STATOR WITH PINS FOR AN ELECTRICAL MACHINE

Description

[0001] The invention relates to a stator with pins for an electrical machine, in particular an electric motor. State of the art

[0002] Electric machines are well known and are increasingly being used as electric motors to power vehicles. An electric machine consists of a stator and a rotor.

[0003] The stator comprises a plurality of slots in which the windings are guided. The windings can be formed from insulated copper rods called pins. The rotor is located inside the stator and is connected to a rotor shaft.

[0004] Such a pin, UPin or hairpin motor is known, for example, from DE 11 2013 006 691 T5, DE 10 2010 053 719 A1, EP 3 096 441 A1, US 2011 / 0025162 A1, WO 2012 / 072754 A2 or US 9,136,738 B2. Task and solution

[0005] The object of the present invention is to provide a stator according to claim 1 with windings of pins, which is easy to manufacture.

[0006] According to the invention, a stator for an electrical machine comprises a plurality of pins which are arranged on concentric circles at different distances from a stator center in slots in the stator, and each concentric circle forms a layer, wherein four pins in different layers are connected to one another in series and form a winding, a first pin of the winding is located in a first slot in the 4n-1 layer, where n is a natural number, a second pin of the winding is located in a second slot in the 4n layer, wherein the second slot has a first radial distance in a first circumferential direction of the stator from the first slot, a third pin of the winding is located in a third slot in the 4n-2 layer, wherein the third slot is adjacent to the first slot, a fourth pin of the winding is located in a fourth slot in the 4n-3 layer, wherein the fourth slot is adjacent to the second slot.The layers can be numbered in ascending order from the outside to the center of the stator. Natural numbers do not include zero.

[0007] A stator with the winding according to the invention is easy to manufacture and generates an efficient electromagnetic field with less iron or steel.

[0008] This reduces core losses and improves the utilization of the lamination core. These connections create an electrically conductive connection between the pins in the slots. The connection can be achieved by welding conductors to the pins, or the pins can be configured as double pins, so-called upins, thus establishing a connection upon insertion into the stator. Another connection type is welding pin end sections bent toward each other.

[0009] According to the invention, the third and fourth grooves are located in the circumferential direction on the same adjacent side of the first and second grooves.

[0010] The rotating field generated with such a winding has fewer disturbing harmonics and therefore less torque ripple and smaller torque fluctuations, as well as better NVH behavior.

[0011] According to the invention, there is a first distance between the first groove and the second groove and between the third and the fourth groove and a second distance between the third and the second groove, and the second distance is smaller than the first distance.

[0012] A stator with windings distributed on slots with different spacing has fewer resistive AC losses and lower saturation.

[0013] According to the invention, the stator has a first and a second end face, and the first and second pins on the second end face are connected to one another by means of a first connection type, the second pin and the third pin on the first end face are connected to one another by means of a second connection type, and the third pin and the fourth pin on the second end face are connected to one another by means of a third connection type, wherein the first, second, and third connection types differ from one another. The different connection types enable improved production. Alternating the connection types on different end faces enables the efficient formation of a winding around the stator teeth located between the slots.

[0014] Even connection types on the same front side of the stator can differ due to different bending directions of a pin base towards the inside or outside of the stator.

[0015] A combination of the previously mentioned connection types on different or identical stator faces is also possible. Using the same connection type on the same faces and different connection types on different stator faces allows for simple and fast production. For example, on one face, the connection is made using a type of pre-bent pin, so-called double pins or upins, while on another face of the stator, individual pins or one side of the double pin is welded together. The welding points can be located at the bases of the pins or double pins.

[0016] According to the invention, the stator has at least two windings and at least the fourth pin in the fourth slot is connected to a fifth pin in the 4n-1 layer in a fifth slot by means of a fourth connection type.

[0017] According to the invention, the stator has a plurality of windings which extend over the entire circumference of the stator and thereby form a partial coil.

[0018] The windings therefore have a symmetry which creates a uniform rotating field.

[0019] In a further embodiment, one pin of each of two partial coils can be connected to one another by means of a fifth connection type or a sixth connection type and form a coil.

[0020] These pins can be so-called end pins, as they mark the end of a partial coil.

[0021] Preferably, the partial coils can form six coils and be assigned to three phases such that two coils assigned to the same phase are located in three adjacent slots, and two layers of the two outer slots are each occupied by pins from other phases. Further preferably, an input of at least two coils can be connected to one another using a seventh connection type.

[0022] The seventh type of connection can be made by a conductor attached to the pins or by a conductive ring.

[0023] In a preferred embodiment of the invention, an output of at least two coils can be connected to one another and the two coils can thereby be connected in parallel and in particular assigned to one phase.

[0024] The two coils can be connected in parallel and can also be powered by the same phase. The parallel connection can be achieved by connecting a first and a fifth or a fourth and an eighth end pin in pairs.

[0025] Furthermore, two phases can each have a nearly identical current and voltage profile, allowing a six-phase inverter to drive only one three-phase motor. This arrangement enables current sharing among the switching elements in the inverter.

[0026] Two coils in the same slots can thus be connected in parallel and fed from one phase, creating a stator with windings for a three-phase electrical machine.

[0027] According to the invention, a vehicle has an electric machine with a stator according to one of the preferred embodiments. Character description

[0028] Figure 1 shows a stator. Figure 2 shows a stator with eight slots and four layers. Figure 3 shows a winding diagram of a first partial coil. Figure 4 shows a winding diagram of a second partial coil. Figure 5 shows a stator with a first and second partial coil and their connection to one another, thus forming a first coil. Figure 6 shows a winding diagram of a further partial coil. Figure 7 shows a winding diagram of a further partial coil. Figure 8 shows a stator with two further partial coils and their connection to one another, thus forming a second coil. Figure 9 shows a stator with two coils, each consisting of two partial coils. Figure 10 shows a stator with two further coils. Figure 11 shows a stator with two further coils. Figure 12 shows a stator with six coils. Figure 13 shows a winding diagram of two coils. Figure 14 shows a vehicle with an electrical machine, in particular an electric motor, with a stator with an inverter.

[0029] Figure 1shows a stator 1 with a plurality of slots 5 in which pins 2, 3 are guided. The stator 1 has a first end face 7 and an opposite second end face 9. On the first end face 7, inputs 81, 87, 101, 107, 111, 117 and outputs 83, 85, 103, 105, 113, 115 of partial coils for connecting the pins to a power source for operating the electrical machine are shown. Of course, a rotor is also required to operate an electrical machine. The connection pins are located close together, allowing for short connecting lines.

[0030] Figure 2 shows a stator 1 with slots and pins on four layers, where only eight slots 51, 52, 53, 54, 55, 56, 57, 58 are shown. Pins 21, 22 are arranged in the slots. The pins are located next to each other in a slot, in the example of the Figure 2There is space for four pins next to each other in a slot. The four pins within a slot are therefore located on different concentric circles L1, L2, L3, L4 around the center point M of the stator, forming individual layers. Between each two slots there is a first distance 11. This first distance 11 is between all Figure 2 shown grooves are identical.

[0031] Figure 3 shows the stator 1 from Figure 2 The pins are still arranged on concentric circles, i.e. layers, although the concentric circles are not shown for better presentation. In Figure 3shows which pins are connected in series. A first pin 21, which is also an end pin, is located in a first slot 51 in layer L3. This first pin 21 is connected by means of a first connection type 61, shown as a solid line, to a second pin 22 in a second slot 58. The second pin 22 is located in layer L4. The second pin 22 is connected by means of a second connection type 62, shown as a short dashed line, to a third pin 23 in a third slot 91. The third slot 91 is located radially adjacent to the first slot 51 and between the first slot 51 and the second slot 58. The third pin 23 is located in layer L2.

[0032] The third groove 91 has a second distance 13 from the second groove 58. The second distance 13 is one groove shorter than the first distance 11 from the previous figure.

[0033] Experts will understand that the different distances always refer to the same layer. For example, the distance between two grooves is naturally smaller on layer 4 than on layer 1, since the radius of layer 4 is smaller than that of layer 1.

[0034] The third pin 23 is connected to a fourth pin 24 via a third connection type 63, shown as a dotted line. The fourth pin 24 is located in a fourth groove 98. The fourth groove 98 is located radially adjacent to the second groove 58 and between the second groove 58 and a fifth groove 57. The fourth pin 24 is located in layer L1.

[0035] The connection of the first, second, third and fourth pins forms a first turn 41.

[0036] The fourth pin 24 is connected to a fifth pin 25 in the fifth slot 57 by means of a fourth connection type 64, shown as a dashed line. The fifth pin 25 is located in layer L3. The previously described serial connection of the subsequent pins in the stator begins again with the fifth pin 25, with the fifth pin 25 being similar to the first pin 21, except that the slot is offset by 90 degrees. Unlike the first pin 21, the fifth pin 25 is not an end pin, as it is connected to two other pins, whereas the first end pin 21 is only connected to one pin, the second pin 22.

[0037] The serial connection of the fifth pin 25 with further pins in three further slots 56, 97 and 96 forms a second turn 42. The first, second and third connection types 61, 62, 63 between these pins are identical to the respective first, second and third connection types 61, 62, 63 of the pins of the first turn 41.

[0038] The two windings 41, 42 are connected by the fourth connection type 64. Continuing the serial connection, the third winding 43 and fourth winding 44 are formed in four additional slots 55, 54, 95, and 94, as well as 53, 52, 93, and 92. The windings 41, 42, 43, and 44 are each connected by the fourth connection type 64. The fourth connection type 64 between the respective windings is thus identical. The first, second, and third connection types 61, 62, and 63 between the pins of windings 43, 44 are also identical to the first, second, and third connection types 61, 62, and 63 of the first and second windings 41, 42.

[0039] The four windings 41, 42, 43, and 44 form a first partial coil by winding counterclockwise around the stator 1. The first pin 21 also has an input 81 for connecting a power source. The first pin 21 of winding 41 thus represents a first end pin. The partial coil ends with pin 28 in layer L1 of winding 44. The last pin 28 of winding 44 thus represents a second end pin.

[0040] Figure 4 shows a stator 1, where eight further slots 71, 72, 73, 74, 75, 76, 77, 78 are shown.

[0041] Pins 31, 32, 33, 34, 35, 38 are connected in the same way as pins 21, 22, 23, 24, 25, 28 of the Figure 3 Even the connection types are identical to the Figure 3 and is made clear by the same reference numerals and line representation. In the same way as Figure 3described, the windings 45, 46, 47, 48 are formed and are connected to each other counterclockwise by the fourth connection type 64.

[0042] The four windings 45, 46, 47, and 48 form a second sub-coil by circumventing stator 1 in a counterclockwise direction. The sub-coil begins with a first pin 31, which is a third end pin. The sub-coil ends with pin 38 of winding 48. The last pin 38 of winding 48 in layer L1 thus represents a fourth end pin. The fourth end pin 38 also has an output 83 for connecting a power source. Of course, input 81 and output 83 can also be interchanged.

[0043] Figure 5 shows a pin assignment through the first and second partial coil from Figure 3 and 4, which are represented by black squares. Like reference numerals denote like pins, slots, and connections in the figures. The sixth pin 28 of the fourth turn 44 of the first sub-coil in slot 92, layer L1, which is also a second end pin, and the first pin 31 of the first turn 45 of the second sub-coil in slot 71, layer L3, which is also a third end pin, are connected to a fifth connection type 65.

[0044] The two partial coils thus form a first coil 201 with an input 81 and an output 83 after two radial revolutions around the stator in a counterclockwise direction. A third distance 15 shown in the figure is two slots shorter than the first distance 11 and one slot shorter than the second distance 13 from the previous figures.

[0045] Figure 6shows a stator 1. The pins are further arranged on concentric circles, i.e. layers, whereby the concentric circles are not shown for clarity. It shows which pins, represented as black squares on a white background, are connected in series and form a first partial coil of a second coil 202. A fifth end pin 21a is located in the first slot 51 in layer L4. The fifth end pin 21a also has an input 87 for connecting a power source. The fifth end pin 21a is connected by means of the first connection type 61 to a sixth pin 26a in the slot 52. The sixth pin 26a is located in layer L3. The sixth pin 26a is connected by means of the fourth connection type 64 to a fourth pin 24a in layer L1 in the slot 93.

[0046] The fourth pin 24a is connected to a third pin 23a via a third connection type 63, shown as a dotted line. The third pin 23a is located in a groove 94. The groove 94 is located radially adjacent to the groove 54 and between the groove 53 and the groove 54. The third pin 23a is located in layer L2.

[0047] The third pin 23a is connected to a second pin 22a via a second connection type 62, shown as a short dashed line. The second pin 22a is located in slot 53. Slot 53 is located radially adjacent to slot 93 and between slot 93 and slot 94. The second pin 22a is located in layer L4.

[0048] The second pin 22a is connected to a fifth pin 25a via a first connection type 61, shown as a solid line. The fifth pin 25a is located in the slot 54. The slot 54 is radially adjacent to the slot 94 and between the slot 94 and the slot 95. The fifth pin 25a is located in layer L3. The serial connection of the first, second, third, and fourth pins 25a, 22a, 23a, and 24a forms a first turn 41.

[0049] The fifth pin 25a is connected to a seventh pin 27a via a fourth connection type 64, shown as a dashed line. The seventh pin 27a is located in slot 95. Slot 95 is radially adjacent to slot 55 and between slot 55 and slot 54. The seventh pin 27a is located in layer L1. With the seventh pin 27a, the previously described serial connection of the subsequent pins in the stator begins again, with the seventh pin 27a being similar to the fourth pin 24a, except that the slot is offset by 90 degrees.

[0050] The serial connection of the seventh pin 27a with further pins in three further slots 96, 55 and 56 forms a second winding 42. The first, second and third connection types 61, 62, 63 between these pins are identical to the respective first, second and third connection types 61, 62, 63 of the pins of the first winding 41.

[0051] The two windings 41, 42 are connected by the fourth connection type 64. By continuing the serial connection, a third winding 43 is formed in four further slots 97, 98, 57, and 58.

[0052] A fourth winding 44 is special because it does not have a second connection type. This winding 44 is formed by a sixth connection type 66, which in conjunction with Figure 8 described and shown therein. The sixth connection type connects a sixth end pin 28a of the first partial coil with a seventh end pin 31a, which is Figure 7 is shown.

[0053] Figure 7shows a stator 1, where eight further slots 71, 72, 73, 74, 75, 76, 77, 78 are shown.

[0054] The pins are still arranged on concentric circles, i.e. layers, although the concentric circles have not been shown for clarity. It shows which pins, represented as black squares on a white background, are connected in series and form a second partial coil of a second coil 202. A seventh end pin 31a is located in slot 71 in layer L4. This seventh end pin 31a is connected to a sixth pin 36a in slot 72 by means of the first connection type 61. The sixth pin 36a is located in layer L3. The sixth pin 36a is connected to a fourth pin 34a in layer L1 in slot 53 by means of the fourth connection type 64.

[0055] The fourth pin 34a is connected to a third pin 33a via a third connection type 63, shown as a dotted line. The third pin 33a is located in a groove 54. The groove 54 is located radially adjacent to the groove 74 and between the groove 74 and the groove 73. The third pin 33a is located in layer L2.

[0056] The third pin 33a is connected to a second pin 32a via a second connection type 62, shown as a short dashed line. The second pin 32a is located in slot 73. Slot 73 is located radially adjacent to slot 53 and between slot 53 and slot 54. The second pin 32a is located in layer L4.

[0057] The second pin 32a is connected to a fifth pin 35a via a first connection type 61, shown as a solid line. The fifth pin 35a is located in the slot 74. The slot 74 is radially adjacent to the slot 54 and between the slot 54 and the slot 55. The fifth pin 35a is located in layer L3. The connection of the first, second, third, and fourth pins forms a first turn 45.

[0058] The fifth pin 35a is connected to a seventh pin 37a via a fourth connection type 64, shown as a dashed line. The seventh pin 37a is located in slot 55. Slot 55 is located radially adjacent to slot 75 and between slot 75 and slot 74. The seventh pin 37a is located in layer L1. The previously described serial connection of the subsequent pins in the stator begins again with the seventh pin 37a, with the seventh pin 37a being provided with a 90-degree offset from the slot, similar to the fourth pin 34a.

[0059] The serial connection of the seventh pin 37a with further pins in three further slots 56, 75 and 76 forms a second turn 46. The first, second and third connection types 61, 62, 63 between these pins are identical to the respective first, second and third connection types 61, 62, 63 of the pins of the first turn 45.

[0060] The two windings 45, 46 are connected by the fourth connection type 64. The continuation of the serial connection forms the third winding 47 in four additional grooves 57, 58, 77, and 78. The fourth winding 48 is special because it does not have a second connection type. This winding 48 is formed by the sixth connection type 66, which, in conjunction with Figure 8 described and shown there.

[0061] The eighth end pin 38a also has an output 85 for connecting a power source. Of course, input 87 and output 85 can also be interchanged.

[0062] Figure 8 shows a pin assignment through the two partial coils from Figure 6 and 7 , which are represented by black squares on a white background. Like reference numerals denote like pins, slots, and connections in the figures. Pin 28a of the fourth turn 44 of the first sub-coil in slot 92, layer L2, which is also a sixth end pin, and the first pin 31a of the fourth turn 48 of the second sub-coil in slot 71, layer L4, which is also a seventh end pin, are connected to a sixth connection type 66.

[0063] The two partial coils thus form a second coil 202 with an input 87 and an output 85 after two radial revolutions around the stator in a clockwise direction. A third distance 15 shown in the figure is two slots shorter than the first distance 11 and one slot shorter than the second distance 13 from the previous figures.

[0064] Figure 9shows a pin assignment through the first coil 201 from Figure 5 , which is represented by black squares. Like reference numerals denote like pins, grooves, and connections in the figures. Furthermore, the second coil 202 is shown in the Figure 8 represented as black squares on a white background, located in the same slots but different layers. The sub-coils of the two coils are connected with the fifth connection type 65 (first coil) or the sixth connection type 66 (second coil). The two connection types 65 and 66 are similar and differ only in their location in different layers.

[0065] Thus, two coils are shown, each consisting of two sub-coils. The inputs and outputs of the coils are also shown. The input 81 of the first coil is located at slot 51, and the output 83 is located at slot 52. The input 87 of the second coil is also located at slot 51, and the output 85 is located at slot 52. The inputs and outputs of both coils are thus located in the same slot.

[0066] Figure 10 shows a pinout by a third and fourth coil in the black squares with a white dot and the white squares with a black dot. This is created by a Figure 3 , 4 , 5 , 6 , 7 , 8A familiar winding pattern is shown, which is offset by two slots clockwise compared to the pins and connections of the partial coils shown there. Also shown are the inputs 101 and outputs 103 of the third coil and the inputs 107 and outputs 105 of the fourth coil. The inputs and outputs of both coils are thus located in the same slot.

[0067] Figure 11 shows a pin assignment by a fifth and sixth coil, shown in the black squares with a white cross and the white squares with a black cross. This is created by a Figure 3 , 4 , 5 , 6 , 7A familiar winding pattern is shown, which is offset by four slots clockwise compared to the pins and connections of the partial coils shown there. Also shown are the inputs 111 and outputs 113 of the fifth coil and the inputs 117 and outputs 115 of the sixth coil. The inputs and outputs of both coils are thus located in the same slot.

[0068] Figure 12 shows a pin assignment through the six coils as a combination of the Figure 9 , 10 and 11. In particular, the position of the inputs 81, 87, 101, 107, 111, 117 and outputs 83, 85, 103, 105, 113, 115 shows that the coils can be connected within 11 slots each. For the exemplary stator with 48 slots, the inputs and outputs can thus be connected within one-third of the stator circumference. Purely in terms of the inputs and outputs, separate wiring would also be possible within five slots if the coils and their inputs and outputs were Figure 10 be rotated 45 degrees counterclockwise. Figure 12 The embodiment shown leads to a connection of the inputs and outputs according to Figure 1 .

[0069] Figure 13shows the winding pattern of two sub-coils of the first coil 201 and the second coil 202. The consecutive "slot number" in the table is not a reference symbol. The reference symbols with arrows on the slots are identical to the previous figures and allow for comparison with these figures.

[0070] Figure 14 is a schematic diagram of an embodiment of a vehicle 403, for example a hybrid vehicle or an electric vehicle, comprising an electric machine 401, in particular an electric motor, with an embodiment of the stator 1 for driving the vehicle 403. Furthermore, the vehicle 403 can have an inverter 405 which supplies the electric machine 401 with an alternating current from a direct current source. List of reference symbols

[0071] 1Stator 2, 3Pin 7First end 9Second end 11First distance 13Second distance 15Third distance 21First end pin 28Second end pin 31Third end pin 38Fourth end pin 21aFirst end pin 28aSecond end pin 31aThird end pin 38Fourth end pin 22 - 27, 22a - 27aPins 32 - 37, 32a - 37aPins 41 - 48Winding 51 - 58Slots 61First connection type 62Second connection type 63Third connection type 64Fourth connection type 65Fifth connection type 66Sixth connection type 71 - 78Slots 81, 87, 101, 107, 111, 117Input 83, 85, 103, 105, 113, 115 Output 91 - 98 Slots 201 First coil 202 Second coil 401 Electric machine 403 Vehicle 405 Inverter L1, L2, L3, L4 Layer M Stator center point

Claims

1. Stator (1) for an electric machine (100), comprising a first end face (7), an opposite second end face (9) and a multiplicity of pins (21, 22, 23, 24, 25), which are arranged on concentric circles at different distances from a stator centre point (M) in slots (51-58, 91-98) in the stator (1), wherein each concentric circle forms a layer (L1, L2, L3, L4), wherein - the stator (1) has a multiplicity of windings (41, 42), which extend over the entire circumference of the stator (1) and thereby form a partial-coil; - in each case four pins (21, 22, 23, 24, 25) in different layers (L1, L2, L3, L4) are connected to one another in series and form a winding (41), - a first pin (21) of the first winding (41) is located in a first slot (51) in the third layer (L3), - a second pin (22) of the first winding (41) is located in a second slot (58) in the fourth layer (L4) and is connected to the first pin (21) on the second end face (9) by means of a first type of connection (61), wherein the second slot (58) is at a first radial distance (11) from the first slot (51) in a first circumferential direction of the stator (1), - a third pin (23) of the first winding (41) is located in a third slot (91) in the second layer (L2) and is connected to the second pin (22) on the first end face (7) by means of a second type of connection (62), wherein the third slot (91) lies adjacent to the first slot (51), - a fourth pin (24) of the first winding (41) is located in a fourth slot (98) in the first layer (L1) and is connected to the third pin (23) on the second end face (9) by means of a third type of connection (63), wherein the fourth slot (98) lies adjacent to the second slot (58), wherein the third and fourth slots (91, 98) in the circumferential direction lie on the same neighbouring side of the first and second slots (51, 58), wherein the first distance (11) lies between the third slot (91) and the fourth slot (98), a second distance (13) lies between the third slot (91) and the second slot (58) and the second distance (13) is smaller than the first distance (11), - at least the fourth pin (24) in the fourth slot (98, 96, 94) is connected to a fifth pin (25) in the third layer (L3) in a fifth slot (57) by means of a fourth type of connection (64), - with the fifth pin (25), the serial connection of the subsequent pins in the stator (1) begins again, and - the first, second and third types of connection (61, 62, 63) differ from one another.

2. Stator (1) according to Claim 1, wherein two partial-coils are provided, which are connected to one another by means of a fifth type of connection (65) or a sixth type of connection (66) and form a coil (201, 202).

3. Stator (1) according to Claim 2, wherein the stator (1) has three phases, wherein in each case two coils (201, 202) are assigned to one of the three phases in such a way that in each case two coils which are assigned to the same phase are located in three adjacent slots (51-58, 71-78, 91-98) and thus in each case two layers of the two outer slots (71-78, 91-98) are occupied with pins of other phases.

4. Stator (1) according to Claim 3, wherein respective inputs (81, 101, 111, 87, 107, 117) of at least two coils (201, 202) are connected to one another by means of a sixth type of connection (66).

5. Stator (1) according to Claim 4, wherein respective outputs (83, 103, 113, 85, 105, 115) of at least two coils (201, 202) are connected to one another and the two coils (201, 202) as a result are connected in parallel.

6. Vehicle (403) having an electric machine (401) with a stator (1) according to one of the preceding claims.