STATOR FOR AN ELECTRIC MACHINE

The present disclosure relates in particular to a stator for an electric machine, to an electric machine having such a stator and to an aircraft having such an electric machine.

Such stators comprise a body, e.g. in the form of a laminated core, a plurality of stator teeth anchored on the body, and a plurality of tooth windings wound around the stator teeth. Electric machines having such a stator comprise, e.g., a rotor, for example a permanently excited rotor, which is rotatable relative to the stator. Applying voltages to the tooth windings, in particular temporally variable voltages, causes magnetic fields to build up, which magnetic fields move the rotor relative to the stator.

Especially in polyphase rotating-field machines, in particular having a permanently excited rotor, it proves to be problematic if a short circuit between turns occurs inside the stator winding. In particular in such electric machines, the problem exists that, in the event of a short circuit between turns during intended operation, a large electrical current can be induced, which current can result in thermal destruction of the tooth windings. This is particularly relevant not only, but particularly, in aircraft in which, e.g., permanently excited rotating-field machines are used.

DE 10 2017 217 751 A1 proposes an electric machine in which a respective winding of a stator tooth has a first electrical conductor which describes a plurality of turns arranged circumferentially around the stator tooth, and a second electrical conductor which is electrically insulated from said first electrical conductor and has a plurality of turns arranged circumferentially around the respective stator tooth. This makes it possible to considerably improve electrical safety with respect to short circuits in the region of the stator winding. However, the design of this electric machine is relatively complex.

The object of the present invention is to specify a further improved stator for an electric machine.

According to one aspect, there is provision for a stator for an electric machine. The stator comprises a body, e.g. in the form of a laminated core, a plurality of stator teeth anchored on the body, and a plurality of, e.g. at least three, tooth windings. Each of the tooth windings comprises a first electrical conductor which runs from one end portion, via at least one winding portion around at least one stator tooth (or via a plurality of winding portions around one of a plurality of stator teeth in each case), to another end portion. Each of the tooth windings further comprises a second electrical conductor which is electrically insulated from the first electrical conductor and which runs from one end portion, via the at least one winding portion around the same at least one stator tooth (or on a plurality of winding portions around each of the same stator teeth), to another end portion. In this case, there is provision for one end portion of each of the first and second electrical conductors of the plurality of tooth windings to be or able to be electrically connected to an inverter. Furthermore, there is provision for the respective other end portion of the first electrical conductors of the tooth windings to be electrically connected to one another at a (first) star point.

Such an electrical connection of the tooth windings formed by the two electrical conductors electrically insulated from one another makes it possible to use half-bridge inverters instead of full-bridge inverters, which despite the high degree of safety achieved with respect to short circuits allows for an electric machine with a relatively simple design. The stator is thus in particular improved in that an electric machine which is safe and which nevertheless has a simple design is therefore made possible.

Each of the first and second electrical conductors has exactly two end portions and establishes a direct, continuous electrical connection between the two end portions. The electrical conductor comprises the winding portions between the two end portions of the respective electrical conductor. The electrical conductor comprises, e.g., no tap between the two end portions of the respective electrical conductor. At least three electrical conductors meet one another at the star point. The star point forms a tap. The first electrical conductors of the tooth windings are electrically isolated from the second electrical conductors of the tooth windings. The first electrical conductors and the second electrical conductors are electrically insulated from one another.

The stator comprises, e.g., at least (in particular exactly) three tooth windings, each for one phase of a three-phase AC current. The stator thus comprises, e.g., six (first and second) electrical conductors in total.

All the first electrical conductors of each of the tooth windings are electrically connected to one another at a first star point. Optionally, (the respective other ends facing away from the inverter of) all the second electrical conductors of each of the tooth windings are electrically connected to one another at a second star point.

Turns of the first and second electrical conductors are arranged in a bifilar manner. Seen along the turn axis, the first and second conductors alternate, for example. Due to the fact that the turns of the first and second electrical conductors are arranged in a bifilar manner, a short circuit between turns may thus initially occur between the first and second electrical conductors. If an electrical charge is applied to the tooth winding elements formed by the first and second electrical conductors, it is thus possible to considerably reduce the effect of a short circuit between turns. It is even possible to identify the short circuit between turns and to shut down the electric machine in a safe manner in order to avoid dangerous operating states.

For example, each of the first electrical conductors of the tooth windings runs around each of a plurality of stator teeth and/or each of the second electrical conductors of the tooth windings runs around each of a plurality of stator teeth, in particular in each case around the same stator teeth as the associated first electrical conductor.

According to one aspect, there is provision for an electric machine. The electric machine comprises the stator according to any configuration described herein. The electric machine can further comprise a rotor which is mounted movably, in particular rotatably, relative to the stator.

In the electric machine, the stator provides, e.g., a substantially circular opening for accommodating the rotor. The rotor is arranged in the opening, e.g., in a rotatably mounted manner, wherein an air gap is formed between the rotor and the stator. This type of construction is also referred to as an internal rotor. Alternatively, there is provision for a type of construction in which the rotor radially surrounds the stator. Such types of construction are also called external rotors.

The electric machine is an apparatus which converts electrical energy into mechanical energy, in particular kinetic energy, in a motor mode, and/or mechanical energy into electrical energy in a generator mode. The movement is, e.g., a rotational movement performed by the rotor. The stator is, e.g., arranged in a rotationally fixed manner with respect to a mount bearing the electric machine. A rotational movement is therefore in particular a rotational movement of the rotor in relation to the stator.

The electric machine is operable as a motor and/or as a generator.

Furthermore, the electric machine can be operable as a transformer. The electric machine is then thus designed for use as a transformer. In particular, the electric machine can be operated as a transformer and simultaneously as a motor and/or generator.

The electric machine can comprise a first inverter and a second inverter. The first inverter and the second inverter can be designed such that they can be operated independently of the respective other inverter. This allows increased fail-safety.

Optionally, the first inverter is electrically connected to the first electrical conductors of each of the tooth windings, and/or the second inverter is electrically connected to the second electrical conductors of each of the tooth windings.

For example, the first inverter and the second inverter are configured to provide the same electrical phase of a polyphase AC voltage, in particular three-phase AC voltage, on the first and second electrical conductors of the respective tooth windings in an electrically isolated manner. The phases of the two inverters can, but do not have to, be synchronized with one another and are asynchronous in an alternative configuration.

The electric machine can further comprise a first energy source (and/or an energy store, e.g. an accumulator) which is electrically connected to the first inverter, and/or a (second) energy source (and/or an energy store, e.g. an accumulator) which is electrically connected to the second inverter. The respective energy source provides electrical energy to the respective inverter. This allows further increased fail-safety. Alternatively or in addition, the electric machine can further comprise an energy source which is electrically connected to the first inverter, and/or an energy store which is electrically connected to the second inverter. The energy source provides electrical energy to the respective inverter. The energy store draws electrical energy. This allows energy from the energy source connected to the first inverter to be reallocated to the energy store connected to the second inverter. This reallocation allows balanced energy states of the energy source and the energy store to be established.

The first energy source (and/or a first energy store) is electrically isolated from the second energy source (and/or the second energy store). This allows the first and second electrical conductors of the tooth windings to be operated independently.

The first inverter and/or the second inverter can each have a plurality of, in particular three, inverter units, e.g. each for one electrical phase of a polyphase AC voltage, in particular a three-phase AC voltage. Each of the inverter units comprises (or consists of), e.g., a half-bridge circuit.

According to one aspect, there is provision for a vehicle, in particular an aircraft, comprising the electric machine according to any configuration described herein, in particular for driving a thrust-generating apparatus, e.g. a propeller. As already mentioned at the outset, the advantages of the electric machine described herein apply especially to a vehicle, in particular an aircraft.

Embodiments will now be described by way of example with reference to the figures, in which:

FIG. 1 shows a schematic sectional illustration of a basic design of a permanently excited, three-phase electric machine in the form of an internal rotor;

FIG. 2 shows a schematic, perspective exploded view of a design of a stator of the electric machine according to FIG. 1 with tooth windings;

FIG. 3 shows a schematic illustration of part of a tooth winding of the stator according to FIG. 2, in which turns of a first and second electrical conductor are arranged in a bifilar manner;

FIG. 4 shows a schematic illustration of a permanently excited electric machine for operation at a three-phase AC voltage;

FIGS. 5 and 6 show schematic circuit diagram illustrations of tooth windings and inverters of the electric machine according to FIG. 2 and FIG. 4, respectively;

FIG. 7 shows another schematic circuit diagram illustration of tooth windings and inverters; and

FIG. 8 shows an aircraft in the form of an airplane having an electrically driven propeller and the electric machine according to FIG. 1.

FIG. 1 shows a schematic sectional illustration of a rotating electric machine 2 in the form of a permanently excited synchronous machine. It can be seen from FIG. 1 that the electric machine 2 in the present case is in the form of an internal rotor. The electric machine 2 comprises a stator 1 which has an opening, in particular a through-opening, which is not denoted, in which a rotor 20 is arranged in a rotatably mounted manner.

The stator 1 comprises a body 10 in the form of a laminated core, on which stator teeth 11 are provided with respect to an air gap L between the body 10 of the stator 1 and the rotor 20. The stator teeth 11 protrude radially from the body 10, in the present case radially inward. The stator 1 has a stator winding which comprises a plurality of tooth windings 12A-12C. The stator winding in the present case is designed for three-phase operation, that is to say is connected to a three-phase AC voltage having phases U, V, W. During intended operation of the electric machine 2, the AC voltage is applied to the stator winding as appropriate.

The rotor 20 in the present case is in the form of a salient-pole rotor which comprises permanent magnets for providing the magnetic flux. In the present configuration, there is provision for the rotor 20 to have exactly one magnetic north pole N and one magnetic south pole S. In alternative configurations, there can also be provision for more magnetic poles in alternation in the circumferential direction transverse to an axis of rotation of the rotor 20 (relative to the stator 1).

The rotor 20 is rotatably mounted. As a result of the three-phase AC voltage, the phases U, V, W thereof each being phase-shifted by 120°, a magnetic rotating field is generated during intended operation, which magnetic rotating field interacts with the permanently excited magnetic field provided by the rotor 20 such that a corresponding rotational movement of the rotor 20 in relation to the stator 1 can be brought about in motor mode. In the present case, provision is made for the electric machine 2 to be used as a drive motor for a propeller of an aircraft. Alternatively or in addition, the electric machine 2 can be used as a generator for a propeller (for regeneration) of an aircraft, of a wind turbine or turbine or of a piston engine or else for the hybrid drive of an airplane. Alternatively or in addition, the electric machine 2 can also be used as a transformer. For this case, the rotor 20 can rotate or remain stationary in the electric machine 2. Alternatively or in addition, the electric machine 2 can also be used as a drive motor, generator and transformer (as required in each case). The portions of the stator winding which are assigned to the respective phases U, V, W are schematically illustrated in FIG. 1. One of the tooth windings 12A-12C is in each case respectively assigned to one of the phases U, V, W.

The stator winding of the electric machine 2 is connected to two inverters 13A, 13B which are independent of one another and each have a three-phase design. The inverters 13A, 13B provide the AC voltage having the three phases U, V, W. The inverters 13A, 13B draw the electrical energy required for the intended operation in each case from an energy source 3A, 3B connected to one of the two inverters 13A, 13B. The energy sources (or energy stores) 3A, 3B are electrically isolated from one another and are operable independently of one another. In the present configuration, each of the energy sources 3A, 3B is a DC voltage source which provides electrical energy from a suitable electrical energy store, for example an accumulator or the like, or which stores electrical energy in a suitable electrical energy store, for example an accumulator or the like. Alternatively or additionally, fuel cells and/or the like or, in the case of stationary applications, an energy supply from a public energy supply network may also be provided as the source.

The inverters 3A, 3B have inverter units assigned for providing the phases U, V, W, which inverter units are explained in more detail further below in connection with FIG. 5, for example. In this case, each inverter unit has its own half-bridge circuit. The half-bridge circuits are connected to a DC link circuit, which is not illustrated any further in FIG. 1, of the respective inverter 3A, 3B in order to thus be supplied with electrical energy or to thus supply electrical energy. The DC link circuits can have a voltage of 25 V or more, of 100 V or more or e.g. in the range from 800 to 3000 V.

It is noted here that the half-bridge circuit has a series circuit comprising two electronic switching elements (e.g. transistors) which are connected to the respective link circuit DC voltage of the inverter 3A, 3B. The electronic switching elements are operated by a control unit 131, 141 of the respective inverter in a clock mode which provides clock patterns in the form of a PWM signal, for example. The corresponding phase U, V, W of the three-phase AC voltage is then available at a respective center tap of the half-bridge circuits. Appropriate filtering is carried out by the inductance of the tooth windings 12A-12C, with the result that an appropriate AC current is obtained for each of the phases U, V, W, which AC current can be virtually sinusoidal if the inverter units are suitably controlled.

For the sake of simplicity, the inverters 3A, 3B are counted as part of the electric machine 2 here, but together therewith can also be referred to as an electric drive device.

FIG. 2 shows a schematic exploded illustration of the stator 1 of the electric machine 2. It can be seen that the stator 1 has the body 10, in which stator teeth 11 can be assembled with the annular body 10 by means of a mechanical connection and can thus be anchored, in particular mechanically fixed, thereon. Alternatively, the stator teeth 11 are, e.g., formed in one piece with the body 10.

The stator teeth 11 are fitted with respective winding portions 122 of the tooth windings 12A-12C. The stator winding has a plurality of tooth windings 12A-12C. A respective one of the tooth windings 12A-12C is generally arranged at least on one of the stator teeth 11. In the present case, each of the tooth windings 12A-12C extends over a plurality of, here two (specifically two opposite), stator teeth 11. For this purpose, the tooth windings 12A-12C generally each have at least one, here a plurality of, namely two, winding portions 122. Each winding portion 122 surrounds (exactly) one stator tooth 11.

Each of the tooth windings 12A-12C has a respective first electrical conductor 120 which, on each of the winding portions 122, is arranged in a plurality of turns circumferentially around the respective stator tooth 11. The first electrical conductor 120 comprises one or more corresponding connecting portions between the winding portions 122.

Each of the tooth windings 12A-12C further has a respective second electrical conductor 121 which, on each of the winding portions 122, is likewise arranged in a plurality of turns circumferentially around the respective stator tooth 11. The second electrical conductor 121 comprises one or more corresponding connecting portions between the winding portions 122.

The tooth windings 12A-12C are connected up in the electric machine as appropriate such that the three-phase connection to the inverters 13, 14 is present. In this case, the first electrical conductors 120 of the tooth windings 12A-12C are connected to the first inverter 13, and the second electrical conductors 121 of the tooth windings 12A-12C are connected to the second inverter 14.

FIG. 3 shows a schematic illustration of a winding portion 122 of one of the tooth windings 12A-12C. The first electrical conductor 120 in this case is wound around the stator tooth 11, which is not illustrated in FIG. 3. In the present instance, the winding is in the form of an elongated coil. Depending on the configuration and design, there can also be provision for a multilayer winding to be provided in order to be able to achieve, for example, a correspondingly high magnetic potential with a predefined electrical current.

Furthermore, the winding portion 122 of the tooth winding 12A-12C comprises the respective second electrical conductor 121, which is electrically insulated from the first electrical conductor 120. The second electrical conductor 121 also has a plurality of turns arranged circumferentially around the same stator tooth 11. The respective turns of the first and second electrical conductors 120, 121 are arranged in a bifilar manner. That is to say that one turn of the first electrical conductor 120 is always respectively arranged between two adjacent turns of the second electrical conductor 121 (and vice versa) in the longitudinal extent of the winding portion 122. This has the advantage that, in the event of a short circuit between two adjacently arranged turns, the short circuit always occurs between the first electrical conductor 120 and the second electrical conductor 121. A short circuit thus does not occur inside a winding of the same electrical conductor. This makes it possible to prevent large currents in the case of a short circuit between turns, and therefore large thermal and electrical stresses.

FIG. 4 shows a schematic illustration of an electric machine 2′ in the form of a synchronous machine which, in contrast to the electric machine 2 according to FIGS. 1 and 2, now has a twelve-pole rather than a six-pole design. The corresponding stator therefore has twelve stator teeth 11. These are arranged equidistantly in the circumferential direction in the present case. The rotor 20 is again arranged in a through-opening formed through the stator, which rotor likewise has a twelve-pole design in this configuration and therefore provides six north poles N and six south poles S arranged in alternation in the circumferential direction. Here too, there is provision for the magnetic flux provided by the rotor 20 to be provided by permanent magnets arranged, e.g., in the region of the outer circumference of the rotor 20.

Here too, each of the stator teeth 11 is equipped with a winding portion 122 of one of the three tooth windings. Each of the three tooth windings again has a respective first electrical conductor and a respective second electrical conductor (illustrated by different line thicknesses in FIG. 4 purely for the purposes of illustration) which are wound onto the respective stator teeth 11 in a bifilar manner in this configuration. This electric machine 2′ is likewise designed to be supplied with a three-phase AC voltage, each of the phases again being denoted using U, V, W.

FIG. 5 shows an electrical interconnection of the tooth windings 12A-12C and the inverters 13, 14 of the electric machine 2 according to FIG. 1.

The two inverters 13, 14 each comprise three inverter units 130A-130C, 140A-140C, one for each one of the three phases U, V, W. As already described, each inverter unit 130A-130C, 140A-140C has its own half-bridge circuit. An optional capacitor is used as a low-pass filter in each case.

A first DC voltage is applied to the inverter units 130A-130C of the first inverter 13 (designated by HVA+ and HVA−). A second DC voltage is applied to the inverter units 140A-140C of the second inverter 14 (designated by HVB+ and HVB−). The first and second DC voltages are optionally identical and alternatively are different. For example, the first and second DC voltages are 25 V or more, 100 V or more or 800 to 3000 V.

In this case, all six winding portions 122 for the six stator teeth 11 are shown, each winding of the first and second electrical conductors 120, 121 being illustrated only schematically.

Initially, the tooth winding 12A for a first phase W will be considered. The tooth winding 12A comprises a first electrical conductor 120 and a second electrical conductor 121. Both electrical conductors 120, 121 extend over winding portions 122 on the same (two) stator teeth 11 but are electrically insulated from one another. Both electrical conductors 120, 121 have two end portions WA1, WA2, WB1, WB2. Both electrical conductors 120, 121 are free of taps between their end portions WA1, WA2, WB1, WB2. The electrical conductors 120, 121 each establish an electrical connection between the respective two end portions WA1, WA2, WB1, WB2. The winding portions 122 of the tooth winding 12A lie between the end portions WA1, WA2, WB1, WB2 of the electrical conductors 120, 121.

The end portions of the first electrical conductor 120 of the tooth winding 12C for a first phase W are denoted using WA1 and WA2. One end portion WA2 of the first electrical conductor 120 is electrically connected to the first inverter 13 (specifically to a first inverter unit 130A thereof), and the other end portion WA1 of said first electrical conductor is electrically connected to a first star point 123.

The end portions of the second electrical conductor 121 of the tooth winding 12C for the first phase W are correspondingly denoted using WB1 and WB2. One end portion WB1 of the second electrical conductor 121 is electrically connected to the second inverter 14 (specifically to a first inverter unit 140A thereof), and the other end portion WB2 of said second electrical conductor is electrically connected to a second star point 124.

The end portions of the first electrical conductor 120 of the tooth winding 12B for a second phase V are denoted using VA1 and VA2. One end portion VA2 of the first electrical conductor 120 is electrically connected to the first inverter 13 (specifically to a second inverter unit 130B thereof), and the other end portion VA1 of said first electrical conductor is electrically connected to the first star point 123.

The end portions of the second electrical conductor 121 of the tooth winding 12B for the second phase V are correspondingly denoted using VB1 and VB2. One end portion VB1 of the second electrical conductor 121 is electrically connected to the second inverter 14 (specifically to a second inverter unit 140B thereof), and the other end portion VB2 of said second electrical conductor is electrically connected to the second star point 124.

The end portions of the first electrical conductor 120 of the tooth winding 12C for a third phase U are denoted using UA1 and UA2. One end portion UA2 of the first electrical conductor 120 is electrically connected to the first inverter 13 (specifically to a third inverter unit 130C thereof), and the other end portion UA1 of said first electrical conductor is electrically connected to the first star point 123.

The end portions of the second electrical conductor 121 of the tooth winding 12C for the third phase U are correspondingly denoted using UB1 and UB2. One end portion UB1 of the second electrical conductor 121 is electrically connected to the second inverter 14 (specifically to a third inverter unit 140C thereof), and the other end portion UB2 of said second electrical conductor is electrically connected to the second star point 124.

FIG. 6 shows essentially the same interconnection as FIG. 5, but more winding portions 122 are illustrated. It can be seen that the tooth windings 12A-12C can have a smaller or larger number of winding portions 122 depending on the application, e.g. in total six (cf. in particular FIGS. 2 and 5), twelve (cf. in particular FIG. 4) or 18.

While the tooth windings 12A-12C are arranged between the inverters 13, 14 according to FIGS. 5 and 6, it is pointed out that this arrangement is only exemplary.

Furthermore, it can be seen that in FIGS. 5 and 6 the end portions, connected to the inverters 13, 14, of the first and second conductors 120, 121 of each individual one of the tooth windings 12A-12C face away from one another with respect to the common winding portions 122.

FIG. 7 shows a modified arrangement in this regard. The end portions of the first and second electrical conductors 120, 121 of each individual one of the tooth windings 12A-12C accordingly originate from the same winding portion 122 (and also from the same end of the winding portion 122).

FIG. 8 shows an aircraft 4 in the form of an electrically driven airplane. The aircraft 4 comprises a propeller 40 which is driven by the above-described electric machine 2 according to FIG. 2 (alternatively by the electric machine 2′ according to FIG. 4).

The aircraft 4 further comprises two energy sources (and/or energy stores) 3A, 3B, each in the form of an electric battery or of a generator driven, e.g., by a turbine or a piston engine. Such a generator is in particular also in the form of the electric machine 2 described herein. The electric machine 2 is supplied with energy by the energy sources 3A, 3B, or supplies the latter with energy, wherein one energy source 3A is electrically connected to the first inverter 13 while the other energy source 3B is connected to the second inverter 14.

It goes without saying that the invention is not limited to the embodiments described above, and various modifications and improvements can be made without departing from the concepts described here. Any of the features may be used separately or in combination with any other features, unless they are mutually exclusive, and the disclosure extends to and includes all combinations and subcombinations of one or more features that are described herein.

LIST OF REFERENCE SIGNS

- 1 stator
- 10 body
- 11 stator tooth
- 12A-12C tooth winding
- 120 first electrical conductor
- 121 second electrical conductor
- 122 winding portion
- 123 first star point
- 124 second star point
- 13 first inverter
- 130A-130C inverter unit
- 131 control unit
- 14 second inverter
- 140A-140C inverter unit
- 141 control unit
- 2; 2′ electric machine
- 20 rotor
- 3A, 3B energy source
- 4 aircraft
- 40 propeller
- L air gap
- N north pole
- S south pole
- U, V, W phase

STATOR FOR AN ELECTRIC MACHINE

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CPC

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