WO2024255968A1 - Ensemble stator et procédé de production d'un dispositif de retenue de stator - Google Patents

Ensemble stator et procédé de production d'un dispositif de retenue de stator Download PDF

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Publication number
WO2024255968A1
WO2024255968A1 PCT/DE2024/100526 DE2024100526W WO2024255968A1 WO 2024255968 A1 WO2024255968 A1 WO 2024255968A1 DE 2024100526 W DE2024100526 W DE 2024100526W WO 2024255968 A1 WO2024255968 A1 WO 2024255968A1
Authority
WO
WIPO (PCT)
Prior art keywords
stator
fastening means
yoke
receptacle
arrangement
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.)
Pending
Application number
PCT/DE2024/100526
Other languages
German (de)
English (en)
Inventor
Christian Dinger
Ilya Kletsko
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.)
Schaeffler Technologies AG and Co KG
Original Assignee
Schaeffler Technologies AG and Co KG
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 Schaeffler Technologies AG and Co KG filed Critical Schaeffler Technologies AG and Co KG
Publication of WO2024255968A1 publication Critical patent/WO2024255968A1/fr
Anticipated expiration legal-status Critical
Pending legal-status Critical Current

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Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/12—Stationary parts of the magnetic circuit
    • H02K1/18—Means for mounting or fastening magnetic stationary parts on to, or to, the stator structures
    • H02K1/182—Means for mounting or fastening magnetic stationary parts on to, or to, the stator structures to stators axially facing the rotor, i.e. with axial or conical air gap
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/12—Stationary parts of the magnetic circuit
    • H02K1/14—Stator cores with salient poles
    • H02K1/146—Stator cores with salient poles consisting of a generally annular yoke with salient poles
    • H02K1/148—Sectional cores

Definitions

  • the present invention relates to a stator arrangement for an electric axial flow machine comprising a stator and a stator holder connected to the stator, wherein the stator has a disk-shaped stator yoke from which a plurality of stator teeth extend axially, wherein the stator teeth carry a stator winding.
  • the present invention further relates to a method for producing a stator holder. Electric motors are increasingly being used for propulsion in motor vehicles in order to create alternatives to internal combustion engines that require fossil fuels. Considerable efforts have already been made to improve the everyday suitability of electric drives and also to be able to offer users the usual driving comfort.
  • the drive unit is very compact and, thanks to the switchable 2-speed planetary gear set, allows a good compromise between climbing ability, acceleration and energy consumption.
  • Such drive units are also referred to as e-axles or electrically operated drive trains.
  • Axial flux machines are increasingly being used in such electric axes.
  • An axial flux machine is a dynamoelectric machine in which the magnetic flux between the rotor and stator is parallel to the axis of rotation of the rotor. P222035 - 2 - runs. Both the stator and the rotor are often largely disk-shaped.
  • Axial flux machines are particularly advantageous when the axial installation space available in a given application is limited. This is often the case, for example, with the electric drive systems for electric vehicles described at the beginning.
  • Another advantage of the axial flux machine is its comparatively high torque density.
  • the reason for this is the larger air gap area that is available in a given installation space compared to radial flux machines.
  • a smaller iron volume is necessary compared to conventional machines, which has a positive effect on the efficiency of the machine.
  • the object of the invention is to realize a simple and secure attachment of a stator of an axial flux machine to a stator holder.
  • a stator arrangement for an electrical axial flux machine comprising a stator and a stator receptacle connected to the stator, wherein the stator has a disk-shaped stator yoke from which a plurality of stator teeth extend axially, wherein the stator teeth carry a stator winding, wherein the stator receptacle has at least a first fastening means which is formed in one piece with the stator receptacle, wherein the stator yoke is fixed to the stator receptacle in the radial direction via the fastening means.
  • the radial fixing of the stator yoke ensures precise alignment of the stator teeth and also transport and handling of a wound stator during the manufacturing process of the axial flux machine.
  • the rotor is arranged axially next to a stator or between two stators.
  • two rotors are mounted on opposite axial sides of a stator P222035 - 3 - arranged.
  • the axial flow machine according to the invention is preferably configured in an I arrangement. In principle, it is also conceivable that the axial flow machine consists of exactly one stator and exactly one rotor.
  • a plurality of rotor-stator configurations as I-type and/or H-type it is also possible for a plurality of rotor-stator configurations as I-type and/or H-type to be arranged axially next to one another.
  • the rotor-stator configurations of the H-type and/or the I-type are each designed essentially identically, so that they can be combined in a modular manner to form an overall configuration.
  • Such rotor-stator configurations can in particular be arranged coaxially to one another and connected to a common rotor shaft or to several rotor shafts.
  • the stator of the electrical axial flow machine preferably has a stator body with several stator windings arranged in the circumferential direction.
  • the stator body can be designed as a single piece or in segments in the circumferential direction.
  • the stator body can be formed from a stator laminated core with several laminated electrical sheet layers. Alternatively, the stator body can also be formed from a pressed soft magnetic material, such as the so-called SMC material (Soft Magnetic Compound).
  • SMC material Soft Magnetic Compound
  • the rotor of an axial flux machine can alternatively also have a rotor carrier which is equipped with magnetic sheets and/or SMC material and with magnetic elements designed as permanent magnets.
  • the rotor preferably has no other magnetically conductive materials in addition to the permanent magnets.
  • the P222035 - 4 - Permanent magnets can also be accommodated in a rotor made entirely or partially from a plastic.
  • a rotor shaft is a rotatably mounted shaft of an electrical machine to which the rotor or rotor body is coupled in a rotationally fixed manner.
  • the electrical axial flux machine can also have a control device.
  • a control device as can be used in the present invention is used in particular for the electronic control and/or regulation of one or more technical systems of the electrical axial flux machine.
  • a control device has in particular a wired or wireless signal input for receiving in particular electrical signals, such as sensor signals. Furthermore, a control device also preferably has a wired or wireless signal output for transmitting in particular electrical signals. Control operations and/or regulation operations can be carried out within the control device. It is particularly preferred that the control device comprises hardware which is designed to execute software. The control device preferably comprises at least one electronic processor for executing program sequences defined in software. The control device can also have one or more electronic memories in which the data contained in the signals transmitted to the control device can be stored and read out again. The control device can also have one or more electronic memories in which data can be stored in a changeable and/or unchangeable manner.
  • a control device can comprise a plurality of control devices, which are arranged in particular spatially separated from one another in the motor vehicle.
  • Control devices are also referred to as Electronic Control Unit (ECU) or Electronic Control Module (ECM) and preferably have electronic microcontrollers for P222035 - 5 - Carrying out arithmetic operations for processing data, particularly preferably by means of software.
  • the control units can preferably be networked with one another, so that a wired and/or wireless data exchange between control units is possible.
  • bus systems present in the motor vehicle such as CAN bus or LIN bus.
  • control device has at least one processor and at least one memory, which in particular contains a computer program code, wherein the memory and the computer program code are configured with the processor to cause the control device to execute the computer program code.
  • the control unit can particularly preferably comprise power electronics for supplying current to the stator or rotor.
  • Power electronics is preferably a combination of various components which control or regulate a current to the electrical machine, preferably including peripheral components required for this purpose, such as cooling elements or power supplies.
  • the power electronics contains one or more power electronics components which are set up to control or regulate a current. This particularly preferably involves one or more power switches, e.g. power transistors.
  • the power electronics particularly preferably have more than two, particularly preferably three separate phases or current paths, each with at least one separate power electronics component.
  • the power electronics are preferably designed to control or regulate a power with a peak power, preferably continuous power, of at least 1,000 W, preferably at least 10,000 W, particularly preferably at least 100,000 W per phase.
  • the electric axial flow machine is particularly intended for use within a drive train of a hybrid or fully electric motor vehicle.
  • the electric machine is dimensioned so that vehicle speeds of more than 50 km/h, preferably more than 80 km/h and in particular more than 100 km/h can be achieved.
  • the electric motor preferably has an output of more than 50 kW, preferably more than 100 kW and in particular more than 250 kW.
  • the electric machine provides operating speeds of more than 5,000 rpm, particularly preferably more than 10,000 rpm, very particularly preferably more than 12,500 rpm.
  • the electric machine most preferably has operating speeds of between 5,000 and 15,000 rpm, extremely preferably between 7,500 and 13,000 rpm.
  • the electric axial flux machine can preferably also be installed in an electrically operated axle drive train.
  • An electric axle drive train of a motor vehicle comprises an electric axial flux machine and a transmission, the electric axial flux machine and the transmission forming a structural unit.
  • the electric axial flux machine and the transmission are arranged in a common drive train housing.
  • the electric axial flux machine can have a motor housing and the transmission to have a transmission housing, whereby the structural unit can then be effected by fixing the transmission relative to the electric axial flux machine.
  • This structural unit is sometimes also referred to as an e-axle.
  • the electric axial flux machine can particularly preferably also be intended for use in a hybrid module.
  • a hybrid module structural and functional elements of a hybridized drive train can be spatially and/or structurally combined and preconfigured so that a hybrid module can be integrated into a drive train of a motor vehicle in a particularly simple manner.
  • an axial flux machine and a clutch system can be present.
  • the stator holder can be designed as a plate at least in sections; the stator holder is particularly preferably designed as a shell, in which a plate-shaped base is enclosed by a rim extending from it.
  • the stator holder is most preferably formed from a sheet metal. In principle, it would also be possible to form the stator holder from a plastic.
  • the first fastening means is designed as a bolt which extends axially out of the stator holder and is monolithically formed with the stator holder, wherein the first fastening means is coupled to the outer surface of the annular stator yoke.
  • the advantage of this embodiment of the first fastening means is that the monolithically formed bolt can achieve greater stability and rigidity, both of the stator holder and of the joined stator arrangement.
  • the axial alignment of the bolt enables simple assembly and reliable fastening of the stator yoke to the stator holder by axially inserting or plugging in the stator.
  • the coupling of the fastening means to the outer surface of the annular stator yoke also ensures a secure and stable connection between the stator and the stator holder.
  • the bolt is preferably formed by means of a forming process and is accordingly designed as a hollow cylinder.
  • the first fastening means is designed as a hook element extending axially out of the stator holder and formed in one piece with the stator holder, wherein the first fastening means is coupled to the outer surface of the annular stator yoke.
  • the coupling of the fastening means to the outer surface of the annular stator yoke ensures a reliable and stable connection between the stator and the stator holder.
  • the orientation of the hook element also enables easy assembly and disassembly of the stator from the axial direction, which can facilitate maintenance and repair of the axial flow machine.
  • the hook element has a spring elasticity acting in the radial direction, which can help to realize an assembly-friendly snap connection between the stator holder and the stator.
  • the hook element has a hook pointing radially inwards, which can engage and lock into a corresponding form-locking element of the stator yoke.
  • the form-locking element can, for example, be a groove, a recess or a P222035 - 8 - ramp element.
  • a first adapter element is arranged between the first fastening means and the stator yoke and via which the stator yoke is positioned on the first fastening means, wherein the first adapter element is coupled to the outer surface of the annular stator yoke.
  • a second fastening means is designed as a bolt extending axially out of the stator receptacle and monolithically formed with the stator receptacle, wherein the second fastening means is coupled to the inner surface of the annular stator yoke.
  • the advantage of this embodiment of the second fastening means is that the monolithically formed bolt can achieve greater stability and rigidity, both of the stator receptacle and of the joined stator arrangement.
  • the axial alignment of the bolt enables simple assembly and reliable fastening of the stator yoke to the stator holder by axially inserting or plugging in the stator.
  • the coupling of the fastening means to the inner surface of the annular stator yoke also ensures a secure and stable connection between the stator and the stator holder.
  • the bolt is preferably formed by means of a forming process and is accordingly designed as a hollow cylinder.
  • a second fastening means is designed as a hook element extending axially out of the stator holder and formed in one piece with the stator holder, wherein the second fastening means is coupled to the inner surface of the annular stator yoke.
  • the coupling of the second fastening means to the inner surface of the annular stator yoke ensures a reliable and stable connection between the stator and the stator holder.
  • the alignment of the hook element also enables simple assembly and disassembly of the stator from the axial direction, which facilitates maintenance and repair of the P222035 - 9 - axial flow machine.
  • the hook element has a spring elasticity acting in the radial direction, which can help to realize an assembly-friendly snap connection between the stator holder and the stator.
  • the hook element has a hook pointing radially inwards, which can engage and lock into a corresponding form-fitting element of the stator yoke.
  • the form-fitting element can be, for example, a groove, a recess or a ramp element.
  • a second adapter element is arranged between the second fastening means and the stator yoke and via which the stator yoke is positioned on the second fastening means, wherein the second adapter element is coupled to the inner surface of the annular stator yoke. It can also be advantageous to further develop the invention in such a way that a plurality of first fastening means are arranged distributed over the circumference of the outer surface and/or a plurality of second fastening means are arranged distributed over the circumference of the inner surface. The advantage that can be achieved in this way is that a uniform and stable connection is achieved between the stator and the stator holder.
  • the distribution of the fastening means over the circumference ensures a uniform distribution of the forces and loads, which leads to a higher load-bearing capacity and robustness of the axial flow machine.
  • the plurality of first fastening means and/or the plurality of second fastening means were formed on the stator holder by means of a forming process. This can achieve a high level of precision and accuracy in the formation of the fastening means by using forming processes. In addition, production can be carried out efficiently and inexpensively by forming processes.
  • the object of the invention can also be achieved by a method for producing a stator arrangement comprising the following steps: ⁇ Providing a stator with a disk-shaped stator yoke from which a plurality of stator teeth extend axially, ⁇ Providing a stator winding for winding the stator ⁇ Providing a stator holder with at least one first fastening means which is formed integrally with the stator holder and is configured to fix the stator yoke in the radial direction, ⁇ Winding the stator with the stator winding ⁇ Placing the stator holder on the wound stator so that the stator is fixed to the stator holder in the radial direction via the stator yoke.
  • Figure 1 an axial flow machine in a schematic axial sectional view
  • Figure 2 a stator arrangement of an axial flow machine in an exploded view
  • Figure 3 a stator arrangement of an axial flow machine in a perspective view
  • Figure 4 a perspective detailed view of a fastening means of the stator holder on the outer surface of the stator yoke
  • Figure 5 shows three embodiments of fastening means, each in a schematic axial sectional view
  • Figure 6 shows three embodiments of fastening means with adapter elements, each in a schematic axial sectional view
  • Figure 7 shows a motor vehicle with an electric drive train in a schematic view.
  • Figure 1 shows an axial flow machine 2 in I configuration with two axially spaced disc-shaped stators 3, between which the disc-shaped rotor 41 is rotatably mounted on the rotor shaft 42.
  • the stators 3 are fixed to a stator holder 4, which is part of a motor housing of the axial flow machine 2.
  • a stator holder 4 which is part of a motor housing of the axial flow machine 2.
  • such an axial flow machine 2 can be installed in a drive train 43 of a motor vehicle 44.
  • FIGs 2-3 show a stator arrangement 1 for the electric axial flow machine 2 comprising a stator 3 and a stator holder 4 connected to the stator 3, wherein the stator 3 has a disk-shaped stator yoke 5 from which a plurality of stator teeth 6 extend axially, wherein the stator teeth 6 carry a stator winding (not shown).
  • the stator holder 4 has a first fastening means 8 which is formed in one piece with the stator holder 4, wherein the stator yoke 5 is fixed to the stator holder 4 in the radial direction via the fastening means 8.
  • the stator holder 4 is designed like a shell, with a substantially flat base and a border extending out of the base in the axial direction at the edge of the stator holder 4.
  • the stator holder 4 is made from a sheet metal or from a plastic.
  • the first fastening means 8 is designed in the embodiments of Figures 2-3 and Figure 5, illustrations a,b, as a bolt 9 extending axially out of the stator receptacle 4 and formed monolithically with the stator receptacle 4, wherein the first fastening means 8, i.e. the bolt 9, is coupled to the outer surface 10 of the annular stator yoke 5.
  • a second fastening means 13 is present as a bolt 14 extending axially out of the stator receptacle 4 and formed monolithically with the stator receptacle 4, wherein the second fastening means 13 is coupled to the inner surface 15 of the annular stator yoke 5.
  • the annular stator yoke 5 is fixed in the radial direction to the stator receptacle via the bolts 9,14.
  • the bolts 9, 14 are arranged and designed in such a way that they form a slight press fit with the stator yoke 5, so that the latter is also fixed to the stator holder 4 in the axial direction. This makes it possible in particular to handle the stator arrangement 1 safely during assembly of the axial flow machine 2.
  • the two bolts 9, 14 lie on a common radial plane, i.e. are arranged radially aligned with one another.
  • the first fastening means 8 can also be designed as a hook element 11 extending axially out of the stator holder 4 and formed in one piece with the stator holder 4, wherein the first fastening means 8 is coupled to the outer circumferential surface 10 of the annular stator yoke 5.
  • the stator yoke 5 has corresponding grooves 18, 19, in which the respective hook of the hook elements 11, 16 engages in a form-fitting manner, so that the stator 3 is secured radially and axially to the stator holder 4.
  • FIG 5 also shows that a second fastening means 13 is designed as a hook element 16 that extends axially out of the stator holder 4 and is formed in one piece with the stator holder 4, wherein the second fastening means 13 is coupled to the inner surface 15 of the annular stator yoke 5.
  • the hook elements 11, 16 can be designed monolithically with the stator holder 4 or as a separate component that is then fixed to the stator holder 4.
  • the fastening means 8, 13 can be formed monolithically with the stator receptacle 4, in particular by means of a forming process, for example by deep drawing or caulking. Such fastening means 8, 13 can be seen in figures a, b of Figure 5.
  • a first adapter element 12 can also be arranged between the first fastening means 8 and the stator yoke 5 and via which the stator yoke 5 is positioned on the first fastening means 8, the first adapter element 12 being coupled to the outer circumferential surface 10 of the annular stator yoke 5.
  • a second adapter element 17 is arranged between the second fastening means 13 and the stator yoke 5 and via which the stator yoke 5 is positioned on the second fastening means 13, the second adapter element 17 being coupled to the inner circumferential surface 15 of the annular stator yoke 5.
  • the adapter elements 12,17 are fixed to fastening means 8,13, which each form a riveted connection with the adapter elements 12,17.
  • the adapter elements 12,17 engage in grooves 18,19 formed on the stator yoke 5, while in the embodiment of Figure b they engage in a stator groove 20 between two stator teeth 6 and thus fix the stator 3 radially and axially relative to the stator holder 4.
  • Figure c of Figure 6 shows a further embodiment alternative in which the fastening means 8,13 are each designed as a welded connection.
  • the stator arrangement 1 can be manufactured, for example, as follows: P222035 - 14 - First, a stator 3 with a disk-shaped stator yoke 5 from which a plurality of stator teeth 6 extend axially can be provided. A stator winding is also provided for winding the stator 3.
  • a stator holder 4 is also provided with at least one first fastening means 8 which is formed in one piece with the stator holder 4 and is configured to fix the stator yoke 5 in the radial direction.
  • the stator 3 is then first wound with the stator winding and the stator holder 4 is then placed on the wound stator 3 so that the stator 3 is fixed to the stator holder 4 in the radial direction via the stator yoke 5.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Iron Core Of Rotating Electric Machines (AREA)

Abstract

L'invention concerne un ensemble stator (1) pour une machine à flux axial électrique (2), comprenant un stator (3) et un dispositif de retenue de stator (4) qui est relié au stator (3). Le stator (3) a une culasse de stator en forme de disque (5) à partir de laquelle une pluralité de dents de stator (6) s'étendent dans une direction axiale, les dents de stator (6) supportant un enroulement de stator et le dispositif de retenue de stator (4) ayant au moins un premier moyen de fixation (8) qui est formé d'un seul tenant avec le dispositif de retenue de stator (4). La culasse de stator (5) est fixée au dispositif de retenue de stator (4) dans la direction radiale par l'intermédiaire du moyen de fixation (8).
PCT/DE2024/100526 2023-06-14 2024-06-14 Ensemble stator et procédé de production d'un dispositif de retenue de stator Pending WO2024255968A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102023115497.4 2023-06-14
DE102023115497.4A DE102023115497A1 (de) 2023-06-14 2023-06-14 Statoranordnung und Verfahren zur Herstellung einer Statoraufnahme

Publications (1)

Publication Number Publication Date
WO2024255968A1 true WO2024255968A1 (fr) 2024-12-19

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Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/DE2024/100526 Pending WO2024255968A1 (fr) 2023-06-14 2024-06-14 Ensemble stator et procédé de production d'un dispositif de retenue de stator

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DE (1) DE102023115497A1 (fr)
WO (1) WO2024255968A1 (fr)

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2017094271A1 (fr) * 2015-12-03 2017-06-08 三菱電機株式会社 Machine dynamo-électrique à entrefer axial et son procédé de fabrication
EP4084293A2 (fr) * 2010-03-22 2022-11-02 Regal-Beloit Corporation Machine électrique à flux axial et son procédé d'assemblage

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CH630206A5 (en) * 1978-08-28 1982-05-28 Bbc Brown Boveri & Cie Method for producing bindings on the rotor of an electrical machine, for fixing a winding in slots in the rotor, and a device for carrying out the method
AT522711A1 (de) * 2019-07-09 2021-01-15 Miba Sinter Austria Gmbh Stator für eine Axialflussmaschine

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP4084293A2 (fr) * 2010-03-22 2022-11-02 Regal-Beloit Corporation Machine électrique à flux axial et son procédé d'assemblage
WO2017094271A1 (fr) * 2015-12-03 2017-06-08 三菱電機株式会社 Machine dynamo-électrique à entrefer axial et son procédé de fabrication

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