Stator of an electrical machine

Patent metadata

Field	Value
Publication number	US-12244194-B2
Application number	US-202118005423-A
Country	US
Kind code	B2
Filing date	Jul 6, 2021
Priority date	Jul 16, 2020
Publication date	Mar 4, 2025
Grant date	Mar 4, 2025

Abstract

The present invention relates to a stator of an electric machine with a stator body having a stator axis, which stator body comprises stator grooves in which there runs an electric plug-in winding which is formed from multiple conductor elements ( 4 ), conductor elements ( 4 ) being provided which each run with conductor branches through one or two of the stator grooves and protrude from the stator grooves on at least one end face of the stator by means of conductor ends ( 4 b ) and form a winding head, the conductor ends ( 4 b ) of the conductor elements ( 4 ) being arranged in the corresponding winding head in a plurality of groups ( 7 ) distributed in the circumferential direction in relation to the stator axis, each group ( 7 ) comprising a plurality of conductor ends ( 4 b ) arranged in a radial direction in relation to the stator axis, in particular aligned in the radial direction, characterized in that at least one, in particular a plurality, of the conductor ends ( 4 b ) of each group ( 7 ), as viewed in the radial direction, has raised structures ( 8 ) arranged on both sides, in such a way that the raised structures ( 8 ) on a first side ( 14 ) of the conductor end ( 4 b ), when the entire group ( 7 ) of conductor ends ( 4 b ) is clamped between two clamping jaws, permit the conductor end ( 4 b ) adjacent to the first side ( 14 ) and the conductor end ( 4 b ) having structures ( 8 ) to be approached towards one another elastically or plastically by the clamping jaws in order for the relevant conductor ends ( 4 b ) to be welded, and, on an opposite, second side ( 15 ) maintain a distance between the conductor end ( 4 b ) adjacent to the second side ( 15 ) and the conductor end ( 4 b ) having structures ( 8 ) in order to prevent a welding of the relevant conductor ends ( 4 b ).

First claim

The invention claimed is:

1. A stator ( 1 ) of an electrical machine ( 10 ) comprising a stator body ( 2 ) having a stator axis ( 100 ) and comprising stator grooves ( 3 ) in which an electrical plug-in winding runs, which is formed from a plurality of conductor elements ( 4 ), wherein conductor elements ( 4 ) are provided which each run with conductor branches ( 4 a ) through one or two of the stator grooves ( 3 ) and protrude with conductor ends ( 4 b ) from the stator grooves ( 3 ) on at least one end face ( 5 ) of the stator ( 1 ) and form a winding head ( 6 ), wherein the conductor ends ( 4 b ) of the conductor elements ( 4 ) are arranged in the respective winding head ( 6 ) in a plurality of groups ( 7 ) distributed in the circumferential direction in relation to the stator axis ( 100 ), wherein each group ( 7 ) comprises a plurality of conductor ends ( 4 b ) arranged along a radial direction in relation to the stator axis ( 100 ),
wherein
at least one of the conductor ends ( 4 b ) of each group ( 7 ), as viewed in the radial direction, has raised structures ( 8 ) arranged on both sides, in such a way that when the entire group ( 7 ) of conductor ends ( 4 b ) is clamped between two clamping jaws, the raised structures ( 8 ) on a first side ( 14 ) of the conductor end ( 4 b ) permit an approach, effected elastically or plastically by the clamping jaws, between the conductor end ( 4 b ) adjacent to the first side ( 14 ) and the conductor end ( 4 b ) having structures ( 8 ), in order for the relevant conductor ends ( 4 b ) to be welded, and on an opposite second side ( 15 ) maintain a distance between the conductor end ( 4 b ) adjacent to the second side ( 15 ) and the conductor end ( 4 b ) having structures ( 8 ), in order to prevent welding of the relevant conductor ends ( 4 b ).

2. The stator ( 1 ) according to claim 1 , wherein each raised structure ( 8 ) is arranged opposite a raised structure ( 8 ) of another conductor end ( 4 b ) or a side face of another conductor end ( 4 b ).

3. The stator ( 1 ) according to claim 1 ,
wherein each conductor end ( 4 b ) has a first region ( 9 a ) directly adjoining an end face ( 4 c ) of the conductor element ( 4 ) and extending in a longitudinal direction of the conductor element ( 4 ) and a second region ( 9 b ) directly adjoining the first region ( 9 a ) and extending in the longitudinal direction of the conductor element ( 4 ),
wherein at least one conductor end ( 4 b ) having structures ( 8 ) has, on the first side ( 14 ), at least one raised structure ( 8 ) on the second region ( 9 b ), while the first regions ( 9 a ) both of the conductor end ( 4 b ) having the structures ( 8 ) and of the conductor end ( 4 b ) adjacent on the first side ( 14 ) are free of raised structures ( 8 ), and/or
wherein at least one conductor end ( 4 b ) having structures ( 8 ) has, on the second side ( 15 ), at least one raised structure ( 8 ) on the first region ( 9 a ) and at least one raised structure ( 8 ) on the second region ( 9 b ).

4. The stator ( 1 ) according to claim 1 , wherein two connected conductor ends ( 4 b ) have an integrally bonded connection region ( 13 ), wherein at least one of the two electrically connected conductor ends ( 4 b ) has a recess ( 12 ) which directly adjoins the connection region ( 13 ).

5. The stator ( 1 ) according to claim 4 , wherein the integrally bonded connection region ( 13 ) is a weld seam.

6. The stator ( 1 ) according to claim 1 , wherein the raised structures ( 8 ) are formed by punctiform and/or linear and/or V-shaped and/or X-shaped and/or planar elevations.

7. The stator ( 1 ) according to claim 1 , wherein the structures ( 8 ) are produced by embossing or by an application method or by melting or by removal.

8. The stator ( 1 ) according to claim 1 , wherein the plurality of conductor ends ( 4 b ) are aligned in the radial direction.

9. An electrical machine ( 10 ) having a stator ( 1 ) according to claim 1 and a rotor ( 11 ) which can be driven by the stator ( 1 ).

10. A method for producing a stator ( 1 ) of an electrical machine ( 10 ), having the steps of:
arranging conductor branches ( 4 a ) of conductor elements ( 4 ) of a plug-in winding in stator grooves ( 3 ) of a stator body ( 2 ) so that conductor ends ( 4 b ) protrude on at least one end face of the stator body ( 2 ), and
forming a plurality of groups ( 7 ) distributed in a circumferential direction in relation to a stator axis ( 100 ) of the stator body ( 2 ), each group ( 7 ) comprising a plurality of conductor ends ( 4 b ) arranged along a radial direction in relation to the stator axis ( 100 ),
further comprising the steps of:
applying a clamping force ( 200 ) by clamping the entire group ( 7 ) of conductor ends ( 4 b ) between two clamping jaws,
wherein at least one of the conductor ends ( 4 b ) of each group ( 7 ), as viewed in the radial direction, has raised structures ( 8 ) arranged on both sides,
wherein, by means of at least one raised structure ( 8 ) on a first side ( 14 ) of the conductor end ( 4 b ), an approach, effected elastically or plastically by the clamping jaws, takes place between the conductor end ( 4 b ) adjacent to the first side ( 14 ) and the conductor end ( 4 b ) having structures ( 8 ),
wherein, by means of at least one raised structure ( 8 ) on an opposite second side ( 15 ), a distance between the conductor end ( 4 b ) adjacent to the second side ( 15 ) and the conductor end ( 4 b ) having structures ( 8 ) is maintained, and
electrically connecting the conductor end ( 4 b ) having at least one structure ( 8 ) to the conductor end ( 4 b ) adjacent on the first side ( 14 ) and elastically or plastically deformed.

11. The method according to claim 10 , further comprising the step of introducing a radial distance between the conductor end ( 4 b ) having structures ( 8 ) and the conductor end ( 4 b ) adjacent on the second side ( 15 ).

12. The method according to claim 10 , wherein conductor ends ( 4 b ) to be connected electrically are integrally bonded.

13. The method according to claim 12 , wherein conductor ends ( 4 b ) to be connected electrically are welded.

14. The method according to claim 13 , wherein conductor ends ( 4 b ) to be connected electrically are laser welded.

15. The method according to claim 10 , wherein the plurality of conductor ends ( 4 b ) are aligned in the radial direction.

Assignees

• Bosch Gmbh Robert

Inventors

• Heider Andreas
• Boley Meiko
• Goranovic Nikola
• Hein Tobias

Classifications

• H02K15/35 Primary

  Form-wound windings · CPC title

• H02K3/50

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

• H02K3/28 Primary

  Layout of windings or of connections between windings (windings for pole-changing H02K17/06, H02K17/14, H02K19/12, H02K19/32) · CPC title

• H02K15/0081

  Electricity · mapped topic