The present patent application is based on, and claims priority from, German Application No. DE 10 2017 223 519.5, filed Dec. 21, 2017, which is incorporated herein by reference in its entirety.
The invention relates to a stator of a three-phase electronically commutated DC motor, having a stator core, an insulating material body and a coil wire.
An important application of such stators is brushless DC motors for motor vehicles with a dual-voltage on-board power supply. In many applications, the usual 12V is adequate as a supply voltage. Due to the increase in the number of consumers with higher energy requirements, such as main cooling water pumps, the introduction of an on-board electrical system with a higher voltage level will be indispensable in the future. It is likely that a 48V on-board electrical system in parallel with the existing 12V electrical system will prevail. In principle, the higher voltage causes less power to be consumed by the individual consumers. In electric motors, this means that smaller coil wires with a smaller wire diameter can be used. These have a relatively thin insulating layer. Due to imperfections in the lacquer insulation or abrasion due to micro-vibrations, short circuits can arise between coil wires of different phases and thus of different voltage potentials. This would result in failure of the affected electric motor.
The invention relates to a stator of a three-phase electronically commutated DC motor, having a stator core, an insulating material body and a coil wire, wherein the stator core has a closed back iron and a plurality of stator poles pointing radially inwardly from the back iron, which contacts the insulating material body axially at the stator core, and covers both the back iron and also the stator poles.
The present invention is aimed at three-phase internal-rotor motors, which are wound by a needle-winding method, in particular as brushless DC motors having a diameter of about 40 to 80 mm and a power range between about 300W and about 2 kW. When winding the stators, it is advantageous if the complete stator can be wound continuously without interruption with a single coil wire. In installing the wire on the stator, as a rule, up to four wires are laid in parallel. Wire crossings cannot be avoided either in a compact design. There is therefore the risk of contacts and thus of short circuits.
An object of the invention is a stator for a brushless DC motor designed in such a way that it is designed for a 48V on-board electrical system, being especially compact and nevertheless reliably preventing coil wires of different phases from touching each other and an economical production process being used.
In order to ensure defined conditions and the smallest possible movements of the coil wires both in the stator coils and in the connecting lines between the coils and between the phases, attention should be paid to ensuring an adequate wire tension. The geometry of the insulating material body also plays an essential role in this. In the case of connecting wires laid in a circular path, it is relatively easy to achieve a wire installation which is always play-free. For this reason, it is provided that phase wire sections are laid in wire guidance contours, which run along a circular path. Here the wire guidance contours should be designed such that no contacts are possible between phase wire sections laid in parallel around an annular wire guidance region or between skewedly crossing phase wire sections. Due to a helical course of a section of the wire guidance contours it is possible to shift the axial position of the coil wire by a contour level and achieve a compact structure.
A reliable separation of phase wire sections is provided when each phase wire section is guided in its own wire guide contour. These are separated from each other by a wall and even with a faulty wire insulation assure a short-free operation.
Depending on requirements, the wire guidance contour may also be interrupted without departing from the scope of protection of the invention. This relates in particular to an external distal wire guidance contour at the end of which a phase wire section is guided radially inwardly to a stator pole.
It is intended that the coil wires be always under mechanical tensile stress. This is effected on the one hand by the geometry of the wire guidance contours, which have a substantially circular course, as well as by a defined force with which the coil wire is kept under tension during the winding process. Here, areas with openings around the coil wire are to be avoided. In the optimal case phase wire sections run without play within the wire guidance contours. In this way no vibrations can arise and consequently no wire breaks will occur.
At various locations around the wire guidance region it may be necessary to depart from the circular shape of the wire guidance contours. This is often necessary in crossing areas or in places where other technical obstacles require the wire to be diverted.
In order nevertheless to maintain wire tension as strong as possible, this diversion is provided in the form of a chord, if at all possible, with continuous transitions between the circle segment and the chord section. Alternatively, a further circle segment with a significantly greater radius than the circumference may be provided instead of a chord section. In this case, wire tension is largely preserved.
Particularly advantageous are the above-mentioned deviations from the circular shape in regions in which an axially extending phase wire section skewedly passes radially externally a phase wire section of a different phase, said section running circumferentially. In the case of a wire guide contour optimally adapted to the wire diameter, short circuits can thereby be reliably avoided.
It is preferably provided that all axially extending phase wire sections skewedly pass radially externally a phase wire section of a different phase, said section running circumferentially. This is necessary when the phase wire sections are laid between the coils of the first winding phase in a first wire guidance contour, said contour being located at the outer axial end of the wire guidance region facing away from the stator, the second phase wire sections in an adjacent middle wire guidance contour and the third phase wire sections in a wire guidance contour close to the stator.
For the winding operation it is intended that the insulating material body have radially projecting permanent, removable or reversible deflectors. Permanent deflectors are to be provided when sufficient installation space can be made available. In a more compact design, the deflectors can after the winding process be severed, folded or bent, depending on the geometric design. This usually requires an additional process step, unless bending is performed during assembly of a housing.
It is intended here that a circumferentially laid phase wire section is guided at a deflector in an axial direction and crosses at least one axially adjacent wire guidance contour, which at this point has a non-circular section. The phase wire section guided in the axial direction here moves away from the stator. In this way the phase wire section running circumferentially will always deviate away from contact with a phase wire section running axially. The phase wire section running axially must also be guided by means of a wall between the phase wire sections, said wall having no recess. It is also conceivable that, in order to avoid an increase in diameter, the phase wire section running axially also be sunk into the wall between the wire guidance sections. In this case the deviation from the circular shape of the adjacent wire guidance contour would have to be implemented correspondingly more clearly in order to ensure a sufficient distance between the various phase wire sections.
A special feature of this invention is that at least some of the wire deflectors project radially between two wire guide contours. In this way, the phase wire sections can be laid more flexibly, so that it is also possible in a simplified manner to wind the complete stator continuously using a single coil wire.
Since the wire guide contours lie close together, the wire deflectors projecting radially between the wire guidance contours are radial extensions of walls between the wire guidance contours. So that the phase wire sections can be laid in the wire guidance contours it makes sense for the deflectors to be formed flat, like the walls.
In the embodiment of the insulating material body according to the invention, it is not necessary for the wire guidance contours to have slot-like wire feedthroughs passing through the wire guidance region. This permits a more stable design for the wire guidance region and a higher wire tension can be achieved.
It may be necessary for the insulating material body to have centering contours which correspond to corresponding contours of the stator and/or of a housing, wherein the centering contours have the shape of a recess. These centering contours hold the stator centered with respect to a housing or provide anti-rotation protection or serve for better positional assignment. Even on such centering contours, the insulation of the phase wire sections must not be impaired, so for this reason it is also provided here for the wire guidance contours in the region of the centering contours to have a recess whose depth is dimensioned such that a phase wire section can be completely accommodated therein, without protruding into the region of the centering contours.
Depending on space requirements, different embodiments of the insulating material body may be useful. If the diameter of the stator and thus of the DC motor is to be kept low, it is expedient for the annular wire guidance region to axially extend the insulating material body. If the axial installation space is limited, the annular wire guidance region can also radially expand the insulating material body.
The terminal projections in each case connect axially to the wire guidance region. These are designed in such a way as to have shaft-like housing contours for accommodating an insulation displacement contact, wherein slot-like radial recesses in the shaft wall are provided for receiving a radial phase wire section.
It is appropriately provided for limiting means to be present axially on the wire guidance region which are integral with the insulating material body and which prevent the radial phase wire sections from shifting or deflecting in the circumferential direction. As a result, the degrees of freedom of the wire become restricted and the oscillation tendency significantly reduced.
For structural reasons it is expedient for a wire guidance contour to have a leadout contour in one end region, whereby the wire guidance contour merges steplessly into a guide-free section of the wire guidance region. Before the leadout contour, flat deflectors are provided which facilitate a wire deflection. The wire guide contour then ends and merges with the leadout contour. The deflectors for the phase wire sections can be removed after winding, since as a result of the wire tension the coil wire can no longer escape from the wire guidance contours.
In many applications, such as electric oil pumps, a printed circuit board for electrically driving the motor is located near the winding circuit. In order to optimize the printed circuit board layout, it is advantageous for the phase connections to lie close to one another, preferably in an angular range of not more than 120°.
The stator and an electric motor with this stator are preferably designed for an on-board power supply voltage of 48V, with a voltage range of 24V to 60V or 36V to 60V or 40V to 60V.
The stator is designed for an on-board power supply voltage of 36V, with a voltage range of 24V to 48V or for an on-board power supply voltage of 110V, with a voltage range of 90V to 150V.
It is further provided that the energy for energizing the stator is supplied by a direct current source, by an alternating current source, by a three-phase current source or by a pulsed direct current.
The stator has a diameter in the range between 40 and 80 mm or between 40 and 160 mm or between 40 and 200 mm. Finally, the stator and an electric motor with this stator are designed for a power range between 300W and 2 kW or between 300W and 4 kW or between 300W and 6 kW. In addition, an electric motor with a stator according to any one of the preceding claims is claimed.
The exemplary embodiments of the invention are subsequently further explained, based on the drawings. The following is shown:
and
Note: The reference numbers with index and the corresponding reference numbers without index refer to details with the same name in the drawings and the drawing description. The reference number list contains only reference numbers without index for the sake of simplicity.
In describing preferred embodiments of the present invention illustrated in the drawings, specific terminology is employed for the sake of clarity. However, the invention is not intended to be limited to the specific terminology so selected, and it is to be understood that each specific element includes all technical equivalents that operate in a similar manner to accomplish a similar purpose.
Limiting means 25c that are integral with the insulating material body 5c axially adjoin the wire guidance region 10c and prevent radial phase wire sections 8c from shifting or deflecting, said limiting means leading not into one of the slot-like recesses 16c but rather to a coil of a stator pole 4c. To enable reliable installation of the coil wire during the winding operation, in particular when laying the circumferential wire section 7c by 90° in an axial direction (axial phase wire section 9c), flat deflectors 11c and cylindrical deflectors 15c are provided. If the deflectors 11c are arranged between two wire guidance contours 12c, they will be flat like the wall 22c and formed as an extension thereof. The flat geometry is required in order to enable installation of the phase wire section 7c into the wire guidance contour 12. Cylindrical deflectors 15c may be provided that are wider than the wall 22c when they are arranged at the axially outer end of the wire guidance region 10c. Furthermore, a helical section 19c of wire guidance contours 12 can be seen.
Modifications and variations of the above-described embodiments of the present invention are possible, as appreciated by those skilled in the art in light of the above teachings. It is therefore to be understood that, within the scope of the appended claims and their equivalents, the invention may be practiced otherwise than as specifically described.
Number | Date | Country | Kind |
---|---|---|---|
10 2017 223 519.5 | Dec 2017 | DE | national |