Module for an electric machine

Abstract

A module (1) for an electric machine (2) comprises: a first and a second support (10A, 10B) spaced apart in a spacing direction (X) and each having a first mounting point (100A, 100B) and a second mounting point (100C, 100D) offset thereto along an offset direction (Y) perpendicular to the spacing direction (X); an iron core arrangement (11A-11D) arranged between the first and the second support (10A, 10B), which defines a first section (110) extending from the first mounting point (100A) of the first support (10A) to the second mounting point (100D) of the second support (10B); and a second section (111) extending from the second mounting point (100C) of the first support (10A) to the first mounting point (100B) of the second support (10B). extends, and a coil (12) running along the iron core arrangement (11A-11D).

Description

[0001] The present disclosure relates in particular to a module for an electric machine, to a stator for an electric machine, to an electric machine and to a method for manufacturing such a module.

[0002] Vehicles, especially aircraft, are powered by a wide variety of propulsion systems. Internal combustion engines, such as piston engines or gas turbine engines, enable long ranges and high speeds. Electric drive units, on the other hand, allow the use of sustainably generated energy and are often particularly low-maintenance and quiet. Advances in battery and fuel cell technology are constantly expanding the applications of electric drive units.

[0003] For electric motors and other electrical machines, especially electric drive units, there is a constant drive to improve various performance parameters, such as energy efficiency, power-to-weight ratio, or service life. At the same time, it may be desirable to manufacture electrical machines in the simplest and most reliable way possible. However, these objectives can conflict with each other. Manufacturing modules with coils, for example, for the stators of electrical machines, can be challenging.

[0004] The task is to improve a module with a coil for an electric machine.

[0005] According to one aspect, a module for an electrical machine is specified. The module comprises a first and a second support, spaced apart from each other in a spacing direction, each having a first mounting point and a second mounting point offset from it along an offset direction. The offset direction is perpendicular to the spacing direction. Furthermore, the module comprises an iron core assembly arranged between the first and the second support. The iron core assembly has a first section and a second section. The first section extends from the first mounting point of the first support to the second mounting point of the second support. The second section extends conversely from the second mounting point of the first support to the first mounting point of the second support. The module also includes a [missing information] surrounding the iron core assembly (e.g.,electrical coil running around at least one of the sections of the iron core arrangement.

[0006] This arrangement makes it possible to first position the iron core assembly and then wind the coil around it. The resulting unit can then be connected to the supports to form the module. This allows for simplified, e.g., automated manufacturing, whereas other designs of iron core assemblies may require assembling sections of an iron core assembly individually onto an already wound coil. This can be difficult to automate. Furthermore, the module described here offers expanded possibilities for coil arrangement. Thus, an improved module with a coil for an electric machine is provided.

[0007] The iron core assembly comprises or consists of a soft magnetic material. Each section of the iron core assembly serves as the iron core for the coil. The iron core assembly comprises (or consists of) iron. For example, the iron core assembly comprises or consists of a nickel-iron alloy, a silicon-iron alloy, and / or a cobalt-iron alloy. The iron core assembly can be configured as a laminated core or, for example, comprise or consist of a soft magnetic compound (SMC).

[0008] The first and / or second section may be designed in an S-shape. This allows for a particularly simple design and manufacturing process for the sections themselves. Furthermore, S-shaped sections facilitate the assembly of the module.

[0009] For example, the first section and the second section are arranged and / or designed together in an X-shape or H-shape. The coil can be positioned so that it is received by the two or four recesses formed by the X- or H-shape between the arms of the H-shape or the X-shape.

[0010] The first and second sections can run in planes that are parallel to each other and parallel to both the spacing and offset directions. This allows the magnetic field of the coil to be guided across this offset, enabling effective drive of the rotor.

[0011] Alternatively, the first and second sections can run in the same plane parallel to both the spacing and offset directions. This allows, for example, a particularly simple fabrication of the iron core assembly.

[0012] The first and second sections can be designed as separate components. Alternatively, the first and second sections can be rigidly connected to each other via the supports. This allows for particularly easy assembly of the coil and the sections of the iron core assembly.

[0013] For example, the first section and the second section are identical. This allows for particularly simple manufacturing.

[0014] Furthermore, it is possible for the first and second sections to be designed together as a single, one-piece component. This allows for a structural improvement of the module and also simplifies the grounding of the iron core assembly.

[0015] The iron core assembly can comprise a multitude of first and second sections. These multiple first and second sections can be connected via a connecting link, e.g., a central link (e.g., in one piece). This allows for particularly easy handling when winding through the coil.

[0016] The coil can have a first and a second winding section, which are sections of a common winding around the iron core assembly. A crossing point of the iron core assembly can be located between the first and second winding sections. This allows for secure mounting of the coil. Alternatively, the coil can be designed as a coil lying around the electrical machine. For example, the coil runs along one side of the iron core assembly.

[0017] The first and second winding sections are arranged offset from each other along the direction of the distance. This enables effective guidance of the magnetic field.

[0018] The coil can be a first coil, with the module having a second coil. The second coil can have a first and a second winding section, which are sections of a common winding around the iron core assembly, wherein the intersection point of the iron core assembly is located between the first and second winding sections of the second coil. Such an arrangement makes it possible, by appropriately energizing the coils, to selectively set a magnetic north or south pole at any of the attachment points, and the opposite pole at an adjacent one.

[0019] The coil can be mounted at an angle to the iron core assembly with respect to the spacing and offset directions. This allows for particularly easy assembly.

[0020] The first and second supports can each be in the form of a flat plate, which are, for example, aligned parallel to each other.

[0021] The fastening points are each designed, for example, in the form of an opening into which the iron core assembly is inserted (and glued, for example).

[0022] According to one aspect, a module for an electrical machine is specified, in particular according to any of the embodiments described herein. The module comprises an iron core arrangement defining a first section and a second section, wherein the first section and the second section intersect at a point of intersection, and a coil extending around the iron core arrangement. Regarding the advantages, reference is made to the above information. The first section and the second section can be formed integrally or in multiple parts and separately from each other.

[0023] According to one aspect, a stator for an electrical machine is specified, comprising a support to which several modules, each according to any of the embodiments described herein, are attached.

[0024] According to one aspect, an electrical machine is specified, comprising a stator with one or more modules, each according to any of the embodiments described herein, and a rotor rotatably mounted relative to the stator.

[0025] The electric machine includes, for example, a ground potential, with the iron core assembly being electrically connected to this ground potential. This prevents electrostatic charges from forming.

[0026] According to one aspect, a vehicle, in particular an aircraft, is specified, comprising a drive unit for propelling the vehicle with the electric machine according to any of the embodiments described herein.

[0027] According to one aspect, a method for manufacturing a module for an electrical machine, in particular the module according to any of the embodiments described herein, is described. The method comprises placing an iron core assembly with a first section and a second section; and mounting a coil on the placed iron core assembly such that the coil runs around the iron core assembly (e.g., the coil is wound around it or placed on it in an already wound state).The method further comprises, before or after mounting the coil, attaching the iron core arrangement to a first and a second support such that these are spaced apart from each other in a spacing direction and each has a first attachment point and a second attachment point arranged offset thereto along an offset direction perpendicular to the spacing direction, and that the iron core arrangement is arranged between the first and the second support with the first section extending from the first attachment point of the first support to the second attachment point of the second support and the second section extending from the second attachment point of the first support to the first attachment point of the second support.

[0028] Exemplary embodiments are now described with reference to the figures; the figures show: Fig. 1 an aircraft with several electric machines to drive several propellers; Fig. 2 a cutaway view of one of the aircraft's electrical machines according to Fig. 1 with a stator and a rotor; Fig. 3 a module of the stator of the electric machine according to Fig. 2 with a first and a second support, an iron core arrangement and a coil; Fig. 4 a top view of part of the module according to Fig. 3; Fig. 5 an iron core arrangement with a coil for the module according to Fig. 3; Fig. 6 a component of the iron core arrangement according to Fig. 5; Fig. 7 the iron core arrangement according to Fig. 3 with two coils; Fig. 8 the iron core arrangement according to Fig. 5 with two coils; Fig. 9 the iron core arrangement according to Fig. 3 with two diagonally mounted coils; Fig. 10 a module for the stator of the electric machine according to Fig. 2; Fig. 11 an iron core arrangement for the module according to Fig. 3 and according to Fig. 10; and Fig. 12 a further iron core arrangement for the module according to Fig. 3 and according to Fig. 10.

[0029] Fig. Figure 1 shows an aircraft 3, exemplified as an air taxi. The aircraft 3 comprises a cabin 30 and several electric drive units, four in this example. Each electric drive unit includes an electric machine 2, in the form of an electric motor, and one or more propellers 32. Each electric machine 2 drives its respective propeller(s) 32. For this purpose, each propeller 32 is operatively connected to a rotor of the respective electric machine 2 (e.g., rigidly connected to it, for example via a shaft, and / or coupled to it via a gearbox). A battery system 31 with one or more electric batteries supplies electrical current to operate the electric machines 2. For this purpose, inverters 33 generate an alternating voltage for the electric machines 2 from a direct voltage of the battery system 31. In this example, the electric machines 2 are direct drives.

[0030] Aircraft 3 is shown here as an example of a vertically launching and landing aircraft, although a design as a fixed-wing aircraft is also possible.

[0031] Fig. 2 illustrates the basic structure of one of the examples shown. Fig. 1 electrical machines of identical construction 2.

[0032] The electric machine 2 comprises a stator 20 and a rotor 21 rotatable about an axis of rotation relative to the stator 20. The rotor 21 is rotatably mounted on the stator 20 by means of bearings 22, here in the form of ball bearings, or alternatively, for example, plain bearings. The electric machine 2 is shown here as an example of an external rotor. The rotor 21 surrounds the stator 20. The stator 20 is arranged inside the rotor 21. The stator 20 can be mounted to a supporting structure of the aircraft 3 by means of a mounting area, here in the form of a flange 201, and is in the state according to Fig. 1 assembled.

[0033] The rotor 21 comprises a shaft flange 210, on which a shaft can be mounted and in the state according to Fig. 1 is mounted. The rotor 21 then drives the propeller 32 via the shaft.

[0034] The stator 20 also has a mounting bracket 200. Modules 1 with coils 12, 13 of the stator 20 are mounted on the mounting bracket 200; these are in Fig. 2 is not shown for the sake of simplicity, but is instead illustrated separately in the figures described below.

[0035] The rotor 21 further comprises several permanent magnets 211. These are fixedly mounted on the rotor 21. The permanent magnets 211 interact with magnetic fields generated by the coils 12, 13, causing the rotor 21 to rotate about its axis of rotation relative to the stator 20. Each of the several modules 1 is thereby supplied with, for example, one phase of an alternating voltage, e.g., a three-phase alternating voltage.

[0036] The stator 20 is designed for multiphase, in this case three-phase, operation and is connected to a three-phase alternating voltage with phases U, V, W. During normal operation of the electrical machine 2, the coils 12, 13 are accordingly energized with the alternating voltage.

[0037] The electric machine 2 extends around the axis of rotation. The electric machine 2 is designed as a transverse flux machine, although an axial flux machine or a radial flux machine would also be conceivable. The coils 12, 13 of the stator 20 extend section by section in the circumferential direction around the axis of rotation.

[0038] The present design provides for the electric machine 2 to serve as a drive motor for the respective propeller 32. It may also be possible to operate the electric machine 2 in generator mode. When operating as an electric motor, the electric machine 2 can, for example, be driven with 100 kW, 1 MW, or even 10 MW. The cross-section of the electrical conductors of the coils 12 and 13 is correspondingly large.

[0039] Fig. 3 and Fig. Figure 4 shows one of the previously mentioned modules 1 of the stator 20. The stator 20 comprises several, e.g., three or, as in the present example, six such modules 1, although in other embodiments only one such module 1 could be provided. Such a module 1 can also be referred to as a phase module.

[0040] Module 1 has an iron core assembly 11A and a coil 12 wound on it. As in Fig. 3 and Fig. As can be seen in Figure 4, module 1 of the stator 20 of the electric machine 2 comprises a first support 10A and a second support 10B, each in the form of a (planar) plate. The supports 10A and 10B are spaced apart from each other along a spacing direction X. The supports 10A and 10B are aligned parallel to each other. The supports 10A and 10B are aligned perpendicular to the spacing direction X.

[0041] The electrical coil 12 runs between the two supports 10A, 10B. The coil 12 is arranged between the two supports 10A, 10B of module 1.

[0042] The iron core assembly 11A comprises several first sections 110 and several second sections 111. Each of the first sections 110 is formed by a component B1. Each of the second sections 111 is formed by a component B2. The first and second sections 110 and 111 each form an iron core for the coil 12.

[0043] Sections 110 and 111 each extend from the first support 10A to the second support 10B. Sections 110 and 111 are each rigidly connected to the first support 10A and rigidly connected to the second support 10B. In this case, sections 110 and 111 engage with both the first support 10A and the second support 10B. For this purpose, supports 10A and 10B have attachment points 100A-100D to which sections 110 and 111 are rigidly connected. The attachment points 100A-100D are each designed as a receptacle (i.e., an opening, here exemplified as a through-hole) into which one end of each section 110 and 111 is inserted. An adhesive bonds the respective ends of sections 110 and 111 to the receptacles.

[0044] As particularly evident Fig. As can be seen in Figure 4, the present design provides that the first and second supports 10A, 10B, which are spaced apart from each other in the spacing direction X, each have a first fastening point 100A, 100B and a second fastening point 100C, 100D. The second fastening points 100C, 100D are arranged offset from the respective first fastening point 100A, 100B along an offset direction Y perpendicular to the spacing direction X.

[0045] The iron core assembly 11A comprises several first sections 110 and several second sections 111, e.g., more than two, more than five, as in the example shown, ten, or even more than ten. For the sake of simplicity, reference will occasionally be made to only one pair consisting of a first section 110 and a second section 111. However, the explanations apply equally to the other pairs of the iron core assembly 11A. The coil 12 runs around the iron core assembly 11A. The coil 12 runs around the arrangement of the first and second sections 110, 111. The coil 12 is wound around the iron core assembly 11A.

[0046] In the present case, the four fastening points 100A-100D of the pair of the first and second sections 110, 111 are arranged at the four corners of an (imaginary) rectangle, as can be seen in particular from the Fig. 4 is evident. In the view of the Fig. In section 4, the first two fastening points 100A, 100B are located on the left, and the second two fastening points 100C, 100D are located on the right. The first and second fastening points 100A, 100C of the first support 10A are located at the top, and the first and second fastening points 100B, 100D of the second support 10B are located at the bottom.

[0047] The first section 110 of the iron core arrangement 11A (the one component B1) extends from the first fastening point 100A of the first support 10A to the second fastening point 100D of the second support 10B (in the present example, therefore, from top left to bottom right).

[0048] The second section 111 of the iron core arrangement 11A (the other component B2) extends from the second attachment point 100C of the first support 10A to the first attachment point 100B of the second support 10B (in the present example, therefore, from top right to bottom left).

[0049] Subsequently, the two sections 110 and 111 intersect at a crossing point K. The first section 110 and the second section 111 are arranged together in an X-shape.

[0050] Starting from intersection point K, the first section 110 has a first arm A1, which extends to the first attachment point 100A of the first girder 10A. Starting from intersection point K, the first section 110 also has a second arm A2, which extends to the second attachment point 100D of the second girder 10B. Starting from intersection point K, the second section 111 has a first arm A1, which extends to the second attachment point 100C of the first girder 10A. Starting from intersection point K, the second section 111 also has a second arm A2, which extends to the first attachment point 100B of the second girder 10B.

[0051] In this example, the first section 110 and the second section 111 are each S-shaped. Compared to a (also possible) straight configuration of sections 110, 111, this results in larger recesses 113A, 113B between the four arms A1, A2 of the first and second sections 110, 111 for the coil 12. In the example shown, the coil 12 is wound into the recess 113A formed between the two first arms A1 and the first support 10A, and into the recess 113B formed between the two second arms A2 and the second support 10B. The first section 110 and the second section 111 are identical parts. They have the same shape and size. The first and second sections 110, 111 are arranged as mirror images of each other.

[0052] The coil 12 comprises several turns W around the iron core assembly 11A. Each turn W comprises a first and a second winding section 120, 121. The winding sections 120, 121 of the coil 12 run concentrically along a circular segment around the axis of rotation of the rotor 21. The winding sections 120, 121 of a turn W are connected to each other at one end (in this case, they merge into each other), as shown in Fig. Figure 3 illustrates this using one of the turns W with a dashed line. At the opposite end, the winding sections 120 and 121 transition into, for example, another winding W. The coil 12 is formed by a (continuous) electrical conductor. It may be provided that the electrical conductor of the coil 12 is encased (e.g., section by section) in a potting compound, which is in contact with sections 110 and 111.

[0053] As in the Fig. 3 and Fig. As can be seen in Figure 4, the electrical conductor is bent multiple times to describe the turns W of the coil 12. In this case, the coil 12 is arc-shaped and can also be described as banana-shaped. The turns W each describe two curved end sections, which have a first, small radius of curvature, and two longer sections, which have a second, larger radius of curvature. The second radius of curvature is larger than the first radius of curvature.

[0054] The intersection point K of the first and second sections 110, 111 is located between the first and second coil sections 120, 121. The first and second coil sections 120, 121 are offset from each other along the spacing direction X.

[0055] The iron cores in the form of sections 110 and 111 comprise or consist of iron. Sections 110 and 111 may comprise or consist of a ferromagnetic metal alloy. Sections 110 and 111 have the form of retaining ribs and hold the two supports 10A and 10B together. In this case, sections 110 and 111, together with the coil 12, form an inductor. Sections 110 and 111 conduct the magnetic flux of the coil 12. Furthermore, sections 110 and 111 fix the coil 12 to the supports 10A and 10B. Thus, sections 110 and 111 have two functions: an electromagnetic and a mechanical one, namely, holding the coil 12 to the supports 10A and 10B. Sections 110 and 111, for example, are made of sheet metal, in particular as stacks of sheet metal with several layers of sheet metal insulated from each other, or as SMC.

[0056] Sections 110 and 111 are both flat. Their thickness is significantly less than their width and length.

[0057] As in Fig. 3 and Fig. As shown in Figure 4, the first section 100 and the second section 111 run in planes that are parallel to each other and parallel to the spacing direction X and the offset direction Y. Each of the sections 110, 111 runs in a plane parallel to the spacing direction X and the offset direction Y, specifically with the width and length of the respective section 110, 111. The two sections 110, 111 are abutting each other, although a spaced arrangement (in the direction perpendicular to the spacing direction X and the offset direction Y) is also possible. The first section 110 and the second section 111 are according to Fig. 3 and Fig. 4, as already mentioned, are designed as separate components B1, B2 and are firmly connected to each other via each of the carriers 10A, 10B, but via the other material (e.g. a plastic, e.g. PEEK) of the carriers 10A, 10B.

[0058] The Fig. 5 and Fig. Figure 6 illustrates another iron core arrangement 11B, which is surrounded by the coil 12 in the same manner as described above. In one embodiment, module 1 has the iron core arrangement shown above instead of the iron core arrangement 11A. Fig. 5 and Fig. 6 up.

[0059] According to the Fig. 5 and Fig. 6. A first section 110 and a second section 111 are formed together as a single component B3. The first section 100 and the second section 111 are also in the same plane, which is aligned parallel to the distance direction X and the offset direction Y.

[0060] The first section 110 and the second section 111 intersect at a crossing point K. The first arm A1 and the second arm A2 of the first section 110 are connected via the crossing point K. The first arm A1 and the second arm A2 of the second section 111 are also connected via the crossing point K. The first section 110 and the second section 111 thus share the crossing point K. The first section 110 and the second section 111 together form an X-shape. The crossing point K can be viewed opposite Fig. If it is also widened further, then the component is H-shaped.

[0061] The iron core arrangement 11B therefore defines a first section 110 extending from the first attachment point 100A of the first support 10A to the second attachment point 100D of the second support 10B, and a second section 111 extending from the second attachment point 100C of the first support 10A to the first attachment point 100B of the second support 10B.

[0062] Fig. Figure 7 illustrates the iron core arrangement 11A according to Fig. 3, whereby the remaining components of module 1 are not shown again. The iron core assembly 11A is surrounded by the coil 12 in the same manner as described above. However, coil 12 is only one of two coils 12, 13 and is therefore also referred to as the first coil 12 for ease of reference, while the other coil 13 is referred to as the second coil 13.

[0063] The second coil 13 is also wound around the iron core assembly 11A. The second coil 13 has several turns W, each with a first and a second winding section 130, 131, which are sections of a common turn W around the iron core assembly 11A, with the intersection point K of the iron core assembly 11A being located between the first and second winding sections 130, 131 of the second coil 13. Both coils 12, 13 extend (partially) concentrically around the axis of rotation of the rotor 21 relative to the stator 20. The second coil 13 is oriented such that its opening area between the winding sections 130, 131 is perpendicular to the opening area between the winding sections 120, 121 of the first coil 12. The winding sections 130, 131 of the second coil 13 are spaced apart from each other along the offset direction Y.

[0064] The second coil 13 runs in the recordings 113C, 113D (cf. Fig. 6), which are formed between the first arm A1 of the first section 110 and the second arm A2 of the second section 111, as well as between the first arm A1 of the second section 111 and the second arm A2 of the first section 110.

[0065] The coils 12 and 13 are wound perpendicular to each other.

[0066] Fig. Figure 8 illustrates the iron core arrangement 11B according to Fig. 5, whereby the remaining components of module 1 are not shown again. The iron core assembly 11B is surrounded by the coil 12 in the same manner as described above. The coil 12 is analogous to the example according to Fig. 7 only one of two coils 12, 13. The second coil 13 is arranged as above in connection with Fig. 7 explained.

[0067] Fig. 9 illustrated, using the example of the iron core arrangement 11A according to Fig. 3, that the coils 12, 13 can be arranged diagonally on the iron core arrangement 11A instead of crosswise.

[0068] According to Fig. In section 9, the first coil 12 is mounted obliquely onto the iron core assembly 11A with respect to the distance direction X and the offset direction Y. The second coil 13 is also mounted obliquely onto the iron core assembly 11A with respect to the distance direction X and the offset direction Y, specifically, in this example, relative to the first coil 12.

[0069] The first coil 12 is wound around the first arms A1 of the first sections 110, the second coil 13 is wound around the second arms A2 of the first sections 110.

[0070] Alternatively, only one of the two coils 12, 13 is provided. Furthermore, three or four coils can also be provided, e.g., two according to Fig. 9 and another coil wound around the first arms A1 of the second sections 111, and / or another coil wound around the second arms A2 of the second sections 111. This allows for even more variable orientations of the magnetic fields. Furthermore, the second coil 13 enables an increased power density.

[0071] The in Fig. 9 shown arrangement and in connection with Fig. The coil arrangements 12, 13 described in section 9 are possible for all iron core arrangements 11A-11D described herein.

[0072] Fig. Figure 10 illustrates, firstly, that more than one iron core arrangement 11B can be arranged on the first and second supports 10A, 10B. For example, any two of the iron core arrangements described herein (e.g., two analogously constructed iron core arrangements, in the example of the Fig. 10 two iron core arrangements 11B accordingly Fig. 5) attached side by side to the supports 10A, 10B. The coils 12, 13 can be mounted on the respective iron core arrangement as described.

[0073] Furthermore, it shows Fig. 10, that a coil 12 can also be wound around sections of adjacent iron core assemblies 11B. In the present case, the coil 12 is arranged around the first arm A1 of the second sections 111 of one iron core assembly 11B and around the first arm A1 of the first sections 110 of the other iron core assembly 11B. The manufacturing process is particularly simple because the coil 12 can simply be inserted. A second coil can be arranged accordingly on the opposite side (on the second support 10B).

[0074] The Fig. 11 and Fig. Figure 12 illustrates that the several first sections 110 and the several second sections 111 can also be connected in one piece via a common connecting bridge 112, here exemplified in the form of a central bridge.

[0075] The connecting web 112 is shown here as having a rectangular cross-section with rounded corners. The connecting web 112 extends along a portion of a circle. In the example shown, the connecting web 112 connects the several first and second sections 110, 111 at their intersection points K.

[0076] According to Fig. 11 the first and second sections 110, 111 belonging to a pair arranged together are arranged offset from each other, in this case in a direction that is perpendicular to the spacing direction X and perpendicular to the offset direction Y.

[0077] Sections 110, 111 and the connecting web 112 together form a single component B4. One or more coils 12, 13 are arranged on it as described above.

[0078] Alternatively or in addition to the coils 12, 13 arranged as described above, it may be provided that one or more electrical coils are wound around the connecting web 112. An exemplary section of such a coil is shown in Fig. 12 illustrated by a dashed line.

[0079] In Fig. Furthermore, 11 illustrates a ground potential of the electric machine, where the iron core arrangement 11DC is shown according to Fig. 11 is electrically connected to ground potential. This is the case with the one-piece iron core arrangements according to Fig. 11 and Fig. 12 is particularly easy to implement (and optionally provided), but also possible with the other iron core arrangements 11A and 11B described herein (for which, for example, components B1-B3 are electrically connected). This prevents static charging.

[0080] Fig. Figure 12 shows an iron core arrangement 11D corresponding to the iron core arrangement 11C according to Fig. 11, wherein the first and second sections 110, 111 of each pair run in the same plane. The iron core arrangement 11D is formed by a one-piece component B5.

[0081] The one-piece iron core assemblies 11C, 11D enable increased stability. Furthermore, the supports 10A, 10B can be easily omitted in the one-piece iron core assemblies 11C, 11D. Thus, the iron core assembly 11C, 11B can be attached, for example, to the bracket 200 or another component of the stator 20, e.g., by screwing it to it.

[0082] In a process for manufacturing a module 1 for the electrical machine 2, the following steps are provided: First, an iron core arrangement 11A-11D with one or more first sections 110 and one or more second sections 111 is placed, e.g. on a flat surface (e.g. in the form of one of the supports 10A, 10B) or on a holding device.

[0083] Then (immediately afterwards or after one or more intermediate steps), at least one coil 12 is mounted on the positioned iron core assembly 11A-11D such that the coil 12 extends around at least one of the sections 110, 111 of the iron core assembly 11A-11D. For example, the coil 12 is simply inserted (see figure). Fig. 10), attached or wound (see e.g. Fig. 6 and Fig. 5).

[0084] Before or after mounting the coil (12), the iron core assembly 11A-11D is fastened to the first and second supports 10A, 10B. The fastening is carried out such that the beams 10A, 10B are spaced apart from each other in a spacing direction X and each has a first fastening point 100A, 100B and a second fastening point 100C, 100D arranged offset therefrom along an offset direction Y perpendicular to the spacing direction X, and that the iron core arrangement 11A-11D is arranged between the first and the second beams 10A, 10B, with the first section 110 extending from the first fastening point 100A of the first beam 10A to the second fastening point 100D of the second beam 10B, and the second section 111 extending from the second fastening point 100C of the first beam 10A to the first fastening point 100B of the second beam 10B (see e.g. Fig. 4).

[0085] In a method for manufacturing a module 1 for the electrical machine 2, the following steps are provided: providing an iron core arrangement 11A-11D in any of the embodiments described herein and mounting a coil on the iron core arrangement.

[0086] It is understood that the disclosure is not limited to the embodiments described above and that various modifications and improvements may be made without deviating from the concepts described herein. Any of the features may be used separately or in combination with any other features, provided they are not mutually exclusive, and the disclosure extends to and encompasses all combinations and subcombinations of one or more features described herein. Reference symbol list 1 module 10A, 10B carrier 100A-100D Mounting point 11A-11D Iron core arrangement 110 first section 111 second section 112 Connecting bridge 113A-113D recording 12 (first) coil 120, 121 winding section 13 (second) coil 130, 131 winding section 2 electric machine 20 Stator 200 bracket 201 Flange 21 Rotor 210 wave flange 211 Permanent magnet 22 warehouses 3 aircraft 30 cabin 31 Battery system 32 propellers 33 inverters A1, A2 Arm B1-B5 component K Intersection point W turn X Distance direction Y offset direction

Claims

[1] Module (1) for an electric machine (2), comprising: - a first and a second support (10A, 10B) spaced apart from each other in a spacing direction (X) and each having a first fixing point (100A, 100B) and a second fixing point (100C, 100D) offset to it along an offset direction (Y) perpendicular to the spacing direction (X), - an iron core arrangement (11A-11D) located between the first and second beams (10A, 10B), defining a first section (110) extending from the first attachment point (100A) of the first beam (10A) to the second attachment point (100D) of the second beam (10B), and defining a second section (111) extending from the second attachment point (100C) of the first beam (10A) to the first attachment point (100B) of the second beam (10B), and - a coil (12) surrounding the iron core arrangement (11A-11D). [2] Module (1) according to claim 1, wherein the first section (110) and / or the second section (111) is / are S-shaped. [3] Module (1) according to claim 1 or 2, wherein the first section (110) and the second section (111) are jointly arranged or formed in an X-shape or an H-shape. [4] Module (1) according to one of the preceding claims, wherein the first section (100) and the second section (111) extend in planes that are parallel to each other and parallel to the spacing direction (X) and the offset direction (Y). [5] Module (1) according to any one of claims 1 to 3, wherein the first section (100) and the second section (111) extend in the same plane parallel to the distance direction (X) and the offset direction (Y). [6] Module (1) according to any one of claims 1 to 4, wherein the first section (110) and the second section (111) are designed as separate components (B1, B2) and are firmly connected to each other via the supports (10A, 10B). [7] Module (1) according to claim 6, wherein the first section (110) and the second section (111) are designed as identical parts. [8] Module (1) according to any one of claims 1 to 5, wherein the first section (110) and the second section (111) are formed together as a single component (B3-B5). [9] Module (1) according to claim 8, wherein the iron core arrangement (11C, 11D) comprises a plurality of first sections (110) and second sections (111) which are integrally connected to one another via a connecting web (112). [10] Module (1) according to one of the preceding claims, wherein the coil (12) has a first and a second winding section (120, 121) which are sections of a common winding (W) around the iron core arrangement (11A-11D), wherein a crossing point (K) of the iron core arrangement (11A-11D) is arranged between the first and the second winding section (120, 121). [11] Module (1) according to claim 10, wherein the first and second winding sections (120, 121) are arranged offset from each other along the spacing direction (X). [12] Module (1) according to claim 11, wherein the coil (12) is a first coil and the module (1) has a second coil (13), wherein the second coil (13) has a first and a second winding section (130, 131) which are sections of a common winding (W) around the iron core arrangement (11A-11D), wherein the intersection point (K) of the iron core arrangement (11A-11D) is arranged between the first and the second winding section (130, 131) of the second coil (13). [13] Module (1) according to any one of claims 1 to 9, wherein the coil (12) is mounted obliquely on the iron core arrangement (11A-11D) with respect to the spacing direction (X) and the offset direction (Y). [14] Module (1) according to one of the preceding claims, wherein the first and the second support (10A, 10B) are each formed in the form of a flat plate which are aligned parallel to each other. [15] Module (1) according to one of the preceding claims, wherein the fastening points (100A-100D) are each formed in the form of an opening into which the sections (110, 111) of the iron core arrangement (11A-11D) are glued. [16] Module (1) for an electric machine (2), in particular according to one of the preceding claims, comprising: - an iron core arrangement (11A-11D) defining a first section (110) and a second section (111), wherein the first section (110) and the second section (111) intersect at a crossing point (K), and - a coil (12) surrounding the iron core arrangement (11A-11D). [17] Stator (20) for an electric machine (2), comprising a support (200) to which several modules (1) according to one of the preceding claims are attached. [18] Electric machine (2) comprising a stator (20) with one or more modules (1) according to any one of claims 1 to 16, or the stator (20) according to claim 17, and a rotor (21) rotatably mounted relative to the stator (20). [19] Electric machine (2) according to claim 18, comprising a ground potential, wherein the iron core arrangement (11A-11D) is electrically connected to the ground potential. [20] Vehicle, in particular aircraft (3), comprising the electric machine (2) according to claim 18 or 19 for propelling the vehicle. [21] Method for manufacturing a module (1) for an electrical machine (2), the method comprising: - Placing an iron core assembly (11A-11D) with a first section (110) and a second section (111); - Mounting a coil (12) on the placed iron core assembly (11A-11D) such that the coil (12) runs around the iron core assembly (11A-11D); and - before or after mounting the coil (12): Attaching the iron core assembly (11A-11D) to a first and a second support (10A, 10B) in such a way as to ◯ that these are spaced apart from each other in a spacing direction (X) and each has a first fastening point (100A, 100B) and a second fastening point (100C, 100D) arranged offset to it along an offset direction (Y) perpendicular to the spacing direction (X) and ◯ that between the first and the second girder (10A, 10B) the iron core arrangement (11A-11D) is arranged with the first section (110) extending from the first attachment point (100A) of the first girder (10A) to the second attachment point (100D) of the second girder (10B), and the second section (111) extending from the second attachment point (100C) of the first girder (10A) to the first attachment point (100B) of the second girder (10B).

Images