Stator segment, stator for an electric machine of a wind turbine, and method for producing the stator segment

Abstract

A stator segment (26) for a stator of an electric machine (20) of an industrial wind turbine (10) is provided, comprising: at least two support segments (28), which run at least partially in the circumferential direction and are spaced apart from each other in the axial direction, for transferring loads occurring during operation; a first connecting plate (32) which runs in the axial direction and is inserted in the support segments (28) at an angle to a radial direction; a second connecting plate (34) which runs in the axial direction and is inserted in the support segments (28) at an angle to the radial direction, wherein an intermediate space (36) is kept free between the first connecting plate (32) and the second connecting plate (34); and a connecting element (38), which is inserted into the intermediate space (36) in the radial direction, for connection to a laminated core (40) carrying stator windings, wherein the connecting element (38) is connected to the first connecting plate (32) by a first weld seam (46) and to the second connecting plate (34) by a second weld seam (48). As a result of the fastening of the laminated core (40) by means of the connecting element (38) and by means of the fixing of the connecting element (38) in the intermediate space (36) between the connecting plates (32, 34) by welding, cost-effective and simple production of a stator of an electric machine (20) is made possible.

Description

[0001] Stator segment Stator for an electrical machine of a wind turbine and method for producing the stator segment

[0002] Description

[0003] The invention relates to a stator segment with the aid of which a stator of an electrical machine of an industrial wind turbine can be formed, as well as a method for producing such a stator segment.

[0004] EP 3 872 964 A1 shows a segmented stator for an electrical machine of a wind turbine, in which support segments are provided which partly run in the circumferential direction and are spaced apart from one another in the axial direction, into which U-shaped connecting elements running in the axial direction are inserted in the radial direction, wherein the connecting elements have openings in order to screw a dovetail guide which can be connected to a laminated core for receiving stator windings to the connecting elements.

[0005] DE 10 2008 063 783 A1 shows a manufacturing method for a segmented stator for an electrical machine of a wind turbine, in which a laminated core of a stator segment of the stator, intended to receive stator windings, is screwed to a clamping device for the duration of the manufacturing step of bonding the laminated core, wherein the clamping device has zigzag-shaped welded sheets between a radially inner tube piece and a radially outer tube piece and a screw connection is provided between the laminated core and the clamping device in a space between the zigzag-shaped sheets.

[0006] US 8 319 389 B2 shows a segmented stator for an electrical machine of a wind turbine, in which a laminated core intended to accommodate stator windings is held in a form-fitting manner on a support structure by means of a screwed-on holding element.

[0007] There is a constant need to be able to produce a stator for an electrical machine inexpensively and easily.

[0008] It is the object of the invention to show measures that enable a cost-effective and simple production of a stator of an electrical machine.

[0009] The object is achieved by a stator segment having the features of claim 1, a stator having the features of claim 12, a method having the features of claim 13, and a data agglomerate having the features of claim 15. Preferred embodiments are specified in the subclaims and the following description, each of which, individually or in combination, can represent an aspect of the invention. If a feature is presented in combination with another feature, this merely serves to simplify the presentation of the invention and is in no way intended to imply that this feature cannot also be a further development of the invention without the other feature.

[0010] One aspect of the invention relates to a stator segment for a stator of an electrical machine of an industrial wind turbine, comprising at least two support segments extending at least partially in the circumferential direction and spaced apart from one another in the axial direction for transferring loads occurring during operation, a first connecting plate extending in the axial direction and inserted at an angle to a radial direction in the support segments, a second connecting plate extending in the axial direction and inserted at an angle to the radial direction in the support segments, wherein a gap is kept free between the first connecting plate and the second connecting plate, a connecting element inserted in the radial direction into the gap for connection to a laminated core carrying stator windings,wherein the connecting element is connected to the first connecting plate via a first weld seam and to the second connecting plate via a second weld seam.

[0011] During production of the stator segment, the stator segment can be assembled in a frame-like manner using the support segments and the connecting plates, resulting in a stable and rigid structure of the stator segment in a lightweight design. This enables good support of the forces occurring in a stator during operation of the stator segment, in particular the electromagnetic forces when the stator interacts with a rotor in the electrical machine, at low production costs. Compared to screwing the laminated cores to the connecting plates, welding enables a smaller number of components. In addition, welding creates a permanent connection that cannot come loose due to the acting electromagnetic forces during operation. This improves the operational reliability and service life of the stator segment.This takes advantage of the knowledge that the connecting element, particularly in the welded state, can hold the laminated core mechanically immobile. A direct welded connection to the laminated core is avoided. Instead, in a situation in which the connecting element holds and / or fixes the laminated core immobile, the connecting element can be welded to the connecting sheets. This makes it possible to optimize the connecting element for its mechanical properties and its weldability, while the laminated core can be optimized for its electromagnetic properties as part of an electromagnetic core without having to consider the weldability of the laminated core. A potentially difficult direct welding of the laminated core to the connecting sheets and / or to the support segments is avoided and replaced by an easier-to-produce welded connection between the connecting element and the connecting sheets.By fastening the laminated core with the aid of the connecting element and fixing the connecting element in the space between the connecting sheets by welding, a cost-effective and simple production of a stator of an electrical machine is possible.

[0012] By welding the connecting element to the connecting plates, a radially captive connection can be created. By simultaneously welding the first connecting plate and the second connecting plate to the connecting element, the connecting element can be retained on the support segments via the connecting plates inserted into the support segments. At the same time, the connecting element inserted into the gap can positively block the relative mobility of the respective connecting plate in a receiving slot of the respective support segment, so that the connecting plates are also retained in the support segments.

[0013] The gap between the first connecting plate and the second connecting plate can be large enough for the first connecting plate and the second connecting plate to be inserted into a receiving slot provided in the respective support segment without abutting against each other. At the same time, the gap is large enough for a radially extending projection of the connecting element to be inserted into the gap and welded to the connecting plates that define the gap.

[0014] The respective weld seam can be created, for example, by electric welding or oxyacetylene welding. Preferably, an auxiliary material is melted to form the respective weld seam, which can in particular be part of a welding electrode, so that the material of the connecting element and the associated connecting plate does not have to be used to form the respective weld seam. It is sufficient that the material of the connecting element and the associated connecting plate is melted sufficiently on the surface to create a material-to-material bond with the respective weld seam.

[0015] The connecting plates can be punched from a flat metal sheet. Preferably, a large portion of the connecting plates are designed as identical parts.

[0016] In particular, the first connecting plate is arranged and aligned in a mirror image to the second connecting plate.

[0017] The angle a at which the respective connecting plate is bevelled to the radial direction can be, for example, 0° < a < 90°, in particular 10° < a < 80°, preferably 30° < a < 60° and particularly preferably a = 45° ± 10°.

[0018] The connecting element can, on the one hand, form a connection with the laminated core and, on the other hand, form a welded connection with the connecting plates. The connecting element can have a shoulder that extends into the space between the connecting plates, with the shoulder preferably extending over a large part of the distance between the adjacent support segments. The connecting element is preferably designed as a rod aligned in the axial direction. For example, the connecting element has a roughly T-shaped cross-section.

[0019] The support segments can be punched out of a flat metallic sheet. Preferably, a majority or even all of the support segments are designed as identical parts. The respective support segment can form at least part of the extension of the stator in the circumferential direction. Preferably, the support segment is curved with a radius of the stator, which is composed of several support segments. The respective support segment can have at least one receiving slot into which the respective connecting plate can be inserted. Preferably, the connecting plate can be inserted into the receiving slot with a portion in the radial direction, although it is also possible for the connecting plate to be inserted into the receiving slot by a relative movement in the axial direction.Preferably, a part of the connecting plate projects beyond the extent of the receiving slot in an area axially adjacent to the support segment, so that an axial stop is formed between the connecting plate and the support segment, which axial stop determines the relative position of the at least one connecting plate to the at least one support segment.

[0020] The stator, which can be assembled using the at least one stator segment, is essentially annular and defines the axial direction, the radial direction and the circumferential direction through its annular shape. The stator can be designed for an internal rotor or an external rotor. The individual stator segments can each be individually fastened to a corresponding support structure in the electrical machine and / or connected to one another to form a closed ring to form the stator of the electrical machine. Since the individual stator segments weigh significantly less than the entire stator, assembly of the stator is considerably simplified and is only possible in applications where heavy assembly equipment, such as a crane, cannot easily be found, for example in an offshore wind turbine.

[0021] The electric machine can comprise a stator composed of stator segments and a rotor that interacts with the stator. The rotor can be coupled, in particular via a wind gear, to a wind rotor of the wind turbine, so that the electric machine, in generator mode, can generate electrical energy, in particular for a public power grid, from the wind energy acting on the wind rotor.

[0022] Industrial wind turbines are primarily designed to generate energy from wind power. The electrical energy generated from wind power can be fed into a public power grid, in particular, to supply energy consumers with renewable energy. A wind turbine gearbox designed for an industrial wind turbine is designed specifically for an output of over 1.0 MW, preferably over 5.0 MW, and particularly preferably over 7.5 MW, and is accordingly robust and large-volume.

[0023] In particular, the laminated core is fastened to the connecting element, wherein the laminated core is pressed against the support segments and / or the connecting plates via the connecting element with a contact force, wherein in particular the laminated core rests flat against the support segments and / or the connecting plates. The connecting element can, for example, have a positive connection with the laminated core, which makes it possible to press the laminated core against the contact force, in particular immovably, when the connecting element is pushed and / or pulled into the intermediate space. The laminated core can be precisely aligned during assembly and fixed in the intended end position by the applied contact force, wherein this contact force is maintained after the connecting element has been welded to the connecting plates. This achieves a precise and stable connection of the stator segment in a cost-effective manner.

[0024] The contact pressure can be provided by pulling on a shoulder of the connecting element that projects into the gap. For this purpose, for example, a clamp can engage the shoulder and be pulled with the desired force. However, it is also possible to hook a hook onto the shoulder of the connecting element and apply the contact pressure by pulling on the hook. Likewise, an internal or external thread can be provided in the connecting element, with which a tool for tightening the connecting element can be temporarily screwed. With the help of the applied contact pressure, the connecting element can press the laminated core flat against a corresponding surface of the support segments and / or the connecting sheets, so that the applied contact pressure can prevent an unnecessary gap between the laminated core and the rest of the stator segment.Preferably, the connecting element is centered within the intermediate space on the first connecting plate and on the second connecting plate in a tangential direction. The first connecting plate and the second connecting plate can have mutually facing side surfaces which form a slot, in particular a radially and axially extending slot, for the intermediate space. The extent of the slot can be so large that tilting of the connecting element within the slot-shaped intermediate space can be avoided or limited to a tolerable extent. Preferably, a fit is formed between the connecting element and the intermediate space delimited by the connecting plates, in particular a slot-shaped one. If the connecting plates are aligned in a radial direction, the tangential spacing of the connecting plates can form the fit of the intermediate space for the attachment of the connecting element to be inserted into the intermediate space.If the connecting plates are aligned at an angle to the radial direction, for example, in a roof-shaped and / or arrow-shaped configuration, it is possible to chamfer the connecting plates along their thickness in such a way that the mutually facing side surfaces are parallel, and the gap can be designed as a slot-shaped fit for the connecting element. The correct alignment of the connecting element when inserted into the gap and when welded can be ensured by centering, which also ensures the correct alignment of the laminated core, which is fixedly positioned with the help of the connecting element.

[0025] Particularly preferably, the connecting element has a connecting contour, in particular a dovetail contour, for axially sliding on the laminated core. The connecting contour can in particular have a hook engaging in an undercut, so that a captive fastening in the radial direction is formed. The laminated core can be aligned relative to the support segments via the axial displaceability. Once the laminated core has reached its designated end position relative to the support segments, the connecting element can be moved further and further into the intermediate space in the radial direction, so that the connecting contour can press the laminated core against it with a contact force, whereby an at least frictional positional fixation of the laminated core within the stator segment can be achieved.In the radial direction, even a gapless, positive-locking positional fixation for the laminated core can be achieved, which is designed to be permanent due to the welded connection of the connecting element to the connecting plates. The laminated core can have a thicker radial extension in the area of ​​the connection contour in order to form the corresponding positive connection. Preferably, the support segments and / or the connecting plates have a corresponding recess to avoid an unnecessary gap between the laminated core and the remaining stator segment.

[0026] In particular, a welding area with a V-shaped cross-section is / are formed between the connecting element and the first connecting plate and / or between the connecting element and the second connecting plate to form the first weld seam and / or second weld seam designed as a fillet weld. In particular outside the intermediate space into which the connecting element can be inserted, one side of the connecting plate can run at an angle to the connecting element, so that a V-shaped free space is created between the connecting plate and the connecting element, which, after welding, defines the welding area filled with the fillet weld. The V-shaped alignment of the surfaces of the connecting plate and the connecting element facing one another makes it easier to guide a welding electrode and / or welding wire in the axial direction along the direction of the fillet weld to be created.This simplifies production and can be carried out particularly quickly.

[0027] Preferably, the first weld seam and the second weld seam are formed on different, mutually facing side surfaces of the connecting element. The connecting element can thus be held firmly in place with approximately symmetrical holding forces applied via the weld seams. Any distortion that may occur during the creation of one weld seam can be fully or partially compensated for by the creation of the other weld seam.

[0028] Particularly preferably, the connecting element, the first connecting plate, and the second connecting plate are made from a material different from the laminated core, in particular different from electrical steel, wherein in particular the connecting element, the first connecting plate, and the second connecting plate are made from a weldable steel. The laminated core can in particular comprise sheet laminations made from electrical steel. The electrical steel can be designed in accordance with EN 10106 or EN 10107. Since the connecting element, and not the laminated core, is welded to the connecting plates, a welded connection to the laminated core is avoided. A welded connection to a material consisting of electrical steel, which has poor weldability, is thereby avoided. Instead, the connecting element and the connecting plates can be made from a material with better weldability than electrical steel.

[0029] In particular, at least one first connecting plate and / or at least one second connecting plate has a curved cross-section at a tangential end of the support segments and a straight cross-section at all other points. The curved shape of the connecting plate prevents the connecting plate from protruding at the tangential end of the stator segment, particularly if the shape is beveled to the radial direction. The curved connecting plate can, for example, be inserted in the axial direction into a receiving slot in the support segment. The curved connecting plate can be made from a flat, punched sheet that was bent after punching. The remaining connecting plates are preferably made from a flat, punched sheet, particularly off-the-tool. In one embodiment, the sheet metal package as well as the support segments and / or the connecting plates are coated with a baked enamel.The bonding varnish allows the laminations of the laminated core to bond together securely. This makes it possible, in principle, to apply the bonding varnish only after the connecting element has been welded to the connecting plates, resulting in an even better bond between the stator segment and uniform surface protection. This prevents any deterioration of the bonding varnish coating due to thermal influences during welding. However, it is also possible to first coat the laminated core with the bonding varnish, then bake it, which in particular achieves a defined preload in the receiving elements, and finally connect the laminated core, preferably in an axially compressed state, to the support segments and / or the connecting plates by welding the connecting element.In this case, it is possible to coat the support segments and / or the connecting plates with the baking varnish or not.

[0030] Particularly preferably, the laminated core has, at least at one point in the circumferential direction, a receiving finger which projects in the radial direction and is formed at least partially in a common circumferential region with the connecting element, for delimiting a stator slot. The receiving finger can cover at least part of the connecting element when viewed in the radial direction. Since no screw connection is provided for fastening the laminated core, it is not necessary to provide a particularly wide stator slot in the area where the laminated core is fastened in the stator segment, which offers sufficient space for the insertion of a screwdriver. Instead, the width of the stator slot in the tangential direction can be adapted to the requirements for accommodating stator windings, thereby avoiding unnecessary cavities without stator windings.In particular, the connecting element is provided exclusively on the underside of the laminated core facing the support segments, allowing the shape of the laminated core on the opposite upper side to be designed in almost any way. This also makes it possible to provide the stator slot offset from the gap in the circumferential direction and / or to form the receiving finger in a radial extension of the gap.

[0031] In particular, an air gap is provided directly at the axial ends of the laminated core. Since the laminated core can already be correctly positioned and secured using the connecting element, it is not necessary to provide a front-end plate in the axial direction that acts as an axial stop to determine the axial relative position of the laminated core. The design of the stator segment can thus be simplified with a very small axial extension and a small number of components.

[0032] A further aspect of the invention relates to a stator for an electrical machine of an industrial wind turbine having a plurality of stator segments arranged one behind the other in the circumferential direction, each of which can be designed and further developed as described above. The electrical machine can in particular be configured as an external rotor or an internal rotor. The stator can in particular be designed and further developed as explained above with reference to the stator segment. By fastening the laminated core with the aid of the connecting element and fixing the connecting element in the space between the connecting sheets by welding, a cost-effective and simple production of a stator of an electrical machine is possible.

[0033] A further aspect of the invention relates to a method for producing a stator segment, which can be designed and developed as described above, in which first the first connecting plate and the second connecting plate are inserted into the support segments, subsequently the connecting element is inserted into the intermediate space, wherein the laminated core is already connected to the connecting element or is subsequently connected to the connecting element, subsequently a contact force is applied to the connecting element to press the laminated core onto the support segments and / or onto the connecting plates, wherein at the same time the connecting element is welded to the first connecting plate and / or to the second connecting plate. The method can be designed and developed in particular as explained above with reference to the above aspects.By fastening the laminated core with the aid of the connecting element and fixing the connecting element in the space between the connecting sheets by welding, a cost-effective and simple production of a stator of an electrical machine is possible.

[0034] Preferably, before the laminated core is pressed on, the laminated core is aligned in the axial direction. In particular, a limiting plate acting in the axial direction is used for alignment. The limiting plate is removed from the stator segment after pressing or welding. The laminated core can be displaced in the axial direction along the connecting element with the aid of an aid, such as the limiting plate, or without aids, in order to position the laminated core in the designated end position and subsequently fix it by pressing and welding the connecting element. An axial stop permanently attached to the stator segment can be omitted.

[0035] One aspect of the invention further relates to a data agglomerate with data packets summarized in a common file or distributed across different files for depicting the three-dimensional shape and / or the interactions of all components provided in the stator segment, which can be designed and further developed as described above, or the stator, which can be designed and further developed as described above, wherein the data packets are prepared for the purpose of additive manufacturing of the components of the stator segment or the stator, in particular by 3D printing, when processed by a data processing device for operating a machine tool for the additive manufacturing of devices,and / or when processed by a data processing device for carrying out a technical simulation, to carry out a simulation of the functioning of the stator segment or the stator and to output the simulation results generated thereby for further use, in particular for the purpose of providing proof of fatigue strength as a function of variable loads and / or variable temperature loads and, if necessary, to compare it with measurement data determined on a real-life device according to the invention and / or on a prototype of the device according to the invention. The data packets of the data agglomerate are specifically adapted to the inventive design of the respective device according to the invention described above.in order to adequately represent the inventive interaction of the components of the inventive device during processing in the data processing device. The data packets can, in particular, be stored spatially distributed, but adapted to one another in such a way that, if all data packets are combined in a common data processing device, the data agglomerate thus assembled provides all the necessary data for additive manufacturing and / or technical simulation with the aid of the data processing device for the inventive device.

[0036] For example, the data packets are each separate parts of a data library (“library”), which are combined to form the data agglomerate and are adapted to each other with respect to their relative dimensions and / or absolute dimensions and / or material properties corresponding to the respective device according to the invention. The data agglomerate can represent a virtual embodiment of the respective device according to the invention in the manner of a so-called “digital twin,” which enables a virtual investigation in the form of a simulation or a real objectification using an additive manufacturing process. Such a digital twin is described, for example, in US 2017 / 286572 A1, the disclosure of which is hereby incorporated by reference as part of the invention.

[0037] When the data processing device of the machine tool processes the data agglomerate, the device according to the invention is produced, so that after processing the data agglomerate in the data processing device, the device according to the invention is obtained, at least in the form of a prototype. In particular, each data packet can represent a separately implemented component of the respective associated device according to the invention, so that the individual components can easily be assembled, actually and / or virtually, in terms of their relative position and / or relative mobility in order to realize the interactions essential to the invention. In particular, it is possible, with the aid of the respective data packets, to produce the various components of the respective device separately and, if appropriate, from different materials by additive manufacturing and subsequently assemble them to form a prototype of the respective device.The division of the data of the data agglomerate into different data packets thus enables a simple sequential additive production of components of the respective device that are movable relative to one another in the form of a kit (“kit of parts”), which is designed to only be assembled in a meaningful way for the inventive interaction of the components of the prototype for the solution of the problem underlying the invention.

[0038] Additionally or alternatively, it is possible to use the data packets of the data agglomerate in a virtual environment during a technical simulation to calculate and / or predict the individual components of the respective device, their interactions, the physical state, and / or the change in physical parameters as a function of various boundary conditions and / or over time of the associated device according to the invention, and to further use them to verify whether the device according to the invention is sufficiently suitable for the intended purpose based on the assumed design and taking into account the assumed simulated influences. If the data agglomerate is processed by a data processing device that maps the simulation environment, it is possible to examine the behavior of the device according to the invention taking into account boundary conditions, in particular changing ones.This makes it possible, for example, to investigate centrifugal force effects on individual components of the device according to the invention as a function of various static and / or dynamic loads and / or different operating temperatures, whereby such simulation results can be incorporated into the preparation of a fatigue strength verification. Preferably, the simulation results obtained after processing the data agglomerate in the data processing device for the simulation environment are stored in order to compare them with measurement data determined on an actually produced device according to the invention and / or on a prototype of the device according to the invention. This makes it possible to assess the quality of the simulation results obtained with the aid of the data agglomerate and / or, in particular in the case of particularly significant deviations, to identify measurement errors and / or an erroneous measurement.Non-destructive quality control of the device according to the invention is thereby simplified and improved.

[0039] The data agglomerate enables the cost-effective production of prototypes and / or computer-based simulations to study the functionality of the rotating body and / or the holding tool, identify problems in the specific application, and find improvements. The solution to the problem underlying the invention can be easily and cost-effectively verified using the data agglomerate.

[0040] Fig. 1 : a schematic perspective view of a wind turbine,

[0041] Fig. 2: a schematic perspective view of a part of a stator segment during manufacture,

[0042] Fig. 3: a schematic front view of the stator segment from Fig. 2 at the end of production.

[0043] Fig. 4: a schematic detailed view of the stator segment from Fig. 3,

[0044] Fig. 5: a schematic perspective view of the stator segment from Fig. 4 during a layering of the laminated core and

[0045] Fig. 6: a schematic perspective view of the stator segment from Fig. 3 from below.

[0046] The wind turbine 10 shown in Fig. 1 can be used to generate electrical energy from wind power. For this purpose, the wind turbine 10 has a wind rotor 12 that can be rotated by wind power. The wind rotor 12 is coupled to a drive train 14. For this purpose, the wind rotor 12 is connected to a rotor shaft 16, which is coupled within the drive train 14 to a gearbox 18 in order to convert the torque introduced via the wind rotor 12 and the rotor shaft 16. The torque converted in the gearbox 18 is fed to an electric machine 20 operated in generator mode. The electric machine 20 can have a rotor coupled to the output of the gearbox 18, which interacts with a stator in order to generate electrical energy in generator mode of the electric machine 20.However, it is also possible, in a variant referred to as "direct drive," to couple the electric motor 20 directly to the rotor shaft 16, thus eliminating the intermediate transmission 18. The electrical energy generated by the electric motor 20 can be fed to a rechargeable battery and / or a power grid. In the illustrated embodiment, the drive train 14 is entirely housed in a nacelle 22, which is attached to an upper free end of a tower 24.

[0047] The stator segment 26, partially shown in Fig. 2, can form part of the stator of the electric machine 20. The stator segment 26 has at least two support segments 28, which extend partially in the circumferential direction and are spaced apart from one another in the axial direction and in which receiving slots 30 are formed. A first connecting plate 32, which extends at an angle to a radial direction, and a second connecting plate 34, which is arranged in a mirror image of the first connecting plate 32, can be provided in the receiving slots 30. In particular, several pairs of first connecting plates 32 and second connecting plates 34 are provided. The connecting plates 32, 34 can be designed as flat, off-the-tool stamped parts of a metallic sheet, wherein the connecting plates 32, 34 can be curved at the tangential ends of the stator segment 26 for installation space reasons.A gap 36 remains at the tapered ends of the first connecting plate 32 and the second connecting plate 34. As shown in Fig. 3, a connecting element 38 extending in the axial direction, rod-shaped and with a roughly T-shaped cross-section, can extend into the gap 36, the shoulder 42 of which protrudes in the radial direction can even be centered on the first connecting plate 32 and the second connecting plate 34. With the help of the connecting element 38, a laminated core 40 can be pressed against the support segments 28 and the connecting plates 32, 34 with as little gap and as even a flat surface as possible. For this purpose, the shoulder 42 of the connecting element 38 can be pulled, for example.

[0048] As shown in Fig. 4, the connecting element 38 can have a connecting contour 44 designed as a dovetail contour, with which a captive connection with the laminated core 40 can be established in the radial direction. The connecting contour 44 can have enough play to allow the laminated core 40 to be displaced in the axial direction on the connecting element 38. However, if the connecting element 38 is tightened, the laminated core 40 can be fixed in a movement-resistant manner. In this pressed-on state, the connecting element 38 can be welded to the first connecting plate 32 and the second connecting plate 34. The essentially radial orientation of the shoulder 42 of the connecting element 38 in the intermediate space 36 and the angled orientation of the associated connecting plates 32, 34 to the radial direction result in a V-shaped welding space between the connecting element 38 and the connecting plates 32, 34.In this welding space, a first weld seam 46, designed as a fillet weld, can be formed between the shoulder 42 of the connecting element 38 and the first connecting plate 32, and a second weld seam 48, designed as a fillet weld, can be formed between the shoulder 42 of the connecting element 38 and the second connecting plate 34. Since the laminated core 40 does not have to be screwed in the area of ​​the intermediate space 36, it is possible for a receiving finger 50, with the aid of which a stator groove 52 for a stator winding can be defined, to be positioned at least partially in a radial extension of the connecting element 38 and / or of the, in particular, slot-shaped, intermediate space 36. As shown in Fig. 5, the laminated core 40 can be displaced in the axial direction along the connecting element 38 until the intended end position is found, with or without an auxiliary tool. Thereafter, as shown in Fig.As shown in Figure 6, the projection 42 of the connecting element 38 is tightened, thereby holding the laminated core 40 in place with a clamping force. In this position, the connecting element 38 can be welded to the connecting plates 32, 34 to obtain the stator segment 26.

Claims

P a t e n t a n s p r ü c h e 1. Stator segment (26) for a stator of an electrical machine (20) of an industrial wind turbine (10), comprising at least two support segments (28) extending at least partially in the circumferential direction and spaced apart from one another in the axial direction for transferring loads occurring during operation, a first connecting plate (32) extending in the axial direction and inserted at an angle to a radial direction in the support segments (28), a second connecting plate (34) extending in the axial direction and inserted at an angle to the radial direction in the support segments (28), wherein an intermediate space (36) is kept free between the first connecting plate (32) and the second connecting plate (34), a connecting element (38) inserted in the radial direction into the intermediate space (36) for connection to a laminated core (40) carrying stator windings,wherein the connecting element (38) is connected to the first connecting plate (32) via a first weld seam (46) and to the second connecting plate (34) via a second weld seam (48).

2. Stator segment (26) according to claim 1, wherein the laminated core (40) is fastened to the connecting element (38), wherein the laminated core (40) is pressed onto the support segments (28) and / or the connecting plates (32, 34) with a contact force via the connecting element (38), wherein in particular the laminated core (40) rests flatly on the support segments (28) and / or on the connecting plates (32, 34).

3. Stator segment (26) according to claim 1 or 2, wherein the connecting element (38) is centered within the intermediate space (36) on the first connecting plate (32) and on the second connecting plate (34) in the tangential direction.

4. Stator segment (26) according to one of claims 1 to 3, wherein the connecting element (38) has a connecting contour (44), in particular a dovetail contour, for axially sliding on the laminated core (40).

5. Stator segment (26) according to one of claims 1 to 4, wherein between the connecting element (38) and the first connecting plate (32) and / or between the connecting element (38) and the second connecting plate (34) a welding region with a V-shaped cross section is / are formed for forming the first weld seam (46) and / or second weld seam (48) formed as a fillet weld.

6. Stator segment (26) according to one of claims 1 to 5, wherein the first weld seam (46) and the second weld seam (48) are formed on different side surfaces of the connecting element (38) facing away from one another.

7. Stator segment (26) according to one of claims 1 to 6, wherein the connecting element (38), the first connecting plate (32) and the second connecting plate (34) are made of a material different from the laminated core (40), in particular different from electrical steel, wherein in particular the connecting element (38), the first connecting plate (32) and the second connecting plate (34) are made of a weldable steel.

8. Stator segment (26) according to one of claims 1 to 7, wherein at least one first connecting plate (32) and / or at least one second connecting plate (34) is a tangential end of the support segments (28) has a curved cross-section and a straight cross-section at all other points.

9. Stator segment (26) according to one of claims 1 to 8, wherein the laminated core (40) and the support segments (28) and / or the connecting sheets (32, 34) are coated with a baking varnish.

10. Stator segment (26) according to one of claims 1 to 9, wherein the lamination package (40) has at least one location in the circumferential direction a receiving finger (50) which projects in the radial direction and is formed at least partially in a common circumferential region with the connecting element (38) for delimiting a stator groove (52).

11. Stator segment (26) according to one of claims 1 to 10, wherein an air gap is directly adjacent to the axial ends of the laminated core (40).

12. Stator for an electrical machine (20) of an industrial wind turbine (10) with a plurality of stator segments (26) arranged one behind the other in the circumferential direction, each according to one of claims 1 to 11.

13. A method for producing a stator segment (26) according to one of claims 1 to 12, wherein firstly the first connecting plate (32) and the second connecting plate (34) are inserted into the support segments (28), subsequently the connecting element (38) is inserted into the intermediate space (36), wherein the laminated core (40) is already connected to the connecting element (38) or is subsequently connected to the connecting element (38), subsequently, a contact pressure is applied to the connecting element (38) to press the laminated core (40) onto the support segments (28) and / or onto the connecting plates (32, 34), wherein at the same time the connecting element (38) is welded to the first connecting plate (32) and / or to the second connecting plate (34).

14. The method according to claim 13, wherein before the laminated core (40) is pressed on, the laminated core (40) is aligned in the axial direction, wherein in particular a limiting plate acting in the axial direction is used for the alignment, wherein the limiting plate is removed from the stator segment (26) after the pressing on or after the welding.

15. Data agglomerate with data packets summarized in a common file or distributed across different files for mapping the three-dimensional shape and / or the interactions of all components provided in the stator segment (26) according to one of claims 1 to 11 or the stator according to claim 12, wherein the data packets are prepared to carry out additive manufacturing of the components of the stator segment (26) or of the stator, in particular by 3D printing, when processed by a data processing device for operating a machine tool for the additive manufacture of devices and / or to carry out a simulation of the functioning of the stator segment (26) or of the stator when processed by a data processing device for carrying out a technical simulation and to output the simulation results generated thereby for further use,in particular for the purpose of providing proof of fatigue strength in dependence on changing loads and / or changing temperature loads.

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