Multi-layer wave winding for a power-generating component of an electric machine

Abstract

The invention relates to a multi-layer wave winding (1) for a power-generating component of an electric machine, comprising at least two mat parts (2, 3), namely a first mat part (2) and a second mat part (3), the two mat parts (2, 3) each having a plurality of conductors (2a, 2b, 2c, 2d, 2e, 2f, 2g, 2h, 2i, 2j, 2k, 2l, 3a, 3b, 3c, 3d, 3e, 3f, 3g, 3h, 3i, 3j, 3k, 3l) that run parallel and are arranged in an undulating structure, the conductors (2a, 2b, 2c, 2d, 2e, 2f, 2g, 2h, 2i, 2j, 2k, 2l) of the first mat part (2) forming an input conductor section (4) at a first end (A) of the wave winding (1) and the conductors (3a, 3b, 3c, 3d, 3e, 3f, 3g, 3h, 3i, 3j, 3k, 3l) of the second mat part (3) forming an output conductor section (5) at the first end (A) of the wave winding (1), the conductors (2a, 2b, 2c, 2d, 2e, 2f, 2g, 2h, 2i, 2j, 2k, 2l) of the first mat part (2) and the conductors (3a, 3b, 3c, 3d, 3e, 3f, 3g, 3h, 3i, 3j, 3k, 3l) of the second mat part (3) each having a connecting conductor section (6a, 6b) at a second end (B) of the wave winding (1).

Description

[0001] Multi-layer wave winding for a power-generating component of an electric machine

[0002] The invention relates to a multilayer wave winding for a power-generating component of an electrical machine comprising at least two mat parts, namely a first mat part and a second mat part, wherein the two mat parts each have several parallel conductors arranged in a wave-like structure, wherein the conductors of the first mat part form an input conductor section at a first end of the wave winding and the conductors of the second mat part form an output conductor section at the first end of the wave winding, and wherein the conductors of the first mat part and the conductors of the second mat part each have a connecting conductor section at a second end of the wave winding.

[0003] State of the art

[0004] A power-generating component of an electrical machine is generally understood to be a stator or a rotor of an electrical machine.

[0005] For example, the stator of an electric machine has a stator core configured to hold a winding arrangement within stator slots of the core. The winding arrangement generally consists of electrical conductors held within the stator slots, and these conductors can have different configurations.

[0006] Multi-layer wave windings, for example, consist of several layers of wire windings (conductors) arranged on top of each other to form a wave-like structure. The multi-layer arrangement of the windings allows for...

[0007] The MGA134WO optimizes the magnetic and electrical properties of the electric machine, resulting in higher power density and improved heat dissipation. Multilayer wave windings represent a promising winding technology aimed at improving the performance, efficiency, and reliability of electric machines.

[0008] Electrical machines equipped with multilayer shaft windings are used in a wide variety of applications, including industrial drives, electric vehicles, wind turbines, and other high-performance applications. The ability to arrange the windings in multiple layers allows for flexible design and adaptation of the electrical machine to specific requirements and operating conditions.

[0009] The present invention aims to overcome the known disadvantages and limitations of conventional winding techniques by providing an innovative multilayer wave winding that enables improved efficiency, higher power density, and a longer machine lifespan. The precise arrangement of the windings in multiple layers ensures a uniform distribution of magnetic flux and optimal use of available space.

[0010] The object of the invention is to provide a multilayer wave winding for a power-generating component of an electric machine, which is improved particularly with regard to manufacturing effort.

[0011] Description of the invention

[0012] The problem is solved by a multilayer wave winding with the features according to claim 1.

[0013] Multilayer wave winding is used in a power-generating component, such as a stator or rotor of an electric machine.

[0014] MGA134WOThe multilayer wave winding according to the invention comprises at least two mat parts, namely a first mat part and a second mat part, wherein the two mat parts each have several parallel conductors arranged in a wave-shaped structure.

[0015] According to the invention, at a first end of the wave winding, the conductors of the first mat part form an input conductor section and the conductors of the second mat part form an output conductor section.

[0016] Furthermore, according to the invention, at a second end of the wave winding, the conductors of the first mat part and the conductors of the second mat part each form a connecting conductor section.

[0017] According to the present invention, in the area of ​​the respective connecting conductor section, all conductors of a phase of a mat part are connected in parallel via a first connecting element, wherein the first connecting element of a phase of the first mat part is electrically connected to the first connecting element of the same phase of the second mat part via a single second connecting element.

[0018] In an advantageous embodiment of the present invention, the conductors of the input conductor section and the conductors of the output conductor section form at least one connection, wherein in the area of ​​the input conductor section and in the area of ​​the output conductor section all conductors of a phase of a mat part are connected in parallel via a first connecting element and wherein the first connecting element of a phase of a mat part is electrically connected via a second connecting element to at least one further connecting element of a phase of a mat part or to an external component, depending on the connection plan.

[0019] In a particularly preferred embodiment of the present invention, the respective first connecting element of a phase of the first mat part,

[0020] MGA134WO the respective first connecting element of the same or a phase of the second mat part and the respective second connecting element are formed in one piece, i.e. as a one-piece component.

[0021] Preferably, the conductors of the input conductor section of the first mat part are arranged parallel to the conductors of the output conductor section of the second mat part at the first end of the wave winding.

[0022] Furthermore, preferably the conductors of the connecting conductor section of the first mat part are arranged parallel to the conductors of the connecting conductor section of the second mat part at the second end of the wave winding.

[0023] In an advantageous embodiment of the present invention, the first mat part and the second mat part each comprise twelve parallel conductors, wherein four conductors form one phase.

[0024] Description of the characters

[0025] Fig. 1 shows a schematic representation of two interwoven mat sections of a multi-layer wave winding.

[0026] Fig. 2 shows a detailed view of connecting conductor sections of a first mat part and a second mat part.

[0027] Fig. 3 shows a detailed view of an input conductor section of a first mat section and an output conductor section of a second mat section.

[0028] Figs. 4 - 8 each show a schematic representation of a conductor routing of a respective phase of a multi-layer wave winding in different design variants.

[0029] MGA134WO The invention is discussed below with reference to several exemplary embodiments. The exemplary power-generating component is, in all embodiments, a stator for a three-phase electric machine.

[0030] The construction of a stator with a multilayer wave winding 1 is a stator design in which winding mats are used to form the phase-specific windings.

[0031] The multi-layered wave winding 1 comprises two mat parts 2, 3, namely a first mat part 2 and a second mat part 3 - in Fig. 1 , Fig. 2 and Fig. 3, a side view of these two interwoven mat parts 2, 3 is shown in different levels of detail.

[0032] The two mat parts 2, 3 each have several parallel conductors 2a, 2b, 2c, 2d, 2e, 2f, 2g, 2h, 2i, 2j, 2k, 2I, 3a, 3b, 3c, 3d, 3e, 3f, 3g, 3h, 3i, 3j, 3k, 3I which are arranged in a wave-like structure.

[0033] The multilayer wave winding 1 forms three phases 11a, Va, W. a, Ub, Vb, Wb from, wherein at least two separate conductors 2a, 2b, 2c, 2d, 2e, 2f, 2g, 2h, 2i, 2j, 2k, 2I, 3a, 3b, 3c, 3d, 3e, 3f, 3g, 3h, 3i, 3j, 3k, 3I are provided to form a phase lla, Va, Wa, Ub, Vb, Wb. Each phase Ua, Va, Wa, Ub, Vb, Wb is formed by at least two ladders 2a, 2b, 2c, 2d, 2e, 2f, 2g, 2h, 2i, 2j, 2k, 2I, 3a, 3b, 3c, 3d, 3e, 3f, 3g, 3h, 3i, 3j, 3k, 3I of the first mat section 2 and at least two ladders 2a, 2b, 2c, 2d, 2e, 2f, 2g, 2h, 2i, 2j, 2k, 2I, 3a, 3b, 3c, 3d, 3e, 3f, 3g, 3h, 3i, 3j, 3k, 3I of the second mat section 3, wherein the first mat section 2 forms the The current flows clockwise, and the second mat part 3 conducts the current counterclockwise.

[0034] The first mat section 2 and the second mat section 3 each have an identical number of ladders 2a, 2b, 2c, 2d, 2e, 2f, 2g, 2h, 2i, 2j, 2k, 2I, 3a, 3b, 3c, 3d, 3e, 3f, 3g, 3h, 3i, 3j, 3k, 3I.

[0035] MGA134WO In the embodiments according to Fig. 4, Fig. 5 and Fig. 6, the first mat section 2 and the second mat section 3 each have twelve conductors 2a, 2b, 2c, 2d, 2e, 2f, 2g, 2h, 2i, 2j, 2k, 21, 3a, 3b, 3c, 3d, 3e, 3f, 3g, 3h, 3i, 3j, 3k, 31, wherein four conductors 2a, 2b, 2c, 2d, 2e, 2f, 2g, 2h, 2i, 2j, 2k, 21, 3a, 3b, 3c, 3d, 3e, 3f, 3g, 3h, 3i, 3j, 3k, 31 are connected to a phase Ua, Va, W connected in parallel a , Ub, Vb, Wb are (q = 4).

[0036] Figure 7 shows a highly simplified example of a conductor routing of a phase Ua, Ub of a multi-layer wave winding 1, in which the first mat part 2 and the second mat part 3 each have nine conductors 2a, 2b, 2c, 2d, 2e, 2f, 2g, 2h, 2i, 3a, 3b, 3c, 3d, 3e, 3f, 3g, 3h, 3i, wherein three conductors 2a, 2b, 2c, 2d, 2e, 2f, 2g, 2h, 2i, 3a, 3b, 3c, 3d, 3e, 3f, 3g, 3h, 3i are connected in parallel to form a phase Ua, Va, Wa, Ub, Vb, Wb (q = 3).

[0037] Figure 8 shows a highly simplified example of a conductor routing of a phase Ua, Ub of a multilayer wave winding 1, in which the first mat part 2 and the second mat part 3 each have six conductors 2a, 2b, 2c, 2d, 2e, 2f, 3a, 3b, 3c, 3d, 3e, 3f, wherein two conductors 2a, 2b, 2c, 2d, 2e, 2f, 3a, 3b, 3c, 3d, 3e, 3f are connected in parallel to form a phase Ua, Va, Wa, Ub, Vb, Wb (q = 2).

[0038] The number of conductors 2a, 2b, 2c, 2d, 2e, 2f, 2g, 2h, 2i, 2j, 2k, 2I, 3a, 3b, 3c, 3d, 3e, 3f, 3g, 3h, 3i, 3j, 3k, 3I per mat part 2, 3 is given by

[0039] qxm, wherein

[0040] q is the number of stator slots per pole per phase Ua, Va, Wa, Ub, Vb, Wb and m is the number of phases Ua, Va, Wa, Ub, Vb, Wb of the electrical machine.

[0041] In the present embodiments, the multilayer wave winding 1, and thus the electrical machine, is always three-phase (m = 3), and the number of successive stator slots of each magnetic pole and each phase Ua, Va, Wa, Ub, Vb, Wb of the electrical machine is four, three, or two (q = 4, 3, or 2), i.e., the four, three, or two are parallel to each other.

[0042] MGA134WO electrically connected conductors 2a, 2b, 2c, 2d, 2e, 2f, 2g, 2h, 2i, 2j, 2k, 21, 3a, 3b, 3c, 3d, 3e, 3f, 3g, 3h, 3i, 3j, 3k, 31 are on each pole and phase lla, Va, W a , Ub, Vb, Wb of the electrical machine are arranged distributed across four, three, and two successive stator slots along the circumference of the electrical machine, respectively.

[0043] At a first end A of the multilayer wave winding 1, the conductors 2a, 2b, 2c, 2d, 2e, 2f, 2g, 2h, 2i, 2j, 2k, 2I, 3a, 3b, 3c, 3d, 3e, 3f, 3g, 3h, 3i, 3j, 3k, 3I of the first mat part 2 form an input conductor section 4 and the conductors 2a, 2b, 2c, 2d, 2e, 2f, 2g, 2h, 2i, 2j, 2k, 2I, 3a, 3b, 3c, 3d, 3e, 3f, 3g, 3h, 3i, 3j, 3k, 3I of the second mat part 3 form an output conductor section 5. An electrical connection to an inverter is established via the input conductor section 4 and the output conductor section 5. The conductors 2a, 2b, 2c, 2d, 2e, 2f, 2g, 2h, 2i, 2j, 2k, 2I of the input conductor section 4 of the first mat section 2 are arranged parallel to the conductors 3a, 3b, 3c, 3d, 3e, 3f, 3g, 3h, 3i, 3j, 3k, 3I of the output conductor section 5 of the second mat section 3 at the first end A of the multilayer wave winding 1.

[0044] At a second end B of the wave winding 1, the conductors 2a, 2b, 2c, 2d, 2e, 2f, 2g, 2h, 2i, 2j, 2k, 2I, 3a, 3b, 3c, 3d, 3e, 3f, 3g, 3h, 3i, 3j, 3k, 3I of the first mat part 2 and the conductors 2a, 2b, 2c, 2d, 2e, 2f, 2g, 2h, 2i, 2j, 2k, 2I, 3a, 3b, 3c, 3d, 3e, 3f, 3g, 3h, 3i, 3j, 3k, 3I of the second mat part 3 each form a connecting conductor section 6a, 6b. The conductors 2a, 2b, 2c, 2d, 2e, 2f, 2g, 2h, 2i, 2j, 2k, 2I of the connecting conductor section 6a of the first mat part 2 are arranged parallel to the conductors 3a, 3b, 3c, 3d, 3e, 3f, 3g, 3h, 3i, 3j, 3k, 3I of the connecting conductor section 6b of the second mat part 3 at the second end B of the multilayer wave winding 1.

[0045] In the area of ​​the respective connecting conductor section 6a, 6b, all conductors 2a, 2b, 2c, 2d, 2e, 2f, 2g, 2h, 2i, 2j, 2k, 2I, 3a, 3b, 3c, 3d, 3e, 3f, 3g, 3h, 3i, 3j, 3k, 3I are of one phase Ua, Va, W a, Ub, Vb, Wb of a mat section 2, 3 connected in parallel via a first connecting element 7a, 7b, wherein the first connecting element

[0046] MGA134WO7a of a phase Ila, Va, W a The first mat section 2 is electrically connected via a second connecting element 8 to the first connecting element 7b of the same phase 11b, 12b, 13b, 14b, 15b of the second mat section 3. The two first connecting elements 7a, 7b and the second connecting element 8 connecting them are each designed as a single unit, namely as a single component or part.

[0047] In the area of ​​the input conductor section 4 and in the area of ​​the output conductor section 5, all conductors 2a, 2b, 2c, 2d, 2e, 2f, 2g, 2h, 2i, 2j, 2k, 21, 3a, 3b, 3c, 3d, 3e, 3f, 3g, 3h, 3i, 3j, 3k, 31 of a phase 11a, Va, Wa, 12b, Vb, Wb of a mat section 2, 3 are connected in parallel via a first connecting element 7a, 7b, and the first connecting element 7a, 7b of a phase 11a, Va, Wa, 12b, Vb, Wb of a mat section 2, 3 is connected via a second connecting element 8 to at least one further first connecting element 7a, 7b of a phase 11a, Va, Wa, 12b, Vb, Wb, depending on the connection diagram. Wb of a mat section 2, 3 or an external component, such as an inverter, is electrically connected. In the present case, the first connecting element 7a of phase Va of the input conductor section 4 of the first mat section 2 is electrically connected to the first connecting element 7b of phase 11b and the first connecting element 7b of phase Wb of the output conductor section 5 of the second mat section 3.Here, the first connecting element 7a of phase Va of the input conductor section 4 of the first mat section 2, the first connecting element 7b of phase 11b, and the first connecting element 7b of phase Wb of the output conductor section 5 of the second mat section 3 are manufactured as single units. The first two connecting elements 7a of phases Va and Wa of the input conductor section 4 of the first mat section 2, as well as the first connecting element 7b of phase Vb of the output conductor section 5 of the second mat section 3, are electrically connected to the external component (the inverter).

[0048] MGA134WO reference number

[0049] 1 Multi-layer wave winding

[0050] 2 First mat section

[0051] 2a -2I Leader of the first mat section

[0052] 3 Second mat part

[0053] 3a - 3I Leader of the second mat section

[0054] 4 Entrance ladder section

[0055] 5 Output conductor section

[0056] 6a Connecting conductor section of the first mat section 6b Connecting conductor section of the second mat section 7a First connecting element of the first mat section 7b First connecting element of the second mat section 8 Second connecting element

[0057] A First end of the multilayer wave winding B Second end of the multilayer wave winding lla, V a , W a Phase of the first mat section

[0058] llb, Vb, Wb Phase of the second mat section

[0059] MGA134WO

Claims

Claims 1. Multilayer wave winding (1) for a power-generating component of an electrical machine comprising at least two mat parts (2, 3), namely a first mat part (2) and a second mat part (3), wherein the two mat parts (2, 3) each have several parallel conductors (2a, 2b, 2c, 2d, 2e, 2f, 2g, 2h, 2i, 2j, 2k, 2I, 3a, 3b, 3c, 3d, 3e, 3f, 3g, 3h, 3i, 3j, 3k, 3I) arranged in a wave-like structure, wherein the conductors (2a, 2b, 2c, 2d, 2e, 2f, 2g, 2h, 2i, 2j, 2k, 2I) of the first mat part (2) are connected at a first end (A) of the wave winding (1) form an input conductor section (4) and the conductors (3a, 3b, 3c, 3d, 3e, 3f, 3g, 3h, 3i, 3j, 3k, 3I) of the second mat part (3) form an output conductor section (5) at the first end (A) of the wave winding (1), wherein the conductors (2a, 2b, 2c, 2d, 2e, 2f, 2g, 2h, 2i, 2j, 2k, 2I) of the first mat part (2) and the conductors (3a, 3b, 3c, 3d, 3e, 3f, 3g, 3h, 3i, 3j, 3k,3I) of the second mat part (3) at a second end (B) of the wave winding (1) each have a connecting conductor section (6a, 6b), characterized in that in the area of ​​the respective connecting conductor section (6a, 6b) all conductors (2a, 2b, 2c, 2d, 2e, 2f, 2g, 2h, 2i, 2j, 2k, 2I, 3a, 3b, 3c, 3d, 3e, 3f, 3g, 3h, 3i, 3j, 3k, 3I) of a phase (Ua, Va, W, a , Ub, Vb, Wb) of a mat part (2, 3) are connected in parallel via a first connecting element (7a, 7b) and wherein the first connecting element (7a) of a phase (Ua, Va, Wa) of the first mat part (2) is electrically connected via a single second connecting element (8) to the first connecting element (7b) of the same phase (Ub, Vb, Wb) of the second mat part (3). MGA134WO2. Multilayer wave winding (1) according to claim 1 , characterized in that the conductors (2a, 2b, 2c, 2d, 2e, 2f, 2g, 2h, 2i, 2j, 2k, 2I, 3a, 3b, 3c, 3d, 3e, 3f, 3g, 3h, 3i, 3j, 3k, 3I) of the incoming conductor section (4) and the conductors (2a, 2b, 2c, 2d, 2e, 2f, 2g, 2h, 2i, 2j, 2k, 2I, 3a, 3b, 3c, 3d, 3e, 3f, 3g, 3h, 3i, 3j, 3k, 3I) of the outgoing conductor section (5) form at least one connection, wherein in the area of ​​the incoming conductor section (4) and in the area of ​​the outgoing conductor section (5) all conductors (2a, 2b, 2c, 2d, 2e, 2f, 2g, 2h, 2i, 2j, 2k, 2I, 3a, 3b, 3c, 3d, 3e, 3f, 3g, 3h, 3i, 3j, 3k, 3I) of one phase (Ua, Va, W a, Ub, Vb, Wb) of a mat part (2, 3) are connected in parallel via a first connecting element (7) and wherein the first connecting element (7a, 7b) of a phase (Ua, Va, Wa, Ub, Vb, Wb) of a mat part (2, 3) is electrically connected via a second connecting element (8) to at least one further first connecting element (7a, 7b) of a phase (Ua, Va, Wa, Ub, Vb, Wb) of a mat part (2, 3) or an external component, depending on the connection diagram.

3. Multilayer wave winding (1) according to claim 1 or 2, characterized in that the respective first connecting element (7a) of a phase (Ua, Va, Wa) of the first mat part (2), the respective first connecting element (7b) of the same or of a phase (Ub, Vb, Wb) of the second mat part (3) and the second connecting element (8) are formed in one piece, i.e. as a one-piece component.

4. Multilayer wave winding (1 ) according to claim 1 , 2 or 3, characterized in that the conductors (2a, 2b, 2c, 2d, 2e, 2f, 2g, 2h, 2i, 2j, 2k, 2I) of the input conductor section (4) of the first mat part (2) are arranged at the first end (A) of the wave winding (1 ) parallel to the conductors (3a, 3b, 3c, 3d, 3e, 3f, 3g, 3h, 3i, 3j, 3k, 3I) of the output conductor section (5) of the second mat part (3). MGA134WO5. Multilayer wave winding (1 ) according to one of claims 1 to 4, characterized in that the conductors (2a, 2b, 2c, 2d, 2e, 2f, 2g, 2h, 2i, 2j , 2k, 2I) of the connecting conductor section (6a) of the first mat part (2) are arranged at the second end (B) of the wave winding (1 ) parallel to the conductors (3a, 3b, 3c, 3d, 3e, 3f, 3g, 3h, 3i, 3j, 3k, 3I) of the connecting conductor section (6b) of the second mat part (3).

6. Multilayer wave winding (1) according to any one of claims 1 to 5, characterized in that the first mat part (2) and the second mat part (3) each comprise twelve parallel conductors (2a, 2b, 2c, 2d, 2e, 2f, 2g, 2h, 2i, 2j, 2k, 2I, 3a, 3b, 3c, 3d, 3e, 3f, 3g, 3h, 3i, 3j, 3k, 3I), wherein each comprises four conductors (2a, 2b, 2c, 2d, 2e, 2f, 2g, 2h, 2i, 2j, 2k, 2I, 3a, 3b, 3c, 3d, 3e, 3f, 3g, 3h, 3i, 3j, 3k, 3I) a phase (Ua, Va, Wa, Ub, V b , Wb) train. MGA134WO

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