The invention relates to a stator of an electrical machine, to an electrical machine, and to a method for producing same.
Made known by DE 10 261617 A1 is an electrical machine in which a connection of the stator to the pole housing, made of metal, is effected by means of a shrink process. The pole housing in this case is heated and the stator lamination pack is inserted in the heated state. Upon cooling, the housing shrinks, and as a result sits tightly on the stator. In order to achieve a greater press fit, in this case the stator is pressed into the pole housing, metal shavings being produced as the sheet-metal laminations are pushed into the metal housing. During the assembly process, such shavings can become distributed inside the motor housing, and thus also impair the functioning of the electronics. However, such a strong press fit is necessary, in particular, in order for individually produced stator segments to be reliably positioned and permanently fixed in the pole housing.
The stator according to the invention, the electrical machine according to the invention, and the method according to the invention, for producing such a machine, have the advantage that the formation of a circumferential shoulder on an axial extension of the insulation mask prevents metal shavings from being able to become freely distributed in the motor housing when the stator is pressed into the pole housing. The shoulder of the insulation mask, extending in the circumferential direction, in this case is radially tightly contiguous with the inner wall of the pole housing, such that the shavings that are produced can be held captive between the insulation mask and the inner wall of the housing. Free-moving metal shavings inside the housing are thereby prevented from being able to produce an electrical short circuit at the current-carrying parts.
The shoulder radially contiguous with the inner wall of the pole housing, together with the stator pack, in this case forms a receiving space in which shavings produced during the pressing-in operation, or other dirt particles, remain enclosed. If, for example, during the operation of pressing the sheet-metal laminations into the pole well, shavings are produced at the end face of the lamination pack, during the further pressing-in operation they are held captive between the contiguous shoulder and the end face of the lamination pack.
Particularly advantageously, axially extending webs of the insulation laminations, which likewise are radially contiguous with the inner wall of the pole housing, are realized between the contiguous shoulder and the end face of the lamination pack. As a result, the individual receiving spaces are also closed off in the circumferential direction by the axial webs. The circumferential shoulder can thus be realized as a plurality of individual angular segments, having gaps arranged between them, the receiving pockets being reliably closed by the axial walls of the webs. The axial webs are radially contiguous with the axial extension of the insulation mask, such that, by means of the axial webs, the circumferential shoulder is also reliably contiguous with the inner wall of the pole housing.
In a preferred embodiment of the stator, the insulation mask has a shoulder contiguous with the inner wall only at one axial end. This is sufficient, since the stator pack is pressed only once in one direction into the pole housing, and thus metal particles can be released only at one axial end face of the lamination pack during the pressing-in operation. Preferably, the connection wires for interconnecting the electrical windings are arranged on the end face of the lamination pack that is opposite to the insertion direction. They can thus easily be electrically contacted, even if the lamination pack is inserted into a closed pole well, at the free, open side of the pole well.
If the lamination pack is produced in a plurality of individual stator segments realized separately in the circumferential direction, these single segments are arranged in a ring and pressed into the pole housing. In order for the individual stator segments to be reliably positioned in a permanent manner in relation to each other, a high pressing force, into the pole housing, is required. These separately produced stator segments preferably have a single tooth winding, in which each stator segment respectively has its own insulation mask. Such an insulation mask may be realized, for example, in two parts, in which respectively one half is pushed from each axial side onto the stator tooth.
In the case of such an embodiment having single stator segments, the sheet-metal laminations are mutually contiguous in the circumferential direction, the insulation masks preferably not touching each other in the circumferential direction. Gaps are thus realized in the circumferential direction between the respective insulation masks of the individual segments. The shoulder extending in the circumferential direction is thus not realized so as to be continuous over the entire circumference, but is subdivided, according to the number of single stator segments, into single angular segments of individual insulation laminations, and thus also of individual angular ranges of the circumferential shoulder. These individual angular segments of the circumferential shoulder then always have at least two axial webs which, with the circumferential angular segment of the shoulder and the lamination pack, form the walls of the receiving space. Such a realization of individual stator segments, having separate insulation mask that have a single tooth winding, has the advantage, in comparison with a stator composed of annular sheet-metal laminations, that a higher slot space factor can be achieved by the single tooth winding.
In order to achieve a defined press fit of the stator within the pole housing, the stator pack is not contiguous with the inner wall of the pole housing over the entire circumference. Rather, only defined pressure application regions are realized, which extend over a particular angular range. Realized between them are angular ranges at which the stator pack is not supported radially on the inner wall. For example, realized in each case between individual single stator segments, where the latter are not mutually contiguous in the circumferential direction, are such angular range at which the stator is not radially contiguous with the inner wall of the pole housing. The shoulder of the insulation lamination extending in the circumferential direction therefore preferably extends exclusively over the angular ranges at which the stator laminations are radially contiguous with the inner wall of the pole housing. In a preferred embodiment, the pressure contact region in the circumferential direction also does not extend over the entire angular range of a single stator segment, but only over selected angular ranges of the single stator segment. It is advantageous in this case to realize the axial webs at the limits of the angular range of the pressure application regions, since the distance in the circumferential direction between the axial webs can thereby be reduced.
Since, when the stator is being pressed-in, the shavings are produced only in the angular range of the pressure application regions, the axial webs may be correspondingly arranged in the circumferential region in which the stator is not pressed radially against the inner wall of the pole housing. It is thereby ensured that, wherever the axial end surface of the stator laminations forms a pressure application region with the inner wall, a closed receiving space, which holds the resulting metal particles captive, is always realized over the entire angular range of the pressure application region.
Preferably, a single stator segment has two separately realized pressure application regions, which are arranged at a distance apart from each other in the circumferential direction. Realized between these two pressure application regions there is a radial depression on the outer circumference of the stator segment, in which no press fit is produced. If these two pressure application regions are arranged non-symmetrically on the single stator segment with respect to the circumferential direction, this asymmetry can be used to predefine the axial alignment of the single segments for the winding operation and for the operation of pressing into the housing.
In order that, during the pressing-in operation, the shoulder of the insulation mask allows the pole housing to be inserted more easily, realized at the end face of the shoulder, on the radial outer side, is a radius or a phase, which serves as an insertion aid when the stator is being pressed axially into the housing. In this case the diameter of the shoulder increases in the axial direction in such a manner that the circumferential edge of the shoulder is radially contiguous, in a reliably sealing manner, with the inner wall of the pole housing. The shoulder thus forms a type of circumferential sealing lip, which closes off the receiving space at the axial end face of the stator.
Preferably, the axial webs are directly contiguous with the uppermost sheet-metal lamination of the stator pack, opposite to the shoulder in the axial direction. The uppermost sheet-metal lamination, which is pressed radially against the inner wall of the pole housing, thus forms the surround of the receiving space that is axially opposite the shoulder.
To produce an electrical machine, the connections of the windings of the stator are electrically interconnected. For this purpose, an electronics unit, which connects the connection wires of the electrical windings to each other, is arranged at an open side of the pole housing. On the side of the stator that is opposite this electronics unit, the windings advantageously do not have any free connection wires, such that, on this side, the stator can be pushed, against a closed base surface of the pole housing, into the latter. In this case, the receiving pockets of the insulation mask are always arranged on the axial side of the stator on which the latter is pushed into the pole housing.
In the production of the electrical machine, it is particularly favorable to insert the stator, into the pole housing, first by the axial end face at which the end surface of the uppermost lamination is formed by the punch draw-in side. This means that, here, the radially outer edge at the end surface of the stator pack does not form a punch burr as a result of the draw-in of the uppermost sheet-metal lamination in a punching die. Instead, in the sheet-metal stack of the lamination pack, on the axially opposite side, the end surface of the stator pack is then realized with a corresponding punch burr of the outermost sheet-metal lamination. If the punch draw-in side is inserted first at the axial end surface of the stator pack into the pole housing, the creation of metal shavings can be reduced significantly. Accordingly, the shoulder of the insulation lamination, which extends in the circumferential direction and which is radially contiguous with the inner wall of the pole housing, is likewise realized on this axial side of the stator. For the purpose of producing the electrical machine, the stator may be pressed into a pole housing in a cold state, in which case very high pressing-in forces are required here. Alternatively, the pole housing may be heated, and the stator consequently pressed into the pole housing with a reduced pressing-in force. The production of metal shavings can also be reduced by this method.
Further features of the invention will become apparent from the further expositions of the description and from the drawings, as described in the following exemplary embodiments of the invention.
Arranged axially above the interconnection plate 22 is an end plate 54 which, at its radially outer periphery, is welded to the pole well 15. The end plate 54 has a second bearing seat 55, which engages axially in the central opening 44 of the interconnection plate 22. Accommodated in the second bearing seat 55 is a second rolling bearing 56, by means of which the rotor shaft 20 is rotatably mounted in the stator 16. The second rolling bearing 56 is realized, for example, as a ball bearing, and constitutes a floating bearing for the rotor 18. In this case, an outer ring 58 of the second rolling bearing 56 is fastened in a rotationally fixed manner in the second bearing seat 55, and the inner ring 57 is fastened in an axially displaceable manner on the rotor shaft 20. The second rolling bearing 56 in this case is arranged axially in the same plane as the interconnection plate 22, such that the electrical machine 10 is realized in a very compact manner in the axial direction 4. In the exemplary embodiment, the end plate 54 has individual radial webs 59, projecting through between which, axially upward, are the fastening portions 25 realized as receiving sleeves 27. The coil-wire ends 19 of the coils 63 are inserted in holes 35 of the receiving sleeves 27. Likewise, the connection pins 26 extend from the plastic body 21 through the end plate 54, to enable them to be connected to corresponding contacts 30 of the connection plug 37. For the purpose of vibration damping, the interconnection plate 22 is pressed, by axial spring means 246, axially downward from the end plate 54 against the coil carriers 36. The spring means 246 generates an axial bias, which holds the interconnection plate 22 exactly positioned, including over a large temperature range and in the case of high vibration loads. Since the spring means 246 are realized so as to be independent from the end plate 54, the elasticity of the material can be optimally adapted to the temperature differences and to the occurring accelerations. The rotor 18 is axially biased, by means of a compression spring 86, with respect to the second rolling bearing 56. The compression spring 86 is supported, on the one hand, on the rotor body 65 and, on the other hand, on the inner ring 57 of the second rolling bearing 56.
Arranged above the end plate 54 is a connector housing 33, arranged on which is the outer connection plug 37, not represented in greater detail, for supplying electric power to the electrical machine 10. Arranged on the connector housing 33, on its inner side 39, are the electrical contacts 30, which are connected to the connection pins 26 of the interconnection plate 22. The interconnection plate 22 is connected both to the coil-wire ends 19 and to the electrical contacts 30 of the connection plug 38. For example, the electrical contacts 30 extend axially downward as contact lugs 34, such that they are arranged directly adjacent to the connection pins 26 and are then, for example, welded to each other. Fastened in the connector housing 33 is a sensor element 74, which acts in combination with a signal generator 75 on the rotor shaft 20, in order to sense its rotor position. For this purpose, following the mounting of the end plate 54, a magnet holder 78, which accommodates a sensor magnet 76, is pressed-on at the free end 80 of the rotor shaft 20. Its rotating magnetic field is sensed by the sensor element 74, which is realized as a high-resolution magnetic-field sensor 77. Joined to the connector housing 33 there is a metal cover 81, which is fixedly welded in a tight manner to the flange 32 of the pole well 15. Both the connector housing 33 and the metal cover 81 each have a circular circumferential wall 82, 83, which are arranged radially next to each other. Pressed-in between the connector housing 33 and the inner wall of the metal cover 81 is a radial sealing ring 84, which seals the electrical machine 10 toward the connection plug 37. Furthermore, arranged between the connector housing 33 and the metal cover 81 is an axial spring element 85, which presses the connector housing 33 axially against the flange 32 of the pole well 15.
In the exemplary embodiment, the insulation mask 61 has an axial extension 102, which projects beyond the winding carriers 36 in the axial direction 4, at the lower end. The axial extension 102 in this case forms a radial bearing contact surface 104 for the electrical coils 17. Realized at the axial end 106 of the axial extension 102, on the radially outer side, is a shoulder 108, which extends in the circumferential direction 2 and which is tightly contiguous with an inner wall 115 of the pole housing 15 in the radial direction 3. The axial extension 102 is contiguous with an end surface 112 of the winding carrier 36, axially opposite to the axial end 106. The winding carrier 36 is composed, for example, of individual stacked sheet-metal laminations 113, and has a yoke element 118, on which at least one stator tooth 120 extends radially inward. In the represented section through the yoke element 118, by means of a radial outer wall 119 it is radially contiguous, with a press fit, with an inner wall 115 of the pole housing. A cavity, which serves as a receiving space 122 for dirt particles and/or metal shavings, is realized axially between the shoulder 108, extending in the circumferential direction 2, and the end face 112 of the lowermost sheet-metal lamination 113. If, in the production of the electrical machine 10, the stator 16 is pressed axially into the pole housing 15, metal fragments, which are produced by the friction between the sheet-metal laminations 113 and in the inner wall 115, are held captive in the receiving space 122. The sheet-metal laminations 113 in this case may be realized as single-piece ring laminations that are closed in the circumferential direction 2, or as individual angular segments that belong to a plurality of individual segments 62 of the stator 16. Accordingly, the shoulder 108 may likewise be realized as a closed annular shoulder, or as a plurality of separate angular ranges 128, which belong to the individual insulation laminations 61 of the respective single tooth segments 62. On the left side, the receiving space 122 is relatively small, such that its radial dimension 123 is less than the rest of the radial extent 124 of the axial extension 102. Likewise, the axial extent 125 of the receiving space 122 is less than the rest of the axial extent 126 of the axial extension 102.
By contrast, in the case of an alternative embodiment, on the right side the radial extent 123 of the receiving space 122 is greater than the radial extent 124 of the axial extension 102 in this region. Likewise, the axial extent 125 of the receiving space 122 is greater than the total axial extent 126 of the axial extension 102 as far as the end face 122. By contrast, at the axially opposite end of the stator 16, in the region of the flange 32, the insulation lamination 61 does not have a shoulder that is radially contiguous with the inner wall 115. Instead, here the spacers 42 of the interconnection plate 22 are arranged radially between the insulation lamination 61 and the inner wall 115. Since also virtually no metal shavings are produced at this end of the winding carriers 36, it is possible there to dispense with an arrangement of receiving spaces 122 for the metal fragments. On this side, the coil-wire ends 19 are electrically connected to the interconnection plate 22, such that there are no open coil-wire ends arranged at the opposite axial end 106 of the winding carriers 36. In the exemplary embodiment, the axial extension 102 extends, with the shoulder 108, approximately to a closed base 40 of the pole housing 115. Owing to the receiving spaces 122 arranged there, the metal shavings are prevented from migrating radially inward along the base 40 and being swirled around there by the rotation of the rotor 18.
Represented in
It is to be noted that, with regard to the exemplary embodiments shown in the figures and the description, there are numerous possibilities for combining the individual features with each other. The invention thus relates both to the use of individual angular segments 62 and to a closed annular stator 16. The arrangement of the receiving spaces may in this case be adapted to the specific design of the outer contour of the sheet-metal laminations 113 with their pressure application surfaces 105. The drive unit 10 of the invention is particularly suitable as an embodiment of an EC motor for adjusting movable components in the motor vehicle. Such an electric motor according to the invention, having metal fragment protection, in this case can be used particularly favorably in the outer region, such as, for example, in the engine compartment, where it is exposed to extreme weather conditions and vibrations.
Number | Date | Country | Kind |
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10 2016 222 614.2 | Nov 2016 | DE | national |
Filing Document | Filing Date | Country | Kind |
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PCT/EP2017/078524 | 11/8/2017 | WO | 00 |