An electric machine

Abstract

The present invention relates to an interior permanent magnet electric machine (1) with flat wire winding which enables the alternating current (AC) electrical signals at the inverter output to be efficiently converted into torque and speed, and is optimized for electric vehicle thrust systems.

Description

[0001] DESCRIPTION

[0002] AN ELECTRIC MACHINE

[0003] Technical Field

[0004] The present invention relates to an interior permanent magnet electric machine with flat wire winding which enables the alternating current (AC) electrical signals at the inverter output to be efficiently converted into torque and speed, and is optimized for electric vehicle thrust systems.

[0005] Background of the Invention

[0006] The magnetic flux density that can be provided at the stator in electric machines is limited due to the nature of magnetic materials. Electric machines can be used both in the area where the magnetic material acts linearly and in the area where it reaches saturation depending on the different torque requirements. Since magnetic flux leakage will increase at the point where it reaches saturation, the torque increase in the machine is limited. Furthermore, if there is not enough steel area in the stator teeth, the torque is limited at a much lower order. Today, it is common to use an interior permanent magnet synchronous electric machine (IPMSM) to overcome the problems mentioned above. This type of electric machine consists of a rotor with a magnet embedded therein, which provides movement by rotating around a shaft, and a fixed-position stator in which the copper windings are present. During the movement, the magnetic field created by the magnets in the rotor interacts with the magnetic field created by the copper windings in the stator, and in mechanical tracking, it provides the charging of the battery by acting as a motor if the stator is leading and as a generator if the rotor is leading. Since the geometric optimization of magnetic flux paths in providing motion is important in terms of generating torque in the most efficient way, today, the optimization of the steel field gains importance given the geometry of the stator, which consists of slots and teeth and increases magnetic oscillation.

[0007] The use of a V-skew layers separated at different angles in the rotor and designing the magnet pockets in a V- shape is common in order to reduce torque ripple in interior permanent magnet synchronous electric machines. On the other hand, placing an air gap (pole cap) at the ends of the pockets of the magnets in the rotor is used to prevent demagnetization, while parallel slot configuration and flat wire windings are used in the stator. In addition, interlocks are used for sheet metal joining in the stator and rotor. Furthermore, given the limited space in which interior permanent magnet synchronous electric machines will be mounted, the use of liquid cooling for the cooling thereof is a common practice that reduces the package size of the machine. Although the state of the art includes the use of the interior permanent magnet synchronous electric machines, today, there is a need for optimizations for an electric machine that can operate at high torque and speed.

[0008] The United States patent document no. US2014375160A1, an application included in the state of the art, discloses an electric motor system with a reduced production cost which will prevent the decrease of the magnetic flux. The system has an electromagnet structure that has at least one coil body mounted on the stator or rotor in the electric motor. The coil body may consist of enamelled copper wire and is used to generate a magnetic field that varies with time. When the system operates as a generator, the electrical voltage induced in the coil is switched off. The stator or rotor comprises a permanent magnet structure by means of the system. Preferably, the electromagnet structure is part of the stator, and the permanent magnet structure is part of the rotor. The permanent magnet structure has a first set and a second set of permanent magnets, whereby the permanent magnets of the particular set are positioned at specific locations. The number of permanent magnets corresponds to each other and / or is an integer multiple. The magnetic field strength of the first set is greater than the magnetic field strength of the second set, thus, the magnetic field strength of all magnets in the set is the same. Summary of the Invention

[0009] An object of the present invention is to realize an interior permanent magnet synchronous electric machine with flat wire windings which enables the alternating current (AC) electrical signals at the inverter output to be efficiently converted into torque and speed, and is optimized for electric vehicle thrust systems.

[0010] Another object of the present invention is to realize an interior permanent magnet synchronous electric machine which has a rotor optimized in terms of the performance requirements with respect to the torque that the magnet will provide.

[0011] A further object of the present invention is to realize an interior permanent magnet synchronous electric machine which can be mechanically mounted with several different transmission types and several different inverter circuits.

[0012] A further object of the present invention is to realize an interior permanent magnet synchronous electric machine which can be integrated into different electric vehicles, such as electric land vehicles, aircrafts, and vessels by providing different combinations of speed, torque and power.

[0013] A further object of the present invention is to realize an interior permanent magnet synchronous electric machine which comprises a cooling system having a cooling channel optimized by taking into account the cooling liquid pressure loss and cooling performance.

[0014] A further object of the present invention is to realize an interior permanent magnet synchronous electric machine wherein flat wire windings that lead to low loss and provide better thermal conductivity with uniform winding structure and distribution in terms of its distribution in the slot are used. Detailed Description of the Invention

[0015] “An Electric Machine” realized to fulfil the objectives of the present invention is shown in the figures attached, in which:

[0016] Figure 1 is an exploded perspective view of an inventive electric machine.

[0017] Figure 2 is a view of the rotor in an inventive electric machine.

[0018] Figure 3 is an exploded perspective view of the rotor in an inventive electric machine.

[0019] Figure 4 is a view of the rotor layer in an inventive electric machine.

[0020] Figure 5 is a view of the male rotor sheet with offset in an inventive electric machine.

[0021] Figure 6 is a view of the female rotor sheet metal in an inventive electric machine.

[0022] Figure 7 is a view of the male rotor sheet metal in an inventive electric machine.

[0023] Figure 8 is a view of the magnet in an inventive electric machine.

[0024] Figure 9 is a view of the resolver shaft in an inventive electric machine.

[0025] Figure 10 is a view of the rotor shaft in an inventive electric machine.

[0026] Figure 11 is a view of the rotor balance plate in an inventive electric machine.

[0027] Figure 12 is a view of the mounted stator in an inventive electric machine.

[0028] Figure 13 is a view of the slot section of the stator in an inventive electric machine.

[0029] Figure 14 is a view of the stator in an inventive electric machine.

[0030] Figure 15 is an exploded view of the stator in an inventive electric machine.

[0031] Figure 16 is a sheet metal geometry of the stator in an inventive electric machine.

[0032] Figure 17 is a view of the flat wire stator winding distribution in an inventive electric machine. Figure 18 is a view of the driver connection of the windings in an inventive electric machine.

[0033] Figure 19 is a view of the inner housing in an inventive electric machine.

[0034] Figure 20 is an isometric view of the inner housing in an inventive electric machine.

[0035] Figure 21 is a view of the outer housing in an inventive electric machine.

[0036] Figure 22 is a view of the outer housing lid in an inventive electric machine.

[0037] Figure 23 is a intersectional view of an inventive electric machine.

[0038] The components illustrated in the figures are individually numbered, where the numbers refer to the following:

[0039] 1. Electric Machine

[0040] 2. Stator

[0041] 3. Inner Housing

[0042] 4. Rotor

[0043] 5. Sealing Element

[0044] 6. Outer Housing

[0045] 7. Outer Housing Lid

[0046] 8. Resolver Stator

[0047] 9. Resolver Rotor

[0048] 10. Shaft

[0049] 11. Pressure Plate

[0050] 12. HV Connector

[0051] 13. Input Adapter

[0052] 14. Output Interface Part

[0053] 15. Wave Washer

[0054] 16. Connection Element An inventive interior permanent magnet synchronous electric machine (1) which enables the alternating current (AC) electrical signals at the inverter output to be efficiently converted into torque and speed comprises at least one stator (2) which comprises flat copper windings on the surface thereof and enables a gyromagnetic field to be created in its interior by means of the copper windings; at least one inner housing (3) which holds the stator (2) and performs cooling operation by means of the liquid channels located thereon; at least one rotor (4) which is connected to the shaft and rotates inside the stator (2) and in which magnets are embedded therein; a plurality of sealing elements (5) which provide sealing between the connection of the rotor (4) and the stator (2); at least one outer housing (6) which covers the liquid channels used for cooling by being located on the inner housing (3), comprises at least one entrance for cables thereon, and is used for connection to the vehicle by creating a connection interface for the inverter and transmission; at least one outer housing lid (7) which is located on the outer housing (6) and provides access and protection to the electrical interfaces with the inverter; at least one resolver stator (8) which includes an exciter winding and two phase windings; wherein the exciter windings form a transformer with the rotor (4); wherein the voltage induced in the rotor (4) is induced in the cos- and sin- windings; and which enables the instantaneous angular position and angular velocity of the rotor (4) to be measured; at least one resolver rotor (9) which induces the voltage in the cos- and sin- windings in the resolver stator (8) with the rotation of the shaft and enables the instantaneous angular position and angular velocity of the rotor (4) to be measured by means of the voltage varying depending on the angle; at least one shaft (10) which is used to connect the resolver to the rotor (4) shaft; at least one pressure plate (11) which is used to connect the resolver to the lid (7); at least one high voltage (HV) connector (12) which is located on the outer housing (6) and enables the busbar and the motor driver busbar element to be connected in insulation from the metal surface of the outer housing (6); at least one input adapter (13) which is located on the outer housing (6) and is used for the entrance of the cooling liquid; at least one outlet interface part (14) which is located on the outer housing (6) and is used for the exit of the cooling liquid; and at least one wave washer (15) which is used to balance the axial loads on the bearing on the shaft of the rotor (4).

[0055] The stator (2) included in the inventive electric machine (1) comprises flat copper windings on the inner surface thereof and enables a magnetic field to be created for the rotor (4) with the magnet embedded therein to rotate and the magnetic flux coming from the rotor (4) to be transferred back to the rotor (4). The stator inside which the rotor (4) rotates is in a fixed structure and is a magnetic structure consisting of electrical sheet metal.

[0056] The stator (2) has a parallel slot configuration suitable for flat wire winding. The copper dimensions in the stator (2) are 3.8mm x 1.72mm and the optimum loss value is obtained at each speed considering the requirements at both low speed and high speed. In the stator (2), the locations of the phase inputs and outputs are determined in order to enable the busbar connection of four parallel current paths per phase with a single process. Furthermore, a higher torque is obtained at high speeds with the flat q-axis notch in the stator (2) compared to the structure without notch. At the same time, the q-axis inductance is reduced with the flat q-axis notch, while the torque ripple of the machine at high speeds is reduced compared to the structure without notch.

[0057] Circulating currents are minimized by equalizing the value of the opposite electromotive force (back-emf) connected to the winding in the stator (2) in the distribution of the four parallel current paths in the slot in the winding diagram. On the other hand, winding in the stator (2) is a distributed winding in 48 slots, 8 poles configuration; the fundamental frequency component of the back-emf is maximized; and the end-winding length is shortened by means of the integral slot pitch factor. With the 48 slots and 8 poles configuration in the stator (2), the inverter switching frequency is enabled to reach the high speeds required by the vehicle requirements and the mechanical vibration and noise are reduced with the 48 / 8 ratio compared to different slot / pole ratios. Possible inductive bearing currents are prevented by the use of the bearing electrically insulated (insulated coating) on the resolver side of the stator (2). In addition, the mechanical integrity is strengthened by joining the stator (2) sheet metals linearly along the length of the stator (2) with laser welding at 12 welding points with 0.4 mm recesses from the outside so as not to affect the magnetic flux paths in the outer diameter of the stator (2).

[0058] A Grade 2 enamel insulation is used on the stator (2) according to the 400V voltage architecture. Also, a 0.22mm slot insulation paper is used in the stator (2) according to the 400V voltage architecture. The varnish in the slot of the stator (2) is filled by trickling process. In the stator (2), the slot insulation paper is folded on the rotor (4)-stator (2) air gap side in order not to affect the thermal resistance of the slotstator (2) outer wall. In addition, the slot corner fillets in the stator (2) are determined based on the copper fillets and insulation paper thickness.

[0059] The stator (2) comprises cooling channels with a design that can move the cooling liquid in a tangential direction around itself in a spiral structure, and thus a homogeneous temperature distribution at the desired values on its surface is ensured. The sectional and projection geometries of the cooling channels of the stator (2) are designed in such a way as to keep the heat transfer and cooling liquid pressure drop value within the desired limits. In addition, the stator (2) cooling channel structure can be optimized by adjusting the channel width and depth according to different cooling needs. In the inventive electric machine (1), when the sheet metals are brought together for mounting the stator (2), the sheet metal packages are rotated by 120° for each third of the length of the stator (2) mounting. The undulations that may occur in the stator (2) package are prevented by this rotation process and it is also ensured that a more balanced magnetic field is created in the stator (2) by preventing the magnetic dipoles in the sheet metal roll from aligning in the same direction.

[0060] The inner housing (3) included in the inventive electric machine (1) holds the stator (2) with a close fit and enables the machine to be cooled by the rotor (4) rotating by means of the cooling liquid passing through the liquid channels thereon. There is at least one bearing that carries the rotor (4) on the inner housing (3).

[0061] The rotor (4) included in the inventive electric machine (1) rotates inside the stator (2), and has magnets embedded therein and is connected to the shaft. In the preferred embodiment of the invention, the magnetic field of the rotor (4) functions as a regen when it is in front of the magnetic field of the stator (2), and as a motor when the stator (2) is in front of the rotor (4).

[0062] The rotor (4) comprises six (3x2) layers in three different orientations with a 2.5- degree angle between them in order to reduce torque ripple. The torque ripples are reduced by realizing the six layers of the rotor (4) in a V-skew format. At the same time, the length of the arc swept by the magnets in the rotor (4) is chosen close to the 5 / 6 ratio of the arc length swept by one pole jump, the 5thharmonic is reduced, and the high-speed performance and vibration-noise are improved. The rotor (4) also has a lug structure optimized to minimize torque ripple.

[0063] A 0.1 mm gap is left between the edges of the rotor (4) slots and the edges of the magnets in order to enable easy placement of magnets in the rotor (4) without affecting the centrifugal strength during the mass production phase. A V-shaped slot (V-groove) is located on the outer diameter of the rotor (4) in the d-axis direction in order to measure the skew tolerance of the rotor (4). In addition, mechanical stabilization and reduction of thermal resistance are provided by the use of a transfer molding process in fixing the magnets in the rotor (4). The magnets in the rotor (4) are protected against corrosion by an overmolding cap. Mounting process on the rotor (4) is facilitated by means of a chamfer of 0.5mm on the edges of the permanent magnets of the rotor (4).

[0064] In the preferred embodiment of the invention, the rotor (4) is produced with a special tooth structure (serration-serrated structure) in order to improve the mounting and shaft adhesion properties of the inner diameters of the sheet metals thereof. On the other hand, the rotor (4) is joined to the stator (2) with sheet metal adhesive in order to minimize iron loss (iron loss / core loss) and to reduce vibrationnoise. In the process of pressing the rotor substack sheet metals, each sheet metal is pressed by being rotated ninety degrees. In this way, undulations that may occur in the rotor (4) substack package are prevented. At the same time, it is ensured to create a more balanced magnetic field in the rotor (4) by preventing the magnetic dipoles in the rotor (4) sheet metal roll from aligning in the same direction.

[0065] In the preferred embodiment of the invention, a balance plate is placed in front of / behind the outer layers in such a way as not to cover the magnets in order to ensure the balance of the rotor (4). The balancing process is facilitated by the tab left on the balance plate.

[0066] The rotor (4) comprises eight interlocks between the rotor (4) V-barriers, in the center orientation of the rotor (4) lamination web, at the level of the lower paddle of the magnet pockets, and in the q-axis, so as not to affect the magnetic flux paths, and which enables the rotor (4) sheet metals to be locked in production by the presence of eight interlocks in the d-axis between the magnets and the outer diameter of the rotor (4).

[0067] The outer housing (6) included in the inventive electric machine (1) encloses the water channel by surrounding the stator (2) and provides entrance to the busbar and resolver cables. The outer housing (6) and the stator (2) cooling channels are joined so as to provide sealing with a precise mounting. At the same time, the outer housing (6) provides mechanical interfaces with the inverter and the transmission, as well as connection with the vehicle. In the preferred embodiment of the invention, the outer housing (6) and the inner housing (3) are connected to each other by a connection element (16). Preferably, the outer housing (6) is in such a way that it is suitable for different inverter and transmission configurations.

[0068] In the preferred embodiment of the invention, after being fixed to the rotor (4), the outer housing (6) is mounted to the inner housing (3) to which the stator (2) is fixed. In this way, a 2-part assembly is realized.

[0069] The outer housing lid (7) included in the inventive electric machine (1) provides the transportation and protection of its electrical interfaces with the inverter. In the invention, the current output from the inverter is carried on four separate parallel paths in order to meet the current demand. A connection element (16) is used for fixing the outer housing lid (7) to the outer housing (6).

[0070] The resolver stator (8) included in the inventive electric machine (1) comprises exciter windings and two phase windings. The exciter winding and the rotor (4) form a rotary transformer in the resolver stator (8). The voltage induced in winding (4) in the rotor then induces voltage in cos- and sin- windings in the stator (2). In this way, the instantaneous angular position and angular velocity of the machine can be measured, and when this information is transferred to the inverter side, the closed-loop torque and speed control required to drive the machine is provided.

[0071] The resolver rotor (9) included in the inventive electric machine (1) induces voltage in the cos- and sin- windings of the resolver stator (8) with the rotation of the shaft and enables the instant angular position and angular speed of the machine to be measured by means of this voltage that varies depending on the angle. When this information is transferred to the inverter, the closed-loop torque and speed control required to drive the machine is provided.

[0072] The shaft (10) included in the inventive electric machine (1) connects the resolver to the rotor (4) shaft and is suitable for the use of different resolver models. The inventive electric machine (1) further comprises a connection element (16) for fixing a half shaft bearing.

[0073] The pressure plate (11) included in the inventive electric machine (1) is used for fixing the resolver in its place. The resolver is fixed by means of the connection element (16) of the pressure plate (11).

[0074] The HV connector (12) included in the inventive electric machine (1) enables the machine busbar and the motor driver busbar to be connected in an insulated manner from metal surfaces. For the connection of the motor busbar and the motor driver busbar, a connection element (16) which has more pressure than other bolts due to its special head structure and improves the electrical conduction is used. The HV connector (12) is connected to the outer housing (6) via the connection element (16).

[0075] The input adapter (13) included in the inventive electric machine (1) is used to enable the cooling liquid coming from another metal interface to be transferred to the outer surface of the stator (4) without leaking.

[0076] The outlet interface part (14) included in the inventive electric machine (1) makes the cooling liquid leaving the outer housing (6) suitable for the outlet interface.

[0077] The wave washer (15) included in the inventive electric machine (1) is used to balance the axial loads on the bearing located on the inner housing (3). In the inventive electric machine (1), the flat wire size and slot dimensions in the stator (2) have been optimized by taking into account the criteria of reproducibility and performance. While smaller slot dimensions affect the torque obtained from the motor in an increasing trend, smaller slot dimensions increase the losses as less copper can be placed in the same slot. In the inventive electric machine (1), an optimization is provided between these two constraints in order to meet the performance criteria, and all flat wire dimension tolerances and corner fillets, enamel insulation thickness and tolerances, in-slot insulation paper and thickness, and production tolerances are taken into account for reproducibility.

[0078] In the inventive electric machine (1), as the flat wire configuration provides more copper volume in the slot for the same geometry, less losses can be achieved for the same geometry. The use of flat wire affects the machine performance significantly compared to wire-winding, as copper losses are the main factor in the losses of the electric machine (1). Furthermore, in the inventive electric machine (1), geometrical optimization of the slot lugs and the slot openings has been realized with the aim of reducing vibration and noise since the advantage of axial placement and radial placement is not possible with flat wire. Besides, the thermal resistance between the slot and the cooling channel is reduced and higher cooling performance is achieved by means of filling the air gaps in the slot with more copper volume. Due to the high power density in the package of the inventive electric machine (1), a high amount of heat dissipation occurs and since this situation causes the electric machine subcomponents to reach critical temperature values, there is a cooling system with a high heat transfer coefficient in the electric machine (1) in order to remove the high heat dissipation from the outer housing (6) and to obtain a homogeneous temperature distribution below the critical temperature value in the subcomponents.

[0079] In the inventive electric machine (1), the design expected to be in parallel with the optimization in the stator (2) has torque optimization also on the basis of the rotor (4) in the d and q axes, which have an important role in interior magnet electric machines. In the q-axis of the electric machine (1), there is a notch in order to increase the high-speed performance. By means of this notch, relatively higher torque and lower torque ripple can be achieved at high speeds. This feature facilitates torque control by keeping the current angle on the motor control side away from the 85-degree band at high speeds. In the event that these critical angles are exceeded, there are major changes in the torque value even in small changes and ripples of the angle. If the angle reaches 90 degrees, it may cause the average torque to reset.

[0080] In the inventive electric machine (1), as the thicknesses of the barriers are important in terms of meeting the maximum speed requirements of the machines, the thicknesses of the barriers are optimized so as to enable the magnets to resist the centrifugal forces that occur at the maximum speed value. In the rotor (4) optimization, minimizing the leakage flux of the magnets is taken into consideration in order to improve the torque value at low speeds, and the angle between the magnet slots is defined as 100 degrees in order to obtain the optimum average torque and torque ripple balance. In order to facilitate the reproducibility of the inventive electric machine (1), sizing is carried out in such a way that there will be a gap of at least 0.1 mm between the edges of the magnet and the margins of the magnet slot. Similarly, a slot is used during the arrangement of the parts of the rotor (4) in order to validate the skew angle in the rotor (4).

[0081] In terms of making the inventive electric machine (1) suitable for mass production, sheet metals are joined at points that will not affect the magnetic flux distribution so as to meet the vehicle level torque requirements. For the joining of the sheet metals in the stator (2), 12 welding points and 12 interlock points are determined. As for the joining of the sheet metals in the rotor (4), 8 interlock points close to the outer diameter and 8 interlock points close to the shaft area are determined. The number of interlock points is realized by taking into account the ratio of the stator (4) slot - magnet pole of the electric machine (1). In the inventive electric machine (1), the magnet pole - stator slot ratio selected in terms of reducing the noise and vibration of the machine is selected so as to cause low noise. In addition, the inventive electric machine is resistant to the road-related loading types that may be encountered in the event that it is used in electric vehicles and is in a structure that will ensure optimum operation in different environmental conditions in electric vehicles.

[0082] In the inventive electric machine (1), the stator (2) and the rotor (4) are made of sheet steel. For this purpose, the steel sheet roll is prepared, the steel sheet is placed on the conveyor, laminations for the rotor (4) and the stator (2) are pressed by applying pressure along two strips on the steel sheet. In this configuration, the rotor (4) and the stator (2) are cut over the same area in each strip as they do not have intersecting areas. After the stator (2) length reaches the specified size within the tolerances, the stator lamination pressing is finished and a QR code is engraved on the flat surface where the burrs of the stator sheet metals are facing. After the rotor (4) length reaches the specified size within the tolerances, the rotor lamination pressing ends. The stator (2) is subjected to laser welding from 12 points while under the press. Finally, stator (2) parts are collected in one tray and rotor parts in another tray.

[0083] The insulation papers placed in the mounting process of the stator (2) are placed inside the slots in such a way that they enter from the side of the surface where the QR code is not present. The enamelled flat copper wire that will be placed in the stator (2) is pulled from the winding roll and shaped to provide the desired bends and the wires are cut after reaching the appropriate length. The wire is mechanically cut with diamond cutters at the points on the stator (2) where the wires are to be welded, and the copper surface is exposed. The wires are lined up in a housing chamber so as to be placed axially on the stator (2). The wires are removed from the slot and placed into the slots from the QR code engraved side of the stator (2) on which insulating paper is placed, and in the meantime, the papers are held so that the insulating paper does not slip from the bottom. The twisting of the flat wires is realized on the side where the windings will be welded by turning the stator (2) while holding the windings after the wires are placed. Then, with the help of pins and visual controls, the circumferential, tangential and axial alignment of the coppers is realized and all four pairs of layers in each stator (2) slot are joined by laser welding at the same time. In the inventive electric machine (1), the welding quality is evaluated by image processing methods and the welding points are coated with epoxy powder coating. After coating, the stator (2) is turned upside down and the welding of the busbar and motor phase terminals is realized. In addition, in order to varnish the slots of the stator (2), varnish is flowed from the outermost laminations of the stator (2) through two nozzles positioned close to the slot entrances while the stator rotates (trickling). High voltage tests are also performed for the stator (2) windings.

[0084] In the mounting process of the rotor (2), the rotor parts are taken to the rotor magnet placement line with a tray. After the surface cleanliness, smoothness and mechanical integrity of the magnets are checked with a camera, the demagnetized magnets are pushed into the slots in the rotor (4) parts. The rotor (4) and magnets are heated together up to 180°C. The rotor parts are stacked in such a way that six of them will overlap and the skew angle will be respected. Transfer molding liquid is applied with pressure from the top of the stacked rotor (4) parts and after the polymerization of the liquid is completed, the position of the magnets in their slots is fixed. After the magnet fixing operation, the placement of the balance plates is performed, and the mounting of the shaft to the rotor parts that have been applied with the balance plates and transfer molding is carried out. Then, shaft mounting and balancing operation of the rotor is realized on the rotor (4) parts where the balance plates are present. Then, the resolver spindle is nailed to the rotor shaft, bearings are mounted on the rotor, and the magnetization process of the magnets is carried out respectively. After the magnetization process, magnetization measurement and skew angle measurement are performed with the magnetic flux meter matrix. Finally, QR code placement is performed for the traceability of the respective parts in the rotor. Industrial Application of the Invention

[0085] In order to form the inventive electric machine (1), the mounted stator (2) is placed in the inner housing (3) and the mounted rotor (4) is placed in the outer housing (6). After the outer housing (6) is heated to 100°C, the inner housing (3) is inserted into the outer housing (6) with a close fit. Then, the mounting process is finalized by attaching the temperature sensor to the stator busbar, nailing the stator (2) part of the resolver to the outer housing (6) and subjecting the electric machine (1) to the end-of-line test.

[0086] Within these basic concepts; it is possible to develop various embodiments of the inventive “An Electric Machine (1)”; the invention cannot be limited to examples disclosed herein and it is essentially according to claims.

Claims

CLAIMS1. An interior permanent magnet synchronous electric machine (1) which enables the alternating current (AC) electrical signals at the inverter output to be efficiently converted into torque and speed; characterized by at least one stator (2) which comprises flat copper windings on the surface thereof and enables a gyromagnetic field to be created in its interior by means of the copper windings; at least one inner housing (3) which holds the stator (2) and performs cooling operation by means of the liquid channels located thereon; at least one rotor (4) which is connected to the shaft and rotates inside the stator (2) and in which magnets are embedded therein; a plurality of sealing elements (5) which provide sealing between the connection of the rotor (4) and the stator (2); at least one outer housing (6) which covers the liquid channels used for cooling by being located on the inner housing (3), comprises at least one entrance for cables thereon, and is used for connection to the vehicle by creating a connection interface for the inverter and transmission; at least one outer housing lid (7) which is located on the outer housing (6) and provides access and protection to the electrical interfaces with the inverter; at least one resolver stator (8) which includes an exciter winding and two phase windings; wherein the exciter windings form a transformer with the rotor (4); wherein the voltage induced in the rotor (4) is induced in the cos- and sin- windings; and which enables the instantaneous angular position and angular velocity of the rotor (4) to be measured; at least one resolver rotor (9) which induces the voltage in the cos- and sin- windings in the resolver stator (8) with the rotation of the shaft and enables the instantaneous angular position and angular velocity of the rotor (4) to be measured by means of the voltage varying depending on the angle; at least one shaft (10) which is used to connect the resolver to the rotor (4) shaft;at least one pressure plate (11) which is used to connect the resolver to the lid (7); at least one high voltage (HV) connector (12) which is located on the outer housing (6) and enables the busbar and the motor driver busbar element to be connected in insulation from the metal surface of the outer housing (6); at least one input adapter (13) which is located on the outer housing (6) and is used for the entrance of the cooling liquid; at least one outlet interface part (14) which is located on the outer housing (6) and is used for the exit of the cooling liquid; and at least one wave washer (15) which is used to balance the axial loads on the bearing on the shaft of the rotor (4).

2. An interior permanent magnet synchronous electric machine (1) according to Claim 1; characterized by the stator (2) which comprises flat copper windings on the inner surface thereof and enables a magnetic field to be created for the rotor (4) with the magnet embedded therein to rotate and the magnetic flux coming from the rotor (4) to be transferred back to the rotor (4).

3. An interior permanent magnet synchronous electric machine (1) according to Claim 1 or 2; characterized by the stator (2) which has a parallel slot configuration suitable for flat wire winding.

4. An interior permanent magnet synchronous electric machine (1) according to any one of the preceding claims; characterized by the stator (2) wherein the copper dimensions are 3.8mm x 1.72mm and the optimum loss value is obtained at each speed considering the requirements at both low speed and high speed.

5. An interior permanent magnet synchronous electric machine (1) according to any one of the preceding claims; characterized by the stator (2) which obtains higher torque at high speeds with its flat q-axis notch than without a notch6. An interior permanent magnet synchronous electric machine (1) according to any one of the preceding claims; characterized by the stator (2) wherein circulating currents are minimized by equalizing the value of the opposite electromotive force (back-emf) connected to the winding in the distribution of the four parallel current paths in the slot in the winding diagram.

7. An interior permanent magnet synchronous electric machine (1) according to any one of the preceding claims; characterized by the stator (2) wherein the winding is distributed in 48 slots, 8 poles configuration; the fundamental frequency component of the back-emf is maximized; and the end-winding length is shortened by means of the integral slot pitch factor.

8. An interior permanent magnet synchronous electric machine (1) according to any one of the preceding claims; characterized by the stator (2) wherein possible inductive bearing currents are prevented by the use of the bearing electrically insulated (insulated coating) on the resolver side.

9. An interior permanent magnet synchronous electric machine (1) according to any one of the preceding claims; characterized by the stator (2) wherein the mechanical integrity is strengthened by joining the sheet metals thereof linearly along the length of the stator (2) with laser welding at 12 welding points with 0.4 mm recesses from the outside so as not to affect the magnetic flux paths in the outer diameter of the stator (2).

10. An interior permanent magnet synchronous electric machine (1) according to any one of the preceding claims; characterized by the stator (2) wherein a Grade 2 enamel insulation is used thereon according to the 400V voltage architecture11. An interior permanent magnet synchronous electric machine (1) according to any one of the preceding claims; characterized by the stator (2) which comprises cooling channels with a design that can move the cooling liquid in a tangentialdirection around itself in a spiral structure, and thereby ensuring a homogeneous temperature distribution at the desired values on its surface.

12. An interior permanent magnet synchronous electric machine (1) according to any one of the preceding claims; characterized by the stator (2) wherein the sectional and projection geometries of the cooling channels are designed in such a way as to keep the heat transfer and cooling liquid pressure drop value within the desired limits.

13. An interior permanent magnet synchronous electric machine (1) according to any one of the preceding claims; characterized by the inner housing (3) which holds the stator (2) with a close fit and enables the machine to be cooled by the rotor (4) rotating by means of the cooling liquid passing through the liquid channels thereon.

14. An interior permanent magnet synchronous electric machine (1) according to any one of the preceding claims; characterized by the inner housing (3) on which there is at least one bearing that carries the rotor (4).

15. An interior permanent magnet synchronous electric machine (1) according to any one of the preceding claims; characterized by the rotor (4) which comprises six (3x2) layers in three different orientations with a 2.5-degree angle between them in order to reduce torque ripple.

16. An interior permanent magnet synchronous electric machine (1) according to any one of the preceding claims; characterized by the rotor (4) wherein the torque ripples are reduced by realizing the six layers in a V-skew format.

17. An interior permanent magnet synchronous electric machine (1) according to any one of the preceding claims; characterized by the rotor (4) which has a lug structure optimized to minimize torque ripple.

18. An interior permanent magnet synchronous electric machine (1) according to any one of the preceding claims; characterized by the rotor (4) wherein a 0.1 mm gap is left between the edges of the rotor (4) slots and the edges of the magnets in order to enable easy placement of magnets without affecting the centrifugal strength.

19. An interior permanent magnet synchronous electric machine (1) according to any one of the preceding claims; characterized by the rotor (4) wherein a V- shaped slot (V-groove) is located on the outer diameter of the rotor (4) in the d-axis direction in order to measure the skew tolerance thereof.

20. An interior permanent magnet synchronous electric machine (1) according to any one of the preceding claims; characterized by the rotor (4) wherein mechanical stabilization and reduction of thermal resistance are provided by the use of a transfer molding process in fixing the magnets.

21. An interior permanent magnet synchronous electric machine (1) according to any one of the preceding claims; characterized by the rotor (4) which is produced with a special tooth structure (serration-serrated structure) in order to improve the mounting and shaft adhesion properties of the inner diameters of the sheet metals thereof.

22. An interior permanent magnet synchronous electric machine (1) according to any one of the preceding claims; characterized by the rotor (4) which is joined to the stator (2) with sheet metal adhesive in order to minimize iron loss (iron loss / core loss) and to reduce vibration-noise.

23. An interior permanent magnet synchronous electric machine (1) according to any one of the preceding claims; characterized by the rotor (4) wherein abalance plate is placed in front of / behind the outer layers in such a way as not to cover the magnets in order to ensure the balance thereof.

24. An interior permanent magnet synchronous electric machine (1) according to any one of the preceding claims; characterized by the rotor (4) which comprises eight interlocks between the rotor (4) V-barriers, in the center orientation of the rotor (4) lamination web, at the level of the lower paddle of the magnet pockets, and in the q-axis, so as not to affect the magnetic flux paths, and which enables the rotor (4) sheet metals to be locked in production by the presence of eight interlocks in the d-axis between the magnets and the outer diameter of the rotor (4).

25. An interior permanent magnet synchronous electric machine (1) according to any one of the preceding claims; characterized by the outer housing (6) which encloses the water channel by surrounding the stator (2) and provides entrance to the busbar and resolver cables.

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