Winding, component for an electric machine, electric machine, electric axle drive, motor vehicle, and method for producing a winding

Abstract

The invention relates to a winding (110) for a component of an electric machine. The component comprises an annular laminated core with a plurality of slots, which extend axially through the laminated core, for receiving input sections and output sections of wires (U1, U2, U3, U4, U5, U6) of at least one winding (110) section, which has a winding direction, in a plurality of winding layers (L1, L2, L3, L4, L5, L6) arranged in a radially adjacent manner. A first wire (U1) has a first connection pin (200) and another first connection pin (210). In a first circuit region (R1, 325), a first sub-section of a first wire (U1) spans a number of slots of the laminated core with a layer jump (315a) over precisely one winding layer away in the winding direction. In a second circuit region (R2, 335), a second sub-section of the first wire (U1) spans the number of slots of the laminated core (115) with the layer jump (315a) over precisely one winding layer away opposite the winding direction.

Description

[0001] Winding, component for an electrical machine, electrical machine, electric axle drive, motor vehicle and method for producing a winding

[0002] The present invention relates to a winding, a component for an electrical machine, an electrical machine, an electric axle drive, a motor vehicle and a method for producing a winding.

[0003] Electrical machines may include components with windings made of, for example, copper wires for conducting electrical energy to generate magnetic fields.

[0004] Against this background, the present invention provides an improved winding, an improved component for an electric machine, an improved electric machine, an improved electric axle drive, an improved motor vehicle, and an improved method for producing a winding according to the main claims. Advantageous embodiments emerge from the subclaims and the following description.

[0005] The advantages achievable with the invention are, in particular, that a winding is created which can have a uniform distribution of wires, whereby axial installation space can be saved.

[0006] A winding is provided for a component of an electrical machine, wherein the component comprises an annular laminated core having a plurality of grooves extending axially through the laminated core for receiving input sections and output sections of wires of at least one winding strand of the winding having a winding direction in a plurality of radially adjacently arranged winding layers.

[0007] A first wire has a first connection pin and another first connection pin. In a first circuit region, a first section of a first wire spans a number of slots of the laminated core with a layer jump across exactly one winding layer in the winding direction. In a second circuit region, a second section of the first wire spans the number of slots of the laminated core with the layer jump across exactly one winding layer, opposite to the winding direction.

[0008] The connection pins of the first wire can be arranged on a wiring side of the winding in a first circuit region.

[0009] The electrical machine can be, for example, an electric drive or another electrical machine, for example, for a vehicle. The electrical machine can comprise various components, such as a rotor and a stator, similar to known electric motors. The component, for example, an annular stator or rotor, can be designed as a laminated core consisting of several individual laminations, through which the slots extend for receiving input and output sections of wires. The slots can be numbered consecutively along the circumference of the laminated core, so that each slot can be assigned a unique position.

[0010] An electrical voltage can be applied to the wire via the wire's connecting pins. The wire can be a flat wire.

[0011] The winding can, for example, be an endless, embossed, braided winding. The approach presented here can therefore also be understood as a wound, stepped winding for a stator or rotor of an electrical machine.

[0012] Spanning the number of slots—here seven slots are just an example—of the laminated core across exactly one winding layer can represent a phase shift. The phase shift can also be referred to as layer jump and / or chord shift. In a multi-layer winding, chord shift can be described as the displacement of the winding layers. This displacement can smooth the excitation curve and thus reduce the harmonics of the induced voltage. The chord shift can reduce the induced voltage amplitude, which is taken into account by the chord shift factor. The approach presented here creates a concentric winding in the stator or rotor, good insulation strength, and a compact winding overhang. In addition, the winding allows for a high degree of cantilever clearance and high electric machine performance.

[0013] The first wire can be a flat wire with an outer conductor side and an inner conductor side. In the first circuit region, the outer conductor side of the input section and the inner conductor side of the output section of the first subsection of the wire can each be radially aligned. In the second circuit region, the outer conductor side of the input section and the inner conductor side of the output section of the second subsection of the first wire can each be radially aligned. The outer conductor side and the inner conductor side can be oriented radially outwards or radially inwards. In this way, twisting of the winding overhang of the first wire in the first circuit region can be avoided, thereby enabling uniform winding distribution and thus thinning of the winding overhang.

[0014] A first number of adjacent winding layers can be assigned to a first group. A second number of adjacent winding layers can be assigned to a second group. A third number of adjacent winding layers can be assigned to a third group. The first section of the first wire can run in the first circuit region between the third group and the second group. The second section of the first wire can run in the second circuit region between the second group and the first group. Depending on the embodiment of the component, which can also be referred to as a stator type, the winding, which can also be referred to as a winding mat, can have more than one or two circuit regions. The circuit regions can also be referred to as spanning regions.

[0015] The first wire can run outside the first circuit region for one circuit, starting from the first connection pin, until it reaches the first circuit region again, exclusively within the third group. The first wire can then run outside the first circuit region for a second circuit, until it reaches the first circuit region again, exclusively within the second group. The first wire can then run outside the first circuit region for a third circuit, until it reaches the further first connection pin in the first circuit region again, exclusively within the first group. This winding pattern can advantageously achieve electrical and mechanical symmetry of the winding. Furthermore, the winding pattern can enable simple and cost-effective manufacturing.

[0016] A second wire can have a second connection pin and a further second connection pin. In the first circuit region, a first section of a second wire can span the number of slots of the laminated core with the layer jump over exactly one winding layer in the winding direction. In the second circuit region, a second section of the second wire can span the number of slots of the laminated core with the layer jump over exactly one winding layer in the opposite direction to the winding direction.

[0017] The second wire can run outside the second circuit area for one circuit, starting from the second connection pin, until it reaches the second circuit area again, exclusively within the first group. The second wire can then run outside the second circuit area for a second circuit, until it reaches the second circuit area again, exclusively within the second group. The second wire can then run outside the second circuit area for a third circuit, until it reaches the further second connection pin in the second circuit area again, exclusively within the third group.

[0018] The sections of the first wire running between the groups can span the number of slots of the laminated core with layer jumps on one circuit side, while the sections of the second wire running between the groups can span the number of slots of the laminated core with layer jumps on a counter-circuit side. The sections of the first wire and the second wire can be routed parallel to one another within the first circuit region and the second circuit region. Outside the circuit regions, the sections of the first wire and the second wire can be routed crosswise to one another.

[0019] The first connection pin of the first wire can be arranged on the winding layer. The further first connection pin of the first wire can be arranged on a further winding layer. The second connection pin of the second wire can be arranged on the further winding layer. The further second connection pin of the second wire can be arranged on the winding layer.

[0020] The winding layer can correspond to a radially outer winding layer and the further winding layer can correspond to a radially inner winding layer.

[0021] A component for an electrical machine comprises an embodiment of a winding mentioned herein and the annular laminated core with the plurality of slots extending axially through the laminated core for receiving input sections and output sections of wires of at least one winding phase of the winding in a plurality of radially adjacent winding layers.

[0022] The component may have a further winding. The slots may be configured to receive further input and output sections of wires of the further winding into the plurality of radially adjacent winding layers.

[0023] An electric machine has an embodiment of a component mentioned herein. The component is designed as a stator or rotor of the electric machine and includes the winding.

[0024] The electric machine is suitable, for example, for an electric axle drive. Such an electric axle drive for a motor vehicle comprises at least one named electric machine, a transmission device, and a power converter. The power converter can be designed, for example, as an inverter. Using the power converter, an electrical current required to operate the electric machine can be provided. Using the transmission device, a torque provided by the electric machine can be converted into a drive torque for driving at least one wheel of the motor vehicle. The transmission device can have a gearbox for reducing the speed of the electric machine and, optionally, a differential.

[0025] Accordingly, a motor vehicle may comprise a said electric machine and additionally or alternatively a said electric axle drive.

[0026] A method for producing an embodiment of a winding mentioned herein comprises a step of tensioning the first wire, a step of performing a lifting movement, a step of embossing, a step of guiding, and a step of repeating. In the guiding step, the lifting movement is performed to bend the first wire to an opposite side using a bending head. In the embossing step, a layer jump is embossed into the first wire. The embossing step is carried out in parallel with the guiding step. In the guiding step, the first wire is guided to the opposite side using a wire guide. The guiding step is carried out in parallel with the guiding step and the embossing step.In the repetition step, the steps of tensioning, passing, stamping, and guiding are performed repeatedly to create the winding. During winding production, twisting the wire around its axis in the end section, the turning area, can be eliminated. This significantly improves the insulation of the wire. Uneven winding distribution, which can lead to thinning in the winding heads, can be avoided.

[0027] The invention is explained in more detail by way of example with reference to the accompanying drawings. They show:

[0028] Fig. 1 is a partial view of an embodiment of a component; Fig. 2 is a view of a first wire for an embodiment of a winding;

[0029] Fig. 3 is a partial view of an embodiment of a winding;

[0030] Fig. 4 is a schematic partial representation of an embodiment of a winding;

[0031] Fig. 5 is a schematic partial representation of an embodiment of a winding;

[0032] Fig. 6 is a schematic partial representation of an embodiment of a winding;

[0033] Fig. 7 is a tabular representation of a winding diagram for an embodiment of a winding;

[0034] Fig. 8 is a tabular representation of a winding diagram for an embodiment of a winding;

[0035] Fig. 9 is a tabular representation of a winding diagram for an embodiment of a winding;

[0036] Fig. 10 is a representation of a winding diagram for an embodiment of a winding;

[0037] Fig. 11 is a representation of a winding diagram for an embodiment of a winding;

[0038] Fig. 12 is a partial view of windings for an embodiment of a component;

[0039] Fig. 13 is a representation of a winding diagram for an embodiment of a winding;

[0040] Fig. 14 is a representation of a winding diagram for an embodiment of a winding;

[0041] Fig. 15 shows a schematic representation of an embodiment of a method for producing a winding;

[0042] Fig. 16 shows a schematic representation of an embodiment of a method for producing a winding;

[0043] Fig. 17 shows a schematic representation of an embodiment of a method for producing a winding;

[0044] Fig. 18 is a flowchart of an embodiment of a method for producing a winding; Fig. 19 is a schematic representation of an embodiment of a winding; and

[0045] Fig. 20 is a representation of an embodiment of a motor vehicle.

[0046] In the following description of preferred embodiments of the present invention, the same or similar reference numerals are used for the elements shown in the various figures and having a similar effect, whereby a repeated description of these elements is omitted.

[0047] Fig. 1 shows a partial representation of an embodiment of a component 100 of an electrical machine 105 with a winding 110. According to the embodiment shown here, the component 100 has a winding 110, a further winding 120 and an additional winding 130.

[0048] The component 100 is designed merely as an example as a stator and comprises an annular laminated core 115 with a plurality of slots N extending axially through the laminated core 115, of which only a few slots are shown for the sake of clarity and only one is provided with the reference symbol N. The slots N are designed to accommodate input sections and output sections of wires U1, U2, U3, U4, U5, U6 of at least one winding phase of the winding 110 in a plurality of radially adjacent winding layers.

[0049] The stator shown here is designed merely as an example to accommodate the winding 110, to accommodate the total of three windings 110, 120, 130, wherein the winding 110 is assigned to a U-phase, the further winding 120 is assigned to a W-phase, and the additional winding 130 is assigned to a V-phase. In one embodiment, each winding 110, 120, 130 is formed with six wires wound in parallel.

[0050] The wires of winding 110 are designed, merely by way of example, as flat wires for conducting an electrical energy flow. The partial strands are arranged offset from one another, for example, in the circumferential direction of the laminated core 115. The wires can also be referred to as pins, whereby the winding pattern shown here can be referred to as pin over two pins, since one wire spans two other wires.

[0051] A first wire LH, for example, has an input section, an output section, and a partial strand that connects the input section and the output section. The partial strand spans a number of slots N of the laminated core 115 with a layer jump across exactly one winding layer.

[0052] Fig. 2 shows a representation of a first wire LH for one embodiment of a winding. The first wire LH has a first connection pin 200 and another first connection pin 210. An electrical voltage is applied to the wire LH via the connection pins 200, 210.

[0053] The first wire LH has a plurality of sections 205, 215 that can be guided in a loop-like manner through the slots of the laminated core. In a wound state, the sections 205, 215 span the number of slots of the laminated core with the layer jump over exactly one winding layer. The layer jump is described and illustrated in more detail in the following figures.

[0054] Fig. 3 shows a partial representation of an embodiment of a winding 110 for a component. It shows a top view of a wiring side 305 of the winding 110, wherein the winding 110 is similar to or corresponds to the winding in Fig. 1.

[0055] The winding 110 is formed merely by way of example as an endlessly embossed braided winding mat 300 for a stator or a rotor, wherein the winding 110 can also be referred to as a stator winding 310 or rotor winding 310. The winding 110 has a plurality of wires, wherein the winding 110 is described here merely by way of example with reference to the first wire U1 and a second wire U4. The first wire U1 is wound merely by way of example in a first winding direction in a plurality of radially adjacent winding layers L1, L2, L3, L4, L5, L6. The first wire LH, with the layer jump 315a, spans a number of slots over exactly one winding layer in a first circuit region R1, 325. More precisely, a first section of the first wire LH spans the number of slots of the laminated core with the layer jump 315a from the winding layer L6 to the winding layer L5.A second subsection of the first wire LH spans the number of slots of the laminated core with the layer jump 315a from the winding layer L4 to the winding layer L3 and a third subsection spans the number of slots of the laminated core with the layer jump 315a from the winding layer L2 to the winding layer L1.

[0056] The second wire U4 is wound, for example, in a second circuit region R2, 335, opposite to the winding direction. A first section of the second wire U4 spans the number of slots of the laminated core with the layer jump 315b from the winding layer L2 to the winding layer L3. A second section of the second wire U4 spans the number of slots of the laminated core with the layer jump 315b from the winding layer L4 to the winding layer L5.

[0057] The winding 110 described here forms a winding head 320 on the circuit side 305 due to the routing of the wires U1, U4. The first wire U1, for example, is radially rectified with a conductor outer side 330 and a conductor inner side 340.

[0058] In other words, Fig. 3 shows a stepped, braided winding 110 that fits precisely and concentrically in the stator. The entire winding mat 300, with its overrunning, braided, insulated wires U1, U4, is circular, requires less tolerance, is therefore less stressed when expanding in the stator, and offers more space for subsequent components, such as wiring and liners. In the individual slots of the stator, the winding distribution, including the winding overhang 320, is more oriented, more insulation-robust, and more compact. The architecture of the winding 110 in the stator also has positive effects on more effective performance of the electrical machine.

[0059] In other words, Fig. 3 shows an endlessly embossed, braided winding mat 300 for a stator / rotor winding 310, which consists of a plurality of braided wires U1, U4, which can also be referred to as conductors. In the winding overhang 320 on the circuit side 305 there is the first circuit region R1, 325, in which the layer jump 315a occurs in 3D embossing in the first winding direction and the second circuit region R2, 335 with the layer jump 315b in 3D embossing in the second winding direction R2, wherein the layer jump 315b in the second circuit region R2, 335 can also be referred to as an opposite 3D embossed layer jump. The characteristic of the winding mat 300 is that the conductor outer side 330 alternates back and forth from the outside to the inside depending on the layer.

[0060] Fig. 4 shows a schematic partial representation of an embodiment of a winding 110. The winding 110 is similar to the winding from Fig. 1, with the exception that a side view of the winding 110 is shown.

[0061] The winding 110 has the circuit side 305 and a reversing region side 400 opposite the circuit side 305. On the circuit side 305, for example, the layer jumps 315a, 315b occur.

[0062] Fig. 5 shows a schematic partial representation of an embodiment of a winding 110. The winding 110 is similar to the winding from Fig. 4, with the exception that a section of the winding 110 is shown.

[0063] On the circuit side 305, the layer jump 315b is marked. On the turning area side 400, the circuit areas 325, 335 are marked, which can also be referred to as section A and section B. The wires are wound in the circuit areas 325, 335 such that the wires are not intertwined in a region 500. In this region 500, the wires have, for example, a long end section 505, and the layer jumps 315a, 315b are, for example, positive layer jumps. On the circuit side 305, the wires have, for example, a negative imprint 520.

[0064] In other words, the wires from winding layer L1 have an end section 515 which is shaped in the opposite direction when all slot sections 510 of layer 1 or layer 2 are radially filled with winding. Thus, the wires jump radially from winding layer L1 into winding layer L2. Winding layer L2 is only as long as the first circuit region 325, which can also be referred to as section A, then the wires jump radially into winding layer L3 in the second circuit region 335, which can also be referred to as section B. In the second circuit region 335, on the turning region side, the wires have 400 positive layer jumps, and the wires are not interwoven in the winding mat in circuit regions 325, 335.

[0065] Fig. 6 shows a schematic partial representation of an embodiment of a winding 110. The winding 110 is similar to the winding in Fig. 4.

[0066] The wires of winding 110 are, for example, flat wires, stranded wires as flat wires, similar to flat wires, or round wires. The layer jumps are designed in a relative form and are optionally designed with or without a local phase jump 605.

[0067] Either on the switching side or the counter-switching side, the winding 110 has a pin over > 1 pin design 600.

[0068] Fig. 7 shows a tabular representation of a winding pattern 700 for one embodiment of a winding 110 for a component. The winding pattern 700 is shown for the winding 110, another winding 120, and an additional winding 130.

[0069] The winding pattern 700 shown here is exemplified for a component with a laminated core with, for example, 54 slots and a respective number of holes 3 for accommodating, for example, three windings 110, 120, 130. The positions 1 to 54 of the slots along the circumference of the laminated core are indicated in the top four rows of the table, wherein the top row corresponds to an outer backtwist layer 705, the row arranged below it corresponds to the winding 110, the row arranged below it corresponds to the further winding 120 and the row arranged below it corresponds to the additional winding 130. The winding 110 is assigned, for example, to the U phase, the further winding 120, for example, to a W phase and the additional winding 130 is assigned, for example, to the V phase.For example, each winding 110, 120, 130 is formed with a plurality of wires U1, U2, U3, U4, U5, U6, wherein the winding pattern 700 is shown here only as an example using the wires U1, U2, U3, U4, U5, U6 for the winding 110 in the U phase.

[0070] Six rows below the position markings correspond, by way of example, to six winding layers L1, L2, L3, L4, L5, L6 of the windings 1 10, 120, 130. In this case, the first winding layer L1 shown in the topmost of the six rows in the illustration shown here corresponds, by way of example, to a radially outermost winding layer. A second winding layer L2 is arranged adjacent to the first winding layer L1, i.e. in the row directly below it in the table shown here. The third winding layer L3 is arranged adjacent to the second winding layer L2, and the fourth winding layer L4 is arranged adjacent to the third winding layer L3. The fifth winding layer L5 is arranged adjacent to the fourth winding layer L4, and the sixth winding layer L6 is arranged adjacent to the fifth winding layer L5.

[0071] The winding layers L1, L2, L3, L4, L5, L6 are assigned to different groups, with the winding layers L1, L2 being assigned to a first group 710. The winding layers L3, L4 are assigned to a second group 715, and the winding layers L5 and L6 are assigned to a third group 720. According to one exemplary embodiment, the first group 710 corresponds to a radially outer group of the winding 110. The second group 715 corresponds to a radially central group, and the third group 720 corresponds to a radially inner group of the winding 110.

[0072] In the bottom row of the table shown here, inputs and outputs for inserting wires from windings 1 10, 120, 130 into the laminated core and for leading wires from windings 1 10, 120, 130 out of the laminated core are marked purely as examples. The first wire U1 forms the first connection pin 200 and the further first connection pin 210. The first connection pin 200 is arranged, for example, at winding layer L6 and the further first connection pin 210 is arranged at winding layer L1. The first wire U1 is led into the laminated core, for example, with the first connection pin 200 in winding layer L6 and is led out of the laminated core with the further first connection pin 210 in winding layer L1. The first wire U1 is led circumferentially through the laminated core in the first winding direction.

[0073] For this purpose, the first wire U1 has a plurality of input sections, output sections, and subsections, wherein, for example, a subsection connects an input section and an output section. The input sections are designed to be inserted into slots of the laminated core, and output sections are designed to be inserted out of slots of the laminated core. The subsections are designed to span a number of slots of the laminated core.

[0074] The first circuit region R1, 325 is formed between the first connection pin 200 and the further first connection pin 210. In this circuit region R1, 325, a first partial section of the first wire U1 running between the third group 720 and the second group 715 spans a number of slots of the laminated core with the layer jump 315a over exactly one winding layer. By way of example only, the number of slots corresponds to seven slots and the layer jump 315a occurs, for example, from the winding layer L5 to the winding layer L4. Likewise in the first circuit region R1, 325, a second partial section of the first wire U1 running between the second group 715 and the first group 710 spans the number of slots of the laminated core with the layer jump 315a over exactly one winding layer. The layer jump 315a occurs, for example, from the winding layer L3 to the winding layer L2.

[0075] Outside the first circuit region R1, 325, the first wire U1 runs exclusively within the third group 715 for a first circuit, starting from the first connection pin 200 in the first winding direction, until it reaches the first circuit region R1, 325 again. More precisely, the first wire U1 runs alternately in the winding layer L6 and the winding layer L5 within the third group 720. In the first circuit region R1, 325, the previously described layer jump 315a then occurs between the third group 720 and the second group 715.

[0076] For a second circuit, the first wire U1 subsequently runs outside the first circuit region R1, 325 until it reaches the first circuit region R1, 325 again, exclusively within the second group 715. More precisely, the first wire U1 runs alternately in the winding layer L4 and the winding layer L3 within the second group 715. In the first circuit region R1, 325, the previously described layer jump 315a then occurs between the second group 715 and the first group 710.

[0077] For a third circuit, the first wire U1 subsequently runs outside the first circuit region R1, 325 until it reaches the further first connection pin 210 in the first circuit region R1, 325 exclusively within the first group 710. More precisely, the first wire U1 runs alternately in the winding layer L2 and the winding layer L1 within the first group 710.

[0078] The second wire U4 is wound similarly to the first wire U1, with the second wire U4 being wound opposite to the winding direction.

[0079] The second wire U4 forms a second connection pin 730 and a further second connection pin 740. The second connection pin 730 is arranged, for example, at the winding layer L1, and the further second connection pin 740 is arranged at the winding layer L6. The second wire U4 is guided, for example, with the second connection pin 730 in the winding layer L1 into the laminated core and with the further second connection pin 740 in the winding layer L6 out of the laminated core. The second wire U4 is guided circumferentially through the laminated core in the second winding direction R2. The second circuit region R2, 335 is formed between the second connection pin 730 and the further second connection pin 740. In this circuit region R2, 335, a first section of the second wire U4 running between the first group 710 and the second group 715 spans the number of slots of the laminated core with the layer jump 315b over exactly one winding layer.The layer jump 315b occurs, for example, from the winding layer L2 to the winding layer L3. Also in the second circuit region R2, 335, a second section of the second wire U4 extending between the second group 715 and the third group 720 spans the number of slots of the laminated core with the layer jump 315b over exactly one winding layer. The layer jump 315b occurs, for example, from the winding layer L4 to the winding layer L5.

[0080] Outside the second circuit region R2, 335, the second wire U4 runs for a first circuit starting from the second connection pin 730 in the second winding direction R2 until it reaches the second circuit region R2, 335 again, exclusively within the first group 710. More precisely, the second wire U4 runs alternately in the winding layer L1 and the winding layer L2 within the first group 710. In the second circuit region R2, 335, the previously described layer jump 315b then occurs between the first group 710 and the second group 715.

[0081] For a second circuit, the second wire U4 subsequently runs outside the second circuit region R2, 335 until it reaches the second circuit region R2, 335 again, exclusively within the second group 715. More precisely, the second wire U4 runs alternately in the winding layer L3 and the winding layer L4 within the second group 715. In the second circuit region R2, 335, the previously described layer jump 315b then occurs between the second group 715 and the third group 720.

[0082] For a third circuit, the second wire U4 subsequently runs outside the second circuit region R2, 335 until it reaches the further second connection pin 740 in the second circuit region R2, 335 exclusively within the third group 720. More precisely, the second wire U4 runs alternately in the winding layer L5 and the winding layer L6 within the third group 720.

[0083] According to one embodiment, the first wire U1 runs in the first winding direction in the first circuit region R1, 325 on a circuit side and the second wire U4 runs in the second winding direction R2 in the second circuit region R2, 335 on a counter-circuit side.

[0084] Within the circuit regions R1, 325, R2, 335, for example, all sections of the wires U1, U4 are routed parallel to one another. Outside the circuit regions R1, 325, R2, 335, for example, all sections of the first wire U1 in the first winding direction intersect with all sections of the second wire U4 in the second winding direction R2. In other words, the sections within the circuit regions R1, 325, R2, 335 are not intertwined.

[0085] In other words, the winding pattern 700 is provided for a braided winding 110. In the first circuit region R1, 325, the first wire U1 runs in the crown region on the circuit side from + to -. The first wire U1 is not braided in the first circuit region R1, 325. Outside the first circuit region R1, 325, the first wire U1 is wound as a standard winding.

[0086] In the second circuit area R2, 335, the second wire U4 runs in the crown area on the counter-circuit side from + to - and is not intertwined in the second circuit area R2, 335.

[0087] The wires U1, U4 in the circuit areas R1, 325, R2, 335 are not braided, but rather stacked on top of each other with a pin over 2 pin design or another winding design.

[0088] The layer jumps 315a, 315b occur multiple times in the winding 110, for example, once in each of four layers, depending on the number of parallel wires. A design change occurs before the end of the circuit, which depends on the number of wires. The winding pattern 700, for example, enables a winding 110 with a matryoshka doll principle with a wire-saving wire transition or layer transition on the counter-circuit side and the circuit side. With the winding pattern 700, a compact winding head is created in the circuit areas R1, 325, R2, 335, which can also be referred to as interconnection areas, thereby creating space. Furthermore, the concentricity of the winding 110 is improved.

[0089] Marker: what is at the top in the bending block area stays at the top and goes into the screw.

[0090] Fig. 8 shows a tabular representation of a winding pattern 700 for one embodiment of a component winding 110. The winding pattern 700 is similar to the winding pattern shown in Fig. 7, except that the winding pattern 700 is only partially shown for the first group 710 and the second group 715.

[0091] The first wire U1 is guided, for example, in the first winding direction from the winding layer L1 into the winding layer L2 and from the winding layer L2 back into the winding layer L1. This guidance is repeated until the first wire U1, for example in the winding layer L2, reaches the first circuit region R1, 325, which can also be referred to as section B. In the first circuit region R1, 325, the first wire U1 runs between the first group 710 and the second group 715 and, by means of layer jump 315a, spans the number of slots from the winding layer L2 to the winding layer L3. In the second circuit region 335, there is no layer jump of the first wire U1.

[0092] In other words, Fig. 8 shows, by way of example, the winding pattern 700 of the three wires U1, U2, U3, which can also be referred to as winding conductors, in the winding layers L1, L2, L3, L4, which are wound and / or shaped in the winding mat 300 and comprise the following features in the transition from the winding layer L1 to the winding layer L2 and from the winding layer L3 to the winding layer L4: The first wire LH, for example, lies in the winding layer L1 in the groove section 510 and has a positive embossing in the layer jump region in order to reach the winding layer L2 in the second circuit region 335. In the second circuit region 335 on a turning side, the first wire LH has a long end section with a positive embossing, wherein the first wire LH is not intertwined in the winding layer L2 in the second circuit region 335.

[0093] In the subsequent turning area in the first circuit area R1, 325, the first wire LH has a negative imprint and enters the winding layer L3. Following the previous winding pattern 700, the wires follow in a transition area, winding mat 300. The conductor outer side 330 and the conductor inner side 430 alternate from the inside to the outside, depending on the position; this transition 800 is illustrated by arrows.

[0094] Fig. 9 shows a tabular representation of a winding pattern 700 for one embodiment of a winding 110 for a component. The winding pattern 700 is similar to the winding pattern shown in Fig. 8, except that the second circuit region 335 is highlighted.

[0095] According to one exemplary embodiment, the first wire LH runs from the second group 715 into the first group 710. This takes place in the first circuit region R1, 325, which can also be referred to as section B. The first wire U1 therefore runs from the winding layer L3 into the winding layer L2. Starting from the first circuit region R1, 325, the first wire U1 runs into the second circuit region 335, which can also be referred to as section A. The first wire U1 therefore runs from the winding layer L2 into the winding layer L1. The second circuit region 335 is highlighted by dashed lines merely as an example. Within the first group 710, the first wire LH then runs to the further first connection pin, which is not shown here.

[0096] Fig. 10 shows a representation of a winding pattern 700 for an embodiment of a winding 110 for a component. The winding pattern 700 is similar to the winding pattern from Fig. 7. The first wire U1 is inserted into the laminated core with the first connection pin 200 at an entry position 5 of the slots in the third group 720 or in the winding layer L6. At an exit position 16 of the slots in the winding layer L5 in the third group 720, the first wire U1 is led out again in order to be led back in at an entry position 24 in the winding layer L6. This guidance, which can also be referred to as the first circuit, takes place within the third group 720 up to a position 51. Starting from position 51 in the winding layer L5, the layer jump 315a into the winding layer L4 in the entry position 5 takes place.

[0097] Starting from there, the first wire U1 is guided directly into the winding layer L3 and from there runs alternately in the winding layer L4 and the winding layer L3, i.e. the second group 715, which corresponds to a second circuit.

[0098] This guidance takes place within the second group 715 up to a position 51. Starting from position 51 in the winding layer L3, the layer jump 315a takes place into the winding layer L2 in the input position 5.

[0099] From there, the first wire U1 is guided directly into the winding layer L1 and, from there, alternates between the winding layer L2 and the winding layer L1, i.e., the first group 710, which corresponds to a first circuit. In the starting position 51 in the winding layer L1, the first wire U1 is guided out of the laminated core again at the further first connection pin 210.

[0100] Fig. 11 shows a representation of a winding pattern 700 for an embodiment of a winding 110 for a component. The winding pattern 700 is similar to the winding pattern shown in Fig. 10, except that the layer jumps 315a and the first circuit region R1, 325, in which the layer jumps 315a of the first wire U1 occur, are highlighted by dashed lines.

[0101] Fig. 12 shows a partial representation of windings 110, 120, 130 for one exemplary embodiment of a component. Windings 110, 120, 130 are similar to the windings in Fig. 1. Only sections of wires U1, U2, U3 of the first winding 110 are shown as examples. For example, wire U1 spans wires U2, U3, corresponding to a pin-over-two-pin layout. The further winding 120 with wires W1, W2, W3 and the additional winding 130 with wires V1, V2, V3 are wound according to the same principle.

[0102] Fig. 13 shows a representation of a winding pattern 700 for an embodiment of a winding 110 for a component. The winding pattern 700, which can also be referred to as a winding mat, is similar to the winding pattern from one of the figures described above, with the exception that in Fig. 13, the winding pattern 700 is shown as a partially stacked matrix. The region outside the first circuit region 325 is shown stacked, and the layer jumps 325a in the first circuit region 325 are shown spaced apart from one another.

[0103] Fig. 14 shows a representation of a winding pattern 700 for an embodiment of a winding 110 for a component. The winding pattern 700 is similar to the winding pattern shown in Fig. 13, except that in Fig. 14, the winding pattern 700 is shown as a fully stacked matrix.

[0104] Fig. 15 shows a schematic representation of an embodiment of a method 1500 for producing a winding. The winding is similar to the winding from one of the figures described above. More specifically, Fig. 15 shows a beginning of the method 1500.

[0105] For this purpose, the first wire U1 is tensioned in a tensioning device 1502. More precisely, the first wire U1, or a portion of the first wire U1, is tensioned between two tensioning elements 1505, 1510, which corresponds to a step 1530 of tensioning the first wire U1.

[0106] A wire guide 1515 is arranged on another portion of the first wire U1 to guide the first wire U1. A bending head 1520 for bending the first wire LH is arranged between the clamping device 1400 and the wire guide 1515.

[0107] Fig. 16 shows a schematic representation of an embodiment of a method 1500 for manufacturing a winding. The method 1500 corresponds to the method of Fig. 15, with Fig. 16 showing the method 1500 during the winding manufacturing process.

[0108] The first wire U1 is bent to the opposite side by means of the bending head 1520. This is performed with a lifting movement 1600, whereby this process is referred to as step 1630 of performing a lifting movement. The wire guide 1515 also guides the first wire U1 to the opposite side, which is referred to as step 1650 of guiding the first wire U1 to the opposite side. The guiding step 1650 takes place chronologically parallel to the guiding step 1630.

[0109] In parallel to the step 1630 of carrying out and the step 1650 of guiding, the layer jump 315a is embossed into the first wire U1 in a step 1640 of embossing.

[0110] The dashed lines indicate the individual bending and guiding steps. Additionally, the section of the first wire U1 is clamped in a third clamping element 1605.

[0111] In summary, on one switching side of the winding mat, the corresponding wire U1 is tensioned between the tensioning elements 1505, 1510, which can also be referred to as figures. The wire LH is gripped and tensioned by the bending head 1520, and the first wire LH is brought to the opposite side with the lifting movement 1600 and placed in a positioned position. In parallel, the embossing 1640 of the layer jump 315a on the wire LH takes place. In parallel, the wire LH is brought to the opposite side by the wire guide 1515 so that the wire LH does not rotate about its axis. The previously described method is repeated as required by the winding mat. Fig. 17 shows a schematic representation of an embodiment of a method 1500 for producing a winding. The method 1500 corresponds to the method from Fig. 15 and Fig. 16, with Fig. 17 showing the method 1500 after the manufacturing process.

[0112] The bending head 1520 and the wire guide 1515 are arranged in their final position. The steps described in Figures 15 to 16 are repeated in a repetitive step to produce the winding.

[0113] Fig. 18 shows a flowchart of an embodiment of a method 1500 for producing a winding. The winding resembles the winding from one of the figures described above. The method 1500 corresponds, for example, to the method described in Figs. 15 to 17.

[0114] The method 1500 includes step 1530 of tensioning the first wire, step 1630 of performing a lifting movement, step 1640 of coining, step 1650 of guiding, and step 1800 of repeating. In step 1630 of coining, the lifting movement is performed to bend the first wire to an opposite side using a bending head. In step 1640 of coining, a layer jump is coined into the first wire. The coining step 1640 is performed in parallel with step 1630 of coining. In step 1650 of guiding, the first wire is guided to the opposite side using a wire guide. The guiding step 1650 is performed in parallel with step 1630 of coining and step 1640 of coining.In the repeating step 1800, the steps of tensioning 1530, passing 1630, embossing 1640, and guiding 1650 are repeatedly performed to produce the winding.

[0115] Fig. 19 shows a schematic representation of an embodiment of a winding 110. The winding 110 is similar to the winding from one of the figures described above. A top view of the winding 110 is shown. In other words, a wound, stepped braided winding with permanent phase jumps or only local phase jumps in the stator is shown. Each wire layer is radially positioned on a circular ring 1900. The entire winding mat, with its overtaking, braided, insulated wires, can be applied circularly and stress-free to the expansion tool and expanded into the stator. In the individual stator slots, the winding distribution, including the winding overhang, is oriented, insulation-robust, and compact. The architecture of the winding in the stator has positive effects on the effective performance of an electrical machine.

[0116] Fig. 20 shows an illustration of an embodiment of a motor vehicle 2000. The motor vehicle 2000 has an electric axle drive 2010 with an electric machine 105, as described, for example, with reference to the preceding figures. Electrical energy for operating the electric machine 105 is provided by a power supply device 2002, for example, a battery. For example, the power supply device 2002 provides a direct current, which is converted into an alternating current, for example, a three-phase alternating current, using a power converter 2004 of the transmission device and supplied to the electric machine 105.

[0117] A shaft driven by the electric machine 105 is coupled directly or using a transmission device 2006 to at least one wheel 2008 of the motor vehicle 2000. Thus, the motor vehicle 2000 can be propelled using the electric machine 105. According to one embodiment, the electric axle drive 2010 comprises a housing in which the power converter 2004, the electric machine 105, and the transmission device 2006 are arranged in an integrated manner.

[0118] Reference symbol

[0119] Component electrical machine

[0120] winding

[0121] Laminated core additional winding additional winding first connection pin

[0122] Section further first connection pin further section

[0123] Changing mat

[0124] Wiring page

[0125] Stator winding / rotor winding a Layer jump of the first wire b Layer jump of the second wire

[0126] Winding head first circuit area

[0127] Conductor outside second circuit area

[0128] Manager's page

[0129] Turning area side

[0130] Area long end section

[0131] Groove sections

[0132] End section negative embossing 00 Pin over > 1 Pin design 05 local phase shift 00 Winding scheme 05 outer reverse twist layer 10 first group 15 second group 20 third group 30 second connection pin

[0133] 740 additional second connection pin

[0134] 800 Change of the outer layer and inner layer

[0135] 1500 Method for producing a winding

[0136] 1502 clamping device

[0137] 1505 clamping element

[0138] 1510 additional clamping elements

[0139] 1515 Wire Guide

[0140] 1520 bending head

[0141] 1530 Step of tensioning

[0142] 1600 lifting movement

[0143] 1605 third clamping element

[0144] 1640 Step of minting

[0145] 1650 Step of Leading

[0146] 1800 steps of repetition

[0147] 1900 circular ring

[0148] 2000 motor vehicles

[0149] 2002 Energy supply facility

[0150] 2004 Power converter 2006 Gearbox device

[0151] 2008 bike

[0152] 2010 electric axle drive

[0153] L1 first winding layer

[0154] L2 second winding layer

[0155] L3 third winding layer

[0156] L4 fourth winding layer

[0157] L5 fifth winding layer

[0158] L6 sixth winding layer

[0159] N grooves

[0160] R1 first circuit area

[0161] R2 second circuit area

[0162] U1 first wire

[0163] U2 third wire

[0164] U3 fourth wire

[0165] U4 second wire

[0166] U5 fifth wire

[0167] U6 sixth wire

[0168] V1 first wire of the additional winding

[0169] V2 third wire of the additional winding

[0170] V3 fourth wire of the additional winding

[0171] W1 first wire of the further winding

[0172] W2 third wire of the further winding

[0173] W3 fourth wire of the further winding

Claims

Patent claims 1 . Winding (110) for a component (100) of an electrical machine (105), wherein the component (100) comprises an annular laminated core (115) with a plurality of slots (N) extending axially through the laminated core (115) for receiving input sections and output sections of wires (U1, U2, U3, U4, U5, U6) of at least one winding phase of the winding (110) having a winding direction in a plurality of radially adjacently arranged winding layers (L1, L2, L3, L4, L5, L6), wherein a first wire (U1) has a first connection pin (200) and a further first connection pin (210), wherein in a first circuit region (R1, 325), a first partial section of a first wire (U1) has a number of slots of the laminated core (115) with a layer jump (315a) spanned over exactly one winding layer in the winding direction, wherein in a second circuit area (R2,335) a second section of the first wire (U1) spans the number of slots of the laminated core (115) with the layer jump (315a) over exactly one winding layer opposite to the winding direction., 2. Winding according to claim 1, wherein the first wire (U1) is a flat wire with an outer conductor side (330) and an inner conductor side (340), wherein in the first circuit region (R1, 325) the outer conductor side (330) of the input section and the inner conductor side (340) of the output section of the first subsection of the first wire (U1) are each radially rectified, wherein in the second circuit region (R2, 335) the outer conductor side of the input section and the inner conductor side of the output section of the second subsection of the first wire (U1) are each radially rectified.

3. Winding according to one of the preceding claims, wherein a first number of adjacent winding layers (L1, L2) is assigned to a first group (710), wherein a second number of adjacent winding layers (L3, L4) is assigned to a second group (715), wherein a third number of adjacent winding layers (L5, L6) is assigned to a third group (720), wherein the first section of the first wire (U1) runs in the first circuit region (R1, 325) between the third group (720) and the second group (715), wherein the second section of the first wire (U1 ) in the second circuit area (R2, 335) between the second group (715) and the first group (710).

4. Winding (110) according to one of the preceding claims, wherein the first wire (U1) runs outside the first circuit region (325) for one circuit starting from the first connection pin (200) until it reaches the first circuit region (R1, 325) again exclusively within the third group (720), then runs outside the first circuit region (R1, 325) for a second circuit until it reaches the first circuit region (R1, 325) again exclusively within the second group (715), then runs outside the first circuit region (R1, 325) for a third circuit until it reaches the further first connection pin (210) in the first circuit region (R1, 325) again exclusively within the first group (710).

5. Winding (110) according to one of the preceding claims, wherein a second wire (U4) has a second connection pin (730) and a further second connection pin (740), wherein in the first circuit region (R1, 325) a first partial section of a second wire (U4) spans the number of slots of the laminated core (115) with the layer jump (315b) over exactly one winding layer in the winding direction, wherein in the second circuit region (R2, 335) a second partial section of the second wire (U4) spans the number of slots of the laminated core (115) with the layer jump (315b) over exactly one winding layer opposite to the winding direction.

6. Winding (110) according to claim 5, wherein the second wire (U4) runs outside the second circuit region (335) for one circuit starting from the second connection pin (730) until reaching the second circuit region (335) again exclusively within the first group (710), then runs outside the second circuit region (R2, 335) for a second circuit until reaching the second circuit region (R2, 335) again exclusively within the second group (715), then runs outside the second circuit region (R2, 335) for a third circuit until reaching the further second connection pins (740) in the second circuit region (R2, 335) runs exclusively within the third group (720).

7. Winding (1 10) according to one of the preceding claims, wherein the partial sections of the first wire (U1) running between the groups (710, 715, 720) span the number of slots (N) of the laminated core (1 15) with layer jump (315a) on one circuit side, wherein the partial sections of the second wire (U4) running between the groups (710, 715, 720) span the number of slots (N) of the laminated core (1 15) with layer jump (315b) on a counter-circuit side.

8. Winding (1 10) according to one of the preceding claims, wherein the first connection pin (200) of the first wire (U1) is arranged on the winding layer (L6), wherein the further first connection pin (210) of the first wire (U1) is arranged on a further winding layer (L1), wherein the second connection pin (730) of the second wire (U4) is arranged on the further winding layer (L1), wherein the further second connection pin (740) of the second wire (U4) is arranged on the winding layer (L6).

9. Winding (1 10) according to one of the preceding claims, wherein the winding layer (L1) corresponds to a radially outer winding layer and wherein the further winding layer (L6) corresponds to a radially inner winding layer.

10. Component (100) for an electrical machine (105) with a winding (110) according to one of the preceding claims 1 to 8 and with the annular laminated core (115) with the plurality of grooves (N) extending axially through the laminated core (115) for receiving input sections and output sections of wires (U1, U2, U3, U4, U5, U6) of at least one winding phase of the winding (110) in a plurality of radially adjacent winding layers (L1, L2, L3, L4, L5, L6). 1 1. Component (100) according to claim 10, comprising a further winding (120), wherein the grooves (N) are designed to receive further input sections and Output sections of wires of the further winding (120) are formed into the plurality of radially adjacent winding layers (L1, L2, L3, L4, L5, L6).

12. Electrical machine (105) with a component (100) according to one of claims 10 to 11, wherein the component (100) is designed as a stator or as a rotor of the electrical machine (105) and comprises a winding (110) according to one of claims 1 to 9.

13. Electric axle drive (2010) for a motor vehicle (2000) with at least one electric machine (105), a transmission device (2006) and a power converter (2004), characterized in that the electric machine (105) is designed according to claim 12.

14. Motor vehicle (2000) comprising an electric machine (105) according to claim 12 and / or an electric axle drive (2010) according to claim 13.

15. A method (1500) for manufacturing a winding (110) according to any one of claims 1 to 9, wherein the method (1500) comprises the following steps: tensioning (1530) the first wire (U1); Performing (1630) a lifting movement (1600) to bend the first wire (U1) to an opposite side using a bending head (1520); Embossing (1640) a layer jump (315a) in the first wire (U1), parallel in time to the step (1630) of carrying out; guiding (1650) the first wire (U1) to the opposite side, using a wire guide (1515), in parallel time with the step (1630) of passing and the step (1640) of embossing; and Repeating (1800) the steps of tensioning (1530), passing (1630), embossing (1640) and guiding (1650) to produce the winding (110).

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