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WO2023227464A1 - Enroulement, machine électrique et procédé de fabrication - Google Patents

Enroulement, machine électrique et procédé de fabrication Download PDF

Info

Publication number
WO2023227464A1
WO2023227464A1 PCT/EP2023/063428 EP2023063428W WO2023227464A1 WO 2023227464 A1 WO2023227464 A1 WO 2023227464A1 EP 2023063428 W EP2023063428 W EP 2023063428W WO 2023227464 A1 WO2023227464 A1 WO 2023227464A1
Authority
WO
WIPO (PCT)
Prior art keywords
winding
axis
section
web
conductor
Prior art date
Application number
PCT/EP2023/063428
Other languages
German (de)
English (en)
Inventor
Roland Kasper
Original Assignee
Roland Kasper
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Roland Kasper filed Critical Roland Kasper
Publication of WO2023227464A1 publication Critical patent/WO2023227464A1/fr

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Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
    • H02K3/12—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors arranged in slots
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/04—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings, prior to mounting into machines
    • H02K15/0435—Wound windings
    • H02K15/0478—Wave windings, undulated windings
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K2213/00—Specific aspects, not otherwise provided for and not covered by codes H02K2201/00 - H02K2211/00
    • H02K2213/03—Machines characterised by numerical values, ranges, mathematical expressions or similar information

Definitions

  • the invention relates to a winding for an electrical machine, an electrical machine with a winding and the production of a winding or an electrical machine.
  • an object of the invention is a multi-phase wave winding with high packing density for electrical machines, in particular for electrical machines with high specific torque and high efficiency.
  • a multi-phase wave winding with a high packing density enables electrical machines that, in addition to a low mass and a small volume, also have a high power density and a high energy efficiency, especially for applications in a wide speed range.
  • Preferred areas of application of the invention are in the field of drives for e-mobility, e.g. electric cars, electric aircraft, electric drones, electric motorcycles, electric bicycles, electric boats and other vehicles. Further preferred areas of application include the drive of electrical machines, e.g. in power tools, machine tools, toys, industrial drives. There are a variety of other areas of application.
  • an electric machine in particular an electric motor, in particular for one of the above-mentioned areas of application, it is advantageous if the highest possible torque and the highest possible efficiency are provided in relation to the lowest possible active masses and manufacturing costs used.
  • a winding of the machine in particular a wave winding, it is desirable if it has a compact design, a good filling factor and enables largely automated production.
  • the document EP 2 124 317 A1 describes the basic structure of an electrical machine, in particular its stator with three-phase winding, which are each inserted into grooves which are arranged in the circumferential direction of the stator. Each phase is arranged in one of three pairs of adjacent slots. The portions of the winding that extend outside the slots of the stator core connect the portions in the slots.
  • the document EP 1 179 880 A2 relates to an electrical machine with a three-phase winding.
  • the document describes engines for a high speed range of approximately 2000 to 5000 rpm.
  • the document US 2006/0226727 A1 describes a stator for an electrical machine with a generally cylindrical stator core with a plurality of teeth defining a plurality of grooves.
  • the stator is designed for multi-phase winding.
  • a protruding section of the winding, which connects two parts to be inserted into the slots, has a triangular two-dimensional shape.
  • the document EP 1 381 140 A2 relates to a multi-phase winding for a rotating electrical machine. A plurality of segments of the winding are connected via winding heads. There are two types of winding heads with small and large dimensions.
  • DE10 321 956 A1 describes an electrical machine which contains a stator core which has circumferentially arranged grooves which alternate between odd and even grooves. Each groove has radial pin positions arranged in adjacent pairs to define radial layers.
  • a hair pin winding includes a first path of interconnected hair pins arranged in the stator core such that for each of the radial layers, the first path is arranged in the odd and even slots the same number of times.
  • Another possibility is a distributed winding in which all coils, or at least all coils of the same phase, are manufactured as a continuous piece that is inserted into the grooves of the ferromagnetic core.
  • the first type of distributed winding is a loop winding, such as in document WO 2005/050816 A2 (PCT/CA2004/001978). Each conductor goes around a single magnetic pole several times before moving on to the next pole.
  • the document EP 2 695 284 B1 presents a compact multi-phase wave winding for an electrical machine with high specific torque, which comprises winding layers stacked in the radial direction, the winding heads being curved in the radial direction at their beginning, in the middle and at the end, so that two adjacent, mutually parallel, straight sections of a conductor lie in approximately the same radial position.
  • the winding heads of a layer lie alternately in a tangential direction on both sides of the stator.
  • the proposal is made to create cavities through plastic deformation of the winding heads, which should enable the winding heads of different phases to be crossed easily.
  • the document US 2022/0021264 A1 presents a stator whose slots contain straight conductor pieces and whose winding heads are realized by end caps on both sides of the stator in order to reduce the manufacturing effort for the stator and winding.
  • the document DE 10 2011 111 352 B4 discloses an electric motor with an ironless air gap winding consisting of several tangentially arranged conductors in one phase, which are fixed directly on the ferromagnetic stator core, with an overlap of the winding heads occurring in such a way that in a 3-phase motor there are three winding heads lie on top of each other.
  • the document DE 102016 100 744 B3 discloses an electrical machine that combines a slot and an air gap winding in such a way that the winding webs of the air gap winding are radial are arranged above the winding webs of the slot winding, so that the magnetic field of the permanent magnets is used by both windings at the same time.
  • the document DE 199 09 026 A1 describes a method and a device for producing coils in the form of a wave winding for electrical machines.
  • a large number of winding wires are fed to the rotating mandrel of a winding device.
  • the wire on the mold core is gripped using grippers and moved in a transport direction to produce the winding heads of the wave winding, with the mold core being rotated.
  • a wave winding is created on the mold core, which is then transferred to a transport device.
  • the transport device rotates synchronously with the mold core so that the resulting wave winding can be generated continuously.
  • Windings with discrete coils have unfavorable mechanical and geometric properties and require the connection of a large number of electrical contacts when building a phase.
  • This design also has disadvantages from a geometric point of view, as the fill factors that can be achieved are limited, which in turn limits the efficiency.
  • a problem with distributed winding is the lack of space for the frequent crossings of the winding heads of adjacent coils for a larger number of turns around individual stator teeth or a group of teeth.
  • An additional problem is the rapid and non-destructive insertion of the complexly arranged conductors into the slots.
  • crossovers of the sequential winding heads which belong to adjacent phases of the winding and cross over one another very closely.
  • the individual wires are thicker and therefore not as easily deformable in the area of the winding heads.
  • the winding heads only deform into the correct shape with considerable pressure, which can cause damage to the insulation of the winding.
  • the winding head has a disadvantageous axial projection, which increases the winding head length and thus the electrical resistance.
  • Proposals for reducing the installation space by radially deflecting the conductors in the winding head area can only be implemented with very small bending radii and are therefore problematic in terms of production technology and for reasons of operational safety.
  • a curvature in the radial direction with a relatively small radius of curvature places high stress on the material during production.
  • a large bending radius leads to a large head projection and thus to an undesirably long winding head.
  • a small bending radius is required in the middle of the head to limit the radial expansion of the winding head.
  • the winding heads are stacked in the axial direction, which results in longer winding head packages, unfavorable efficiency and an increased axial installation space.
  • the pins of well-known hair-pin windings form very long winding heads for forming and welding reasons. This increases the axial installation space and increases the phase resistance of the machine. A large number of welds are required, the production of which requires a complex and complex quality-assured manufacturing process. Each individual weld increases the phase resistance and thus reduces the energy efficiency of the machine.
  • winding mats of any length with small mold cores can be formed, but relatively large winding heads are created, no specific winding head shapes are possible and the transfer of the winding mat from the mold core to the stator is a complex and complex process.
  • the current state of the art therefore does not yet offer any satisfactory solutions in the area of electrical machines.
  • the aims of the invention are to design the properties and the manufacturing process of a winding for an electrical machine in such a way that Electric machines with high performance and/or quality in terms of efficiency, torque, power and other properties can be easily constructed and manufactured cost-effectively with low mass and volume.
  • an object of the invention is to provide a compact winding, the solution preferably having as little negative effect as possible on the performance data of the machine and the winding preferably being easy to manufacture.
  • the invention comprises a winding for an electrical machine, in particular a multi-phase wave winding, the winding comprising at least one first conductor, which is arranged in the form of a plurality of webs and a plurality of winding heads, the webs and winding heads alternating one after the other along the first or respective conductor and a respective one Winding head forms a connection between two webs, with a first winding head connecting a first and a second web of the first conductor, with a second winding head of the first or a second conductor connecting a third and a fourth web of the first or second conductor, wherein the first and the second winding head cross and the third web is arranged between the first and the second web, with a first axis being parallel to at least the first web, with a second axis being parallel to a direction of a relative movement of a rotor of the electrical machine to a stator of the electrical machine, wherein a third axis is perpendicular to the first and second axes,
  • the second winding head can be guided through the area of the offset and this results in a particularly compact overall height in relation to the third axis. This is further achieved by the offset without restricting the web width and/or the height at which the web is arranged in relation to the third axis. This means that a high power density can be achieved with a compact design.
  • the offset represents a structurally simple solution so that production can be carried out easily and reliably.
  • the first, second and third axes ultimately form a coordinate system of the winding or the electrical machine.
  • the electrical machine can basically be a rotary machine or a linear machine, with the coordinate system applying accordingly.
  • the relative movement of a rotor of the electrical machine to a stator of the electrical machine takes place on a straight or more complex path that deviates from a circular shape.
  • the relative movement of the rotor to the stand takes place on a circular path.
  • the second axis in a linear machine runs along the movement path, typically straight.
  • the relative movement of the rotor to the stand runs on a circular path, and the second axis is therefore viewed as circular in the context of a rotary machine in the context of this application.
  • elements are stated to be parallel to the second axis, it is understood that in the context of a rotary machine they are concentric to the circular second axis.
  • the axes can be referred to individually or each as a path.
  • this forms a radial axis and is correspondingly dependent on the angle at which the winding or the electrical machine is viewed.
  • the end of the section is arranged offset from the end of the first web against the first direction by an offset, the offset being at least 0.3, preferably at least 0.5, preferably at least 0.8, preferably at least 1.0, times corresponds to a height of at least the first web in relation to the third axis. Installation space can be saved according to the offset.
  • a web is generally preferably cylindrical. i.e. a web generally includes a cross-section that is constant along its length.
  • the cross section can basically be round or square or have another shape. It is further advantageous with regard to the power density if at least the first and second webs are designed with the same cross section and/or are arranged at the same height and/or at the same position in a conductor stack with respect to the third axis.
  • the conductor can have an at least substantially square cross section in the area of at least the first web and/or in the section. This allows a high filling factor of the groove, which is also typically angular in cross section.
  • a square cross section, in particular of a conductor can preferably be at least substantially rectangular, in particular with side edges of the cross section of different lengths.
  • a conductor with a square cross-section can also have a rounding or a chamfer in the corner area.
  • a cross-sectional shape of the conductor in the section can be at least essentially the same as a cross-sectional shape of the conductor in the area of at least the first web.
  • a particularly compact design with a high filling factor of the groove can be achieved by a further embodiment in which the conductor in the area of at least the first web has a web width in relation to the third axis and a web width in relation to the second axis, the web width being in In relation to the third axis, it is in particular larger than the web width in relation to the second axis.
  • the web width in relation to the third axis can also be smaller than the web width in relation to the second axis, for example in the case of radially stacked webs.
  • the conductor in the section has a section width in relation to the third axis and a section width in relation to the first axis, wherein the section width in relation to the third axis is preferably smaller than the section width in relation to the first axis. It is further preferably provided that the section width in relation to the third axis is at least substantially equal to the web width in relation to the second axis and/or wherein the section width in relation to the first axis is at least substantially equal to the web width in relation to the third Axis is.
  • a further advantageous example includes that the conductor in the area of at least the first web has a rectangular cross section with a wider edge parallel to the third axis and a narrower edge parallel to the second axis, the conductor in the section has a rectangular cross section with a wider edge parallel to the first axis and a narrower edge parallel to the third axis.
  • a cross-sectional area of the conductor in the section is at least substantially equal to or larger than a cross-sectional area of the conductor in the region of the first, second, third and/or fourth web. This ensures that the electrical resistance is no greater than in the area of the web and thus high efficiency is achieved.
  • Cross-sectional area means an area dimension, for example in mm 2 .
  • the second web has an end in the first direction along the third axis, the end of the section being arranged offset from the end of the second web against the first direction, in particular by the same offset as between the end of the section and the end of the first bridge.
  • the embodiments described here which relate to only the first web and, if applicable, its spatial relationship to the first winding head, can be transferred accordingly to the second web and/or to further webs and the winding heads connected to these webs.
  • a particularly compact embodiment is characterized in that the second web has an end in the first direction along the third axis, the ends of the first and second webs being arranged at the same height in the first direction with respect to the third axis.
  • the overall height of the winding head in relation to the third axis is therefore limited in particular to the overall height of at least the first web.
  • the section preferably has a length with respect to the second axis of at least 0.2, more preferably at least 0.4, particularly preferably at least 0.6, preferably at least 0.8, preferably about 1.0, times a distance between the first and the second web in relation to the second axis.
  • a further example includes that the section of the first winding head with respect to the second axis is provided in the region of the second winding head and/or wherein the section of the first winding head is provided with respect to the second axis in an intersection region of the first and second winding heads.
  • the second winding head can extend in particular in an area starting from the section in the first direction.
  • the conductor in the section has a section width with respect to the third axis that is smaller than a web width of the conductor in the web with respect to the third axis. This allows even more installation space to be saved in relation to the third axis. It is particularly advantageous if the section width is at most 1.0, preferably at most 0.8 times, preferably at most 0.6 times, particularly preferably at most or about 0.5 times, preferably at most 0.3 times, as large as the web width .
  • the first web has a second end in a first opposite direction with respect to the third axis, the section having a second end in the first opposite direction, the second end of the web and the second end of the section is at least substantially at the same height with respect to the third axis.
  • the first web and the section in the opposite direction end at the same height and are in particular aligned. This is particularly advantageous with regard to the installation space in relation to the third axis.
  • the conductor runs in the section at least substantially perpendicular to the first axis and/or parallel to the second axis. This saves additional installation space, especially with regard to the first axis.
  • a conductor can, for example, be designed either as a solid conductor or as a bundle of strands.
  • a web is formed in particular by a conductor.
  • several webs, in particular of the same phase can be arranged grouped and/or stacked.
  • Several grouped conductors can be collectively referred to as a line.
  • a line typically forms one phase of the electrical machine.
  • One or more lines or phases can be provided.
  • the conductor in the area of the second winding head has a section in which the conductor runs at least substantially perpendicular to the third axis, in particular wherein the third and/or the fourth web extends in a second direction along the third axis End, in particular wherein the section of the second winding head has an end in the second direction along the third axis, in particular wherein the end of the section of the second winding head is arranged offset from the end of the third and / or fourth web against the second direction.
  • the section of the second winding head spans the first and/or second web with respect to the second axis.
  • the second direction can in particular be opposite to the first direction or correspond to the first opposite direction.
  • section of the first winding head and the section of the second winding head can overlap.
  • section of the first winding head and the section of the second winding head can overlap with respect to the second axis.
  • section of the first winding head and the section of the second winding head can run parallel to one another and/or to the second axis.
  • the section of the first winding head is a first section, wherein the conductor in the area of the first winding head has a second section in which the conductor runs at least substantially perpendicular to the third axis.
  • the second web can have an end along the third axis in a first opposite direction to the first direction.
  • the second section may have an end in the first opposite direction with respect to the third axis.
  • the end of the second section can be arranged offset from the end of the second web along the first opposite direction.
  • This embodiment proves to be particularly advantageous in that a second winding head - corresponding to a viewing direction with respect to the third axis - is guided over the first winding head in the area of the first section and a third winding head is guided under the first winding head in the area of the second section can.
  • This has particular advantages with regard to the production of the winding because increased flexibility in the order in which the conductors are laid on top of each other or winding heads is given. In particular, it is possible for several lines or phases of a three-phase winding to simply be placed one on top of the other and for no complicated nesting to be necessary.
  • the conductor can preferably have the same cross section in the first and second sections, in particular wherein the cross sections of the conductor in the first and second sections are arranged parallel to the third axis and/or offset with respect to the third axis.
  • the conductor comprises a step between the first and second sections, in particular with respect to the third axis.
  • a step and/or an offset can be provided between the first web and the section of the first winding head.
  • the winding can preferably be designed as a multi-phase winding and/or as a wave winding.
  • the offset according to the invention between the section of the winding head and the web proves to be particularly advantageous in these embodiments.
  • the webs can in particular be aligned parallel to one another and/or arranged evenly distributed over the circumference of a stator or rotor.
  • the invention also includes an electrical machine with a winding of the type described above.
  • the electric machine can be an electric motor and/or an electric generator, or the machine can be used as a motor and/or generator.
  • the electric machine can be a rotary machine or a linear machine.
  • the winding can be arranged on the stator or on the rotor of the electrical machine. The same may apply to one or more permanent magnets.
  • the electrical machine comprises a core.
  • the winding can be a core winding.
  • the core can comprise a plurality of grooves, in each of which, for example, at least one web can be arranged. For example, several webs, in particular one phase, can also be arranged in each groove.
  • the plurality of webs in a groove can preferably be arranged stacked along the third axis.
  • the electrical machine can also be designed to be coreless and/or grooveless.
  • the winding of this electrical machine can also be called air gap winding.
  • Several webs, in particular of one phase, can, for example, be arranged next to one another along the second axis.
  • the electrical machine can preferably be designed as a synchronous machine and/or as a permanent magnet machine, particularly preferably as a permanent magnet synchronous machine, PMSM for short.
  • the winding and the electrical machine, as described herein, can be made particularly compact, although production is particularly simple.
  • the invention also relates to a method for producing a winding of the type described above for an electrical machine, in particular an electrical machine of the type described above.
  • One embodiment of the manufacturing method includes that at least the first web and the section of the first winding head are manufactured from a component, in particular wherein the component is formed.
  • an elongated conductor material can be provided, of which a longitudinal section is provided for the first web and a longitudinal section is provided for the section.
  • a solid wire or a bundle of strands can be used as an elongated conductor material.
  • the conductor material between the longitudinal section for the first web and the longitudinal section for the section can, for example, be bent around a first bending axis, in particular starting from a substantially straight state of the conductor material.
  • the bend can preferably be at least substantially 90°.
  • the first bending axis can preferably be perpendicular to a longitudinal axis of the conductor material and/or parallel to the third axis in relation to a state installed in the electrical machine.
  • the conductor material is twisted between the longitudinal section for the first web and the longitudinal section for the section, preferably by at least substantially 90°.
  • a combination of bending and turning represents a simple possibility for flexible shaping and proves to be advantageous for the winding heads according to the invention.
  • the bending and twisting can occur overlapping in time or one after the other.
  • a component in particular the conductor material in the longitudinal section for the section, is massively formed, in particular extruded, to produce the section.
  • an advantageous method is hereby disclosed, namely a method for producing a winding for an electrical machine or for producing an electrical machine with a winding, wherein at least one first conductor in the form of a plurality of webs and a plurality of winding heads is provided for the winding, wherein the webs and winding heads alternately follow one another along the conductor and a respective winding head forms a connection between two webs, with a shaping for at least a first winding head comprising solid forming.
  • This method is particularly simple and, in particular, allows shaping essentially without changing the cross-sectional area. This is particularly advantageous because essentially no or at least only a small reduction in the conductivity of the winding head can be expected.
  • a forming force can preferably be applied to the conductor section in a direction of force for the section, the direction of force being parallel to the third axis and/or opposite to the first direction in relation to a state installed in the electrical machine.
  • the offset according to the invention can thus be produced in a particularly simple manner between the ends of the web and winding head.
  • the massive forming to produce the section can take place, for example, before and/or after bending. In principle, solid forming during bending is also possible.
  • At least the first web and the first winding head are assembled from separate components, in particular by means of welding, soldering or a press connection.
  • one end of the first web and one end of the first winding head are placed against each other on corresponding joining surfaces, which are at least substantially parallel to the first axis and then welded together at the joining surfaces.
  • the second web and the first winding head can be assembled from separate components, in particular by means of welding, soldering or a press connection.
  • one end of the second web and one end of the first winding head are placed against each other on corresponding joining surfaces, which are at least substantially parallel to the first axis and are then welded together at the joining surfaces.
  • At least one web can, for example, also be joined together with an associated winding head by means of a press connection.
  • the press connection can preferably have a conical or a cylindrical hub.
  • a press connection allows a simple and reliable connection without welding. It is also advantageous if the hub of the connection is heated before connection. This makes connecting easier.
  • the hub can basically be provided on the web or on the winding head.
  • the second web can be connected in one piece to the first winding head.
  • the second web and the first winding head can be produced from one component, in particular by forming and/or as described above with respect to the first web.
  • a winding can be assembled, for example, from completely individual webs or “I-pins” and winding heads in the manner described above.
  • a web with a winding head can be produced from a component by forming, resulting in a substantially L-shaped component or L-pin.
  • a winding head can be produced from a component together with two webs by forming, resulting in a substantially U-shaped component or U-pin. The two webs can then be joined together at their other ends, for example as described above, with another winding head.
  • a web in general, for example, can be inserted into a slot or a combination of a web and a winding head (L-pin) or two webs and a winding head (U-pin) can be inserted into the slots.
  • the joining process proceeds in particular as described.
  • the individual web or I-pin, the L-pin or the U-pin can each preferably be a formed part. These parts are preferably coated after forming but before insertion into the respective groove. Subsequently, joining with the further webs or winding heads can advantageously take place. After joining, the joining point and, if not already done, the joined winding head are preferably coated.
  • the production of the winding comprises a shaping step for shaping at least one of the winding heads, with an insulation step being carried out after the shaping step, in which an electrically insulating coating, in particular a lacquer, is applied to the winding, in particular to the at least one Winding head and / or at least one joint between winding head and web is applied.
  • an electrically insulating coating in particular a lacquer
  • the shaping step may include a forming step.
  • the forming step can include, for example, one of the forming processes described above, in particular bending and turning by preferably at least substantially 90° and/or massive forming.
  • the webs can also be reshaped.
  • the isolation step then preferably also takes place after the forming.
  • the entire winding is then preferably coated or insulated.
  • the entire winding is then preferably coated or insulated.
  • only parts of the winding i.e. web or I-pin, L-pin or U-pin, can initially be used be coated.
  • the joining points and in particular the joined winding heads are preferably coated.
  • the electric machine may include a ferromagnetic core with alternating teeth and grooves distributed, for example, circumferentially around the ferromagnetic core.
  • the winding may include one or more layers stacked around the circumference of the ferromagnetic core with respect to the third axis and/or in the radial direction and inserted into the slots. If NP represents the number of phases of the electrical machine, the winding can consist, for example, of NP or a multiple of NP conductors.
  • Each conductor can have parallel, straight segments inserted into the slots as webs and/or curved segments as winding heads, which connect the adjacent webs of a phase, in particular a direction parallel to the second axis and/or in a tangential direction.
  • NP teeth and/or NP-1 grooves can preferably be arranged between two adjacent webs of the same phase.
  • the winding heads can be arranged in relation to the third axis and/or radially stacked in a hollow cylindrical winding head window.
  • winding heads and/or a corresponding winding head window are provided at both ends of the webs with respect to the first axis.
  • the winding heads can be arranged coaxially on both sides of the core with respect to the first axis.
  • the winding heads can preferably be arranged with respect to the third axis and/or radially centered to the slots or by a maximum of twice the winding height above or below or inside or outside the circle formed by the slot centers.
  • the winding heads of three phases each, in particular at least one layer, can be radially stacked in two layers on both sides of the stator with respect to the first axis.
  • the winding heads can be arranged in a tangential direction with alternating radial winding head positions, so that an internal winding head of one phase covers a part of the two right and left outer winding heads of the other two phases and an external winding head of a phase covers a part of each both right and left inner winding heads of the other two phases are covered, which means that in a phase, viewed in the direction of travel from the beginning of the phase to the end, there are always two winding heads one after the other in one layer, aligned alternately on the inside and outside on different stator sides.
  • the winding heads can also be arranged in a tangential direction with a constant radial winding head position, so that all internal winding heads belong to one phase, all external winding heads belong to a further phase and the remaining phase exclusively winding heads with two radially offset sections and in particular an offset between the sections having.
  • the sections lie in particular on the inner and outer winding heads.
  • the winding heads can be stacked in multiples of three phases in the radial direction in one of the two defined arrangements and, for phase numbers that are not multiples of three, one or two phases can be placed in the remaining free positions in accordance with the division remainder.
  • the height of the winding head package HH of a layer consisting of all inner and outer and cranked winding heads can preferably correspond to the winding web height HW or be in the range between 50% and 200% of the winding web height HW.
  • the tangential course of the winding head can preferably run at a right angle or at an angle between 60° and 90° to the web direction.
  • the cross-sectional shape of the conductor can be circular, rectangular, or any shape.
  • the conductor can, for example, comprise one thick or several thin wires, in particular strands, or profiles.
  • the size and shape of the cross section can change along the conductor.
  • the material may be or include copper and/or another material with good electrical conductivity.
  • the conductor or layers can be manufactured partially or completely in or outside the ferromagnetic core.
  • Each phase may comprise a number NL of conductors arranged tangentially in series, where NL may preferably be greater than or equal to one.
  • a coil of each phase in one layer may include one or more conductors and the same conductor may be present in more than one layer.
  • a tangential conductor continuation direction at the radial transition of the conductor to the next layer can be made constant or can bend in the opposite direction.
  • the stator can, for example, have no grooves and/or teeth.
  • the winding can be fixed on the stator in the air gap.
  • winding webs can be arranged on the stator at a magnetic pole angle of 2*NP.
  • Phase terminals can be formed by shortening and, if necessary, radially bending and/or deforming the winding head pieces at the beginning of the phase and can thereby be arranged axially behind the winding heads.
  • a star point rail can be formed, for example, by shortening and joining the winding head pieces at the phase ends and, if necessary, radially bending and deforming the winding head piece, in particular the third phase.
  • an axial installation space with the depth of the winding head projection AH, with the height up to the magnets and/or with a width greater than a magnetic pool pair can be created, which can be used to accommodate a sensor.
  • the shape of a winding head can be semicircular, triangular, straight or U-shaped or have another geometric shape.
  • the height of the conductor HW in the winding head can be reduced in order to be able to stack the winding heads in pairs in the radial direction without requiring additional radial installation space.
  • the current-carrying cross section of the conductor can preferably not be reduced, but can be increased if necessary and/or shape changes can be carried out with continuous transitions in order to keep the phase resistance as small as possible.
  • the entire winding can be manufactured in one step, for example, or the phases are prefabricated individually, then woven or stacked to form a winding and then inserted into the slots, or the winding webs are inserted into the slots and then connected to the winding heads using joining technology .
  • the winding heads can be done, for example, by bending a solid wire or a stranded bundle with an aspect ratio greater than or equal to 2:1 in a torsion step with a 90° torsion angle about a torsion axis parallel to the web axis and/or a bending step about two radial axes by 90° each.
  • aspect ratio refers to the ratio of the lengths of the side edges of a rectangular cross-section of the conductor.
  • the winding heads can be made, for example, by bending a radially stacked solid wire stack with an aspect ratio of the individual wire less than 2:1 in a torsion step with a 90° torsion angle about a torsion axis parallel to the web axis and/or a bending step about two radial axes by 90° each.
  • winding heads and optionally the winding webs can be produced by massive forming, for example extrusion or forging, in particular of conductor profiles.
  • winding heads and winding webs can be connected, for example, by joining, such as welding or clamping, either outside the stator or preferably after inserting the winding webs into the stator.
  • the sections of the winding heads can also be designed to be at least partially stepped or offset and/or two sections can be provided on the winding head, between which a step or offset is provided.
  • the step or offset can be arranged approximately tangentially in the middle of the winding head.
  • the part of the winding head can lie in front of the step or crimping point, as in a winding head lying on top, and the part of the winding head can lie after the step or crimping point, like in a winding head lying at the bottom. This order can also be swapped.
  • the winding heads can, for example, be manufactured additively and/or connected to non-additively manufactured winding webs inside or outside the stator.
  • the winding heads and winding webs can be additively manufactured inside or outside the stator.
  • the winding heads can be manufactured by bending a wire bundle from a number of profile wires arranged horizontally next to one another, e.g. by bending in two radial axes and a bend or two closely spaced bends of +90° and -90° around a tangential axis, which the curved part of the winding head is deformed upwards or downwards relative to the winding web by at least half of the winding web height HW.
  • the winding heads can, for example, also be bent radially in the direction of the stator core and, if necessary, be contacted mechanically and/or thermally with the stator.
  • the winding head packages can, for example, also be baked, cast and/or integrated into a carrier substance.
  • the winding heads can, for example, be stacked radially in at least one layer of a slot winding and/or at least one layer of an air gap winding.
  • the winding can be designed as a self-supporting air gap winding with either radially stacked or partially cranked winding heads.
  • the winding heads can be baked, cast or embedded in a carrier substance and, if necessary, provided with radially or axially arranged support rings.
  • the winding webs can be baked, cast or embedded in a carrier substance.
  • the winding can be produced inexpensively.
  • a high packing density, a large conductor cross section and short winding heads are achieved to reduce the phase resistance and the size. This is achieved, among other things, by an alternating arrangement of the winding heads in radial layers of a winding layer.
  • the shaping and/or the connection of the winding heads to the winding webs are gentle on the material.
  • the connection can optionally be designed with a reduction in the winding head height without reducing the current-carrying cross section.
  • profile wires or profiles preferably in portrait format (aspect ratio greater than 1:1) in combination with a winding head and winding web that are geometrically, material- and production-technically adapted.
  • the conductor or conductors can be produced, for example, as a continuous mat using a forming process, for example with a high dimensional stability to simplify handling, transport and positioning for inserting the winding webs into the stator slot.
  • the conductor can also be inserted/inserted into the slot as discrete winding webs and connected to the winding heads using a joining process.
  • the invention provides a highly efficient, in particular multi-phase, winding structure with high packing density and a cost-effective and precise manufacturing method for wave windings that can replace existing solutions and open up new fields of application.
  • existing manufacturing processes for electrical machines only the manufacturing and feeding of the very easy-to-handle/transportable winding mat or an existing hair-pin manufacturing process needs to be replaced.
  • the efficiency and specific torque of electrical machines are significantly increased and manufacturing costs are reduced.
  • an increase in the efficiency of electrical machines can be achieved by reducing the phase resistance while simultaneously reducing the axial and radial installation space of electrical machines, in particular by minimizing the axial and tangential winding head length as well as the radial winding head height without reducing the current-carrying conductor cross section in combination with a very high filling factor in the slot or in the air gap, b) reducing the weight of electrical machines maximum use of the copper content and the reduction of the iron content as well as c) the reduction of the costs for electrical machines through inexpensive winding and stator production.
  • the higher efficiency, the higher specific torque and the reduced installation space can open up new fields of application, especially in the areas of e-mobility, micro-mobility and lightweight drives as well as in all areas of application in which very high efficiency in combination with low weight is required is.
  • the electrical machines with the winding according to the invention can cover a very wide speed range. Due to the low copper losses and the high torque, the machines are suitable as torque motors or wind power generators even in the very low speed range. Due to the low iron losses and high efficiency, the machines are also suitable for applications with very high speeds, for example in the field of micro drives or as generators, for example for gas turbines.
  • the figures show examples of multi-phase wave windings with high packing density of an electrical machine or “e-machine” with a high specific torque and high efficiency.
  • the machine is designed, for example, as an external rotor.
  • the embodiment shown is suitable, for example, for the direct drive of electric vehicles, electric drones and for the direct operation of generators in wind turbines, which are advantageous fields of application of the invention.
  • the invention of course also relates to the other known embodiments, designs or types of electrical machines.
  • the illustrated embodiments of the machine have a radial orientation of the magnetic field. Constructions with a different orientation of the magnetic field are also possible.
  • the versions of the electrical machine shown include permanent magnets. In principle, the invention can also be implemented in an induction machine or another type of machine.
  • the illustrated versions of the electrical machine include alternating radially magnetized permanent magnets.
  • other magnet topologies such as a Halbach array, can also be used.
  • the illustrated versions of the electrical machine include a tangentially and axially uniform and axially aligned structure of the rotor and stator.
  • Tangentially and axially inhomogeneous or axially inclined structures can also be used, e.g. the magnets or the stator slots, e.g. to reduce the cogging torque or for manufacturing reasons, can be used with an adapted winding. All grooves in the application example are drawn open for reasons of simplicity. It is obvious that they can be completely or partially closed, for example by a cover element or a specially shaped pole piece.
  • the designs of the electrical machine shown include a rotor and a stator iron yoke. However, sandwich structures with several rotor or stator iron connections can also be used, for example.
  • Constructive solutions according to the present invention can of course also be used for linear drives, in particular where the active part of the machine extends in a straight section over the length of the machine.
  • Fig. 1 shows a cut-away spatial view of the active parts of a permanently excited electric machine with a slotted stator with a wave winding with high packing density and with radially alternating winding heads.
  • Fig. 2 shows different views of the active parts of the electric machine: a) front view; b) side view; c1) Section through the side view; c2) enlarged section of c1 ; d) Detail of the front view with winding heads; e) Section through the front view a winding head window; f) Detail of the front view with phase terminals and star point rail.
  • Fig. 3 shows a perspective section of the electric machine in the area of the phase terminals and star point rail.
  • Fig. 4 shows a phase of a wave winding in different views: a) perspective view, front view, side view and top view, b) section through the front view with axial and radial extent of a winding head window.
  • Fig. 5 shows a planar mat of a wave winding with one layer in different designs: a) with phase clamps on one side, b) with phase clamps on two sides.
  • Fig. 6 shows a section of the mat from Fig. 5 a).
  • Fig. 7 shows a section of the stator with the winding inserted.
  • Fig. 8 shows a planar mat of a wave winding with three layers in different views: a) perspective view; b) Detail of the perspective view with the winding heads.
  • Fig. 9 shows a planar mat of a wave winding with winding heads with a central offset in different views: a) perspective view with phase terminals on one side, b) detail from Fig. 9 a) with the winding heads.
  • Fig. 10 shows diagrams of various stackings of the wave windings with high packing density over the circumference of the machine: a) No stacking, one rotation; b) stacking continuously; b1) two-layer; b2) three-layer; c) 2-partition, no stacking; d) 2-partition, stacking backwards; d1) two-layer; d2) three-layer; e) 3- division, no stacking; f) 3-partition, stacking in three layers; f1) continuous; f2) backwards.
  • Fig. 11 shows diagrams of the winding head arrangement of a wave winding in different versions: a) three-phase; b) four-phase; c) five-phase.
  • Fig. 12 shows examples of different winding head designs: a) spatially bent solid wire or stranded wire bundle; b) vertically stacked double wire bent; c) Profile from solid forming; d) Profile for welded joint; e) Profile for clamp connection with webs; f) Winding head cranked from solid forming; g) Winding head of an air gap winding with several parallel wires.
  • Fig. 13 shows a cut-away spatial view of the active parts of a permanently excited electric machine with a slotless stator with an embodiment of the winding as an air gap winding.
  • Fig. 14 shows sections through the active parts of the electric machine from Fig. 13: a) front view with winding head window; b) Section across the stator ring; c) enlarged section of section b).
  • the first exemplary embodiment in Fig. 1 shows an electrical machine 1 designed as a rotary machine with an outer rotor or rotor 32 and an inner stator or stator 33, it being understood that a reverse design is also possible.
  • the stator 33 is designed as a grooved stator, into which a three-phase wave winding 2 with high packing density with radially alternating winding heads is inserted, together with the other active parts of a permanently excited electric synchronous motor.
  • the magnets are magnetized in the radial direction and the magnetization takes place alternately in the tangential direction.
  • the magnetic flux generated in the permanent magnet 4 passes through the air gap 5 and is then passed through the ferromagnetic stator core 6, which is made of magnetic steel or another material with high permeability.
  • the number of teeth 7 and grooves 8 is usually the product of the number of phases NP and the number of magnets NM, but can also deviate from this.
  • the groove width is at least as large as the width of the inserted conductor pieces 9.
  • a winding 2 which consists of one or more layers 28.
  • Fig. 1 shows a winding with a layer 28.
  • the winding 2 consists of NP or a multiple of NP conductors 9, which fill the slots 8.
  • Fig. 1 shows three phases 15, 16 and 17.
  • NP is preferably three or a multiple of three.
  • NP generally preferably has a value greater than or equal to two.
  • Each conductor 9 consists of parallel straight segments, the winding webs 10, as well as angled connecting pieces, the winding heads 11.
  • the straight winding webs 10 are of the same length.
  • the axially arranged straight winding webs 10 are tangentially connected by angled winding heads 11.
  • the winding heads 11 are arranged geometrically in a hollow cylinder 12, which is indicated by dashed lines in FIG. 2 d).
  • a hollow cylinder 12 is provided coaxially on both sides of the stator core.
  • the winding heads of the three phases are radially stacked in a tangential direction, alternating in an outer and an inner layer in such a way that an internal winding head 13 covers a part of the two right and left external winding heads 14 and an external winding head 14 each covers part of the two winding heads 13 located on the right and left.
  • a coordinate system is shown in Fig. 1.
  • a first axis A1 is parallel to at least one first web 11.
  • the first axis A1 is parallel to a rotation axis of the rotary machine.
  • a second axis A2 runs parallel to a direction of a relative movement of a rotor or rotor of the electrical machine 1 to a stator or stator of the electrical machine 1.
  • the second axis A2 is perpendicular to the first axis A1.
  • a third axis A3 is perpendicular to the first axis A1 and the second axis A2.
  • the respective conductor of the phases 15, 16, 17 has a section 31 in the area of a respective winding head 11, in which the conductor runs at least essentially perpendicular to the third axis and, in the present embodiment, also parallel to the second axis A2.
  • the position and alignment of the axes basically depend on the point of the machine that is being viewed. Since the machine 1 shown here as an example is a rotary machine, the third axis A3 in particular is aligned radially. This means that, for example, with a winding head 11 other than the one provided here with the coordinate system in the drawing, the axis A3 has a different angle to the viewer of FIG. 1.
  • the axis A2 is circular - corresponding to the relative movement between barrels 32 and stand 33.
  • the coordinate system is therefore ultimately a cylindrical coordinate system. For a linear machine with a straight guideway, the coordinate system would be a Cartesian coordinate system.
  • Fig. 2 shows a) a front view and b) a side view of the electric machine 1.
  • the projection or the axial length of the winding heads AH over the stator core should be as small as possible in order to keep the axial length and the phase resistance as low as possible. This is achieved by a special course of the winding head 11.
  • a section 31 of the conductor in the area of the winding head 11 runs perpendicular to the third axis A3 or tangentially. It is preferred if the section runs perpendicularly or at an angle greater than 60° to the web direction or to the first axis.
  • FIGS. 2 c1) and c2) A cross-sectional view is shown in FIGS. 2 c1) and c2), with FIG. 2 c2) showing an enlargement of the winding heads 11, 13, 14 shown on the left in FIG. 2 c1). It can be seen how a web 10 extends across the width of the stator core. A winding head 11 is connected to the ends of the web 10 in relation to the first axis A1.
  • Fig. 2 c2 two overlapping winding heads 11, namely an upper winding head 14 and a lower winding head 13, are visible.
  • the winding head 14 connects to the web 10.
  • the winding head 13 connects two other webs with each other and intersects with the winding head 14 of the web 10.
  • the sectional plane lies in a section 31 of the winding head 13, namely a section 31 in which the conductor runs at least essentially perpendicular to the third axis A3.
  • a first direction 35 runs along the third axis A3.
  • the web 10 has an end 36 in the first direction 35.
  • the winding head 14 also has a section 31 which has an end 37 with respect to the first direction 35, which is shown in FIG. 2 c2).
  • the end 37 of the section 31 of the winding head 14 is arranged offset from the end 36 of the (first) web 10 against the first direction 35, namely by an offset 38.
  • the offset 38 in this embodiment is 0.5 times the height HW of the ( first) web in relation to the third axis A3.
  • a corresponding, mirror-inverted offset exists in the section 31 of the (second) winding head 13 with respect to the webs which this winding head 13 connects.
  • the (first) web 10 has a second end 41 in a first opposite direction 39 with respect to the third axis A3 in a first opposite direction 35.
  • the section 31 of the (first) winding head 14 has a second end 42 in the first opposite direction 39.
  • the second end 41 of the web 10 and the second end 42 of the section 31 are at least essentially at the same height with respect to the third axis A3.
  • the dimensions are referenced in the image plane, namely a section width AB1 in relation to the first axis A1 and a section width AB3 in relation to the third axis A3.
  • the section width AB3 in relation to the third axis A3 is smaller than the section width AB1 in relation to the first axis A1.
  • the section width AB3 in relation to the third axis A3 is at least essentially equal to the web width WW, see Fig. 2 e)
  • the section width AB1 in relation to the first axis A1 is at least essentially equal to the web width HW with respect to the third axis A3.
  • This can be achieved, for example, in a particularly simple manner by massively forming the conductor material, in particular starting from the cross section present in the web. The introduction of a forming force could take place at least essentially parallel to the third axis A3.
  • the winding heads 11 are extremely compact. Firstly, the radial height HH of the winding head row is only as large as the web height HW. Secondly, the axial length AH of the winding heads 11 is also extremely short, and is simple to manufacture.
  • a width or tangential length of the winding head WH, see FIG. 2 d), is smaller than 75% of a magnetic period in this exemplary embodiment.
  • a height of the winding head package HH, see also Fig. 2 d), consisting of inner winding heads 13 and outer winding heads 14, advantageously corresponds to the winding web height HW, see for example Fig. 2 c1) and c2), but can also be in the range between 50% and 200% of the winding web height HW.
  • Fig. 2 e) shows a section through the front view of the stator with an installation space 12 of the winding heads.
  • the installation space 12 is ideally centered radially to the slots 8, but can also be, for example, a maximum of twice the winding web height HWinner or outside the circle formed by the slot centers.
  • a length LA of a section 31 A of a first winding head 11.1 is marked.
  • the conductor in the area of section 31.A runs perpendicular to the third axis A3 and parallel to the second axis A2.
  • the length LA forms a length of the section 31. A with respect to the second axis A2 or in the tangential direction.
  • axis A2 is circular, since the electrical machine shown here as an example is a rotary machine and since the relative movement of the rotor 32 to the stator 33 is correspondingly circular.
  • a distance between two webs 10 of the same phase, which are therefore connected via a winding head, not shown here, is designated DS.
  • the length LA of the section 31. A, see FIG. 2 d), in particular of each section 31, is preferably at least 0.2, preferably at least 0.4, more preferably 0.6 times DS.
  • a second winding head is designated 11.2.
  • the second winding head 11.2 is one of a different phase than that of the winding head 11.1.
  • the second winding head 11.2 also has a section 31. B in which the conductor runs at least substantially perpendicular to the third axis A3.
  • the axis A3 in a rotary machine as shown here is radial. Depending on at what angle or at what position along axis A2 the winding is viewed, axis A3 has a different angle to the observer than that shown in Fig. 2 d).
  • section 31.A of the first winding head 11.1 and the section 31.B of the second winding head 11.2 are arranged in an overlapping manner and overlap with respect to the second axis A2.
  • section 31 runs.
  • the sections 31. A and 31. B are offset in relation to the third axis A3, in particular in such a way that they are in relation do not overlap on the third axis A3.
  • phase terminals 21, 22 and 23 are visible. These can be produced, for example, by shortening and, if necessary, radially bending and deforming the winding head pieces at the beginning of the phase.
  • a star point rail is created by shortening the winding head pieces at the phase ends 24, 25 and 26, if necessary radially bending and deforming the winding head piece 26 and contacting the winding head pieces or phases.
  • the phase terminals 21, 22 and 23 are preferably arranged axially behind the winding heads, so that they do not require any additional axial installation space and are easy to contact.
  • the star point rail which is formed from the shortened last winding heads 24, 25 and 26 and is contacted using a usual joining process, for example welding, is located in the area of the winding heads and therefore also takes up little or no additional installation space.
  • Fig. 2 f) shows a possible embodiment.
  • an axial installation space 27 is created, highlighted here with a tangential length L27 and a radial height H27, which can be used, for example, to accommodate a position sensor.
  • the available installation space 27 extends with L27 in the tangential direction over more than one magnetic period AM and is therefore sufficiently large for magnetic field measurements to determine the rotor position.
  • the axial depth corresponds to the winding head projection AH.
  • the radial height H27 extends up to the magnet 4.
  • a sensor for example a position sensor, can thus be integrated without taking up additional installation space. If some of the terminals mentioned are not bent, the installation space is correspondingly reduced in the tangential and/or radial direction.
  • a perspective section through the active motor parts in Fig. 3 shows the area of the phase terminals and the star point rail.
  • the shape of a winding head 11 can basically be semicircular, triangular, straight or U-shaped or can have another geometric shape, in particular one that enables the shortest possible connection of two adjacent winding webs of the same phase.
  • the height of the conductor HW in the winding head 11, see FIGS. 2 c1) and c2), is preferably reduced in order to be able to stack the winding heads 11 in pairs in the radial direction without requiring additional radial installation space.
  • the current-carrying cross section is preferably not reduced or, if necessary, increased in order to keep the phase resistance as small as possible. Changes in shape are carried out with constant transitions so as not to impede the flow of current.
  • the winding webs 10 preferably have at least a length which corresponds to the depth of the stator core along the first axis A1, usually the smallest possible excess length DH - see Fig. 4 b) - in order to ensure the insulation strength of the winding and / or the production of the winding heads and to make assembly easier. Additional insulation of the stator sides, e.g. through a coating or a cover disk, enables very small excess lengths DH.
  • FIG. 4 a shows different views of a phase or a conductor with radially alternating winding heads.
  • the side view (top horizontal) illustrates the radial positioning of the winding heads, according to which, viewed in the direction of travel from the beginning of the phase to the end, there are always two winding heads lying one after the other at the bottom (corresponds to winding head 13) or at the top (corresponding to winding head 14), aligned alternately on different stator sides.
  • 4 b) shows a section through the front view of a phase, the radial position of the lower winding heads 13 and upper winding heads 14 as well as the axial and radial extent of the winding head window 12.
  • a phase can be made from one or more solid wires or profiles of any cross-section or from a bundle of strands of any cross-section.
  • the entire winding can be manufactured either in one step inside or outside the stator, or the phases 15, 16 and 17 can be prefabricated individually, then woven into a winding and then inserted into the slots, or
  • the winding webs 10 are inserted into the slots 8 and then connected to the winding heads 11 by joining.
  • the winding webs 10 are located in the stator slots 8 and fill them as completely as possible.
  • Each winding head 11 runs tangentially over part of the magnetic period.
  • Fig. 5 shows two versions of a winding mat with radially alternating winding heads, namely in Fig. 5 a) an embodiment with all phase terminals on one side of the mat and in Fig. 5 b) with phase terminals on both sides of the mat.
  • Arrangement a) has the advantage that the phase connections are easier to contact because they are spatially close to one another on the same side.
  • Arrangement b) has the advantage that a gap-free mat is created that is easier to handle.
  • Fig. 5 shows the dense structure of the winding head package, in which the winding heads of the three phases are arranged in two radially stacked layers without gaps.
  • Fig. 6 shows a section of the winding mat consisting of three phases 15, 16 and 17 with winding heads alternating at the bottom 13 and at the top 14.
  • the winding 2 is in a state before being inserted into the stator slots 8. Specifically, the mat is essentially spread out flat. In this state, axis A2 is straight. In the orientation shown, the winding 2 or mat could also be used in a linear motor, for example.
  • Fig. 7 shows a winding 2 comprising the phases 15, 16 and 17 with winding heads alternating at the bottom 13 and at the top 14, which is inserted into the stator slots 8.
  • the compact multi-phase wave winding 2 can consist of more than one layer 28.
  • Fig. 8 shows an exemplary embodiment of the structure of a winding mat consisting of three layers 28.1, 28.2 and 28.3.
  • the height of the winding heads is ideally matched to the height of the winding layer, so that any number of layers can be stacked radially without collision, without taking up additional radial installation space. However, it is also possible to use higher or lower winding heads, which increases the height of the winding head package.
  • Fig. 8 shows three stacked individual mats with radially alternating winding heads. A longer winding mat can also be made and then stacked and inserted onto the stator.
  • the winding mat from FIG. 8 can, for example, simply be a stack of three winding mats according to FIG. 5 a) or b
  • Fig. 9 a shows a further embodiment of a winding mat with a layer consisting of three phases.
  • the first phase 15 only has lower winding heads 13 here. All winding heads of the third phase 17 are upper winding heads 14.
  • the second phase 16 has cranked winding heads 30, which proportionately occupy the lower and upper part of the winding head window or the lower and upper layers.
  • This form of wave winding with cranked winding heads 30 also enables the three phases to be stacked in an optimal space.
  • Fig. 9 b) shows a section with the winding heads 13, 30, 14. The advantage of this arrangement is that the three phases only have to be stacked radially one after the other in order to produce a winding mat.
  • the position of the webs and the winding head window corresponds to the wave winding with radially alternating winding heads, as described above, so that winding mats of both designs can be used equally and even mixed.
  • the layers 28 can be stacked one above the other on the stator, basically over the entire circumference of the machine in the radial direction or only on individual segments of the stator or in a combination, as shown as an example in FIG. 10.
  • the radial transition between the individual layers 28 can take place in such a way that the sequence of winding webs 10 and winding heads 11 runs in the same or in the opposite tangential direction.
  • the layers 28 can also be intertwined.
  • the split configurations allow the voltage level to be lowered by connecting the split segments in parallel.
  • phase number NP is preferably equal to three or a multiple of three, since in this case a particularly high packing density of the winding heads can be achieved.
  • Fig. 11 shows examples of an arrangement scheme with radially alternating winding heads for a) three phases, b) four phases and c) five phases.
  • the winding head arrangements at the beginning of a phase can be chosen arbitrarily as long as the alternating order is maintained. With three phases, there is a very compact winding head arrangement in two layers, each in one level of lower level E1 and upper level E2 without gaps. By radially stacking the winding heads of three-phase arrangements, compact six-, nine-, etc. - phase arrangements can be created. The winding head height of the three-phase arrangement used must be halved, divided into thirds, etc. if the radial installation space is to be maintained. Phase numbers NP that are not a multiple of three can be represented as shown in Fig. 11 b) using the example of four phases and Fig. 11 c) using the example of five phases.
  • a four-phase winding is created, for example, from a tightly packed three-phase winding and an additional fourth phase inserted into the remaining free space.
  • a total of three layers are occupied by the winding heads, each in a level of lower level E1, middle level E2 and upper level E3.
  • a five-phase winding is created, for example, from a tightly packed three-phase winding and two additional fourth and fifth phases inserted sequentially into the two free spaces.
  • a total of four layers are occupied by the winding heads, each in a level of the lowest level E1, second level E2, third level E3 and top level E4. Due to the individual phases, the winding head package has gaps in the tangential direction and therefore requires additional installation space compared to a three-, six- or nine-phase arrangement.
  • the winding 2 consists of conductors 9, the cross section of which can be circular, rectangular, trapezoidal or another cross section, whereby a conductor 9 can consist of many thin wires or a solid wire or profile.
  • the size and shape of the cross section can change along the conductor. Copper or another material with good electrical conductivity can be used.
  • Adapting the conductor cross section to the slot geometry enables a high fill factor.
  • the high fill factor enables good thermal contacts and lower electrical resistance.
  • the height HW and width WW of the conductor 9 represent the conductor dimensions in radial and tangential dimensions. With a circular or square cross section, the width and height are identical.
  • Each phase can consist of any number NL of conductors tangential order, whereby one is preferred for slot windings for NL.
  • a winding described herein can be produced by different methods and from different semi-finished products, which in turn have an impact on the possible winding head and winding web designs. Examples of these manufacturing processes are: a) Bending and/or twisting, in particular in several axes b) Joining c) Mass forming d) Additive manufacturing
  • the production of the winding can involve bending a solid wire or a stranded bundle in several axes, for example according to FIG. 12 a).
  • the bending of a solid wire or a stranded bundle is preferably carried out in two forming steps in order to limit the stress on the material.
  • the tangential section 31 of the winding head 11 is formed in a torsion step with a 90° torsion angle about a torsion axis, item 34 in FIG. 12 a), parallel to the web axis.
  • a bending step about two radial axes, item 44 in Fig. 12 a) two bends of 90 ° are carried out in order to represent a curved shape of the winding head 11.
  • the winding head 11 then has the height of the web width.
  • an aspect ratio of the web of 2:1 provides a winding head package at the height of the winding web HW and thus a very compact arrangement.
  • the minimum bending radius is preferably limited to 3 to 4 times the wire width WW, which results in an axial winding head length of, for example, 4*WW+HW+DH. With an aspect ratio of 2:1 this results in 6*WW+DH.
  • the cross section of the winding web is determined by the cross section of the solid wire or stranded bundle used.
  • Fig. 12 a) shows an exemplary embodiment of a winding head made of spatially bent solid wire. A bundle of strands is characterized, for example, by the fact that it does not consist exclusively of vertically stacked wires.
  • a phase is created when several alternating winding heads and winding webs made of solid wire or a stranded bundle are bent sequentially. Three phases can then be woven into a winding mat.
  • the winding heads of all three phases are preferably made from three solid wires or stranded bundles in one step and the Winding mat is built up directly during bending.
  • the shape and order of the winding heads result from the arrangement in Fig. 12 a) and/or Fig. 11.
  • the production can also include bending a solid wire in several axes, in particular a conductor with a radially offset section 31 and a conductor without a radial offset can be combined, as shown in Fig. 12 b).
  • a solid wire with a high aspect ratio or the fill factor deterioration of the stranded bundle for example two or more radially stacked solid wires, preferably with a square cross section, can be used.
  • the bends remain in the same manner and order as with a solid wire/stranded bundle, but are simplified due to the significantly lower resistance moments of the thinner solid wires.
  • the axial combined winding head length is, for example, 5*WW+DH.
  • the cross section of the winding web is determined by the cross section of the wire used.
  • Fig. 12 b) shows an embodiment with two conductors with radially stacked and bent square solid wires. More than two wires can also be stacked with adjusted wire heights to further reduce the section modulus of the wires. When several alternating winding heads are bent sequentially, a phase is created. Three phases can then be woven into a winding mat. The winding heads of all three phases are preferably made from three stacked solid wire pairs in one step and the winding mat is built up during bending. The shape and order of the winding heads result from the arrangement in Fig. 12 b) and/or Fig. 11.
  • a wide range of freedom in shaping the winding head and/or winding web is achieved by massive forming, for example extrusion or forging, of the winding heads.
  • massive forming for example extrusion or forging
  • the favorable flow properties of copper are used to create an ideal winding head geometry, without being limited by bending radii.
  • Due to the high flexibility during forming axially very short winding heads can be produced and the cross-sectional changes can be continuously shaped.
  • the axial winding head length can be shortened, for example, to 3*WW+DH, for example with an aspect ratio of 2:1.
  • the winding web can also be adapted, for example, to a trapezoidal shape or another desired geometry, for example by massively forming the winding web or by selecting a semi-finished product with a suitable geometry, whereby the fill factor can be significantly increased, especially with a smaller stator diameter.
  • the cross sections used in the winding web and winding head are independently selectable.
  • the starting material is, for example, bare copper or another material with high electrical conductivity such as wire, profile or other semi-finished product.
  • the insulation is applied after the phase/winding has been completed, for example by painting.
  • Fig. 12 c shows an exemplary embodiment of a massively formed winding head.
  • a phase is created.
  • Three phases can then be woven into a winding mat.
  • the winding heads of all three phases are preferably manufactured from three profiles in one step and the winding mat is built up during massive forming.
  • the shape and order of the winding heads result from the arrangement in Fig. 12 c) and Fig. 11.
  • the winding head 11 shown in FIG. 12 c) can be formed from a solid wire with a substantially rectangular cross section by first bending the wire into a U-shape so that webs 10 are aligned parallel. Mass forming can then take place in such a way that the area between the parallel webs 10 is essentially pressed flat. This creates a cross section with essentially the same cross-sectional area as in the area of the webs 10, the height in this exemplary embodiment being essentially halved and the width being essentially doubled.
  • the cross-sectional shape essentially corresponds to that of the webs 10, but is rotated by 90°.
  • a first direction 35, an end 36 of the web 10 in the first direction 35 and an end 37 of the section 31 in the first direction 35 are also indicated. There is an offset 38 between the end 36 and the end 37.
  • winding heads and webs are each conical.
  • cylindrical joining surfaces are also possible.
  • winding heads it is possible to insert winding webs with a geometrically adapted cross-section and insulated, for example painted, into the slots, which in this case can also be partially or completely closed.
  • the winding heads can be prefabricated using forming technology, for example by punching or by a cutting process, for example by laser cutting, or other manufacturing processes.
  • the joining process between winding web 10 and winding head 11 is carried out, for example, by welding, clamping, riveting, extrusion, another joining method or a combination of these methods.
  • the joint must be subsequently insulated.
  • the cross sections used in the winding web and winding head can be selected independently. Due to the compact At the joint, very short winding heads can be produced axially.
  • the axial winding head length can be shortened to 3*WW+DH with a selected distance of WW between stator and winding head, especially with an aspect ratio of 2:1. Depending on the joining method chosen, a slight increase in the contact resistance between the winding web and the winding head can be expected.
  • Fig. 12 d shows an exemplary embodiment of a winding head for a welded connection, in which the winding web is butt-joined to the winding head, for example by plasma welding.
  • a first web (not shown in FIG. 12 d) and the winding head 11 are assembled from separate components, with one end of the first web and one end of the winding head 11 on corresponding joining surfaces (the joining surface of the winding head 11 is in Fig
  • the Winding head 11 are assembled from separate components, with one end of the second web and one end of the winding head 11 being placed against each other on corresponding joining surfaces, which are at least substantially perpendicular to the first axis A1, and then welded together at the joining surfaces.
  • Fig. 12 e shows an exemplary embodiment of a winding head and a suitable winding web for a clamp connection.
  • the shape of the joint can, for example, be slightly conical, as in Fig. 12 e), or take on another geometric shape. Alternating concave and convex elevations or depressions on the surface of both joining partners improve the mechanical and electrical connection.
  • the order of the winding heads results, for example, from the arrangement in Fig. 11.
  • FIG. 12 f shows an exemplary embodiment of a winding head 11, which has a first section 31.1 with an offset 38.1, as described with reference to FIG. 12 c), relative to a first web 10.1.
  • a second section 31.2 is also provided, in which the conductor runs at least essentially perpendicular to the third axis A3.
  • the second web 10.2 has an end 36.2 in a first opposite direction 39 along the third axis A3, opposite the first direction 35.
  • the second section 31.2 has an end 37.2 in the first opposite direction 39 in relation to the third axis A3.
  • the end 37.2 of the second section 31.2 is opposite the end 36.2 of the second web 10.2 arranged offset along the first opposite direction 39, namely by an offset 38.2.
  • the first section 31.1 and the second section 31.2 are thus ultimately designed to be mirror-inverted.
  • a step or offset 40 is provided between the first section 31.1 and the second section 31.2.
  • such cranked winding heads can be used.
  • the offset 40 lies approximately in the middle of the tangentially extending section of the winding head, so that the part of the winding head lies in front of the offset point, as in the case of an overhead winding head 14, and the part of the winding head lies after the offset point, as in the case of an underlying winding head 13. This order can also be swapped.
  • the winding head 30 of FIG. 9 b) can advantageously be designed according to FIG. 12 f). All winding head designs shown in FIG. 12 can basically be designed in a cranked form.
  • the exemplary embodiment according to FIG. 12 f) can, for example, be produced similarly to that of FIG. 12 c), in particular by massive forming and preferably with prior bending of an elongated starting material.
  • the cross section of the elongated starting material is preferably rectangular, in particular with different aspect ratios and / or an aspect ratio of 2: 1. It is also advantageous if the cross section remains in the area of the webs 10, i.e. H. the cross section of the webs 10 corresponds to that of the starting material. It is therefore only necessary to deform the cross section in the area of the winding head 11.
  • additive manufacturing of the winding heads and/or winding webs is also possible.
  • Additive manufacturing processes offer a very high level of flexibility in both the shape and design of the winding. Similar to joining, insulated winding webs 10 can be inserted or inserted into the open or closed slots, after which the winding heads 11 are additively manufactured as a connection between two adjacent winding webs 10 of a phase and, in particular, contacted at the same time. In this case, only the winding heads 10 need to be re-insulated. Similar to solid forming the individual phases 15, 16 and 17 or the entire winding 2, consisting of winding webs 10 and winding heads 11, are manufactured additively, either outside the stator 6 as a prefabricated winding mat or directly in the slots 8 of the stator as an integrated winding.
  • insulation can be carried out in a separate step.
  • insulation is part of additive manufacturing.
  • the axial winding head length can be shortened, for example, to 3*WW+DH, especially with an aspect ratio of 2:1.
  • All winding head geometries listed in FIG. 12 can be produced using additive manufacturing. The order of the winding heads results, for example, from the arrangement in Fig. 11.
  • FIG. 13 shows an electrical machine 29 with a slotless stator, on which a three-phase wave winding with high packing density 2 is applied as an air gap winding with radially alternating winding heads, together with the other active parts of a permanently excited electric synchronous motor.
  • This machine 29 has an even number NM of permanent magnets 4 on the rotor iron 3.
  • the magnets 4 are magnetized in the radial direction and the magnetization takes place alternately in the tangential direction.
  • the magnetic flux After passing through the air gap 5 and the wave winding 2 lying in the air gap, the magnetic flux is guided through the ferromagnetic stator core 6, which consists of magnetic steel or another material with high permeability.
  • the stator has no grooves or teeth, which means it is very low and easy to implement and, due to its design, avoids cogging torque.
  • a winding 2 which can consist of one or more layers 28, for example with stacking similar to Fig. 8.
  • Fig. 13 shows the winding with a layer 28.
  • the winding 2 can be NP or a multiple of NP conductors 9, which lie directly in the air gap, where NP represents the number of phases.
  • NP is preferably three or a multiple of three or any value greater than or equal to two.
  • Each phase here comprises several adjacent, parallel, straight segments, the winding webs 10, as well as angled connecting pieces, the winding heads 11.
  • the straight winding webs 10 are of the same length. To reduce eddy currents, each phase is divided into NL individual wires.
  • the number NL of individual wires results from the speed range in which the machine is operated and the cross section of the individual wires.
  • the individual wires can have a round, preferably a rectangular, generally any cross-section.
  • the axially arranged, straight winding webs 10 are tangentially connected by angled winding heads 11, which are arranged in particular geometrically in a hollow cylinder or winding head window, which lie coaxially on both sides of the stator core.
  • the winding heads of the three phases lie radially stacked in a tangential direction, alternating on an outer and an inner layer in such a way that an internal winding head 13 covers and covers a part of the two winding heads 14 on the right and left External winding head 14 covers part of the two winding heads 13 on the right and left.
  • Fig. 14 a) shows a detail from the front view of the electric machine 29 with the winding head window 12.
  • Fig. 14 b shows a section through the active parts of the slotless electric machine 29.
  • the projection of the winding heads AH over the stator core should be as small as possible in order to keep the axial length and the phase resistance as low as possible. This is achieved by a tangential course of the winding head at right angles or at an angle greater than 60° to the web direction.
  • the width of the winding head WH is preferably smaller than 75% of a magnetic period.
  • the height of the winding head package HH, see FIG. 14 c), is preferably in the range between 50% and 200% of the winding web height HW.
  • the radial position of the winding head package can be aligned centrally to the winding web as in FIG. 13 b) or, for example, can be shifted radially downwards or upwards by a maximum of two winding web heights HW.
  • a respective conductor in the area of the (first) winding head 13 has a section 31 in which the conductor runs at least essentially perpendicular to the third axis A3 and here also perpendicular to the first axis A1.
  • the (first) web 10 has an end 36 in a first direction 35 along the third axis A3.
  • the section 31 of the winding head 13 has an end 37 in the first direction 35 along the third axis A3.
  • the end 37 of the section 31 of the winding head 13 is arranged offset from the end 36 of the first web 10 against the first direction 35.
  • An end 42 of the section 31 of the first winding head 13 in a first opposite direction 39 opposite the first direction 35 is offset from an end 41 of the web 10 in the opposite direction 39.
  • the winding heads can, for example, be bent radially in the direction of the stator core 6 and, for example, fixed to it. By making thermal contact with the stator core 6, for example, an improvement in heat dissipation and thereby a significant reduction in the winding head temperature is achieved.
  • Another possibility for increasing the mechanical rigidity is to bake, cast, glue or otherwise embed the winding heads 11 in a carrier substance.
  • a further embodiment of the electrical machine is characterized in that the stator core 6 is replaced by a second rotor equipped with permanent magnets and the winding 2 is positioned freely in the air gap.
  • the winding heads 11 are baked, glued, cast or embedded in a carrier substance in order to be able to transmit torque and forces to the stationary parts of the machine.
  • additional fastening rings can be attached inside, outside or on both sides of the winding heads 11.
  • the winding webs are preferably also baked, glued, cast or embedded in a carrier substance in order to increase the mechanical stability.
  • the winding 2 forms a completely iron-free stator of the machine.
  • completely or multiple wrapping layers are preferably used.
  • the shape of the winding head can be semicircular, triangular, straight, U-shaped or have another geometric shape, in particular one that enables the shortest possible connection of two adjacent winding webs of the same phase.
  • the height of the winding HW is preferably retained in the winding head of the air gap winding, but it can also be reduced in order to reduce the radial height of the winding head package.
  • the winding webs at least preferably have a length which corresponds to the depth of the stator core along the axis A1, and usually the smallest possible excess length in order to ensure the insulation strength of the winding and/or to facilitate the production of the winding heads and assembly.
  • the winding webs 10 are tightly packed on the stator core 6 in a tangential direction in order to achieve a high filling factor.
  • Two NP winding webs 10 preferably cover one magnetic period.
  • the sequential arrangement of the winding webs and winding heads together forms a phase of a wave winding with a radially alternating positioning of the winding heads 11, in that, viewed in the running direction from the beginning of the phase to the end of the phase, there are always two winding heads 11 lying one after the other, alternating at the bottom 13 and at the top 14 aligned on both sides of the stator.
  • Fig. 14 b) shows the axial and radial extent AH and HH of the winding head window 12.
  • Fig. 12 g) shows an exemplary embodiment with seven individual wires or conductors 9. The stator protrusion of a respective conductor 9 forms a winding head 11. All in Fig. 12 g) shown winding heads have a section 31 with an offset from the respectively assigned web 10.
  • the production takes place, for example, from a wire bundle of NL profile wires arranged horizontally next to one another by bending in two radial axes 44 in order to achieve the curved shape, and a subsequent bending around a tangential axis 45, which adjusts the curved part by at least half of the winding web height HW outside (outer winding head 14) or inside (inner winding head 13) deformed relative to the respective winding web.
  • a step 46 is provided by the offset, with the respective section 31 being offset upwards in relation to the image plane compared to the corresponding web 10.
  • cranks on the inner 13 and on the outer winding head can also be divided asymmetrically, but preferably in such a way that there is always a distance of one winding web height between the outer 14 and inner 13 winding head.
  • the entire winding can either be manufactured in one step or the phases can be prefabricated individually and then woven into a winding mat (winding heads with radially alternating positioning) or laid (offset winding heads).
  • the winding mat can be completely prefabricated outside the stator and then applied to the stator by gluing or another joining method, or it can be manufactured directly on the stator.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Manufacture Of Motors, Generators (AREA)

Abstract

L'invention concerne un enroulement pour une machine électrique, l'enroulement comprenant au moins un premier conducteur, qui est disposé sous la forme de plusieurs bandes et de plusieurs têtes d'enroulement, les bandes et les têtes d'enroulement alternant successivement le long du premier conducteur ou du conducteur respectif et une tête d'enroulement respective formant une connexion entre deux bandes, une première tête d'enroulement connectant une première et une deuxième bande du premier conducteur, une deuxième tête d'enroulement du premier ou d'un deuxième conducteur connectant une troisième et une quatrième bande du premier ou du deuxième conducteur, la première et la deuxième têtes d'enroulement se croisant et la troisième bande étant disposée entre la première et la deuxième bande, un premier axe étant parallèle à au moins la première bande, un deuxième axe étant parallèle à une direction d'un mouvement relatif d'un rotor de la machine électrique par rapport à un support de la machine électrique, un troisième axe étant perpendiculaire au premier et au deuxième axe, le conducteur ayant, dans la région de la première tête d'enroulement, une partie dans laquelle le conducteur s'étend au moins sensiblement perpendiculairement au troisième axe, la partie ayant une extrémité dans une direction le long du troisième axe, la partie ayant une extrémité dans la première direction le long du troisième axe, l'extrémité de la partie étant disposée en décalé par rapport à l'extrémité de la première bande opposée à la première direction, et la partie couvrant la troisième bande en relation avec le deuxième axe.
PCT/EP2023/063428 2022-05-24 2023-05-18 Enroulement, machine électrique et procédé de fabrication WO2023227464A1 (fr)

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