Device for switching between different winding configurations of an electric machine, electric machine, vehicle, method for manufacturing the electric machine

Abstract

A device (100) for switching between different winding configurations of an electric machine, wherein the device (100) comprises a housing (101) being arranged to be mounted on a winding head of the machine, the housing (101) having sleeves (102) for receiving winding ends of windings of the winding head, the device (100) comprising switches (202), in particular power semiconductor switches, for switching between the different winding configurations, the switches (202) being arranged in the housing (101). The device comprising an electric machine, a vehicle comprising the electric machine, and a method for manufacturing the electric machine.

Description

[0001] The invention relates to a device for switching between different winding configurations of an electric machine, an electric machine comprising the device, a vehicle comprising the electric machine, and a method for manufacturing the electric machine, in particular for the vehicle.

[0002] DE 10 2014 018 317 A1 already discloses a device according to the preamble of claim 1.

[0003] DE 10 2022 129 131 A1 discloses a stator switching module.

[0004] DE 10 2020 126 340 A1 relates to an inverter. An inverter housing has second phase terminals for electrical connection to the second terminals of the phase windings of the stator winding. A switching unit with electronic switching elements is arranged in the inverter housing. This unit is connected to the first and second phase terminals and is configured to switch the stator winding between a star connection and an n-gon connection corresponding to the number of phases of the stator winding.

[0005] US 2003 / 0178896A1 discloses an induction motor. A stator assembly has a plurality of conductive windings. Each switching assembly is electrically connected between one end of at least one of the windings and a power supply busbar ring assembly with at least one conductor. The busbar assembly connects the power supply to one or more of the switching assemblies.

[0006] A device for switching between different winding configurations of an electric machine comprises a housing, the housing being designed to be attached to a winding head of the machine, the housing having sleeves for receiving winding ends, and the device including switches, in particular power semiconductor switches, for switching between the different winding configurations, the switches being arranged in the housing. This particularly compact design makes it possible to implement the winding switching in a small installation space.

[0007] The sleeves are preferably designed to be slipped onto the winding ends and screwed or welded to them. This simplifies assembly.

[0008] The sleeves are preferably arranged on one side of the housing, wherein the sleeves are designed to receive the winding ends on one side of the winding head, the shape of the housing on that side corresponding at least partially to the shape of the winding head on that side. This means that the shape of the housing is adapted to the shape of the winding head.

[0009] It can be provided that the housing is designed to receive part of the winding ends of a circularly designed winding head, wherein the housing includes a circular segment-shaped part for receiving the part of the winding ends, or that the housing is designed to receive the winding ends of a circularly designed winding head, wherein the housing includes a circular part for receiving the winding ends.

[0010] The device may include connections for linking the winding ends to power electronics located outside the housing, with the connections and sleeves being interconnected via electrical links and switches to enable switching. This arrangement allows the device to function as an AC interface to an inverter of the electric machine and to be integrated directly into the drive at the winding head of the electric machine.

[0011] For example, it is provided that the housing extends along an axis, with the connections outside the housing projecting radially from the housing to the axis and / or with the sleeves projecting outside the housing along the axis.

[0012] The device is designed to switch at least two windings per phase between a series and a parallel winding configuration. The electric machine is driven by current in different phases. The windings of the electric machine can be divided into a varying number of parallel branches per phase. The torque-speed characteristic of the electric machine can be influenced by the number of parallel branches. The device is designed to allow this variable behavior, for example, by switching between several winding switching concepts. Examples of these concepts include star-delta connections and parallel connections.

[0013] For cooling purposes, the device may include a cooling system integrated into the housing.

[0014] An electric machine comprising the device has the advantages described for the device.

[0015] A vehicle incorporating the electric machine exhibits the advantages described for the device.

[0016] A method for manufacturing an electric machine, particularly for a vehicle, involves sliding the sleeves of the device onto the winding ends of the electric machine and connecting them, in particular by screwing or welding. This allows for the simple manufacture of an electric machine, especially for driving a vehicle, with a small installation space.

[0017] Further advantageous embodiments can be found in the following description and the drawing. The drawing shows: Fig. 1 a schematic representation of a device for switching between different winding configurations of an electrical machine according to an exemplary embodiment, Fig. 2 a schematic representation of a side view of the device according to the exemplary embodiment, Fig. 3 a schematic representation of a front view of the device according to the exemplary embodiment, Fig. 4. A flowchart showing the steps of a process for manufacturing the electrical machine using the device.

[0018] In Fig. 1 is a device 100 for switching between different winding configurations of an electrical machine, shown schematically according to an exemplary embodiment.

[0019] According to the exemplary embodiment, the electrical machine has windings for three phases U, V, W with two branches per phase. The device 100 according to the exemplary embodiment is designed to switch between the various winding configurations that can be realized with the two branches per phase.

[0020] The device 100 is designed to switch two windings per phase between a series and a parallel configuration of the windings.

[0021] Device 100 is not limited to the version for the electric machine with three phases and windings with two branches per phase. Device 100 can, for example, be configured for windings with more branches per phase, as described for switching the branches in the exemplary embodiment. A star-delta connection configuration is also possible.

[0022] The device 100 comprises a housing 101.

[0023] The device 100 comprises sleeves 102 for connecting winding ends of windings of the electrical machine.

[0024] The device 100 includes terminals 103 for connecting the winding ends to power electronics arranged outside the housing 101.

[0025] The sleeves 102 are arranged on one side of the housing 101.

[0026] The sleeves 102 are designed to receive the winding ends on one side of the winding head.

[0027] The housing 101 extends along an axis 104. According to the exemplary embodiment, the terminals 103 extend radially outside the housing 101 to the axis 104. This means that the terminals 103 project radially from the housing 101. The terminals 103 can also project in a different orientation to the axis 104.

[0028] According to the exemplary embodiment, the sleeves 102 extend outside the housing 101 along the axis. This means that the sleeves 102 project axially from the housing 101. The sleeves 102 can also extend in a different orientation relative to the axis 104.

[0029] The shape of the housing 101 on the side of the housing 101 is, for example, at least partially corresponding to a shape of the winding head on the side of the winding head.

[0030] In this example, the housing 101 is shaped like a circular sector. The circular sector-shaped housing 101 is designed, for example, to accommodate part of the winding ends of a circularly designed winding head.

[0031] The housing can also be designed to accommodate the winding ends of a circular winding head. The housing for accommodating the winding ends of the circular winding head includes, for example, a circular section for receiving the winding ends.

[0032] For the circularly designed winding head, it can be provided that the device comprises several circular sector-shaped housings 101, which together form a circle for the circularly designed winding head.

[0033] In Fig. 2 The device 100 is shown schematically in a side view according to the exemplary embodiment.

[0034] Fig. Figure 2 shows two sleeves 102 as examples, each containing a winding end 201. Fig. Figure 2 shows an example of connection 103.

[0035] The sleeves 102 can be attached to the winding ends 201. The sleeves 102 can be screwed or welded to the winding ends 201, for example.

[0036] The device 100 comprises switches 202, in particular power semiconductor switches, for switching between different winding configurations. The switches 202 are arranged in the housing 101.

[0037] The switches 202 are implemented as SiC MOSFETs, for example. However, a different type of switch can be used for individual or all switches 202, e.g., IGBT, MOSFET, relay, contactor, thyristor.

[0038] In this example, switches 202 are bidirectional, conducting and blocking.

[0039] The device 100 according to the exemplary embodiment comprises electrical connections 203.

[0040] The terminals 103 and the sleeves 102 are connected to each other via the electrical connections 203 and the switches 202 in such a way that switching between the different winding configurations is made possible.

[0041] In Fig. Figure 3 shows the device 100 schematically in a front view according to the exemplary embodiment.

[0042] Fig. 3 represents three terminals 103 and the sleeves 102 for the beginnings and ends of coils for three different phases U, V, W, wherein the phases U, V, W each have two branches.

[0043] The terminal 103 for phase U is connected via at least one of the electrical connections 203 and one of the switches 202 to the sleeve 102 for a beginning 301 of a coil for the first branch of phase U, which can be disconnected by the switch 202.

[0044] The terminal 103 for phase U is connected via one of the electrical connections 203 to the sleeve 102 for a beginning 302 of a coil for the second branch of phase U.

[0045] The terminal 103 for phase V is connected via at least one of the electrical connections 203 and one of the switches 202 to the sleeve 102 for a beginning 303 of a coil for the first branch of phase V, which can be disconnected by the switch 202.

[0046] The terminal 103 for phase V is connected via one of the electrical connections 203 to the sleeve 102 for a beginning 304 of a coil for the second branch of phase V.

[0047] The terminal 103 for phase W is connected via at least one of the electrical connections 203 and one of the switches 202 to the sleeve 102 for a beginning 305 of a coil for the first branch of phase W via the switch 202 in a way that can be disconnected.

[0048] The terminal 103 for phase W is connected via one of the electrical connections 203 to the sleeve 102 for a beginning 306 of a coil for the second branch of phase W.

[0049] The sleeve 102 for the end 307 of the coil for the first branch of phase U, the sleeve 102 for the end 308 of the coil for the first branch of phase V and the sleeve 102 for the end 309 of the coil for the first branch of phase W are connected to each other via one of the connections 203, e.g. a busbar.

[0050] Device 100 provides further features, not in the Fig. 3 shown connections 203 and switch 202.

[0051] The sleeve 102 for the end 310 of the coil for the second branch of phase U, the sleeve 102 for the end 311 of the coil for the second branch of phase V and the sleeve 102 for the end 312 of the coil for the second branch of phase W are each connected via at least one of the connections 203 and one of the switches 202 to a common connection 203, e.g. a busbar, which can be disconnected via the respective switch 202.

[0052] The sleeve 102 for the beginning 304 of the coil for the first branch of phase U is separably connected to the sleeve 102 for the end 310 of the coil for the second branch of phase U via at least one of the connections 203 and one of the switches 202, and via the switch 202. The sleeve 102 for the beginning 305 of the coil for the first branch of phase V is separably connected to the sleeve 102 for the end 311 of the coil for the second branch of phase V via at least one of the connections 203 and one of the switches 202, and via the switch 202. The sleeve 102 for the beginning 306 of the coil for the first branch of phase W is separably connected to the sleeve 102 for the end 312 of the coil for the second branch of phase W via at least one of the connections 203 and one of the switches 202, and via the switch 202.

[0053] In this example, connections 203 are routed three-dimensionally in housing 101.

[0054] The device may include a cooling system integrated into the housing.

[0055] The cooling system, for example, incorporates 101 cooling channels in the housing for efficient heat dissipation. The 103 connections are, for example, sealed watertight against the cooling system.

[0056] The cooling system, particularly in the case of oil cooling of the machine, may provide that the housing 101 is flooded with oil.

[0057] In Fig. Figure 4 shows a flowchart with steps of a process for manufacturing an electrical machine using device 100.

[0058] The procedure includes a step 401.

[0059] In step 401, the device 100 and the electric machine with the winding head are provided.

[0060] The procedure includes a step 402.

[0061] In step 402, the sleeves 102 are pushed onto the winding ends of the electric machine and connected to the winding ends, in particular by screwing or welding.

[0062] The method can be used, for example, in the manufacture of a vehicle comprising the device 100 and the electric machine.

Claims

[1] A device (100) for switching between different winding configurations of an electric machine, characterized by , that the device (100) comprises a housing (101), wherein the housing (101) is designed to be arranged on a winding head of the machine, wherein the device (100) comprises switches (202) for switching between the different winding configurations, wherein the switches (202) are arranged in the housing (101), characterized by , that the housing (101) has sleeves (102) for receiving winding ends of windings, that the switches (202) are power semiconductor switches, and that the device (100) is designed to switch at least two windings per phase between a series and a parallel configuration of the windings. [2] The device (100) according to claim 1, characterized by that the sleeves (102) are designed to be plugged onto the winding ends and screwed or welded to the winding ends. [3] The device (100) according to any of the preceding claims, characterized by , that the sleeves (102) are arranged on one side of the housing (101), wherein the sleeves (102) are designed to receive the winding ends on one side of the winding head, wherein the shape of the housing (101) on the side of the housing (101) is at least partially designed to correspond to a shape of the winding head on the side of the winding head. [4] The device (100) according to any one of the preceding claims, characterized by , that the housing (101) is designed to receive part of the winding ends of a circularly designed winding head, wherein the housing (101) comprises a circular segment-shaped part for receiving the part of the winding ends, or that the housing (101) is designed to receive the winding ends of a circularly designed winding head, wherein the housing (101) comprises a circular part for receiving the winding ends. [5] The device (100) according to any one of the preceding claims, characterized by , that the device (100) comprises terminals for connecting the winding ends to power electronics arranged outside the housing (101), wherein the terminals and the sleeves (102) are connected to each other via electrical connections (203) and the switches (202) so that switching is made possible. [6] The device (100) according to claim 5, characterized by , that the housing (101) extends along an axis (104), wherein the terminals outside the housing (101) extend radially to the axis (104) from the housing (101) and / or wherein the sleeves (102) extend outside the housing (101) along the axis (104). [7] The device (100) according to any one of the preceding claims, characterized by that the device (100) includes a cooling system integrated into the housing (101). [8] Electric machine, characterized by, that the electric machine comprises the device (100) according to any one of claims 1 to 7. [9] vehicle, characterized by that the vehicle comprises the electric machine according to claim 8. [10] Method for manufacturing an electric machine, in particular for a vehicle, characterized by , that the sleeves (102) of the device (100) according to one of claims 1 to 7 are pushed onto winding ends of the electrical machine and connected to the winding ends, in particular screwed or welded.

Images