Stator comprising a temperature sensor for measuring the temperature of a winding in an electric drive machine of a motor vehicle, electric drive machine having a stator, and motor vehicle

Abstract

The invention relates to a stator (10) for an electric drive machine (100) of a motor vehicle (K), comprising: a stator main body (20); at least one winding assembly (30), which has, at least in regions, single pins (32, 34) that are arranged in respective grooves of the stator main body (20) and that have, at least in pairs, conductively interconnected single-pin connection regions (42, 44); and at least one temperature sensor (90), which is at least indirectly and thermally conductively connected to the winding assembly (30). The stator (10) comprises at least two special pins (62, 64), which are interconnected and form a special-pin holding region (70), which protrudes over at least the majority of the single-pin connection regions (42, 44) and on which the at least one temperature sensor (90) is arranged. Further aspects of the invention relate to an electric drive machine (100) having a stator and to a motor vehicle (K) having an electric drive machine (100).

Description

[0001] Stator with a temperature sensor for detecting the winding temperature in an electric drive motor of a motor vehicle, electric drive motor with a stator and motor vehicle

[0002] The invention relates to a stator for an electric drive motor of a motor vehicle, comprising a stator base body, at least one winding arrangement comprising individual pins arranged at least partially in respective slots of the stator base body, which individual pins have individual pin connection areas that are electrically conductively connected to one another at least in pairs, and at least one temperature sensor that is at least indirectly and thermally conductively connected to the winding arrangement. Further aspects of the invention relate to an electric drive motor with a stator and to a motor vehicle.

[0003] In the stators of electric drive machines, it may be necessary to implement a temperature sensor for detecting the current temperature of current-carrying conductor sections on the stator. These conductor sections can, for example, be individual winding regions of endless wave windings. For this purpose, a stator for an electric machine, in particular for a drive machine designed as a drive machine for an electrically driven motor vehicle, is known from WO 2022 / 002295 A1, for example. The stator comprises a stator body with a plurality of stator windings and a temperature sensor for detecting the temperature of at least one section of a stator winding. The temperature sensor, together with a conductor section, is arranged in a trough-shaped receptacle of an add-on part and is fixed in the receptacle by means of a potting compound.The conductor section is designed in thermally conductive contact with the temperature sensor as a component of the stator winding or as a section thermally conductively connected to the stator winding.

[0004] The object of the present invention is to provide a stator, an electric drive machine and a motor vehicle of the type mentioned at the outset, in which improved maintenance is possible.

[0005] This object is achieved by a stator having the features of patent claim 1, by an electric drive motor having the features of patent claim 8, and by a motor vehicle having the features of patent claim 9. Advantageous embodiments with expedient further developments of the invention are specified in the subclaims.

[0006] A first aspect of the invention relates to a stator for an electric drive motor of a motor vehicle, comprising a stator base body, at least one winding arrangement comprising individual pins arranged at least partially in respective slots of the stator base body, which individual pins have individual pin connection regions that are electrically conductively connected to one another at least in pairs, and at least one temperature sensor that is at least indirectly and thermally conductively connected to the winding arrangement. The winding arrangement can also be referred to as a hairpin winding or hairpin wave winding and can be designed as such. The individual winding regions can be arranged at least partially in respective slots of the stator base body.

[0007] According to the invention, it is provided that the stator has at least two special pins which are connected to one another and form a special pin holding region which projects beyond at least a large part of the individual pin connection regions and on which the at least one temperature sensor is arranged.

[0008] This is advantageous because the arrangement of the temperature sensor on the special pin holding area, which protrudes from the majority of the individual pin connection areas, provides improved accessibility to the temperature sensor during any maintenance of the electric drive motor or stator. In other words, by arranging the temperature sensor on the special pin holding area, which protrudes from the majority of the individual pin connection areas, it can be replaced with particularly little effort and, for example, with a low risk of a tool colliding with the individual pin connection areas.A further advantage is that the temperature sensor, due to its arrangement on the special pin holding area, enables at least a qualitative measurement of the temperature of a particularly hot spot during operation of the electric drive machine, or at least allows conclusions to be drawn about the course of this temperature or an average temperature value of a winding temperature of the winding arrangement. A further advantage is that the special pin holding area represents an interface, i.e. a fastening point, also called a measuring interface, for the temperature sensor on the winding arrangement, which can be provided without significant disruption to a stator manufacturing process. The temperature sensor is preferably arranged in an insulation-free, i.e., stripped, zone of the special pin holding area.The temperature sensor can, for example, be plugged onto the special pin holding area or fixed to the special pin holding area by a so-called clip connection, thereby creating a reversible and thus non-destructively removable fixation of the temperature sensor to the special pin holding area. The special pin holding area forms a measuring interface, i.e., a connection point for fixing the temperature sensor, which makes it possible to hold the temperature sensor securely in an exposed and easily accessible location for maintenance, so that the temperature sensor can be easily replaced in the event of a fault. This prevents any damage to the insulation of the individual pins and thus the winding arrangement during maintenance work, as well as any undesirable deformation of the individual pins beyond a process-safe level.

[0009] The invention is based on the finding that, in the case of stators of electric drive motors, it may be necessary to implement a temperature sensor for detecting the current temperature on a conductor, such as a single pin. It has proven particularly advantageous if the temperature sensor is mounted as close as possible to a so-called hotspot of the electric drive motor, but in any case in a sub-region or component region that qualitatively exhibits the temperature profile of the hotspot or an average value of a winding temperature occurring in the winding arrangement, or at least exhibits a temperature profile proportional to the temperature profile of the hotspot or the average value.

[0010] The arrangement of the temperature sensor proposed according to the present invention, for example in applications with a winding arrangement designed as a hairpin winding, enables a corresponding temperature measurement at a location freed from the insulation material, so that no stripping and thus damage to the insulation of individual pins on the winding arrangement is necessary for temperature determination.

[0011] In an advantageous development of the invention, the special pin holding region projects beyond the majority of the individual pin connection regions in the axial direction of the stator and / or in the radial direction of the stator. This is advantageous because it provides improved accessibility to the special pin holding region and thus also to the at least one temperature sensor for maintenance work. The special pin holding region can project from the majority of the individual pin connection regions in the axial direction of extension and thus parallel to a rotational axis of a rotor of the electric machine and parallel to a longitudinal axis of the rotor and the stator of the electric machine.Alternatively, the special pin holding area can protrude from the majority of the individual pin connection areas in the radial direction of extension, thus perpendicular to the rotational axis of the rotor of the electric machine, as well as perpendicular to the longitudinal axis of the rotor and the stator of the electric machine. Furthermore, the special pin holding area can protrude diagonally from the majority of the individual pin connection areas, thus both in the axial direction of extension and in the radial direction of extension.

[0012] In a further advantageous development of the invention, the special pin holding region projects beyond an intermediate plane region in the axial direction of extension, wherein the intermediate plane region is delimited by two planes in the axial direction that are parallel to one another and oriented perpendicular to the axial direction of extension, and at least the majority of the individual pin connecting regions is arranged in the intermediate plane region, wherein a first plane of the two parallel planes is tangent to an end face of the stator base body facing the special pin holding region, and a second plane of the two parallel planes is tangent to the majority of the individual pin connecting regions or is at a distance from the majority of the respective individual pin connecting regions that corresponds at most to an average winding diameter of a line element assigned to the winding arrangement.This is advantageous because it allows maintenance of the temperature sensor and, if necessary, its replacement without the risk of a tool used for maintenance or replacement colliding with the individual pin connection areas. The winding diameter can be the total diameter of a conductive element assigned to the winding arrangement, i.e., the total diameter of the conductive core of the conductive element including the insulation surrounding this core. The conductive element can be designed as one of the individual pins.

[0013] In a further advantageous development of the invention, the special pin holding area projects beyond the stator base body in the radial direction of extension of the stator. This is advantageous because the special pin holding area is thus particularly easily accessible and the temperature sensor can thus be subjected to particularly low-effort maintenance. The special pin holding area can project outwards or inwards beyond the stator base body in the radial direction of extension. If the special pin holding area projects inwards beyond the stator base body in the radial direction of extension, the special pin holding area can overlap with a stator base body interior in the axial direction of extension. In other words, when viewing the stator along the axial direction of extension, the holding area can overlap the stator base body interior, in which a rotor and a rotor shaft of the electric drive machine can be arranged.

[0014] In a further advantageous development of the invention, the stator has busbar connecting pins, which are designed for a current-conducting connection to a busbar of the stator and are spaced apart from the special pin holding area. Due to the spacing of the busbar connecting pins from the special pin holding area, the busbar does not hinder any maintenance work on the temperature sensor. The busbar connecting pins, like the special pin holding area, can advantageously protrude from the majority of the individual pin connection areas. The stator busbar can also be referred to and / or designed as a busbar, a phase connection bar, or a star point bar.

[0015] In a further advantageous embodiment of the invention, the at least two special pins are connected to one another by a material bond. This particularly durable material bond can preferably be a welded joint, which can ensure particularly uninterrupted heat conduction.

[0016] In a further advantageous development of the invention, the temperature sensor is arranged at a special pin holding area tip of the special pin holding area, which corresponds to a holding area section of the special pin holding area furthest away from the majority of the individual pin connection areas. As a result, the temperature sensor has a particularly large distance from the majority of the individual pin connection areas, which facilitates any maintenance work, while still allowing a particularly meaningful temperature measurement to be performed at the special pin holding area tip.

[0017] A second aspect of the invention relates to an electric drive machine having at least one stator according to the first aspect of the invention. In this electric drive machine, both temperature measurement and maintenance of the temperature sensor can be performed in an improved manner.

[0018] A third aspect of the invention is a motor vehicle with at least one electric drive motor according to the second aspect of the invention. Improved temperature monitoring and maintenance can be performed on the electric drive motor of the motor vehicle. The preferred embodiments presented with respect to one of the aspects and their advantages apply accordingly to the other aspects of the invention, and vice versa.

[0019] 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 alone in the figures can be used not only in the respective combination specified, but also in other combinations or on their own, without departing from the scope of the invention.

[0020] Further advantages, features and details of the invention emerge from the claims, the following description of preferred embodiments and from the drawings.

[0021] The invention is explained once again below using a specific embodiment. This shows:

[0022] Fig. 1 is a schematic perspective view of a partial region of a stator, with a stator base body, with a winding arrangement which comprises individual pins arranged at least in regions in respective slots of the stator base body, which individual pins have individual pin connection regions which are electrically connected to one another at least in pairs, and with special pins which are connected to one another and form a special pin holding region provided for holding a temperature sensor, which special pin holding region projects beyond at least a large part of the individual pin connection regions;

[0023] Fig. 2 is an abstract representation of a motor vehicle and an electric drive machine which comprises the stator, wherein a temperature sensor is arranged on the special pin holding area.

[0024] Fig. 1 shows a partial region of a stator 10 for an electric drive machine 100, shown abstractly in Fig. 2. The electric drive machine 100 serves as a traction machine of a motor vehicle K, also shown abstractly in Fig. 2.

[0025] The stator 10 has a stator base body 20 and a winding arrangement 30, which in this case is designed as a so-called hairpin winding. The winding arrangement 30 comprises individual pins 32, 34 arranged at least in regions in respective slots of the stator base body 20, which have individual pin connection regions 42, 44 that are electrically conductively connected to one another at least in pairs. Furthermore, the stator 10 has a temperature sensor 90, which is at least indirectly and thermally conductively connected to the winding arrangement 30. The winding arrangement 30 can extend in the circumferential direction U of the stator 10 along the stator base body 20.

[0026] The stator 10 has a plurality of special pins 62, 64, each integrally connected to one another, which form a special pin holding region 70 that projects beyond at least a majority of the individual pin connection regions 42, 44 and on which the at least one temperature sensor 90 is arranged. The temperature sensor 90 is arranged at a special pin holding region tip 72 of the special pin holding region 70 and is reversibly and releasably fixed. The special pin holding region tip 72 corresponds to a holding region section of the special pin holding region 70 that is furthest away from the majority of the individual pin connection regions 42, 44 in the axial direction of extension A of the stator 10 and / or in the radial direction of extension R of the stator 10.

[0027] The special feature of the winding arrangement 30 is that it comprises a plurality of individual, bent wires which, prior to joining, take the form of hairpins. These hairpins are interlaced or twisted with one another after being joined in the respective slots, also called stator slots, and then welded together, particularly in pairs. The welded hairpins represent conductor pairs, which form, for example, the individual pin connection regions 42, 44 and also the special pin holding regions 70, the latter being formed by the special pins 62, 64, which are cut to a greater axial height than the individual pins 32, 34.

[0028] The special pin holding region 70 can project beyond the majority of the individual pin connection regions 42, 44 generally in the axial extension direction A of the stator 10, as shown in Fig. 1 and Fig. 2. Additionally or alternatively, the special pin holding region 70 can project beyond the majority of the individual pin connection regions 42, 44 generally in the radial extension direction R of the stator 10, which is not further shown here. The special pin holding region 70 can also project beyond the stator base body 20 in the radial extension direction R of the stator 10. The special pin holding region 70 projects beyond an intermediate plane region EZB shown in Fig. 1 in the axial extension direction A. The intermediate plane region EZB is delimited in the axial extension direction A by two planes E1, E2 that are parallel to one another and oriented perpendicular to the axial extension direction A. At least the majority of the single-pin connection regions 42, 44 are arranged in the intermediate level region EZB.A first plane E1 of the two parallel planes E1, E2 is tangent to an end face 22 of the stator base body 20 facing the special pin holding region 70. A second plane E2 of the two parallel planes E1, E2 is tangent to the majority of the individual pin connection regions 42, 44 or has a distance A1 from the majority of the respective individual pin connection regions 42, 44, which corresponds at most to an average winding diameter D_W of a conducting element 31 assigned to the winding arrangement 30. The conducting element 31 can correspond to one of the individual pins 32, 34 of the winding arrangement 30.

[0029] The stator also has respective busbar connecting pins 56, 58, which are designed for electrically conductive connection with busbars of the stator 10 (not shown here), which extend, for example, in the circumferential direction U, and are spaced apart from the special pin holding region 70. Just like the special pins 62, 64, the busbar connecting pins 56, 58 can also project beyond the majority of the individual pin connecting regions 42, 44 in the axial direction A and additionally or alternatively in the radial direction R.

[0030] In summary, the present invention enables a measurement tap in a measurement plane axially offset relative to the individual pins 32, 34 above the intermediate plane region EZB. The measurement tap for the temperature sensor 90 can be made without damaging the insulation material in the remaining part of the winding arrangement 30 or without having to interrupt the winding arrangement 30 or weaken it with an additional weld to implement another measurement tap.

[0031] List of reference symbols

[0032] 10 Stator

[0033] 20 stator base body

[0034] 22 front side

[0035] 30 Winding arrangement

[0036] 31 Line element

[0037] 32 single pin

[0038] 34 single pin

[0039] 42 single-pin connection area

[0040] 44 single-pin connection area

[0041] 56 Busbar connection pin

[0042] 58 Busbar connection pin

[0043] 62 special pin

[0044] 64 special pin

[0045] 70 special pin holding area

[0046] 72 special pin holding area tip

[0047] 90 Temperature sensor

[0048] 100 electric drive motors

[0049] A Axial extension direction

[0050] A1 distance

[0051] D_W winding diameter

[0052] ECB intermediate level area

[0053] E1 first level

[0054] E2 second level

[0055] R radial extension direction

[0056] K Motor vehicle

[0057] U circumferential direction

Claims

Claims 1. Stator (10) for an electric drive machine (100) of a motor vehicle (K), with a stator base body (20), with at least one winding arrangement (30) which comprises individual pins (32, 34) arranged at least in regions in respective slots of the stator base body (20), which individual pins have individual pin connection regions (42, 44) which are electrically conductively connected to one another at least in pairs, and with at least one temperature sensor (90) which is connected at least indirectly and thermally conductively to the winding arrangement (30), characterized in that the stator (10) has at least two special pins (62, 64) which are connected to one another and form a special pin holding region (70) which projects beyond at least a large part of the individual pin connection regions (42, 44) and on which the at least one temperature sensor (90) is arranged.

2. Stator (10) according to claim 1, characterized in that the special pin holding region (70) projects beyond the majority of the individual pin connecting regions (42, 44) in the axial extension direction (A) of the stator (10) and / or in the radial extension direction (R) of the stator (10).

3. Stator (10) according to claim 2, characterized in that the special pin holding region (70) projects beyond a plane intermediate region (EZB) in the axial extension direction (A), wherein the plane intermediate region (EZB) is delimited by two planes (E1, E2) which are parallel to one another and oriented perpendicular to the axial extension direction (A) in the axial extension direction (A), and at least the majority of the individual pin connecting regions (42, 44) are arranged in the plane intermediate region (EZB), wherein a first plane (E1) of the two parallel planes (E1, E2) is tangent to an end face (22) of the stator base body (20) facing the special pin holding region (70), and a second plane (E2) of the two parallel planes (E1, E2) is tangent to the majority of the individual pin connecting regions (42, 44) or is at a distance (A1) from the majority of the respective single-pin connection areas (42, 44), which corresponds to a maximum of an average Winding diameter (D_W) of a line element (31) assigned to the winding arrangement (30).

4. Stator (10) according to one of the preceding claims, characterized in that the special pin holding region (70) projects beyond the stator base body (20) in the radial extension direction (R) of the stator (10).

5. Stator (10) according to one of the preceding claims, characterized in that the stator has busbar connecting pins (56, 58) which are designed for current-conducting connection to a busbar of the stator (10) and are spaced from the special pin holding area (70).

6. Stator (10) according to one of the preceding claims, characterized in that the at least two special pins (62, 64) are integrally connected to one another.

7. Stator (10) according to one of the preceding claims, characterized in that the temperature sensor (90) is arranged at a special pin holding area tip (72) of the special pin holding area (70), which corresponds to a holding area section of the special pin holding area (70) furthest away from the majority of the individual pin connection areas (42, 44).

8. Electric drive machine (100) with at least one stator (10) according to one of claims 1 to 7.

9. Motor vehicle (K) with at least one electric drive machine (100) according to claim 8.

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