Method for producing a stator for an electric machine by means of a production device, stator and production device

Abstract

The invention relates to a method for producing a stator (10), comprising the steps of: providing a stator laminate (12) for the stator (10); (S1) separating the stator laminate (12) into at least one star-type laminate (20) and one yoke laminate (22) by means of the production device (32); (S2, S3) providing at least one further stator laminate (12) for the stator (10); (S1) separating the further stator laminate (12) into at least one further star-type laminate (20) and one further yoke laminate (22) by means of the production device (32); (S2, S3) joining the yoke laminate (22) and the at least one further yoke laminate (22) to form a yoke laminate stack (24) and joining the star-type laminate (20) and the at least one further star-type laminate (20) to form a star-type laminate stack (26) by means of the production device (32); (S4) providing at least two coils (28) on the star-type laminate stack (26) by means of the production device (32); and (S5) joining the yoke laminate stack (24) to the star-type laminate stack (26) with the coils (28) to form the stator (10) by means of the production device (32).

Description

[0001] Description

[0002] Method for producing a stator for an electrical machine by means of a production device, stator and production device

[0003] The invention relates to a method for producing a stator for an electrical machine by means of a manufacturing device according to the applicable patent claim 1. Furthermore, the invention relates to a stator produced by the method and to a manufacturing device for producing such a stator.

[0004] The two-part stator structure is already known from the prior art, requiring a tight fit between the two stator components to enable high magnetic induction in the air gap between the stator and the rotor. The printed and sintered electrical sheets do not have sufficient precision to ensure reliable joining while also ensuring a gap that is not too large at the joints between the two stacks.

[0005] With printed sheets and large tolerances, the gaps in the prior art are very large. This reduces motor torque at low speeds. A method for producing a material layer is described in EP 3595148 B1.

[0006] The object of the following invention is to provide a method for producing a stator, a stator and a manufacturing device for producing a stator, by means of which an improved stator can be produced.

[0007] This object is achieved by a method, a stator and a manufacturing device according to the independent patent claims. Advantageous embodiments are specified in the subclaims. One aspect of the invention relates to a method for producing a stator for an electrical machine by means of a manufacturing device. A stator lamination for the stator is provided. The stator lamination is separated into at least one star lamination and one yoke lamination by means of the manufacturing device. At least one further stator lamination is provided. The further stator lamination is separated into at least one further star lamination and a further yoke lamination by means of the manufacturing device. The yoke lamination and the at least one further yoke lamination are joined to form a yoke lamination stack, and the star lamination and the at least one further star lamination are joined to form a star lamination stack by means of the manufacturing device.At least two coils are produced or provided on the star core by means of the manufacturing device. This is followed by joining the yoke core with the star core and the coils to form the stator by means of the manufacturing device.

[0008] In particular, this allows for improved stator production. The invention has the particular advantage that only one stator sheet, which is later separated into the star sheet and the yoke sheet, needs to undergo a printing and sintering process. This shortens the throughput time for printing and sintering, thus saving costs, particularly for sintering aids, energy, and the like.

[0009] In particular, it is intended that a corresponding coil be attached to each tooth tip of the star plate. In other words, the more teeth the star plate has, the more coils are arranged on the star plate stack.

[0010] In particular, a manufacturing method is proposed in which the gaps at the joints of the two stator packages are kept small, which in turn allows the torque of the electrical machine to be kept constant or increased even at low speeds compared to the prior art.

[0011] According to an advantageous embodiment, the star plates are insulated from one another. In particular, this prevents induced currents in the star plate stack. This has the advantage that no leakage currents occur, thus increasing the efficiency of the electrical machine.

[0012] In a further advantageous embodiment, the yoke plates are insulated from one another. In particular, this prevents induced currents in the yoke plate stack. This has the advantage that no leakage currents occur, thus increasing the efficiency of the electrical machine.

[0013] It is also advantageous if the star-shaped laminations are glued together. In particular, the adhesive can serve as insulation, for example. The star-shaped lamination stack can be manufactured in a simple manner using the bonding process.

[0014] Furthermore, it has proven advantageous if the yoke plates are glued together. In particular, the adhesive can serve as insulation, for example. The yoke plate stack can be manufactured easily using the bonding process.

[0015] It is also advantageous if the yoke plate and the star plate are finely calibrated after separation. In particular, this makes it possible to reduce burrs when punching or separating the stator plate, whereby the electrical machine achieves greater efficiency. Fine calibration can be carried out using punching or laser cutters, for example. It is also advantageous if the star plate and / or the yoke plate are eroded for fine calibration. In particular, erosion can also remove burrs, whereby the accuracy can be increased accordingly. This makes it possible to achieve an increase in the efficiency of the electrical machine.

[0016] A further advantageous embodiment provides for the stator lamination to be separated by punching. Thus, the corresponding separation of the stator lamination can be achieved using a punching process. Furthermore, fine calibration can also be performed using the punching process. This allows the stator lamination to be separated in a simple manner.

[0017] It is also advantageous if the stator sheet is laser-cut for separation. In particular, fine calibration can be performed during laser cutting. This allows the stator sheet to be separated easily.

[0018] It is intended that the stator lamination be provided with at least two materials. In particular, the materials can be, for example, a first material as the main material, from which the majority of the stator lamination is provided. The second material can, in particular, also be a metallic material, which, however, is formed differently from the first material. This can increase the efficiency of the electric machine.

[0019] It is intended that at least between tooth tips on the star plate a different material is provided than for the rest of the stator plate.

[0020] In other words, for example, the first material, from which the main part of the star plate is made, is metallic. Between the tooth tips, the second material, which is formed differently from the first material, is then provided. This can, for example, prevent magnetic fluxes between the tooth tips. Furthermore, mechanical strength can be achieved between the tooth tips without any magnetic leakage between the tooth tips.

[0021] It has also proven advantageous if the other material is made of a non-magnetic metal. In particular, the non-magnetic metal allows for high mechanical strength without magnetic scattering between the tooth tips.

[0022] Furthermore, it has proven advantageous if the stator lamination is manufactured using a sintering or printing process. In particular, this allows simple stator laminations to be produced, which are then adapted accordingly in the subsequent step. This makes it possible to provide an efficient electrical machine in a simple manner.

[0023] A further aspect of the invention relates to a stator which is manufactured by a manufacturing method according to the preceding aspect.

[0024] Furthermore, the invention also relates to an electrical machine with at least one stator according to the preceding aspect and with a rotor.

[0025] Yet another aspect of the invention relates to a manufacturing device for producing a stator according to the preceding aspect and for carrying out a method according to the preceding aspect. In particular, the method is also carried out by means of the manufacturing device.

[0026] Advantageous embodiments of the method are to be regarded as advantageous embodiments of the stator, the electrical machine, and the manufacturing device. The stator, the electrical machine, and the manufacturing device, in particular, have specific features enabling the corresponding method steps to be carried out.

[0027] For use cases or application situations that may arise during the method and which are not explicitly described here, it may be provided that, in accordance with the method, an error message and / or a request to enter user feedback is issued and / or a standard setting and / or a predetermined initial state is set.

[0028] Regardless of the grammatical gender of a particular term, persons with male, female or other gender identity are included.

[0029] Further features of the invention emerge from the claims, the figures and the description of the figures. The features and combinations of features mentioned above in the description as well as the features and combinations of features mentioned below in the description of the figures and / or shown in the figures can be encompassed by the invention not only in the respectively specified combination, but also in other combinations. In particular, the invention can also encompass embodiments and combinations of features which do not have all the features of an originally formulated claim. Furthermore, the invention can encompass embodiments and combinations of features which go beyond the combinations of features set out in the references to the claims or deviate from them.

[0030] Showing:

[0031] FIG 1 is a schematic plan view of an embodiment of a stator lamination;

[0032] FIG 2 is a schematic plan view of an embodiment of a yoke plate; FIG 3 is a schematic plan view of an embodiment of a star plate;

[0033] FIG 4 is a schematic plan view of an embodiment of a manufactured stator.

[0034] The invention is explained in more detail below with reference to specific exemplary embodiments and associated schematic drawings. In the figures, identical or functionally equivalent elements may be provided with the same reference numerals. The description of identical or functionally equivalent elements may not necessarily be repeated for different figures.

[0035] In particular, Figures 1 to 5 show different steps of the manufacturing method for producing a stator 10 for an electrical machine (not shown).

[0036] FIG. 1 shows a first step S1, FIG. 2 shows a second step S2, FIG. 3 shows a third step S3, and FIG. 4 shows three steps S4, S5 and S6.

[0037] FIG. 1 shows, particularly in the first step S1, that a stator lamination 12 can be provided for the stator 10. In the present exemplary embodiment, the stator lamination 12 is provided in particular with two materials. In particular, the stator lamination 12 comprises a soft magnetic material 14 with, in particular, an iron content of more than 98%.

[0038] Furthermore, an amagnetic material 16 is shown, which is formed in particular between respective tooth tips 18 on the stator lamination 12 or on a star lamination 20 (Fig. 3). In particular, the stator lamination 12 thus comprises at least two different materials, in particular the soft magnetic material 14 and the amagnetic material 16.

[0039] FIG. 2 shows, in particular, a separated yoke sheet 22. In particular, the stator sheet 12 was separated into at least the star sheet 20 (FIG. 3) and the yoke sheet 22. For example, a stamping process, a laser cutting process, or the like could be used. This is shown, in particular, as the second step S2.

[0040] FIG. 3 again shows the separated star plate 20. In the following exemplary embodiment, the star plate 20 comprises the tooth tips 18 as well as the soft magnetic material 14 and the non-magnetic material 16.

[0041] In particular, steps S2 and S3 are performed multiple times. In other words, a plurality of stator laminations 12 are provided, which are separated into a plurality of star laminations 20 and yoke laminations 22 using a punching or laser cutting process.

[0042] FIG 4 then again shows the production of the stator 10, in particular with the further steps S4, S5 and S6.

[0043] In the further steps S4, for example, the individual yoke plates 20 are joined to form a yoke plate package 24 and the individual star plates 22 are joined to form a star plate package 26.

[0044] In the fifth step S5, coils 28 are produced on the star core 26. The coils 28 can also be produced independently of the star core 26. Thus, there are two possibilities. The coils 28 are produced on the star core 26, or independently produced coils 28, for example, wound coil bodies, are joined to the stator teeth of the star core 26.

[0045] This is followed by the sixth step S 6 , in which the yoke core 24 is again joined to the star core 26 and the coils 28 to form the stator 10.

[0046] In particular, FIG. 4 shows that a gap 30 is present between the yoke core 24 and the star core 26. However, according to the method, this gap is very small, which allows high torques of the electric machine to be achieved at low speeds.

[0047] In particular, it is further provided that the star plates 20 are insulated from one another. Furthermore, the yoke plates 22 are also insulated from one another. Furthermore, it can be provided that the star plates 22 are glued together to form the star plate stack 26. Furthermore, the yoke plates 22 are also glued together to form the yoke plate stack 24.

[0048] Furthermore, it can be provided that the yoke plate 22 and the star plate 20 are finely calibrated after the separation. For fine calibration, the star plate 20 and / or the yoke plate 22 can be eroded. Furthermore, punching for fine calibration or laser cutting for fine calibration can also be provided.

[0049] Overall, FIGS. 1 to 4 show that, in order to minimize the gap 30 at the joints of the corresponding stator cores 24, 26, the corresponding manufacturing method is proposed. The stator laminations 12 are produced by a printing and sintering process. The stator laminations 12 thus produced preferably contain both the subsequent yoke lamination 22 and the subsequent star lamination 20.

[0050] In a special embodiment, the stator lamination 12 is manufactured from two materials. A non-magnetic material 16 establishes the connection between the tooth tips 18. This minimizes magnetic leakage between the stator teeth during operation of the electric motor or machine.

[0051] The yoke plates 22 and star plates 20 produced in this way are already close to their final contour. In a calibration process, in particular fine calibration, which occurs, for example, during punching, laser cutting, or eroding, the two plates, in particular the yoke plate 22 and the star plate 20, are separated from each other, and the required degree of tolerance, which is in particular in the range of IT5 to IT9, is produced.

[0052] The star sheets 20 and the yoke sheets 22 are then each insulated and packaged into respective sheet stacks.

[0053] To manufacture the stator 10, the star cores 26 are fitted with the coils 28 and then the yoke core 24 is fitted over the star core 26 fitted with coils.

Claims

Patent claims 1. A method for producing a stator (10) for an electrical machine by means of a manufacturing device (32), comprising the steps: - Providing a stator sheet (12) for the stator (10); (Sl) - Separating the stator lamination (12) into at least one star lamination (20) and one yoke lamination (22) by means of the manufacturing device (32); (S2, S3) - Providing at least one further stator sheet (12) for the stator (10); (Sl) - Separating the further stator lamination (12) into at least one further star lamination (20) and one further yoke lamination (22) by means of the manufacturing device (32); (S2, S3) - joining the yoke plate (22) and the at least one further yoke plate (22) to form a yoke plate stack (24) and joining the star plate (20) and the at least one further star plate (20) to form a star plate stack (26) by means of the manufacturing device (32); (S4) - Providing at least two coils (28) on the star core (26) by means of the manufacturing device (32); (S5) and - Joining the yoke lamination stack (24) with the star lamination stack (26) with the coils (28) to the stator (10) by means of the manufacturing device (32), wherein the stator lamination (12) is provided with at least two materials (14, 16), wherein at least between tooth tips (18) on the star lamination (20) a different material (16) is provided than for the remaining stator lamination (12).

2. Method according to claim 1, characterized in that the star plates (20) are insulated from one another.

3. Method according to claim 1 or 2, characterized in that the yoke plates (22) are insulated from one another.

4. Method according to one of the preceding claims, characterized in that the star plates (20) are glued together.

5. Method according to one of the preceding claims, characterized in that the yoke plates (22) are glued together.

6. Method according to one of the preceding claims, characterized in that the yoke plate (22) and the star plate (20) are finely calibrated after the separation.

7. Method according to claim 6, characterized in that for fine calibration the star plate (22) and / or the yoke plate (20) is eroded.

8. Method according to one of the preceding claims, characterized in that the stator sheet (12) is punched for separation.

9. Method according to one of claims 1 to 7, characterized in that the stator sheet (12) is laser cut for separation.

10. Method according to one of the preceding claims, characterized in that the other material (16) is provided from a non-magnetic metal.

11. Method according to one of the preceding claims, characterized in that the stator sheet (12) is produced by means of a sintering process or a printing process.

12. Stator (10) which is manufactured by a manufacturing method according to one of claims 1 to 11.

13. Manufacturing apparatus (32) for manufacturing a stator (10) according to claim 12 and for carrying out a method according to one of claims 1 to 11.

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