Stator having a temperature sensor for 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), having: a stator main body (20); at least one winding arrangement (30) which has a plurality of individual winding regions (32, 34) arranged in respective slots of the stator main body (20); at least one busbar (60) which is electrically conductively connected to at least one individual winding region end (36) of at least one of the individual winding regions (32, 34); and at least one temperature sensor (90) which is at least indirectly and thermally conductively connected to the at least one busbar (60). The at least one busbar (60) and the at least one individual winding region end (36) are interconnected by means of a connecting region (40). The busbar (60) has a holding region (70) on which the at least one temperature sensor (90) is arranged and which projects from a winding head (50) of the winding arrangement (30), said winding head comprising individual winding region bends (42, 44) of each of the individual winding regions (32, 34). Further aspects of the invention relate to an electric drive machine (100) having at least one stator (10), and to a motor vehicle (K) having at least one electric drive machine (100).

Description

[0001] Stator with a temperature sensor for 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 having a plurality of individual winding regions arranged in respective slots of the stator base body, at least one busbar electrically connected to at least one individual winding region end of at least one of the individual winding regions, and at least one temperature sensor at least indirectly and thermally conductively connected to the at least one busbar. Further aspects of the invention relate to an electric drive motor having a stator and to a motor vehicle. The winding arrangement can generally also be designed as an endless winding or endless wave winding and be referred to as such.Alternatively, the winding arrangement may generally be designed as a hairpin winding and referred to as such.

[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 motor, and a motor vehicle of the type mentioned above, which allow for improved maintenance. 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 10, and by a motor vehicle having the features of patent claim 11. Advantageous embodiments with expedient further developments of the invention are specified in the subclaims.

[0005] 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 having a plurality of individual winding regions arranged in respective slots of the stator base body, at least one busbar electrically connected to at least one individual winding region end of at least one of the individual winding regions, and at least one temperature sensor at least indirectly and thermally conductively connected to the at least one busbar. The winding arrangement can also be referred to as an endless winding and designed as such. Alternatively, the winding arrangement can also be referred to as a hairpin winding and designed as such. The individual winding regions can be arranged, at least in regions, in respective slots of the stator base body.

[0006] According to the invention, it is provided that the at least one busbar and the at least one individual winding region end are connected to one another via a connecting region, and the busbar has a holding region on which the at least one temperature sensor is arranged and which projects from a winding head of the winding arrangement comprising respective individual winding region bends of the individual winding regions.

[0007] This is advantageous because the arrangement of the temperature sensor on the holding area protruding from the winding overhang 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 holding area protruding from the winding overhang, it can be replaced with particularly little effort and, for example, with little risk of a tool colliding with the winding overhang. A further advantage is that by arranging the temperature sensor on the holding area, it enables at least a qualitative measurement of the temperature of a particularly hot spot during operation of the electric drive motor, also known as a "hotspot," 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 individual winding areas.A further advantage is that the holding area represents an interface, i.e., a fastening point, also called a measuring interface, for the temperature sensor on the winding head, which can be provided without significant disruption to the stator manufacturing process. The temperature sensor is preferably arranged in an insulation-free, i.e., stripped, zone of the holding area. The temperature sensor can, for example, be plugged onto the holding area or fixed to the holding area by a so-called clip connection, thereby creating a reversible and thus non-destructively removable fixation of the temperature sensor to the holding area.The holding area forms a measuring interface, i.e., a connection point for securing the temperature sensor. This allows the temperature sensor to be held securely in an exposed location that is easily accessible for maintenance, allowing the temperature sensor to be easily replaced in the event of a fault. This prevents any damage to the insulation of the individual winding areas and thus the winding head, not least during maintenance work, as well as any undesirable deformation of the individual winding areas beyond a process-safe level. The busbar can also be referred to and / or designed as a busbar, a phase connection bar, or a star-point bar.In contrast to the connection area, via which the at least one busbar is electrically connected to the at least one end of the individual winding area, the holding area can be designed exclusively to hold the at least one temperature sensor. In other words, it can be provided that no current is conducted via the holding area.

[0008] The invention is based on the finding that in stators of electric drive machines it may be necessary to implement a temperature sensor for detecting the current temperature on a conductor, such as the busbar, or on the stator. It has proven particularly advantageous if the temperature sensor is attached as close as possible to a so-called hotspot of the electric drive machine, but in any case to a partial area or component area that qualitatively has the temperature profile of the hotspot or an average value of a winding temperature occurring at the winding overhang or on the entire winding arrangement, in particular an endless wave winding or endless winding, or at least has a temperature profile proportional to the temperature profile of the hotspot or the average value.The arrangement of the temperature sensor proposed according to the present invention, for example in applications with endless wave winding, enables a corresponding temperature measurement at a location free of insulation material, so that no stripping and thus damage to the insulation of the individual winding areas, for example at the winding head, is necessary for temperature determination.

[0009] In an advantageous development of the invention, the holding region protrudes in the axial extension direction and / or in the radial extension direction of the stator from at least a majority of the individual winding region bends. This is advantageous because it provides improved accessibility to the holding region and thus also to the at least one temperature sensor for maintenance work. The holding region can protrude in the axial extension direction and thus parallel to a rotational axis of a rotor of the electrical machine and parallel to a longitudinal axis of the rotor and the stator of the electrical machine from the majority of the individual winding region bends. Alternatively, the holding region can protrude in the radial extension direction and thus perpendicular to the rotational axis of the rotor of the electrical machine and perpendicular to the longitudinal axis of the rotor and the stator of the electrical machine from the majority of the individual winding region bends.Furthermore, the holding area can protrude diagonally and thus in both the axial extension direction and the radial extension direction from the majority of the individual winding area bends.

[0010] In a further advantageous development of the invention, the holding region projects beyond a plane intermediate region in the axial extension direction, wherein the plane intermediate region is delimited by two planes in the axial extension direction that are parallel to one another and oriented perpendicular to the axial extension direction, and at least the majority of the individual winding region bends are arranged in the plane intermediate region, wherein a first plane of the two parallel planes is tangent to an end face of the stator base body facing the busbar, and a second plane of the two parallel planes is tangent to the majority of the individual winding region bends or has a distance from the majority of the respective individual winding region bends 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 to be carried out without any risk of a tool used for maintenance or replacement colliding with the bends of the individual winding areas. The winding diameter can be the total diameter of a conductor element forming the winding arrangement, i.e., the total diameter of the conductive core of the conductor element including the insulation surrounding this core.

[0011] In a further advantageous development of the invention, the holding region projects beyond the stator base body in the radial direction of extension of the stator. This is advantageous because the holding region is thus particularly easily accessible and the temperature sensor can thus be subjected to particularly low-effort maintenance. The holding region can project outwards or inwards beyond the stator base body in the radial direction of extension. If the holding region projects inwards beyond the stator base body in the radial direction of extension, the holding region 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 region can overlap the stator base body interior, in which a rotor and a rotor shaft of the electric drive machine can be arranged.

[0012] In a further advantageous development of the invention, the holding region is spaced from the connecting region. This is advantageous because the spacing allows for simplified assembly or disassembly of the temperature sensor without causing a collision with the connecting region. The holding region can preferably be spaced from the connecting region in the radial direction of extension of the stator. Thus, the holding region can preferably be arranged further outward in the radial direction of extension of the stator than the connecting region. In other words, the holding region can be at a greater distance in the radial direction of extension from an axis of rotation about which a rotor of the electric drive machine can rotate during operation than the connecting region.

[0013] In a further advantageous development of the invention, the connecting area is formed at least partially by a protruding portion of the busbar that protrudes from the winding head. This is advantageous because the protruding portion allows for particularly uninterrupted heat conduction between the temperature sensor arranged on the holding area and the busbar.

[0014] In a further advantageous development of the invention, the connection area is formed by a material-to-material connection between the end of the individual winding area and the busbar. The material-to-material connection can be direct, i.e., by a direct material connection between the busbar and the end of the individual winding area, or indirect, i.e., by interposing additional elements, such as a conductor section, in particular the winding arrangement. The material-to-material connection can preferably be a welded joint, which can ensure particularly uninterrupted heat conduction between the winding head and the busbar.

[0015] In a further advantageous development of the invention, the temperature sensor is arranged on the holding area at a distance from the end of the individual winding area. This makes the temperature sensor particularly accessible for maintenance work.

[0016] In a further advantageous development of the invention, the temperature sensor is arranged at a holding area tip, which corresponds to a holding area section of the holding area furthest from the winding head. The arrangement of the temperature sensor at the holding area tip ensures particularly good accessibility to the temperature sensor for any maintenance work.

[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 relates to a motor vehicle having at least one electric drive motor according to the second aspect of the invention. The electric drive motor of the motor vehicle can be subjected to improved temperature monitoring and maintenance.

[0019] The preferred embodiments and their advantages presented with respect to one of the aspects apply accordingly to the other aspects of the invention and vice versa.

[0020] The features and feature combinations mentioned above in the description, as well as the features and feature combinations mentioned below in the description of the figures and / or shown alone in the figures, can be used not only in the respective combinations specified, but also in other combinations or on their own, without departing from the scope of the invention. Further advantages, features, and details of the invention emerge from the claims, the following description of preferred embodiments, and 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 in which a busbar and an individual winding region end are connected to one another via a connecting region, wherein the busbar has a holding region which protrudes from a winding head of the winding arrangement comprising respective individual winding region bends of the individual winding regions; and

[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 holding area.

[0024] Fig. 1 shows a schematic perspective view of a portion of a stator 10, which is associated with an electric drive motor 100, shown in abstract form in Fig. 2. The electric drive motor 100 serves to drive a motor vehicle K, also shown in highly abstract form in Fig. 2.

[0025] The stator 10 has a stator base body 20 with at least one winding arrangement 30, which has a plurality of individual winding regions 32, 34. The individual winding regions 32, 34 are arranged on the stator base body 20 and are guided at least in sections through respective slots of the stator base body 20. In other words, the individual winding regions 32, 34 are arranged in the respective slots of the stator base body 20. A busbar 60 of the stator 10 is, in this case, electrically conductively connected to an individual winding region end 36 of one of the individual winding regions 32, 34. The busbar 60 can generally be designed as a star busbar, star point busbar, or as a phase busbar or phase connection busbar. In this case, the individual winding region end 36 is assigned, by way of example, to the individual winding region 32. A temperature sensor 90 is at least indirectly and thermally conductively connected to the busbar 60. Referring to Fig.1 shows that the busbar 60 and the individual winding region end 36 are connected to one another via a common connecting region 40. In order to hold the temperature sensor 90 at a distance from the connecting region 40 and thus at a distance from the individual winding region end 36, the busbar 60 has a holding region 70 on which the at least one temperature sensor 90 is arranged. Fig. 1 and Fig. 2 show that the holding region 70 protrudes from a winding head 50 of the winding arrangement 30, which comprises respective individual winding region bends 42, 44 of the individual winding regions 32, 34.

[0026] Although Fig. 1 and Fig. 2 only show the protrusion of the holding region 70 from the winding head 50 in the axial direction of extension A of the stator 10, the holding region 70 can additionally or alternatively also protrude from the winding head 50 in the radial direction of extension R of the stator 10, although this is not shown further here. Overall, the holding region 70 can therefore protrude from at least a majority of the individual winding region bends 42, 44 in the axial direction of extension A and additionally or alternatively in the radial direction of extension R of the stator 10.

[0027] Furthermore, it can be seen in Fig. 1 that the holding region 70, like the connecting region 40, projects beyond an intermediate plane region EZB in the axial extension direction A. The intermediate plane region EZB is delimited in the present case by two planes parallel to one another and oriented perpendicular to the axial extension direction A, namely a first plane E1 and a second plane E2 in the axial extension direction A. At least the majority of the individual winding region bends 42, 44 are arranged in the intermediate plane region EZB, wherein the 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 busbar 60, i.e., can run, for example, along the end face 22. The second plane E2 of the two parallel planes E1, E2 either tangent to the majority of the individual winding region bends 42, 44 or, as in Fig.1 - has a distance A1 from the majority of the respective individual winding region bends 42, 44. The value of the distance A1, measured in the axial direction A in this case, can, for example, correspond to a maximum value of an average winding diameter D_W of a line element 31 assigned to the winding arrangement 30.

[0028] The holding region 70, which is spaced apart from the connecting region 40, in particular in the radial direction of extension R and / or in the axial direction of extension A, can in principle and advantageously also project beyond the stator base body 20 inwards in the radial direction of extension R of the stator, i.e. in the direction of a stator base body interior, or outwards.

[0029] Also evident from Fig. 1 is that the busbar 60 comprises a projection region 64 partially forming the connecting region 40 and protruding from the winding overhang 50, and a busbar main section 63 connected, in particular in one piece, to the projection region 64. The busbar main section 63 can run in a circumferential direction U along the stator base body 20, for example, parallel to the end face 22 of the stator base body 20. The busbar main section 63 can lead to stator windings of the stator 10 (not shown here) and be electrically connected to them. Fig. 1 shows that both the projection region 64 and the holding region 70 branch off from the busbar main section 63. The busbar main section 63 is longer than the holding region 70 or the projection region 64.In addition, the holding area 70 is longer than the projection area 64, wherein the holding area 70 projects beyond the projection area 64 in the axial extension direction A.

[0030] The holding region 70 and the main busbar section 63 can enclose an angle a between one another, which can advantageously be an angle of greater than 45°, preferably greater than 70°, and particularly preferably greater than 80°. In the present case, the angle a is 90°, i.e., the angle a is configured as a right angle, whereby the main busbar section 63 runs along the stator base body 20 in a particularly space-saving manner, and the holding region 70 enables particularly good accessibility for any maintenance of the temperature sensor 90. In other words, the holding region 70 protrudes perpendicularly and thus in the axial extension direction A from the winding head 50.

[0031] The connecting region 40 is formed not only by the projection region 64 of the busbar 60 projecting from the winding head 50 but also by a projection 37 of the end 36 of the individual winding region projecting from the winding head 50.

[0032] The projection 37 extends largely parallel to the projection region 64, thereby providing a space-saving arrangement. The term "largely parallel" in the context of the present disclosure means that the projection 37 and the projection region 64 enclose an intermediate angle with an angular value of less than 20°, preferably less than 10°. It can be seen in Fig. 1 and Fig. 2 that the projection 37 and the projection region 64 are oriented parallel to one another in this case. This intermediate angle can thus be configured as a zero angle.

[0033] Overall, the busbar 60 and the individual winding region 32 are integrally connected to one another at the connecting region 40, which projects beyond the winding head 50 in the axial direction A and additionally or alternatively in the radial direction R of the stator 10, namely, in this case, by means of a welded joint. In other words, the connecting region 40 is formed by the integral connection of the individual winding region end 36 to the busbar 60, in particular by the integral connection of the projection 37 and the projection region 64.

[0034] By arranging the temperature sensor 90 at a holding area tip 72 of the holding area 70, which corresponds to a holding area section of the holding area 70 furthest away from the winding head 50 in the axial extension direction A and additionally or alternatively in the radial extension direction R, the temperature sensor 90 is arranged at a distance from the individual winding area end 36 on the holding area 70.

[0035] The temperature sensor 90, shown schematically in Fig. 2, is in direct thermally conductive contact with the busbar 60 exclusively via the holding region 70, which is designed as a one-piece component of the busbar 60, i.e., in other words, is directly thermally conductively connected. The materially bonded connection between the projection region 64 of the busbar 60 and the individual winding region end 36 or the projection 37 also enables heat conduction from the individual winding region 32 of the winding arrangement 30 to the temperature sensor 90, so that at least one temperature value representative of the temperature prevailing at the winding arrangement 30 can be measured at the temperature sensor 90. The individual winding region end 36 is designed as a one-piece individual winding region component of the individual winding region 32.

[0036] In summary, the holding area 70, in particular the holding area tip 72 of the holding area 70, represents a measuring tap for the temperature sensor 90. The basic idea here is to arrange this measuring tap at the beginning or end of the winding arrangement 30 without damaging insulation material, for example in the area of ​​the winding overhang 50, i.e. in zones of the winding arrangement 30 spaced from the holding area 70, or without having to interrupt the winding arrangement 30 specifically for a possible implementation of the measuring tap and thereby weakening it, for example, by means of an additional weld. The holding area 70, and thus also the holding area tip 72, can in principle be arranged at any location in the circumferential direction U along the busbar 60. In Fig. 1 and Fig.2, the holding region 70 is offset only in the radial direction of extension R relative to the connecting region 40, but a significant advantage of the invention is that the holding region 70 can additionally or alternatively be designed as a branch of the busbar 60 offset in the circumferential direction U relative to the connecting region 40, i.e. in other words can protrude from the busbar main section 63.In other words, an intermediate region 66 of the busbar 60 can generally be located between the holding region 70 and the connecting region 40, which intermediate region 66 runs in the circumferential direction U along the busbar main section 63 of the busbar and can, for example, be several centimeters long, for example 1 cm, 2 cm, 3 cm, 4 cm, 5 cm, 6 cm, 7 cm, 8 cm, 9 cm, 10 cm, 11 cm, 12 cm, 13 cm, 14 cm, 15 cm, 16 cm, 17 cm, 18 cm, 19 cm or 20 cm, to name just a few possible lengths of the intermediate region 66, which allow particularly good accessibility of the temperature sensor 90 for maintenance work without there being a risk of collision with the connecting region 40.

[0037] The holding area 70 thus generally allows temperature measurement at a distance from the stator base body 20, which may comprise a laminated core not shown here.

[0038] To form the connection area 40, the single-winding area end 36 of the single-winding area 32 of the winding arrangement 30 is cut to length a little further from the laminated core and thus from the stator base body 20. The busbar 60 (phase connection bar, star point bar) is extended (rerouted) by the same amount in the axial extension direction A and additionally or alternatively in the radial extension direction R through the projection area 64, whereby the common connection, in particular by welding, of the single-winding area end 36 at its projection to the projection area 64 is made, forming the connection area 40. Depending on requirements, the method can be applied to one or more phases or conductors.

[0039] It is clear that the stator 10 can also have a plurality of holding regions 70 with respective temperature sensors 90, which can be arranged offset from one another in the circumferential direction U on the busbar 60. This advantageously allows a temperature gradient to be determined, via which, for example, a temperature level at the winding head 50 can be determined with little effort.

[0040] List of reference symbols

[0041] 10 Stator

[0042] 20 stator base body

[0043] 22 front side

[0044] 30 Winding arrangement

[0045] 31 Line element

[0046] 32 single winding range

[0047] 34 single winding area

[0048] 36 Single winding range end

[0049] 37 overhang

[0050] 40 connection area

[0051] 42 Single winding area bending

[0052] 44 Single winding area bending

[0053] 50 winding head

[0054] 60 busbar

[0055] 63 Main conductor rail section

[0056] 64 Overhang area

[0057] 66 Intermediate area

[0058] 70 holding area

[0059] 72 Holding area peak

[0060] 90 Temperature sensor

[0061] 100 electric drive motors

[0062] A Axial extension direction

[0063] A1 distance

[0064] D_W winding diameter

[0065] ECB intermediate level area

[0066] E1 first level

[0067] E2 second level

[0068] R radial extension direction

[0069] K Motor vehicle

[0070] 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 has a plurality of individual winding regions (32, 34) which are arranged in respective slots of the stator base body (20), with at least one busbar (60) which is electrically conductively connected to at least one individual winding region end (36) of at least one of the individual winding regions (32, 34), and with at least one temperature sensor (90) which is at least indirectly and thermally conductively connected to the at least one busbar (60), characterized in that the at least one busbar (60) and the at least one individual winding region end (36) are connected to one another via a connecting region (40), and the busbar (60) has a holding region (70) on which the at least one temperature sensor (90) is arranged and which is guided by a,respective individual winding area bends (42, 44) of the individual winding areas (32, 34) comprising the winding head (50) of the winding arrangement (30).

2. Stator (10) according to claim 1, characterized in that the holding region (70) protrudes in the axial extension direction (A) and / or in the radial extension direction (R) of the stator (10) from at least a large part of the individual winding region bends (42, 44).

3. Stator (10) according to claim 2, characterized in that the 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) oriented parallel to one another and perpendicular to the axial extension direction (A) in the axial extension direction (A), and at least the majority of the individual winding region bends (42, 44) are arranged in the plane intermediate region (EZB), wherein a first plane (E1) of the two parallel planes (E1, E2) has a plane facing the busbar (60). Front side (22) of the stator base body (20) is tangent and a second plane (E2) of the two parallel planes (E1, E2) is tangent to the majority of the individual winding area bends (42, 44) or has a distance (A1) from the majority of the respective individual winding area bends (42, 44) which corresponds at most to 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 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 holding region (70) is spaced from the connecting region (40).

6. Stator (10) according to one of the preceding claims, characterized in that the connecting region (40) is formed at least partially by a projection region (64) of the busbar (60) projecting from the winding head (50).

7. Stator (10) according to one of the preceding claims, characterized in that the connecting region (40) is formed by a material connection of the individual winding region end (36) to the busbar (60).

8. Stator (10) according to one of the preceding claims, characterized in that the temperature sensor (90) is arranged on the holding region (70) at a distance from the end (36) of the individual winding region.

9. Stator (10) according to one of the preceding claims, characterized in that the temperature sensor (90) is arranged at a holding area tip (72) which corresponds to a holding area section of the holding area (70) furthest away from the winding head (50).

10. Electric drive machine (100) with at least one stator (10) according to one of claims 1 to 9.

11. Motor vehicle (K) with at least one electric drive machine (100) according to claim 10.

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