Stator array and method for manufacturing a stator array

Abstract

The present invention relates to a stator arrangement (20) with a high voltage interface (30) for realizing an electrical connection between a stator (25) and a high voltage electronic device (35). To simplify the manufacture of the stator arrangement (20), the high voltage interface (30) is combined with a centering mechanism (38) that is centered on a cooling sleeve (24) that includes a stator receiving space for the stator (25).

Description

Technical Field

[0001] The present invention relates to a stator array provided with a high-voltage interface for realizing an electrical connection between a stator and a high-voltage electronic device. The present invention further relates to a method for manufacturing such a stator array.

Background Art

[0002] From German Patent Document 1, a stator array of an electric machine including a housing and a stator is known. The stator has a stator body and at least one winding head. In this case, the stator body and the winding head are cast with a thermally conductive epoxy resin.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] The problem of the present invention is to simplify the manufacture of a stator array provided with a high-voltage interface for realizing an electrical connection between a stator and a high-voltage electronic device.

Means for Solving the Problems

[0005] This problem is solved in a stator array with a high-voltage interface for realizing an electrical connection between the stator and high-voltage electronics, wherein the high-voltage interface is combined with an alignment mechanism that aligns with a cooling sleeve containing stator receiving spaces for the stator. The cooling sleeve is used to realize cooling for the stator array. For cooling, a cooling fluid can be guided through or along the cooling sleeve. The stator includes, for example, a stator body with stator windings, a stator core, and a winding head. In the case of casting, impregnation, and / or overmolding, casting resin, impregnation resin, and / or plastic material penetrate and surround the stator. The high-voltage electronics include, for example, an inverter. The inverter may be located separately from the stator array. The stator array is advantageously used together with the rotor to realize electric drive for gas transporters, particularly for air compressors. In an advantageous embodiment of an air compressor, the high-voltage electronics, particularly the inverter, are housed together with the stator in a common housing. This type of air compressor is also called a built-in electric-driven air compressor. A high-voltage interface is used to provide an electrical connection between the high-voltage electronics and the electric drive unit, particularly in stator arrays with stators. A centering mechanism provides an interface between the cooling sleeve and the stator, which may also be called the stator unit. The centering mechanism is advantageous because it allows for perfect alignment of the stator or stator unit, particularly with the outer diameter of the cooling sleeve. For sealing, a compression fitting may be used between the centering mechanism and the cooling sleeve.

[0006] An advantageous embodiment of the stator array is characterized in that the alignment mechanism includes a ring body, and the ring body secures the alignment mechanism to the end of the cooling sleeve. Thus, a simple, robust, and cost-effective interface geometry is provided between the stator or stator unit and the cooling sleeve.

[0007] A further advantageous embodiment of the stator array is characterized in which the ring body has a centering ring, and the centering mechanism is perfectly centered on the outer diameter of the cooling sleeve by the centering ring. Thus, optimal centering in the cooling sleeve is possible with very good positioning accuracy. Furthermore, a robust and secure seal is made possible by compression fittings and / or auxiliary sealing mechanisms.

[0008] A further advantageous embodiment of the stator array features a centering ring of the centering mechanism that is frictionally coupled to the cooling sleeve. A suitable compression fitting can easily ensure a high-pressure-resistant seal between the centering ring and the cooling sleeve.

[0009] A further advantageous embodiment of the stator arrangement is characterized by the provision of a radial O-ring to seal between the cooling sleeve and the centering ring. The O-ring is received, for example, in an annular groove provided on the outer circumference of the centering sleeve. This radial O-ring may be provided either alternatively or additionally to the compression fitting described above.

[0010] A further advantageous embodiment of the stator array is characterized by the ring body being in full surface contact with the end face of the cooling sleeve. Full surface contact with the end face avoids undesirable angular errors.

[0011] A further advantageous embodiment of the stator array is characterized in that the coupling portion extends radially outward from the ring body. The coupling portion allows electrical connection cables to extend from the stator to high-voltage electronic devices. The coupling conductor may be implemented as a current track or contact tongue.

[0012] A further advantageous embodiment of the stator array is characterized by having multiple connection sleeves arranged radially outward at a single coupling portion, with these connection sleeves extending axially from the coupling portion. This simplifies the connection of high-voltage electronic devices to the stator array.

[0013] In the method for manufacturing the aforementioned stator array, the above problem is solved by either or additionally aligning the stator with the cooling sleeve using the alignment mechanism before casting and / or overmolding the stator together with the high-voltage interface. Thus, the stator can be easily and very precisely positioned in the stator receiving space of the cooling sleeve.

[0014] The present invention further relates to a stator array alignment mechanism and / or cooling sleeve for the aforementioned stator array. The stator array alignment mechanism and cooling sleeve are available separately on the market.

[0015] The present invention also relates, in some cases, to a gas transport device, particularly an air compressor, for supplying gas, in particular compressed air, in a fuel cell system, having the aforementioned stator array.

[0016] Further advantages, constituent elements, and details of the present invention will become apparent from the following description, in which various embodiments are described in detail with reference to the drawings. [Brief explanation of the drawing]

[0017] [Figure 1] This is a perspective view of an air supply device equipped with a housing, in which a control connection mechanism is coupled to a current connection mechanism via a current track within the housing. [Figure 2] This is a perspective view of a stator array equipped with a high-voltage interface incorporated into an alignment mechanism that is aligned with a cooling sleeve. [Figure 3] Figure 2 is a perspective view of the alignment mechanism. [Figure 4] Figure 4 is a longitudinal cross-sectional view of the stator array. [Figure 5] This is an enlarged view of a portion of Figure 4, which shows a radial O-ring between the cooling sleeve and the alignment ring of the alignment mechanism. [Modes for carrying out the invention]

[0018] Figure 1 shows the air supply device 1 in a perspective view. The air supply device 1, also called an air compressor, is used to provide compressed air in a mobile fuel cell system. The mobile fuel cell system is also used to supply electrical energy, for example, converted into driving energy for an automobile via an electric motor, in an automobile equipped with the fuel cell system.

[0019] The air supply device 1 includes a housing 2 composed of a plurality of parts, having an air connection part 3 for supplying air and an air connection part 4 for discharging compressed air. To compress air, the air supply device 1 includes, for example, a compressor wheel rotatable inside a compressor volute.

[0020] The driving of the compressor wheel is performed by an electric motor disposed within the housing 2. The electric motor includes a rotor rotatable inside a stator.

[0021] The stator of the electric motor includes a current connection mechanism 5 for supplying a three-phase alternating current to the stator. The current connection mechanism 5 is coupled to a control connection mechanism 6 via a coupling mechanism 10 including three vertically long contact members 7, 8, 9.

[0022] The control connection mechanism 6 is associated with, for example, a cable outlet 40 connected to an inverter disposed separately and not shown in Figure 1 as suggested by the three shown and outgoing cables 39. However, the inverter may be incorporated within the housing 2 of the air supply device 1. In this case, the cable outlet 40 is not provided.

[0023] Figures 2 and 4 show the stator array 20 including a stator 25 from different perspectives. The stator 25 is disposed within a stator receiving space of a cooling sleeve 24.

[0024] The stator 25 includes a stator body with a stator core, stator windings, and winding head, which are known in terms of their configuration and function. A rotor (not shown) is located inside the stator 25, and the rotor is used to embody the motor drive of the air supply device shown in Figure 1.

[0025] The cooling sleeve 24 is advantageously located inside a common housing of the air supply unit, which is implemented as an air compressor, along with a high-voltage electronic device 35, which is only schematically shown in Figure 2. A cooling medium, such as cooling water, is advantageously circulated around the outer circumference of the cooling sleeve. The cooling sleeve 24 is used to provide cooling for the stator 25, which can become extremely hot when the rotor is operating at very high rotational speeds of over 100,000 revolutions per minute.

[0026] Figure 2 shows that stator conductors 21, 22, and 23 extend from the ends of the stator 25. Stator conductors 21 through 23 are electrically connected to a high-voltage electronic device 35 via a high-voltage interface 30. The high-voltage electronic device 35 includes, for example, an inverter.

[0027] The high-voltage interface 30 is combined with a centering mechanism 38. The centering mechanism 38 includes a ring body 46, which makes full surface contact with the right end face of the cooling sleeve 24 in Figure 4. A coupling portion 45 extends radially outward from the ring body 46 of the centering mechanism 38.

[0028] The connecting portion 45 has four connecting sleeves 41 to 44 formed therein, and these connecting sleeves are essentially straight cylindrical in shape. The connecting sleeves 41 to 44 extend in the axial direction.

[0029] The concept of axial direction relates to the axis of rotation of the rotor that can rotate within the stator 25. Axial direction means the direction of this axis of rotation or a direction parallel to it. Correspondingly, the concept of radial direction means the direction lateral to this axis of rotation.

[0030] The cable ends 27 to 29 of the stator conductors 21 to 23 are connected to contact tongues 31, 32, and 33 that protrude radially inward from the ring body 46 inside the ring body 36. Connection sleeves 41 to 43 are attached to the cable ends 27 to 29 on the inverter side. A fourth connection sleeve 44 is used to embody further functions not mentioned herein.

[0031] Figures 3 and 4 show that the alignment mechanism 38 has an alignment ring 50, which has the form of a substantially straight cylindrical portion. As is clear from the outlines in Figures 2 to 4, the alignment ring 50 is perfectly aligned with the outer diameter portion of the cooling sleeve 24.

[0032] For sealing purposes, the joint between the alignment ring 50, the alignment mechanism 38, and the outer circumference of the cooling sleeve 24 is implemented as a compression fitting. Alternatively or additionally, a radial O-ring 48 is provided to seal the space between the cooling sleeve 24 and the alignment ring 50 of the alignment mechanism 38. [Explanation of Symbols]

[0033] 20 stator array 24 Cooling Sleeves 25 Status 30 High-voltage interfaces 35 High-voltage electronic devices 38 Alignment Mechanism 41-44 Connection Sleeve 45 Joint part 46 ring bodies 48 O-rings 50 Heart-to-Heart Ring

Claims

1. A combination of a stator array (20), a centering mechanism (38), and a cooling sleeve (24), wherein the stator array (20) comprises a high-voltage interface (30) for realizing an electrical connection between a stator (25) and a high-voltage electronic device (35), and the high-voltage interface (30) is combined with the centering mechanism (38) which is centered on the cooling sleeve (24) which includes a stator receiving space for the stator (25), The alignment mechanism (38) includes a ring body (46), and the ring body is used to fix the alignment mechanism (38) to the end of the cooling sleeve (24). The connecting portion (45) extends radially outward from the ring body (46), A combination of a stator array, a centering mechanism, and a cooling sleeve, characterized in that a connecting sleeve (41-44) is positioned on the radially outer side of the coupling portion (45), the connecting sleeve extends axially from the coupling portion (45), and the connecting sleeve is formed so as to connect the high-voltage electronic device (35) and the cooling sleeve (24) on the radially outer side.

2. A combination of the stator arrangement, alignment mechanism, and cooling sleeve according to claim 1, characterized in that the ring body (46) has an alignment ring (50), and the alignment mechanism (38) is perfectly aligned with the outer diameter portion of the cooling sleeve (24) by the alignment ring.

3. A combination of the stator array, alignment mechanism and cooling sleeve according to claim 2, characterized in that the alignment ring (50) of the alignment mechanism (38) is frictionally coupled to the cooling sleeve (24).

4. A combination of the stator arrangement, alignment mechanism and cooling sleeve according to claim 2 or 3, characterized in that a radial O-ring (48) is arranged to seal the space between the cooling sleeve (24) and the alignment ring (50).

5. A combination of the stator arrangement, alignment mechanism and cooling sleeve according to any one of claims 1 to 3, characterized in that the ring body (46) is in complete surface contact with the end face of the cooling sleeve (24).

6. A method for manufacturing a combination of a stator array (20), a centering mechanism, and a cooling sleeve according to any one of claims 1 to 3, characterized in that the stator (25) is centered on the cooling sleeve (24) by the centering mechanism (38) before casting and / or overmolding the stator (25) together with the high-voltage interface (30).

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