Winding head for an electrical machine and method for producing a winding head

Abstract

The invention presented relates to a winding head (100) for an electrical machine (200), wherein the winding head (100) comprises a plurality of winding bars (101, 601, 602, 603, 604, 605, 606) arranged in layers, wherein each winding bar (101) comprises a front surface and a rear surface, wherein each winding bar (101) comprises a base surface and a cover surface, wherein each winding bar (101) comprises a left side surface and a right side surface, wherein the front surface, the rear surface, the base surface and the cover surface each extend along a longitudinal axis of a winding bar (101), wherein a height of the left side surface and the right side surface is determined by a material thickness of the respective winding bar (101), and wherein respective winding bars (101) are stacked on one another in such a way that the base surface of a first winding bar (101) a cover surface of an adjacent winding bar (101) is at least partially superimposed,wherein respective winding bars (101) are spaced apart from one another, and wherein respective winding bars (101) extend in their course through the winding head (100) from an initial position to a target position, wherein the initial position differs from the target position.,

Description

[0001] The presented invention relates to a winding head for an electrical machine, a stator, an electrical machine and a method for producing the winding head, according to the appended claims.

[0002] Winding heads are part of electrical machines for providing electrical power and / or for providing electrical current.

[0003] Winding heads usually comprise electrical conductors wound in several layers, which are assigned to different phases, for example.

[0004] Winding heads are known whose layers are stacked on top of each other in such a way that their maximum heights add up to the total height of a wire mesh.

[0005] Furthermore, DE 102 39 730 A1 describes a stator for a rotating field machine in which the respective layers in the wire mesh area are flattened in order to make the stator as compact as possible.

[0006] Furthermore, DE 10 2017 102 314 A1 describes a stator comprising flat wire windings that run parallel at least in some areas.

[0007] Within the scope of the invention presented, a winding overhang for an electrical machine, a stator, an electrical machine, and a method for producing the winding overhang are presented. Further features and details of the invention emerge from the respective subclaims, the description, and the drawings. Features and details described in connection with the winding overhang according to the invention naturally also apply in connection with the stator according to the invention, the electrical machine according to the invention, and the method according to the invention for producing the winding overhang, and vice versa, so that with regard to the disclosure of the individual aspects of the invention, reference is always made to each other.

[0008] Against this background, it is an object of the invention presented to provide a particularly compact winding head for an electrical machine.

[0009] Thus, according to a first aspect of the invention presented, a winding head for an electrical machine is presented.

[0010] The winding head presented comprises a plurality of winding bars arranged in layers, each winding bar comprising a front surface and a rear surface, each winding bar comprising a base surface and a cover surface, each winding bar comprising a left side surface and a right side surface, the front surface, the rear surface, the base surface and the cover surface each extending along a longitudinal axis of a winding bar, a height of the left side surface and the right side surface being determined by a material thickness of the respective winding bar, and respective winding bars being stacked on top of one another in such a way that the base surface of a first winding bar at least partially overlies a cover surface of an adjacent winding bar, the respective winding bars being spaced apart from one another,and wherein respective winding bars extend through the winding head from an initial position to a target position, wherein the initial position differs from the target position.,

[0011] In the context of the invention presented, a winding bar is understood to mean an elongated metallic conductor, in particular a flat wire.

[0012] In the context of the invention presented, a layer is understood to mean a position of a winding bar in a stack of several winding bars.

[0013] The winding head presented is based on a special winding of the winding bars into one another, so that the base area of ​​a first winding bar overlaps a cover area of ​​an adjacent winding bar at least in part and respective winding bars extend in their course through the winding head from an initial position to a target position, wherein the initial position differs from the target position.

[0014] The superposition, in which the respective winding bars are guided parallel to each other with minimal distance from each other, achieves a particularly compact arrangement of the winding bars.

[0015] Furthermore, by transferring the respective winding bars from an initial position to a target position different from the initial position, a self-twisted winding head is provided, whereby the installation height of the winding head is further minimized.

[0016] For example, a respective winding bar can be transferred from a starting position, such as a first position, to a plurality of target positions, such as a second, third, fourth, fifth, or sixth position. Furthermore, a respective winding bar can be transferred from a starting position to a target position and back to the starting position.

[0017] The winding bars of the winding head presented run in several layers, with each winding bar changing its position as it passes through the winding head.

[0018] In order to change the position of a winding bar, it is bent or curved particularly sharply in one area, creating a free space into which another winding bar can engage, causing the winding head to twist in on itself.

[0019] For example, it can be provided that a cross-section of the base area and the cover area is larger than a cross-section of the front area and the rear area

[0020] It can be provided that respective winding bars are bent radially outwards or radially inwards, wherein respective winding bars are aligned with their flat side in the axial direction.

[0021] By aligning the winding bars in the axial direction, the installation height of the winding head is further minimized.

[0022] By bending the winding bars radially outwards or inwards, the packing density of the winding head is maximized.

[0023] It can further be provided that each winding bar extends from an initial position in an initial layer over a predetermined initial length, wherein the initial length merges into a path which transfers the winding bar from the initial layer to the target layer.

[0024] Over an initial length, each winding bar can be guided parallel to an adjacent winding bar and then transferred to the target position, for example by bending or curving.

[0025] It can further be provided that at least two selected winding bars run together as a stack, so that the starting layers of the selected winding bars lie directly above one another and the target layers of the selected winding bars lie directly above one another and the at least two selected layers run directly next to one another.

[0026] By designing at least two winding bars as a stack, so that the at least two winding bars run, for example, completely parallel to each other, a particularly compact design of the winding head is achieved.

[0027] It can further be provided that a first number of selected winding bars run in a first row and a second number of selected winding bars run in a second row, wherein the first row runs along a radial axis of the winding head at least in regions next to the second row.

[0028] By having several rows of winding bars or parts of winding bars running next to each other in the radial direction, the packing density of the winding head is maximized and the installation height of the winding head is minimized.

[0029] It can further be provided that at least a third number of winding bars engages in the first row and / or the second row, and a fourth number of winding bars runs in a third row, so that four layers of winding bars running at least partially next to each other along the radial axis of the winding head form three rows.

[0030] By engaging one row of winding bars with another row of winding bars, the packing density of the winding head is maximized and the expansion of the winding head in the radial direction is minimized or the free space inside the winding head is maximized.

[0031] According to a second aspect, the presented invention relates to a stator for an electrical machine in a motor vehicle.

[0032] The stator comprises a stator base body with a first base body end face, a second base body end face, a base body longitudinal axis, stator teeth, and stator slots formed between the stator teeth, wherein in each stator slot a plurality of winding bars are arranged one above the other in the radial direction, wherein respective winding bars are assigned to one of several phases of the stator and form winding heads on the first base body end face and the second base body end face, wherein the winding bars on the first base body end face are interlaced in the circumferential direction and are mechanically and electrically coupled to a respective winding bar in a circumferentially offset stator slot, wherein at least some of the number of winding bars in a respective winding head are interlaced in the radial direction in such a way thatthat respective winding bars in adjacent stator slots on the first base body end face are transferred in the circumferential direction from an initial position to a target position, and wherein the initial position differs from the target position.

[0033] In particular, the presented stator comprises at least one possible design of the presented winding head.

[0034] According to a third aspect, the presented invention relates to an electrical machine, such as a generator or a motor, wherein the electrical machine comprises at least one possible embodiment of the presented winding head and / or one possible embodiment of the presented stator.

[0035] Due to the winding head and the stator presented, the electrical machine presented is particularly compact and powerful.

[0036] It may be provided that the electrical machine has fewer than seven poles.

[0037] In particular, the presented electrical machine can have 3 or 6 poles.

[0038] It can further be provided that the winding head is integrated into a stator or a rotor of the electrical machine.

[0039] According to a fourth aspect, the presented invention relates to a method for producing a winding head for an electrical machine.

[0040] The presented method comprises forming the winding head from a plurality of layers of winding bars, each winding bar comprising a front surface and a rear surface, each winding bar comprising a base surface and a cover surface, each winding bar comprising a left side surface and a right side surface, the front surface, the rear surface, the base surface and the cover surface each extending along a longitudinal axis of a winding bar, a height of the left side surface and the right side surface being determined by a material thickness of the respective winding bar, and respective winding bars being stacked on top of one another in such a way that the base surface of a first winding bar at least partially overlies a cover surface of an adjacent winding bar, respective winding bars being arranged at a distance from one another, and respective winding bars being arranged in such a way,that they change from an initial position to a target position as they pass through the winding head, whereby the initial position differs from the target position.

[0041] The method presented is used in particular for producing the winding overhang presented. It can be provided that a number of selected winding bars are each guided in an initial group to an initial position and in a target group to a target position, with the respective initial groups and respective target groups being guided as a row along a radial axis of the winding overhang, at least in some areas, next to each other.

[0042] By guiding several winding bars together in a group, such as an initial group to a target group, a particularly compact arrangement of the winding bars is achieved, since the winding bars can be guided parallel to one another, for example, with a minimum distance between the winding bars for electrical insulation.

[0043] It can further be provided that a first number of selected winding bars are guided in a first row and a second number of selected winding bars are guided in a second row, wherein the first row runs along a radial axis of the winding head at least in regions next to the second row.

[0044] By having several rows of winding bars or parts of winding bars running next to each other in the radial direction, the packing density of the winding head is maximized and the installation height of the winding head is minimized.

[0045] It can further be provided that at least a third number of selected winding bars is guided in a further row, wherein the further row is inserted into the first row and / or the second row, so that three rows are formed by four layers of winding bars running at least partially next to one another along the radial axis of the winding head.

[0046] By inserting winding bars into an existing row, an overlay of several winding bars in a row is achieved, so that radial expansion of the winding head is minimized.

[0047] It can further be provided that at least a fifth number of selected winding bars is guided in a further row, wherein the further row is inserted into the second row and / or the third row, so that four rows are formed by six layers of winding bars running at least partially next to one another along the radial axis of the winding head.

[0048] Further advantages, features, and details of the invention will become apparent from the following description, which describes embodiments of the invention in detail with reference to the drawings. The features mentioned in the claims and in the description may be essential to the invention individually or in any combination. They show: Fig. 1 a first possible design of the winding head presented, Fig. 2 a second possible design of the winding head presented, Fig. 3 a third possible design of the winding head presented, Fig. 4 a possible design of the presented electrical machine with a possible design of the presented stator, Fig. 5 a detailed representation of a possible design of the winding head presented, Fig. 6 a further detailed representation of a possible design of the winding head presented, Fig. 7 a possible design of the presented procedure.

[0049] In Fig. 1 shows a part of a winding head 100 for an electrical machine 200.

[0050] The winding head 100 comprises a plurality of winding bars 101, which are arranged in layers 1 to 6, for example.

[0051] The winding bars 101 are made of flat wire, for example, and are electrical conductors and electrically insulated from each other by a minimum distance.

[0052] In Fig. 1, all winding bars 101 are stacked on top of each other, creating a high winding head 100, which, however, provides a free interior area for I-pins or a circuit, as indicated by arrow 103. This allows a circuit to be integrated into the winding head 100.

[0053] In Fig. Figure 2 shows a winding head 100 in a configuration with four rows 105, 107, 109, and 111 extending radially adjacent to one another. Layers 5 and 6 extend individually, while layers 1 and 3, as well as layers 2 and 4, are stacked on top of one another, so that layers 1 to 4 extend in the four rows 105, 107, 109, and 111.

[0054] In Fig. Figure 3 shows a winding head 100 in a configuration with four rows 105, 107, 109, and 111 extending radially next to one another. Layers 3 and 4 are inserted into layers 1 and 2, and layers 5 and 6 are inserted into layers 3 and 4.

[0055] Here it can also be seen that each winding bar 101 comprises a front surface 113 and a rear surface 115, each winding bar 101 comprises a base surface 117 and a cover surface 119, and each winding bar 101 comprises a left side surface 121 at a left end and a right side surface 123 at a right end.

[0056] The front surface 113, the rear surface 115, the base surface 117 and the cover surface 119 each extend along a longitudinal axis of a winding bar 101, wherein a height of the left side surface 121 and the right side surface 123 is determined by a material thickness of the respective winding bar 101, and wherein respective winding bars 101 are stacked on one another in such a way that the base surface 117 of a first winding bar 101 overlaps a cover surface 119 of an adjacent winding bar 101 at least in some areas.

[0057] In Fig. 4 shows an electrical machine 200. The electrical machine 200 comprises a stator 201 having a winding head 100 according to Fig. 1 includes.

[0058] In Fig. Figure 5 shows a winding head 100 in a transparent view, in which a single winding bar 101 is shown marked. Here, it can be seen that the winding bar 101 changes from a fourth layer as the starting layer to a first layer as the target layer.

[0059] In Fig. 6 shows a winding head 100 in a view in which several winding bars 601, 602, 603, 604, 605 and 606 are shown marked and additionally shown separately from further winding bars 101 of the winding head 100.

[0060] Here it can be seen that the winding bars 601, 602, 603, 604, 605 and 606 each have a front surface 607, a rear surface 608 opposite the front surface 607, a base surface 609 and a cover surface 610 opposite the base surface 609.

[0061] In Fig. 7 shows a method 300 for producing a winding head 100 for an electrical machine 200.

[0062] The method 300 comprises a forming step 301 in which the winding head is formed from a plurality of layers of winding bars, each winding bar comprising a front surface and a rear surface, each winding bar comprising a base surface and a cover surface, each winding bar comprising a left side surface and a right side surface, the front surface, the rear surface, the base surface, and the cover surface each extending along a longitudinal axis of a winding bar, a height of the left side surface and the right side surface being determined by a material thickness of the respective winding bar, and respective winding bars being stacked on top of one another in such a way that the base surface of a first winding bar at least partially overlies a cover surface of an adjacent winding bar, respective winding bars being arranged spaced apart from one another, and respective winding bars being arranged in such a waythat they change from an initial position to a target position as they pass through the winding head, whereby the initial position differs from the target position. List of reference symbols 100 winding head 101 winding bar 103 Arrow 105 first row 107 second row 109 third row 111 fourth row 113 front surface 115 rear surface 117 floor space 119 deck area 121 left side panel 123 right side panel 200 electric machine 201 Stator 300 procedures 301 educational step 601 winding bar 602 winding bar 603 winding bar 604 winding bar 605 winding bar 606 winding bar QUOTES CONTAINED IN THE DESCRIPTION

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

[0000] DE 102 39 730 A1

[0005] DE 10 2017 102 314 A1

[0006]

Claims

[1] Winding head (100) for an electrical machine (200), wherein the winding head (100) comprises a plurality of winding bars (101, 601, 602, 603, 604, 605, 606) arranged in layers, wherein each winding bar (101) comprises a front surface (113) and a rear surface (115), wherein each winding bar (101) comprises a base surface (117) and a cover surface (119), wherein each winding bar (101) comprises a left side surface (121) at a left end and a right side surface (123) at a right end, wherein the front surface (113), the rear surface (115), the base surface (117) and the cover surface (119) each extend along a longitudinal axis of a winding bar (101), wherein a height of the left side surface (121) and the right side surface (123) is determined by a material thickness of the respective winding bar (101), and wherein respective winding bars (101) are stacked on top of one another in such a way that the base surface (117) of a first winding bar (101) overlaps a cover surface (119) of an adjacent winding bar (101) at least in some areas, wherein respective winding bars (101) are spaced apart from each other, and wherein respective winding bars (101) extend through the winding head (100) from an initial position to a target position, where the initial position differs from the target position. [2] Winding head (100) according to claim 1, characterized by , that respective winding bars (101) are bent radially outwards or radially inwards, wherein respective winding bars (101) are aligned with their flat side in the axial direction. [3] Winding head (100) according to claim 1 or 2, characterized by , that each winding bar (101) extends from an initial position in an initial position over a predetermined initial length, wherein the initial length merges into a path which transfers the winding bar (101) from the initial position to the target position. [4] Winding head (100) according to one of the preceding claims, characterized by that at least two selected winding bars (101) run together as a stack, so that the starting layers of the selected layers lie directly above one another and / or the target layers of the selected layers lie directly above one another and the at least two selected layers run parallel to one another at least in some areas. [5] Winding head (100) according to one of the preceding claims, characterized by , that a first number of selected winding bars (101) runs in a first row (105) and a second number of selected winding bars (101) runs in a second row (107), wherein the first row (105) runs along a radial axis of the winding head (100) at least partially adjacent to the second row (107). [6] Winding head (100) according to claim 5, characterized by that at least a third number of winding bars (101) engages in the first row (105) and / or the second row (107), and a fourth number of winding bars (101) runs in a third row (109), so that four layers of winding bars (101) running at least partially next to one another along the radial axis of the winding head form three rows. [7] Stator (201) for an electric machine (200) in a motor vehicle, the stator (201) comprising: a stator base body with a first base body end face, a second base body end face, a base body longitudinal axis, stator teeth and stator slots formed between the stator teeth, wherein in each stator slot a plurality of winding bars (101) are arranged one above the other in the radial direction, wherein respective winding bars (101) are assigned to one of several phases of the stator (201) and form winding heads (100) on the first base body end face and the second base body end face, wherein the winding bars (101) are interlaced in the circumferential direction on the first base body end face and are mechanically and electrically coupled to a respective winding bar (101) in a circumferentially offset stator slot, wherein at least some of the number of winding bars (101) in a respective winding head (100) are interlaced in the radial direction such that respective winding bars (101) in adjacent stator slots on the first base body end face are transferred in the circumferential direction from an initial position to a target position, wherein the initial position differs from the target position. [8] Electrical machine (200), wherein the electrical machine (200) comprises at least one winding head (100) according to one of claims 1 to 6 and / or a stator (201) according to claim 7. [9] Electrical machine (200) according to claim 8, characterized by that the electrical machine (200) has fewer than seven poles. [10] Electrical machine (200) according to claim 9, characterized by that the winding head (100) is integrated into a stator (201) or into a rotor of the electrical machine (200). [11] Method (300) for producing a winding head (100) for an electrical machine (200), the method (300) comprising: Forming (301) the winding head (100) from a plurality of winding bars (101) arranged in layers, wherein each winding bar (101) comprises a front surface (113) and a rear surface (115), wherein each winding bar (101) comprises a base surface (117) and a cover surface (119), wherein each winding bar (101) comprises a left side surface (121) and a right side surface (123), wherein the front surface (113), the rear surface (115), the base surface (117) and the cover surface (119) each extend along a longitudinal axis of a winding bar (101), wherein a height of the left side surface (121) and the right side surface (123) is determined by a material thickness of the respective winding bar (101), and wherein respective winding bars (101) are stacked on top of one another in such a way that the base surface (117) of a first winding bar (101) overlaps a cover surface (119) of an adjacent winding bar (101) at least in some areas, wherein respective winding bars (101) are arranged at a distance from one another, and wherein respective winding bars (101) are arranged such that they change from an initial position to a target position in their course through the winding head (100), where the initial position differs from the target position. [12] Method (300) according to claim 10 or 11, characterized by , that a number of selected winding bars (101) are each guided in an initial group to an initial position and in a target group to a target position, wherein respective initial groups and respective target groups are guided as a row along a radial axis of the winding head (100) at least in some areas next to each other. [13] Method (300) according to claim 11 or 12, characterized by , that a first number of selected winding bars (101) are guided in a first row (105) and a second number of selected winding bars (101) are guided in a second row (107), wherein the first row (105) runs along a radial axis of the winding head (100) at least partially adjacent to the second row (107). [14] Method (300) according to claim 13, characterized by that at least a third number of selected winding bars (101) is guided in a further row (109), wherein the further row (109) is inserted into the first row (105) and / or the second row (107), so that three rows are formed by four layers of winding bars (101) running at least partially next to one another along the radial axis of the winding head (100).

Images