Winding, component for an electric machine, electric machine, electric axle drive and motor vehicle

Abstract

A winding (110) for a component of an electric machine comprises an annular laminated core with a plurality of slots extending axially through the core for receiving at least one winding strand (111) of the winding (110) in a plurality of radially adjacent winding layers (L1, L2, L3, L4, L5, L6, L7, L8, L9). The winding (110) comprises the winding strand (111), which consists of a first wire (U1) and a second wire (U4). The first wire (U1) forms a first terminal pin (200) and a second first terminal pin (210), the second wire (U4) forming a second terminal pin (205) and a second second terminal pin (215).The wires (U1, U4) are connected to each other via the further first connection pin (210) and the further second connection pin (215), wherein the second wire (U4) is wound exclusively in one winding layer (L1, L9) and wherein the first wire (U1) is wound both in the winding layer (L1, L9) and in at least one further winding layer (L2, L3, L4, L5, L6, L7, L8) of the winding layers.

Description

[0001] The present invention relates to a winding, a component for an electrical machine, an electrical machine, an electric axle drive and a motor vehicle.

[0002] Electrical machines may include components with windings made of, for example, copper wires for conducting electrical energy to generate magnetic fields.

[0003] Against this background, the present invention provides an improved winding, an improved component for an electric machine, an improved electric machine, an improved electric axle drive, and an improved motor vehicle according to the main claims. Advantageous embodiments emerge from the subclaims and the following description.

[0004] The winding presented here advantageously has a compact circuit, which saves axial space.

[0005] A winding is provided for a component of an electrical machine, wherein the component comprises an annular laminated core with a plurality of slots extending axially through the laminated core for receiving at least one winding strand of the winding in a plurality of radially adjacent winding layers. The winding comprises the winding strand, which is composed of a first wire and a second wire. The first wire forms a first terminal pin and another first terminal pin, wherein the second wire forms a second terminal pin and another second terminal pin.The wires are connected to one another via the further first connection pin and the further second connection pin, wherein the second wire is wound exclusively in at least one winding layer and wherein the first wire is wound both in the at least one winding layer and in at least one further winding layer of the winding layers that differs from the at least one winding layer.

[0006] The electrical machine can be, for example, an electric drive or another electrical machine, for example for a vehicle. The electrical machine can comprise various components, such as a rotor and a stator, similar to known electric motors. The component, for example an annular stator, can be designed as a laminated core made up of several individual sheets through which the slots for receiving the winding strand of the winding extend. The slots can be numbered along the circumference of the laminated core so that each slot can be assigned a unique position. A winding strand can be composed of two wires. An electrical voltage can be applied to the winding strand via the connection pins of the winding strand. The winding can, for example, be a stamped and braided winding, a so-called braided winding.The approach presented here can therefore also be understood as braided winding with an odd number of layers and / or as a continuous distributed winding for the electrical machine with an odd number of layers.

[0007] The first connection pin of the first wire and the second connection pin of the second wire can be arranged on the winding layer. The further first connection pin of the first wire can be arranged on the further winding layer. The further second connection pin of the second wire can be arranged on an additional winding layer arranged adjacent to the further winding layer. This winding scheme can advantageously achieve electrical and mechanical symmetry of the winding.

[0008] The first wire can be wound continuously along a first winding direction of the winding. The second wire can be wound continuously along a second winding direction of the winding, which is opposite to the first winding direction. This winding pattern can advantageously achieve electrical and mechanical symmetry of the winding. Furthermore, the winding pattern can enable simple and cost-effective manufacturing.

[0009] The winding layer can correspond to a radially outer winding layer or a radially inner winding layer. If the winding layer corresponds to the radially outer winding layer, the further winding layer can correspond to the radially inner winding layer. If the winding layer corresponds to the radially inner winding layer, the further winding layer can correspond to the radially outer winding layer.

[0010] The first wire can be wound in adjacent radially outer winding layers and in adjacent radially inner winding layers. The second wire can be wound exclusively in adjacent radially outer winding layers or exclusively in adjacent radially inner winding layers. This winding pattern allows for a compact winding head width.

[0011] The majority of the radially adjacent winding layers can correspond to an odd number of winding layers. This allows for high flexibility in electromagnetic designs.

[0012] The winding can comprise a second winding strand, which can be composed of a third wire and a fourth wire. The third wire can form a third connection pin and a further third connection pin. The fourth wire can form a fourth connection pin and a further fourth connection pin. The wires can be connected to one another via the further third connection pin and the further fourth connection pin. The fourth wire can be wound exclusively in the at least one winding layer, and the third wire can be wound both in the at least one winding layer and in the at least one further winding layer of the winding layers. This combination advantageously allows the previously described advantages to be optimally implemented.

[0013] Furthermore, a component for an electrical machine with a variant of the previously presented winding is presented. The component comprises the annular laminated core with a plurality of slots extending axially through the laminated core for receiving at least one winding strand of the winding in a plurality of radially adjacent winding layers. This combination advantageously allows the previously described advantages to be optimally implemented.

[0014] The component can have an additional winding, wherein the slots are designed to accommodate at least one additional winding strand of the additional winding in the plurality of radially adjacent winding layers. According to one embodiment, the component can comprise three windings. The windings can, for example, correspond to three different phases, all of which can be wound according to the same winding pattern. This advantageously allows for the realization of a compact component with optimized interconnection of the individual phases.

[0015] An electrical machine may comprise a component, which may be embodied either as a stator or as a rotor. For example, the component may comprise the winding.

[0016] The electric machine is suitable, for example, for an electric axle drive. Such an electric axle drive for a motor vehicle comprises at least one named electric machine, a transmission device, and a power converter. The power converter can be designed, for example, as an inverter. Using the power converter, an electrical current required to operate the electric machine can be provided. Using the transmission device, a torque provided by the electric machine can be converted into a drive torque for driving at least one wheel of the motor vehicle. The transmission device can have a gearbox for reducing the speed of the electric machine and, optionally, a differential.

[0017] Accordingly, a motor vehicle may comprise a said electric machine and additionally or alternatively a said electric axle drive.

[0018] The invention is explained in more detail by way of example with reference to the accompanying drawings. They show: Fig. 1 a schematic representation of an embodiment of a component for an electrical machine; Fig. 2 a schematic representation of a winding strand of an embodiment of a winding; Fig. 3 shows an illustration of an embodiment of a component; Fig. 4 a tabular representation of a winding scheme for an embodiment of a winding; Fig. 5 a tabular representation of a winding diagram for an embodiment of a winding; and Fig. 6 a representation of an embodiment of a motor vehicle.

[0019] In the following description of preferred embodiments of the present invention, the same or similar reference numerals are used for the elements shown in the various figures and having a similar effect, whereby a repeated description of these elements is omitted.

[0020] Fig. Figure 1 shows a schematic representation of an embodiment of a component 100 for an electrical machine 105. Component 100 is shown in a three-dimensional view. According to the embodiment shown here, component 100 has a winding 110, another winding 120, and an additional winding 130.

[0021] The component 100 is designed merely as an example as a stator and comprises an annular laminated core 115 with a plurality of slots N extending axially through the laminated core 115, of which, for the sake of clarity, only one is provided with the reference symbol N. The slots N are designed to accommodate at least one winding strand 111 of the windings 110, 120, 130 in a plurality of radially adjacent winding layers

[0022] The component 100 has a connection side 112 and a wiring side 113. Connection pins of the windings 110, 120, 130 are arranged on the wiring side 113.

[0023] The stator shown here is designed merely as an example to accommodate a total of three windings 110, 120, 130, with winding 110 being assigned to a U-phase, the further winding 120 being assigned to a W-phase, and the additional winding 130 being assigned to a V-phase. In one exemplary embodiment, each winding 110, 120, 130 is formed with three parallel winding strands 111.

[0024] Each winding strand consists of two wires, each forming two connecting pins. The wires are connected to each other via two of the connecting pins. Fig. 2, the winding strand 111 is described and shown in more detail.

[0025] According to one embodiment, each of the windings 110, 120, 130 has a plurality of connection pins for applying an electrical voltage at the innermost winding layer or at the outermost winding layer. For example, the windings 110, 120, 130 each have 18 connection pins at the innermost winding layer. Furthermore, each of the windings 110, 120, 130 has a plurality of connection pins for connecting wires of individual winding strands. For example, the windings 110, 120, 130 each have 9 connection pins at the outermost winding layer and 9 connection pins at a winding layer adjacent to the outermost winding layer.

[0026] According to one embodiment, first connection pins of three winding strands of the winding 110, first connection pins of three winding strands of the further winding 120, first connection pins of three winding strands of the additional winding 130, second connection pins of the three winding strands of the winding 110, second connection pins of the three winding strands of the further winding 120 and second connection pins of the three winding strands of the additional winding 130 are arranged directly adjacent to one another in the innermost winding layer.

[0027] According to one exemplary embodiment, in the outermost winding layer, further first connection pins of three winding strands of winding 110, further first connection pins of three winding strands of the further winding 120, and further first connection pins of three winding strands of the additional winding 130 are arranged directly adjacent to one another. Furthermore, in a winding layer adjacent to the outermost winding layer, further second connection pins of the three winding strands of winding 110, further second connection pins of the three winding strands of the further winding 120, and further second connection pins of the three winding strands of the additional winding 130 are arranged directly adjacent to one another, in the same grooves N as in the outermost winding layer.

[0028] Fig. Figure 2 shows a schematic representation of a winding strand 111 of an embodiment of a winding. The winding strand 111 is similar to or corresponds to the winding strand of Fig. 1.

[0029] The winding strand 111 is composed of a first wire U1 and a second wire U4, wherein the wires U1, U4 represent connected sections of the winding strand 111. Each of the wires U1, U4 has a plurality of subsections that are guided in a loop-like manner through the grooves of the laminated core.

[0030] The first wire U1 forms a first connection pin 200 and another first connection pin 210. The second wire U4 forms a second connection pin 205 and another second connection pin 215. The wires U1 and U4 are connected to each other via the additional first connection pin 210 and the additional second connection pin 215. An electrical voltage is applied to the winding strand 111 via the connection pins 200 and 205 of the winding strand 111.

[0031] Fig. Figure 3 shows an illustration of an embodiment of a component 100. Component 100 is similar to the component from one of the previously described figures. A section of component 100 is shown in a top view.

[0032] Each winding 110, 120, 130 has three winding strands which are wound continuously in the winding layers L1, L2, L3, L4, L5, L6, L7, L8, L9.

[0033] Fig. Figure 4 shows a tabular representation of a winding pattern 400 for one embodiment of a winding 110 for a component. More specifically, the winding pattern 400 is shown for the three windings 110, 120, and 130.

[0034] The winding pattern 400 shown here is exemplified for a component with a laminated core with, for example, 72 slots and a respective number of holes 3 for accommodating, for example, three windings 110, 120, 130. The positions 1 to 72 of the slots along the circumference of the laminated core are indicated in the top four rows of the table, wherein the top row corresponds to an outer backtwist layer 405, the row arranged below it corresponds to the winding 110, the row arranged below it corresponds to the further winding 120 and the row arranged below it corresponds to the additional winding 130.

[0035] For example, winding 110 is assigned to the U phase, the further winding 120 is assigned to a W phase, and the additional winding 130 is assigned to the V phase only. For example, each winding 110, 120, 130 is formed with a total of three parallel winding strands, each with a plurality of wires U1, U2, U3, U4, U5, U6.

[0036] Nine rows below the position markings correspond, for example, to nine winding layers L1, L2, L3, L4, L5, L6, L7, L8, L9 of the windings 110, 120, 130. In this illustration, the first winding layer L1, shown in the topmost of the ten rows, corresponds, for example, to a radially outermost winding layer. A second winding layer L2 is arranged adjacent to the first winding layer L1, i.e., in the row directly below it in the table shown here. The third winding layer L3 is arranged adjacent to the second winding layer L2, and the fourth winding layer L4 is arranged adjacent to the third winding layer L3.

[0037] The fifth winding layer L5 is arranged adjacent to the fourth winding layer L4 and the sixth winding layer L6 is arranged adjacent to the fifth winding layer L5.

[0038] Adjacent to the sixth winding layer L6 is the seventh winding layer L7, followed by the eighth winding layer L8 and the ninth winding layer L9. The majority of the radially adjacent winding layers L1, L2, L3, L4, L5, L6, L7, L8, and L9 correspond to an odd number of winding layers.

[0039] In the bottom row of the table shown here, inputs and outputs for inserting wires of the windings 110, 120, 130 into the laminated core and for leading wires of the windings 110, 120, 130 out of the laminated core are marked merely as examples.

[0040] In the following Fig. 4 the winding pattern 400 is shown and described in more detail.

[0041] Fig. 5 shows a tabular representation of the winding pattern 400 for an embodiment of a winding 110 for a component. The winding pattern 400 corresponds to the winding pattern shown in Fig. 4, except that connection pins of winding 110 are shown.

[0042] In this exemplary embodiment, the winding 110 comprises, for example, three winding strands. One of the winding strands is composed of the first wire U1 and the second wire U4.

[0043] The first wire U1 forms a first connection pin 200 and a further first connection pin 210. The second wire U4 forms a second connection pin 205 and a further second connection pin 215. The wires U1, U4 are connected to one another via the further first connection pin 210 and the further second connection pin 215. The first connection pin 200 and the second connection pin 205 are each shown by an arrow merely as an example. The direction of the arrow of the first connection pin 200 additionally indicates the position in which the winding strand 111 is inserted into the first winding layer L1, here merely as an example. The direction of the arrow of the second connection pin 205 indicates the position in which the winding strand 111 is led out of the first winding layer L1. The connection pins 200, 205 are therefore arranged on the first winding layer L1.The further first connection pin 210 is located on the ninth winding layer L9, and the further second connection pin 215 is located on the eighth winding layer L8. This is where the first wire U1 and the second wire U4 connect.

[0044] According to the winding scheme 400 shown here, the second wire U4 is wound exclusively in the winding layers L1, L2, L3, L4, L5, L6, L7, L8 and the first wire U1 is wound both in the winding layers L1, L2, L3, L4, L5, L6, L7, L8 and in the radially inner winding layer L9.

[0045] Alternatively, a reversed arrangement is also possible, so that the second wire U4 is wound in the winding layers L1, L2, L3, L4, L5, L6, L7, L8 as well as in the radially inner winding layer L9 and the first wire U1 is wound in the winding layers L1, L2, L3, L4, L5, L6, L7, L8 as well as in the radially inner winding layer L9.

[0046] The first wire U1 is arranged, for example, in an entry groove of the grooves, wherein the entry groove is arranged at an entry position 68 within the first winding layer L1. The first wire U1 is guided from the entry position in a first winding direction R1 into the second winding layer L2. From the second winding layer L2, the first wire U1 is guided back into the first winding layer L1. The first wire U1 is therefore wound continuously in the radially adjacent winding layers L1, L2. Starting from a position 6 within the second winding layer L2, the first wire U1 is guided into the third winding layer L3 and wound continuously in the radially adjacent winding layers L3, L4.This winding pattern 400 is identical for the subsequent winding layers L5, L6, L7, L8, with the first wire U1 being wound continuously in the fifth winding layer L5 and the sixth winding layer L6, as well as in the seventh winding layer L7 and the eighth winding layer L8. Since the majority of the radially adjacent winding layers L1, L2, L3, L4, L5, L6, L7, L8, L9 correspond to an odd number of winding layers, the first wire U1 is wound in the ninth winding layer L9.

[0047] Starting from the radially inner winding layer L9, the first wire U1 is connected to the second wire U4. This is done via the additional connection pins 210, 215. An arrow direction of the additional connection pins 210, 215 indicates the direction in which the first wire U1 is connected to the second wire U4. The second wire U4 is arranged at a position 15 in the eighth winding layer L8 and is wound continuously in the eighth winding layer L8 and the seventh winding layer L7 along a second winding direction R2 of the winding, which is opposite to the first winding direction R1.

[0048] This winding pattern 400 is identical for the subsequent winding layers L6, L5, L4, L3, L2, L1, wherein the second wire U4 is wound continuously in the sixth winding layer L6 and the fifth winding layer L5, the fourth winding layer L4 and the third winding layer L3, as well as in the second winding layer L2 and the first winding layer L1.

[0049] According to one embodiment, winding 110 comprises the second winding strand, which is composed of a third wire U2 and a fourth wire U5. The third winding strand of winding 110 is composed of a fifth wire U3 and a sixth wire U6. The winding strands are wound identically to the first winding strand.

[0050] In the winding scheme 400 described and shown here, the second wire U4 is wound exclusively in the winding layers L1, L2, L3, L4, L5, L6, L7, L8, and the first wire U1 is wound both in the winding layer L9 and in the winding layers L1, L2, L3, L4, L5, L6, L7, L8. Alternatively, the second wire U4 is wound exclusively in the winding layers L2, L3, L4, L5, L6, L7, L8, L9, and the first wire U1 is wound both in the winding layer L1 and in the winding layers L2, L3, L4, L5, L6, L7, L8, L9.

[0051] In other words, the winding layer L9 is wound exclusively from the wires U1, U2, U3 of the winding 110, the wires W1, W2, W3 of the further winding 120, and the wires V1, V2, V3 of the additional winding 130. The winding layers L1, L2, L3, L4, L5, L6, L7, L8 are wound from the wires U1, U2, U3, U4, U5, U6 of the winding 110, the wires W1, W2, W3, W4, W5, W6 of the further winding 120, and the wires V1, V2, V3, V4, V5, V6 of the additional winding 130.

[0052] The winding pattern 400 shown here is intended for a stamped and braided winding 110, with a number of holes Q 3, an odd number of layers L, here for example nine layers in the slot.

[0053] Either only the radially inner winding layer L9 or only the radially outer winding layer L1 is wound in the slot from half of the adjacent wires, for example 9 wires, of for example 18 parallel wires for the entire winding.

[0054] Either only the radially inner winding layer L9 or only the radially outer winding layer L1 in the slot has two radial layers in the winding head on both sides.

[0055] Either 18 connection pins are arranged on the radially inner winding layer L9 and 9 connection pins each on the radially outer winding layer L1 and the second outermost winding layer L2 or 18 connection pins are arranged on the radially outer winding layer L1 and 9 connection pins each on the radially inner winding layer L9 and the second innermost layer L8.

[0056] The approach presented here enables greater flexibility for electromagnetic designs, an odd number of layers, and good manufacturability. Furthermore, a highly symmetrical winding head is possible on both sides, resulting in favorable thermal behavior and good electromagnetic compatibility (EMC). The 400 winding pattern achieves a compact winding head width.

[0057] Fig.6 shows an illustration of an embodiment of a motor vehicle 600. The motor vehicle 600 has an electric axle drive 610 with an electric machine 105, as described, for example, with reference to the preceding figures. Electrical energy for operating the electric machine 105 is provided by a power supply device 602, for example a battery. For example, the power supply device 602 provides a direct current, which is converted into an alternating current, for example a three-phase alternating current, using a power converter 604 of the transmission device and is supplied to the electric machine 105. A shaft driven by the electric machine 105 is coupled directly or using a transmission device 606 to at least one wheel 608 of the motor vehicle 600.Thus, the motor vehicle 600 can be propelled using the electric machine 105. According to one embodiment, the electric axle drive 610 comprises a housing in which the power converter 604, the electric machine 105, and the transmission device 606 are arranged in an integrated manner. Reference symbol 100 components 105 electric machine 110 winding 111 first winding strand of the winding 112 Connection page 113 Wiring page 115 sheet package 120 additional windings 130 additional windings 200 first connection pin 205 second connection pin 210 additional first connection pin 215 additional second connection pin 400 winding pattern 405 outer reverse twist layer 600 motor vehicles 602 Energy supply facility 604 power converters 606 Gearbox device 608 wheels 610 electric axle drive L1 first winding layer L2 second winding layer L3 third winding layer L4 fourth winding layer L5 fifth winding layer L6 sixth winding layer L7 seventh winding layer L8 eighth winding layer L9 ninth winding layer N grooves R1 first winding direction R2 second winding direction U1 first wire of the winding U2 third wire of the winding U3 fifth wire of the winding U4 second wire of the winding U5 fourth wire of the winding U6 sixth wire of the winding W1 first wire of the further winding W2 third wire of the further winding W3 fifth wire of the further winding W4 second wire of the further winding W5 fourth wire of the further winding W6 sixth wire of the further winding V1 first wire of the additional winding V2 third wire of the additional winding V3 fifth wire of the additional winding V4 second wire of the additional winding V5 fourth wire of the additional winding V6 sixth wire of the additional winding

Claims

[1] Winding (110) for a component (100) of an electrical machine (105), wherein the component (100) comprises an annular laminated core (115) with a plurality of slots (N) extending axially through the laminated core (115) for receiving at least one winding strand (111) of the winding (110) in a plurality of radially adjacent winding layers (L1, L2, L3, L4, L5, L6, L7, L8, L9), wherein the winding (110) comprises the winding strand (111), which is composed of a first wire (U1) and a second wire (U4), wherein the first wire (U1) forms a first connection pin (200) and a further first connection pin (210), wherein the second wire (U4) forms a second connection pin (205) and a further second connection pin (215), wherein the wires (U1, U4) are connected to one another via the further first connection pin (210) and the further second connection pin (215), wherein the second wire (U4) is connected exclusively in at least one winding layer (L1,L9) and wherein the first wire (U1) is wound both in the at least one winding layer (L1, L9) and in at least one further winding layer (L2, L3, L4, L5, L6, L7, L8) of the winding layers that differs from the at least one winding layer (L1, L9). [2] Winding (110) according to claim 1, wherein the first connection pin (200) of the first wire (U1) and the second connection pin (205) of the second wire (U4) are arranged on the winding layer (L1, L9), wherein the further first connection pin (210) of the first wire (U1) is arranged on the further winding layer (L2, L3, L4, L5, L6, L7, L8). [3] Winding (110) according to one of the preceding claims, wherein the further second connection pin (215) of the second wire (U4) is arranged on an additional winding layer (L8) arranged adjacent to the further winding layer (L9). [4] Winding (110) according to one of the preceding claims, wherein the first wire (U1) is wound continuously along a first winding direction (R1) of the winding (110) and wherein the second wire (U4) is wound continuously along a second winding direction (R2) of the winding (110) opposite to the first winding direction (R1). [5] Winding (110) according to one of the preceding claims, wherein the winding layer (L1) corresponds to a radially outer winding layer (L1) or a radially inner winding layer (L9). [6] Winding (110) according to one of the preceding claims, wherein the first wire (U1) is wound in adjacent radially outer winding layers (L1, L2) and in adjacent radially inner winding layers (L8, L9). [7] Winding (110) according to one of the preceding claims, wherein the second wire (U4) is wound exclusively in mutually adjacent radially outer winding layers (L1, L2) or exclusively in mutually adjacent radially inner winding layers (L8, L9). [8] Winding (110) according to one of the preceding claims, wherein the plurality of radially adjacent winding layers (L1, L2, L3, L4, L5, L6, L7, L8, L9) corresponds to an odd number of winding layers. [9] Winding (110) according to one of the preceding claims, wherein the winding (110) comprises a second winding strand which is composed of a third wire (U2) and a fourth wire (U5), wherein the third wire (U2) forms a third connection pin and a further third connection pin, wherein the fourth wire (U5) forms a fourth connection pin and a further fourth connection pin, wherein the wires (U2, U5) are connected to one another via the further third connection pin and the further fourth connection pin, wherein the fourth wire (U5) is wound exclusively in the at least one winding layer (L1, L9) and wherein the third wire (U2) is wound both in the at least one winding layer (L1, L9) and in the at least one further winding layer (L2, L3, L4, L5, L6, L7, L8) of the winding layers. [10] Component (100) for an electrical machine (105) with a winding (110) according to one of the preceding claims and with the annular laminated core (115) with the plurality of grooves (N) extending axially through the laminated core (115) for receiving at least one winding strand (111) of the winding (110) in a plurality of radially adjacent winding layers (L1, L2, L3, L4, L5, L6, L7, L8, L9). [11] Component (100) according to claim 10, comprising a further winding (120), wherein the grooves (N) are designed to receive further winding strands of the further winding (120) in the plurality of radially adjacently arranged winding layers (L1, L2, L3, L4, L5, L6, L7, L8, L9). [12] Electrical machine (105) with a component (100) according to one of claims 10 to 11, wherein the component (100) is designed as a stator or as a rotor of the electrical machine (105) and comprises a winding (110) according to one of claims 1 to 9. [13] Electric axle drive (1110) for a motor vehicle (1100) with at least one electric machine (105), a transmission device (1106) and a power converter (1104), characterized by that the electrical machine (105) is designed according to claim 12. [14] Motor vehicle (1100) comprising an electric machine (105) according to claim 12 and / or an electric axle drive (1110) according to claim 13.

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