Modular system for manufacturing a stator for an electric machine, and method for manufacturing a stator for an electric machine from a modular system

Abstract

The invention relates to a modular system for manufacturing a stator for an electric machine, comprising - a stator assembly having a stator core and a stator winding with multiple winding connections, and - multiple busbar arrangements for manufacturing stators with a different interconnection of the stator winding, wherein the busbar arrangements each have multiple stator winding connection points for connection to the winding connections of the stator winding, multiple phase connection points and multiple connecting lines for connecting the stator winding connection points to the phase connection points, wherein the stator winding connection points and the phase connection points of the multiple busbar arrangements are each arranged geometrically identically in relation to one another, and wherein the stator winding connection points and the phase connection points of the multiple busbar arrangements are each connected differently to one another via the connecting lines.

Description

[0001] Modular system for producing a stator for an electrical machine, method for producing a stator for an electrical machine from a modular system

[0002] The invention relates to a modular system for producing a stator for an electrical machine. Furthermore, the invention relates to a method for producing a stator for an electrical machine from such a modular system.

[0003] The use of electrical machines in mobile, stationary, or industrial applications is widespread, displacing the use of conventional drives such as the combustion engine. To meet the wide range of different technical requirements, electrical machines are manufactured for specific applications using different manufacturing processes and are wired differently. For example, the electrical machine can be wired in a star or delta configuration, comprising a different number of parallel or series connections to provide different power levels depending on the application. Since different applications each require a different electrical machine and thus a different manufacturing process, the number of manufacturing processes and thus the manufacturing effort can be very large.

[0004] Against this background, the task arises of reducing the effort required to manufacture electrical machines with different configurations.

[0005] The task is solved by a modular system for the production of a stator for an electrical machine with

[0006] - a stator assembly comprising a stator core and a stator winding with a plurality of winding terminals, and

[0007] - a plurality of busbar arrangements for producing stators with different connections of the stator winding, wherein the busbar arrangements each have a plurality of stator winding connection points for connection to the winding connections of the stator winding, a plurality of phase connection points and a plurality of connecting lines for connecting the stator winding connection points to the phase connection points, wherein the stator winding connection points and the phase connection points of the plurality of busbar arrangements are each arranged geometrically identically relative to one another, and wherein the stator winding connection points and the phase connection points of the plurality of busbar arrangements are each connected to one another differently via the connecting lines.

[0008] The modular system according to the invention for producing a stator for an electrical machine comprises a stator assembly comprising a stator core and a stator winding with a plurality of winding terminals. The stator core can comprise magnetizable electrical steel sheets. The stator winding can be single-part or multi-part. Furthermore, the stator winding has a plurality of winding terminals, by means of which the electrical machine can be electrically contacted in different ways.

[0009] The modular system also includes multiple busbar assemblies. These busbar assemblies can be configured differently to produce stators with different stator winding connections. The busbar assembly suitable for the respective application can be electrically connected to the stator. Busbar assemblies according to the invention can each comprise multiple bars made of electrically conductive materials. Busbar assemblies can preferably be arranged on an end face of the electrical machine, in particular on a winding overhang of the stator. They can be connected to the winding terminals of the stator winding and enable different stator winding connections. In terms of their external dimensions, busbar assemblies can be arranged flush with the winding overhang, the stator assembly, or the electrical machine.They can be ring-shaped, hollow-cylindrical, or have another rotationally symmetrical geometry, and each have an inner and outer diameter. Busbar arrangements can also have a uniform outer contour with a constant outer diameter. Thus, they can at least partially surround the stator or stator winding. They can have sections extending in a radial direction of the electrical machine, for example, projections for electrical contact.

[0010] The busbar arrangements each have a plurality of stator winding connection points for connection to the winding terminals of the stator winding. By means of the electrical connection between a busbar arrangement and the winding terminals of the stator winding at the stator winding connection points, the electric machine can be supplied with energy, for example, in motor mode, or energy can be provided by the electric machine, for example, in generator mode. Furthermore, the busbar arrangements have a plurality of phase connection points, by means of which the electric machine can be supplied with a plurality of, in particular phase-shifted, currents. Furthermore, the busbar arrangements comprise a plurality of connecting lines for connecting the stator winding connection points to the phase connection points.In other words, busbar assemblies can be designed as adapters between an electrical network and the stator assembly. The connecting lines can be arranged inside or outside the respective busbar assemblies. The connecting lines can also be arranged partially inside and partially outside the busbar assemblies.

[0011] According to the invention, the stator winding connection points and the phase connection points of the multiple busbar assemblies are each arranged geometrically identically relative to one another. The stator winding connection points and the phase connection points of one busbar assembly can be arranged in alignment with the stator winding connection points and the phase connection points of another busbar assembly with respect to the rotor axis of the electric machine. In other words, corresponding connecting lines of the respective stator winding connection points and phase connection points of different busbar assemblies can each be arranged parallel to the rotor axis.

[0012] Furthermore, the stator winding connection points and the phase connection points of the multiple busbar assemblies are each connected differently to one another via the connecting lines. Due to the different connections of the stator winding connection points and phase connection points, different interconnections of the stator of the electrical machine can be formed. This results in the advantage that a single stator assembly can, in principle, be used to manufacture differently interconnected stators by selecting suitable busbar assemblies from the set of multiple busbar assemblies. Since only one suitable busbar assembly needs to be selected and connected, and the interfaces of the busbar assemblies are identical, a common manufacturing process can be used.With the modular system according to the invention, stators with different technical specifications can thus be manufactured using a single manufacturing process. This reduces the effort required to manufacture differently configured electrical machines. A preferred embodiment of the invention provides that the multiple busbar assemblies each have twelve stator winding connection points and / or three phase connections. Three-phase current can be supplied to the electrical machine via the three phase connections. The electrical machine can therefore be operated, for example, as a synchronous or asynchronous motor. The twelve stator winding connection points of a busbar assembly can all be used to contact the winding connections.

[0013] In a preferred embodiment of the invention, the plurality of busbar assemblies each have at least three phase bars, a cover bar, and a base bar. The three phase bars can form the connecting lines of the busbar assemblies between the stator winding connection points and the phase connection points. The phase bars can be arranged parallel to one another, at least in sections. For electrical contacting of the phase bars, recesses, in particular circular ones, and / or elements for plug-in, clamp-in, or latching contacts or the like can be formed in the phase bars. The phase bars can be partially or completely covered on one or more sides by the cover and / or base bars. A section for electrically grounding the busbar assemblies can be formed in the cover or base bars of each busbar assembly.Pins, bolts, or similar components, as well as corresponding recesses, can be formed in the phase, cover, and base rails to enable precise positioning of all rails relative to one another. Furthermore, the phase, cover, and base rails can be connected to one another or to other components using the pins or bolts, for example, through a transition or press fit.

[0014] In a preferred embodiment of the invention, it is provided that the phase busbars, the cover busbars, and the base busbars are curved, in particular circular, and can be arranged in a circumferential direction of the stator assembly. As a result of curved phase, cover, and base busbars, the busbar arrangements can have a curved shape. This achieves the advantage of low volume and installation space requirements. In particular, the phase busbars, the cover busbars, and the base busbars can be circular. Thus, they can be arranged with optimized geometry on an outer contour of the stator assembly of the electrical machine. The phase, cover, and base busbars are preferably arranged along a direction parallel to the rotor axis. The circular shape can preferably extend in the circumferential direction of the stator assembly.

[0015] A preferred embodiment of the invention provides that the multiple phase rails of a busbar arrangement each have different arc lengths. By using different arc lengths, material stress on the busbar arrangements can be optimized, thereby saving costs, since all phase rails can be designed to be just as long as the respective application requires.

[0016] In a preferred embodiment of the invention, each phase busbar has at least one stator winding connection pin, with all stator winding connection pins extending substantially perpendicular to a base body of the respective associated phase busbar. The stator winding connection pins form the electrical contacts of the busbar arrangements. They are arranged at the stator winding connection points. Furthermore, they can each have a polygonal, round, or oval cross-section. In addition, the stator winding connection pins can be at least partially hollow. The stator winding connection pins preferably extend perpendicular to the base body of the respective phase busbar and preferably parallel to the rotor axis. The stator winding connection pins can be arranged along a circumferential direction of the respective phase busbars.In the case of curved phase rails, the stator winding connection pins can be formed on a smaller diameter of the phase rail, ie on the side of the phase rail facing the stator assembly, or on a larger diameter of the phase rail, ie on the side of the phase rail facing away from the stator assembly.

[0017] A preferred embodiment of the invention provides that the stator winding connection points are formed at least in one periphery of the cover rails. Stator winding connection points can be formed as recesses on an outer contour or in the periphery of the cover rails. This can facilitate the assembly of the busbar assemblies. Furthermore, the production of peripheral stator winding connection points can be designed more flexibly, since they can be produced, for example, by drilling or milling.

[0018] In a particularly preferred embodiment of the invention it is provided that the

[0019] Stator winding connection pins protrude through the stator winding connection points.

[0020] Stator winding connection pins can each extend from the bottom to the top of the cover rails. For stator winding connection points designed as through-holes, they can be inserted; for peripherally designed stator winding connection points, they can be inserted or pushed into the stator winding connection points.

[0021] In a preferred embodiment of the invention, the phase rails each have a stepped section, in which a phase connection point is formed. Sections can be created by bending the phase rails at two right angles. In other words, the phase rails can each comprise a web extending perpendicular to the base body of the phase rails and a section extending parallel to the base body of the phase rails. Preferably, a phase connection point is formed on each section. Phase, cover, and base rails can be aligned in such a way that several phase connection points formed on different rails of a busbar arrangement can be arranged in an overlapping manner.In particular, a first / second / third phase connection point of the cover busbar can be arranged so that it overlaps the phase connection point of a first / second / third phase busbar. To save space, the webs of different phase busbars can also be of different lengths. Furthermore, the sections of different phase busbars can be of different lengths.

[0022] Another object of the invention is a method for producing a stator for an electrical machine from a modular system, wherein a modular system as described above is provided, wherein one of the plurality of busbar arrangements is selected depending on a desired wiring of the stator winding and wherein the selected busbar arrangement is connected to the stator assembly.

[0023] The method achieves the same advantages and technical effects as mentioned in the context of the above-mentioned system and its preferred embodiments.

[0024] Further details and advantages of the invention will be explained below with reference to the exemplary embodiments illustrated in the drawings. These show: Fig. 1a shows a first exemplary embodiment of a busbar arrangement according to the invention, each in a schematic top view, a schematic side view, and another schematic side view, in which the busbar arrangement is mounted on an electrical machine;

[0025] Fig. 1b shows a first phase rail of the busbar arrangement from Fig. 1a in three schematic views;

[0026] Fig. 1c shows a second phase rail of the busbar arrangement from Fig. 1a in three schematic views;

[0027] Fig. 1d shows a third phase rail of the busbar arrangement from Fig. 1a in three schematic views;

[0028] Fig. 1e shows the cover rail of the busbar arrangement from Fig. 1a in a schematic top view and a side view;

[0029] Fig. 1f shows the base rail of the busbar arrangement from Fig. 1a in a schematic top view and a side view;

[0030] Fig. 2 shows a second embodiment of a busbar arrangement according to the invention, each in a schematic plan view, a schematic side view and a further schematic side view, in which the busbar arrangement is mounted on an electrical machine; and

[0031] Fig. 3 shows a third embodiment of a busbar arrangement according to the invention in a schematic plan view.

[0032] The differently configured busbar assemblies 20 shown in Fig. 1-3 can be used as part of a modular system 1 according to the invention for producing a stator 3 for an electrical machine 5. Since the differently configured busbar assemblies 20 each have stator winding connection points Li to L12 and phase connection points II, V, W, which are arranged geometrically identically relative to one another in all different busbar assemblies 20, one of the plurality of busbar assemblies 20 can be selected and connected to the stator assembly 10 during production depending on a desired wiring of a stator winding 14 of a stator assembly 10.

[0033] Fig. 1a shows a busbar arrangement 20 of a modular system 1 according to the invention for producing a stator 3 for an electrical machine 5. Fig. 1a consists of three parts. The top of Fig. 1a shows the busbar arrangement 20 in a plan view. The middle of Fig. 1a shows the same busbar arrangement 20 in a side view. Furthermore, the bottom of Fig. 1a shows the same busbar arrangement 20 in a further side view, wherein the busbar arrangement 20 is arranged on a stator assembly 10 of the electrical machine 5.

[0034] The stator assembly 10 has a stator core 12 and, in the embodiment shown in Fig. 1a, a stator winding 14 with twelve winding terminals. The stator core 12 forms a base body of the stator 3 and comprises a magnetizable stator core. The twelve winding terminals of the stator winding 14 are connected, in particular soldered, to the busbar arrangement 20 in such a way that a delta connection is realized.

[0035] The busbar arrangement 20 is circularly arc-shaped and has twelve stator winding connection points Li to L^. The stator winding 14 of the stator 3 is connected to the busbar arrangement 20 via the stator winding connection points Li to L12 by means of its winding connections. In addition, the busbar arrangement 20 has three phase connection points II, V, and W, via which the busbar arrangement 20 is connected to a power-supply network, so that the electric machine 5 can be operated as a three-phase motor. Furthermore, the busbar arrangement 20 has three connecting lines designed as phase bars 22i, 222, 22s. The first, second, and third phase bars 22i, 222, 22s connect the stator winding connection points Li to L12 to the phase connection points II, V, W.

[0036] The busbar arrangement 20 has, in addition to the three phase bars 22i, 222, 22s, a cover bar 24 and a base bar 26. Three phase connection points II, V, W are formed in the cover bar 24 and are arranged at a distance from one another in a circumferential direction. In addition, a phase connection point U is formed in the first phase bar 22i, a phase connection point V in the second phase bar 222, and a phase connection point W in the third phase bar 22s. The phase connection points U are arranged so as to overlap. Analogously, the phase connection points V are arranged so as to overlap. The phase connection points W are also arranged so as to overlap. By inserting an electrical contact into the phase connection points II, V, W, the electrical machine 5 can be supplied with energy via the phase bars 22i, 222, 22s.

[0037] The busbar arrangement 20 has twelve stator winding connection pins 22', via which the stator 3 is electrically connected to the busbar arrangement 20. The three phase rails 22i, 222, 22s each comprise four stator winding connection pins 22' with a rectangular cross-section. The stator winding connection pins 22' protrude from an underside of the cover rail 24 through the stator winding connection points Li to L12 to an upper side of the cover rail 24. They are arranged parallel to one another and to a rotor axis of the electrical machine 5, indicated by a circle in Fig. 1a, wherein the circle refers to the upper part, i.e., the top view of the busbar arrangement 20, of Fig. 1a.

[0038] Fig. 1b shows three views of the first phase rail 22i from Fig. 1a. The first phase rail 22i has a circular-arc-shaped base body and four stator winding connection pins 22'. At a free end of the base body, the first phase rail 22i is bent twice. As a result of the bend, the first phase rail 22i has a web 23 formed perpendicular to the base body and a section 22" formed parallel to the base body. The phase connection point U is formed in the section 22".

[0039] Fig. 1c shows the second phase busbar 222 from Fig. 1a in three views. Like the first phase busbar 22i, the second phase busbar 222 has a circular arc-shaped base body and four stator winding connection pins 22'. At a free end of the base body, the second phase busbar 222 is bent twice, similar to the first phase busbar 22i. As a result of the bent, the second phase busbar 222 has a web 23 formed perpendicular to the base body and a section 22" formed parallel to the base body. The phase connection point V is formed in the section 22".

[0040] Fig. 1d shows three views of the third phase busbar 22s from Fig. 1a. Like the first and second phase busbars 22i, 222, the third phase busbar 22s has a circular arc-shaped base body and four stator winding connection pins 22'. At a free end of the base body, the third phase busbar 22s is bent twice, similar to the first and second phase busbars 22i, 222. As a result of the bent, the third phase busbar 22s has a web 23 formed perpendicular to the base body and a section 22" formed parallel to the base body. The phase connection point W is formed in the section 22". Webs 23 and sections 22" of the first, second and third phase busbars 22i, 222, 22s have different lengths to save space and material.

[0041] Fig. 1e shows the cover rail 24 from Fig. 1a in a top and a side view. The cover rail 24 is circularly arc-shaped and has twelve stator winding connection points Li to L12, whereby only the stator winding connection points Li, L5 and L12 are provided with reference numerals in the plan view of the cover rail 24, at the top in Fig. 1e. All stator winding connection points Li to L12 are formed on one side, in a periphery of the cover rail 24. Furthermore, a stator winding connection pin 22' is each arranged in the stator winding connection points Li to L12, whereby the stator winding connection pins 22' are only shown in the plan view of the cover rail 24, at the top in Fig. 1e. The stator winding connection pins 22' extend from a bottom side of the cover rail 24 to a top side of the cover rail 24. To simplify the assembly of the busbar 20, the cover rail 24 further has two bolts 24'.For this purpose, a tip is formed at each free end of the bolts 24' to facilitate assembly of the cover rail 24 with, for example, the base rail 26.

[0042] Fig. 1f shows the base rail 26 from Fig. 1a in a top and a side view. The base rail 26 is circularly arc-shaped and has twelve stator winding connection points L1 to L12, whereby only the stator winding connection points L2, L? and L are provided with reference numerals in the top view of the base rail 26, at the top in Fig. 1f. In addition, two recesses 26' are formed in a base body of the base rail 26, which are arranged correspondingly with regard to the position of the bolts 24' - from, for example, Fig. 1e. The bolts 24' can be inserted into the recesses 26', and the busbar arrangement 20 can be closed at the same time.

[0043] Fig. 2 shows a second exemplary embodiment of a busbar arrangement 20 of a modular system 1 according to the invention for producing a stator 3 for an electrical machine 5. A key difference between the first exemplary embodiment according to Fig. 1a and the second exemplary embodiment according to Fig. 2 is the interconnection. While the busbar arrangement 20 of Fig. 1a implements a delta connection, the busbar arrangement 20 of Fig. 1a is implemented as a star connection. For this reason, the second exemplary embodiment has an additional, fourth phase rail 224, which can be operated as a neutral conductor, particularly during three-phase operation.

[0044] Fig. 3 also shows a third exemplary embodiment of a busbar arrangement 20 according to the invention in a plan view. The busbar arrangement 20 according to Fig. 2 has, in addition to the stator winding connection points Li to L^ on a side facing the stator 3, further stator winding connection points Li' to I_12' on a side facing away from the stator 3.

[0045] Reference symbol

[0046] 1 Modular system

[0047] 3 Stator

[0048] 5 Electric machine

[0049] 10 Stator assembly

[0050] 12 Stator core

[0051] 14 Stator winding

[0052] 20 Busbar arrangement

[0053] Lj stator winding connection points

[0054] Lj' Additional stator winding connection points

[0055] 221 First phase rail

[0056] 222 Second phase rail

[0057] 22s Third phase rail

[0058] 224 Fourth phase rail

[0059] 22' stator winding connection pins

[0060] 22" section

[0061] 23 jetty

[0062] 24 lid rail

[0063] 24' bolt

[0064] 26 Base rail

[0065] 26' recess

[0066] 27 Earthing connection point

[0067] U phase connection point

[0068] V Phase connection point

[0069] W Phase connection point

Claims

Patent claims Modular system (1) for producing a stator (3) for an electrical machine (5) with - a stator assembly (10) having a stator core (12) and a stator winding (14) with a plurality of winding terminals, and - a plurality of busbar arrangements (20) for producing stators (3) with different connections of the stator winding (14), wherein the busbar arrangements (20) each have a plurality of stator winding connection points (Li to L12) for connection to the winding connections of the stator winding (14), a plurality of phase connection points (II, V, W) and a plurality of connecting lines for connecting the stator winding connection points (Li to L12) to the phase connection points (II, V, W), wherein the stator winding connection points (Li to L12) and the phase connection points (II, V, W) of the plurality of busbar arrangements (20) are each arranged geometrically identically relative to one another, and wherein the stator winding connection points (Li to L12) and the phase connection points (II, V, W) of the plurality of busbar arrangements (20) are each connected to one another differently via the connecting lines.Modular system (1) according to claim 1, characterized in that the plurality of busbar arrangements (20) each have twelve stator winding connection points (Li to L12) and / or three phase connections (II, V, W). Modular system (1) according to claim 1 or 2, characterized in that the plurality of busbar arrangements (20) each have at least three phase rails (22j), a cover rail (24) and a base rail (26). Modular system (1) according to claim 3, characterized in that the phase rails (22j), the cover rails (24) and the base rails (26) are arc-shaped, in particular circular-arc-shaped, and can be arranged in a circumferential direction of the stator assembly (10). Modular system (1) according to claim 4, characterized in that the plurality of phase rails (22j) each have different busbar arrangements (20). Have arc lengths. Modular system (1) according to claim 3, 4 or 5, characterized in that each phase rail (22j) has at least one stator winding connection pin (22'), wherein all stator winding connection pins (22') extend substantially perpendicular to a base body of the respectively associated phase rail (22j). Modular system (1) according to claim 6, characterized in that the stator winding connection points (Li to L12) are formed at least in a periphery of the cover rails (24). Modular system (1) according to claim 7, characterized in that the stator winding connection pins (22') protrude through the stator winding connection points (Li to L12). Modular system (1) according to one of claims 3 to 8, characterized in that the phase rails (22j) each have a stepped section (22"), in which a phase connection point (II, V, W) is formed.Method for producing a stator (3) for an electrical machine (5) from a modular system, wherein a modular system (1) according to one of the preceding claims is provided, wherein one of the plurality of busbar arrangements (20) is selected depending on a desired wiring of the stator winding (14), and wherein the selected busbar arrangement (20) is connected to the stator assembly (10).

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