4, the winding gap 5 has a gap cross-section SQ, which is larger in the region of end faces 19, 19' of the electrical machine 1, a first end face 19 and a second end face 19' arranged opposite the first end face 19, than in the rest of the winding gap 5. In other words, the displacement body 6 for the preferred fixing of the windings 4 should have a variable cross-section Q.

[0028] In Fig. Figure 2 illustrates the electrical machine 1 according to the prior art in a partial axial plan view. The displacement body 6 of the electrical machine 1 has a cross-section Q that is constant over its entire length. It can be seen that the winding gap 5 between the windings 4 and the displacement body 6 is not completely closed, so that the fixation of the windings 4 is not ensured.

[0029] The displacer body 6, which is exemplified in Fig. Figure 2, shown in an axial top view of the electrical machine 1, has a first end region 9 and a second end region 13 facing away from the first end region 9, as shown, for example, in Fig. 15 is shown.

[0030] The first end region 9, which faces the first end face 19, is designed for the inlet of cooling water flowing through the displacement body 6, which is guided in a cooling channel 7 located in the displacement body 6. The second end region 13, which faces the second end face 19', is designed for the discharge of the cooling water towards the stator.

[0031] The displacer body 6 extends axially along a longitudinal axis 8 of the electric machine 1. An intermediate element 11 of the displacer body 6 is arranged between the first end region 9 and the second end region 13, which has a cross-section Q that is constant along its length.

[0032] In Fig. Figure 3 shows a section of a radial top view of the second end face 19' of the electrical machine 1 according to a first embodiment. The displacer body 6 has a variable cross-section Q, wherein the cross-section Q in its first end region 9 is larger than the cross-section Q of the intermediate element 11. Preferably, the cross-section Q of the displacer body 6 is larger than the cross-section Q of the intermediate element 11 in both its end regions 9, 13. Or, in other words, the displacer body 6 is locally spread along the longitudinal axis 8. The winding gap 5 is completely filled to ensure secure fixation of the windings 4.

[0033] The displacer body 6 of the electric machine 1 according to the invention is multi-part, in particular designed in a modular construction. In other words, the displacer body 6 is not designed as a single-piece component, but consists of at least two individual parts, a first individual part 12 and a second individual part 21, which are preferably manufactured separately from each other. The displacer body 6 could also be manufactured from more than two individual parts 12, 21.

[0034] At this point, the displacement body 6 will be explained in more detail with regard to the possible modular construction and the resulting individual parts 12, 21.

[0035] The intermediate section 11 of the displacement body 6 can be configured as the first module 14. The first end region 9, which is configured for coolant supply, can be configured as the second module 15. The second end region 13, which is configured for coolant discharge and is located opposite the first end region 9, can be configured as the third module 22. In other words, the displacement body 6 consists of at least three modules 14, 15, 22, each of which can be manufactured independently of one another or partially in combination with one of the individual parts 12, 21.

[0036] In Fig. 3 The electrical machine 1 according to the first embodiment has the displacer body 6 designed such that the first module 14 and the third module 22 are formed in one piece together, and the second module 15 is connected by means of a Fig. The displacement body 6 is realized in the form of the reinforcing ring 16 of the electric machine 1. Thus, the displacement body 6 also has at least two individual parts 12, 21. Or in other words, the displacement body 6 is realized in two parts with the help of the first individual part 12 and with the help of the reinforcing ring 16 formed in the form of the second individual part 21.

[0037] In Fig. Figure 4 illustrates the electric machine 1 according to the first embodiment in a section of a radial top view of the second end face 19'. Coolant drainage is preferably effected by means of a cover ring of the electric machine 1, which is not shown in detail. The cover ring can be designed to accommodate the third module 22.

[0038] In Fig. Figure 5 illustrates the electric machine 1 in a radial top view of the second end face 19', with the first module 14 being located between the windings 4, wherein the in Fig. 5 The second module 15, not shown in detail, is formed in one piece with the first module 14.

[0039] In Fig. Figure 6 shows a radial top view of a section of the electrical machine 1 according to the invention, with the displacer body 6 formed from the two individual parts 12 and 21. The first module 14, which together with the second module 15 is designed as the first individual part 12, has the third module 22, which is designed as the second individual part 21.

[0040] The third module 22 is designed for coolant removal from the cooling channel 7 and has two outlet openings 23 on an element surface 28 facing the stator, which are connected to a collecting basin 18' formed in the third module 22.

[0041] The third module 22 is in the Fig. Figures 7 to 9 illustrate different views. It features the collecting basin 18', which is located opposite the cooling channel 7 formed in the first module 14.

[0042] In Fig. 10 is the electrical machine 1 according to the invention. Fig. Figure 6 illustrates an axial top view. The third module 22 is designed to seal the cooling channel 7 in the axial direction. In other words, the third module 22 is closed on its outer surface 24 facing away from the collecting basin 18'.

[0043] The in Fig. The reinforcement ring 16 shown in Figure 11 has a radially extending annular projection 17 arranged opposite the first module 14. This projection includes the collection basin 18 for receiving and conveying the cooling water into the cooling channel 7, as well as a supply channel 25, both of which are formed by a milling process. The supply channel 25 is connected to the collection basin 18 in a way that allows flow through it.

[0044] In Fig. Figure 12 illustrates a cross-section of the reinforcing ring 16 in conjunction with a rotor shaft 20 of the electric machine 1. The coolant, which is preferably in the form of a lubricant, is conveyed by means of the rotor shaft 20 via the collecting basin 18 into the cooling channel 7.

[0045] Similarly, especially to achieve a cost-effective reinforcement ring 16', as described in Fig. As illustrated in Figure 13, the second module 15, which is manufactured independently of the first module 14 and the third module 22, is designed similarly to the third module 22, being configured to supply coolant into the cooling channel 7. Thus, it would be possible to manufacture the first module 14 and the second module 15 together as a single component 12 and to design the third module 22 as the second component 21.

[0046] It could also be that all three modules 14, 15, 22 are manufactured independently of each other, so that in addition to the first single part 12 and the second single part 21, a third single part forms the displacer body 6.

[0047] The in Fig. 14 Reinforcing ring 16' shown in a section, which is a variant of the one shown in accordance with Fig. The reinforced ring 16, which is formed in 11, also has the ring projection 17, which, however, exclusively comprises the supply channel 25. The production of the supply channel 25 according to Fig. The fabrication of the reinforcement ring 16', as described in section 14, is easily accomplished, since a tool for producing the feed channel 25 formed in the ring projection 17 can be positioned starting from an outer ring surface 26 of the reinforcement ring 16', and this tool can produce the feed channel 25 in a single axial line L. Thus, the feed channel 25 can be produced in a cost-effective manner in the form of a bore.

[0048] In an outer ring 27 of the reinforcement ring 16' having the outer ring surface 26, a passage opening 29 is to be provided, which, however, is closed with the help of the second module 15, as shown in the Fig. 15 and Fig. 16 is illustrated.

[0049] In Fig. Figure 14 shows the reinforcing ring 16' in a section in conjunction with the rotor shaft 20. The through-opening 29 is open. Fig. Figure 15 illustrates in a section the reinforcement ring 16' in connection with the rotor shaft 20 and the second module 15, wherein the second module 15 has a closed element surface 28 facing the outer ring 27, which closes the passage opening 29 against outflow of the coolant.

[0050] Especially in Fig. Figure 16, which illustrates a cross-sectional view of the reinforcement ring 16' in conjunction with the rotor shaft 20, the second module 15, and the first module 14, shows that the coolant supply originates from the rotor 20 and flows through the supply channel 25 into the second module 15, and from the second module 15 into the coolant channel 7. The second module 15 has an opening 31 on its further element surface 30, which faces the supply channel 25, to receive the coolant. The coolant can enter the second module 15 through this opening. In this variant of the displacer body 6, the coolant channel 7 has three cooling channel sections: a first cooling channel section 36, a second cooling channel section 37, and a third cooling channel section 38, which are located separately from one another in the first module 14.

[0051] In Fig. Figure 17 illustrates the second module 15 in a perspective view. It has an element base 32 containing the collection basin 18', which is fully enclosed by an element frame 33. In addition to providing the collection basin 18', the element frame serves as a form-fitting connection to the first module 14.

[0052] It can be seen that the second module 15 and the third module 22 have the same basic body, and thus this basic body can be manufactured in large quantities, whereby in a further manufacturing step the openings 23, 31 necessary according to the functions of the modules 15, 22 are to be formed in the basic body.

[0053] In Fig. Figure 18 illustrates a section of the first module 14 in a perspective view, showing the variant with the three cooling channel sections 36, 37, and 38. The first module 14 has a shoulder 35 at its end 34 facing the second module 15, which serves to receive the second module 15 in the form of a plug connection. In other words, the second module 15 can be securely arranged on the first module 14 by means of the shoulder 35, with the first module 14 being at least partially received by the second module 15. Likewise, the first module 14 could also have the shoulder 35 at its end facing the third module 22 (not shown in detail) for this purpose.

[0054] In Fig. Figure 19 shows a section of the electric machine 1 in a further embodiment in an axial plan view. The displacement body 6 has the cooling channel 7 with its cooling channel sections 36, 37, 38.

[0055] For the cost-effective production of the displacement body 6, comprising the cooling channel 7 in several cooling channel sections 36, 37, 38, the first module 14 is divided in one variant along the longitudinal axis 8, in particular designed as a two-part structure, as shown in Fig. Figure 20 illustrates a front view of the first module 14 according to the variant.

[0056] Between the cooling channel sections 36, 37, 38, webs 41 are formed, which provide a support structure for absorbing forces exerted on the displacer body 6 by the windings 4. Insertion of the displacer body 6, in particular in the form of the first component 12, comprising the first module 14 and either the second module 15 or the third module 22, into the winding gap 5 along the longitudinal axis 8 causes forces to be exerted on the first component 12 by displacing the windings 4.

[0057] The effect of the displacer body 6 depends on its overall stiffness. If, for example, it is too flexible and thus has low overall stiffness, its effect is less than if it has high overall stiffness. The webs 41 can increase the overall stiffness because the integrated cooling channel sections 36, 37, 38 can no longer be deformed, or at least not to the same extent. It could also happen that the cooling channels become so compressed that the coolant can no longer flow through the cooling channel sections 36, 37, 38, thus blocking the flow and preventing cooling. This can be avoided with the help of the webs 41.

[0058] It goes without saying that the connection of the individual parts 12, 21, regardless of whether it is a material-bonded, a form-bonded or a force-bonded connection, is designed to create a tight cooling channel 7 or tight cooling channel sections 36, 37, 38. Reference symbol list 1 Electric Machine 2 Rotor 3 winding carriers 4 windings 5 winding gap 6 displacer bodies 7 Cooling channel 8 Longitudinal axis 9 First end area 10 Sheet metal cutting 11 Intermediate element 12 First single part 13 Second end area 14 First Module 15 Second Module 16, 16' Reinforcing ring 17 ring lead 18, 18' Collection basin 19, 19' first front face, second front face 20 Rotor shaft 21 Second individual part 22 Third Module 23 Exit opening 24 outdoor area 25 Supply channel 26 Outer ring area 27 Outer ring 28 element area 29 Passage opening 30 Additional element area 31 element opening 32 Element floor 33 element frames 34 End paragraph 35 36 First cooling channel section 37 Second cooling channel section 38 Third cooling channel section 39 First sub-module 40 Second sub-module 41 Bridge L line SQ gap cross-section Q cross-section QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] DE 19 62 591 A1

[0003] DE 10 2012 217 711 A1

[0004] DE 10 2021 210 498 A1

[0005] EP 2 985 885 A1

[0006] EP 3 916 963 A1

[0006] WO 2010 / 099974 A2

[0007] DE 10 2019 212 391 A1

[0008]

Claims

[1] Electrical machine (1) with a displacement body (6), wherein the electrical machine (1) is designed in the form of a separately excited, directly cooled synchronous machine, comprising a housing in which a rotor (2), comprising winding supports (3) arranged in a star shape relative to one another, each having a winding (4), is rotatably received, and which is surrounded by a stator, and wherein a winding gap (5) is formed between adjacent windings (4), in which the displacement body (6) is received with a cooling channel (7), characterized byin that the displacement body (6) is designed in several parts, consisting of at least two individual parts (12, 21), wherein the individual parts (12, 21) have a first module (14) in the form of an intermediate element (11) of the displacement body (6), and / or a second module (15) in the form of a first end region (9) of the displacement body (6) and / or a third module (22) in the form of a second end region (13) of the displacement body (6). [2] Electrical machine (1) according to claim 1, characterized by that the individual parts (12, 21) are connected to one another by means of a material-locking and / or form-locking and / or force-locking connection [3] Electrical machine (1) according to claim 1 or 2, characterized by that the cooling channel (7) has at least a first cooling channel section (36) and a second cooling channel section (37), which are formed separately from one another by means of a web (41). [4] Electrical machine (1) according to claim 3, characterized by that the first module (14) having the cooling channel (7) has a first sub-module (39) and a second sub-module (40). [5] Electrical machine (1) according to claim 4, characterized by that the first sub-module (39) and the second sub-module (40) are manufactured in the form of an identical part. [6] Electrical machine according to one of the preceding claims, characterized by that the displacement body (6) is designed to be spread along its longitudinal extent along a longitudinal axis (8) of the electrical machine (1). [7] Electrical machine (1) according to claim 6, characterized by that the second module (15) and / or the third module (22) are spread out along the longitudinal extent of the displacement body (6). [8] Electrical machine (1) according to one of the preceding claims, characterized bythat the first module (14) has a shoulder (35) at its end (34) facing the second module (15) or the third module (22). [9] Electrical machine (1) according to one of the preceding claims, characterized by that the second module (15) and / or the third module (22) each have a collecting basin (18') for forwarding the coolant. [10] Electrical machine (1) according to one of the preceding claims, characterized by that a reinforcement ring (16') of the electrical machine (1) is designed to receive the second module (15), and / or that a cover ring of the electrical machine (1) is designed to receive the third module (22). [11] Electrical machine (1) according to one of the preceding claims, characterized by that the third module (22) is designed for coolant outlet, wherein an element surface (28) facing the stator has at least one outlet opening (23).

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