Plug-in coil, busbar, device, stator, vehicle and method for producing a device for a stator

Abstract

A plug-in coil for arrangement on a busbar is proposed. The plug-in coil comprises a contact region, a deformation region, and a spacing region. The contact region is designed for electrical contact with the busbar. The contact region is arranged at one end of the plug-in coil. A longitudinal extension of the plug-in coil is rectilinear in the contact region. The deformation region borders the contact region, and a longitudinal extension of the plug-in coil is curved in the deformation region. The spacing region borders the deformation region, and a longitudinal extension of the plug-in coil is rectilinear in the spacing region.

Description

[0001] The present invention relates to a plug-in coil, a busbar, a device, a stator, a vehicle and a method for producing a device for a stator.

[0002] In an electrical machine, plug-in coils of a stator can be electrically contacted via a busbar. During operation of an electrical machine, a contact point between a plug-in coil and a busbar is exposed to oscillations and vibrations that can lead to stress on the contact point. This can impair or even destroy the contact between the plug-in coil and the stator. To prevent this, plug-in coil supports can be used to ensure vibration resistance, particularly for long plug-in coils. In addition, a winding head, including the plug-in coils and the contact points with the busbars, can be potted to ensure vibration resistance. These additional measures are time-consuming and costly.Against this background, it is an object of the present invention to improve contact between a plug-in coil and a busbar, in particular by providing an improved plug-in coil and / or an improved busbar.

[0003] The object of the invention is achieved by a plug-in coil, a busbar, a device, a stator, a vehicle, and a method for producing a device for 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.

[0004] According to a first aspect of the invention, a plug-in coil for arrangement on a busbar is proposed. The plug-in coil comprises a contact region, a deformation region, and a spacing region. The contact region is designed for electrical contact with the busbar. The contact region is arranged at one end of the plug-in coil. A longitudinal extension of the plug-in coil is rectilinear in the contact region. The deformation region borders the contact region, and a longitudinal extension of the plug-in coil is curved in the deformation region. The spacing region borders the deformation region, and a longitudinal extension of the plug-in coil is rectilinear in the spacing region. By curving the plug-in coil in the deformation region, a shape of the plug-in coil can be advantageously adapted for arrangement on a busbar. Optionally or alternatively, a prestress of the plug-in coil can be achieved by curving the plug-in coil in the deformation region.This allows the plug-in coil to be advantageously positioned on a busbar. The different areas of the plug-in coil can thus improve contact between the plug-in coil and a busbar.

[0005] In one embodiment, the contact area and the deformation area together can have a maximum length of 20 mm. This maximum length of 20 mm allows for a compact stator design.

[0006] According to a second aspect of the invention, a busbar for receiving a plug-in coil is proposed. The busbar comprises a contact region and a through-opening. The contact region is designed for electrical contact with the contact region of the plug-in coil as described above. The through-opening is designed for the passage of the plug-in coil. The plug-in coil can be advantageously arranged on the busbar through the through-opening. In particular, the through-opening, in interaction with the deformation region, can lead to advantageous contact between the two contact regions, i.e. the contact region of the plug-in coil and the contact region of the busbar. The through-opening can enable more precise positioning of the plug-in coil relative to the busbar. This can improve the supporting function of the busbar.In particular, a plug-in coil can be arranged through the through-hole in such a way that it can be contacted on the inside of the busbar. By contacting the plug-in coil on the inside of the busbar, the mechanical stability of the contact between the plug-in coil and the busbar can be increased.

[0007] According to a third aspect of the invention, a device for a stator is proposed. The device comprises a plug-in coil as described above and a busbar as described above. The contact area of the busbar is electrically contacted with the contact area of the plug-in coil. The deformation area of the plug-in coil is arranged within the recess of the busbar. The area in which the contact area of the busbar and the contact area of the plug-in coil touch or are electrically contacted with one another is also referred to as the contact surface. By arranging the deformation area of the plug-in coil within the recess of the busbar, stiffening of the contact surface or electrical contact between the busbar and the plug-in coil can be achieved. This can increase a fatigue-critical natural frequency.This can lead to less relative movement of the plug-in coil relative to the busbar, which can reduce stress on the contact surface, such as a welding surface. This can result in a longer service life for the contact between the plug-in coil and the busbar.

[0008] In one embodiment, the curvature of the longitudinal extension of the plug-in coil in the deformation region can point away from or towards the contact region of the busbar. This means that the through-opening can be arranged overlapping with the contact region of the busbar in a plan view and the deformation region curves away from the contact region of the busbar, or the through-opening can be arranged next to the contact region of the busbar and the deformation region curves towards the contact region of the busbar. This allows an arrangement of the busbar relative to the plug-in coil to be varied. For example, a dimension of the busbar can be reduced by arranging the through-opening below the contact region of the busbar.

[0009] In one embodiment, the deformation region can be positively connected to an end face of the recess, or the device can further comprise an insulating structure, and the insulating structure can be clamped between the deformation region of the plug-in coil and an end face of the recess. The positive connection can improve contact between the busbar and the plug-in coil. This can provide additional fixation of the plug-in coil relative to the busbar.

[0010] In one embodiment, the device can further comprise a damping element. The damping element is arranged in the through-opening. The damping element can improve the fixation of the plug-in coil relative to the busbar. Optionally or alternatively, the damping element can dampen vibration of the device. The improved fixation and / or the damped vibration can improve the mechanical stability of the contact surface between the plug-in coil and the busbar. This can increase the service life of the device.

[0011] According to a fourth aspect of the invention, a stator comprising the device as described above is proposed. By using a device in a stator, the service life of the stator can be improved.

[0012] According to a fifth aspect of the invention, a vehicle is proposed. The vehicle comprises an electric machine configured to drive the vehicle. The electric machine comprises a stator and a device as described above, or a stator as described above. Particularly when used in a vehicle, a stator according to the invention or a device according to the invention can reduce the need for repairs due to the vibrations occurring in a vehicle.

[0013] According to a sixth aspect of the invention, a method for producing a stator is proposed. The method comprises inserting a plug-in coil through a through-opening of a busbar, wherein a contact region of the plug-in coil is arranged at a distance from a contact region of the busbar. The method further comprises acting on an end of the plug-in coil such that a rectilinear longitudinal extent of the plug-in coil is curved in a deformation region and the contact region of the plug-in coil is brought into contact with the contact region of the busbar. By deforming the deformation region, the contact region of the plug-in coil can advantageously be brought into contact with the contact region of the busbar. Furthermore, the busbar can serve to support the plug-in coil, in particular the end of the plug-in coil comprising the contact region of the plug-in coil.This can improve the mechanical stability of a connection between the plug-in coil and the busbar. Optionally, the method can include electrically contacting the contact area of the plug-in coil with the contact area of the busbar.

[0014] 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 shows side views of various plug-in coils for arrangement on a busbar; Fig. 2a and Fig. 2b show oblique, side views of various embodiments of a busbar for receiving a plug-in coil; Fig. 3a-3h show different views of different embodiments of a device for a stator; Fig. 4a-4h show different views of different embodiments of a device for a stator; Fig. 5a-5c show various oblique, lateral plan views of a stator comprising a device according to Fig. 3; Fig. 6 shows an embodiment of a vehicle; and Fig. 7 shows a block diagram of an embodiment of a method for producing a device for a stator.

[0015] Fig. 1a and Fig. 1b show side views of various plug-in coils 100a, 100b for arrangement on a busbar. The plug-in coil 100a, 110b comprises a first contact region 110a, 110b. The contact region 110a, 110b is arranged at one end of the plug-in coil 100a, 100b. The contact region 110a, 110b is designed for electrical contact with the busbar. A longitudinal extension of the plug-in coil is rectilinear in the contact region 110a, 110b (indicated by the dashed line).

[0016] Furthermore, the plug-in coil 100a, 100b comprises a deformation region 120a, 120b. The deformation region 120a, 120b borders the contact region 110a, 100b. In particular, the deformation region 120a, 120b borders directly the contact region 110a, 110b. This means that along the longitudinal extent of the plug-in coil 100a, 100b, the deformation region 120a, 120b can be located directly adjacent to the contact region 110a, 110b. The spacing region 130a, 130b borders the deformation region 120a, 120b, and a longitudinal extent of the plug-in coil 100a, 100b is rectilinear in the spacing region 130a, 130b. Due to the curvature of the plug-in coil 100a, 100b in the deformation region 120a, 120b, the shape of the plug-in coil can be advantageously adapted for arrangement on a busbar. For example, the plug-in coil 100a, 100b can be adapted to different busbars, as described in more detail, e.g., with reference to Fig. 2. Optionally or alternatively, the curvature of the plug-in coil 100a, 100b in the deformation region 120a, 120b can achieve a prestressing of the plug-in coil 100a, 100b. This allows the plug-in coil 100a, 100b to be advantageously arranged on a busbar. The different regions of the plug-in coil 100a, 100b can thus improve contact between the plug-in coil 100a, 100b and a busbar.

[0017] In one embodiment, the contact region 110a, 110b and the deformation region 120a, 120b together can have a maximum length of 20 mm. The maximum length of 20 mm allows for a compact stator design. Alternatively, the maximum length can be 30 mm, 40 mm, 50 mm, or 10 mm.

[0018] The plug-in coil 100a, 100b can, for example, be inlay windings or hairpin plug-in coils. A hairpin plug-in coil is generally understood to be a plug-in coil with a U-shaped geometry. In addition to hairpin plug-in coils with a U-shaped geometry, the so-called I-pin technology and the wave winding concept (continuous hairpin) are also considered plug-in coil technologies. The plug-in coil 100a, 100b can therefore be manufactured using one of these processes, for example.

[0019] The curvature of the plug-in coil 100a, 100b in the deformation region 120a, 120b can correspond to a curvature of the longitudinal extent of a maximum of 30°, or a maximum of 25°, or a maximum of 20°, or a maximum of 15°, or a maximum of 10°, or a maximum of 5°. This means that a longitudinal extent of the plug-in coil 100a, 100b can largely extend along the same direction in the contact region 110a, 110b and the spacing region 130a, 130b. For example, the contact region 110a, 110b and the spacing region 130a, 130b can largely extend in the x-direction. Accordingly, no change in the direction of the longitudinal extent of the plug-in coil 100a, 100b can occur due to the deformation region 120a, 120b. The deformation region 120a, 120b cannot be designed to deflect a longitudinal extension of the plug-in coil 100a, 100b, for example because a curvature of the deformation region 120a, 120b is too small.The curvature of the deformation region 120a, 120b can in particular only be large enough for arrangement on a busbar, in particular a busbar as described with reference to . Fig. 2a and Fig. 2b.

[0020] Fig. 2a and Fig. 2b show oblique, lateral plan views of various embodiments of a busbar 200a, 200b for receiving a plug-in coil. The busbar 200a, 200b comprises a contact area 210 and a through-opening 220a, 220b. The contact area 210 is designed for electrical contact with the contact area of the plug-in coil, as described with reference to Fig. 1. The through-opening 220a, 220b is designed for the passage of the plug-in coil (as described with reference to Fig. 1). This means that a plug-in coil can be passed through the through-opening 220a, 220b, so that the plug-in coil can be arranged on a radially inner side surface 212 of the busbar 200a, 200b. Accordingly, the contact region 210 can be formed on a radially inner side surface 212 of the busbar 200a, 200b. As a result, the plug-in coil can be supported by the radially inner side surface 212. Furthermore, the plug-in coil can be supported in the region of the through-opening 220a, 220b through the through-opening 220a, 220b. This can, for example, reduce vibration or oscillation of the plug-in coil.

[0021] As in Fig. 2a, the through-opening 200a can be arranged in a radial region of the contact region 210. That is, in a plan view, the through-opening 200a can be arranged below the contact region 210. Alternatively, as shown in Fig. 2b, the through-opening 200b can be arranged radially spaced from the contact area 210. This means that, in a plan view, the through-opening 200b can be arranged radially inward relative to the contact area 210. By arranging the through-opening 220a, 220b, a curvature of the plug-in coil can be adjusted. This allows, for example, a dimension of the contact area between the busbar 200a, 200b and the plug-in coil to be adjusted (as described with reference to Fig. 3 and Fig. 4 described in more detail).

[0022] Fig. 3a-3h and 4a-4h show different views of different embodiments of a device 300, 400 for a stator. Fig. 3 shows a device 300 comprising a plug-in coil 100a as described with reference to Fig. 1 and a busbar 200a as described with reference to Fig. 2 described. Fig. 4 shows an apparatus 400 comprising a draw coil 100b as described with reference to Fig. 1 and a busbar 200b as described with reference to Fig. 2 described.

[0023] As in the Fig. 3 and Fig. 4, the contact area 110 of the busbar 200a, 200b is in contact with the contact area 210 of the plug-in coil 100a, 100b. This contact forms a contact surface that electrically contacts the busbar 200a, 200b with the plug-in coil 100a, 100b. A concrete representation of the electrical connection is shown in the Fig. 3 and Fig. 4 is not shown for reasons of clarity. The electrical connection between the busbar 200a, 200b and the plug-in coil 100a, 100b can be provided, for example, by welding, soldering, screwing, or press-fitting. For example, a welded connection or a soldered connection can define a contact surface between the busbar 200a, 200b and the plug-in coil 100a, 100b.

[0024] The dimensions of the contact surface can depend on the arrangement of the through-hole. The arrangement of the through-hole can vary the curvature of the deformation area of the plug-in coil 100a, 100b. By varying the curvature of the deformation area of the plug-in coil 100a, 100b, the contact area between the plug-in coil 100a, 100b and the busbar 200a, 200b can be varied.

[0025] As in Fig. 3e, Fig. 3f, Fig. 4e and Fig. As can be seen in Figure 4f, the contact area between the plug-in coil or 100a, 100b and the busbar 200a, 200b can be varied by curving the plug-in coil 100a, 100b. For example, by arranging the through-hole below the contact area of the busbar 200a, the contact area can be increased relative to the contact area for the busbar 200b. Optionally, a dimension of the contact area for the busbar 200a can be adjusted by a dimension of the through-hole.

[0026] On the one hand, a larger contact area can be advantageous because it can improve electrical contact. On the other hand, the electrical contact between plug-in coil 100a, 100b and busbar 200a, 200b can result in lower fatigue strength for the contact area of plug-in coil 100a, 100b and the contact area of busbar 200a, 200b. This means that a smaller contact area can reduce the area with reduced fatigue strength. Accordingly, the dimensioning of the through-hole and / or the arrangement of the through-hole can be adjusted depending on the required parameters. This results in a wide variety of design freedoms for the device 300, 400.

[0027] In particular, by using the through-hole and the associated curvature of the plug-in coil 100a, 100b, an oscillating movement of the device 300, 400 during operation can be shifted away from the contact surface, for example, into the deformation region and / or the spacing region of the plug-in coil 100a, 100b. In the deformation region and / or the spacing region of the plug-in coil 100a, 100b, the mechanical properties of the plug-in coil are less strongly influenced by the electrical contact between the contact region of the plug-in coil 100a, 100b and the contact region of the busbar 200a, 200b compared to the contact region of the plug-in coil 100a, 100b. This means that the areas of the plug-in coil 100a, 100b which are not electrically contacted with the busbar 200a, 200b along a longitudinal extent of the plug-in coil 100a, 100b can have a higher fatigue strength.By shifting vibrations and / or oscillations to these areas, the service life of the device 300, 400 can be increased.

[0028] In one embodiment, the curvature of the longitudinal extension of the plug-in coil in the deformation area can be directed away from the contact area of the busbar (see Fig. 3 and Fig. 1a) or towards it (see Fig. 4 and Fig. 1 b) show.

[0029] In one embodiment, the deformation region can be positively connected to an end face of the through-opening. The positive connection of the deformation region of the plug-in coil to an end face of the through-opening enables force transmission between the busbar 200a, 200b and the plug-in coil 100a, 100b. This allows vibrations and / or oscillations to be transmitted from the plug-in coil 100a, 100b to the busbar 200a, 200b. This allows mechanical stress on the plug-in coil 100a, 100b to be reduced. In particular, the busbar 200a, 200b can thus additionally support the plug-in coil 100a, 100b in the area of the through-opening. Alternatively, the device 300, 400 may comprise an insulation structure clamped between the deformation region of the plug-in coil 100a, 100b and an end face of the through-opening.

[0030] In one embodiment, the device 300, 400 may further comprise a damping element. The damping element is arranged in the through-opening 220a, 220b. The damping element may be in contact with the plug-in coil 100a, 100b. As a result, vibration and / or oscillation can be transmitted from the plug-in coil 100a, 100b to the damping element. This means that the damping element can reduce mechanical stress on the plug-in coil 100a, 100b.

[0031] The damping element can, for example, be a clamping element, for example, having a conical shape. The clamping element can be made of plastic, rubber, and / or an elastomer. The clamping element can, for example, have elevations and / or depressions, for example in the form of compression ribs.

[0032] Optionally or alternatively, the damping element can press or press the plug-in coil 100a, 100b against the busbar 200a, 200b. This can improve the damping of the mechanical load on the plug-in coil 100a, 100b by the busbar 200a, 200b.

[0033] The damping element can improve the fixation of the plug-in coil 100a, 100b relative to the busbar 200a, 200b. Optionally or alternatively, the damping element can dampen vibration of the device 300, 400. The improved fixation and / or the dampened vibration can improve the mechanical stability of the contact surface between the plug-in coil 100a, 100b and the busbar 200a, 200b. This can increase the service life of the device 300, 400.

[0034] Optionally, the device 300, 400 can be reshaped. For example, reshaping can reduce mechanical stress on the contact surface. In particular, reshaping can fix the plug-in coil 100a, 100b relative to the busbar 200a, 200b. This means that reshaping can increase the stability of the contact surface between the busbar 200a, 200b and the plug-in coil 100a, 100b. For example, reshaping can include or be overmolding of the device 300, 400. Optionally or alternatively, reshaping can include or be bonding the busbar 200a, 200b to the plug-in coil 100a, 100b.

[0035] Fig. 5a-5c show various oblique, lateral plan views of a stator 500 comprising a device according to Fig. 3. The Fig. 5 corresponds to one embodiment. In other embodiments, the stator 500 may comprise a device according to Fig. 4 or devices according to Fig. 3 and Fig. 4 include.

[0036] The stator 500 comprises a winding head from whose end face a plurality of plug-in coils 540 protrude. A plurality of busbars 550 are arranged on the plurality of plug-in coils 540 (for reasons of clarity, not all plug-in coils and busbars are designated by a reference numeral). For example, a busbar can be arranged on only one plug-in coil and electrically contacted therewith. Optionally, a busbar 552 can be arranged on three plug-in coils and electrically contacted therewith. In this case, the busbar 552 can function as a star point.

[0037] Fig. 6 shows an embodiment of a vehicle 600. The vehicle includes an electric machine 610 configured to drive the vehicle 600. The electric machine 610 includes a device 620, such as described, for example, with reference to Fig. 3 and / or 4 or a stator 630, such as described with reference to Fig. 5. The device 620 according to the invention has additional advantages, particularly in the field of application of a vehicle: strong vibrations and / or oscillations can occur during operation of a vehicle. This vibration and / or oscillation can lead to considerable stress on a circuit, in particular on a contact surface between a busbar and a plug-in coil. By using the device 620, mechanical stress on the contact surface can be reduced. This can increase the service life of the vehicle or individual components of the vehicle, for example the stator.

[0038] Fig. 7 shows a block diagram of an embodiment of a method 700 for manufacturing a device for a stator. The method 700 can be used, for example, to manufacture a device as described with reference to Fig. 3 and / or Fig.4. The method 700 comprises pushing 710 a plug-in coil through a through-opening of a busbar, wherein a contact region of the plug-in coil is arranged at a distance from a contact region of the busbar. Furthermore, the method 710 comprises acting 720 a force on one end of the plug-in coil, such that a rectilinear longitudinal extent of the plug-in coil is curved in a deformation region and the contact region of the plug-in coil is brought into contact with the contact region of the busbar. By deforming the deformation region, the contact region of the plug-in coil can advantageously be brought into contact with the contact region of the busbar. Optionally, the method 710 can comprise, after the force has been applied, electrically contacting the contact region of the plug-in coil with the contact region of the busbar. For example, the electrical contacting can comprise soldering, welding or screwing.consist of them. The electrical contact can therefore fix the plug-in coil to the busbar. In particular, the electrical contact can form the contact surface between a contact area of the plug-in coil and a contact area of the busbar. Reference symbol 100a, 100b plug-in coil 110a, 100b contact area 120a, 120b deformation area 130a, 130b distance range 200a, 200b busbar 210 Contact area 212 radially inner side surface 220a, 220b passage opening 300 device 400 device 500 stator 540 plug-in coil 550, 552 busbar 600 vehicles 610 electric machine 620 device 630 Stator 700 Method for producing a device for a stator 710 Inserting a plug-in coil through a through hole 720 Force acting on one end of the plug-in coil

Claims

[1] A plug-in coil (100) for arrangement on a busbar, comprising: a contact region (110), wherein the contact region (110) is designed for electrical contact with the busbar, wherein the contact region (110) is arranged at one end of the plug-in coil (100) and wherein a longitudinal extension of the plug-in coil (100) in the contact region (110) is rectilinear; a deformation region (120) adjacent to the contact region (110) and wherein a longitudinal extension of the plug-in coil (100) is curved in the deformation region (120); and a spacing region (130) adjacent to the deformation region (120) and wherein a longitudinal extension of the plug-in coil (100) in the spacing region (130) is rectilinear. [2] The plug-in coil (100) of claim 1, wherein the contact region (110) and the deformation region (120) together have a maximum length of 20 mm. [3] A busbar (200a, 200b) for receiving a plug-in coil (100), comprising: a contact region (210), wherein the contact region (210) is designed for electrical contact with the contact region (210) of the plug-in coil (100) of claim 1 or 2; and a through-opening (220a, 220b), wherein the through-opening (220a, 220b) is designed for the passage of the plug-in coil (100). [4] A device (300, 400) for a stator, comprising a plug-in coil (100) according to claim 1 or 2 and a busbar (200a, 200b) according to claim 3, wherein the contact region (210) of the busbar (200a, 200b) is electrically contacted with the contact region (110) of the plug-in coil (100); and wherein the deformation region (120) of the plug-in coil (100) is arranged within the through-opening (220a, 220b) of the busbar (200a, 200b). [5] The device (300, 400) according to claim 4, wherein the curvature of the longitudinal extent of the plug-in coil (100) in the deformation region (120) points away from or towards the contact region (210) of the busbar (200a, 200b). [6] The device (300, 400) according to claim 4 or 5, wherein the deformation region (120) is positively connected to an end face of the through-opening (220a, 220b) or the device (300, 400) comprise an insulation structure, wherein the insulation structure is clamped between the deformation region (120) of the plug-in coil (100) and an end face of the through-opening (220a, 220b). [7] The device (300, 400) according to claim 4 or 5, further comprising a damping element, wherein the damping element is arranged in the through opening (220a, 220b). [8] A stator (500) comprising: a device (300, 400) according to any one of claims 4-7. [9] Vehicle (600), comprising: an electric machine (610) configured to drive the vehicle (600), wherein the electric machine (610) comprises a stator (500) according to claim 8 or a device (300, 400) according to any one of claims 4-7. [10] Method (700) for producing a device for a stator, comprising inserting (710) a plug-in coil through a through-opening of a busbar, wherein a contact region of the plug-in coil is arranged at a distance from a contact region of the busbar; and acting (720) a force on one end of the plug-in coil such that a rectilinear longitudinal extension of the plug-in coil is curved in a deformation region and the contact region of the plug-in coil is brought into contact with the contact region of the busbar.

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