Method and device for producing a stator of an electric rotating machine, stator and electric rotating machine
Patent Information
- Application Number
- EP2023792883
- Authority / Receiving Office
- EP · EP
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2022-10-17
- Filing Date
- 2023-10-10
- Publication Date
- 2025-08-27
Smart Images
Figure 1.1
Abstract
Description
[0001] Method and device for producing a stator of an electrical rotary machine, stator and electrical rotary machine
[0002] The invention relates to a method for producing a stator of an electric rotary machine and a device for producing a stator of an electric rotary machine. Furthermore, the invention relates to the stator of the electric rotary machine and to an electric rotary machine itself, which comprises at least one stator produced by the presented method.
[0003] Stators of electrical rotating machines have multiple phases, which are realized by differently arranged windings in the stator body. A common method for integrating these windings of electrical conductors into the stator body is to prepare the windings on a drawing mandrel and then draw them into slots on the inside of the starter body. Here, the conductor sections are inserted into the slots using an expanding tool in a single movement from radially inward to radially outward.
[0004] This process involves a relatively large number of individual work steps and a corresponding expenditure of time and investment.
[0005] DE102020212922A1 discloses a stator for an electric machine of a motor vehicle, comprising an annular yoke with an inner side directed inwards in the radial direction of the yoke, wherein on the inner side of the yoke a plurality of pole teeth are positively connected to the yoke, the pole teeth are arranged at a distance from one another in the circumferential direction of the yoke, each pole tooth has a pole shaft and a pole shoe adjacent to the pole shaft, wherein the pole shoe is formed on a side of the pole tooth facing away from the yoke, and an endless stator winding is formed between the pole teeth, wherein a smallest distance Ak between two pole shoes of adjacent pole teeth in the circumferential direction of the stator is smaller than a maximum width Bmax of the endless stator winding in the circumferential direction of the stator.To manufacture the stator, winding sections are inserted radially from the outside into slots between teeth of a tooth arrangement arranged along a circumference. Based on this, the present invention is based on the object of providing a method and a device for manufacturing a stator of an electrical rotary machine, which enable the stator to be manufactured in a simple, reliable, and cost-effective manner.
[0006] This object is achieved by the method according to claim 1 and by the device according to claim 8. Advantageous embodiments of the method are specified in subclaims 2 to 7. An advantageous embodiment of the device is specified in subclaim 9. In addition, a stator according to claim 9 and an electrical rotary machine according to claim 10 are provided.
[0007] 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.
[0008] The invention relates to a method for producing a stator of an electrical rotary machine, in which winding sections are introduced from the radial outside into slots between teeth of a tooth arrangement arranged along a circular circumference.
[0009] In this case, a respective winding section is displaced radially within a slot by means of a feed device in different angular positions of the tooth arrangement in incremental feed movements. Before a winding section is displaced within the slot, the winding section is held along the circumference of the tooth arrangement and / or along a radial direction by means of at least one positioning unit.
[0010] A winding section can comprise multiple conductor strands. The teeth form the outer contour of an ideal cylinder in sections. The teeth are elongated shaped elements that extend parallel to a central axis of the ideal cylinder. They are arranged in series along the circumference. These teeth or elongated shaped elements as a whole form a tooth arrangement that runs coaxially to the central axis of the ideal cylinder. The teeth can be individual teeth or a stator body of an external rotor motor, in which the teeth are firmly connected to one another on the radial inside. The tooth arrangement can be fixed in a holding device.
[0011] The direction from the radial outside, along which the winding sections are inserted, refers to the outer contour of the ideal cylinder.
[0012] In angular positions of the tooth arrangement, a winding section is pushed radially inward in an incremental step.
[0013] The radial displacement of a winding section can be realized by means of a radial slider which acts from the radial outside on the respective winding section.
[0014] The radial slider can exert a radially acting force on the winding section at least in one axial end region of the tooth arrangement for the purpose of displacing it. Optionally, the radial slider can be configured such that it applies a radially inward force to the winding section only at specific points or only over a partial region of the winding section. In particular, in this embodiment of the method, the radial slider can act on the winding section at both axial end regions of the tooth arrangement in order to exert forces on the winding section, pressing the winding section into the slot and simultaneously forming the axially extending winding heads on both sides.
[0015] The advantage of this embodiment of the method lies in particular in the fact that the radially acting slider can be adapted in the axial direction with regard to the positions of the force introduction points it realizes, so that stators of different axial lengths can be manufactured with a radial slider.
[0016] Furthermore, forces of different strengths can be introduced on both axial sides of the tooth arrangement in order to design the winding heads forming at these axial end areas with different inner and / or outer diameters.
[0017] The engagement area of the slider in the axial end areas of the winding can be made larger in the circumferential direction than the actual wire width. This geometric limitation exists due to the stator slot width for a comparable continuous slider that is engaged over the entire axial winding length. The advantage of this arrangement is that the main forming forces of the radial displacement occur in the winding overhang and, due to their proximity, are passed directly to the tool and fixture. This results in better dimensional accuracy of the winding during assembly. Secondly, the larger engagement area can be used to reduce wire stress by distributing the assembly forces over larger tools or fixtures.
[0018] Contact surfaces are distributed. This allows for gentler wire processing and reduces the risk of wire damage or possible tapering of the wire insulation.
[0019] After a rotation of at least 360° of the tooth arrangement, at least one additional winding section can be inserted from the radial outside into a slot in which a winding section is already positioned. The additional winding section can also be displaced radially within the slot in incremental feed movements, so that the additional winding section also displaces the winding section(s) previously arranged in the slot radially within the slot in incremental feed movements. In this way, the winding sections can be incrementally inserted down to the bottom of the slot.
[0020] The positioning unit can have two contact elements per slot, which are arranged along a second circumference radially spaced from the circumference of the tooth arrangement and each have at least one shoulder extending in the circumferential direction. The contact elements can be arranged axially next to the tooth arrangement and can be moved radially inward, and with the shoulders of the contact elements can apply a force to a winding section in the radial direction and hold the winding section between them along the circumferential direction. The contact elements can be arranged on both axial sides of the tooth arrangement and act on the winding sections there. In addition to positioning and fixing the winding sections, the positioning unit can also be used to partially shape the winding mat in the winding head area.
[0021] In an advantageous embodiment of the method presented, it is provided that the contact elements are moved in the axial direction in addition to the radial movement in order to tighten or tension the winding section introduced into a slot during assembly.
[0022] After positioning the winding sections using the positioning unit, the positioning unit and the tooth arrangement with the winding sections arranged in its slots can be rotated by the amount of the tooth arrangement's pitch before an incremental insertion process is carried out. After the incremental insertion process of a winding section into a slot has been carried out, the positioning unit can be rotated back by the amount of the tooth arrangement's pitch. A slot that is free on the radial outside can then be equipped with a winding section. The pitch here is the length of the arc from one tooth to the next. If several winding sections are already arranged in several slots, several incremental insertion processes are carried out in several slots.
[0023] The presented method makes it possible to insert a complete winding mat into a single-tooth fixture from the outside radially. Afterward, it is only necessary to connect the individual teeth on one radial side to form a complete stator body. Winding the stator teeth from the outside makes it possible to optimally shape the teeth and the gaps or grooves between them with regard to the electromagnetic flux, thus influencing the efficiency of an electrical rotating machine with a stator as described.
[0024] After the winding sections have been inserted into the slots, a winding head created axially to the side of the teeth can be mechanically reshaped to ensure or facilitate outer ring assembly.
[0025] A further aspect of the present invention is a device for producing a stator of an electrical rotary machine, in which winding sections are inserted radially from the outside into slots between teeth of a tooth arrangement arranged along a circular circumference. The device comprises a holding device for securing the tooth arrangement and a feed device for displacing respective winding sections in different angular positions of the tooth arrangement in incremental feed movements radially within a slot. The holding device serves to clamp and thus fix the individual teeth.
[0026] The device may comprise a feed device with which winding sections can be fed tangentially to the circumference of the tooth arrangement and can be positioned at angular positions of the grooves.
[0027] Such a feed device can have several so-called combs, in whose tooth gaps winding sections can be received and advanced by translatory movements of the combs. In this way, a complete winding mat can be fed to the holding device.
[0028] The feed device is designed in such a way that it ensures that the winding sections are transferred to the slots due to the translational movement of the winding sections.
[0029] The feed device can comprise a plurality of radial slides, by means of which radial displacements of individual winding sections can be effected from the outside. Furthermore, the device can have a positioning unit with which, before the displacement of a winding section in the slot, the winding section can be held by means of at least one tooth arrangement along the circumference and / or in the radial direction.
[0030] The positioning unit can have two contact elements per groove, which are arranged along a second circumference radially spaced from the circumference of the tooth arrangement and each have at least one shoulder extending in the circumferential direction, wherein the contact elements are arranged axially next to the tooth arrangement and are displaceable radially inward, wherein the shoulders of the contact elements can apply a force to a winding section in the radial direction and hold the winding section between them along the circumferential direction.
[0031] The holding device and the positioning unit can be rotatable relative to the feed device, so that after positioning the winding sections by means of the positioning unit, the tooth arrangement with the winding sections arranged in its slots can be rotated by the amount of the tooth arrangement's pitch. After the incremental insertion process of a winding section into a slot, the positioning unit can be rotated back by the amount of the tooth arrangement's pitch. In this way, a slot free on the radial outer side can be equipped with a winding section.
[0032] A further aspect of the present invention is a stator of an electrical rotary machine, which can be manufactured in particular according to the described method. The stator has winding sections in slots between teeth of a tooth arrangement arranged along a circular circumference, wherein the stator has a winding head on each axial side of the tooth arrangement. An outer diameter of a first winding head, formed on a first axial side of the tooth arrangement, is smaller than the outer diameter of a second winding head formed on a second axial side of the tooth arrangement. Alternatively or additionally, it can be provided that the inner diameter of the second winding head formed on the second axial side of the tooth arrangement is larger than the inner diameter of the first winding head formed on the first axial side of the tooth arrangement.
[0033] The two axial sides mentioned are axially facing away from one another. The fact that the outer diameter of the first winding overhang formed on the first axial side of the tooth arrangement is smaller than the outer diameter of a second winding overhang formed on a second axial side of the tooth arrangement serves the purpose of allowing a yoke to be connected to the tooth arrangement in a simplified manner using positive and / or frictional engagement. The fact that the inner diameter of the second winding overhang formed on the second axial side of the tooth arrangement is larger than the inner diameter of the first winding overhang formed on the first axial side of the tooth arrangement serves the purpose of allowing a rotor to be arranged in a simplified manner in the space radially surrounded by the tooth arrangement and the produced winding.
[0034] During assembly, the yoke and the rotor can be moved from axially opposite sides to or into the tooth arrangement.
[0035] The slots in which the winding sections are positioned can nevertheless continue to run parallel to one another. Furthermore, according to the invention, an electric rotary machine is provided which has at least one stator manufactured according to the described method.
[0036] 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
[0037] Figure 1 : the feeding of winding sections to the tooth arrangement by means of the feeding device,
[0038] Figure 2: the holding device with teeth and non-engaged positioning unit,
[0039] Figure 3: the holding device with teeth and engaged positioning unit,
[0040] Figure 4: the holding device with teeth and engaged positioning unit in rotated position,
[0041] Figure 5: the holding device with teeth and engaged positioning unit as well as with engaged feed device,
[0042] Figure 6: the holding device with teeth and non-engaged positioning unit and with engaged feed device,
[0043] Figure 7: the holding device with teeth and non-engaged and reversed positioning unit as well as with engaged feed device,
[0044] Figure 8: the holding device with teeth and re-engaged positioning unit as well as with engaged feed device,
[0045] Figure 9: the holding device with teeth and engaged positioning unit and with non-engaged feed device,
[0046] Figure 10: the holding device with teeth and engaged positioning unit as well as with engaged feed device and two winding sections arranged in a groove each, and Figure 11: the holding device with teeth and engaged positioning unit as well as with engaged feed device and three winding sections arranged in a groove each.
[0047] Figure 1 illustrates the feeding of winding sections 30 to the tooth arrangement 1 by means of the feeding device 40. Several winding sections 30, each comprising two conductor strands 31, are arranged in tooth gaps 42 of combs 41, which exert translational movements 43 on the tooth arrangement 1 and thus transport the winding sections 30 in the direction of the tooth arrangement 1.
[0048] The winding sections 30 are transferred from the feed device 40 to the tooth arrangement 1, so that the winding sections 30 are positioned in grooves 20 between individual teeth 10 on the radial outer side of the tooth arrangement 1.
[0049] Figure 2 shows the holding device 50, with which the teeth 10 and thus the entire tooth arrangement 1 are held in such a way that the teeth 10 are arranged along a circumferential direction and are accordingly positioned on their outer side essentially along an ideal cylinder outer surface.
[0050] Furthermore, a positioning unit 60 which is not engaged with the winding sections 30 is shown here.
[0051] Figure 3 shows a state in which the positioning unit 60 has been actuated, so that individual contact elements 61, in the form of so-called fingers, which are arranged axially next to the tooth arrangement 1 and comprised by the positioning unit 60, have moved radially inward. Each of the contact elements 61 comprises a shoulder 62 on both sides, which, upon the radially inward movement of a respective contact element 61, come into contact with adjacent winding sections 30 along the circumference. This allows the winding sections 30 to be positioned in the radial direction. Due to the fact that each contact element 61 forms a projection 63 between the shoulders, which runs between the adjacent winding sections 30, positioning of the winding sections along the circumferential direction is also realized.
[0052] Figure 4 illustrates that the holding device 50 with the teeth 10 and the engaged positioning unit 60 has been rotated by the amount of the pitch 80 of the tooth arrangement 1 in a rotation 81 in order to enable the renewed feeding of a winding section 30 in a free slot 20 by the feeding device 40.
[0053] Figure 5 shows that the positioning unit 60 is still engaged, and that a feed device 70 additionally acts on the winding sections 30. The feed device 70 comprises a plurality of sliders 71, which are arranged distributed around a circumference on the radial outer side of the tooth arrangement 1. These sliders 71 have been displaced radially inward and thus press on the individual winding sections 30 arranged in the slots 20. However, the action of the sliders 71 only results in incremental feed movements 72 of the winding sections 30 in the slots 20.
[0054] However, due to the fact that the rotation of the holding device 50 and the positioning unit 60 described in Figure 4 takes place, and after each rotation the feed device 70 or its slider 71 acts on the winding sections 30, a plurality of incremental feed movements 72 take place, so that the winding sections 30, after they have rotated with the holding device 50 by at least 180°, are already arranged relatively deep in the respective slots 20.
[0055] Figure 6 illustrates that after the incremental feed movements 72 have been executed, the positioning unit 60 or its contact elements 61 are retracted radially and thus disengaged from the winding sections 30. The action of the feed device 70 or its slider 71 on the winding sections 30 is maintained.
[0056] Starting from Figure 6, Figure 7 illustrates a movement in which the positioning unit 60 or its contact elements 61 are moved by the amount of the pitch 80 in a reverse rotation 82. The action of the feed device 70 or its slider 71 on the winding sections 30 is maintained. Figure 8 illustrates that the action of the feed device 70 or its slider 71 on the winding sections 30 is maintained and, at the same time, the positioning unit 60 or its contact elements 61 again act on the winding sections 30.
[0057] Figure 9 illustrates that the action of the feed device 70 or its slider 71 on the winding sections 30 is then terminated by the slider 71 moving radially outward again. The action of the positioning unit 60 or its contact elements 61 on the winding sections 30 is maintained. This ensures that an unintentional entrainment of winding sections 30 during the extension movement of the slider 71 from the tooth arrangement 1 by the contact elements 61 is hindered or prevented. Figure 10 shows a state in which winding sections 30 initially placed in slots 20 have already been rotated more than 360°. By further feeding additional winding sections 32 by means of the feed device 40, these additional winding sections 32 reach slots 20 in which winding sections 30 were already placed.This results in two winding sections, of which, as already explained, each winding section 30 comprises two conductor strands 31, already being arranged in some slots 20, as shown in Figure 10.
[0058] Figure 11 illustrates the continuation of the process, in which further rotation of the tooth arrangement 1 and the supply of additional winding sections 32, as well as the execution of the above-described movements of the positioning unit and the feed device, result in three winding sections being arranged in slots 20, which essentially fill the respective slots 20. This means that the winding section 30 first placed in the slot 20 now rests against the slot base 21 of the respective slot 20.
[0059] The continuation of the above-mentioned process steps leads to the complete filling of the slots 20 with winding sections 30,32 and consequently to the complete production of windings of the stator.
[0060] The method and device proposed here for producing a stator of an electrical rotating machine provide solutions for producing a stator in a simple, reliable, and cost-effective manner.
[0061] Tooth arrangement
[0062] Tooth
[0063] Nut
[0064] Groove base
[0065] Winding section
[0066] Cable harness further winding section
[0067] Feed device
[0068] Comb
[0069] Tooth gap translational movement
[0070] Holding device
[0071] Positioning unit
[0072] Investment element
[0073] shoulder
[0074] projection
[0075] Feed device
[0076] Slider incremental feed movement
[0077] Amount of division
[0078] rotation
[0079] Back rotation
Claims
Patent claims Method for producing a stator of an electrical rotary machine, in which winding sections (30) are introduced from the radial outside into slots (20) between teeth (10) of a tooth arrangement (1) arranged along a circular circumference, wherein a respective winding section (30) is displaced radially in a slot (20) by means of a feed device (70) in different angular positions of the tooth arrangement (1) in incremental feed movements (72), characterized in that before the displacement of a winding section (30) in the slot (20), the winding section (30) is held by means of at least one positioning unit (60) along the circumference of the tooth arrangement (1) and / or along a radial direction.Method for producing a stator according to claim 1, characterized in that the radial displacement of a winding section (30) is realized by means of a radial slider (71) that acts radially from the outside on the respective winding section (30). Method for producing a stator according to claim 2, characterized in that the radial slider (71) exerts a radially acting force on the winding section (30) at least in one axial end region of the tooth arrangement (1) for the purpose of displacing it.Method for producing a stator according to one of claims 2 and 3, characterized in that after a rotation of at least 360° of the tooth arrangement (1) in a groove (20) in which a winding section (30) is already positioned, at least one further winding section (32) is introduced from radially outside, and the further winding section (32) is displaced radially in the groove (20) in incremental feed movements (72), so that the further winding section (32) engages the winding section or sections (30) previously arranged in the groove (20) or the winding sections previously arranged in the groove (20). Winding sections (30) are also displaced radially in the slot (20) in incremental feed movements (72). Method for producing a stator according to one of the preceding claims, characterized in that the positioning unit (60) has two contact elements (61) for each slot (20), which are arranged along a second circumference spaced radially from the circumference of the tooth arrangement (1) and each have at least one shoulder (62) extending in the circumferential direction, wherein the contact elements (61) are arranged axially next to the tooth arrangement (1) and are displaced radially inward, and with the shoulders (62) of the contact elements (61) apply a force to a winding section (30) in the radial direction and hold the winding section (30) between them along the circumferential direction.Method for producing a stator according to one of the preceding claims, characterized in that after positioning of the winding sections (30) by means of the positioning unit (60), the positioning unit (60) and the tooth arrangement (1) with winding sections (30) arranged in its slots (20) and before carrying out an incremental insertion process are rotated by the amount of the pitch (80) of the tooth arrangement (1), and after carrying out the incremental insertion process of a winding section (30) in a slot (20), the positioning unit 60 is rotated back by the amount of the pitch (80) of the tooth arrangement (1) and a slot (20) which is free on the radial outer side is equipped with a winding section (30).Device for producing a stator of an electrical rotary machine, in which winding sections (30) are introduced from the radial outside into slots (20) between teeth (10) of a tooth arrangement (1) arranged along a circular circumference, wherein the device has a holding device (50) for fixing the tooth arrangement (1) and a feed device (70) for displacing respective winding sections (30) in different angular positions of the tooth arrangement (1) in incremental feed movements (71) radially in a slot (20). Device for producing a stator according to claim 7, characterized in that the device has a feed device (40) with which winding sections (30) can be fed tangentially to the circumference of the tooth arrangement (1) and can be positioned at angular positions of the slots (20).Stator of an electrical rotary machine, in which winding sections (30) are arranged in slots (20) between teeth (10) of a tooth arrangement (1) arranged along a circular circumference, wherein the stator has a winding head on each axial side of the tooth arrangement (1), wherein an outer diameter of a first winding head formed on a first axial side of the tooth arrangement (1) is smaller than the outer diameter of a second winding head formed on a second axial side of the tooth arrangement (1); and / or the inner diameter of the second winding head formed on the second axial side of the tooth arrangement (1) is larger than the inner diameter of the first winding head formed on the first axial side of the tooth arrangement (1). Electrical rotary machine, comprising at least one stator manufactured according to one of claims 1 to 6.