Stator for an electric machine, as well as an electric machine comprising a stator, and method for manufacturing a stator with fixing elements for connecting wires

Abstract

Stator (10), in particular for an electric machine (12), an electric machine (12), and a method for manufacturing a stator (10), with individual, separate stator segments (22), each having a radially outer yoke region (24) with a radially inwardly projecting stator tooth (26), wherein the yoke regions (24) abut each other in the tangential direction (9) and together form a stator ring (14), wherein insulating masks (30) are arranged on the individual stator segments (22), on which single-tooth coils (40) are wound, and at least two single-tooth coils (40) are connected to each other by means of at least one continuous connecting wire (42), wherein the connecting wires (42) are bent radially inward between two adjacent insulating masks (30), and the at least one inwardly bent connecting wire (42) is pressed radially inward by at least one comb-like fixing element (44),wherein the at least one connecting wire (42) is arranged axially between two adjacent prongs (45) of the fixing element (44) in order to limit the freedom of movement of the at least one connecting wire (42).

Description

[0001] The invention relates to a stator for an electrical machine, as well as to an electrical machine comprising a stator, and to a method for producing a stator according to the preamble of the independent claims. State of the art

[0002] DE 10 2007 006 095 A1 discloses a manufacturing method for a stator in which a plurality of individual, separate stator cores are wound before being assembled to form a single stator. For winding, two partial cores are arranged opposite one another on a common axis. A connecting wire between the two partial cores is positioned axially above the partial cores, transverse to the radial interior, when the partial cores are arranged to form the stator. In a subsequent process step, additional coil pairs are joined to form a stator, with the coil pairs being electrically connected to one another. Such stator assembly requires an additional assembly tool for arranging the connecting wires between the partial coils, as well as an additional assembly step for contacting the coil pairs.

[0003] DE 10 2021 202 678 A1 describes a method for manufacturing a stator consisting of several individual stator segments arranged at a tangential distance from one another for winding. The electrical winding is wound with a continuous winding wire, which also connects the spaced-apart stator segments. When radially joining the stator segments, the connecting wires between the stator segments are bent using an auxiliary tool, and the stator segments are mechanically connected to one another. Over the service life of the electrical machine, there is a risk that the connecting wires will be damaged, causing a short circuit, or generating vibration noise. These disadvantages are to be remedied by the design according to the invention. Disclosure of the inventionAdvantages of the invention

[0004] The device according to the invention and the method according to the invention with the features of the independent claims have the advantage that the fixing of the inwardly bent connecting wires by means of the fixing elements according to the invention prevents the connecting wires from causing an electrical short circuit. Furthermore, free swinging of the loops of the connecting wires can be prevented, thereby minimizing vibration noise. Sliding the separate fixing elements onto the connecting wires is independent of the design and / or mounting of a wiring board and can therefore be implemented, for example, even in electric motors with a very small outer diameter. The separate fixing elements can be manufactured very cost-effectively from plastic and do not require any additional installation space in the motor housing.The fixing elements according to the invention can be used for a wide variety of motor topologies and for different winding arrangements without design changes.

[0005] The measures listed in the dependent claims allow for advantageous refinements and improvements of the designs specified in the independent claims. It is particularly advantageous if the fixing elements have individual free prongs extending in the radial direction, with slots formed axially therebetween for receiving the connecting wires. To facilitate the radial assembly of the fixing elements, insertion chamfers are formed on the free tips of the prongs, through which the connecting wires are inserted radially into the funnel-shaped slots.

[0006] It is particularly advantageous if the fixing element is comb-shaped, with the free prongs integrally formed on a comb spine. The free prongs are preferably significantly longer than the axial width of the slots between them, so that the free prongs are designed to be elastically movable in the axial direction. For example, the radial length of the prongs is a multiple of the axial width of the slots or the diameter of the connecting wire. This allows two adjacent free prongs to exert an axial clamping force on the inserted connecting wire to secure it.

[0007] The comb-like fixing element is also particularly suitable for securely fixing two or more connecting wires arranged axially one above the other simultaneously. For this purpose, the fixing element has several slots, into each of which a connecting wire can be radially inserted. Preferably, between two slots, each of which accommodates a connecting wire, there is another slot in which no connecting wire is inserted. This allows the free prongs to deform in the axial direction toward the unoccupied slot in order to apply an axially elastic clamping force to the inserted connecting wires.

[0008] It is particularly advantageous if the slot between two adjacent free prongs is conical. When the connecting wire is inserted into the slot from the inside, the slot tapers radially outward, clamping the round wire cross-section in the wedge-shaped slot. At a given cone angle, the clamping force on the connecting wire can be increased by inserting it into the conical slot.

[0009] By forming locking elements on the fixing element, the radial position of the fixing element relative to the stator ring or the insulating mask can be specified, thereby allowing a desired clamping force for the connecting wires to be determined. The locking elements are formed in the radially outer region of the comb back and can then be supported radially on an inner side of the insulating masks or the yoke area in order to be radially clamped relative to the inserted connecting wires. The locking element can be designed, for example, as an axial extension of the comb back, which, in the assembled state, axially overlaps the yoke ring and / or the contact surfaces of the insulating masks.

[0010] According to a further embodiment, two opposing tangential webs are formed on the fixing element, which serve as locking elements. The tangential webs are located in the axially lower area of ​​the comb spine and, when fully assembled, overlap in the tangential direction with the corresponding contact surfaces of the insulating mask. By forming two tangentially opposing locking elements, tilting of the free prongs relative to the radial direction can be prevented, thus ensuring that the connecting wires remain reliably fixed throughout their entire service life, even in the face of vibration and temperature fluctuations.

[0011] It is particularly advantageous to form insertion bevels on the locking elements so that the locking elements engage more easily with the contact surfaces of the insulation masks and / or the yoke ring when radially pushed onto the connecting wires, which are bent radially inward. The locking connection between the fixing element and the stator ring then forms a positive connection in the radial direction, which reliably applies a radial force to the connecting wires toward the stator center axis over their entire service life. This allows even relatively long connecting wires to be reliably insulated from each other and prevented from self-oscillation.

[0012] The fixing elements can be easily held at their comb backs by a gripper of an assembly tool, before being pushed radially inward onto the connecting wires for assembly. The connecting wires can be bent radially inward at the same time as the fixing element, or the fixing element can be pushed onto the connecting wires after the wires have already been bent radially inward. To enlarge the gripper surfaces, a radial extension can be formed on the comb back, or the comb back can be widened tangentially to allow the gripper to better grip the fixing element. In the fully assembled state, the gripper surfaces do not protrude radially beyond the outer circumference of the stator ring, so that the fully wound stator can be inserted axially into a corresponding stator housing without the fixing elements causing interference.

[0013] The fixing element can be manufactured particularly cost-effectively using plastic injection molding, with several fixing elements preferably being integrally connected to one another via predetermined breaking points during injection molding. The fixing elements can then be easily separated at the predetermined breaking points, significantly reducing the production time per fixing element. The fixing element can be injection-molded without undercuts in a slide-less mold, which significantly reduces its production costs.

[0014] The individual stator segments preferably each have individual insulating masks. For example, a first insulating half-shell is placed axially from above and a second insulating half-shell is placed axially from below on the stator segment. The insulating masks cover the toothed shaft on the one hand and project radially beyond it into the yoke area of ​​the stator segments on the other. In the yoke area, axial extensions are formed on the insulating masks, which extend towards the axially attached electronics unit. The tangential dimension of the axial extensions is smaller than the tangential extent of the yoke areas of the stator segments, so that a tangential gap remains between two adjacent axial extensions, into which the connecting wires are bent radially. The conical slots of the fixing elements lie radially against the connecting wires to hold them reliably in position.This has the advantage that the connecting wires do not protrude radially beyond the circumference of the stator segments.

[0015] The single-tooth coils can be electrically contacted particularly easily using contact elements designed as insulation displacement elements. These insulation displacement elements are inserted axially into the receiving pockets in the axial extensions of the insulating mask. The insulation displacement element cuts into the connecting wire inserted into the receiving pocket. Such an insulation displacement connection (IDC) can be formed on each axial extension or only on certain, selected axial extensions. The IDC elements preferably have contact pins that extend axially away from the pocket. The contact pins can, for example, be inserted directly into corresponding through-holes of an electronic circuit board arranged axially above the insulating masks.The wiring of the single-tooth coils takes place directly on the electronic circuit board, which eliminates the need for a separate wiring board with punched conductor elements.

[0016] The radial outer surface of the axial extensions can be used particularly advantageously for guiding the connecting wires, wherein structured guide elements in the form of grooves or edges can preferably also be formed. After winding a first stator segment, the winding wire is guided radially outwards through a receiving pocket and then guided in the circumferential direction along the outside of the receiving pocket to the adjacent axial extension. The connecting wire completely encloses the adjacent axial extension, in particular on its outside, and is then guided radially inwards to the toothed shaft to form the next single-tooth coil. Between the two adjacent axial extensions, which all or only partially have a receiving pocket, at least one connecting wire is preferably bent radially inwards with a radial indentation and is pressed radially inwards by a corresponding fixing element.The connecting wires can run on the radial outer side of the axial extensions, for example, obliquely to the front side of the stator ring, so that a wire start and a wire end of the respective single-tooth coil do not touch on the outer side of the axial extension.

[0017] The stator is preferably used in an electrical machine, for example, an electronically commutated EC motor. The stator is composed of individual T-shaped stator segments, which are assembled after winding to form the closed stator ring. A rotor is arranged radially inside the stator and mounted in the stator housing. The stator's electrical winding consists of single-tooth coils, which are controlled by the electrical machine's control electronics. The secure fixing of the connecting wires using the fixing elements ensures reliable operation without the risk of short circuits and without disturbing vibration noises.

[0018] The stator according to the invention is preferably manufactured using a pre-cut or click-cut process, in which the individual stator segments initially remain connected to one another in a closed stator ring. During punching of the laminations, the individual T-segments are particularly advantageously connected to the axially adjacent laminations in a single operation by means of punched stacks. The punched stacks reliably hold the individual laminations of the T-segments axially together after they have been separated, so that their tooth shafts can be easily wound using a coil wire. Two or more T-segments can be wound continuously one after the other using an uninterrupted winding wire. For winding the stator segments, they are arranged with a tangential distance from one another so that, for example, a nozzle of a needle winder has sufficient space between the individual stator teeth.The single-tooth coils remain connected to each other by the uninterrupted connecting wire. This has the advantage that fewer coil wire ends need to be connected separately. The stator segments are then radially compressed until they touch each other tangentially. The connecting wires are bent radially inward during this process. To control the single-tooth coils, an electronics board is placed axially over the insulation masks, and the single-tooth coils are electrically connected to the electronics board.

[0019] By manufacturing a stator base body using the so-called "precut" process, the advantages of a freely accessible toothed shaft for winding can be combined with the advantages of a stator yoke, whose individual T-segments leave only a minimal joint gap. In a first step, all of the T-shaped laminations are almost completely separated from a single sheet layer during punching, and then pressed axially back into their original position in a second step. This creates a predetermined breaking point at the separation points between the yoke sections, while the individual T-segments remain connected to one another over their entire circumference as the stator base body. Connecting lugs can be punched out along the separation line in the first yoke sections, which engage tangentially with corresponding recesses in the adjacent yoke sections.During stamping, the individual sheet metal layers are preferably axially connected to one another using stamped stacks. Immediately before winding the tooth shafts, the individual T-shaped stator segments are separated from the stator base body. After winding the tooth shafts, the separated T-segments are reassembled in their original position to form a stator ring, with the dividing lines interlocking exactly tangentially.

[0020] Alternatively, the stator can be manufactured using the click-cut process, in which the dividing lines between two adjacent yoke sections are completely punched through. However, a puzzle-like contour is punched out along the dividing lines, creating a positive fit with respect to the tangential direction. This ensures that the individual stator segments are held together in a form-fitting manner to form a stator ring before winding. For winding, the form-fitting connection is separated using an appropriate separating force, separating the T-segments. After winding, the stator segments are reassembled according to their previous position at the tangential form-fitting connection, with the connecting wires being formed inward with radial indentations. Short description of the drawings

[0021] Embodiments of the invention are illustrated in the drawings and explained in more detail in the following description.

[0022] They show: Fig. 1 a first embodiment of a stator according to the invention, Fig. 2 a detailed view of a fixing element according to Fig. 1, Fig. 3 a section of another embodiment of a stator, and Fig. 4 a further embodiment of fixing elements according to the invention.

[0023] Fig. 1 shows a stator 10 of an electrical machine 12, which is designed, for example, as an electrically commutated motor. The stator 10 is composed of individual T-shaped stator segments 22, each having a radially outer yoke region 24, from which a stator tooth 26 extends inward in the radial direction 7 toward the stator axis 11. Insulating masks 30, onto which an electrical winding 41 is wound, are placed on the individual stator segments 22. The insulating masks 30 have axial extensions 32 that extend in the axial direction 8 as an extension of the yoke regions 24. The axial extensions 32 have guide structures 35 on their radial outer surfaces 34 for connecting wires 42, by means of which the electrical windings 41 of the individual stator teeth 26 are connected to one another. The electrical winding 41 here consists of single-tooth coils 40, the number of which corresponds to the number of stator segments 22.The stator segments 22 are wound individually, with the stator segments 22 being arranged at a tangential distance from one another during winding, so that, for example, sufficient space is available for a nozzle of a needle winder between two adjacent stator teeth 26. At least two single-tooth coils 40 are wound with an uninterrupted, continuous winding wire 39. The winding wire 39 forms a connecting wire 42 between two single-tooth coils 40, which is guided along the radially outer circumference 34 of the axial extensions 32. After the individual stator segments 22 have been wound, they are reassembled radially to form a stator ring 14, so that the yoke regions 24 abut one another at separation points 21 in the circumferential direction 9.In this case, the connecting wire 42 is bent radially inward into a space 33 between two axial extensions 32 as a radial indentation 43, since the tangential distance between two adjacent stator segments 22 decreases after winding. In . Fig. 1, the axial extensions 32 have pockets 36 that accommodate insulation displacement elements 59. The insulation displacement elements 59 here have 8 contact pins 58 in the axial direction, which can, for example, be directly contacted with an electronics board 60 that can be arranged axially above the insulating masks 30. For this purpose, the electronics board 60 has, for example, through-holes 63 into which the contact pins 58 can be axially inserted. After winding a first single-tooth coil 40, the winding wire 39 is guided outwards in the radial direction 7 through the pocket 36 of the insulating mask 30 and then guided in the circumferential direction 9 along the radial outer surface 34 to the radial outer surface 34 of the adjacent axial extension 32.The winding wire 39 is guided radially outward around the adjacent axial extension 32 and through the next intermediate space 33 radially inward to the stator tooth 26, in order to be wound thereafter to the next single-tooth coil 40. After the winding of this single-tooth coil 40 is completed, the winding wire 39 is again guided radially outward through the corresponding pocket 36 and guided in the circumferential direction 9 over the next intermediate space 33 to the next axial extension 32. In this way, in particular, all single-tooth coils 40 can be wound using a single, uninterrupted winding wire 39. Between two adjacent axial extensions 32, the winding wire 39 forms the connecting wire 42, which has the radial indentation 43 in the intermediate space 33 between two adjacent axial extensions 32. The guide elements 35 for the connecting wires 42 are designed here as grooves or edges that run in the circumferential direction 9.The guide elements 35 optionally extend with an inclination towards the axial direction 8 so that the beginning and the end of the winding wire 39 of a specific single-tooth coil 40 do not collide with each other on the radial outer surface 34 of the respective insulating mask 30.

[0024] The stator segments 22 are each composed of axially stacked laminations 15, which are preferably punched out. For example, the individual laminations 15 are connected to one another in the axial direction 8 by means of punched packages. The separation point 21, at which the adjacent yoke regions 24 abut one another in the circumferential direction 9, is produced, for example, using the precut or click-cut process, in which the stator segments 22 are still held together in the circumferential direction 9 as a stator ring 14 after the punching process. This can be achieved by not completely punching through the separation point 21 as a predetermined breaking point in the precut process, and only separating it immediately before winding. In the click-cut process, the individual laminations 15 are completely punched through in the axial direction 8, but are held together as a stator ring 14 by means of a positive connection with respect to the circumferential direction 9, like a puzzle connection.

[0025] After the individual stator segments 22 have been wound, they are reassembled according to their original position, whereby the connecting wire 42 between two adjacent stator segments 22 is pressed radially inwards into the space 33 between two adjacent axial extensions 32 as a radial indentation 43. In Fig. 1, a connecting lug 19 is formed at the separation point 21 on a first yoke region 24, which engages into a corresponding recess 18 in the adjacent yoke region 24. This separation point 21 with the connecting lug 19 and the recess 18 can be formed either by means of a pre-cut process as a predetermined breaking point, or by means of a click-cut process as a positive connection in the tangential direction 9.

[0026] In Fig. 1 schematically shows a fixing element 44 which is pushed onto the inwardly bent connecting wires 42 in the radial direction 7. The connecting wires 42 are fixed in slots 49 between prongs 45 of the fixing element 44 in order to prevent the connecting wires from swinging freely during operation of the electrical machine 12. The fixing element 44 is preferably latched directly onto the insulating masks 30 and / or onto the inside of the stator ring 14 in order to exert a radial force 17 inward onto the connecting wires 42. For example, stop surfaces 31 are formed on the radial inside of the axial extensions 32, against which latching elements 50 of the fixing element 44 are radially supported.

[0027] In Fig. 2 is a fixing element 44 made of Fig. 1 is shown schematically in an enlarged view. The fixing element 44 has a comb-like back 46, from which individual free prongs 45 extend in the radial direction 7 towards the stator axis 11. In the axial direction 8, slots 49 are formed between the prongs 45, which receive the connecting wires 42. The slots 49 preferably have a cone 89 that tapers radially from the inside to the outside. As a result, the connecting wires 42 are clamped in the slots 49 when the centering element 44 is pushed radially on, preferably by means of a slight press fit. Radially inward at the free tips 47, the prongs 45 have insertion chamfers 48 so that the connecting wires 42 can be more easily threaded into the slots 49. In the axial direction 8, a plurality of free prongs 45 - for example five - with a plurality of slots 49 in between - for example four - are formed.If several connecting wires 42 are fixed by a single fixing element 44, at least one unoccupied slot 49 is preferably arranged between two slots 49m occupied by a connecting wire 42, so that the prongs 45 can deform elastically in the axial direction 8 when pushed onto the connecting wires 42. The free prongs 45 form the comb-like fixing element 44 with the comb back 46. Gripping surfaces 87 are preferably formed on the comb back 46, on which gripping surfaces an assembly tool can hold the fixing element 44 during its assembly. In this case, the fixing element 44 can be pushed on radially, for example, together with the radial inward bending of the connecting wires 42. Alternatively, the fixing elements 44 can also be pushed onto the radial indentations 43 of the connecting wires 42 only after the formation of the latter.To ensure that the fixing element 44 remains permanently fixed relative to the stator 10, the fixing element 44 is preferably locked to the insulating masks 30 by means of locking elements 50. For this purpose, two opposing webs 88 are formed in the tangential direction 9 on the axial lower side 86 of the fixing element 44. The free ends of the webs 88 form the locking elements 50, which are elastically deformable upon radial insertion of the fixing element 44 and, in the final position of the fixing element 44, are radially supported on the radially inner stop surfaces 31 of the insulating masks 30. To facilitate the insertion of the locking elements 50, insertion bevels 90 are formed on the free ends 98 of the webs 88, which slide along the axial extensions 32 in the radial direction 7.Optionally, an axial extension 91 can be formed on the fixing element 44 on its axially lower side 86 on the comb back 46, which also serves as a locking element 50 and is supported, for example, radially on the inside of the stator ring 14. An insertion bevel 90 can also be formed on the radial outer side of the axial extension 91 so that the fixing element 44 can be positioned axially overlapping the stator ring 14 - during its assembly preferably at an inclination angle to the starter axis 11. To form a secure clamping connection, a radial length 85 of the free prongs 45 is greater than a diameter 82 of the connecting wire 42 (preferably, the length 85 is a multiple of the diameter 82). The cone 89 is adapted accordingly to the radial length 85 of the free prongs 45 in order to form an optimal clamping connection with the connecting wires 42.

[0028] Fig. 3 shows a stator 10 with a further embodiment of fixing elements 44. Individual tooth coils 40 are arranged on the stator teeth 26 and are continuously connected to one another by means of connecting wires 42. When the stator segments 22 are joined together, the yoke regions 24 of the individual stator segments 22 abut one another in the tangential direction 9; preferably, the connecting lug 19 of one stator segment 22 engages the corresponding recess 18 of the adjacent stator segment 22. The connecting wires 42 are inserted, for example, in the radial direction 7, back into the pockets 36 for the insulation displacement elements 59. In the spaces 33 between the axial extensions 32 of the insulating masks 30, the connecting wires 42 are bent radially inward toward the starter axis 11 as radial indentations 43.The comb-like fixing element 44 is supported radially on the inside of the yoke ring 24, with the axial extension 91 being formed on the comb back 46 on the axially lower side 86. The axial extension 91 is supported as a locking element 50 on the yoke ring 24 in order to exert a radial force 17 inward on the connecting wires 42 inserted into the slots 49. In the exemplary embodiment, a tangential extension 38 of the insulating mask 30 is arranged between the inside of the laminations 15 of the stator ring 14 and the axial extension 91, against which the locking element 50 rests radially. To assemble the fixing element 44, its longitudinal axis is tilted relative to the stator center axis 11 in such a way that the insertion bevel 90 on the axial extension 91 slides more easily axially into the stator ring 14 on the axial end face 23.Due to the clamping effect of the connecting wires 42 inserted into the slots 49, the fixing element 44 is supported radially inward and radially clamped outward relative to the inner side of the stator ring 14. The free prongs 45 again have insertion phases 48 at their free tips 47, at which the connecting wires 42 slide into the slots 49. The further the fixing element 44 is pushed toward them in the radial direction 7, the stronger the axial clamping force of the prongs acts on the connecting wires 42 inserted into the cones 89. In this example, too, two free, unoccupied slots 49 are arranged in the comb-shaped fixing element 44 between the slots 49, each of which is occupied by a connecting wire 42. As a result, the free prongs 45 can be elastically deflected in the axial direction 8 when the clamping forces occur when the connecting wires 42 are inserted.The fixing elements 44 do not extend beyond the outer circumference of the yoke ring 24 in the radial direction 7 so that the wound stator 10 can be inserted into a corresponding stator housing 13 in the axial direction 8. A rotor of the electric machine 12 is then inserted into the interior of the stator 10 along the stator center axis 11. Depending on the winding sequence of the single-tooth coils 40, the connecting wires 42 either run directly between two adjacent single-tooth coils 40, or they are guided on the radial outer side 34 of the axial extensions 32 in the guide elements 35 to the next but one stator tooth 26 or to a stator tooth 26 that is even further away in the tangential direction 9. Therefore, in a specific intermediate space 33 between two axial extensions 32, two or more connecting wires 42 can also be arranged axially one above the other.Preferably, exactly one fixing element 44 is arranged in each intermediate space 33, but at least in each intermediate space 33 in which a connecting wire 42 with a radial indentation 43 is arranged. In this embodiment, SKV elements 59 can also be inserted into the pockets 36, which are electrically connected directly to an electronic circuit board 60, or alternatively can be formed as an integral component of conductor elements of a separate interconnection board.

[0029] In Fig. Figure 4 shows the manufacturing process of a further variant of the fixing elements 44. The fixing elements 44 are manufactured from plastic by injection molding, with a preferred method involving the simultaneous molding of several fixing elements 44 in a single mold. Fig. 4, the fixing elements are connected to one another at their comb backs 46 by means of a predetermined breaking point 84 immediately after removal from the injection molding tool. The individual fixing elements 44 are then separated from one another at the predetermined breaking points 84, for example, by being cut off. In this embodiment, the fixing elements 44 do not have webs 88 in the tangential direction 9, but merely an axial extension 91 on the comb back 46, which is designed as a locking element 50. On the locking element 50, for example, an insertion bevel 90 is again formed, by means of which the axial extension 91 can slide in the axial direction 8 into the inside of the yoke areas 24. Thus, the fixing elements 44 of the Fig. 4 according to the execution according to Fig.3 are clamped radially within the starter ring 14. A radial bulge 83 is formed on the comb back 46 as gripper surfaces 87, on which an assembly tool can hold the fixing element 44. Alternatively, the fixing elements 44 can also be manufactured as separate individual parts by injection molding.

[0030] It should be noted that, with regard to the exemplary embodiments shown in the figures and in the description, a wide variety of combinations of the individual features are possible. For example, the number and geometry of the prongs 45 and the corresponding slots 49 can be adapted to the course of the connecting wires 42. Likewise, the locking elements 50 with the tangential rises 88 and / or the axial extension 91 and the required bevels 90 can be varied accordingly. Likewise, the design of the axial extensions 32 on the insulating masks 30 can be varied and, in particular, can be designed with axial pockets 36 for the SKV elements 59 or, or, can be designed merely as axial extensions 32 with the guide elements 35.The connecting wires 42 can be connected directly to an electronics circuit board 60 via the SKV elements 59, or contacted via other electrical connecting elements, for example, with a wiring board. The individual stator segments 22 are preferably manufactured using the so-called precut or click-cut technique; however, other single-tooth segments can also be used, in which at least two single-tooth coils are wound with a continuous winding wire. The electrically commutated machine 12 is particularly suitable for the rotary drive of components or for the adjustment of parts in motor vehicles, but is not limited to this application. QUOTES CONTAINED IN THE DESCRIPTION

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

[0000] DE 10 2007 006 095 A1

[0002] DE 10 2021 202 678 A1

[0003]

Claims

[1] Stator (10) for an electrical machine (12), with individual, separate stator segments (22), each having a radially outer yoke region (24) with a radially inwardly projecting stator tooth (26), wherein the yoke regions (24) abut one another in the tangential direction (9) and together form a stator ring (14), wherein insulating masks (30) are arranged on the individual stator segments (22), onto which single-tooth coils (40) are wound, and at least two single-tooth coils (40) are connected to one another by means of at least one continuous connecting wire (42), wherein the connecting wires (42) are bent radially inwards between two adjacent insulating masks (30), and the at least one inwardly bent connecting wire (42) is pressed radially inwards by at least one comb-like fixing element (44), wherein the at least one connecting wire (42) is axially arranged between two adjacent prongs (45) of the fixing element (44) is arranged,to limit the freedom of movement of the at least one connecting wire (42). [2] Stator (10) according to claim 1, characterized by that insertion phases (48) for the connecting wires (42) are formed on free tips (47) of the comb-like arranged prongs (45). [3] Stator (10) according to claim 1 or 2, characterized by that the prongs (45) are connected to one another opposite their free tips (47) by means of a comb back (46), and slots (49) are formed in the axial direction (8) between the prongs (45) which receive the at least one connecting wire (42), the length (85) of the prongs (45) being at least as large as the diameter (82) of the connecting wires (42). [4] Stator (10) according to one of the preceding claims, characterized bythat at least two connecting wires (42) engage axially one above the other in exactly one fixing element (44), wherein a free slot (49) without a connecting wire (42) is arranged axially between two connecting wires (42) [5] Stator (10) according to one of the preceding claims, characterized by that the prongs (45) extend with the free tips (47) radially towards the central axis (11) of the stator (10), wherein the slots (49) between adjacent prongs (45) form a cone (89) with respect to the radial direction (7), in which cone in particular the at least one connecting wire (42) is clamped by the radial insertion of the fixing element (44) towards the central axis (11). [6] Stator (10) according to one of the preceding claims, characterized bythat the fixing element (44) is supported via its comb back (46) in the radial direction (7) on the yoke region (24) and / or the insulating masks (30) in order to exert a radial force (17) towards the central axis (11) on the at least one connecting wire (42). [7] Stator (10) according to one of the preceding claims, characterized by that on the fixing element (44) - in particular on an axially lower side (86) of the comb back (46) - two locking elements (50) are formed which are opposite one another in the tangential direction (9) and which, in the inserted state of the fixing element (44), are locked to two adjacent insulating masks (30). [8] Stator (10) according to one of the preceding claims, characterized bythat insertion bevels (90) are formed on the comb back (46) and / or on the locking elements (50), by means of which the fixing element (44) can be positioned radially within corresponding stop surfaces (31) of the insulating masks (30) with the formation of a positive connection with respect to the radial direction (7). [9] Stator (10) according to one of the preceding claims, characterized by that gripper surfaces (87) are formed on the fixing element in the (44) radial region of the comb back (46), on which gripper surfaces an assembly tool can hold the fixing element (44) when it is pushed radially onto the connecting wires (42). [10] Stator (10) according to one of the preceding claims, characterized by that the fixing element (44) is designed as a plastic injection-molded part, wherein in particular a plurality of fixing elements (44) are integrally connected to one another during injection molding and are only then separated at predetermined breaking points (84). [11] Stator (10) according to one of the preceding claims, characterized by that axial extensions (32) are formed on the insulating masks (30), in which pockets (36) for axially receiving insulation displacement connection (SKV) elements (59) are formed, and the connecting wires (42) are guided in the radial direction (7) through the pockets (36) and / or in the tangential direction (9) on a radial outer side (34) around the extensions (32), and between two adjacent axial extensions (32) have radially inwardly bent indentations (43) which are fixed by means of the fixing elements (44). [12] Stator (10) according to one of the preceding claims, characterized by that the connecting wires (42) are electrically contacted by means of SKV elements (59) which have contact pins (58) extending in the axial direction (8) and which can be inserted directly into an electronic circuit board (60) of a control electronics system. [13] Electrical machine (12) with a stator (10) according to one of claims 1 to 12, wherein the stator (10) is composed of individual, T-shaped stator segments (22), and electrical windings (41) of the individual T-shaped stator segments (22) are designed to be electronically commutable by means of control electronics, and a rotor is arranged within the stator (10) which can be driven by the stator (10). [14] Electrical machine (12) according to claim 13, wherein the control electronics is designed as an electronic circuit board (60) - in particular circular or ring-shaped - which is arranged axially directly above the insulating masks (30) and is connected to the single-tooth coils (40) by means of the SKV elements (59) - and in particular the electrical machine has no further circuit board. [15] Method for producing a stator (10), in particular according to one of the preceding claims, characterized by following procedural steps: - Manufacturing individual stator segments (22) and placing insulating masks (30) on the stator segments (22) - Winding the insulating masks (30) with single-tooth coils (40), wherein at least two single-tooth coils (40) are wound through by means of a continuous connecting wire (42), wherein a tangential distance is formed between two adjacent stator segments (22) - Then join the stator segments (22) to form the stator ring (14) - When radially joining the stator segments (22), the at least one connecting wire (42) is bent inwards as a radial indentation (43) between two adjacent insulating masks (30) - Then pushing comb-like fixing elements (44) in the radial direction (7) onto the inwardly bent connecting wires (42), wherein the connecting wires (42) are held in slots (49) between adjacent prongs (45) of the fixing element (44) - preferably in order to avoid vibration of the connecting wires (42) during operation.

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