Stator for an electric motor or a generator, in particular for an external rotor motor

Abstract

The stator has a ring area from which teeth (1, 2) protrude. The teeth each have an arm (4) that extends from the ring area, has a web (5) running transversely to it at the free end and carries at least one winding. It has at least one coil (SP1) wound by a winding wire (43) and is accommodated in a winding space (54, 55) extending from the ring area. The winding space (54, 55) is divided by at least one divider (14, 15) into successive winding sections, which are provided on the arm (4). With the divider (14, 15), the respective winding space section (54, 55) can be adapted to the wire diameter and the number of windings in such a way that the start and end of the wire can be provided in the radially inner ring area of the stator.

Description

[0001] Stator for an electric motor or a generator, in particular for an external rotor motor

[0002] The invention relates to a stator for an electric motor or a generator, in particular for an external rotor motor, according to the preamble of claim 1.

[0003] The stator winding is often created using a so-called orthocyclic winding process. Here, the first layer of the coil is wound so that each turn crosses the axis line orthogonally, i.e. at a right angle, over most of its circumference. With previous orthocyclic windings, particularly with continuously wound adjacent teeth and with coils wound one above the other (e.g. for parallel connection of the coils), there is the problem that in external rotor motors the wire start and end have to be in the area of ​​the inner diameter for contact. However, this is not possible for all desired combinations of wire diameters and number of turns because, for example, the last turn is in the area of ​​the tooth center and in the worst case the winding direction runs from radially inside to outside.If the winding wire is to be guided radially inward in this case, this will result in the winding wire being pulled back, potentially creating loose wires. These can cause problems during further winding or later during use of the stator.

[0004] Another problem is the lack of space in the radially inner area for the wires or the winding needle required for winding. The space between adjacent teeth of the stator tapers radially inward, so there is less space for the winding wire in the radially inner ring area than in the radially outer area.

[0005] If the winding wire is to be continued from one tooth to another, the last turn of the winding wire must be in the radially inner

[0006] CONFIRMATION COPY ring area in order to be able to wrap this tooth after the wire transition to the adjacent tooth.

[0007] To influence the position of the wire end, it is known to place the beginning of the winding wire over a slot in the end face of an insulating element, such as an insulating washer, to a more favorable position. However, if the number of turns is too high, a new layer must still be started during winding, so that in a coil wound over a first coil, there is insufficient space for the turns or the winding needle.

[0008] The invention is based on the object of designing the generic stator in such a way that a simple and reliable winding is achieved.

[0009] This object is achieved according to the invention in the generic stator with the characterizing features of claim 1.

[0010] In the stator according to the invention, the winding space is divided by at least one separating web into successive winding space sections provided on the arm of the tooth. Using the separating web, the respective winding space section can be matched to the wire diameter and number of turns so that the wire start and end can be provided in the radially inner annular region of the stator. The design according to the invention also makes it possible to provide the transition of the winding wire from one tooth to the other in the radially inner annular region. Depending on the diameter of the winding wire and the number of turns, the separating webs can be provided so that a suitable distribution of the turns is achieved such that the wire end and start are in the annular region and the wire transition from one tooth to the other can also take place in this region.The separating webs are advantageously located on the top and bottom of the stator teeth. This ensures proper winding of the stator teeth.

[0011] In an advantageous embodiment, the separating webs are arranged so that the winding space sections have different lengths. Thus, the radially outer winding space section can be shorter in the radial direction of the teeth than the radially inner winding space section. Since the distance between adjacent teeth is greater in the area of ​​the radially outer winding space section than in the area of ​​the radially inner winding space section, the radially outer winding space section can be filled primarily with the winding wire, so that the space in the radially inner winding space section can be used for the wire start and end or for the transition to the next tooth.

[0012] In an advantageous embodiment, the separating webs of at least some of the teeth have a passage for the winding wire on the top or bottom. This passage allows the winding wire to be easily guided from one winding space section to the other during the winding process.

[0013] In a preferred embodiment, the guides extend at an angle oblique to the longitudinal direction of the teeth. The winding wire runs at a corresponding angle as it passes through this passage. The so-called laying angle should preferably be as small as possible to prevent the winding wire from colliding with a guide element radially delimiting one winding space section or with the tooth in the area of ​​this passage.

[0014] The separator is preferably positioned on the tooth so that the end of the coil or winding wire is in the ring area.

[0015] In order to ensure a perfect winding, in an advantageous embodiment the radially inner angular space section has such a width in the circumferential direction of the stator that the number of layers of the coil in this winding space section is even.

[0016] Advantageously, the radially outer winding space section has a width in the circumferential direction of the stator such that the number of coil layers in this winding space section is a multiple of the layers in the radially inner winding space section. This makes it possible to easily and reliably guide the winding wire laterally over the separating webs when creating additional layers without adversely affecting the winding.

[0017] Preferably, the thickness of the separating web having the passage, measured at the base of the separating web, is an integer multiple of the diameter of the winding wire. Such a design advantageously contributes to the winding wire being able to be wound over the separating web during a winding, particularly an orthocyclic winding, of a second coil.

[0018] The winding wire can be easily guided if at least one guide element is provided at the free end of the arms of the teeth to deflect the winding wire.

[0019] Advantageously, the gate body radially limits the radially outer winding space section.

[0020] To ensure that the winding wire is properly guided in the area of ​​the guide body and / or a deflection body during the winding process, they are equipped with at least one axial locking element. This prevents the winding wire from slipping axially off the guide body and / or the deflection body during the winding process.

[0021] Reliable and flawless locking is advantageously achieved when the axial locking element protrudes transversely from the gate body and / or the deflection element. Advantageously, the separating web is part of an insulating element made of electrically non-conductive material, which rests on the end faces of the teeth.

[0022] Advantageously, the insulating element is an insulating disc arranged on the front sides of the teeth of the stator.

[0023] Instead of the insulating disc, it is also possible to provide the separating webs as part of an overmolding of a stator package.

[0024] The subject matter of the application arises not only from the subject matter of the individual patent claims, but also from all information and features disclosed in the drawings and the description. Even if they are not the subject matter of the claims, they are claimed as essential to the invention insofar as they are novel, individually or in combination, over the prior art.

[0025] Further features of the invention emerge from the further claims, the description and the drawings.

[0026] The invention is explained in more detail with reference to two embodiments shown in the drawing.

[0027] Fig. 1 shows a perspective view of a switching side of a stator according to the invention in an unwound state,

[0028] Fig. 2 shows a perspective view of an underside of the stator according to the invention according to Fig. 1,

[0029] Fig. 3 shows a perspective and enlarged view of part of the switching side of the stator according to the invention without winding, Fig. 4 shows a perspective and enlarged view of part of the switching side of the stator according to the invention in another view,

[0030] Fig. 5 in plan view and in an enlarged view a part of the switching side of the stator according to the invention with winding wires of a first coil.

[0031] Fig. 6 shows a perspective and enlarged view of part of the underside of the stator according to the invention, showing the beginnings and ends of the first coil,

[0032] Fig. 7 in a representation corresponding to Fig. 5 the winding of the stator with the first coil on the switching side,

[0033] Fig. 8 in a representation corresponding to Fig. 7 the winding of a second coil,

[0034] Fig. 9 shows in perspective the wire laying of a second coil on the underside of the stator,

[0035] Fig. 10 the winding of the second coil on the switching side of the stator,

[0036] Fig. 11 the wire laying on the switching side of the stator,

[0037] Fig. 12 shows a perspective view of an insulating disc provided for a switching side of the stator according to the invention,

[0038] Fig. 13 shows a perspective view of an insulating disc provided for the underside of the stator according to the invention.

[0039] Fig. 1 shows a stator that can be part of an electric motor or a generator. The stator has a stator core 1, which, in a known manner, consists of stacked sheet metal laminations that are firmly connected to one another, for example, by an adhesive bond, a welded bond, a form-fit connection, or the like. The stator core 1 has a central circular through-opening 2.

[0040] The stator core 1 has a cylindrical inner ring 3, from which arms 4 protrude radially. They are evenly distributed over the circumference of the stator core 1 and are each provided with a circumferentially extending web 5 at the free, radially outer end. As shown in Fig. 1, the webs 5 and the arms 4 extend over the height of the stator core 1. The webs 5 advantageously protrude the same distance in the circumferential direction over both sides of the arms 4.

[0041] The arms 4 and the webs 5 are spaced apart from each other in the circumferential direction of the stator.

[0042] The arms 4 and the webs 5 each form teeth 1 to 12 of the stator, which are wound with winding wire in a manner to be described below.

[0043] Adjacent arms 4 define slots 6 through which the winding of the stator 1 runs in a manner to be described.

[0044] From the end face of the inner ring 3 visible in Fig. 1, there are axially projecting pockets 7 for insulation displacement contacts for contacting the winding wire.

[0045] The receiving pockets 7 are advantageously spaced apart from one another in the circumferential direction. The receiving pockets 7 each have a slot-shaped receptacle 8 (Fig. 3) extending in the circumferential direction, into which the insulation displacement contact is inserted. The receptacle 8 is advantageously crossed halfway along by a transverse slot 9, which extends only over part of the height of the receiving pocket 7 and through which the winding wire runs in a manner to be described below. The receptacle 8 and the transverse slot 9 are open to the free end face of the receiving pockets 7. This allows the insulation displacement contacts to be inserted axially into the receptacles 8, contacting the winding wire running in the radial direction of the stator core 1 in a known manner.

[0046] The side on which the receiving pockets 7 are located is referred to below as the switching side of the stator, because the contacting of the winding wires takes place on this end face.

[0047] Radially projecting from the webs 5 on both ends are guide elements 10, which serve to define the winding space and support the winding on the stator. If necessary, the guide elements 10 can be used to guide the winding wire during wire deflection.

[0048] The gate bodies 10 are essentially identical to one another and extend in the circumferential direction almost over the circumferential width of the webs 5 (Fig. 1 and 2).

[0049] On both end faces of the stator, insulating discs 12, 13 are provided (Fig. 1, 2, 12, 13), forming annular spaces that are radially delimited on the outside by the gate bodies 10. On the switching side (Fig. 1), the annular space is radially delimited on the inside by the receiving pockets 7. On the underside (Fig.

[0050] 2) the annular space is delimited radially inwardly by guide bodies 11, which are arranged next to one another at a distance around the circumference of the inner ring 3 and project axially from the inner ring 3.

[0051] The insulating discs 12, 13 electrically insulate the stator core 1 from the winding. The insulating discs 12, 13 are designed in a known manner to cover the end faces of the arms 4 of the stator core 1, parts of the inner ring 3, and the webs 5. The insulating discs 12, 13 thus form parts of the arms 4 of the stator.

[0052] The insulating disks 12, 13 shown in Figs. 12 and 13 differ slightly in terms of details from the insulating disks 12, 13 shown in Figs. 1 to 11. However, the differences are so minor that they will not be discussed in detail. On the end-face insulating disks 12, 13 there are webs 14, 15 that project axially from the insulating disks 12, 13. The webs 14 extend over the entire circumferential width of the arms 4, 2, while the webs 15 are provided in the region of the radially extending longitudinal sides 16, 17 of the arms 4 and are spaced apart from one another in the circumferential direction. Passages 18 are formed between the webs 15 (Fig. 2).

[0053] The guide bodies 11 located on the underside of the stator package 1 are formed by deflection pins projecting axially from the inner ring 3, which serve to lay a connecting wire between adjacent arms 4.

[0054] The webs 14, 15 and the guide bodies 11 are part of the insulating discs 12, 13, which are attached in a known manner to the two end faces of the stator package 1.

[0055] As can be seen from Figs. 1 and 2, the webs 14, 15 are arranged alternately on the individual arms 4 to form separate winding sections. The webs 14, 15 are radially spaced from the guide elements 10 and the receiving pockets 7 or the guide elements 11 (Figs. 1 and 2). The webs 14, 15 are spaced further apart from the guide elements 10 than from the receiving pockets 7 or the guide elements 11.

[0056] The webs 14, 15 are advantageously located at the same height in the circumferential direction of the stator package 1.

[0057] In Fig. 1, the teeth are numbered 1 to 12. In this example, the stator core 1 has twelve teeth, numbered 1 to 12, each of which is identical. Depending on the size or diameter of the stator, the stator core 1 can have a larger or smaller number of teeth.

[0058] The arms 4 of the teeth are each provided with a groove 19 on their longitudinal sides 16, 17 at the transition to their end faces (Fig. 3), which extends over the entire radial length of the arms 4. As can be seen from Figs. 1 and 2, each arm 4 is advantageously provided with such a groove 19 on its two longitudinal sides at the transition to its end faces. The grooves 19 are provided on the two insulating discs 12, 13, as can be seen from Figs. 12 and 13.

[0059] The groove 19 serves to guide the winding wires neatly in order to enable orthocyclic guidance in a manner to be described later.

[0060] The winding wire is deflected on the gate bodies 10 in a manner to be described below for a 4-group parallel circuit in order to be able to guide the wire end of the second coil from the outside to the inside into the receiving pockets 7.

[0061] As shown in Fig. 3, the receiving pockets 7 are provided with brackets 20 on their rear side facing away from the gate bodies 10. They are designed to connect adjacent receiving pockets 7 to one another. The brackets 20 are provided only optionally. They are connected to the receiving pockets 7 in such a way that they do not extend into the transverse slots 9 of the receiving pockets 7, allowing the winding wires to pass unhindered through the transverse slots 9.

[0062] The design and procedure for winding the stator core 1 described below is explained using teeth 1 and 2. The remaining teeth 3 to 12 of the stator core 1 are wound in the same way.

[0063] As can be seen from Fig. 4, in the area of ​​the receiving pockets 7 there are insertion slots 21 for the winding wire. They are provided on the side facing the gate bodies 10 and are distributed over the circumference of the stator core 1. The insertion slots 21 are located at the level of the transverse slots 8 of the corresponding receiving pockets 7 (Figs. 1 and 4). The insertion slots 21 taper axially from the transverse slots 8 and are located in the area of ​​grooves 6 between adjacent teeth. The insertion slots 21 ensure that the winding wire does not hinder further winding with the winding needle.

[0064] As shown in Fig. 4, a guide piece 22 is provided at the base of one contact pocket 7, which has a triangular outline in the axial direction of the stator core 1. The guide piece 22 rests on the end face of the arm 4 of the tooth 1 and advantageously has a constant axial height over its length measured in the circumferential direction. The triangular guide piece 22 serves to guide the first winding wire, enabling it to be laid orthocyclically.

[0065] As shown in Fig. 1, further such triangular guide pieces 22 are provided along the circumference of the stator core 1. In the exemplary embodiment, such guide pieces 22 are located on teeth 1, 3, 5, 7, 9, and 11 of the switching side, as well as on teeth 2, 4, 6, 8, 10, and 12 on the underside of the stator core 1.

[0066] The guide elements 10 extend in the circumferential direction of the stator core 1 almost over the corresponding circumferential length of the webs 5 of the teeth 1 to 12. As can be seen from Figs. 1 and 2, the guide elements 10 are provided in two structural designs. This is explained in more detail with reference to Figs. 4 and 5.

[0067] The winding body 10 of the tooth 2 has a flat end face 23 facing the receiving pockets 7, which extends in the axial direction of the stator package from the web 5 of the tooth and advantageously runs perpendicular to the end face of the web 5 of the tooth 2.

[0068] The gate body 10 is thickened at half its circumferential length by providing the rear side 24 facing away from the receiving pockets 7 with a bulge. This gives the gate body 10 a radially thickened central section 25. It has a uniform axial height over its circumferential length (Fig. 4) and advantageously transitions into the rear side 24 in a curved manner.

[0069] The side parts 26, 27 (Fig. 4) projecting in the circumferential direction beyond the central part 25 decrease continuously in axial height towards the outside in such a way that the end face 28 of the link body 10 adjoins the end face 29 of the toothed web 5 at an angle.

[0070] The thin side parts 26, 27 are each reinforced on the rear side 24 by a rib 30 projecting transversely from the end face 29 of the web 5. This rib is advantageously formed integrally with the gate body 10 and the insulating disk 12. The ribs 30 are advantageously located approximately halfway across the width of the side parts 26, 27. The ribs 30 are designed such that they do not protrude axially beyond the side parts 26, 27 of the gate body 10, but are advantageously spaced axially from the end face 28 of the gate body 10.

[0071] The described design of the link bodies 10 is provided on the teeth 2, 4, 6 of the stator package 1 (Fig. 1 ).

[0072] The guide bodies 10 assigned to the other teeth 1, 3, 5 have a similar structure to the previously described guide bodies 10. The difference essentially consists in the fact that a deflection element 31 is provided on the end face 28' of the central part 25. It basically has the same outline shape as the central part 25, but is narrower in the radial direction than the central part 25. The end face 32 of the deflection element 31 facing the receiving pockets 7 lies in the same plane as the end face 23 of the guide body 10 (Fig. 5).

[0073] The rear side 33 of the deflection element 31 is radially recessed from the rear side 25' of the central part 25. A nose 34 protrudes from the rear side 33 and is axially spaced from the end face 28' of the central part 25. This creates a passage 35 (Fig. 4) for the winding wire at this point. The free end face 36 of the nose 34 lies, viewed in the axial direction (Fig. 5), in the rear side 25' of the central part 25.

[0074] As can be seen from Fig. 6, the gate bodies 10 on the underside of the stator core 1 are designed in the same way. However, the arrangement of the differently designed winding bodies is different from that on the switching side.

[0075] As a comparison of Figs. 5 and 6 shows, tooth 1 on the switching side (Fig. 5) has the gate body 10 with the deflection element 31. On the underside, tooth 1 is arranged with the gate body 10 without the deflection element 31. Instead, tooth 2 is provided on the underside with the gate body 10 with the deflection element 31, while on the switching side (Fig. 5), tooth 2 has the gate body 10 without the deflection element.

[0076] On both the switching side (Fig. 5) and the underside (Fig. 6), the differently designed gate bodies 10 alternate in the circumferential direction. This design on the switching side and on the underside of the stator is shown in particular in Figs. 12 and 13. On the switching side (Fig. 12), the teeth 2, 4, 6,... are provided with separating webs 14, which are provided on the underside (Fig. 13) on the teeth 1, 3, 5,... Accordingly, the separating webs 15 are provided on the switching side (Fig. 12) on the teeth 1, 3, 5,... and on the underside (Fig. 13) on the teeth 2, 4, 6,...

[0077] The deflection elements 31 are advantageously formed in one piece with the link body 10, which is otherwise designed in the same way as the link body 10 without the deflection element 31.

[0078] The guide body 10 with the lugs 34 forms hooks that prevent the winding wire from slipping upwards at a deflection of the winding wire when the wire end is guided inward into the corresponding receiving pocket 7. Opposite the guide bodies 10 on the underside of the stator core 1 are the guide bodies 11, which are explained in more detail with reference to Fig. 6.

[0079] The guide body 11 has two deflection pins 37 projecting axially from the inner ring 3, which are spaced apart from each other in the circumferential direction and connected by a web 38. It has a smaller axial height than the two deflection pins 37. Adjacent to one deflection pin 37, the web 38 is provided with a front-end recess 39. This recess is located at the level of the corresponding groove 6 between the adjacent teeth 1, 2.

[0080] Another recess 39 is located on the outside of one deflection pin 37, which is at the level of the next groove 6. The two recesses 39 are thus at the level of adjacent grooves 6.

[0081] One deflection pin 37 is located at the level of the tooth 1 , while the adjacent deflection pin 37 of the guide body 11 is provided in the region of the groove 6 between the two teeth 1 , 2 .

[0082] As Fig. 2 shows, the guide bodies 11 are arranged one behind the other at a distance in the circumferential direction and are each provided with the two deflection pins 37.

[0083] The guide bodies 11 are located, viewed in the axial direction, at a distance from the inner wall 40 of the inner ring 3. The front side 41 (Fig. 6) facing the guide bodies 10 is advantageously aligned with the outer side 42 of the inner ring 3.

[0084] The guide bodies 11 can also be provided with lugs 34 (Fig. 13), which also prevent axial slippage of the winding wire. The lugs 34 of the gate bodies 10 and the guide bodies 11 are arranged alternately at an angle to the circumferential direction of the stator, as can be seen in particular in Figs. 12 and 13.

[0085] In Fig. 5, the circles represent the winding wires 43 of the first coil SP1 in cross-section. The arrows indicate the winding direction on the switching side of the stator core. The winding wire is inserted radially from the inside through the transverse slot 9 of one of the receiving pockets 7 at the level of tooth 1. The starting point of the winding process is designated 51.

[0086] On the switching side (Fig. 5) of the stator core 1, the winding wire 43 is guided obliquely with respect to the radially extending longitudinal axis of the arm 4 of the tooth 1 along the triangular guide piece 22. This is indicated in Fig. 5 by the arrow 52.

[0087] The winding wire 43 is guided from the switching side along the respective longitudinal side 16, 17 downwards to the underside of tooth 1. Since there is no triangular guide piece on the underside of tooth 1, the winding wire 43 runs on the underside of the stator core perpendicular to the radial longitudinal axis of the arm 4 of tooth 1.

[0088] By means of the grooves 19, which are provided both on the switching side and on the underside of the stator package, a perfect winding of the winding wire 43 is ensured, which engages in the grooves 19 with the first winding layer WL1.

[0089] As soon as the winding wire 43 comes into the area of ​​the webs 15 on the switching side, the winding wire 43 is guided through the passage 18 between the two webs 15 (arrow 53).

[0090] In this way, the winding wire 43 passes from a winding space 54 into a winding space 55. The winding space 54 is located between the contact pockets 7 and the webs 15 and is advantageously longer in the radial direction of the tooth 1 than the winding space 55 between the webs 15 and the end face 23 of the link body 10.

[0091] Since the groove 19 is provided in both winding spaces 54, 55, a perfect winding in both winding spaces 54, 55 is ensured.

[0092] At the transition from the winding space 54 through the passage 18 to the winding space 55, the winding wire 43 runs on the switching side at a larger angle to the radial longitudinal axis of the arm 4. The course of the winding wire when passing through the passage 18 is marked with 53.

[0093] Since the transition from winding space 54 to winding space 55 occurs on the switching side of the stator core as described, an interrupted web design is not required on the underside of the stator core 1 in the area of ​​tooth 1. Accordingly, the continuous web 14 (Fig. 6) is provided on the underside of tooth 1 instead of the two webs 15.

[0094] Within the winding space 55, the winding takes place in the winding direction 52 until the first layer of the winding is formed in the winding space 55. During the next winding process (arrow 56), the formation of the next layers begins in the winding space 55. In the exemplary embodiment, four layers WL1 to WL4 are formed in the winding space 55.

[0095] The two webs 15 on the switching side of the stator core 1 are circumferentially wide enough to secure the four layers WL1 to WL4 of the first coil SP1 in the radial direction in the winding space 55. The winding layers are also radially secured on the underside by the web 14 on the underside of the stator core 1 (Fig. 6).

[0096] The winding wire in the last layer WL4 of the winding space 55 is guided back through the passage 18 between the two webs 15 on the switching side of the stator core 1 from radially outside to radially inside. The winding direction 57 again runs obliquely to the radial longitudinal direction of the arm 4 of tooth 1. In this case, the winding direction 57 is oppositely oblique to the winding direction 52. In this winding phase, the winding takes place from radially outside to radially inside. After passing through the passage 18, the second layer WL2 is formed in the winding space 54, for example. As soon as the second layer WL2 of the coil SP1 is created in the area of ​​the receiving pocket 7 in the winding space 54, the winding wire is guided along the underside of the stator core 1 to tooth 2. This is indicated by the dashed line 58. Tooth 2 is then wound in the same way as tooth 1.The starting point 51 on tooth 2 corresponds to the starting point 51 on tooth 1, but the starting point 51 on tooth 2 is not on the switching side, but on the underside.

[0097] The webs 15 are advantageously designed so that the winding wire can be guided laterally along the webs 15 as it passes through the passage 18. For this purpose, the webs 15 are provided on their two outer sides with correspondingly inclined guide surfaces 59, 60 (Fig. 6), along which the winding wire 43 can be guided as it passes through the passage 18.

[0098] The end of coil SP1 at tooth 1 is guided to the underside of stator core 1 in the manner described and there guided to tooth 2 by means of deflection pins 37. As can be seen from Fig. 6, winding wire 43 is guided to tooth 2 on the rear side facing away from gate body 10. At starting point 51, winding of tooth 2 then takes place to form the first coil SP1.

[0099] For the sake of clarity, the windings are not shown, as in the case of Fig. 5.

[0100] Starting from the starting point 51, the winding wire 43 is guided along the triangular guide piece 22 at an angle to the radial longitudinal direction of the arm 4 of the tooth 2 on the underside of the stator core 1. In this case, the guide piece 22 is provided on the front side 61 of the guide body 11 facing the gate body 10. Advantageously, the guide piece 22 is formed integrally with the guide body 11. The guide piece 22 rests on the upper side of the arm 4, so that the winding wire can be reliably guided on the underside of the stator core 1.

[0101] On the underside of tooth 2, adjacent to the guide body 10, are two webs 15 that separate the two winding spaces 54, 55. In this case, the winding space 54 is located between the guide body 11 and the webs 15, and the winding space 55 is located between the webs 15 and the guide body 10.

[0102] The winding of tooth 2 is carried out in the same way as for tooth 1. The winding direction is, as described, oblique to the radial longitudinal axis of the arm 4 of tooth 2. The winding space 54 between the two webs 15 and the guide body 11 or the winding space 55 between the webs 55 and the link body 10 is filled with the wire layers WL1, WL2 in the manner described. The winding wire 43 is guided through the passage 18 between the two webs 15 during the winding process. The arrows 57, 62 mark the last winding of the winding wire 43, the end of which is guided back to the switching side (Fig. 5) through the corresponding receiving pocket 7.

[0103] Fig. 7 shows the winding process for producing the first coil SP1 using the two teeth 1 and 2. The winding direction for tooth 2 is the opposite of that for tooth 1, as indicated by the arrows. Tooth 2 is provided with the continuous web 14 on its switching side, while it has the two webs 15 on the underside (not shown), as can be seen from Fig. 6. In tooth 1, on the other hand, the continuous web is located on the underside, while the two webs 15 with the passage 18 are provided on the switching side shown.

[0104] As explained with reference to Fig. 5, the continuous web 14 serves to arrange the windings of the wire parallel to one another and perpendicular to the radial longitudinal direction of the arm 4. The webs 15, on the other hand, ensure that the windings run obliquely to the radial longitudinal direction of the arm 4.

[0105] On both teeth 1, 2, the winding takes place radially outwards from the radially inner region of the arms 4. The winding then takes place from radially outside to radially inside. The end point 63 of the winding on tooth 1 is located directly adjacent to the respective receiving pocket 7. From the end point 63, the wire is guided in the manner described on the underside of tooth 1 along the path 58 to the starting point 51 on the underside of tooth 2. The winding of tooth 2 takes place analogously to the winding of tooth 1.

[0106] At the end point 63' of the first coil SP1 of the tooth 2, the winding wire 43 is guided radially inwards through the transverse slot 9 of the receiving pocket 7.

[0107] Using Figs. 8 to 11, it is described how a second coil SP2 is attached to teeth 1 and 2 in a winding process. The first coil SP1 has been wound on teeth 1, 2 in the manner described. The winding of the second coil SP2 on tooth 2 starts in the receiving pocket 7 on the switching side of the stator core 1 (Fig. 8). The winding process to produce the second coil SP2 begins at the starting point 64 adjacent to the receiving pocket 7. The winding wire 43 is wound perpendicular to the longitudinal axis of the arm 4 of tooth 2. The winding direction is designated 65.

[0108] The winding is carried out up to the continuous web 14 on the switching side of the stator core 1. During the last winding 66 before the web 14, the winding wire is moved back and forth from the web 14 in the longitudinal direction of the arm 4 to create the second coil SP2, as indicated by the movement path 67. By this meandering back and forth winding, the desired number of layers WL1a to WL7a is applied to the first coil SP1. In the process, the layers WL1a to WL7a of the second coil SP2 are created up to the link body 10. In the exemplary embodiment, the second coil SP2 is wound such that it extends in the winding space 54 over part of the radial length, while in the winding space 55 it is provided over its entire radial width. At the end point 68 on the link body 10, the second coil SP2 of tooth 2 is completed. The winding wire is then guided along the path 69 on the underside of tooth 2 to the starting point 70 on the underside of tooth 1.Then the second coil SP2 of tooth 1 is wound on tooth 1 in the same way as tooth 2.

[0109] The winding space 54, 55 and thus the number of possible turns on the teeth 1, 2 is limited by the free space 71 for the winding needle between the two teeth 1, 2. As a result, it may happen that the second coil SP2 cannot end radially on the inside of the arm 4, but that the winding wire has to be guided back inwards on the outside via the link body 10. This case is shown in Fig. 8. The wire 43 is deflected along the path 69 on the underside of the tooth 2 on the radially outer side of the lower winding body in such a way that it can then be guided radially inwards on the underside in the direction of the inner ring 3 and from there to tooth 1.

[0110] Fig. 9 shows this transition on the underside of the teeth 1, 2 from tooth 2 to tooth 1. The wire 43 is first guided in the manner described on the rear side 24 of the link body 10 facing away from the deflection pins 37. It has the deflection element 31 with the nose 34. In order to ensure a clean deflection of the wire 43, the rear side 24' of the deflection element 31 facing away from the deflection pin 37 is curved so that the wire 43 can be deflected radially inwards to the opposite deflection pin 37 without the risk of kinking. The nose 34 of the deflection element 31 prevents the wire 43 from being able to lift axially from the link body 10 or its deflection element 38 in this area.

[0111] Analogous to the deflection element 31, a protruding nose can also be provided on the deflection pin 37, which prevents the wire 43 from slipping out axially. The wire 43 is deflected at the rear side 72 of the deflection pin 37, facing away from the guide body 10. Advantageously, the rear side 72 can be provided with a recess for receiving the wire. The recess extends in the circumferential direction of the deflection pin 37. The rear side 72 and, if present, the recess each merge in a continuous curve into the front side 74 of the deflection pin 37, facing the guide body 10.

[0112] The recess can be provided in addition to or instead of a protruding nose on the deflection pin 37 in order to prevent the winding wire 43 from slipping out axially.

[0113] Due to the described deflection by means of the deflection element 31 and the deflection pin 37, the transition during the winding process from tooth 2 to tooth 1 takes place on its underside.

[0114] As described with reference to Figs. 8 and 9, the end of the coil SP2 is located at tooth 2 at the radially outer end of the arm 4. By means of the link body 10, the wire is guided radially inwards to the deflection pin 37, via which the wire is guided on the underside to tooth 1.

[0115] Fig. 10 and 11 show the winding of the coil SP2 on the switching side of the teeth 1, 2.

[0116] The winding of tooth 2 has been explained with reference to Fig. 8. The wire 43 is fed radially from the inside through the transverse slot 9 of the receiving pocket 7. The starting point 64 of the first layer WL1a of the second coil SP2 is located immediately adjacent to the receiving pocket 7. The first layer WL1a is wound in the manner described up to the continuous web 14. At the web 14, the wire is rewound in the longitudinal direction of the arm 4 to form the second layer WL2a of the second coil SP2 (path 67). The further layers WL3a to WL7a of the second coil SP2 are then produced by repeated back and forth winding, as explained with reference to Fig. 8. These further layers of the second coil SP2 can, as shown by way of example, have different lengths in the radial direction, depending on the design of the stator, but can also be the same length, for example.

[0117] Layers WL2a to WL7a of the second coil SP2 can also be the same length as the first layer WL1a of the second coil SP2. The length of the individual layers of the second coil SP2 can thus be selected according to requirements.

[0118] The winding wire 43 is then guided along the path 69 in the manner described to tooth 1. This transition occurs on the underside of tooth 2.

[0119] At tooth 1, the winding of the second coil SP2 is carried out analogously to the procedure for tooth 2.

[0120] The second coil SP2 with the various layers WL1a to WL7a is generated on tooth 1 in the manner described. The first layer WL1a of the second coil SP2 extends between the inner ring 3 and the webs 15. The further layers WL2a to WL7a of the coil SP2 are generated by the meandering back and forth movement of the winding needle along the path 75.

[0121] Once the further layers WL2a to WL7a of the second coil SP2 have been wound, the wire is deflected at the rear side 24 of the guide body 10 facing away from the receiving pockets 7 and guided radially inward through the transverse slot 9 of the corresponding receiving pocket 7. As explained with reference to Fig. 9 with respect to tooth 2, the winding wire 43 is guided along the deflection element 31 and below the nose 34.

[0122] The beginnings and ends of the two coils SP1, SP2 on teeth 1 and 2 are illustrated in Fig. 11. The two coils SP1, SP2 are shown for tooth 1 in the right half of Fig. 10. Tooth 2 has the same coil configuration. To form the first coil SP1 on tooth 1, the winding wire 43 is guided radially from the inside through the transverse slot 9 of the receiving pocket 7 (start 76).

[0123] Start 77 represents the winding wire which is guided radially from the inside through the transverse slot 9 of the corresponding receiving pocket 7 in order to wind the second coil SP2 on tooth 2.

[0124] 78 marks the end of the first coil SP1 at tooth 2. In this case, the winding wire is guided radially from the outside through the transverse slot 9 of the adjacent receiving pocket 7 radially inwards.

[0125] 79 marks the end of the second coil SP2 at tooth 1. In this case too, the winding wire 43 is guided radially inward from the radial outside through the transverse slot 9 of the associated receiving pocket 7.

[0126] For the sake of clarity, the coils or the individual windings are not shown in Fig. 11.

[0127] In order to position the beginning and end of the first coil SP1 of tooth 1 on the inner diameter in the area of ​​the receiving pockets 7, the combination of wire diameter and number of turns must exactly match the available winding space 54, 55. However, since these conditions are not always met, the webs 14, 15 are positioned such that the end 44 of the first coil SP1 (Fig. 5) lies in the inner diameter area, allowing a simple transition to tooth 2 (arrow 58 in Fig. 5).

[0128] The number of layers of the first coil SP1 in the radially inner winding space 54 should be as even as possible. In the exemplary embodiment, the first coil SP1 in the winding space 54 has two layers WL1, WL2.

[0129] The number of layers in the radially outer winding space 55 should, if possible, be a multiple of the layers WL1 to WL4 in the radially inner winding space 54. In the illustrated embodiment, four layers WL1 to WL4 of the first coil SP1 are located in the radially outer winding space 55. The angle at which the winding wire 43 runs through the passage 18 between the webs 15 (Figs. 5 and 7) should be as small as possible so that the winding wire 43 to be laid does not collide with the guide body 10 or the tooth 1, 2 in the area of ​​the slot. This angle α is indicated in Fig. 8. It refers to the end face 23 of the guide body 10, which runs perpendicular to the longitudinal direction of the arm 4.

[0130] A collision can also be avoided by arranging the webs 14, 15 further radially inward along the arm 4, so that the width of one winding space becomes larger and the width of the other winding space becomes smaller.

[0131] The thickness 79 (Fig. 8) of the webs 15 at the base of the web should be an integer multiple of the diameter of the winding wire. In this case, an orthocyclic winding of the second coil SP2 is possible, which is wound over the web 15 and the first coil SP1.

[0132] By subdividing the winding space 54, 55 by at least one web 14, 15, it is possible, as described, for the transition of the winding wire 43 from tooth 1 to tooth 2 to be located in the radially inner region of the insulating disks 12, 13. The webs 14, 15 can be located on the end faces and / or laterally projecting from the end insulation elements of the individual teeth 1 to 12. The end insulation elements can be formed by the insulating disks 12, 13 or by an overmolding of the stator core 1.

[0133] In the case of overmolding, the webs 14, 15 can also be provided on the side walls of the overmolded arms 4.

[0134] Through the passage 18 between the two webs 14, the winding wire 43 can be guided in a radial or diagonal direction from one winding space to the other. The winding wire 43 can be guided, as previously described, from the winding space 54 to the winding space 55 or vice versa. The webs 15 defining the passage 18 are provided with guides in the form of guide surfaces 59, 60, against which the winding wires 43 can rest. For orthocyclic winding, the wire guides 59, 60 extend at an angle a (Fig. 8) obliquely to the longitudinal axis of the arm 4 of the teeth 1 to 12.

[0135] Since more space is available in the radially outer winding space 55 in the circumferential direction of the stator core 1 than in the radially inner winding space 54, the radially outer winding space 55 can be filled first. This allows the smaller space in the radially inner winding space 54 to be used for the wire start and end, or for the transition of the winding wire 43 to the next tooth. The filling capacity of the radially inner winding space 54 is limited in particular by the winding needle, which must be moved between adjacent teeth during the winding process. The width of the intermediate space 71, measured in the circumferential direction, decreases continuously radially inward.

[0136] The described stator is intended for an external rotor motor in which the rotor surrounds the stator. The beginning and end of the winding wire 43 for contacting are located in the radially inner region of the electrical insulation. In the described embodiment, adjacent teeth 1, 2 are continuously wound by a single winding wire 43. In the embodiment, two coils SP1, SP2 are wound with the winding wire 43, for example, to enable a parallel connection of the coils. The two coils are wound on top of one another. Due to the described design, a perfect winding of the teeth 1 to 12 of the stator results.

[0137] Due to the described design of the stator package 1 with the webs 14, 15, the stator can be wound easily and reliably for use in an external rotor motor. The winding starts in the radially inner area of ​​the respective insulating disk 12, 13, e.g. in one of the receiving pockets 7. The tooth is then wound from radially inside to radially outside in the area of ​​the first winding space 54 up to the separating web 14, 15. The winding wire 43 is then guided through the passage 18 between the webs 15 from the first winding space 54 into the second winding space 55. The tooth is now wound from radially inside to radially outside in the area of ​​the second winding space 55 up to the link body 10, which delimits the winding space 55 radially outwards and is provided at the radially outer end of the arms 4 of the teeth.

[0138] The winding wire 43 is then guided from the radial outside to the radial inside within the second winding space 55. The reciprocating winding of the tooth is continued until the radially outer winding space 55 is completely wound.

[0139] The winding wire 43 is then guided back through the passage 18 from the second winding space 55 into the first winding space 54. The tooth is then wound within the radially inner winding space 54 from radially outside to radially inside. The winding wire 43 is then guided radially inward so that it can be contacted, e.g., in the respective receiving pocket 7 using an insulation displacement contact.

[0140] In the described embodiment, however, the wire is not guided radially inward for contacting, but rather is guided to the next tooth, where it is wound in the radially inner winding space 54. The next tooth is then wound according to the same sequence as the previous tooth.

[0141] It is further possible to wind the second coil SP2 over the first coil SP1 and also over the webs 14, 15 if the webs 14, 15 are designed such that they are flush with the first coil SP1, as shown by way of example in the drawings.

Claims

Claims Stator for an electric motor or a generator, in particular for an external rotor motor, with an annular region (3) from which teeth (1 to 12) protrude, each having an arm (4) extending from the annular region (3), having at the free end a web (5) running transversely to it and carrying at least one winding which has at least one coil (SP1, SP2) wound by a winding wire (43) and is accommodated in a winding space (54, 55) extending from the annular region (3), characterized in that the winding space (54, 55) is divided by at least one separating web (14, 15) into winding space sections (54, 55) lying one behind the other, which are arranged on the arm (4). Stator according to claim 1, characterized in that the separating webs (14, 15) are provided on the top and bottom of the teeth (1 to 12) of the stator.Stator according to claim 1 or 2, characterized in that the separating webs (14, 15) are arranged such that the winding space sections (54, 55) have different lengths. Stator according to one of claims 1 to 3, characterized in that the separating webs (15) of at least some of the teeth (1 to 12) have a passage (18) for the winding wire (43) on the top and / or bottom side. Stator according to claim 4, characterized in that the separating webs (15) having the passage (18) have lateral guides (59, 60) for the winding wire (43). Stator according to claim 5, characterized in that the guides (59, 60) extend at an angle oblique to the longitudinal direction of the teeth (1 to 12). Stator according to one of claims 1 to 6, characterized in that the separating web (14, 15) is positioned on the tooth (1 to 12) such that the end of the coil lies on the annular region (3). Stator according to one of claims 1 to 7, characterized in that the radially inner winding space section (54) has a width in the circumferential direction of the stator such that the number of layers (WL1, WL2) of the coil (SP1) is even. Stator according to one of claims 1 to 8, characterized in that the radially outer winding space section (55) has a width in the circumferential direction of the stator such that the number of layers (WL1 to WL4) of the coil (SP1) is a multiple of the layers in the radially inner winding space section (54). Stator according to one of claims 4 to 9, characterized in that the thickness of the separating web (15) having the passage (18), measured at the base of the separating web (15), is an integer multiple of the diameter of the winding wire (43). Stator according to one of claims 1 to 10, characterized in that at least one guide body (10) for deflecting the winding wire (43) is provided at the free end of the arms (4) of the teeth (1 to 12). Stator according to claim 11, characterized in that the link body (10) radially delimits the radially outer winding section (55). Stator according to claim 11 or 12, characterized in that the link body (10) and / or a deflecting body (37) is provided with at least one axial securing element (34) for the winding wire (43). Stator according to claim 13, characterized in that the axial securing element (34) projects transversely from the link body (10) and / or from the deflecting body (37). Stator according to one of claims 1 to 14, characterized in that the separating web (14, 15) is part of an insulating element (12, 13) resting on the end faces of the teeth (1 to 12). Stator according to claim 15, characterized in that the insulating element (12, 13) is an insulating disk.

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