Patent ID: 12191729

FIG.1andFIG.2each show a first exemplary embodiment of a stator1, whereinFIG.1is a partial perspective view andFIG.2is an associated detailed view in the region of a first end face2aof the stator1.

The stator1has three phases U, V, W (N=3), four pole pairs (P=4) and a hole number two (q=2). The stator comprises a stator core3with 48 slots4and 384 shaped conductors5, which are arranged in eight layers6ato6h(L=8) radially layered in the slots4. Here, the first layer6ais the radially outermost layer and the eighth layer6hthe radially innermost layer, wherein the second to seventh layers6bto6gare denoted in the order of their indexing from the outside to the inside.

The shaped conductors5form four paths7ato7dper phase U, V, W, which can be connected in series or in parallel with one another. The shaped conductors5are further arranged in 16 winding zones8, each extending radially over layers6ato6hand circumferentially over two directly adjacent slots4. Here, the number of winding zones corresponds to twice the number of pole pairs, i.e., the number of poles, and the number of immediately adjacent slots4over which a winding zone8extends corresponds to the number of holes q. Each winding zone8is in turn subdivided into a number of partial winding zones8a,8bcorresponding to the number of holes q, said partial winding zones extending over all layers6ato6hand being immediately adjacent in the circumferential direction. In the present exemplary embodiment, the stator1is formed as a non-chorded stator, and therefore each partial winding zone8a,8bcomprises exactly one slot4.

The shaped conductors5of each path7ato7dare connected in a series circuit, which is provided by connectors arranged at both end faces2a,2bof the stator core3. First connectors9ato9e, second connectors10ato10f, and third connectors11ato11hare provided here.

FIG.3aandFIG.3bshow a winding schema of the stator1according to the first exemplary embodiment.

In the uppermost row ofFIG.3aandFIG.3b, numbers “1” to “48” of the slots4are indicated in a clockwise direction with respect to the end face2a, whereinFIG.3aandFIG.3bare divided between slot4numbers “22” and “23”. The upper table shows, with reference to the slots4and the layers6ato6h, the position of a start and an end of a path7ato7d, respectively, for the phases U, V, W, wherein U+, V+, W+ denote winding zones8in which the shaped conductors5are passed through in a first current direction, and U−, V−, W− denote winding zones8in which the shaped conductors5are passed through in a second current direction opposite to the first current direction. Below the table, for each of paths7ato7dof phase U, the position of a shaped conductor5in the winding zones8is shown in each case. Here, the first connectors9ato9d, the second connectors10ato10f, and the third connectors11ato11hat the first end2aare shown by dashed arrows, and the first connectors9eat the second end2bare shown by solid arrows. As can be seen fromFIG.3aandFIG.3b, each path7ato7dcomprises a number of groups12ato12dof successively series-connected shaped conductors5corresponding to half the number of layers6ato6g. Here, a symbol “x” indicates ends, i.e. outer shaped conductors5with respect to the series connection, of a path7ato7d, which can be connected to a phase connection. A symbol “o” indicates corresponding ends of a path7ato7d, which are connected to form a star point. Remaining shaped conductors5are marked with the symbol “+”.

Pairs of groups12ato12dadjacent with respect to the series connection are each connected by one of the second connectors10ato10f. The second connectors10ato10feach provide an offset by two layers6ato6hin the radial direction. The second connectors10a,10eand10eof the paths7aand7cprovide an offset by five (N·q−1) slots4in the circumferential direction, whereas the second connectors10b,10d,10fof the paths7band7dprovide an offset by seven (N·q+1) slots4in the circumferential direction. Thus, in a particular path7ato7d, the first group12ais located in the eighth layer6hand in the seventh layer6g, the second group12bis located in the sixth layer6fand in the fifth layer6e, the third group12cis located in the fourth layer6dand in the third layer6c, and the fourth group12dis located in the second layer6band in the first layer6a. Consequently, in each winding zone8of a phase U, V, W there is exactly one shaped conductor5of a group12ato12d. In other words, the shaped conductors5of a group12ato12dform a circumferential circuit.

Each group12ato12dis formed by two arrangements13a,13bof four shaped conductors5, which are arranged alternately in the two immediately adjacent layers6ato6hand are connected in series by the first connectors9ato9e. By way of example, the first arrangement13aof the first path7athus comprises the shaped conductors5arranged in the eighth layer6hand in the seventh layer6gand in the slots numbered “19”, “25”, “31” and “47”. Accordingly, the second arrangement13bof the first path7acomprises the shaped conductors5arranged in the eighth layer6hand in the seventh layer6gand in the slots with the numbers “44”, “2”, “8” and “14”. Each first connector9ato9ebetween two shaped conductors directly adjacent with respect to the series connection of an arrangement13a,13bprovides an offset here by six slots4in the circumferential direction and an offset by one layer6ato6hin the radial direction.

The arrangements13a,13bare each located in a different one of the two partial winding zones8a,8bof a winding zone8. Here, the first arrangements13aof the first path7aand of the fourth path7dare located in the first partial winding zone8aof a winding zone8, and the first arrangements13bof the second path7band of the third path7care located in the second partial winding zone8bof a winding zone8. Accordingly, the second arrangements13bof the first path7aand of the fourth path7dare located in the second partial winding zone8bof a winding zone8, and the second arrangements13bof the second path7band the third path7care located in the first partial winding zone8bof a winding zone8.

The arrangements13a,13bof a group12ato12dare connected by one of the third connectors11ato11g. The third connectors11a,11c,11e,11gprovide an offset here by seven (N·q+1) slots4, whereas the third connectors11b,11d,11f,11hprovide an offset by five (N·q−1) slots4. Consequently, the third connectors11a,11c,11e,11gare provided to connect arrangements13a,13barranged in the first partial winding zone8ato arrangements13a,13barranged in the second partial winding zone8b, whereas the third connectors11b,11d,11f,11hare provided to connect arrangements13a,13barranged in the second partial winding zone8bto arrangements13a,13barranged in the first partial winding zone8a. In order to ensure the continuous change between the immediately adjacent layers6ato6h, only the third connectors11a,11c,11e,11gproviding an offset by seven slots4are provided in the first path7aand the third path3c, and only the third connectors11b,11d,11f,11hproviding an offset by five slots4are provided in the second path7band the fourth path7d.

As is further shown inFIG.3aandFIG.3b, the paths7ato7dare subdivided into a number of sets14a,14bcorresponding to the number of holes q, i.e., in the present case two sets14a,14b, wherein the first set14acomprises the first path7aand the second path7b, and the second set14bcomprises the third path7cand the fourth path7d. Both sets14a,14bhave the same sequence of connectors9ato9e,10ato10f,11ato11g, but are separated by one winding zone8or by six (N·q) slots4offset from each other in the circumferential direction.

From the overall view of the paths7ato7c, it thus follows that the winding zones8for the phase U are completely occupied by shaped conductors5. This means that in each partial winding zone8a,8bof a winding zone, all layers6ato6hare occupied by a shaped conductor5. Winding zones8of the other phases V, W are occupied analogously to the phase U with shaped conductors5connected by corresponding connectors9ato9e,10ato10f,11ato11g.

FIGS.4to13andFIGS.15to22each show two shaped conductors5connected by a connector9ato9d,10ato10f,11ato11g.

FIG.4shows two shaped conductors5arranged parallel to each other and formed in one piece with the first connector9a. The first connector9acomprises two protruding portions15a,15bthat protrude at an obtuse angle from the relevant shaped conductor5. The protruding portions15a,15bextend circumferentially and axially at the radial position where the shaped conductor5from which they protrude is located. As can also be seen fromFIG.2, the protruding portions15a,15bthus have an arc shape.

The protruding portions15a,15bare connected to each other at their ends facing away from the shaped conductor5by a transition portion16. The transition portion16provides the offset in the radial direction. Consequently, the transition portion16extends substantially in the circumferential direction and in the radial direction.

A connecting element17, which is formed in one piece with a shaped conductor5, is connected to the shaped conductor5at its end opposite the first connector9a. The connecting element17comprises a protruding portion18, which protrudes from the shaped conductor5at an obtuse angle. The protruding portion18extends from the radial position of the shaped conductor5from which it protrudes, bent radially outward in the circumferential direction and axial direction. As can also be seen fromFIG.1, the protruding portion18thus has an arc shape. Adjacently to the protruding portion18is a joining portion19which extends substantially only in the axial direction.

The first connectors9eprovided at the second end face2bare formed by the integrally bonded joining, for example by welding, of the joining portions19of connecting elements17which adjoin two successive shaped conductors5with respect to the series connection. In this case, the joining portions19are arranged with their flat sides parallel to one another. The fact that the protruding portions18of the connecting elements17are bent outward ensures a sufficient insulating distance between two radially adjacent first connectors9e.

The other components of the stator1shown inFIGS.5to13andFIGS.15to22correspond to the component shown inFIG.4in terms of their structure consisting of two shaped conductors5, a connector9bto9d,10ato10f,11ato11g, which has protruding portions15a,15band a transition portion16, and two connecting elements17, each comprising a protruding portion18and a joining portion19, wherein in each case a different offset in the radial direction and/or circumferential direction is provided. Although the protruding portions15a,15b,18are shown here obliquely, i.e., with a constant pitch in the axial direction, the protruding portions15a,15b,18can in each case or individually have a different form, for example can be bent along the axial direction.

The first connectors9ato9dshown inFIG.4toFIG.7each provide the offset by six slots4in the circumferential direction and the offset by one layer6ato9h. The first connector9ashown inFIG.4provides the offset from the eighth layer6hto the seventh layer7g. The first connector9bshown inFIG.5provides the offset from the fifth layer6eto the sixth layer6f. The first connector9cshown inFIG.6provides the offset from the fourth layer6dto the third layer6d. The first connector9dshown inFIG.7provides the offset from the first layer6ato the second layer6b.

FIG.8toFIG.12show shaped conductors5connected by a second connector10ato10f, respectively.

FIG.8shows the second connector10aandFIG.9the second connector10b. Both connectors10a,10bprovide the offset in the radial direction from the eighth layer6hto the sixth layer6f. The second connector10aprovides an offset in the circumferential direction by five slots4, whereas the second connector10bprovides an offset by seven slots4. As can be seen from a comparison ofFIG.8andFIG.9, the second connector10ais axially shorter than the second connector10bis. As a result, the second connector10ain the first path7acan be arranged at the same radial position axially further inward than the second connector10bcan in the second path7b. This applies analogously to the second connector10ain the third path7cand the second connector10bin the fourth path7d.

FIG.10shows the second connector10candFIG.11the second connector10d. Both second connectors10e,10dprovide the offset in the radial direction from the fifth layer6eto the third layer6c.FIG.12shows the second connector10eandFIG.13the second connector10f. Both second connectors10e,10fprovide the offset in the radial direction from the fourth layer6dto the second layer6b. Analogously to the second connectors10a,10b, the second connectors10c,10eprovide the offset in the circumferential direction by five slots4, and the second connectors10d,10fprovide the offset in the circumferential direction by seven slots4. Again, the second connectors10c,10eare axially shorter than the second connectors10d,10fare, so that the second connectors10c,10ein the first path7aand in the third path7care arranged at the same radial position axially further inward than the second connectors10d,10fin the second path7band in the fourth path7d.

FIG.14shows a plurality of shaped conductors5of the phase W of the stator shown inFIG.1connected by first connectors9ato9dand third connectors11ato11c,11e,11g, wherein the third connectors11d,11f,11hare hidden in the representation shown inFIG.14.

It can be seen clearly that the third connector11bis arranged axially further inward to reduce the winding overhang than the third connector11a, which—like the third connector11b—also connects shaped conductors5arranged in the seventh layer6gand the eighth layer6h. This applies accordingly for the arrangement of the third connectors11c,11d, which connect shaped conductors5arranged in the fifth layer6eand in the sixth layer6f, for the arrangement of the third connectors11e,11f, which connect shaped conductors5arranged in the third layer6cand in the fourth layer6d, and the arrangement of the third connectors11g,11h, which connect shaped conductors5arranged in the first layer11aand in the second layer11b.

With regard to the substantially U-shaped configuration of the pairs of shaped conductors5connected by the third connectors11ato11h, such an axial arrangement of the pairs can also be referred to as a “U-in-U shaped conductor” or “U-inside-U pin”. The explanations regarding the third connectors11ato11hbased onFIG.14can also be applied to the arrangement of the second connectors10ato10f.

FIG.15toFIG.22show shaped conductors5connected by a third connector11ato11h, respectively.

FIG.15shows the third connector11aandFIG.16the third connector11b. Both connectors11a,11bprovide the offset in the radial direction from the eighth layer6hto the seventh layer6g. The third connector11aprovides an offset in the circumferential direction by seven slots4, whereas the third connector11bprovides an offset by five slots4. As can be seen from a comparison ofFIG.15andFIG.16, the third connector11ais axially shorter than the third connector11bis in order to arrange the third connectors11a,11baxially one inside the other at the same radial position as previously described.

FIG.17shows the third connector11candFIG.18the third connector11d. Both third connectors11c,11dprovide the offset in the radial direction from the fifth layer6eto the sixth layer6f.FIG.19shows the third connector11eandFIG.20the third connector11f. Both third connectors11e,11fprovide the offset in the radial direction from the fourth layer6dto the third layer6c.FIG.21shows the third connector11gandFIG.22the third connector11h. Both third connectors11g,11hprovide the offset in the radial direction from the first layer6ato the second layer6b. Similarly to the third connectors11a,11b, the third connectors11c,11e,11gprovide the offset in the circumferential direction by seven slots4and the third connectors11d,11f,11hprovide the offset in the circumferential direction by five slots4.

Consequently, the multi-path winding structure of the stator1can be provided with only four types of first connectors9ato9d, six types of second connectors10ato10fand eight types of third connectors11ato11h. Since the shaped conductors5connected by the aforementioned connectors9ato9d,10ato10fand11ato11hcan be identical, the small number of only eighteen types makes it possible to manufacture the stator1easily and with good automation. In addition, the outer shaped conductors5of paths7ato7dwith respect to the series connection are located in a small connection window (see slots4with numbers13to34inFIG.3aandFIG.3b), which means that a connection device that saves installation space can be used. It is also advantageous that the outer shaped conductors5marked with an “o” inFIG.3aandFIG.3b, which can serve for connection to a star point connector, each have only one intersection with the shaped conductors5marked with an “x”, which can serve as phase connections to an inverter, which simplifies the design structure of the connection device.

Referring again toFIG.2, it can be seen that some of the shaped conductors5in the first layers6aand seventh layers6gof some slots4at the first end face2aare not connected to by first connectors9ato9d, second connectors10ato10f, or third connectors11ato11h. In these regions, there are located outer shaped conductors5of a path7ato7dwith respect to the series connection. These outer shaped conductors are marked inFIG.3aandFIG.3bwith the symbols “o” and “x”.

The free end of these shaped conductors5at the first end face2aprotrudes from the stator core3in a manner extended beyond the transition portions16(seeFIG.4). The free end of the outer shaped conductors5has an obtuse-angled protruding portion20aextending in the axial direction and circumferential direction and a straight portion20badjoining the protruding portion20aand extending further in the axial direction than the transition portions16. The straight portions20bserve for electrical connection to the connection device.

A connecting element17with a protruding portion18and a joining portion19as shown inFIG.4is connected to the second end face2bof the outer shaped conductor5. The joining portion19is joined in an integrally bonded manner to the joining portion19of the second-outer shaped conductor5of the corresponding path7ato9d.

Lastly,FIG.1andFIG.2also show slot boxes20cextending through the slots4, surrounding the shaped conductors5and lining the slots4. The slot boxes serve to electrically insulate the shaped conductors5from the stator core3. Typically, the slot boxes20care made of insulation paper.

FIG.23is a frontal view of the first end face2aof the stator1. In particular, the first connectors9ato9d, the second connectors10ato10f, and the third connectors11ato11hcan be seen here.

FIG.24aandFIG.24bshow a winding schema of a second exemplary embodiment of a stator1. The manner of representation corresponds toFIG.3aandFIG.3b. The explanations for the first exemplary embodiment can be transferred to the second exemplary embodiment, insofar as no deviations are described below. In this context, identical or similarly acting components are provided with the same reference signs.

The stator1according to the second exemplary embodiment is a left-chorded stator1. Accordingly, each partial winding zone8a,8bextends over at least two directly adjacent slots4, wherein each partial winding zone has an offset (V=1) by one slot4in the radial direction. The offsets in the winding zones8have—viewed from radially inward to radially outward—in each case an orientation to the left or counter-clockwise as seen from the first end face2aand occur after four layers6eto6h(L/2).

To provide such a left-chorded stator1, the first connectors9ato9dand third connectors11ato11hdescribed in the first exemplary embodiment are used and are arranged only beyond the offset in the first layer6ato the fourth layer6d, circumferentially offset by a slot4.

With regard to the second connectors10ato10f, the following deviations arise: The second connectors10a,10e, which do not cover the offset, in the first path7aand in the third path7cprovide an offset by five slots4(N·q−1), whereas the second connectors10b,10f, which do not cover the offset, in the second path7band in the fourth path7dprovide an offset by seven slots4(N·q+1). The second connector10c, which covers the offset, in the first path7aand in the third path7cprovides an offset by four slots4(N·q−2), whereas the second connector10d, which covers the offset, in the second path7band in the fourth path7dprovides an offset by six slots4(N·q). Thus, in the second exemplary embodiment, it is also possible to arrange the second connectors10aand10b, the second connectors10c,10d, and the second connectors10e,10faxially one inside the other.

FIG.25is a frontal view of the first end face2aof the stator1according to the second exemplary embodiment. In particular, the first connectors9ato9d, the second connectors10ato10f, and the third connectors11ato11hcan be seen.

FIG.26aandFIG.26bshow a winding schema of a third exemplary embodiment of a stator1. The manner of representation corresponds toFIG.3aandFIG.3b. The explanations for the first exemplary embodiment can be transferred to the third exemplary embodiment, insofar as no deviations are described below. Here, identical or similarly acting components are provided with the same reference signs.

The stator1according to the third exemplary embodiment is a right-chorded stator1. Accordingly, each partial winding zone8a,8bextends over at least two directly adjacent slots4, wherein each partial winding zone has an offset (V=1) by a slot4in the radial direction. The offsets in the winding zones8have—viewed from radially inward to radially outward—in each case an orientation to the right or clockwise as seen from the first end face2aand occur after four layers6eto6h(L/2).

To provide such a right-chorded stator1, the first connectors9ato9dand third connectors11ato11hdescribed in the first exemplary embodiment are used, which are arranged offset in the circumferential direction by a slot4only beyond the offset in the first layer6ato the fourth layer6d.

With regard to the second connectors10ato10f, the following deviations arise: The second connectors10a,10e, which do not cover the offset, in the first path7aand in the third path7cprovide an offset by five slots4(N·q−1), whereas the second connectors10b,10f, which do not cover the offset, in the second path7band in the fourth path7dprovide an offset by seven slots4(N·q+1). The second connector10c, which covers the offset, in the first path7aand in the third path7cprovides an offset by four slots4(N·q), whereas the second connector10d, which covers the offset, in the second path7band in the fourth path7dprovides an offset by eight slots4(N·q+2). Thus, in the third exemplary embodiment, it is also possible to arrange the second connectors10aand10b, the second connectors10c,10dand the second connectors10e,10faxially one inside the other.

FIG.27is a frontal view of the first end face2aof the stator1according to the third exemplary embodiment. In particular, the first connectors9ato9d, the second connectors10ato10fand the third connectors11ato11hcan be seen.

FIG.28andFIG.29are each a circuit diagram of the paths7ato7dof a stator1according to one of the previously described exemplary embodiments.

FIG.28shows for each phase U, V, W that their paths7ato7dare connected in parallel and are connected by a star point connector21to form a star point. A phase connection22is provided on the side of each parallel connection opposite the star point connector21.

FIG.29shows for each phase U, V, W that their paths7ato7dare connected in parallel at one of their ends and are connected to a phase connection22. The other ends of the paths7ato7dare only connected in parallel in pairs, so that two star points are formed by means of two star point connectors21a,21b. Here, the star point connector21aconnects the first paths7aand the second paths7bof each phase U, V, W, and the star point connector21bconnects the third paths7cand the fourth paths7dof each phase U, V, W.

The star point connectors21a,21band phase connections22shown inFIGS.28and29can be provided in all previously described embodiments by the aforementioned connection device, which is arranged at the first end face2a. Of course, according to alternative embodiments, it is also possible that the paths7ato7dof a phase U, V, W are connected in series and/or that a delta connection is provided instead of a star connection.

According to a further exemplary embodiment, it is also possible for a stator to have a number of holes q=1, wherein the third connectors are then omitted. Such a stator then has at least P=4 pole pairs and at least twelve slots. Typically, two paths per phase are then provided.

According to a further exemplary embodiment, it is also possible for a stator to have a number of holes q=3. Then, typically, at least P=12 pole pairs and at least 108 slots are provided. Typically, six paths per phase are then provided. In each group, three arrangements and two third connectors are provided for a hole number q=3, so that each group occupies all three partial winding zones. In each case, three second and third connectors arranged in the same winding zone at the same radial position can then be arranged axially one inside the other, so that “U-in-U-in-U shaped conductors” are formed.

FIG.30is a schematic diagram of a vehicle100with an exemplary embodiment of an electric machine101.

The electric machine101comprises a stator1according to one of the previously described exemplary embodiments and a rotor102arranged rotatable within the stator1. The electric machine101is a rotating field machine, for example a permanently excited synchronous machine or an asynchronous machine. The electric101machine is configured as an electric motor.

The vehicle100is a partially or fully electrically driven vehicle, for example a battery electric vehicle (BEV) or a hybrid vehicle, wherein the electric machine101is set up to drive the vehicle100.

As can be seen fromFIG.3aandFIG.3b, the groups12a-drun in radially opposite directions after a circuit around the stator and a connector10a-10e. As a result, the shaped conductors5of a subsequent group12b-12d, with respect to the previous group12a-12c, each lie alternately in directly adjacent slots of the same partial winding zone8a, b, or in slots of the same partial winding zone8a, bthat are 3 layers apart.

For example, a shaped conductor5of the group12ais arranged in the slot with number “2” in the 8th layer6h. The shaped conductor5of the following group12b, which is also arranged in the slot with number “2”, is arranged in the 5th layer6e. Subsequently, another shaped conductor5of group12ais arranged in the slot with number “8” in the 7th layer6g. The shaped conductor5of the subsequent group12b, which is also arranged in the slot with number “8”, is arranged in the 6th layer6f, i.e. in a directly adjacent layer with respect to the shaped conductor5of group12a.