Stator With Integrated Power Electronics and Additive Manufacturing
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Solution Overview
Problem
Conventional electrical machines face challenges in achieving high power density with compact design and minimizing electrical losses, particularly due to spatial separation of power electronics and high losses in long connecting cables.
Innovation Solution
A stator design with integrated electronic power components and additively manufactured conductive connection elements that connect conductor bars to power electronics, allowing for a compact and efficient electrical connection with low losses, using materials like copper or copper alloys for high conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If power electronics are located outside the machine in a separate enclosure, then electrical losses are reduced through proper insulation, but installation space increases and electrical losses occur along long connecting cables
Solution Approach 1:
The patent merges the power electronics with the stator by integrating the converter directly into the stator housing. This eliminates the need for separate enclosures and long connecting cables, thereby reducing both installation space requirements and electrical losses in connecting leads while maintaining proper electrical insulation through integrated design
2Ease of manufacture
If conventional crimp connections are used to connect conductor bars to power electronics, then assembly is simplified, but electrical losses increase at high current densities
Solution Approach 1:
The patent changes the connection method from conventional crimp connections to friction stir welding. This welding process creates a metallurgical bond with lower contact resistance, significantly reducing electrical losses at high current densities while maintaining manufacturing feasibility through automated welding processes
3Power
If high-voltage and low-current operation is used to achieve high power density, then connecting cable requirements are simplified, but electrical losses increase along the connecting leads
Solution Approach 1:
By integrating the power electronics directly into the stator, the patent eliminates long connecting leads entirely. This allows the system to operate at high power density without suffering from electrical losses in connecting cables, as the converter is positioned immediately adjacent to the conductor bars
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables a compact, high-power electrical machine with reduced electrical losses and increased current-carrying capacity, achieving high power density while minimizing space requirements and insulation needs.
Implementation Method 1
The connection element is made of an electrically conductive material and manufactured using an additive manufacturing process
Data Source
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AI summary
A stator (10) for an electric machine (1) is described, comprising: a stator winding (11) with a plurality of conductor bars (13); at least one power electronic component (25) integrated into the stator (10); and at least one terminal element (15a, 15b) by which either an associated conductor bar (13) is electrically connected to an associated power electronic component (25) or by which several conductor bars (13) are electrically connected to each other; wherein the terminal element (15a, 15b) is made of an electrically conductive material and is manufactured using an additive manufacturing process. Furthermore, an electric machine (1) with such a stator (10) and a method for manufacturing such a stator (10) are described.