WO2007124985A1 - Procédé et dispositif de fabrication d'un enroulement à barres pour le stator d'un moteur électrique - Google Patents

Procédé et dispositif de fabrication d'un enroulement à barres pour le stator d'un moteur électrique Download PDF

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Publication number
WO2007124985A1
WO2007124985A1 PCT/EP2007/052709 EP2007052709W WO2007124985A1 WO 2007124985 A1 WO2007124985 A1 WO 2007124985A1 EP 2007052709 W EP2007052709 W EP 2007052709W WO 2007124985 A1 WO2007124985 A1 WO 2007124985A1
Authority
WO
WIPO (PCT)
Prior art keywords
welding
conductor segments
contactless
stator
zone
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/EP2007/052709
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German (de)
English (en)
Inventor
Thomas Berger
Christoph Schwarzkopf
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Robert Bosch GmbH
Original Assignee
Robert Bosch GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Robert Bosch GmbH filed Critical Robert Bosch GmbH
Publication of WO2007124985A1 publication Critical patent/WO2007124985A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/30—Manufacture of winding connections
    • H02K15/33—Connecting winding sections; Forming leads; Connecting leads to terminals
    • H02K15/35—Form-wound windings

Definitions

  • the invention is based on a method and a device for producing a bar winding for the stator of an electric machine, in particular a claw-pole generator for motor vehicles, as are known from EP 1 043 828 A.
  • This document discloses a method and a device for contactless welding of the ends of a plurality of conductor segments of the winding of an electrical machine, wherein wedge-shaped metal parts are inserted between the ends to be joined of the conductor segments for positioning the conductor segments and to reduce the heating of the winding during welding.
  • the welding process itself is carried out in a conventional manner by an inert gas welding process.
  • the inventive method and apparatus for carrying out the method are characterized by a novel shape and arrangement of the ends to be joined of the conductor segments in the winding of the stator winding, wherein in the contacting region of the conductor segments a defined Melting zone is formed for targeted and thus faster heating of this area, whereby the amount of heat required during the welding process is reduced and thereby the heat load of the remaining coil is reduced.
  • a first advantageous design possibility for the ends of the conductor segments to be welded results from the fact that the ends are tapered towards the melting zone, whereby the amount of heat required to melt the welding zone can be significantly reduced.
  • Another very advantageous possibility for designing the welding zone according to the invention is that the ends of the conductor segments to be joined form a depression in the melting zone, in which the welding beam is directed toward the melting zone, so that only little loss of heat flows away into the remaining regions of the conductor segments.
  • a further expedient variant of the inventive method is to form the conductor segments to be connected of different lengths, so that in the welding area at the end of the shorter conductor segment gradation in the form of a notch is formed, in which the welding beam can be initiated selectively and with low heat flow to other areas ,
  • the ends to be connected of the conductor segments are separated in pairs by an insulation from the ends of the neighboring conductors.
  • Such insulation made of heat-resistant plastic or ceramic can be suitably designed band-shaped and after the bending process of the conductor segments in the region of the winding head be introduced into the spaces between the conductor ends to be connected.
  • an electron beam or a laser beam as the energy beam or to work with a TIG (tungsten inert gas) welding method, in particular with a micro plasma method with a pilot arc for igniting the welding arc.
  • TIG tungsten inert gas
  • the use of an electron beam as an energy beam offers the advantage of a low influence of the structure in the welding zone.
  • the laser beam as an energy beam offers the advantage that with low energy input and thus low thermal stress of the environment of the weld zone a safe
  • the TIG welding process offers the advantage of a cost-effective, contactless welding process with high heat output and thus short welding time, the protective gas sheath shielding the melting zone from the atmosphere and thus from undesired reactions, in particular against oxidation in the melting zone.
  • the micro-plasma process offers the possibility of bundling the welding energy particularly precisely and tightly and thus reducing the heat load on the material surrounding the welding region.
  • the material application and the heating of the welding area are further improved and accelerated when the During welding, the energy beam is directed onto an additional material which, when dripping onto the welding region, further accelerates the welding process by virtue of its residual heat, in addition to the primary heating of the welding region.
  • FIG. 1 is a perspective view of a stator with a bar winding with preformed for the welding process ends of the conductor segments
  • FIG. 2 shows a partial section through the laminated core of the stator with radially extending grooves, each with four conductor segments arranged one above the other, FIG.
  • 3a is a schematic sectional view with four in the winding head of the stator arranged one above the other, in pairs welded conductor segments,
  • 3b is a schematic representation of a wave winding with a welded connection of a conductor pair
  • FIG. 4 shows an arrangement with four conductor segments arranged radially one above the other in the winding head and to be connected in pairs with each other and tapered in the welding region
  • Fig. 5 shows an arrangement with six radially arranged in the winding over each other and in pairs to be joined together conductor segments, which in the welding area a recessed
  • FIG. 6 shows an arrangement with four conductor segments arranged one above the other in the winding head and to be connected in pairs, whereby conductor segments of different lengths in the welding region form a step-shaped melting zone in the form of a notch, FIG.
  • Fig. 7 shows an arrangement according to FIG. 6, wherein in
  • Fig. 8 shows an arrangement of the conductor segments according to Figures 6 and 7, wherein the contactless
  • Fig. 1 shows a perspective, schematic representation of a stator 16 of an electric machine, as used for example in a Klauenpolgenerator for motor vehicles.
  • poles 32 and grooves 34 can be seen, in each of which four conductor segments 36 are arranged radially one above the other.
  • the conductor segments are bent in a known manner on the underside of the stator 16 haarnadelformig and limited by one pole pitch.
  • Their equally long, free ends 42 protrude at the top of the stator 16, also limited by a pole pitch, out of the grooves 34 and are arranged in four concentric rows. This is after the assembly of electrical
  • the machine the free ends 42 in the drive-side winding head 45 of the stator, while the haarnadelformigen deflections 44 protrude at the opposite end winding 46 of the stator 16, which is aligned after the assembly of the electric machine to the wiring side.
  • This arrangement has the advantage that 45 more space for the welded joints is available in the drive-side winding head.
  • the machine axis is designated 27.
  • Fig. 2 shows an enlarged view of a section through the laminated core 17 of the stator 16, wherein in each groove 34 four conductor segments 36 are arranged radially one above the other.
  • the conductor segments are on the one hand on its surface by a paint insulation 38 and on the other hand together insulated by insulating inserts 39 against the laminated core 17 of the stator 16.
  • the introduction of the conductor segments 36 of the stator winding 18 designed as a bar winding takes place by axial insertion of the conductor segments 36 into the grooves 34.
  • Fig. 3 shows in the figure a in schematic form a partial section through the laminated core 17 of the stator 16, from which the free ends 42 of the stator winding 18 protrude.
  • the ends 42 of the stator winding 18 are freed from the paint insulation 38 in the front region 43. Between the not to be welded ends 42 of the
  • Conductor segments 36 is a distance d leave, in addition, a band-shaped insulation 48 can be introduced, for example, a plastic or ceramic tape.
  • FIG. 3 b shows the hairpin-shaped deflection 44 between the conductor segments 36 in the region of the winding head 46, the spreading of the conductor segments 36 about a pole pitch and the clogging of the free ends 42 towards the welding regions. Other conductor segments are indicated by dashed lines.
  • Fig. 4 shows an arrangement with four radially on the drive side winding head 45 arranged one above the other and to be welded together conductor segments 36 whose stripped ends 43 protrude equally far from the laminated core 17 of the stator 16 and at the same height in the winding head
  • the individual conductor segments 36 are denoted by I, II, III, IV, wherein the conductor segments I and II, or III and IV are welded together in the molten zone 40.
  • the respective ends 43 to be welded are beveled on the outside at an angle of 30 ° to 70 °, preferably at an angle of 45 ° and thereby correspondingly curved in cross section, so that the melting zone 40 is reduced and the energy required for the melting of the zone 40th can be reduced.
  • the energy beam is denoted by 52, the energy source by 54.
  • a Plasma welding method can be used, as explained with reference to FIG. 8 closer.
  • an insulation 48 is inserted, on the one hand ensures the distance between the electrically non-contacting conductor segments 36 and forms a protection against an electrical turn and against thermal stress of the adjacent segment during welding.
  • the forces exerted by a clamping device, not shown, during the welding process for positioning and locking the conductor segments are indicated by the arrows 50 and 56. In the axial direction, no forces act on the conductor segments 36 in the inventive contactless welding, so that the conductor segments do not have to be clamped in this direction.
  • Fig. 5 shows an arrangement with six in the drive-side winding head 45 radially superposed conductor segments 36, which are marked with I-VI.
  • the paint insulation 38 shown in the drawings by reinforced lines is again removed.
  • the ends 42 are bevelled in the arrangement of FIG. 5 inwardly so that they kerbformige
  • the energy beam 52 emitted by the energy source 54 is directed, again in this case as an electron beam or as a laser beam. Since in this embodiment, three pairs of conductor segments 36 are arranged one above the other, each one insulation 48 is located between the conductor segments II and III or IV and V. The resulting melt zones 40 are concave in this case and curved inwards. Fig.
  • an additional material 58 is additionally provided in the region of the step at the end of the shorter conductor segment I or IV introduced in wire or rod form in the energy beam 52 and continuously nachgeschoben.
  • the filler material is melted by the energy beam 52 and drips off to the melt zone 40.
  • the residual heat of the melt helps in this process known as "droplet" process to heat the melting zone 40 and simultaneously accelerates the welding process by the application of material, so that less heat flows into the winding area and the insulation 48 correspond to the embodiment in the preceding figures.
  • Fig. 8 shows an arrangement with a water-cooled TIG (tungsten inert gas) welding device.
  • TIG tungsten inert gas
  • a protective gas jacket of argon or helium or a mixture of the two gases covers the arc 62 between the electrode 60 and the molten zone 40 and at the same time protects the molten zone through the protective gas jacket against reactions of the melt with the surrounding atmosphere, in particular against oxidation.
  • the arc 62 is initially ignited at the beginning of the welding process as an auxiliary arc to accelerate the formation of the actual welding arc (micro-plasma welding).
  • the plasma nozzle 64 surrounding the tungsten electrode 60 is water-cooled.
  • the exit of the protective gas is indicated by arrows 66.
  • an additional material can also be introduced into the melting zone 40 in this method, the illustration of which has been dispensed with.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Power Engineering (AREA)
  • Manufacture Of Motors, Generators (AREA)

Abstract

L'invention concerne un procédé et un dispositif de fabrication d'un enroulement à barres (18) pour le stator (16) d'un moteur électrique, notamment d'un alternateur à griffes de véhicules, comportant respectivement une pluralité de segments conducteurs (36) superposés radialement dans la tête d'enroulement (45), dont les extrémités (42) forment une zone de fusion définie (42) du fait de leur forme et/ou disposition dans la zone de contact et sont connectées par paires les unes aux autres au moyen d'un procédé de soudage par fusion sans contact. La formation d'une zone de fusion définie pour la délimitation étroite de la zone de soudage permet de réduire considérablement la quantité de chaleur nécessaire à la fusion de la zone de soudage lors de l'utilisation d'un procédé de soudage par fusion sans contact, et donc de réduire considérablement l'apport de chaleur dans d'autres zones de l'enroulement (18).
PCT/EP2007/052709 2006-04-26 2007-03-21 Procédé et dispositif de fabrication d'un enroulement à barres pour le stator d'un moteur électrique Ceased WO2007124985A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102006019314A DE102006019314A1 (de) 2006-04-26 2006-04-26 Verfahren und Vorrichtung zur Herstellung einer Stabwicklung für den Stator einer elektrischen Maschine
DE102006019314.8 2006-04-26

Publications (1)

Publication Number Publication Date
WO2007124985A1 true WO2007124985A1 (fr) 2007-11-08

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Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/EP2007/052709 Ceased WO2007124985A1 (fr) 2006-04-26 2007-03-21 Procédé et dispositif de fabrication d'un enroulement à barres pour le stator d'un moteur électrique

Country Status (2)

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DE (1) DE102006019314A1 (fr)
WO (1) WO2007124985A1 (fr)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10651699B2 (en) 2014-04-15 2020-05-12 Siemens Aktiengesellschaft Stator of an electric machine and production thereof
WO2021197679A1 (fr) * 2020-03-30 2021-10-07 Robert Bosch Gmbh Machine électrique dotée de conducteurs électriques souples et de moyens d'isolation de mise en forme
JP2024010934A (ja) * 2022-07-13 2024-01-25 トヨタ自動車株式会社 ステータの製造方法及び溶接装置

Families Citing this family (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102012205710A1 (de) * 2012-04-05 2013-10-10 Robert Bosch Gmbh Elektrische Maschine, Statorsegment, Verfahren zur Herstellung
US11088583B2 (en) 2014-12-26 2021-08-10 Hitachi Automotive Systems, Ltd. Rotary-electric-machine stator coil, rotary-electric-machine stator having the same, and rotary electric machine having the same
EP3355445B1 (fr) * 2015-09-25 2021-02-17 Hitachi Automotive Systems, Ltd. Machine électrique rotative et son procédé de fabrication
DE102016222385A1 (de) * 2016-11-15 2018-05-17 Robert Bosch Gmbh Laserschweißverfahren für Stator
DE102017116973A1 (de) * 2017-07-27 2019-01-31 Strama-Mps Maschinenbau Gmbh & Co. Kg Verfahren und Vorrichtung zum Bearbeiten von Leitersegmenten eines Wicklungsträgers einer elektrischen Maschine
FR3104337B1 (fr) * 2019-12-04 2021-11-05 Nidec Psa Emotors Dispositif de maintien de conducteurs électriques à souder
WO2026062760A1 (fr) * 2024-09-18 2026-03-26 Ａｓｔｅｍｏ株式会社 Procédé de fabrication de stator de machine électrique rotative et procédé de fabrication de machine électrique rotative

Citations (4)

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Publication number Priority date Publication date Assignee Title
EP1081830A2 (fr) * 1999-08-06 2001-03-07 Denso Corporation Machine électrique tournante ayant une pluralité de segments de conducteurs et son procédé de fabrication
US20030067239A1 (en) * 2001-10-05 2003-04-10 Denso Corporation Stator arrangement of vehicle AC generator
EP1548914A2 (fr) * 2000-11-06 2005-06-29 Denso Corporation Assemblage de stator pour machine électrique rotative
US20050229381A1 (en) * 2002-02-28 2005-10-20 Denso Corporation Rotary electric machine stator and method of manufacturing the same

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP3104700B1 (ja) * 1999-03-30 2000-10-30 株式会社デンソー 回転電機の巻線接合方法および装置
JP3964116B2 (ja) * 2000-09-12 2007-08-22 三菱電機株式会社 回転電機の固定子
FR2821498B1 (fr) * 2001-02-28 2004-01-16 Valeo Equip Electr Moteur Procede d'assemblage de segments conducteurs d'un bobinage de rotor ou de stator de machine electrique rotative
FR2845536B1 (fr) * 2002-10-07 2005-01-07 Valeo Equip Electr Moteur Agencement de soudage des extremites libres de paires de segments de conducteurs electriques d'un bobinage d'une machine electrique tournante

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1081830A2 (fr) * 1999-08-06 2001-03-07 Denso Corporation Machine électrique tournante ayant une pluralité de segments de conducteurs et son procédé de fabrication
EP1548914A2 (fr) * 2000-11-06 2005-06-29 Denso Corporation Assemblage de stator pour machine électrique rotative
US20030067239A1 (en) * 2001-10-05 2003-04-10 Denso Corporation Stator arrangement of vehicle AC generator
US20050229381A1 (en) * 2002-02-28 2005-10-20 Denso Corporation Rotary electric machine stator and method of manufacturing the same

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10651699B2 (en) 2014-04-15 2020-05-12 Siemens Aktiengesellschaft Stator of an electric machine and production thereof
WO2021197679A1 (fr) * 2020-03-30 2021-10-07 Robert Bosch Gmbh Machine électrique dotée de conducteurs électriques souples et de moyens d'isolation de mise en forme
US12266988B2 (en) 2020-03-30 2025-04-01 Robert Bosch Gmbh Electric machine with flexible electrical conductors and shaping insulations
JP2024010934A (ja) * 2022-07-13 2024-01-25 トヨタ自動車株式会社 ステータの製造方法及び溶接装置
JP7715091B2 (ja) 2022-07-13 2025-07-30 トヨタ自動車株式会社 ステータの製造方法及び溶接装置

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Publication number Publication date
DE102006019314A1 (de) 2007-10-31

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