Method for producing a stator of an electric rotary machine, electric rotary machine stator produced by said method, and electric rotary machine
Patent Information
- Application Number
- EP2023772770
- Authority / Receiving Office
- EP · EP
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2022-10-11
- Filing Date
- 2023-09-07
- Publication Date
- 2025-08-20
AI Technical Summary
Existing methods for producing stators of electric rotary machines require manual placement of phase separators, which is inefficient and costly, especially when dealing with multiple phases and critical potential differences, as they often necessitate reshaping and folding of insulation elements, leading to increased space usage and reduced accessibility during assembly.
A method involving adhesive insulation elements that are pre-fixed to the bays of line elements, allowing them to be carried and positioned automatically during the winding process, ensuring electrical isolation between phases without the need for additional reshaping or folding, and reducing mechanical stress on the winding.
This method simplifies and cost-effectively ensures reliable electrical isolation between conductors of different phases, reducing material usage and manufacturing costs while maintaining consistent quality and precise placement of insulation elements.
Smart Images
Figure 1.1
Abstract
Description
[0001] Method for producing a stator of an electric rotary machine, stator of an electric rotary machine produced thereby, and electric rotary machine
[0002] The present invention relates to a method for producing a stator of an electric rotary machine, a stator of an electric rotary machine produced thereby, and an electric rotary machine comprising the stator.
[0003] Stators of electrical rotating machines have several phases, which are realized by differently arranged windings in the stator body.
[0004] Figure 1 shows, by way of example, a first conducting element winding 21, which is intended to form a first phase of a stator to be manufactured for an electrical rotating machine. The individual conducting elements are arranged in bundles 22, which form first bays 30 on their radial outer sides. These first bays 30 rest on a coil plate. Insulation of the first phase or its conducting elements from other phases or their conducting elements must be ensured. Phase separators are usually used for this purpose, which are placed manually in an otherwise automated production process. Depending on the product design, separation of the electrical potentials within a phase may also be necessary, for example if the beginning and end of the phase are adjacent in the stator. This is particularly relevant when the phases are star-connected, since greater potential differences develop in the winding overhang area.For simplicity, these insulation tasks will also be referred to as phase separators below, even if the actual insulation performance takes place within an electrical phase. In the current state of the art, the finished winding heads of the inserted winding must be spread open using specific tools, such as a setting iron, to install the phase separators in the desired location by manual insertion.
[0005] With an automated approach, drawn-in coils must be specially shaped using robotic handling. The phase separators can be inserted automatically after each coil has been drawn in, but this operation must be performed in a separate processing station. Furthermore, it is necessary to create a three-dimensional shape for the phase separator, for example, by folding it over.
[0006] Connected phase separators in the form of cap-like insulation elements for the slot and winding head of a stator are known, as disclosed, for example, in document CN203984116U, which can be mounted accordingly and using a method according to document US4831715.
[0007] For this purpose, US4831715 A discloses a coil placement machine for positioning coil isolation insulators in slots. The insulators are positioned radially outward in slots before the electrical conductors are arranged there. In an alternative embodiment, end plates are arranged on stators, which provide different chambers for the individual phases and thus achieve phase isolation.
[0008] For the automation of phase separator assembly, gripper systems such as those published in document DE102019105308B4 are known. These systems enable coil shaping and separate assembly after insertion. However, accessibility for assembly is then limited, especially during multi-phase insertion.
[0009] It is also known to position insulation elements in relation to the windings before pulling in the conducting elements of the windings. These insulation elements are carried along in the pulling-in movement of the windings and create an insulating effect between the windings or the phases formed thereby. Such insulation elements are designed, for example, as rings which, when positioned, follow the circumferential arrangement of the stator slots. These rings are used for mixed-phase pulling-in, when several phases or their windings are pulled into the stator body in one pull-in. These rings are placed on the pulling-in mandrel after the first phase has been wound. After a further phase or its winding has been wound, the ring is fixed in place and is also pulled in when the windings are pulled in. However, this only allows for continuous insulation in the winding overhang.Due to its continuous ring design, a circumferential phase separator takes up more space in the installation space of the winding head than separately mounted insulation elements that are used in places with critical potential differences.
[0010] Proceeding from this, the object of the present invention is to provide a method for producing a stator of an electrical rotary machine, a stator of an electrical rotary machine produced thereby and an electrical rotary machine, by means of which conductors of different phases of the stator are electrically insulated from one another in the winding head in a simple, cost-effective and reliable manner.
[0011] This object is achieved by the method for producing a stator of an electric rotary machine according to claim 1, the stator of an electric rotary machine produced thereby according to claim 9, and by the electric rotary machine according to claim 10. Advantageous embodiments of the method for producing the stator are specified in subclaims 2-8.
[0012] The features of the claims can be combined in any technically reasonable manner, whereby the explanations from the following description as well as features from the figures can also be used to comprise additional embodiments of the invention.
[0013] The invention relates to a method for producing a stator of an electrical rotary machine, in which a stator body is provided with slots for receiving sections of conducting elements of windings, at least one first conducting element winding of a first phase is provided outside the stator body, which comprises a plurality of first bays of bundles of first conducting elements, and a first insulating element is fixed to at least one first bay by means of an adhesive connection, wherein at least one first insulating element is assigned to each respective first bay. The first conducting element winding is introduced into first slots of the stator body, wherein the first insulating element is carried along in the movement of the first conducting element winding due to the adhesive connection and is positioned relative to the stator body.
[0014] Accordingly, insulation elements can be arranged on one side of the stator body, such as on the side of the stator's electrical connections, the so-called A-side, prior to insertion and positioned in the winding head during insertion. The provision of the first conducting element winding of the first phase outside the stator body is optionally carried out on a positioning element, which can also be referred to as a insertion mandrel. Here, the first conducting element winding extends through cutouts or radial opening slots.
[0015] A bay is formed by a plurality of curved conductor sections arranged in a bundle. The first insulation element is fixed to a first bay by adhering the first insulation element to at least one conductor element of the bay by means of an adhesive bond.
[0016] The insulation element can be made of an approved and standardized surface insulation material, which is coated with an adhesive to create the adhesive bond. In an advantageous embodiment, the selected surface insulation material is capable of adapting as easily as possible to the resulting shape of the stator bay during assembly. The selected insulation material must meet the appropriate product requirements regarding temperature resistance and dielectric strength.
[0017] The insulation elements create a separation effect between adjacent conductors of different phases of the stator or within a single phase. In other words, by covering the bays of conductor elements with the insulation elements, these are mechanically isolated from other conductor elements of other windings of the stator.
[0018] The insulation elements also fix the line elements in a respective bay relative to one another, thereby keeping the individual line elements in a relatively orderly state and thus facilitating the insertion of the line elements into the slots of the stator body. One embodiment of the described method provides that only one first insulation element is assigned to each respective first bay.
[0019] Furthermore, at least one further conducting element winding of a further phase can be provided outside the stator body, comprising several further bays in bundles of further conducting elements, wherein a further insulation element is fixed to at least one further bay by means of an adhesive connection, and at least one further insulation element is assigned to each respective further bay. Depending on the process configuration, application in an assembly process is also possible in which coils of different phases are inserted, rather than individual phases.
[0020] The further conducting element winding can be introduced into further slots of the stator body, wherein the further insulating element is carried along in the movement of the further conducting element winding due to the adhesive connection and is positioned in relation to the stator body so that insulating elements are arranged between overlapping sections of conducting element windings.
[0021] At least one insulation element is provided for each bundle of conductor elements in a bay. Accordingly, several insulation elements are moved and positioned when a phase is inserted.
[0022] In this way, bundles of conductor elements can be drawn into slots of stators, whereby the bays remain on an axial outer side of the stator and can be insulated there by the insulation elements.
[0023] Before the arrangement of the insulation elements, the line elements can be positioned on a positioning element, such as a drawing-in mandrel, in such a way that the line elements in windings can extend through radial opening slots of the positioning element and can thereby meander between the radial inner side and the radial outer side of the substantially hollow-cylindrical positioning element.
[0024] A pulling tool can pull the line elements into the slots of the stator, whereby the positioning element can have the function of the pulling tool, or an extra tool can be used which transfers the bundles of line elements from the positioning element into the slots of the stator.
[0025] This technique is applicable to the manufacture of stator windings for an internal rotor machine, where the stator surrounds the rotor on its radial outer side. However, this does not exclude the manufacture of stator windings for an external rotor machine, where the rotor surrounds the stator on its radial outer side.
[0026] The application of the method in the manufacture of the winding of an axial flux machine should also not be excluded, whereby the insulation elements can be arranged on the radial outer side and / or the radial inner side of the winding at the bays of the bundles of the line elements realized there, each assigned to the individual bays.
[0027] Furthermore, if the surface insulation element is shaped to match the transition contour of the winding, at least one of the insulation elements can be partially drawn into the slots of the stator body. In this embodiment of the method, the insulating effect provided by an insulation element extends not only to the area outside the stator slots but also to a portion of the slots. In one embodiment, the contour of the insulation element has the inverse shape of the mounting space; thus, when mounting in the adjacent slot area, a strip must be provided on the end contour of the insulation element.
[0028] A respective first insulation element can be configured essentially two-dimensionally and have a surface on one side that is a maximum of 18% of the size of the area covered by the first bay in the plane of the respective first bay on its outer side before the first conductor element winding belonging to the bays is introduced into the slots. A radially extending axis of symmetry of the insulation element can be positioned essentially centrally relative to a center of the first bay.
[0029] In a preferred embodiment, the insulation element has a two-dimensional contour that corresponds to the vertical projection of the bays onto a plane in which the bays run. Typically, this results in a U- or V-shape of the surface insulation element in a simple form, and a butterfly contour with detailed adjustments. Each insulation element can be self-adhesive. After positioning and contacting a respective bay, the insulation element is pre-fixed accordingly, and no further effort is required for the final positioning of the insulation element, as it is carried along in the movement of the line elements and thus automatically brought into its final position.
[0030] The first insulation elements can be placed on a coil plate before the winding is mounted in the stator and before the adhesive connections are made, and the adhesive connections can then be made by pressing the first bays of the conductor elements onto the first insulation elements.
[0031] The adhesive connections are thus automatically realized when the insulation elements are in contact with the line elements of the bays, regardless of whether the insulation elements were previously placed on a coil plate or not.
[0032] The insulation elements can be fed into the adhesive bonding process from a side of the bays facing away from the stator body. First insulation elements can be stored in one or more cassettes that are open or openable on the side facing the stator body, e.g., by means of sliding closure means, so that the first insulation elements can be conveyed from the cassette(s) toward the bays to be fixed there by means of the adhesive connections. The first insulation elements can be provided with an indexing for unambiguous assignment to the respective bays or phases.
[0033] Such cassettes can, for example, be arranged in the coil plate so that the first insulation elements are conveyed to the bays in a vertical direction from bottom to top.
[0034] In an alternative embodiment, first insulation elements can be positioned automatically by a gripper that guides the first insulation elements between the bays and the coil plate.
[0035] Such a gripper can be combined with a conveyor system that transports insulation elements to the vicinity of the stator body, from where individual insulation elements are then assigned to the individual bays by means of the gripper. Such a gripper can also be used, if necessary, to position the start and end sections of the conductor elements and / or to shape the resulting coils.
[0036] Before the adhesive connection is produced, a respective insulation element can have a shape which has a longer extension on a first radial side along the circumferential direction than on a second radial side along the circumferential direction.
[0037] For example, a first radial side can be a radially inner side, and the second radial side can be a radially outer side. The circumferential direction or radial direction refers to the round cross-section of the stator body. The insulation elements can be axially symmetrical with respect to a radially extending axis, so that overall they essentially resemble a butterfly shape. The method for producing a stator of an electrical rotary machine can be implemented on the drawing-in mandrel or the positioning element for positioning the individual windings, or as an intermediate station between the winding station and the drawing-in station.
[0038] The advantages of this method are that only the bays in bundles of existing conductor elements are insulated using the insulation elements, which means that the use of insulation material is comparatively low. The adhesive bonds prevent any unintentional displacement of the insulation elements. Furthermore, unintentional displacement is prevented by the fact that insulation elements can be placed immediately before the conductor elements or coils are pulled into the stator slots. Nevertheless, the insulation elements can be placed very precisely, as there is still a relatively generous amount of space available between the individual bays before the pull-in process. The mechanical stress on the winding and the wire bundle is reduced by the space-saving installation of the insulation element.The insulation elements can be designed in such a way that they not only insulate bays in bundles of existing line elements, but also connection areas of the line elements used.
[0039] The conductor elements can be inserted until mechanical contact is established between the respective insulation element and the stator body or other insulation elements of the winding, such as the slot insulation. The automated arrangement of the insulation elements enables consistent quality and low manufacturing costs.
[0040] It is not necessary to fix the insulation elements with an additional adhesive bond after the first or second insertion.
[0041] Furthermore, no re-forming or folding of the insulation elements is necessary, since the insertion of subsequent coils ensures that previously arranged insulation elements are positioned, fixed and formed in such a way that their shapes are complementary to the adjacent coils or line elements, or this is realized by the already existing process step of free-forming or final forming after the insertion of the coils or phases.
[0042] A further aspect of the present invention is a stator of an electrical rotary machine, comprising a stator body with slots and sections of conducting elements of windings received therein, which form bays outside the slots, wherein insulation elements are fixed to the bays by means of adhesive connections and a respective insulation element is assigned to each bay.
[0043] Such a stator has been manufactured accordingly according to the present method. If the stator is designed such that at least one further insulation element is fixed to at least one bay by means of an adhesive connection, with only one further insulation element being assigned to each further bay, and the further conducting element winding is inserted into further slots of the stator, insulation elements are arranged between overlapping sections of conducting element windings. Furthermore, an electrical rotary machine is provided which has a described stator or has a stator manufactured according to the described method.
[0044] The invention described above will be explained in detail below against the relevant technical background with reference to the accompanying drawings, which show preferred embodiments. The invention is in no way limited by the purely schematic drawings, and it should be noted that the embodiments shown in the drawings are not limited to the dimensions shown. It is shown in
[0045] Figure 1 : a conventional arrangement of line elements of a first phase in perspective view,
[0046] Figure 2: an arrangement of line elements of a first phase with insulation elements according to the present method in perspective view, Figure 3: the detail A from Figure 2 in an enlarged view,
[0047] Figure 4: a stator body equipped with insulation elements according to the present method in perspective view, and
[0048] Figure 5: an insulating element used according to the present method.
[0049] Figure 1 has already been discussed to explain the prior art. Figure 2 shows a stage during the implementation of the present method for producing a stator of an electric rotary machine, in which a first conducting element winding 21 is provided with first insulation elements 50.
[0050] It can be seen that a first conducting element winding 21, which is a bundle of first conducting elements 22, is guided through radial opening slots 62 between drawing-in laminations 61 of a positioning element 60, also referred to as a drawing-in mandrel. This first conducting element winding 21 thus forms a first phase 20 of the entire winding package of the stator to be manufactured. Here, too, the individual conducting elements of the first conducting element winding 21 are embodied in first bays. In contrast to the embodiment shown in Figure 1, however, here first insulation elements 50 are located between the first bays 30 and the coil plate 70, with each first bay 30 being assigned a first insulation element 50.
[0051] The first insulation elements 50 adhere to the first bays 30 or to individual line elements of the bundles 22 by means of adhesive connections 40, as indicated in Figure 3. Figure 3 also shows that a center 31 of a respective first bay 30 lies approximately on a radially extending axis of symmetry of the respective first insulation element 50. This radially extending axis of symmetry of a first insulation element 50 is explained with reference to Figure 5.
[0052] As can also be seen from Figures 2 and 3, the first insulation elements 50 not only cover individual first bays 30, but they also partially cover connection areas 23 of line elements which serve for the electrical connection of the winding.
[0053] Figure 4 shows a stator body 10 assembled according to the present method on its A-side 11, i.e., on the side where the connection area 23 of the conductor elements is realized. In the state shown here, conductor elements of the first phase (not visible here) have already been drawn into individual slots 12 of the stator body 10. Furthermore, slot insulation 13 is located in the slots 12.
[0054] It is evident that, due to the insertion of the winding, the first insulation elements 50, previously arranged by means of an adhesive connection, have also moved toward the stator body 10 and are now positioned and fixed there in an axial end region of the stator body 10. Furthermore, it is evident that the first insulation elements 50 overlap one another in some areas, thus reliably ensuring the insulation of the bundles 22 of first conductor elements located underneath.
[0055] After the first phase has been inserted, additional phases or their bundles of conductor elements can be inserted into the slots 12 of the stator body 10. The already arranged first insulation elements ensure that the conductor elements of the additional phases do not contact the conductor elements of the first phase. Additional conductor element windings can also be equipped with additional insulation elements to create an insulating effect between them.
[0056] Figure 5 shows a top view of a first insulation element 50. This first insulation element is essentially two-dimensional and has a somewhat butterfly shape 52. This means that the first insulation element 50 has a longer extension 51 on one radial side than on the radially opposite side. The first insulation element 50 is essentially symmetrical with respect to a radially extending axis of symmetry 53.
[0057] To explain the radial course of this axis of symmetry 53, reference is made to Figure 3, where it can be seen that this axis of symmetry 53 runs radially with respect to the shape of the course of the first conduction element winding 21.
[0058] The method proposed here for manufacturing a stator of an electric rotating machine makes it possible to electrically insulate conductors of different phases of the stator in the winding head from one another in a simple, cost-effective and reliable manner.
[0059] List of reference symbols
[0060] 10 stator bodies
[0061] 11 A-side
[0062] 12 grooves
[0063] 13 Slot insulation
[0064] 20 first phase
[0065] 21 first line element winding
[0066] 22 bundles of first line elements
[0067] 23 Connection area
[0068] 30 first bay
[0069] 31 Center of the first bay
[0070] 40 adhesive bond
[0071] 50 first insulation element
[0072] 51 longer extension
[0073] 52 butterfly shape
[0074] 53 radial axis of symmetry
[0075] 60 Positioning element
[0076] 61 retractable slat
[0077] 62 radial opening slot
[0078] 70 spool plates
Claims
Patent claims Method for producing a stator of an electric rotary machine, in which -a stator body (10) with grooves (12) for receiving sections of conducting elements of windings is provided, -at least one first conducting element winding (21) of a first phase (20) is provided outside the stator body (10), which comprises a plurality of first bays (30) of first conducting elements (22) present in bundles, -a first insulating element (50) is fixed to at least one first bay (30) by means of an adhesive connection (40), wherein at least one first insulating element (50) is assigned to each respective first bay (30), and -the first conducting element winding (21) is introduced into first slots (12) of the stator body (10), wherein the first insulating element (50) is carried along in the movement of the first conducting element winding (21) due to the adhesive connection (40) and is positioned in relation to the stator body (10).Method for producing a stator of an electric rotary machine according to claim 1, characterized in that at least one further conducting element winding of a further phase is provided outside the stator body (10), which comprises a plurality of further bays in bundles of further conducting elements. -a further insulation element is fixed to at least one further bay by means of an adhesive connection, wherein at least one further insulation element is assigned to each respective further bay, -the further line element winding is introduced into further slots of the stator body (10), wherein the further insulation element is carried along in the movement of the further line element winding due to the adhesive connection and is positioned in relation to the stator body (10) so that insulation elements are arranged between overlapping sections of line element windings.
3. A method for producing a stator of an electric rotary machine according to one of the preceding claims, characterized in that at least one of the insulating elements (50) is partially drawn into grooves (12) of the stator body (10).
4. Method for producing a stator of an electrical rotary machine according to one of the preceding claims, characterized in that the first insulation element (50) is designed essentially two-dimensionally and has a surface on one side which is at most 18% of the size of the area which the first bay (30) covers in the plane of the course of the respective first bay (30) on its outer side before the introduction of the first conducting element winding (21) belonging to the first bays (30) into the slots (12).
5. A method for producing a stator of an electrical rotary machine according to one of the preceding claims, characterized in that the insulating element (50) is self-adhesive.
6. A method for producing a stator of an electrical rotary machine according to one of the preceding claims, characterized in that the first insulation elements (50) are placed on a coil plate (70) before the adhesive connections (40) are made, and then the adhesive connections (40) are made by pressing the first bays (30) of the line elements onto the first insulation elements (50).
7. A method for producing a stator of an electrical rotary machine according to claim 6, characterized in that the insulation elements (50) are fed to the process of producing the adhesive connection (40) from a side of the bays facing away from the stator body (10).
8. A method for producing a stator of an electric rotary machine according to one of the preceding claims, characterized in that a Each insulation element (50) has a shape prior to the production of the adhesive connection (40) that has a longer extension (51) on a first radial side along the circumferential direction than on a second radial side along the circumferential direction. A stator of an electrical rotary machine, comprising a stator body (10) with slots (12) and sections of conducting elements of windings received therein, which form bays (30) outside the slots, wherein insulation elements (50) are fixed to the bays (30) by means of adhesive connections (40), and at least one insulation element (50) is assigned to each bay (30). An electrical rotary machine, comprising a stator according to claim 9 and / or manufactured according to one of claims 1 to 8.