Stator of an electric machine
Patent Information
- Authority / Receiving Office
- EP · EP
- Patent Type
- Applications
- Current Assignee / Owner
- Filing Date
- 2024-03-20
- Publication Date
- 2026-03-04
AI Technical Summary
The existing manufacturing processes for stators of electrical machines require twisting tools to create support points for conductors, which increases manufacturing costs and complexity.
The stator design incorporates first and second lamellae with through-openings aligned at opposite offset angles, allowing for easy twisting without a twisting tool, using alignment elements like pins or sleeves to rotate the lamellae and create support points, while maintaining the magnetic flux and enabling direct cooling of conductors.
This approach reduces manufacturing costs by simplifying the production of stator lamination stacks, allows for effective local clamping of conductors without damaging insulation, and facilitates direct cooling of the stator winding, maintaining magnetic flux integrity.
Smart Images
Figure EP2024057417_31102024_PF_FP_ABST
Abstract
Description
[0001] Description
[0002] title
[0003] Stator of an electrical machine
[0004] State of the art
[0005] The invention is based on a stator of an electrical machine according to the preamble of the main claim.
[0006] A stator of an electrical machine is already known from DE102019206011 A1, comprising a stator core having stator teeth and stator slots formed between the stator teeth, and comprising a stack of laminations. The laminations each have lamination teeth for forming the stator teeth. The stator core comprises a plurality of laminations, each of which has at least one through-opening for forming at least one stator plug-in hole for inserting a connecting element, in particular a pin, bolt, or screw.
[0007] From DE102021204202 A1, it is known that several support points for locally clamping the electrical conductors can be created in the stator slots of the stator laminated core by rotating the laminations of the stator laminated core. Between the tooth flanks of the respective stator slot and the conductor or conductor bundle arranged in the stator slot, at least one slot gap is formed, forming an axially extending slot gap channel through which a cooling medium, in particular oil, can flow. The rotation of the laminations is achieved by a rotating tool of a manufacturing facility, which grips the laminations, for example, at the outer circumference, and rotates them in the circumferential direction.
[0008] Advantages of the invention
[0009] The stator of the electric machine according to the invention with the characterizing features of the main claim has the advantage that the rotation of the laminations for producing the support points is achieved more easily, in particular without a rotation tool of a manufacturing device, thereby reducing the manufacturing costs of the stator.This is achieved according to the invention in that first laminations are provided in the stator laminated core, the through-openings of which are each aligned in the circumferential direction relative to the tooth pole center of the nearest lamination tooth of the respective first lamination in a first relative orientation, in particular offset by an offset angle α, and in that second laminations are provided in the stator laminated core, the through-openings of which are each aligned in the circumferential direction relative to the tooth pole center of the nearest lamination tooth of the respective second lamination in a second relative orientation, in particular offset by an offset angle α, wherein the first and second relative orientations are opposite in the circumferential direction and in particular are of the same size in terms of their magnitude.According to the invention, the first and second laminations are arranged in at least one twisting group comprising at least two of the first laminations and at least one second lamination arranged between the first laminations. Furthermore, according to the invention, the connecting elements are alignment elements that can be inserted into the respective stator plug-in hole to generate an opposite twisting of the laminations of the respective twisting group.
[0010] The alignment elements can also serve to maintain the generated twist. The alignment elements are, for example, metallic, particularly steel.
[0011] The measures listed in the subclaims enable advantageous further developments and improvements of the stator of an electrical machine specified in the main claim.
[0012] The opposite rotation of the laminations of the twisting group is achieved by the alignment element inserted into the stator plug-in hole displacing the first and second laminations protruding in the circumferential direction.
[0013] It is advantageous if a stator yoke is provided connecting the stator teeth, with the respective stator plug hole being formed on a side of the stator yoke facing away from the stator teeth. In this way, the magnetic flux in the stator yoke is not negatively affected, or only slightly so.
[0014] According to a first embodiment, the respective alignment element can be a
[0015] A pin or, according to a second embodiment, a sleeve. The alignment elements are inserted into the stator plug holes, in particular with a loose fit.
[0016] It is also advantageous if the alignment element has a chamfer or conical insertion bevel at the leading end for insertion into the respective stator plug hole. This facilitates the displacement or rotation of the first and second laminations in the circumferential direction.
[0017] It is particularly advantageous if the respective alignment element according to the second embodiment is a sleeve through which a fastening screw for fastening the stator laminated core to a machine housing can be inserted. In this way, the stator insertion holes can be used both for rotating the first and second laminations and thus for creating the support points, as well as for fastening the stator to the machine housing. The fastening screws inserted through the sleeves extend into the threaded holes in the machine housing.
[0018] It is very advantageous if the first and second laminations are identical in shape and arranged laterally inverted in the stator core. This way, only a single type of lamination is required to form a twisting group, making the production of the stator core simpler and more cost-effective.
[0019] It is also advantageous if a stator winding is provided that runs through the stator slots, and if the twisting of the first and second laminations of the respective twisting group allows for local clamping of the conductor bundles of the stator winding in the stator slots. In particular, a conductor bundle of flat wire conductors is clamped locally at at least two support points in each stator slot. In this way, the conductor bundles of the stator winding are fixed in the stator slots.
[0020] It is furthermore advantageous if the conductor bundle of the respective stator slot is enclosed by at least one electrically insulating protective sheath, at least in the region of the respective twisting group. In this way, a varnish insulation of the electrical conductors of the conductor bundle is protected from damage by the twisted laminations of the twisting group. It is also advantageous if third laminations are provided in the stator laminated core, the respective through-opening of which is aligned in the circumferential direction relative to a tooth pole center of a nearest lamination tooth of the third lamination in a third relative orientation, in particular is centered to the tooth pole center. In this way, the conductor bundles in the stator slots in the region of the third laminations are at a distance from the tooth flanks of the respective stator slot, whereby the slot gap channels are created in the respective stator slot.This enables direct cooling of the conductor bundles of the stator winding. The third relative orientation lies between the first and second relative orientations.
[0021] The invention further relates to an electrical machine with a stator according to the invention and with a machine housing, wherein the alignment elements according to the invention project through the stator laminated core and project into recesses, in particular bores, of the machine housing for centering the stator laminated core.
[0022] The invention also relates to a method for producing a stator according to the invention comprising the following steps:
[0023] - stacking a stator laminated core comprising first and second laminations and in particular third laminations,
[0024] - Inserting the stator winding into the stator slots,
[0025] - Inserting the alignment elements into the stator plug-in holes, whereby the first and second laminations are rotated in opposite directions around the stator axis and the conductor bundles are locally clamped in the stator slots.
[0026] Before inserting the alignment elements, the laminations of the stator core are circumferentially aligned to each other so that the stator winding conductors can be inserted into the stator slots with some clearance, resulting in substantially aligned lamination teeth. This enables simple axial assembly of the stator winding without damaging the conductors' enamel insulation. Drawing
[0027] Several embodiments of the invention are shown in simplified form in the drawing and explained in more detail in the following description
[0028] They show:
[0029] Fig.1 is a side view of part of the stator of an electrical machine according to the invention,
[0030] Fig.2 is a sectional view of the stator according to the invention when the stator is cut along the line ll-ll in Fig.1,
[0031] Fig.3A a first lamination of the stator according to Fig.1 and Fig.2,
[0032] Fig.3B a second lamella of the stator according to Fig.1 and Fig.2,
[0033] Fig.3C a third lamination of the stator according to Fig.1 and Fig.2,
[0034] Fig.4A is a partial view of two stator slots of the stator core according to Fig.2 before mounting an alignment element according to the invention,
[0035] Fig.4B shows part of a stator plug hole of the stator core according to Fig.1 to Fig.3 with a twisting group before assembly of the alignment element according to the invention according to a first embodiment,
[0036] Fig. 4C is a partial view of a stator plug hole of the stator core according to Fig. 1 to Fig. 3 with a twisting group after assembly of the alignment element according to the invention according to a first embodiment,
[0037] Fig.4D is a partial view of two stator slots of the stator core according to Fig.2 after assembly of the alignment element according to the invention,
[0038] Fig.5 shows a second embodiment of the alignment element according to the invention after assembly,
[0039] Fig. 6 shows the second embodiment of the alignment element according to the invention after assembly with a fastening screw pushed through the sleeve for attaching the stator to a machine housing. Description of the embodiments
[0040] Fig. 1 shows a side view of a portion of the stator of an electrical machine according to the invention. Fig. 2 shows a sectional view of the stator according to the invention, taken along line II-II in Fig. 1.
[0041] The stator 2 of an electrical machine 1 according to the invention has a stator core 3, on which stator teeth 4 and stator slots 5 formed between the stator teeth 4 are provided, which comprises a stack of laminations 6 and extends around a stator axis 7. The laminations 6 each have lamination teeth 8 for forming the stator teeth 4. The lamination teeth 8 are provided, for example, on the inner circumference 6i of the laminations 6.
[0042] In addition, the laminations 6 each have a plurality of through-openings 9 arranged along the circumference, for example the outer circumference, so that a corresponding plurality of stator plug-in holes 10 are formed on the stator laminated core 3 for inserting a connecting element 1, in particular a pin, bolt, or screw. The respective stator plug-in hole 10 can be a through-hole or a blind hole in the stator laminated core 3. The stator has a stator yoke 16 connecting the stator teeth 4, wherein the respective stator plug-in hole 10 is formed on a side of the stator yoke 6 facing away from the stator teeth 4. Accordingly, the through-openings 9 of the laminations 6 are also formed on a side of the stator yoke 6 facing away from the stator teeth 4.
[0043] According to the invention, first laminations 6.1 according to Fig.3A are provided in the stator laminated core 3, the through-openings 9 of which are arranged in the circumferential direction relative to the tooth pole center 8m of the nearest lamination tooth 8 of the respective first lamination
[0044] 6.1 are aligned in a first relative orientation 12, in particular offset by an offset angle a.
[0045] In addition, second laminations 6.2 according to Fig.3B are provided in the stator laminated core 3 according to the invention, the through-openings 9 of which are arranged in the circumferential direction relative to the tooth pole center 8m of the nearest lamination tooth 8 of the respective second lamination
[0046] 6.2 are aligned in a second relative orientation 13, in particular offset by an offset angle α, wherein the first and second relative orientations 12, 13 are opposite in the circumferential direction and, in particular, are equal in magnitude. According to Fig. 2, the first and second lamellae 6.1, 6.2 are arranged in at least one twisting group 15 comprising at least two of the first lamellae 6.1 and at least one second lamella 6.2 arranged between the first lamellae 6.1.
[0047] According to the invention, the connecting elements 11 are alignment elements which can be inserted into the respective stator plug-in hole 10 according to Fig.4A and Fig.4C in order to produce an opposite rotation of the lamellae 6.1, 6.2 of the respective rotation group 15 according to Fig.4D.
[0048] A first lamination 6.1 of the stator laminated core 3 is shown in detail in Fig.3A and a second lamination 6.2 is shown in detail in Fig.3B, each in a linear representation.
[0049] According to a first embodiment, the respective alignment element 11 may, for example, be a pin, as shown in Fig.4B and Fig.4C.
[0050] The opposite rotation of the lamellae 6.1, 6.2 of the respective rotation group 15 is achieved by the inserted alignment element 11 displacing sections of the first and second lamellae 6.1, 6.2 projecting into the stator plug-in hole 10 in the circumferential direction with respect to the stator axis 7 and thereby rotating them around the stator axis 7 by a rotation angle <|).
[0051] The first and second laminations 6.1, 6.2 can be of identical shape and arranged laterally reversed or sideways to each other in the stator laminated core 3.
[0052] In addition, third laminations 6.3 according to Fig. 3C can be provided in the stator core 3, the respective through-openings 9 of which are aligned with respect to their opening axis 9.1 in the circumferential direction relative to a tooth pole center 8m of a nearest lamination tooth 8 of the third lamination 6.3 in a third relative orientation 14, in particular centered relative to the tooth pole center 8m. A third lamination 6.3 is shown in Fig. 3C in a linear representation.
[0053] The first laminations 6.1 are laminations 6 of a first type, the second laminations 6.2 are laminations 6 of a second type, and the third laminations 6.3 are laminations 6 of a third type. The first, second, and third laminations 6.1, 6.2, 6.3 also have the through-openings 9. The stator 2 comprises a stator winding 18 running through the stator slots 5. A conductor or conductor bundle 19 is arranged in each stator slot 5. The conductor bundle 19 comprises, for example, a stack of flat wire conductors. By twisting the laminations 6.1, 6.2 of the at least one twisting group 15 according to the invention, a local clamping of the conductors or conductor bundles 19 of the stator winding 18 in the stator slots 5 can be achieved. So that the varnish insulation of the conductors of the conductor bundle 19 is not damaged by the local clamping by the slats 6.1,6.2 is damaged, the conductor or conductor bundle 19 of the respective stator slot 5 can be enclosed by at least one electrically insulating protective sheath 20, at least in the region of the respective twist group 15. The protective sheath 20 is designed, for example, in the shape of a sleeve or a cuff.
[0054] The conductor bundles 19 are spaced in the stator slots 5 in the region of the third laminations 6.3 from the tooth flanks 5f of the respective stator slot 5, creating slot gap channels 22 in the respective stator slot 5 through which a cooling medium, in particular oil, can flow along a cooling path 23. This enables direct cooling of the conductor bundles 19 of the stator winding 18.
[0055] Fig.4A to Fig.4D illustrate the process sequence after the production of the stator laminated core 3.
[0056] The production of the stator laminated core 3 comprises the stacking of laminations 6, wherein the stator laminated core 3 comprises first and second laminations 6.1, 6.2 and in particular third laminations 6.3.
[0057] According to an exemplary embodiment, first, second and third slats 6.1, 6.2, 6.3 are provided in a first step.
[0058] In a second step, the third slats 6.3 are stacked to form at least one first sub-package 3.1. For example, three first sub-packages 3.1 are provided.
[0059] In a third step, the first and second laminations 6.1, 6.2 are stacked in several, for example two, twisting groups 15, wherein each twisting group 15 comprises at least two of the first laminations 6.1 and at least one second lamination 6.2 arranged between the first laminations 6.1. The twisting group 15 also forms a sub-package of the stator laminated core. In a fourth step, the twisting groups 15 and the at least one sub-package 3.1 are stacked to form the stator laminated core 3, wherein a first sub-package 3.1 of third laminations 6.3 is arranged between each two twisting groups 15.
[0060] In a fifth step, the stator winding 18 is inserted into the stator slots 5 according to Fig.4A.
[0061] In a sixth step, the at least one alignment element 11 according to Fig. 4B and Fig. 4C is inserted into the respective stator insertion hole 10, whereby the first and second laminations 6.1, 6.2 in the respective twisting group 15 according to Fig. 4D are rotated in opposite directions about the stator axis 7 and the conductor bundles 19 are locally clamped in the stator slots 5. To facilitate the insertion of the alignment element 11 into the stator insertion hole 10 and the twisting of the first and second laminations 6.1, 6.2, the alignment element 11 can have a chamfer or insertion bevel 21 at the leading end.
[0062] Fig.5 shows a second embodiment of the alignment element according to the invention.
[0063] According to the second embodiment, the respective alignment element 11 is, for example, a sleeve.
[0064] Fig.6 shows the second embodiment of the alignment element according to the invention with a fastening screw pushed through the sleeve for fastening the stator to a machine housing.
[0065] The at least one sleeve-shaped alignment element 11 can protrude through the stator laminated core 3 and into a recess 24, in particular a bore 24, of a machine housing 25 for centering the stator laminated core 6. For this purpose, the respective alignment element 11 is longer than the height of the stator laminated core 3.
[0066] A fastening screw 26 can be inserted through the sleeve-shaped alignment element 11 according to the second exemplary embodiment for fastening the stator laminated core 3 to the machine housing 25, which can be part of the electrical machine 1 or part of an electrical axis. Alternatively, the respective alignment element 11 can also be bolt-shaped in a first region for interaction with the stator laminated core 3 according to the invention and have a thread in a second region protruding from the stator laminated core for screwing to the machine housing.
Claims
Claims 1 . Stator (2) of an electrical machine (1) with a stator laminated core (3) on which stator teeth (4) and stator slots (5) formed between the stator teeth (4) are provided and which comprises a stack of laminations (6), wherein the laminations (6) each have lamination teeth (8) for forming the stator teeth (4), wherein the stator laminated core (3) comprises a plurality of laminations (6.1, 6.2, 6.3), on each of which at least one through-opening (9) is provided for forming at least one stator plug-in hole (10) for inserting a connecting element (11), in particular a pin, bolt or screw, characterized in that - first slats (6.1) are provided, the through-openings (9) of which are in Circumferential direction are each aligned relative to the tooth pole center (8m) of the nearest lamella tooth (8) of the respective first lamella (6.1) in a first relative orientation (12), in particular offset by an offset angle (a), - second slats (6.2) are provided, the through-openings (9) of which are in Circumferential direction are each aligned relative to the tooth pole center (8m) of the nearest lamella tooth (8) of the respective second lamella (6.2) in a second relative orientation (13), in particular offset by an offset angle (a), wherein the first and second relative orientations (12, 13) are opposite in the circumferential direction and in particular equal in terms of the amount, - the first and second lamellae (6.1, 6.2) in at least one twisting group (15) comprising at least two of the first slats (6.1) and at least one second slat (6.2) arranged between the first slats (6.1), - the connecting elements (11) are alignment elements which are inserted into the respective Stator plug-in hole (10) can be inserted to generate an opposite rotation of the lamellae (6.1, 6.2) of the respective rotation group (15).
2. Stator according to claim 1, characterized in that the opposite rotation of the lamellae (6.1, 6.2) of the rotation groups (15) is achieved in that the inserted alignment element (11) displaces first and second lamellae (6.1, 6.2) projecting into the stator plug-in hole (10) in the circumferential direction.
3. Stator according to one of the preceding claims, characterized in that a stator yoke (16) connecting the stator teeth (4) is provided, wherein the respective stator plug hole (10) is formed on a side of the stator yoke (16) facing away from the stator teeth (4).
4. Stator according to one of the preceding claims, characterized in that the respective alignment element (11) is a pin or a sleeve.
5. Stator according to one of the preceding claims, characterized in that the alignment element (11) has a chamfer or conical insertion bevel (21) at the leading end for insertion into the respective stator plug hole (10).
6. Stator according to one of claims 4 or 5, characterized in that the respective alignment element (11) is a sleeve through which a fastening screw (26) for fastening the stator laminated core (3) to a machine housing (25) can be inserted.
7. Stator according to one of the preceding claims, characterized in that the first and second laminations (6.1, 6.2) are of the same shape and are arranged laterally reversed to one another in the stator laminated core (3).
8. Stator according to one of the preceding claims, characterized in that third laminations (6.3) are provided, the respective through-opening (9) of which is aligned in the circumferential direction relative to a tooth pole center (8m) of a nearest lamination tooth (8) of the third lamination (6.3) in a third relative orientation (14), in particular is centered to the tooth pole center (8m).
9. Stator according to one of the preceding claims, characterized in that a stator winding (18) is provided which runs through the stator slots (5) and that by rotating the laminations (6.1, 6.2) of the respective rotating group (15) a local clamping of conductor bundles (19) of the stator winding (18) in the stator slots (5) can be achieved.
10. Stator according to claim 9, characterized in that the conductor bundle (19) of the respective stator slot (5) is enclosed by at least one electrically insulating protective sheath (20) at least in the region of the respective twisting group (15).
11. Electrical machine with a stator (2) according to one of the preceding claims and with a machine housing (25), characterized in that the alignment elements (11) protrude through the stator laminated core (3) and protrude into recesses (24), in particular bores, of the machine housing (25) for centering the stator laminated core (3).
12. A method for producing a stator (2) according to one of claims 1 to 10, comprising the steps: - stacking a stator laminated core (3) comprising first and second laminations (6.1, 6.2) and in particular third laminations (6.3), - Inserting the stator winding (18) into the stator slots (5), - Inserting the alignment elements (11) into the stator plug-in holes (10), whereby the first and second laminations (6.1, 6.2) are rotated opposite to each other about the stator axis (7) and the conductor bundles (19) are clamped locally in the stator slots (5).
13. Method according to claim 12, characterized in that the laminations (6) of the stator laminated core (3) are aligned with one another in the circumferential direction before the alignment elements (11) are inserted in such a way that the conductors of the stator winding (18) can be inserted into the stator slots (5) with play, in particular resulting in substantially aligned lamination teeth (8).