Device for conducting a coolant, stator, vehicle and method for producing a stator

Abstract

A device for conducting a coolant is proposed. The device comprises a guide structure comprising a cavity for conducting the coolant and a plurality of webs. The guide structure is partially circumferential and designed for arrangement on an end face of a stator. The plurality of webs extends radially inward from the guide structure by at least 1 cm. One web of the plurality of webs has a tapered shape. The device is formed as a single piece.

Description

[0001] The present invention relates to a device for conducting a coolant, a stator, a vehicle and a method for manufacturing a stator.

[0002] In an electrical machine, the current flow causes high heat losses in the stator windings, which must be dissipated. This dissipation can be achieved, for example, using coolants such as oil or water. These coolants are advantageously applied specifically to the areas of the stator that heat up the most, such as the winding heads. For this purpose, a dispensing device for the coolant can be adapted to the dimensions of the winding heads and their position in a stator housing, for example so that the coolant is applied directly and largely evenly to the winding heads. Such a dispensing device can be designed like a shower head that is directed onto the winding heads. For example, an oil guide ring can be attached to the stator laminated core as part of the shower head after the stator has been manufactured. The use of additional components such asan oil guide ring, but increases the complexity of a manufacturing process and / or costs of manufacturing.

[0003] Against this background, it is an object of the present invention to provide improved cooling of a stator.

[0004] The object of the invention is achieved by a device for conducting a coolant, a stator, a vehicle, and a method for producing a stator according to the independent claims. Further aspects and developments of the invention are set forth in the dependent claims, the following description, and the figures.

[0005] According to a first aspect of the invention, a device for conducting a coolant is proposed. The device comprises a guide structure comprising a cavity for conducting the coolant and a plurality of webs. The guide structure is partially circumferential and designed for arrangement on an end face of a stator.

[0006] The plurality of webs extends radially inwards from the conducting structure by at least 1 cm. One web of the plurality of webs has a tapered shape. The device is formed in one piece. The combination of the conducting structure with the plurality of webs makes it possible to simplify the design of a stator. In particular, the device can be used both for conducting a coolant and for supporting a winding. The plurality of webs can in particular support a winding of the stator. This makes it possible to avoid a complex manufacturing process involving the arrangement of a cooling device after a winding of a stator. In particular, the device for conducting the coolant can already be arranged during the manufacture of the stator. The plurality of webs of the device can allow an arrangement on an end face of a stator.By designing the conductive structure for placement on an end face of a stator, the conductive structure can be arranged during stator production, for example, before the windings are inserted. This avoids the need to arrange a cooling device, e.g., on a radial outer side of the stator, especially after stator production.

[0007] In one embodiment, the guide structure may further comprise an opening for the coolant outlet at an axial end of the guide structure. Through the opening at an axial end, a coolant can be discharged near an area with elevated temperature development, for example, near a winding head. This can improve cooling of the stator.

[0008] In one embodiment, the opening can be formed in a raised portion of the conductive structure. The raised portion allows the opening to be formed at a location on the stator where the coolant can escape, resulting in advantageous cooling. This can improve the cooling effect caused by the device.

[0009] According to a second aspect of the invention, a stator comprising the device as described above and a stator core is proposed. A rear side of the device is arranged on an end face of the stator core. By arranging the device on an end face of the stator core, the device can serve both to conduct the coolant and to support and / or assist the winding of the winding. In particular, the device can be arranged directly on the end face of the stator.

[0010] In one embodiment, the stator can further comprise a winding comprising a plurality of plug-in coils. The plurality of webs can be pressed against the stator core by the plurality of plug-in coils. The plurality of webs can thus serve to support and / or wind the plurality of plug-in coils of the winding. The device can therefore be a twist ring. A twist ring can serve, in particular, for winding (twisting) the plug-in coils. The plug-in coils can be bent over the webs of the twist ring.

[0011] In one embodiment, a web of the plurality of webs can form a pivot point for deforming a plug-in coil of the plurality of plug-in coils. A plug-in coil can thus be deformed by the web. For example, a plug-in coil can be deformed by an external force due to the tapered, e.g., conical shape of the web. This makes it possible to provide a twist ring that is simultaneously designed for winding plug-in coils and for conducting a coolant.

[0012] In one embodiment, the plurality of plug-in coils can be secured by the plurality of webs. This avoids the need for subsequent fixation of the plug-in coils, for example, after the usual removal of a twist ring.

[0013] In one embodiment, the stator may further comprise an insulation structure. The insulation structure may be arranged between the stator core and the winding. The plurality of webs may be at least partially frictionally connected to the insulation structure. The insulation structure may serve to insulate the plug-in coils. The at least partially frictional contact of the plurality of webs with the insulation structure may simplify insulation of the winding.

[0014] In one embodiment, the stator can comprise a maximum of one sealing structure between the stator core and the device. The sealing structure can be frictionally connected to the stator core and the device. The maximum of one sealing structure can simplify the design of the stator. This can minimize costs during production and / or simplify the manufacturing process.

[0015] According to a third aspect of the invention, a vehicle is proposed. The vehicle comprises an electric machine designed to drive the vehicle. The electric machine comprises a stator comprising a stator core and a device as described above or a stator as described above. The device is designed to conduct a coolant through the stator core. By using a device as described above or a stator comprising a device as described above, a manufacturing process for a vehicle can be simplified. Furthermore, a compactly deployable component in the form of the device can increase design flexibility in a vehicle with high weight and space requirements.

[0016] According to a fourth aspect of the invention, a method for producing a stator is proposed. The method comprises arranging a device as described above on an end face of a stator laminated core. The method further comprises arranging a plurality of plug-in coils within the stator laminated core and within the device. The method further comprises winding or twisting the plug-in coils such that a force-fitting connection is created between the stator laminated core of the device and the plurality of plug-in coils. By arranging the device for conducting the coolant before winding the plug-in coils, a cavity for conducting the coolant can be arranged before winding the plug-in coils. This makes it possible to avoid arranging a further cooling device after winding the plug-in coils. This makes it possible to simplify a manufacturing process for the stator.

[0017] The present invention will be described below by way of example only with reference to the accompanying figures. They show: Fig. 1a and Fig. 1b show side plan views of an example of a device; Fig. 2 shows a side (from radially outside) rear view of an embodiment of a device; Fig. 3a and Fig. 3b show side plan views of an embodiment of a stator; Fig. 4a and Fig. 4b show a side view and a top view of another embodiment of a stator; Fig. 5 shows an embodiment of a vehicle; and Fig. 6 shows a block diagram of an example of a method for manufacturing a stator.

[0018] Fig. 1a and Fig. 1b show side plan views of an example of a device 100. Fig. 1a shows a side view from radially outside and Fig. 1b shows a side plan view from the radial inside of the device 100. The device 100 comprises a guide structure 110 comprising a cavity (not shown) for guiding the coolant.

[0019] The cavity is formed within the device 100. This means that the cavity is at least partially completely surrounded by the sides of the device 100. The coolant is at least partially guided through the cavity. The cavity can be connected to or have at least one opening 122 for supplying and / or discharging the coolant.

[0020] Furthermore, the device 100 comprises a plurality of webs 130 (for reasons of clarity, only two webs are designated by a reference numeral). The plurality of webs 130 extend radially inward from the conductive structure 110 by at least 1 cm, or by 1.5 cm, or by 2 cm, or by 2.5 cm, or by 3 cm. The plurality of webs 130 can in particular be designed to be arranged in a slot of a stator. Accordingly, the plurality of webs 130 can extend radially inward from the conductive structure 110 by at least the width of a slot of a stator. For example, the webs can be arranged in a slot of a stator. The plurality of webs 130 can correspond to a plurality of slots of a stator.

[0021] One web of the plurality of webs 130 has a tapered shape. For example, a majority, such as 80%, 90%, or 95%, of the webs of the plurality of webs 130 have a tapered shape. For example, all of the webs of the plurality of webs 130 have a tapered shape.

[0022] The ridge of the plurality of ridges 130 may taper or narrow from a base 134 (attachment to the guide structure 110) to a tip point 136 (radially inner point of the device 100). The ridge of the plurality of ridges 130 may be a three-dimensional shape with the side surfaces tapering at an angle toward the tip point. Optionally, the taper may be conical.

[0023] For example, an end face of the web of the plurality of webs 130 can have rounded edges. The rounded edges can be configured to enable winding of a plug-in coil. In other words, the edges, or one edge, can form a pivot point for winding a plug-in coil. The rounded edges can be configured on an opposite end face of the end face for arrangement on a stator.

[0024] One of the plurality of webs 130 can also be referred to as a twist key. A twist key can be used to twist a plug-in coil over the twist key, for example, to secure the windings in a stator. The twist key is a type of wedge that is placed between the windings in the stator. The plug-in coils containing the windings can be twisted or wound over the twist key to hold them firmly in place. By twisting the plug-in coils in this way, they are securely secured against the forces of operation and remain stable and well insulated. This prevents vibrations, movement, and loosening of the windings during operation of the electrical machine.

[0025] Adjacent webs of the plurality of webs 130 may have parallel sidewalls. That is, adjacent webs may taper such that opposing sidewalls of adjacent webs are parallel. This may simplify the arrangement of a structure between the webs. For example, a rectangular structure may be arranged more easily between adjacent webs. For example, the arrangement of a plug-in coil between adjacent webs may be simplified by opposing parallel sidewalls of adjacent webs.

[0026] Because the device 100 comprises the plurality of webs 130 and a cavity for conducting the coolant, both cooling and winding can be enabled by arranging the device 100.

[0027] The device 100 is integrally formed. The device 100 is comprised of a single piece or part. The device 100 is not assembled from multiple parts. For example, the device 100 may not have any joints, seams, or connections between different parts. Instead, the device 100 is manufactured or molded as a single unit.

[0028] By integrating the twist wedges, i.e., the plurality of webs 130, into the device 100, the assembly of the twist wedges can be omitted during construction, since they are already integrated into the device 100. This eliminates or reduces the costs and time required for manufacturing the twist wedges and also the stator base mount, since the latter can be designed more compactly.

[0029] Furthermore, a risk of cracks in an insulation structure can be reduced by the device 100 because the device 100 can support an insulation structure.

[0030] A height of the twist wedges, i.e. the plurality of webs 130, can be at least 5 mm, or at least 7 mm, or at least 9 mm.

[0031] Furthermore, the device 100 can be designed such that it is not damaged during winding of the plug-in coils. The integrated twist wedges can improve the hold of the winding. In particular, axial slippage of the winding can be prevented. This can reduce or eliminate rejects in the manufacturing process due to excessive play in the groove and / or handling processes.

[0032] Furthermore, the use of device 100 and the associated fixation of the winding eliminates the need for a trickle-coating process. Alternatively, a trickle-coating process can be performed to manufacture a stator. Since the arrangement of a cooling device on a radial outer side of the stator is no longer required, residues of the trickle-coating process can remain on the radial outer side of the stator, for example, the stator laminated core. The use of device 100 eliminates the need to remove residues of the trickle-coating process. In particular, closing holes can play no role (since no holes need to be present for arranging a cooling device), and thus an artificial restriction of the process parameters can be avoided by using device 100.

[0033] The device 100 can make the construction of a stator more economical, the stator more cost-effective, the throughput times of production shorter and the efficiency of the stator improved.

[0034] The device 100 can, in particular, be a solid ring. Using a solid ring can replace the use of two half rings. This can result in material and / or cost savings.

[0035] In one embodiment, the conductive structure 110 may further comprise an opening 122 for the outlet of the coolant at an axial end of the conductive structure 110. The opening 122 may be formed on an end face opposite the end face for arrangement on an end face of the stator. The coolant can exit the conductive structure through the opening 122. In particular, the opening 122 can be arranged such that the coolant exits the conductive structure 110 at a winding of a stator. As a result, the coolant can be used passively to cool the stator. As a result, cooling of the stator can be improved. In particular, the opening 122 can be designed for passively sprinkling the coolant onto a winding of a stator.

[0036] In one embodiment, the opening 122 can be formed in a protrusion 124 of the conductive structure 110. The protrusion 124 allows the opening 122 to be formed at a location on the stator where the coolant can exit and lead to advantageous cooling of the stator winding. This means that the protrusion 124 of the conductive structure 110 can serve or be designed to direct the coolant to a region or area of ​​the stator where cooling is particularly effective and / or required (due to high temperature rises occurring, e.g., at the winding head).

[0037] Fig. 2 shows a lateral (from the radial outside) rear view of an embodiment of a device 200. The device 200 comprises a rear side 250. The rear side 250 is configured for arrangement on an end face of a stator. The rear side 250 can comprise a first region 252 and a second region 254. For example, the first region 252 and the second region 254 can be a bearing surface on the end face of the stator, for example a laminated core of the stator. The first region 252 can be an outer edge of the device 200. The second region 254 can be an end face or an underside of the plurality of webs.

[0038] Fig. 2 further shows an optional contour 260 for arranging a sealing structure, such as a gasket or an adhesive. The optional contour 260 can improve the seal between the device 200 and the stator core. The optional contour 360 can improve the arrangement of the structure.

[0039] Fig. 3a and Fig. 3b show side plan views of an embodiment of a stator 302. Fig. 3a shows a side view from radially inside and Fig. 3b shows a side view from the radial outside of the stator 302.

[0040] The stator 302 comprises a device 300, for example a device as described with reference to Fig. 1 and / or Fig. 2. The device 300 comprises a plurality of webs 330. The stator 302 further comprises a stator core 360. A rear side 350 of the device 300 is arranged on an end face 362 of the stator core 360. The rear side 350 of the device 300 can be arranged directly on the end face 362 of the stator core 360. By arranging the device 300 on the end face 362 of the stator core 360, the plurality of webs 330 can be supported by the end face 326 of the stator core 360. The plurality of webs 330 can correspond to a plurality of slots of the stator 302.

[0041] In one embodiment, the stator 302 may further comprise a winding 340. The winding 340 comprises a plurality of plug-in coils. The plurality of webs 330 are pressed against the end face 362 of the stator core 360 ​​by the plurality of plug-in coils. The device 300 can be pressed against the stator core 360 ​​by winding the plurality of plug-in coils. In particular, the device 300 can be non-positively connected to the stator core 360 ​​by winding the plurality of plug-in coils. Slipping of the device 300 relative to the stator core 360 ​​can be prevented by the winding 340. As a result, a position of the device 300 relative to the stator core 360 ​​can be fixed.

[0042] For example, the device 300 can be arranged on the stator core 360 ​​solely by the winding 340. A further fastening means, such as adhesive or a screw, can be avoided. The device 300 can be firmly arranged on the end face 362 of the stator core 360 ​​solely by the contact pressure of the winding 340. This can reduce the design effort for manufacturing the stator 302. Furthermore, by pressing the device 300 onto the stator core 360, a seal can be simplified. For example, the maximum of one sealing structure described below can be arranged between the stator core 360 ​​and the device 300.

[0043] In one embodiment, a web of the plurality of webs 330 can form a pivot point for deformation of a plug-in coil of the plurality of plug-in coils. This means that a plug-in coil of the plurality of plug-in coils can be formed around a web of the plurality of webs 330. For example, the plug-in coil can be curved around a curvature of an edge of the web. For example, a shape of an edge of the web can specify a curvature of the plug-in coil in a region along a longitudinal extent of the plug-in coil.

[0044] In one embodiment, the plurality of plug-in coils can be fixed by the plurality of webs 330. This can avoid subsequent fixing of the plug-in coils, for example, after the usual removal of a twist ring. For example, a trickling process during the manufacture of a stator 302 can be avoided or simplified. Due to the use of the device 300 and the associated fixing of the plurality of plug-in coils, a trickling resin that reaches the stator laminated core 360 ​​during a trickling process may not be critical, since the use of the device 300 can replace the use of an oil guide ring. As a result, the trickling resin can no longer close or run into bores that are required for the arrangement of the oil guide ring. The device 300 can provide a guide structure that can be arranged before a trickling process takes place.

[0045] Alternatively, a trickling process can be completely avoided due to the fixation of the plurality of plug-in coils by the device 300. This allows a coolant to be optionally conducted within the slot. Cooling of the stator 302 can be improved by optionally conducting a coolant within the slot. The device 300 can therefore enable active slot cooling of the stator 302, in particular directly at the plug-in coil. The device 300 can therefore enable passive cooling by coolant in the stator laminated core 360 ​​and active cooling by coolant in the slot. The device 300 can therefore enable a combination of active cooling and passive cooling of the stator 302. A slot clearance of the stator 302 can be suitably adapted for active cooling.

[0046] Furthermore, by eliminating the trickling process, a heating and cooling process can be eliminated during the manufacture of the stator 302. This can result in time and / or energy savings. In particular, by eliminating the trickling, curing, and cooling steps, time and / or energy savings can be achieved. By eliminating the trickling process, leakage of trickling resin from a bore for arranging a cooling device 300 can be prevented.

[0047] Furthermore, efficiency can be increased, as stator lamination stacks tend to become increasingly longer and require more efficient cooling. By combining active and passive cooling, effective cooling of longer stator lamination stacks can be achieved.

[0048] Furthermore, no individual twist wedges are required for the stator 302. This can result in cost savings, especially in prototype construction. Furthermore, the device 300 can be easily adapted to different axial lengths. This can improve flexibility in the production of a stator 302.

[0049] The stator 302 can comprise two devices, or two devices can be arranged on the stator 302. One device can be arranged on a plug-in side of the stator 302, and one device can be arranged on a winding side of the stator 302. Both devices can be solid rings. The two devices can be arranged during the manufacturing process of the stator 302, for example, placed and / or glued on. By using two solid rings, a manufacturing process can be simplified. In particular, the arrangement of two half rings, as is usual in a cooling device comprising an oil guide ring, can be avoided.

[0050] In one embodiment, the stator 302 can further comprise an insulation structure 370. The insulation structure 370 can be arranged between the stator core 360 ​​and the winding 340. The plurality of webs 330 can be at least partially frictionally connected to the insulation structure 370. The insulation structure 370 can serve to insulate the plurality of plug-in coils. The insulation structure 370 can be arranged after the device 300 has been arranged. The device 300, in particular the plurality of webs 330, can support the insulation structure 370 during or after the winding of the plurality of plug-in coils. The fixed arrangement of the device 300 can therefore ensure permanent support of the insulation structure 370. This can reduce mechanical stress on the insulation structure 370.

[0051] Alternatively or optionally, a height of the plurality of webs 330 can be adapted to a projection of the insulation structure 370. The projection of the insulation structure can refer to a portion of the insulation structure 370 protruding from the stator core 360 ​​(in particular from the end face 362 and / or a rear side). By adapting the height of the plurality of webs 330 to the projection of the insulation structure 370, support of the insulation structure 370 can be improved. This can improve the mechanical stability of the insulation structure 370 during the winding of the plurality of plug-in coils.

[0052] A length of the multitude of webs 330 is in Fig. 3a is smaller than a length of the plurality of plug-in coils. This means that the plug-in coils of the plurality of plug-in coils extend radially inward beyond the plurality of webs 330. Alternatively, in a preferred embodiment, the plug-in coils of the plurality of plug-in coils can be flush with the plurality of webs 330 or can be projected radially inward beyond the plurality of webs 330. This can improve the support of the plug-in coils during winding.

[0053] In one embodiment, the stator 302 can comprise a maximum of one sealing structure between the stator core 360 ​​and the device 300. The sealing structure can be frictionally connected to the stator core 360 ​​and the device 300. For example, the structure can be a rubber seal (e.g., a foam rubber seal), a metallic seal, or a silicone seal. The sealing structure can be squeezed in by winding the plurality of plug-in coils between the rear side 350 of the device 300 and the end face 362 of the stator core 360. The maximum of one sealing structure can simplify the construction of the stator 302. For example, an adhesive layer (see, for example, Fig. 2, in which the device comprises an optional contour for arranging a further sealing structure, for example an adhesive bead).

[0054] Fig. 4a and Fig. 4b show a side view and a top view of another embodiment of a stator 402. The stator 402 comprises a device 400, a stator core 460 and a winding 440. The device 400 is arranged with a rear side on an end face of the stator core 460. In Fig. 4a shows that the device 400 rests directly on the stator core 460. Displacement of the device 400 relative to the stator core 460 is prevented by the winding 440. The contact force of the winding 440 holds the device 400 in a fixed position relative to the stator core 460. Furthermore, a groove 420 for arranging the device 400 is visible. Fig. 4b also shows an opening 422 for discharging the coolant. The opening 422 or the plurality of openings 422 is / are formed in a raised portion of the conductive structure of the device 400. The coolant can exit the conductive structure through the opening 422. This allows the winding 440 of the stator 402 to be passively sprayed with the coolant.

[0055] Fig. 5 shows an embodiment of a vehicle 500. The vehicle includes an electric machine 510 configured to drive the vehicle 500. The electric machine 510 includes a device 520, such as described, for example, with reference to Fig. 1 and / or or Fig. 2 or a stator 530, such as described with reference to Fig. 3 and / or Fig. 4. The device 520 according to the invention offers additional advantages, particularly in the field of vehicle application: The power of the electric machine 510 in the vehicle environment is high, making effective cooling of the winding head all the more important. In addition, versatile components such as the device 520 described here can increase design flexibility in a vehicle 500 with high weight and space requirements.

[0056] Fig. 6 shows a block diagram of an example of a method 600 for manufacturing a stator. The method 600 includes arranging a device as described above (for example, with reference to Fig. 1 and / or Fig.2) and arranging a plurality of plug-in coils within the stator laminated core and within the device. The method further comprises winding the plug-in coils such that a force-fitting connection is created between the stator laminated core of the device and the plurality of plug-in coils. As a result, a device for conducting a coolant can be attached to the stator laminated core by winding the plurality of plug-in coils. By arranging and fastening the device for conducting the coolant during the manufacture of the stator, a manufacturing process of an electrical machine can be simplified and / or improved. In particular, arranging a cooling device after manufacture of a stator can be avoided. Reference symbol 100 device 110 Lead structure 122 Opening 124 Survey 130 jetty 134 Base 136 peak point 200 device 250 Back of the device 252 outer edge 254 Back of the bridges 260 Contour for the arrangement of a sealing structure 300 device 302 Stator 330 jetty 340 winding 350 Back of the device 360 stator lamination stack 362 End face of the stator core 370 insulation structure 400 device 402 Stator 420 groove 422 Opening 440 winding 460 stator lamination stack 500 vehicles 510 electric machine 520 device 530 Stator 600 Method for manufacturing a stator 610 Arranging a stator 620 Arranging a variety of plug-in coils 630 twisting of the plug-in coils

Claims

[1] A device (100) for conducting a coolant, comprising: a guide structure (110) comprising a cavity (120) for guiding the coolant, wherein the guide structure (110) is partially circumferential and designed for arrangement on an end face of a stator; and a plurality of webs (130), wherein the plurality of webs (130) extend radially at least 1 cm inwardly from the guide structure (110), and wherein one web of the plurality of webs has a tapered shape, wherein the device (100) is formed in one piece. [2] The device (100) of claim 1, wherein the guide structure (110) further comprises an opening (122) for the outlet of the coolant at an axial end of the guide structure (110). [3] The device (100) of claim 2, wherein the opening (122) is formed in a protrusion of the guide structure (100). [4] A stator (302; 402) comprising: the device (400) according to any one of the preceding claims; and a stator laminated core (360; 460), wherein a rear side (350) of the device is arranged on an end face (362) of the stator laminated core (360; 460). [5] The stator (302; 402) according to claim 4, further comprising a winding (340; 440) comprising a plurality of plug-in coils, wherein the plurality of webs (330) are pressed by the plurality of plug-in coils against the end face (362) of the stator laminated core (360; 460). [6] The stator (302; 402) of claim 5, wherein a web of the plurality of webs (330) forms a pivot point for deformation of a plug-in coil of the plurality of plug-in coils. [7] The stator (302; 402) according to any one of claims 4-6, further comprising an insulation structure (470) arranged between the stator core (360; 460) and the winding (340; 440), wherein the plurality of webs (330) is at least partially non-positively connected to the insulation structure (470). [8] The stator according to any one of claims 4-7, further comprising a maximum of one sealing structure between the stator laminated core (360; 460) and the device (440), wherein the sealing structure is non-positively connected to the stator laminated core (360; 460) and the device (440). [9] Vehicle (500), comprising: an electric machine (510) configured to drive the vehicle (500), wherein the electric machine (510) comprises a stator (530), wherein the stator (530) comprises a stator core and comprises a device (520) according to any one of claims 1-2 or comprises a stator according to any one of claims 3-8, wherein the device (520) is configured to conduct a coolant through the stator core. [10] Method (600) for producing a stator, comprising Arranging (610) the device according to one of claims 1-8 on an end face of a stator laminated core; Arranging (620) a plurality of plug-in coils within the stator core and within the device; and Twisting (630) the plug-in coils so that a force-locking connection is created between the stator laminated core, the device and the plurality of plug-in coils.

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