Stator winding wire and high-voltage-terminal stator winding wire

Abstract

The present invention relates to a stator winding wire (1) for a high-voltage terminal (2), comprising a stator contact point (5) for electric connection to a connecting wire (3) of a stator, and comprising a bus bar contact point (6) for electric connection to a bus bar (4), the stator winding wire (1) being twisted between the stator contact point (5) and the bus bar contact point (6). The present invention also relates to a high-voltage terminal (2) having a bus bar (4) and a stator winding wire (1) of this kind.

Description

[0001] Stator winding wire and high-voltage terminal stator winding wire

[0002] The present disclosure relates to a stator winding wire for a high-voltage terminal. Furthermore, the present disclosure relates to a high-voltage terminal with at least one busbar ( / busbar) and at least one such stator winding wire. The stator winding wire serves to electrically connect a connecting wire of a stator to a busbar, in particular one that is electrically connectable to power electronics of the stator. The stator winding wire has a stator contact point for electrical connection to the connecting wire and a busbar contact point for electrical connection to the busbar.

[0003] Such high-voltage terminals are already known from the prior art. For example, WO 2022 156 842 A1 discloses a high-voltage terminal for a stator, comprising at least three conductor phases for electrically connecting the high-voltage terminal to power electronics, as well as at least one core phase configured as a rail. Each of the at least three conductor phases is formed from at least two parallel rail strands that are connected via at least one spacer element in an electrically insulating manner from one another and radially spaced from one another. The at least three conductor phases and the at least one core phase are stacked one above the other within the high-voltage terminal to form a rail stack, and are arranged, plugged in, and / or embedded in a plastic element via the spacer elements, electrically insulating from one another.

[0004] The problem is that in the area of ​​the high-voltage terminal, particularly due to the installation of electric motors as unsprung masses in the vehicle, high vibration loads occur, which over the service life can lead to failures in the high-voltage contact between the electric motor and the power electronics.

[0005] Against this background, the present disclosure is based on the object of avoiding or at least mitigating the disadvantages of the prior art. In particular, a stator winding wire or a high-voltage terminal is to be provided with which a eigenmode of the vibration oscillations can be influenced, thereby making it robust against vibration loads.

[0006] This problem is solved by a stator winding wire having the features of the independent patent claim and by a high-voltage terminal having the features of the independent patent claim. Advantageous further developments are the subject of the dependent claims.

[0007] Accordingly, the stator winding wire for a high-voltage terminal, which serves to electrically connect a connecting wire of a stator to a busbar, has a stator contact point for the electrical connection to the connecting wire and a busbar contact point for the electrical connection to the busbar, wherein the stator winding wire is twisted between the stator contact point and the busbar contact point. This means that torsion is introduced at one or more points on the stator winding wire. The torsion of the stator winding wire has the effect that the area moment of inertia is varied by the twisting, i.e. is different on both sides of the torsion point due to the cross-sectional orientation, which in turn can have a beneficial effect on the stiffness and thus the vibration behavior. In particular, this can reduce mechanical stresses when vibrations are excited.

[0008] Thus, the object of the present disclosure is achieved in a generic device in that the stator winding wire is twisted or has a torsion point between the stator contact point and the busbar contact point.

[0009] According to a preferred embodiment, the stator winding wire can be twisted in such a way that an areal moment of inertia of the stator winding wire is specifically changed depending on a loading direction of the stator. This has the advantage that the change in the areal moment of inertia, while the loading direction remains constant, changes the stiffness of the stator winding wire and thus the vibration behavior. According to a preferred embodiment, the stator winding wire can have a torsion such that an areal moment of inertia of the stator winding wire in a first region, which lies on one side between the stator contact point and the torsion and is preferably directly adjacent to the torsion, and an areal moment of inertia of the stator winding wire in a second region, which lies on one side between the busbar contact point and the torsion and is preferably directly adjacent to the torsion, are different.This means that torsion results in a different orientation of the cross-section of the stator winding wire. Thus, the area moment of inertia can be adapted to a specific load direction.

[0010] According to the preferred embodiment, the area moment of inertia in the first region can be greater than the area moment of inertia in the second region in a loading direction of the stator winding wire, which corresponds, for example, to a radial direction of the stator. This allows the area moment of inertia to be adapted particularly advantageously to the load.

[0011] According to a preferred embodiment, the stator winding wire can exhibit a 90° torsion between the stator contact point and the busbar contact point. This has the effect that the stator winding wire on one side of the torsion has an orientation rotated by 90° compared to the other side of the torsion. This means that the area moment of inertia of the stator winding wire on one side of the torsion in a first direction corresponds to the area moment of inertia of the stator winding wire on the other side of the torsion in a second direction, which is perpendicular to the first direction. This allows the rigidity to be influenced particularly favorably.

[0012] According to a preferred embodiment, the stator winding wire can have a rectangular cross-section, preferably over its entire longitudinal extent. According to a further development of the preferred embodiment, the rectangular cross-section can have a short side and a long side, wherein the long side in the first region is substantially parallel to the loading direction of the stator winding wire, and the short side in the second region is substantially parallel to the loading direction of the stator winding wire. This achieves a suitable magnitude of the area moment of inertia.

[0013] According to a preferred embodiment, the stator contact point can be formed at a first longitudinal end of the stator winding wire, and the busbar contact point can be formed at a second longitudinal end of the stator winding wire opposite the first longitudinal end. Thus, the spaced-apart components can be connected to one another by the stator winding wire.

[0014] According to a preferred embodiment, the stator winding wire can be twisted substantially centrally between the stator contact point and the busbar contact point. This means that the torsion point is positioned as far away from the contact points as possible. Since the contact points represent weak points with regard to potential component failure, the positioning of the torsion point can be used to generate a vibration node (at the torsion point) and thus relieve stress in the area of ​​the contact points. This can prevent failure in the area of ​​these weak points in the event of vibration excitation.

[0015] According to a preferred embodiment, the stator contact point can be designed to be welded to the connecting wire. This allows a suitable connection to be established between the connecting wire and the stator contact point.

[0016] According to a preferred embodiment, the busbar contact point can be designed to be welded to the busbar. This allows a suitable connection to be established between the busbar and the busbar contact point.

[0017] The object of the present disclosure is also achieved by a high-voltage terminal for a preferably (purely) electrically operated vehicle, which serves to electrically connect power electronics to connecting wires of a stator. The high-voltage terminal has at least one busbar electrically connectable to the power electronics and at least one stator winding wire configured as described. A first (longitudinal) end of the stator winding wire is electrically connectable to a connecting wire of the stator, and a second (longitudinal) end of the stator winding wire is electrically connected to the busbar.

[0018] According to a preferred embodiment, the busbar and the stator winding wire can be welded together. This creates a suitable connection.

[0019] In other words, the present disclosure relates to a variation of the area moment of inertia in busbars of high-voltage terminals of electric motors to reduce mechanical stresses during vibration excitation. The problem here is that electric motors, which are mounted as unsprung masses in the vehicle, are subject to high vibration loads. These vibration loads can lead to failures in the high-voltage contact between the electric motor and the power electronics in the high-voltage terminal over their lifetime. The present disclosure is intended to provide a way to influence the eigenmode of this vibration and thus make it robust against vibration loads.In particular, this is achieved by introducing torsion at one or more points in a high-voltage terminal consisting of rectangular busbars or winding wires, in order to specifically change the area moment of inertia depending on the load direction. By changing the area moment of inertia, the stiffness of the busbars and thus the vibration behavior changes while the load direction remains the same. The positioning of this change in stiffness can be used to create a vibration node in order to relieve stress in the area of ​​weak points (weld seams, etc.). This can prevent failure due to vibration excitation in the area of ​​these weak points. The figures show a high-voltage terminal consisting of busbars / busbars, which are encapsulated in a plastic body, and winding wires.The winding wires are welded to the busbars on one side and to the stator connecting wires on the other. The winding wires exhibit a 90° torsion, which changes the geometric moment of inertia at this point. When the terminal is excited by an externally induced vibration, the winding wires vibrate, creating mechanical stresses that can lead to fractures at the weld seams. The torsion introduced along the winding wire allows the vibration node to be shifted in a targeted manner, thereby reducing the stresses in the weld seams. This increases the terminal's resistance to vibrations.

[0020] The disclosure is explained below with the help of drawings:

[0021] Fig. 1 shows a perspective view of a stator winding wire according to the present disclosure,

[0022] Fig. 2 shows a section of a side view of a high-voltage terminal according to the present disclosure,

[0023] Fig. 3 shows an enlarged section of Fig. 2, and

[0024] Fig. 4 shows a schematic representation of a core idea of ​​the present disclosure.

[0025] Fig. 1 shows a perspective view of a stator winding wire 1 according to the present disclosure. The stator winding wire 1 is a component of a high-voltage terminal 2 (see Fig. 2). The stator winding wire 1 serves to electrically connect a connecting wire 3 of a stator to a busbar 4 (a busbar).

[0026] The stator winding wire 1 has a stator contact point 5 for electrical connection to the connecting wire 3. Preferably, the stator contact point 5 can be formed at a first longitudinal end of the stator winding wire 1. Preferably, the stator contact point 5, in particular a side surface of the stator winding wire 1, can be designed to be welded to the connecting wire 3.

[0027] The stator winding wire 1 has a busbar contact point 6 for electrical connection to the busbar 4. Preferably, the busbar contact point 6 can be formed at a second longitudinal end of the stator winding wire 1. The second longitudinal end is opposite the first longitudinal end. Preferably, the busbar contact point 5, in particular a side surface of the stator winding wire 1, can be designed to be welded to the busbar 4.

[0028] According to the present disclosure, the stator winding wire 1 is twisted between the stator contact point 5 and the busbar contact point 6, ie, has a torsion point / a torsion 7. Preferably, the stator winding wire 1 can be twisted / twisted or have the torsion 7 substantially centrally between the stator contact point 5 and the busbar contact point 6.

[0029] In particular, the stator winding wire 1 is twisted in such a way that an area moment of inertia of the stator winding wire 1 is specifically changed depending on a loading direction of the stator.

[0030] Preferably, the stator winding wire 1 can have a torsion 7 such that an areal moment of inertia of the stator winding wire 1 in a first region 8, which lies on one side between the stator contact point 5 and the torsion 7, and an areal moment of inertia of the stator winding wire 1 in a second region 9, which lies on one side between the busbar contact point 6 and the torsion 7, are different. In particular, the areal moment of inertia in the first region 8, in a loading direction of the stator winding wire 1, can be greater than the areal moment of inertia in the second region 9 (see Fig. 4).

[0031] In the embodiment illustrated in the figures, the stator winding wire 1 has a torsion 7 of 90° between the stator contact point 5 and the busbar contact point 6. This means that the first region 8 (relative to a reference surface) is offset by a quarter turn relative to the second region 9 (relative to the reference surface).

[0032] Preferably, the stator winding wire 1 can have a rectangular cross-section. In particular, the stator winding wire 1 can have a substantially constant cross-section or a constant cross-sectional shape over its entire longitudinal extent. The rectangular cross-section can have a short side and a long side, wherein the long side in the first region 8 is oriented substantially parallel to the loading direction of the stator winding wire 1, and the short side in the second region 9 is oriented substantially parallel to the loading direction of the stator winding wire 1.

[0033] Fig. 2 shows a high-voltage terminal 2 for a (purely) electrically operated vehicle. Fig. 3 shows an enlarged view of a section from Fig. 2. The high-voltage terminal 2 serves to electrically connect power electronics to the connecting wires 3 of the stator. The high-voltage terminal 2 has at least one busbar 4 which can be electrically connected to the power electronics and is designed like the busbar 4 described, and at least one stator winding wire 1 which is designed like the stator winding wire 1 described. A first end of the stator winding wire 1 is electrically connectable or connected, in particular weldable or welded, to the connecting wire 3 of the stator, and a second end of the stator winding wire 1 is electrically connected, in particular welded, to the busbar 4. In addition, the high-voltage terminal 2 can have a plastic overmolding 10 which surrounds the busbar 4.

[0034] Fig. 4 shows schematically how the torsion 7 acts on the area moment of inertia of the stator winding wire 1. In the second region 9, a loading direction B essentially corresponds to an extension direction of a short side K. In the first region 8, the loading direction B essentially corresponds to an extension direction of a long side L. Thus, in the second region 9, a small area moment of inertia (or smaller compared to the first region 8) acts against the load or loading direction B. Thus, in the first region 8, a large area moment of inertia (or larger compared to the second region 9) acts against the load or loading direction B.

[0035] List of reference symbols

[0036] 1 stator winding wire

[0037] High-voltage terminal

[0038] connecting wire

[0039] Busbar

[0040] 5 Stator contact point

[0041] Busbar contact point

[0042] 7 T orsion / T orsion point

[0043] 8 first area

[0044] 9 second area

[0045] 10 Plastic overmolding

[0046] B Load direction

[0047] K short side

[0048] L long side

Claims

Patent claims 1. Stator winding wire (1) for a high-voltage terminal (2), for electrically connecting a connecting wire (3) of a stator to a busbar (4), with a stator contact point (5) for electrically connecting to the connecting wire (3) and a busbar contact point (6) for electrically connecting to the busbar (4), characterized in that the stator winding wire (1) is twisted between the stator contact point (5) and the busbar contact point (6).

2. Stator winding wire (1) according to claim 1, characterized in that the stator winding wire (1) is twisted in such a way that an area moment of inertia of the stator winding wire (1) is specifically changed depending on a loading direction of the stator.

3. Stator winding wire (1) according to claim 1 or 2, characterized in that the stator winding wire has a torsion (7) such that an area moment of inertia of the stator winding wire (1) in a first region (8), which lies on one side between the stator contact point (5) and the torsion (7), and an area moment of inertia of the stator winding wire (1) in a second region (9), which lies on one side between the busbar contact point (6) and the torsion (7), are different.

4. Stator winding wire (1) according to claim 3, characterized in that the area moment of inertia in the first region (8), in a loading direction of the stator winding wire (1), is greater than the area moment of inertia in the second region (9).

5. Stator winding wire (1) according to one of claims 1 to 4, characterized in that the stator winding wire (1) has a torsion (7) of 90° between the stator contact point (5) and the busbar contact point (6).

6. Stator winding wire (1) according to one of claims 3 to 5, characterized in that the stator winding wire (1) has a rectangular cross-section, wherein the rectangular cross-section has a short side and a long side, wherein the long side in the first region (8) is substantially parallel to the loading direction of the stator winding wire (1) and the short side in the second region (9) is substantially parallel to the loading direction of the stator winding wire (1).

7. Stator winding wire (1) according to one of claims 1 to 6, characterized in that the stator contact point (5) is formed at a first longitudinal end of the stator winding wire (1), the busbar contact point (6) is formed at a second longitudinal end of the stator winding wire (1) opposite the first longitudinal end, and the stator winding wire (1) is twisted substantially centrally between the stator contact point (5) and the busbar contact point (6).

8. Stator winding wire (1) according to one of claims 1 to 7, characterized in that the stator contact point (5) is designed to be welded to the connecting wire (3), and / or that the busbar contact point (6) is designed to be welded to the busbar (4).

9. High-voltage terminal (2) for an electrically operated vehicle, for electrically connecting power electronics to connecting wires (3) of a stator, with at least one busbar (4) electrically connectable to the power electronics and at least one stator winding wire (1) according to one of claims 1 to 8, wherein a first end of the stator winding wire (1) is electrically connectable to a connecting wire (3) of the stator and a second end of the stator winding wire (1) is electrically connected to the busbar (4).

10. High-voltage terminal (2) according to claim 9, characterized in that the busbar (4) and the stator winding wire (1) are welded together.

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