Method for producing an electric motor and electric motor

Patent metadata

Field	Value
Publication number	US-11196322-B2
Application number	US-201716321627-A
Country	US
Kind code	B2
Filing date	Jun 20, 2017
Priority date	Jul 29, 2016
Publication date	Dec 7, 2021
Grant date	Dec 7, 2021

Abstract

In a method for manufacturing an electric motor comprising a rotor and a stator a placeholder for a temperature sensor is inserted in the axial direction between a first coil layer and an adjacent second coil layer of a winding head such that the placeholder is situated in a gap-shaped recess extending between the first and the second coil layers, the first coil layer is then pressed onto a circumferential surface of the placeholder and onto the second coil layer and is plastically deformed such that a space between the lateral surfaces of the two coil layers and the circumferential surface of the placeholder is reduced, and a contact surface between the lateral surface of the first coil layer and the circumferential surface of the placeholder is enlarged. By removing the placeholder, a receiving chamber is subsequently formed in the winding head, into which a temperature sensor is then inserted.

First claim

The invention claimed is:

1. A method for manufacturing an electric motor comprising a rotor and a stator, the stator thereof having a hollow cylindrical stator metal sheet and a distributed winding made up of multiple circumferential coil layers arranged one above the other in a layered manner, the method comprising:
inserting a placeholder for a temperature sensor for detecting a temperature of the winding in the axial direction between a first coil layer and an adjacent second coil layer of a winding head of the winding in such a way that the placeholder is situated in a gap-shaped recess extending into an interior of the winding head between the first coil layer and the second coil layer,
pressing the first coil layer onto a circumferential surface of the placeholder and onto the second coil layer, and plastically deforming the first coil layer such that a space between the lateral surfaces of the two coil layers and the circumferential surface of the placeholder is reduced, and such that a contact surface between the lateral surface of the first coil layer and the circumferential surface of the placeholder is enlarged,
wherein, by subsequent removal of the placeholder, a receiving chamber is formed in the winding head, the receiving chamber extending in the axial direction between the first coil layer and the adjacent second coil layer into an interior of the winding head, and
inserting a temperature sensor into the receiving chamber, such that the temperature sensor is thereupon circumferentially enclosed by the first coil layer and the adjacent second coil layer such that an outer lateral surface of the temperature sensor is in contact with the first coil layer and adjacent second coil layer within the interior of the winding head.

2. The method according to claim 1 , wherein the placeholder is introduced between a radially inner first coil layer or a radially outer first coil layer and an adjacent second coil layer of the winding head.

3. The method according to claim 1 , wherein the pressing of the first coil layer against the placeholder and the second coil layer takes place using a forming die that acts on the first coil layer in the radial direction.

4. The method according to claim 1 , wherein a forming die having a concave recess that extends in the axial direction is used, a section of the first coil layer resting against the placeholder being formed by the concave recess of the forming die.

5. The method according to claim 1 , wherein the gap-shaped recess between the two coil layers-is created by axially inserting a tool mandrel or the placeholder between the two coil layers.

6. The method according to claim 1 , wherein the winding head is impregnated with an impregnation material prior to removal of the placeholder, or wherein placeholder is removed prior to the impregnation, and the receiving chamber for the temperature sensor is closed by off by another, second placeholder which is removed from the receiving chamber after the impregnation.

7. The method according to claim 1 , wherein the stator is inserted into a housing part after the impregnation and the removal of the particular placeholder from the receiving chamber, and the temperature sensor is subsequently inserted into the receiving chamber in the winding head through an opening in the housing part.

8. The method according to claim 1 , wherein, before the stator is inserted into a housing part, an insulating washer with an insertion funnel is situated on the stator metal sheet in such a way that, after insertion, the insertion funnel is situated coaxially with respect to an opening in the housing part and coaxially with respect to the receiving chamber in the winding head of the stator, and during insertion into the opening in the housing part, the temperature sensor is guided by the insertion funnel into the receiving chamber in the winding head.

9. An electric motor comprising:
a rotor,
a stator, the stator having a stator metal sheet, and a distributed winding made up of multiple circumferential ring-shaped coil layers arranged one above the other in a layered manner and having a winding head, and
a temperature sensor for detecting a temperature of the winding configured to be inserted through an opening in a housing part that encloses the stator, at least in sections, and into a receiving chamber arranged between two coil layers that extends into an interior of the winding head,
wherein the temperature sensor is circumferentially enclosed in contact with the two coil layers within the interior of the winding head.

10. The electric motor according to claim 9 , wherein an insulating washer having an insertion funnel that is situated coaxially with respect to the opening in the housing part and coaxially with respect to the receiving chamber is fixed to the stator metal sheet.

Assignees

• Fuchs Martin
• Knoeppel Johannes Daniel
• Wilhelm Nils
• Wist Alex
• Mueller David
• Volkswagen Ag

Inventors

• Fuchs Martin
• Knöppel Johannes Daniel
• Wilhelm Nils
• Wist Alex
• Müller David

Classifications

• H02K3/50

  Fastening of winding heads, equalising connectors, or connections thereto · CPC title

• H02K11/25 Primary

  Devices for sensing temperature, or actuated thereby · CPC title