Housing cover assembly for a winding head of a stator of an electrical machine, stator having a housing cover assembly, electrical machine having a stator

Abstract

The invention relates to a housing cover assembly (1) for a winding head (2) of a stator (3) of an electrical machine (4), comprising a cylindrical hollow body (5) which is designed to be connected at one end to a winding head housing (6) and to be connected to the stator (3) at an opposite end, so that the cylindrical hollow body (5) at least partially covers the winding head (2) in a radially outward direction, characterized in that the cylindrical hollow body (5) has a slot (7), so that the cylindrical hollow body (5) can be bent open for an assembly process with the stator (3). The invention also relates to a stator (3) having a housing cover assembly (1) of this kind, and to an electrical machine (4) having a stator of this kind.

Description

[0001] P241523

[0002] - 1 - Housing cover device for a winding head of a stator of an electric machine, stator with a housing cover device, electric machine with a stator

[0003] The invention relates to a housing cover device for a winding head of a stator of an electric machine, comprising a cylindrical hollow body which is arranged to be connected on one side to a winding head housing and on the opposite side to the stator, such that the cylindrical hollow body at least partially covers the winding head in a radially outward direction, a stator with a housing cover device and an electric machine with such a stator.

[0004] Winding heads for stators are generally known from the prior art. These usually require enclosure. The radial installation space is generally limited and valuable.

[0005] In this context, it has become apparent that there is a need to provide a housing cover device for a winding head of a stator of an electric machine, in particular a need to provide an improved housing cover device for a winding head of a stator of an electric machine.

[0006] It is therefore an object of the present invention to eliminate, or at least partially eliminate, the disadvantages described above in a housing cover device for a winding head of a stator of an electrical machine.

[0007] In particular, the object of the present invention is to provide an improved housing cover device for a winding head of a stator of an electric machine.

[0008] This problem is solved in a generic housing cover device according to the invention by the fact that the cylindrical hollow body includes a slot, so that the cylindrical hollow body is suitable for an assembly process with the stator P241523

[0009] - 2 -is bendable. In particular, the problem is solved by a wheel hub with the features of independent claim 1.

[0010] Furthermore, the problem is solved by a stator having the features of independent claim 9 and an electrical machine having the features of independent claim 10.

[0011] Features disclosed in connection with the housing cover device according to the invention naturally also apply in connection with the stator and the electrical machine according to the invention, and vice versa, so that the disclosure of the individual aspects of the invention always makes or can make reciprocal reference.

[0012] A first aspect of the present invention relates to a housing cover device for a winding head of a stator of an electric machine, comprising a cylindrical hollow body which is arranged to be connected on one side to a winding head housing and on the opposite side to the stator, such that the cylindrical hollow body at least partially covers the winding head in a radially outward direction, characterized in that

[0013] The cylindrical hollow body includes a slot, so that the cylindrical hollow body can be bent open for an assembly process with the stator.

[0014] The term winding head refers to a section of the coil winding that is located outside the laminated core or magnetic core and connects the active winding wires of the coil winding in the slots of the stator, thus creating a closed electrical circuit.

[0015] In this context, the stator refers to a stationary component used to generate a magnetic field that interacts with the rotor of the electric machine. In AC motors, the stator is typically equipped with coil windings through which an alternating current flows. This current generates a rotating magnetic field that drives the rotor. P241523

[0016] - 3 -

[0017] The term "electric machine" refers to a machine that can convert electrical energy into mechanical energy and vice versa. An electric machine can include an electric motor. An electric machine can include a generator. An electric machine can include an AC-based electric motor. An electric machine can include an asynchronous motor. An electric machine can include a synchronous motor.

[0018] The term winding head housing refers to a structural enclosure for protecting the winding head from its environment. The winding head housing may be made of plastic. It may be a single piece or a multi-piece housing. It may also be an injection-molded component. The winding head housing may be designed to be connected to a stator, either directly or indirectly.

[0019] The term "cylindrical hollow body" in this context refers in particular to an annular body designed to close a winding head housing. The cylindrical hollow body may be made of plastic and / or metal. It may be an injection-molded component. The cylindrical hollow body may include at least one interface for connection to the winding head housing. It may include at least one interface for direct and / or indirect connection to the stator. A cross-section of the cylindrical hollow body may include an axially extending wall section. The cylindrical hollow body may be bonded to the stator. It may be bonded to the winding head housing. The cylindrical hollow body may be connected to the winding head housing and / or stator via a plug connection, e.g., a tongue-and-groove system.A cross-section of the cylindrical hollow body can include a radially extending wall section in a sectional view. The axially and radially extending wall sections can serve to enclose the winding head. In other words, the cylindrical hollow body can have an I-shape or an L-shape in a sectional view. The cylindrical hollow body essentially consists of a ring on a diameter. The cylindrical hollow body can be found on P241523.

[0020] - 4 - The cylindrical hollow body can be manufactured to a larger diameter and only formed to its final dimension during assembly. Alternatively, the cylindrical hollow body can be manufactured to a smaller diameter and only bent to its final dimension during assembly.

[0021] In this context, the term "slot" refers to a free space in the outer surface of the cylindrical hollow body, which allows the cylindrical hollow body to be bent open for assembly. The slot can be continuous. The slot can run axially to the cylindrical hollow body. The slot can run obliquely to the cylindrical hollow body. The slot can be straight. The slot can be wavy, for example, S-shaped. The slot can have any shape. The slot can also only partially penetrate the cylindrical hollow body in the axial direction. The slot can also completely penetrate the cylindrical hollow body in the axial direction. The slot allows for flexible expansion of the cylindrical hollow body. The cylindrical hollow body can thus be mounted over the larger winding head. After the cylindrical hollow body is mounted, it can be bent to its final dimensions.The final dimension can be smaller than the winding head diameter. This allows for advantageous space savings. The slot allows the cylindrical hollow body to change its diameter.

[0022] The invention is based on the understanding that the winding heads must be enclosed. For this purpose, closed rings (i.e., cylindrical hollow bodies) without slots are slid over the winding heads. The closed rings must have at least the radial dimensions of the winding head plus an assembly clearance. This reduces radial installation space, particularly in the area where the ring connects to the stator. To achieve a more compact installation space, the invention proposes to design the cylindrical hollow body with slots so that it can be bent open during assembly. This reduces the radial installation space required, which has a beneficial effect on the overall stator design.

[0023] In other words, current solutions are designed so that the lids (i.e., cylindrical hollow bodies) form a closed ring including the adhesive area P241523

[0024] - 5 -over the winding head. This means that, within tolerance, the smallest possible diameter inside the cover must be larger than the winding head. This, in turn, means that the connection of the cover to the stator must also be radially outside this diameter. However, there is usually no radial installation space to position the connection or the ring itself so far outwards. Furthermore, the widening of the winding head creates a relatively large space towards the stator, which accommodates additional oil. Since there is generally only a limited amount of oil available in an E-axis, this area must be filled with material as much as possible to fill the cavity. In the case of a closed cover, this can only be achieved with an additional component. The slotted design of the cylindrical hollow cylinder allows for an additional accumulation of material on the cylindrical hollow body itself.

[0025] The slotted design of the cylindrical hollow body allows it to be expanded with minimal force and slid over the winding head. This eliminates the limitation that the inner diameter of the cylindrical hollow body cannot be greater than that of the winding head.

[0026] This allows the connection point (e.g., the adhesive point on the plastic overmolding of the stator) to be moved further radially inwards, thus saving installation space.

[0027] Additionally, extra material can now be added in the area of ​​the winding head expansion to fill the cavity and reduce the oil volume.

[0028] Advantageous embodiments are claimed in the dependent claims and are explained in more detail below.

[0029] According to a preferred embodiment, the slot can be formed by a first interface surface and a second interface surface on the cylindrical hollow body, wherein the first interface surface and the second interface surface can be configured to be glued together after the assembly process, or wherein the first interface surface and the second interface surface

[0030] - 6 -may be set up to be in contact in a force-locking state in an unloaded state, or wherein the first interface surface and second interface surface may comprise corresponding form-locking connection interfaces which are set up to be connected after the assembly process.

[0031] The slot can simply be straight and glued shut. The slot can incorporate a locking mechanism such as a spring groove or clips with hooks. The slot can be closed entirely, for example, under preload or without preload. The slot can be sealed oil-tight, for example, by gluing. In this way, a cylindrical hollow body can be easily provided that completely shields the winding head from the environment via its outer surface. The cylindrical hollow body can thus be sealed.

[0032] According to a preferred embodiment, the slot in an assembled state can comprise a constant slot width for an outlet of a coolant.

[0033] In other words, the slot is not completely closed when the cylindrical hollow body is assembled. A constant slot width can be achieved, for example, using spacers. These spacers can be attached to the cylindrical hollow body in the form of pins. The spacers can also be located on the stator and / or winding head housing. The constant slot width can be designed during the initial construction of the cylindrical hollow body. The slot can serve as an interface for coolant or as an outlet for the coolant.

[0034] In this way, functional integration for the cylindrical hollow body can be advantageously enabled. In this way, a compact stator can be advantageously achieved. In this way, improved cooling of the coil winding and the winding head can be advantageously enabled.

[0035] According to a preferred embodiment, the slot can have a variable slot width for a coolant outlet in an assembled state. P241523

[0036] - 7- The variable slot width can be achieved, for example, by means of spacer elements of different widths, which are arranged on the stator and / or winding head housing.

[0037] This allows for advantageous optimization of the stator cooling. The coolant flow can be directed precisely. The coolant flow can be throttled precisely.

[0038] According to a preferred embodiment, the slot can be arranged to be aligned circumferentially with a counterpart of the stator and / or the winding head housing during assembly, so that the slot assumes a specific position in the circumferential direction.

[0039] The counterpart can be located on the stator and / or on the winding head housing. Furthermore, it can be aligned so that all areas of the winding head are wetted with coolant.

[0040] The slot can be positioned at the 12 o'clock position when installed in the vehicle. This allows the winding head housing to be filled to its maximum capacity. The slot can also be rotated, for example, to the 10 or 2 o'clock position. This ensures that the coolant flows in only one direction along the cylindrical hollow body, for example, to specifically wet and cool the high-voltage terminal (i.e., the busbars).

[0041] In this way, the flow direction of a coolant exiting through the slot can be advantageously adjusted.

[0042] According to a preferred embodiment, the cylindrical hollow body can have an axially extending wall section, wherein the axially extending wall section can be arranged on an outer lateral surface, wherein the axially extending wall section can be arranged on one side of the slot, and wherein the axially extending wall section can be configured to limit the flow direction of the coolant exiting the winding head through the slot. P241523

[0043] - 8- In this way, the flow direction of the coolant can be advantageously limited at the coolant outlet. For example, the coolant can be directed onto the busbars so that they are additionally cooled.

[0044] According to a preferred embodiment, the cylindrical hollow body can have a first circumferentially extending wall section, wherein the first circumferentially extending wall section can be arranged on an outer lateral surface, and wherein the first circumferentially extending wall section can be configured to limit a flow direction of the cooling fluid flowing on the outer lateral surface of the cylindrical hollow body, and / or wherein the cylindrical hollow body can have a second circumferentially extending wall section, wherein the second circumferentially extending wall section can be arranged on an outer lateral surface, and wherein the second circumferentially extending wall section can be configured to limit a flow direction of the cooling fluid flowing on the outer lateral surface of the cylindrical hollow body.

[0045] In this way, the flow direction of the coolant can be advantageously limited at the outlet. For example, the coolant can be directed onto the busbars, thus providing them with additional cooling. Furthermore, axial splashing of the coolant can be prevented.

[0046] In other words, additional contours are arranged on the cylindrical hollow body, namely axially extending and circumferentially extending sections that guide the oil coming from the slot. Walls or channels can be incorporated for this purpose. The cylindrical hollow body can also be shaped so that the oil must flow directly along the stator wall to prevent it from overflowing axially and flowing into the air gap. This avoids drag losses.

[0047] According to a preferred embodiment, the inner diameter of the cylindrical hollow body can be smaller in a region facing the stator than in a region facing away from the stator, so that a P241523

[0048] - 9 - The receiving area for the winding head in the area facing the stator is smaller than a receiving area in the area facing away from the stator.

[0049] The front section corresponds to the area where the winding head widens. The reduced inner diameter allows for a reduction in the volume that needs to be filled with coolant. In other words, the oil volume is reduced. This, in turn, reduces the pump power and the required amount of coolant. This reduction can be achieved by accumulating material in this area. Advantageously, this material accumulation can be formed integrally with the cylindrical hollow body. Therefore, no additional component is required. This has a positive impact on production costs.

[0050] Another aspect concerns a stator with a housing cover device described in more detail above.

[0051] Another aspect concerns an electric machine with a stator described in more detail above. The electric machine can preferably be an electric motor.

[0052] Another aspect concerns a drive train with an electric machine and / or a stator and / or a housing cover device described above.

[0053] The invention is explained below with the aid of a drawing. The drawing shows:

[0054] Figure 1 shows a housing cover device according to the invention,

[0055] Figure 2 shows a housing cover device according to the invention in a bent-up state,

[0056] Figure 3 shows a housing cover device according to the invention in an assembled state,

[0057] Figure 4 is a sectional view of a [component] according to the invention.

[0058] Housing cover device, P241523

[0059] - 10 -

[0060] Figure 5 shows another sectional view of a housing cover device according to the invention,

[0061] Figure 6 shows a top view of a housing cover device according to the invention.

[0062] Figure 7 shows another top view of a housing cover device according to the invention, and

[0063] Figure 8 shows a stator according to the invention.

[0064] Identical elements are provided with the same reference numerals. Features of the individual embodiments can be interchanged, complement each other, or replace each other.

[0065] Figure 1 shows a housing cover device 1 for a winding head 2 for a stator 3 of an electric machine 4. The electric machine 4 is, in this case, an electric motor for a vehicle's drive train. The winding head 2 is surrounded by a winding head housing 6, which has an L-shaped contour. The winding head housing 6 is indirectly connected to the stator 3 via a plastic overmolding. The winding head housing 6 is bonded to the plastic overmolding. The winding head 2 is surrounded or covered on its outer circumferential side by a cylindrical hollow body 5. The cylindrical hollow body 5 has a continuous slot 7. The continuous slot 7 is formed by two interface surfaces 8 and 9. In this case, the slot 7 has a constant slot width. Alternatively, the slot 7 could have a variable slot width or be closed or sealed.

[0066] Figure 2 shows a housing cover device 1 according to the invention in a bent-up state.

[0067] Figure 3 shows a housing cover device according to the invention in an assembled state. In contrast to Figure 2, the slot 7 is now narrower. P241523

[0068] - 11 - Figure 4 shows a sectional view of a housing cover device 1 according to the invention. The inner diameter of the cylindrical hollow body 5 in the area 13 facing the stator 3 is smaller than in the area 14 facing away from the stator 3. This allows the receiving area 15 for the winding head 2 in the area 13 facing the stator 3 to be smaller than the receiving area 16 in the area 14 facing away from the stator 3.

[0069] Figure 5 shows another sectional view of a housing cover device 1 according to the invention. Here it can be clearly seen that the wall thickness of the cylindrical hollow body 5 is thicker on the side facing the stator 3 than on the side facing away from the stator 3.

[0070] Figure 6 shows a top view of a housing cover device 1 according to the invention. On the outer surface 10 of the housing cover device 1, an axially extending wall section 17 and two circumferentially extending wall sections 11 and 12 for guiding the coolant that exits from the slot 7 are arranged.

[0071] Figure 7 shows another top view of a housing cover device 1 according to the invention. In contrast to Figure 8, a counterpart 21 for adjusting the orientation of the cylindrical hollow body 5 is also shown here. The counterpart 21 is arranged on the plastic overmolding for the stator 3. Busbars 18, which are located in the coolant flow, are also visible.

[0072] Figure 8 shows a stator 3 according to the invention. The stator 3 has a further winding head 19. Coolant, for example, enters there and flows through the stator winding 20 and the winding head 2 before exiting again through the slot 7. P241523

[0073] - 12 - List of reference symbols

[0074] 1 Housing cover device

[0075] 2 winding head

[0076] 3 Stator

[0077] 4 electric machine

[0078] 5 cylindrical hollow bodies

[0079] 6 winding head housings

[0080] 7 slots

[0081] 8 first interface surface

[0082] 9 second interface surface

[0083] 10 outer surface

[0084] 11 First circumferential wall section 12 Second circumferential wall section 13 Facing area

[0085] 14 facing away area

[0086] 15 Recording area in the facing area

[0087] 16 Recording area in the opposite direction

[0088] 17 axially extending wall section

[0089] 18 Busbar

[0090] 19 more winding heads

[0091] 20 coil windings

[0092] 21 counterpart

Claims

P241523 - 13 - Claims 1. Housing cover device (1 ) for a winding head (2) of a stator (3) of an electric machine (4), comprising a cylindrical hollow body (5) which is arranged to be connected on one side to a winding head housing (6) and on the opposite side to the stator (3), such that the cylindrical hollow body (5) at least partially covers the winding head (2) in a radially outward direction, characterized by the fact that the cylindrical hollow body (5) includes a slot (7) so that the cylindrical hollow body (5) can be bent open for an assembly process with the stator (3).

2. Housing cover device (1) according to claim 1, characterized by the fact that the slot (7) is formed by a first interface surface (8) and a second interface surface (9) on the cylindrical hollow body (5), and wherein the first interface surface (8) and the second interface surface (9) are designed to be bonded after the assembly process, or wherein the first interface surface (8) and the second interface surface (9) are arranged to be in contact in a force-fit manner in an unloaded state, or wherein the first interface surface (8) and second interface surface (9) comprise corresponding positive-locking connection interfaces which are designed to be connected after the assembly process.

3. Housing cover device (1) according to claim 1, characterized by the fact that The slot (7) in an assembled state comprises a constant slot width for a coolant outlet.

4. Housing cover device (1) according to claim 1, characterized by the fact that The slot (7) has a variable slot width for a coolant outlet when assembled. P241523 - 14 - 5. Housing cover device (1) according to one of claims 3 or 4, characterized in that the slot (7) is arranged to be aligned in the circumferential direction with a counterpart (21) of the stator during assembly, so that the slot (7) assumes a specific position in the circumferential direction.

6. Housing cover device (1) according to one of claims 3 to 5, characterized in that the cylindrical hollow body (5) has an axially extending wall section (17), wherein the axially extending wall section (17) is arranged on an outer shell surface (10), wherein the axially extending wall section (17) is arranged on one side of the slot, wherein the axially extending wall section (17) is configured to limit a flow direction of the cooling fluid exiting from the winding head (2) through the slot (7).

7. Housing cover device (1) according to one of claims 3 to 6, characterized in that the cylindrical hollow body (5) has a first circumferentially extending wall section, wherein the first circumferentially extending wall section (11) is arranged on an outer lateral surface (10), and wherein the first circumferentially extending wall section (11) is configured to limit a flow direction of the cooling fluid flowing on the outer lateral surface (10) of the cylindrical hollow body (5), and / or the cylindrical hollow body (5) has a second circumferentially extending wall section (12), wherein the second circumferentially extending wall section (12) is arranged on an outer lateral surface (10), and wherein the second circumferentially extending wall section (12) is configured to limit a flow direction of the cooling fluid flowing on the outer lateral surface (10) of the cylindrical hollow body (5).

8. Housing cover device (1) according to one of the preceding claims, characterized in that P241523 - 15 -an inner diameter of the cylindrical hollow body (5) at a region (13) facing the stator (3) has a smaller value than at a region (14) facing away from the stator (3), so that a receiving area (15) for the winding head (2) in the region (13) facing the stator (3) is smaller than a receiving area (16) in the region (14) facing away from the stator (3).

9. Stator (3) with a housing cover device (1) according to one of claims 1 to 8.

10. Electric machine (4) with a stator (3) according to claim 9.

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