Sensor holder, system comprising sensor holder and temperature sensor, electric machine and method for fastening the system
Patent Information
- Application Number
- EP2023761921
- Authority / Receiving Office
- EP · EP
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2022-09-26
- Filing Date
- 2023-08-28
- Publication Date
- 2025-08-06
AI Technical Summary
Existing sensor holders for temperature sensors on electrical machines can only measure temperature at the distal end of the conductor, limiting the accuracy of temperature detection near the winding head.
A sensor holder made of elastic material with a sensor receiving section and a fastening section, allowing the sensor to be plugged onto a conductor end and guided over curved areas, ensuring the temperature sensor is positioned close to the winding head for accurate temperature measurement.
Enables accurate temperature measurement near the winding head by overcoming conductor bends and eliminating the need for thermal treatments, ensuring operational reliability and convenient attachment.
Smart Images
Figure 1.1
Abstract
Description
[0001] Description
[0002] Sensor holder, system comprising sensor holder and temperature sensor, electrical machine and method for fastening the system
[0003] The invention relates to a sensor holder for a temperature sensor of an electrical machine. The sensor holder is made of an elastic material so that the sensor holder can be plugged onto a conductor end of a winding head and guided over a curved region of the conductor end. The invention also relates to a system comprising the sensor holder according to the invention and a temperature sensor arranged in the sensor holder. Furthermore, the invention relates to an electrical machine with the system according to the invention. Furthermore, the invention relates to a method for fastening the system according to the invention.
[0004] Sensor holders for a temperature sensor and for placement on a conductor end of a stator winding are generally known. For example, EP 3537579 B1 describes an insulating ring with such a sensor holder. The sensor holder has a pocket in which a temperature sensor is arranged. Furthermore, the sensor holder has a conductor guide into which a conductor end of the stator winding is guided and pressed against the temperature sensor. The sensor holder is designed such that only the distal conductor end is pressed against the temperature sensor, and thus the temperature can be measured only there.
[0005] An object of the invention is to provide a sensor holder for a temperature sensor of an electrical machine, which can be easily placed on a conductor of a stator winding close to the winding head of the stator winding.
[0006] This problem is solved by the subject matter of the independent patent claims. Preferred developments of the invention are the subject matter of the dependent patent claims, the following description, and the drawings. Each feature can represent an aspect of the invention, both individually and in combination, unless explicitly stated otherwise in the description.
[0007] In a first aspect, the invention relates to a sensor holder for a temperature sensor of an electrical machine, comprising a sensor receiving section, with a cavity and an opening, so that a temperature sensor can be arranged in the cavity via the opening, and a fastening section adjacent to the sensor receiving section and directly connected to the sensor receiving section, which has a through-opening with a closed edge, so that the sensor holder can be plugged onto a conductor end of a stator winding, wherein the sensor receiving section and the fastening section are formed from an elastic material.
[0008] In other words, according to the first aspect of the invention, a sensor holder for a temperature sensor of an electrical machine is provided. The sensor holder comprises a sensor receiving section and a fastening section. The sensor receiving section has a cavity and an opening such that a temperature sensor can be inserted into the cavity of the sensor receiving section via the opening and arranged therein. The fastening section is formed directly adjacent to the sensor receiving section. In other words, the fastening section and the sensor receiving section are firmly or captively connected to one another. The fastening section has a through-opening with a closed edge. A conductor end of a stator winding can thus engage in the fastening opening such that the sensor holder can be plugged onto the conductor end of the stator winding and fixed in place.The sensor receiving section and the fastening section are made of an elastic or flexible material. This allows the sensor holder to be plugged directly onto the conductor end and slid into the appropriate position along the conductor end. The elastic design of the sensor holder allows any bending of the conductor end to be overcome, allowing the temperature sensor to be positioned as close as possible to the end of the stator winding to detect the maximum temperature of the stator or stator winding.
[0009] A preferred development of the invention is that the elastic material is a silicone-containing and / or silicone-like material. In other words, the elastic material comprises silicone at least in sections and / or in part. A silicone-containing material can exhibit increased and permanent flexibility. Thus, this material is particularly suitable for the sensor holder for fixing the sensor holder directly or immediately to the conductor end. Any subsequent thermal treatments for fixing the sensor holder to the conductor end can thus be eliminated.
[0010] Particularly preferably, the silicone-containing material is a non-outgassing material. In other words, the silicone-containing material does not emit vapors, particularly at elevated temperatures, i.e., at temperatures within the operating range of the electrical machine, that could cause damage to other components of the electrical machine. This not only provides a particularly convenient sensor holder that can be plugged onto the conductor end, but also a sensor holder that is operationally reliable.
[0011] In an advantageous development of the invention, it is provided that the fastening section and the sensor receiving section are formed integrally with one another. In other words, it is provided that the fastening section and the sensor receiving section are formed integrally with one another in a single manufacturing process. The sensor holder can thus be produced in a single injection molding process. In other words, the elastic material is poured into an injection mold and subsequently removed from the injection mold. The sensor holder can thus be produced particularly inexpensively. It is conceivable that the fastening section and the sensor receiving section are formed from two different elastic materials. This can be advantageous if the sensor receiving section is to have increased rigidity compared to the fastening section for the arrangement of the temperature sensor.
[0012] Advantageously, both the fastening section and the sensor receiving section are made of the same elastic material. This can have advantages during the manufacturing process. Furthermore, material-related and / or manufacturing-related interfaces are reduced when the fastening section and the sensor receiving section are made of the same material. Furthermore, costs can be reduced because only one material is used.
[0013] In a preferred embodiment of the invention, the sensor receiving section and the fastening section are arranged parallel and / or adjacent to one another with respect to a longitudinal direction of the sensor holder. In other words, the sensor holder has a longitudinal direction. With respect to this longitudinal direction, the sensor receiving section and the fastening section are arranged parallel to one another. Likewise, a longitudinal direction of the cavity in the sensor receiving section and a longitudinal direction of the edge-closed through-opening in the fastening section run parallel to the longitudinal direction of the sensor holder. In this way, the sensor holder can be plugged onto a conductor end of the stator winding, with the temperature sensor consequently also being aligned parallel to the longitudinal direction or the longitudinal profile of the conductor end.This allows for a space-saving arrangement and / or alignment of the temperature sensor in the sensor holder, as it is aligned with the course of the conductor end.
[0014] An advantageous development of the invention is that a length of the sensor receiving section in the longitudinal direction of the sensor holder is longer than a length of the fastening section in the longitudinal direction of the sensor holder. In this way, a particularly flexible sensor holder is provided, since the fastening section is designed to be just long enough to ensure the necessary fastening on the conductor end of the stator winding and to provide maximum flexibility, in particular to overcome bends in the conductor when the sensor holder is displaced along the conductor end in its longitudinal direction. The longer sensor receiving section allows the required and necessary fastening of the temperature sensor to be achieved.
[0015] According to a preferred embodiment of the invention, the fastening section is formed parallel to a sensor head section of the sensor receiving section and / or at the same height as a sensor head section of the sensor receiving section. In other words, the sensor receiving section has a sensor head section that is formed within the cavity on a side facing away from the openings. The temperature sensor is therefore inserted with the sensor head first through the opening into the cavity of the sensor receiving section. The fastening section is formed at the same height as the sensor head section. In this way, the temperature sensor can be held and / or pressed against the conductor end of the stator winding, such that the temperature of the stator winding can be reliably detected via the temperature sensor.
[0016] The temperature sensor is not directly adjacent to the electrical conductor, but is separated by an intermediate wall, namely a wall of the mounting section and sensor receiving section.
[0017] In an advantageous development of the invention, it is provided that the through-opening has a rectangular cross-section, and at least one projection is formed on an inner side of the through-opening facing the sensor-receiving section and / or on an inner side of the through-opening in the region of two opposite side sections of the fastening section. The cross-section of the through-opening is thus preferably adapted to the outer contour of the conductor end of the stator winding. A projection is formed on the inner side of the through-opening facing the sensor-receiving section. This projection acts as a pressing and / or fixing element, so that the sensor holder is securely fastened to the conductor end of the stator winding.It is also conceivable and advantageous for the two side sections of the fastening section, which are connected to the sensor receiving section, to each have a projection on their inner side. This projection can be used to position the sensor holder on the conductor end and to press the sensor holder onto the conductor end.
[0018] In a second aspect, the invention relates to a system comprising the sensor holder according to the invention and a temperature sensor arranged in the sensor holder, wherein the temperature sensor is introduced into the cavity via the opening of the sensor receiving section and is fixed therein in a materially bonded manner.
[0019] According to the second aspect of the invention, it is therefore provided that a temperature sensor is arranged in the sensor holder. The temperature sensor is preferably inserted with the sensor head first through the opening into the cavity. A wiring of the temperature sensor is led out of the opening. The temperature sensor is arranged within the cavity in a materially bonded manner. Due to the materially bonded connection of the temperature sensor within the cavity, it is captively arranged in the sensor holder. In addition, the materially bonded connection of the temperature sensor within the cavity enables better heat transfer from a temperature to be detected through the intermediate wall and the materially bonded connection to the sensor head of the temperature sensor. The material-liquid fixation is preferably a permanently elastic potting compound, which particularly preferably also comprises a silicone-containing material.
[0020] In a third aspect, the invention relates to an electrical machine having a stator with a stator winding, wherein the stator winding has at least one conductor end and the system according to the invention is plugged onto the conductor end, wherein the conductor end engages in the edge-closed through-opening of the fastening section. According to the third aspect of the invention, an electrical machine is provided which has a stator, wherein the stator comprises a stator winding. At the end of the stator, the stator winding has a winding head. The system according to the invention is plugged onto a conductor end of the stator winding in order to measure the temperature close to the winding head.
[0021] In a fourth aspect, the invention relates to a method for fastening the system according to the invention to a stator winding, wherein
[0022] - a stator having a stator winding is provided, and the stator winding has a winding head with a conductor end,
[0023] - the system is plugged onto the end of the conductor, whereby the end of the conductor engages in the through-opening of the fastening section and the system is moved into an end position along a longitudinal direction of the conductor.
[0024] In other words, according to the fourth aspect of the invention, a method for fastening the system to the stator winding is provided. In a first step, a stator is provided which has a stator winding, wherein the stator winding has a winding head at the end of the stator. The winding head comprises a conductor end. The system, consisting of the sensor holder and the temperature sensor arranged in the sensor holder, is plugged onto the conductor end. The conductor end engages in the through-opening of the fastening section and the system is displaced into an end position along a longitudinal direction of the conductor of the stator winding. The end position is preferably designed at a distance from the distal end of the conductor end.Consequently, the stator is first fully manufactured, i.e., the stator winding is arranged in the stator, and the winding head is preferably formed by twisting the winding ends. Preferably, before the stator winding is connected, the temperature sensor is pushed onto the winding end of a conductor of the stator winding, preferably onto the neutral conductor. Thus, a method is provided with which the system, in particular the sensor holder, can be easily arranged on the electrical conductor or the conductor end of the stator winding.
[0025] Finally, an advantageous development of the invention lies in the fact that the system is plugged onto the conductor end after formation of a winding head of the stator winding, wherein the conductor end of the stator winding has a bend in at least one region with an angle a of 90° < a < 160°, °, preferably 95° < a 150°, particularly preferably between 100° < a 140°, relative to the longitudinal axis of the conductor end, and the sensor holder is guided along the conductor over the region of the bend. In other words, the stator winding is fully formed, wherein the conductor end has at least one bent region. Relative to the longitudinal axis of the conductor end, the conductor is bent at an angle a of 90° < a < 160°. The system or the sensor holder is guided over this bent section of the conductor.
[0026] It should be noted that all features described above and below with respect to one aspect of the present invention equally apply to any other aspect of the present invention. Specifically, all features of the sensor mount and / or the system and / or the electric machine and / or the method can also be features of the motor vehicle. This also applies vice versa.
[0027] Further features and advantages of the present invention emerge from the dependent claims and the following exemplary embodiments. The exemplary embodiments are not limiting, but rather are to be understood as examples. They are intended to enable the skilled person to implement the invention. The applicant reserves the right to make individual and / or several of the features disclosed in the exemplary embodiments the subject of patent claims or to incorporate such features into existing patent claims. The exemplary embodiments are explained in more detail with reference to drawings.
[0028] In these show: Fig. 1 a longitudinal section through a system comprising a sensor holder and a temperature sensor;
[0029] Fig. 2 is an isometric view of the system;
[0030] Fig. 3 is a detailed view of the system plugged onto a conductor end of a stator winding;
[0031] Fig. 4 a detailed view of an electrical machine in the area of the plugged-in system;
[0032] Fig. 5 shows a method for attaching the system to the conductor end of a stator winding.
[0033] Fig. 1 shows a longitudinal section through a system 10 comprising a sensor holder 12 and a temperature sensor 14. The sensor holder 12 comprises a sensor receiving section 16 and a fastening section 18. The sensor receiving section 16 has a cavity 20 and an opening 22. The temperature sensor 14 is guided into the cavity 20 of the sensor receiving section 16 via the opening 22. The fastening section 18 is formed directly adjacent to the sensor receiving section 16. It is provided that the sensor receiving section 16 and the fastening section 18 are arranged parallel and / or next to one another with respect to a longitudinal direction 24 of the sensor holder 12. In other words, the sensor holder 12 has a longitudinal direction 24. With respect to this longitudinal direction 24, the sensor receiving section 16 and the fastening section 18 are arranged parallel to one another.
[0034] The fastening section 18 has a closed-edge through-opening 26. Both a longitudinal direction of the cavity 20 and a longitudinal direction of the through-opening 26 run parallel to the longitudinal direction 24 of the sensor holder 12. In this way, the sensor holder 12 can be plugged onto a conductor end 28 of a stator winding 30, and the temperature sensor 14 is consequently aligned parallel to the longitudinal direction or the longitudinal extension of the conductor end 28.
[0035] The sensor receiving section 16 and the fastening section 18 are formed from an elastic or flexible material. In this way, the sensor holder 12 can be plugged directly onto the conductor end 28 and slid into the appropriate position in the longitudinal direction of the conductor end 28. The elastic design of the sensor holder 12 allows any bending of the conductor end 28 to be overcome, so that the temperature sensor 14 can be positioned as close as possible to the winding overhang in order to detect a maximum temperature of the stator winding 30. Due to the elastic design of the sensor holder 12, no thermal final treatment of a conceivable fixing device, such as a plugged-on shrink tube, is required in the final position of the sensor holder 12 on the conductor end 28.Thus, a sensor holder 12 for a temperature sensor 14 is provided, which can be easily placed on a conductor of a stator winding 30.
[0036] In the present exemplary embodiment, the elastic material is a non-outgassing silicone-containing material. In other words, the elastic material comprises silicone at least in sections and / or partially. A silicone-containing material can have increased and permanent flexibility. This material is therefore particularly suitable for the sensor holder 12 in order to fix the sensor holder 12 directly or immediately on the conductor end 28. Because the elastic material is non-outgassing, no harmful vapors escape at elevated temperatures of an electrical machine 32, i.e., at temperatures in the operating range of the electrical machine 32. This not only provides a sensor holder 12 that can be particularly conveniently plugged onto the conductor end 28, but also a sensor holder 12 that is reliable in operation.
[0037] The fastening section 18 and the sensor receiving section 16 are formed integrally with one another. In other words, it is provided that the fastening section 18 and the sensor receiving section 16 are formed integrally with one another in a single manufacturing process. The sensor holder 12 can thus preferably be manufactured in an injection molding process. In other words, the elastic material is poured into an injection mold and subsequently removed from the injection mold.
[0038] Thus, the sensor holder 12 can be manufactured particularly inexpensively.
[0039] A length of the sensor receiving section 16 in the longitudinal direction 24 of the sensor holder 12 is longer than a length of the fastening section 18 in the longitudinal direction 24 of the sensor holder 12. In this way, a particularly flexible sensor holder 12 is provided, since the fastening section 18 is designed to be just long enough to ensure the necessary fastening on the conductor end 28 of the stator winding 30 and to provide maximum flexibility, in particular to overcome bends of the conductor 28 when the sensor holder 12 is displaced on the conductor end 28 in its longitudinal direction. The longer sensor receiving section 16 allows the required and necessary fastening of the temperature sensor 14 to be achieved.
[0040] Fig. 2 shows an isometric view of the system 10. The edge-closed through-opening 26 has a rectangular cross-section, with at least one projection 36 being formed on an inner side of the through-opening 26, which faces the sensor receiving section 16, and on an inner side of the through-opening 26 in the region of two opposite side sections 34 of the fastening section 18. The cross-section of the through-opening 26 is thus preferably adapted to the outer contour of the conductor end 28 of the stator winding 30. A projection 36 is formed on the inner side of the through-opening 26, which faces the sensor receiving section 16. This projection 36 acts as a pressing and / or fixing element, so that the sensor holder 12 is securely fastened to the conductor end 28 of the stator winding 30.It is also provided that the two side sections 34 of the fastening section 18, which are connected to the sensor receiving section 16, each have a projection 36 on their inner side. These projections 36 can be used to position the sensor holder 12 on the conductor end 28 and to press the sensor holder 12 onto the conductor end 28. Fig. 3 shows a detailed view of the system 10 plugged onto a conductor end 28 of the stator winding 30. Starting from a distal end 38 of the conductor end 28 of the stator winding 30, the system 10, comprising the sensor holder 12 with the temperature sensor 14 arranged and encapsulated therein, is plugged onto the conductor end 28 and pushed along a longitudinal extent of the conductor end 28 into an end position. Starting from the distal end 38, the conductor end 28 has two curved and spaced-apart sections relative to a longitudinal axis of the conductor end 28.In the respective area, the conductor is bent at an angle a of 110°. The system 10 is pushed along the insertion path 40 onto the conductor until it reaches its final position.
[0041] Fig. 4 shows a detailed view of the electrical machine 32 in the area of the attached system 10. After the system 10 has been attached to the conductor end 28 via the distal end 38 and moved into its final position on the electrical conductor, the winding head of the stator winding 30 is potted. The system 10 protrudes at least partially into the potting 42. This ensures permanent positioning of the system 10 in the final position. Furthermore, the thermal connection of the temperature sensor 14 to the winding head can be increased.
[0042] Fig. 5 shows a method for attaching the system 10 to the conductor end 28 of a stator winding 30.
[0043] In a first step 100, the stator having the stator winding 30 is provided, wherein the stator winding 30 has a winding head with a conductor end 28.
[0044] In a second step 110, the system 10 is plugged onto the conductor end 28, starting from the distal end 38 of the conductor end 28, wherein the conductor end 28 engages in the through-opening 26 of the fastening section 18. In a third step 120, the system 10 is moved along a longitudinal direction or
[0045] Longitudinal extension of the conductor or the conductor end 28 is shifted to the end position near the winding head.
Claims
Patent claims 1. Sensor holder (12) for a temperature sensor (14) of an electrical machine (32), comprising a sensor receiving section (16) with a cavity (20) and an opening (22) such that a temperature sensor (14) can be arranged in the cavity (20) via the opening (22), and a fastening section (18) adjacent to the sensor receiving section (16) and directly connected to the sensor receiving section (16), which fastening section has a through-opening (26) with a closed edge such that the sensor holder (12) can be plugged onto a conductor end (28) of a stator winding (30), wherein the sensor receiving section (16) and the fastening section (18) are formed from an elastic material.
2. Sensor holder (12) according to claim 1, characterized in that the elastic material is a silicone-containing material.
3. Sensor holder (12) according to one of the preceding claims, characterized in that the fastening section (18) and the sensor receiving section (16) are formed integrally with one another.
4. Sensor holder (12) according to one of the preceding claims, characterized in that the sensor receiving section (16) and the fastening section (18) are arranged parallel and / or next to one another with respect to a longitudinal direction (24) of the sensor holder (12).
5. Sensor holder (12) according to one of the preceding claims, characterized in that a length of the sensor receiving section (16) in the longitudinal direction (24) of the sensor holder (12) is longer than a length of the fastening section (18) in the longitudinal direction (24) of the sensor holder (12).
6. Sensor holder (12) according to one of the preceding claims, characterized in that the fastening section (18) is formed parallel to a sensor head section of the sensor receiving section (16) and / or at the level of a sensor head section of the sensor receiving section (16).
7. Sensor holder (12) according to one of the preceding claims, characterized in that the through-opening (26) has a rectangular cross-section, and on an inner side of the through-opening (26) which faces the sensor receiving section (16) and / or on an inner side of the through-opening (26) in the region of two opposite side sections (34) of the fastening section (18), at least one projection (36) is formed.
8. System (10) comprising a sensor holder (12) according to one of the preceding claims and a temperature sensor (14) arranged in the sensor holder (12), wherein the temperature sensor (14) is inserted into the cavity (20) via the opening (22) of the sensor receiving section (16) and is fixed therein by a material fit.
9. Electrical machine (32), comprising a stator having a stator winding (30), wherein the stator winding (30) has at least one conductor end (28) and the system (10) according to claim 8 is plugged onto the conductor end (28), wherein the conductor end (28) engages in the edge-closed through-opening (26) of the fastening section (18).
10. A method for attaching a system (10) according to claim 8 to a stator winding (30), wherein - a stator having a stator winding (30) is provided, and the stator winding (30) has a winding head with a conductor end (28), - the system (10) is plugged onto the conductor end (28), wherein the conductor end (28) engages in the through-opening (26) of the fastening section (18) and the system (10) is displaced into an end position along a longitudinal direction of the conductor.
11. Method according to claim 10, characterized in that the system (10) after formation of a winding head of the stator winding (30) is plugged onto the conductor end (28), wherein the conductor end (30) of the stator winding (30) has a bend with an angle a of 90° < a < 160°, relative to the longitudinal axis of the conductor end (28), in at least one region, and the sensor holder (12) is guided along the conductor over the region of the bend.