Stator comprising a winding, preferably a hairpin winding

Abstract

Stator comprising a winding, preferably a hairpin winding, for an electric machine, in particular an electric motor or generator, manufactured according to the following method, comprising the steps: - Insertion, in particular insertion, of flat wire winding base bodies (13) into stator slots, wherein the winding base bodies (13) are already spread open at their ends before insertion, in particular immediately adjacent to a slot liner, and / or are mechanically spread open at their ends after insertion, in particular immediately adjacent to a slot liner, to form a first winding head area, - additive application of at least one section of at least one winding head, in particular by layer-by-layer application of a build-up material and locally selective solidification of the build-up material by irradiation with at least one beam impacting the build-up material, wherein the additively applied section implies additional spreading, to form a second winding head area, wherein a transformation zone (16) is provided in the second winding head area (15), such that a flat wire geometry extending at least substantially in the circumferential direction adjoins the transformation zone (16), wherein the flat wire geometry points with one of its flat sides at least substantially towards the stator slots.

Description

[0001] The invention relates to a stator comprising a winding, preferably a hairpin winding, for an electric machine, in particular an electric motor or generator.

[0002] Methods for manufacturing a stator are generally known. Additive manufacturing processes have also been used in this context for some time. The proposed solutions are still considered to have room for improvement.

[0003] The particular objective of the invention is to propose a stator that is relatively easy to manufacture and yet is characterized by high efficiency.

[0004] This problem is solved in particular by the features of claim 1.

[0005] In particular, the problem is solved by a stator comprising a winding, preferably a hairpin winding, for an electric machine, especially an electric motor or generator, manufactured according to the following method, comprising the steps: - Insertion, in particular insertion, of flat wire winding base bodies into stator slots, wherein the winding base bodies are already spread open at their ends before insertion, in particular immediately adjacent to a slot liner, and / or are mechanically spread open at their ends after insertion, in particular immediately adjacent to a slot liner, to form a first winding head area, - additive application of at least one section of at least one winding head, in particular by layer-by-layer application of a build-up material and locally selective solidification of the build-up material by irradiation with at least one beam impacting the build-up material, wherein the additively applied section implies additional spreading to form a second winding head area, wherein a transformation zone is provided in the second winding head area, such that a flat wire geometry extending at least substantially in the circumferential direction adjoins the transformation zone, wherein the flat wire geometry points at least substantially towards the stator slots with one of its flat sides.

[0006] The winding can have a changing cross-section, especially in the area of ​​the winding head.

[0007] Preferably, a cross-section of the winding within the second winding head area, particularly in the transformation zone, can change, especially with regard to the shape and / or the area.

[0008] The winding base bodies can be arranged in the respective groove in such a way that their flat sides are oriented at least substantially radially outwards or inwards.

[0009] The gradient of the winding in the second winding head area can be on average lower than the gradient of the winding in the first winding head area, preferably by at least a factor of 1.2 or at least a factor of 2.

[0010] The width of the winding in the second winding head area can be on average larger than the width of the winding in the first winding head area, preferably by at least a factor of 1.2 or at least a factor of 2.

[0011] The respective conductor can extend upwards immediately before the transformation zone and circumferentially immediately after the transformation zone, possibly with a component extending upwards.

[0012] The respective conductor can extend within the second winding head area over at least 30%, preferably at least 70% and / or at most 99% or at most 95% with a constant cross-section, particularly with regard to its area and / or its shape.

[0013] Furthermore, the respective conductor can have a rectangular cross-section within the first and / or second winding head area, wherein a length-to-width ratio in the second winding head area is preferably equal to or greater than a length-to-width ratio in the first winding head area.

[0014] At least one of the winding base bodies can be U-shaped and / or at least one of the winding base bodies can be I-shaped.

[0015] In one embodiment of the invention, only one winding head or both winding heads are produced at least section by additive application, in particular by layer-by-layer application of a build-up material and locally selective solidification of the build-up material by irradiation with at least one beam striking the build-up material.

[0016] The winding base bodies can be produced by drawing and / or by forming, possibly drawn, blanks and / or by an additive manufacturing process.

[0017] Preferably, the ends of the winding base bodies are leveled, in particular by milling, and / or cleaned before additive application.

[0018] In a preferred embodiment, connecting elements of the winding head can be directly additively applied to the ends of the winding base bodies.

[0019] The winding base bodies can be manufactured in particular by bending from raw material or directly by an additive process.

[0020] The winding base bodies are designed as hairpins or comprise hairpins.

[0021] The raw material, especially for the assembly material, is preferably aluminium material or aluminium powder, copper material or copper powder, in particular pure copper, pure aluminium, an aluminium alloy or a copper alloy.

[0022] In a preferred embodiment, the winding base bodies are spread apart at at least one of their ends, wherein in particular the spread winding base bodies have a distance of at least 0.5 mm, preferably at least 1.0 mm, from each other at the ends.

[0023] In particular, the winding base body section in which the winding base bodies are spread apart against or towards each other can have a height of at least 5 mm, preferably at least 10 mm, in the axial direction (A) of the stator.

[0024] A winding base body section in which the winding base bodies are not spread apart from each other or from each other, can have a projection of at least 5 mm, preferably at least 10 mm, in the axial direction (A) of the stator relative to the stator blank or laminated core (10).

[0025] In particular, the winding base bodies can have a projection of at least 10 mm, preferably at least 20 mm, towards the stator blank or laminated core in the axial direction (A) of the stator.

[0026] The invention is described below with regard to further features and advantages, which are explained in more detail using the following exemplary embodiment.

[0027] This shows: Fig. 1 an oblique view of a stator according to the invention; Fig. 2 the stator according to Fig. 1 in another oblique view; Fig. 3 the stator according to Fig. 1 in a side view; Fig. 4 elements of a stator winding head according to Fig. 1; Fig. 5 elements of the stator winding head according to Fig. 1 including a section of the stator slots; Fig. 6 Another view of elements of the winding head; Fig. 7 Another view of elements of the winding head including cutouts of the stator slots; Fig. 8 Another view of elements of the winding head including a section of the lamination stack; and Fig. 9 a section of a stator according to the invention.

[0028] In the following description, the same reference numbers are used for identical and equivalent parts.

[0029] Fig. Figure 1 shows a stator according to the invention in oblique view; Fig. Figure 2 shows another oblique view of the stator according to Fig. 1. The stator has a winding head 11 and a winding head 12. The winding head 12 can be manufactured from suitable (commercially manufactured, for example by forming, e.g., bending) winding base bodies 13. Alternatively, the winding head 12 can be manufactured as described below for the winding head 11, or in another manner.

[0030] The following section will focus in particular on the winding head 11. The winding head 11 is additively manufactured section by section, in particular by layer-by-layer application of a build-up material and locally selective solidification of the build-up material by irradiation with at least one beam impacting the build-up material. Furthermore (see in particular Fig. 3-5) The winding head has a first winding head region 14 and a second winding head region 15. The first winding head region 14 is preferably formed by the base bodies 13 or preferably (in general) by mechanical forming (i.e., non-additively). The second winding head region 15 is preferably produced additively.

[0031] In the second winding head area 15, a transformation zone 16 is provided such that a flat wire geometry extending at least substantially in the circumferential direction adjoins the transformation zone, with the flat wire geometry pointing at least substantially towards the stator slots with one of its flat sides.

[0032] It should be noted here that all parts described above, considered individually and in any combination, especially the details shown in the drawings, are claimed as essential to the invention. Modifications to this are familiar to those skilled in the art.

[0033] Furthermore, it is noted that the broadest possible scope of protection is sought. Therefore, the disclosure contained in the claims can also be specified by features that are described by further features (even if these further features are not necessarily included). It is explicitly noted that parentheses and the term "in particular" are intended to emphasize the optionality of features in the respective context (which does not imply that a feature is mandatory in the corresponding context without such indication). The term "element" is preferably intended to denote a coherent structure that may, in turn, be connected to at least one other structure (to form a potentially monolithic and / or internally immovable overall structure) or may be distinct from all other structures. Reference symbol list 10 Stator 11, 12 winding head 13 Winding base body 14 first winding head area 15 second winding head area 16 Transformation Zone

Claims

[1] Stator comprising a winding, preferably a hairpin winding, for an electric machine, in particular an electric motor or generator, manufactured according to the following method, comprising the steps: - Insertion, in particular insertion, of flat wire winding base bodies (13) into stator slots, wherein the winding base bodies (13) are already spread open at their ends before insertion, in particular immediately adjacent to a slot liner, and / or are mechanically spread open at their ends after insertion, in particular immediately adjacent to a slot liner, to form a first winding head area, - additive application of at least one section of at least one winding head, in particular by layer-by-layer application of a build-up material and locally selective solidification of the build-up material by irradiation with at least one beam impacting the build-up material, wherein the additively applied section implies additional spreading, to form a second winding head area, wherein a transformation zone (16) is provided in the second winding head area (15), such that a flat wire geometry extending at least substantially in the circumferential direction adjoins the transformation zone (16), wherein the flat wire geometry points with one of its flat sides at least substantially towards the stator slots. [2] Stator according to claim 1, wherein the winding, in particular in the area of ​​the winding head, has a changing cross-section. [3] Stator according to one of the preceding claims, wherein a cross-section of the winding within the second winding head area, in particular in the transformation zone (16), changes, in particular with respect to the shape and / or the area. [4] Stator according to one of the preceding claims, wherein the winding base bodies (13) are arranged in the respective slot such that their flat sides are oriented at least substantially radially outwards or inwards. [5] Stator according to one of the preceding claims, wherein the pitch of the winding in the second winding head area (15) is on average less than the pitch of the winding in the first winding head area, preferably less by a factor of at least 1.2 or at least a factor of 2. [6] Stator according to one of the preceding claims, wherein the width of the winding in the second winding head area (15) is on average larger than the width of the winding in the first winding head area (14), preferably by at least a factor of 1.2 or at least a factor of 2. [7] Stator according to one of the preceding claims, wherein the respective conductor extends upwards immediately in front of the transformation zone (16) and circumferentially immediately after the transformation zone (16), optionally with a component extending upwards. [8] Stator according to one of the preceding claims, wherein the respective conductor extends within the second winding head area over at least 30%, preferably at least 70% and / or at most 99% or at most 95% with a constant cross-section, in particular with respect to its area and / or its shape. [9] Stator according to one of the preceding claims, wherein the respective conductor within the first and / or second winding head area has a rectangular cross-section, wherein a length-to-width ratio in the second winding head area (15) is preferably equal to or greater than a length-to-width ratio in the first winding head area. [10] Stator according to one of the preceding claims, wherein at least one of the winding base bodies is U-shaped and / or wherein at least one of the winding base bodies is I-shaped. [11] Stator according to one of the preceding claims, wherein only one winding head (11, 12) or both winding heads (11, 12) is / are produced at least section by additive application, in particular by layer-by-layer application of a build-up material and locally selective solidification of the build-up material by irradiation with at least one beam impacting the build-up material. [12] Stator according to one of the preceding claims, wherein the winding base bodies (13) are produced by drawing and / or by forming, if applicable drawn, blanks and / or an additive manufacturing process. [13] Stator according to one of the preceding claims, wherein the ends of the winding base bodies (13) are leveled, in particular by milling, and / or cleaned before additive application. [14] Stator according to one of the preceding claims, wherein connecting elements of the winding head are directly additively applied to the ends of the winding base bodies (13). [15] Stator according to one of the preceding claims, wherein the winding base bodies (13) are produced by bending from raw material or directly by an additive process. [16] Stator according to any of the preceding claims, wherein the winding base bodies (13) are or comprise hairpins. [17] Stator according to one of the preceding claims, wherein the raw material, in particular for the assembly material, is aluminium material or aluminium powder, copper material or copper powder, in particular pure copper, pure aluminium, an aluminium alloy or a copper alloy. [18] Stator according to one of the preceding claims, wherein the winding base bodies (13) are spread apart at at least one of their ends, wherein in particular the spread winding base bodies (13) have a distance of at least 0.5 mm, preferably at least 1.0 mm, from each other at the ends. [19] Stator according to one of the preceding claims, wherein the winding base body section in which the winding base bodies (13) are spread apart against or towards each other has a height of at least 5 mm, preferably at least 10 mm, in the axial direction (A) of the stator. [20] Stator according to one of the preceding claims, wherein a winding base body section in which the winding base bodies (13) are not spread apart from each other or from each other, has a projection of at least 5 mm, preferably at least 10 mm, in the axial direction (A) of the stator relative to the stator blank or laminated core (10). [21] Stator according to one of the preceding claims, wherein the winding base bodies (13) have a projection of at least 10 mm, preferably at least 20 mm, towards the stator blank or laminated core in the axial direction (A) of the stator.

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