Electrical machine and method for applying at least one winding to a winding support of an electrical machine

Patent metadata

Field	Value
Publication number	US-11652383-B2
Application number	US-202017016176-A
Country	US
Kind code	B2
Filing date	Sep 9, 2020
Priority date	Sep 10, 2019
Publication date	May 16, 2023
Grant date	May 16, 2023

Abstract

An electrical machine with a winding support is provided, which comprises a cylindrical base body and support teeth projecting radially from the base body and has grooves bounded by the base body and in each case two of the support teeth, and at least one winding supported by the winding support, which winding is formed by conductively connected conductor sections, which are each guided through at least one of the grooves of the winding support and project beyond the winding support at the axial end faces of the winding support, wherein a respective clamping ring is arranged at each axial end face of the winding support, wherein each clamping ring forms support sections that each extend radially along a respective axial end face of a respective one of the support teeth and mechanically contact at least parts of the conductor sections guided through the grooves adjacent to the respective support tooth, wherein the respective support section contacts the axial end face of the respective support tooth in a contact region, which is spaced apart from the adjacent grooves.

First claim

The invention claimed is:

1. An electrical machine, comprising:
a winding support including a cylindrical base body, support teeth projecting radially from the base body, and grooves bounded by the base body and in each case two of the support teeth; and
at least one winding supported by the winding support, wherein the winding is formed by conductively connected conductor sections, wherein the conductively connected conductor sections are each guided through at least one of the grooves of the winding support and project beyond the winding support at axial end faces of the winding support,
wherein a respective clamping ring is arranged at each axial end face of the winding support, wherein each clamping ring forms support sections that each extend radially along a respective axial end face of a respective one of the support teeth and mechanically contact at least parts of the conductor sections guided through the grooves adjacent to the respective support tooth, and
wherein the respective support section contacts the axial end face of the respective support tooth exclusively in a contact region, wherein the contact region is spaced apart from the adjacent grooves.

2. The electrical machine according to claim 1 , wherein the respective support section widens with increasing distance from the end face in a circumferential direction of the winding support at least in a widening section of the respective support section adjacent to the end face of the winding support.

3. The electrical machine according to claim 1 , wherein at least some of the conductor sections are elastically deformed in such a manner that the at least some of the conductor sections exert a respective axial restoring force in a direction aligned with the winding support onto the support sections of both clamping rings mechanically contacted by the at least some of the conductor sections.

4. The electrical machine according to claim 1 , wherein the clamping rings have, between each two of the support sections, a bushing for the conductor sections guided through a respective groove, wherein the bushing is bounded in a radial direction of the winding support by an inner ring and/or an outer ring.

5. The electrical machine according to claim 4 , wherein the end face of the inner ring and/or the outer ring turned away from the winding support may be inclined toward the bushings.

6. The electrical machine according to claim 1 , wherein the electrical machine is a component of a motor vehicle.

7. A method of applying at least one winding to a winding support of an electrical machine, comprising: providing a winding support that comprises a cylindrical base body and support teeth projecting radially from the base body and the winding support has grooves bounded by the base body and in each case two of the support teeth, arranging a respective clamping ring on each axial end face of the winding support, such that support sections of the respective clamping ring each extend radially along a respective axial end face of one of the support teeth, wherein the respective support section exclusively contacts the respective end face in a contact region that is spaced apart from the adjacent grooves, axially inserting conductor sections into at least one of the grooves, bending at least parts of the conductor sections guided through at least one of the grooves in the circumferential direction of the winding support, so as to mechanically contact one of the support sections extending along the end face of one of the support teeth adjacent to the respective groove, and establishing a conductive connection between at least some of the conductor sections, in order to provide the winding.

8. The method according to claim 7 , wherein, prior to the arrangement of the clamping rings on the winding support or between the arrangement of the clamping rings on the winding support and the insertion of the conductor sections, groove insulating papers are inserted axially into the grooves in such a manner that they project axially beyond the clamping rings on both sides after the arrangement of the clamping rings on the winding support.

9. The method according to claim 7 , wherein the support sections of at least one of the clamping rings are connected by an inner ring and/or by an outer ring, wherein the inner ring and/or the outer ring has recesses and/or projections; wherein a tool engages to the inner ring and/or the outer ring after the arrangement of the clamping rings on the winding support, in order to hold or handle the winding support.

10. The method according to claim 7 , wherein at least during the insertion of the conductor sections and/or the bending of the conductor sections and/or the establishment of the conductive connection, a tool engages both clamping rings and presses the clamping rings against the respective end faces of the winding support.

11. The method according to claim 7 , wherein at least parts of the conductor sections may have two axial sections and a connector section connecting them, wherein the axial sections are inserted into different grooves upon the insertion of the conductor sections, wherein, at least during the bending of the conductor sections and/or the establishment of the conductive connection, a tool engages the connector sections and the clamping ring arranged on the side of the winding support turned away from the connector sections, in order to apply a force to the connector sections in the direction of such clamping ring and in order to apply a force to such clamping ring in the direction of the connector sections.

12. The method according to claim 7 , wherein the clamping rings have, between any two of the support sections, a bushing for the conductor sections guided through a respective groove, wherein the bushing is bounded in a radial direction of the winding support by an inner ring and/or by an outer ring, wherein the end face of the inner ring and/or the outer ring turned away from the winding support is inclined towards the bushings, wherein the winding is impregnated by dropping liquid resin onto such end face of the inner ring and/or outer ring.

Assignees

• Audi Ag

Inventors

• Weber Korbinian
• Possen Max

Classifications

• H02K1/182

  to stators axially facing the rotor, i.e. with axial or conical air gap · CPC title

• H02K15/085

  by laying conductors into slotted stators · CPC title

• H02K3/50

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

• H02K15/0428

  Processes or apparatus for simultaneously twisting two or more hairpins · CPC title

• H02K3/345

  between conductor and core, e.g. slot insulation · CPC title