Stator of an electric motor and an electric motor

Abstract

To provide a stator of an electric motor and an electric motor.SOLUTION: The present invention relates to a stator (1, 10) of an electric motor, in particular for a motor vehicle. The stator (1, 10) includes a laminated stator core (2, 11) and a plurality of hairpin-like elements (3, 12). The hairpin-like elements (3, 12) are each made of a metallic material, have two longitudinal legs (4, 13) and a connecting section (5, 14) between the longitudinal legs (4, 13). The laminated stator core (2, 11) has a plurality of slots (6, 15) configured to receive each of the longitudinal legs (4, 13) of the hairpin-like elements (3, 12). The connecting sections (5, 14) of the hairpin-like elements (3, 12) form an annular region (7, 16). The hairpin-like elements (3, 12) each define a plane (18, 19) with their two longitudinal legs (4, 13) of the hairpin-like elements (3, 12). The connecting section (5, 14) of the respective hairpin-like element (3, 12) is tilted out of the plane (18, 19).SELECTED DRAWING: Figure 4

Description

Technical Field

[0001] The present invention relates in particular to a stator of an electric motor and an electric motor for use in a motor vehicle.

Background Art

[0002] In motor vehicles, electric motors are known that have a stator comprising a plurality of hairpin-shaped elements made of a metallic material and having two longitudinal legs and a connection section between the longitudinal legs. These elements are inserted into the slots of the laminated stator core with their legs and are electrically connected at the ends of the legs by means of winding overhangs. In this case, the two legs and the connection section are in one plane and thus define the hairpin-shaped element. After assembling the hairpin-shaped element with the laminated stator core, the connection section projects axially and forms a ring of the connection section. Such hairpin-shaped elements, also known as hairpin conductors, are known from (Patent Document 1) or (Patent Document 2). These hairpin-shaped elements can in this case be formed from a single-piece sheet metal or wire parts or from a plurality of metal stranded wires designed to be connected to one another. Here, the connection sections of the hairpin-shaped elements, taken together, integrally form a ring projecting axially of the stator. Furthermore, it has been found that the insertion of the hairpin-shaped elements into the laminated stator core is very difficult since the connection sections interfere with the insertion of the hairpin-shaped elements.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0004] An object of the present invention is to provide a stator that can be manufactured simply and in a space-saving manner, and a motor having the stator. Furthermore, an object is to provide a method for manufacturing an improved stator.

Means for Solving the Problems

[0005] The object regarding the stator is achieved by the features of claim 1.

[0006] An exemplary embodiment of the present invention is a stator for an electric motor, particularly for an automobile, comprising a laminated stator core and a plurality of hairpin-shaped elements. Each hairpin-shaped element is made of a metallic material and has two longitudinal legs and a connection section between the longitudinal legs. The laminated stator core has a plurality of slots, each of the longitudinal legs of the hairpin-shaped element is received in a slot, the connection sections of the hairpin-shaped elements form an annular region, each hairpin-shaped element defines a plane with its two longitudinal legs, and the connection section of each hairpin-shaped element is inclined from the plane. This shortens the axial length of the stator, and thus reduces the installation space required for the stator. This also facilitates assembly when the inclination ensures better access to the slots for inserting the longitudinal legs.

[0007] In one exemplary embodiment, it is preferable that each hairpin-shaped element defines a plane with its two longitudinal legs, and the connection section of each hairpin-shaped element is inclined from the plane at a first angle. This provides an angled design that simplifies manufacturing and achieves a significant reduction in axial spread.

[0008] Furthermore, the first angle is preferably an acute angle of particularly 5° to 60°, preferably 10° to 40°, particularly 15° to 25°. This provides an angled design that simplifies manufacturing and achieves a significant reduction in axial spread.

[0009] Furthermore, it is advantageous if the connection section is formed by two transverse legs, and the two transverse legs are arranged at a second angle to each other. This also ensures simplified manufacturing and a simple design.

[0010] Also, it is advantageous if the second angle is an angle between 75° and 150°, preferably between 90° and 130°, particularly between 100° and 110°. As a result, the connection section is not too long, and material is also saved.

[0011] It is also advantageous if the hairpin-shaped element consists of a sheet metal strip, a wire element, or a plurality of sheet metal strips or wire elements, i.e., a bundle of individual wires, for example, a stranded conductor. In this way, the hairpin-shaped element can be selected from a suitable material and can be matched to the performance data of the electric motor.

[0012] The object regarding the electric motor is achieved by the features of claim 7.

[0013] Exemplary embodiments of the present invention relate to an electric motor having a stator and a rotor, wherein the stator is designed according to the present invention, particularly for an automobile.

[0014] The object regarding this method is achieved by the features of claim 8.

[0015] Exemplary embodiments of the present invention are methods for manufacturing an electric motor, particularly a stator for an automobile, a. providing a laminated stator core having a plurality of slots; b. providing a plurality of hairpin-shaped elements, each composed of a metallic material and having two longitudinal legs and a connection section between the longitudinal legs; c. inserting each longitudinal leg of the hairpin-shaped element into a respective slot of the laminated stator core such that the connection sections of the hairpin-shaped elements form an annular region; d. contacting the ends of the longitudinal legs and including Regarding a method in which hairpin-shaped elements each define a plane with two longitudinal legs of the hairpin-shaped element, and the connection section of each hairpin-shaped element is inclined from the plane.

[0016] In this way, a method for manufacturing an improved stator is realized.

[0017] It is advantageous for the two longitudinal legs of the hairpin-shaped element to be in a plane. In this case, the two longitudinal legs may or may not be aligned parallel to each other.

[0018] It is also advantageous if the inclination of the connection section from the plane of the longitudinal leg is carried out before and / or after the insertion of the longitudinal leg into the slot. Thereby, the hairpin-shaped element can be pre-manufactured and assembled in a state already having an inclination, or manufactured with a certain degree of inclination in advance and then the final inclination process is carried out after assembly, or alternatively, the inclination process can be carried out for the first time only after the insertion of the longitudinal leg into the slot.

[0019] In a preferred exemplary embodiment, after the insertion of the longitudinal leg, the inclination process is carried out using a drift plug. This has the advantage that all connection sections can be inclined simultaneously, and thus there is only one work step required for this purpose.

[0020] With reference to the drawings, the present invention will be described in detail below by way of exemplary embodiments.

Brief Description of the Drawings

[0021]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Mode for Carrying Out the Invention

[0022] FIG. 1 shows a schematic diagram of a stator 1 according to the prior art. The stator 1 according to the prior art is a stator 1 of an electric motor. The stator 1 has a laminated stator core 2 and a plurality of hairpin-shaped elements 3.

[0023] Here, FIGS. 2 and 3 show corresponding partial views of the hairpin-shaped element 3 according to the prior art. The hairpin-shaped element 3 is made of a metal material and has two longitudinal legs 4 and a connection section 5 between the longitudinal legs 4.

[0024] The laminated stator core 2 has a plurality of slots 6. The slots are optionally provided with slot insulators 6a as if they were backrested. In this case, the hairpin-shaped element 3 is configured such that each of the longitudinal legs 4 of the hairpin-shaped element 3 is received in the slot 6, and the connection section 5 of the hairpin-shaped element 3 forms an annular region 7 protruding in the axial direction 8 of the stator 1.

[0025] FIGS. 2 and 3 show that the hairpin-shaped elements 3 having two longitudinal legs 4 and a connection section 5 each define a plane and are correspondingly of a substantially flat design. Here, the hairpin-shaped element 3 has a three-dimensional shape, and the connection section is curved according to the slot diameter.

[0026] However, in order to form the stator by fitting a plurality of hairpin-shaped elements, the material of the hairpin-shaped element 3 can twist itself. Here, the longitudinal leg 4 and the connection section 5 define a common plane at least roughly, but are slightly displaced from the plane.

[0027] FIG. 4 shows another schematic view of the stator 10 according to the present invention. The stator 10 according to the present invention is, in this case, a stator 10 of an electric motor, particularly an automobile. The stator 10 has a laminated stator core 11 and a plurality of hairpin-shaped elements 12. However, in FIG. 4, not all of the hairpin-shaped elements 12 are installed, so only a part of the hairpin-shaped elements 12 can be seen. When all of the hairpin-shaped elements 12 are installed, they form an annular region in the same manner as can be seen in FIG. 1 regarding the prior art.

[0028] Here, FIGS. 5 to 9 show corresponding views or partial views of the hairpin-shaped element 12 according to the present invention. The hairpin-shaped element 12 is made of a metal material and has two longitudinal legs 13 and a connection section 14 between the longitudinal legs 13. A configuration consisting of a bundle of individual wires is preferred.

[0029] The laminated stator core 11 has a number of slots 15 backed by slot insulators 15a. In this case, the hairpin-shaped element 12 is configured such that each of the longitudinal legs 13 of the hairpin-shaped element 12 is received in a slot 15, and the connection section 14 of the hairpin-shaped element 12 forms an annular region 16 protruding in the axial direction 17 of the stator 10.

[0030] FIGS. 5 to 9 show that the hairpin-shaped element 12 forms a first plane 18 with its two longitudinal legs 13, and the connection section 14 is inclined from this first plane 18. In this case, the connection section also defines a second plane 19 inclined with respect to the first plane 18. Similarly, in order to form the stator 10 by fitting a plurality of hairpin-shaped elements 12, the material of the hairpin-shaped element 12 can also twist itself.

[0031] In this case, each of the hairpin-shaped elements 12 defines a first plane 18 by two longitudinal legs 13, and the connecting section 14 of each hairpin-shaped element 12 is inclined from the plane 18 at a first angle α1.

[0032] The first angle α1 is preferably an acute angle, optionally, particularly an angle in the range of 5° to 60°, preferably 10° to 40°, particularly 15° to 25°.

[0033] Also, FIGS. 5, 6, 7, and 9 show that the connecting section 14 is formed by two lateral legs 20, and the two lateral legs 20 are arranged at a second angle α2 with respect to each other. The second angle α2 is preferably an angle within the range of 75° to 150°, preferably 90° to 130°, particularly 100° to 110°, optionally.

[0034] In this case, the hairpin-shaped element 12 according to the present invention may be composed of a sheet metal strip, a wire element, or a plurality of sheet metal strips or wire elements, such as a stranded wire.

[0035] FIG. 10 shows a method for manufacturing a stator 10, particularly for a motor vehicle. This method includes a. providing a laminated stator core 11 having a plurality of slots 15; b. providing a plurality of hairpin-shaped elements 12, each composed of a metallic material and having two longitudinal legs 13 and a connecting section 14 between the longitudinal legs 13; c. inserting each of the longitudinal legs 13 of the hairpin-shaped element 12 into a respective slot 15 of the laminated stator core 11 such that the connecting section 14 of the hairpin-shaped element 12 forms an annular region 16; d. contacting the ends of the longitudinal legs 13 and includes.

[0036] In this case, the two longitudinal legs 13 of the hairpin-shaped element 12 are designed such that the hairpin-shaped element 12 defines a plane 18 respectively, and the connection section 14 of each hairpin-shaped element 12 is inclined from the plane 18.

[0037] Here, the inclination of the connection section 14 of the longitudinal leg 13 from the plane 18 can be performed before and / or after the insertion of the longitudinal leg 13 into the slot 15.

[0038] FIG. 10 shows that after the insertion of the longitudinal leg 13 into the slot 15, the inclination is performed by the drift plug 21. In the left figure in FIG. 10, the stator is assembled, and the connection section 14 is still arranged within the plane 18, thus forming an annular region 16 that protrudes over a long axial distance. In the central figure, the drift plug 21 is pressed against this annular region 16 in order to bend the connection section 14 and tilt it from the plane 18. In the right figure in FIG. 10, the connection section 14 is inclined from the plane 18, and as a result, an annular region 16 that is flattened and does not protrude much axially is formed.

Explanation of Reference Numerals

[0039] 1 Stator 2 Laminated Stator Core 3 Element 4 Longitudinal Leg 5 Connection Section 6 Slot 6a Slot Insulator 7 Annular Region 8 Axial Direction 10 Stator 11 Laminated Stator Core 12 Element 13 Longitudinal Leg 14 Connection Section 15 Slot 15a Slot Insulator 16 Annular Region 17 Axial Direction 18 First Plane 19 Second Plane 20 horizontal leg 21 drift plug

Claims

1. A stator (10) for an electric motor, particularly for a motor vehicle, comprising a laminated stator core (11) and a plurality of hairpin-shaped elements (12), each of said hairpin-shaped elements (12) being made of a metallic material and having two longitudinal legs (13) and a connection section (14) between said longitudinal legs (13), said laminated stator core (11) having a plurality of slots (15), each of said longitudinal legs (13) of said hairpin-shaped element (12) being received in a slot (15), and said connection section (14) of said hairpin-shaped element (12) forming an annular region (16). In the stator (10), each of said hairpin-shaped elements (12) defines a first plane (18) by means of two longitudinal legs (13) of said hairpin-shaped element (12), and said connection section (14) of each of said hairpin-shaped elements (12) comprises two transverse legs (20) each including at least one straight portion extending on a second plane, said second plane (19) being inclined at a first angle with respect to said first plane (18). The stator (10) is characterized in that.

2. The stator (10) according to claim 1, characterized in that the first angle is an acute angle, particularly between 5° and 60°, preferably between 10° and 40°, particularly between 15° and 25°.

3. The stator (10) according to claim 1 or 2, characterized in that the connection section (14) is formed by the two transverse legs (20), and the two transverse legs (20) are arranged at a second angle with respect to each other.

4. The stator (10) according to claim 3, characterized in that the second angle is an angle between 75° and 150°, preferably between 90° and 130°, particularly between 100° and 110°.

5. The stator (10) according to any one of claims 1 to 4, characterized in that the hairpin-shaped element (12) consists of a sheet metal strip, a wire element, or a plurality of sheet metal strips or wire elements, particularly a bundle of individual twisted wires.

6. An electric motor, particularly for a motor vehicle, having a stator (10) and a rotor, characterized in that the stator (10) is designed as described in at least one of claims 1 to 5.

7. A method for manufacturing a stator (10) for an electric motor, particularly for a motor vehicle, comprising: a. providing a laminated stator core (11) having a plurality of slots (15); b. providing a plurality of hairpin-shaped elements (12), each consisting of a metallic material and having two longitudinal legs (13) defining a first plane, and a connecting section (14) between said longitudinal legs (13), said connecting section (14) including two transverse legs (20) each including at least one straight portion extending on a second plane); c. inserting each of said longitudinal legs (13) of said hairpin-shaped element (12) into a respective slot (15) of said laminated stator core (11) such that said connecting section (14) of said hairpin-shaped element (12) forms an annular region (16); d. bringing the ends of said longitudinal legs (13) into contact; e. performing a tilting operation such that said second plane (19) is tilted from said first plane (18) at a first angle, before and / or after inserting each of said longitudinal legs (13) into a respective slot (15) of said laminated stator core (11). **Claim 8** The method according to claim 7, characterized in that the tilting operation is performed after inserting said longitudinal legs (13), and the tilting operation is performed by a drift plug (21).

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