WO2024255969A1 - Ensemble stator, machine à flux axial et procédé de fabrication d'une machine à flux axial - Google Patents

Ensemble stator, machine à flux axial et procédé de fabrication d'une machine à flux axial Download PDF

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Publication number
WO2024255969A1
WO2024255969A1 PCT/DE2024/100527 DE2024100527W WO2024255969A1 WO 2024255969 A1 WO2024255969 A1 WO 2024255969A1 DE 2024100527 W DE2024100527 W DE 2024100527W WO 2024255969 A1 WO2024255969 A1 WO 2024255969A1
Authority
WO
WIPO (PCT)
Prior art keywords
stator
rivet
axially
openings
yoke
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/DE2024/100527
Other languages
German (de)
English (en)
Inventor
Christian Dinger
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
Priority to CN202480033377.9A priority Critical patent/CN121312042A/zh
Publication of WO2024255969A1 publication Critical patent/WO2024255969A1/fr
Anticipated expiration legal-status Critical
Pending legal-status Critical Current

Links

Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K21/00—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets
    • H02K21/12—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets with stationary armatures and rotating magnets
    • H02K21/24—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos
    • 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
    • H02K15/00—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/02—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
    • H02K15/021—Magnetic cores
    • H02K15/022—Magnetic cores with salient poles
    • 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
    • H02K15/14—Casings; Enclosures; Supports
    • 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
    • H02K1/20—Stationary parts of the magnetic circuit with channels or ducts for flow of cooling medium

Definitions

  • the present invention relates to 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.
  • Electric motors are increasingly being used to power motor vehicles in order to create alternatives to combustion engines that require fossil fuels.
  • Considerable efforts have already been made to improve the everyday suitability of electric drives and to offer users the driving comfort they are used to.
  • An axial flux machine is a dynamoelectric machine in which the magnetic flux between the rotor and stator runs parallel to the axis of rotation of the rotor. Often both the stator and the rotor are largely disk-shaped. Axial flux machines are particularly advantageous when the The axially available installation space is limited in a given application. 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. Furthermore, a smaller iron volume is required compared to conventional machines, which has a positive effect on the efficiency of the machine.
  • a stator arrangement for an electric 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 receptacle has rivet lugs extending axially from the stator receptacle, which each engage in an opening having an undercut and extending axially into the stator yoke and rest against the undercut, so that the stator is fixed axially and radially to the stator receptacle via the rivet connections formed.
  • stator can be easily attached to the stator holder.
  • the rivet connections between the stator and the stator holder enable a stable and reliable connection that can withstand both axial and radial loads.
  • the rivet lugs help to align the components with each other.
  • the rivet lugs are preferably formed monolithically with the stator holder.
  • the rotor is arranged axially next to a stator or between two stators.
  • two rotors are arranged on opposite axial sides of a stator.
  • the axial flow machine according to the invention is preferably configured in an I-arrangement.
  • the axial flux machine consists of exactly one stator and exactly one rotor.
  • 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 it is also preferable for the rotor-stator configurations of the H-type and/or the I-type to be essentially identical 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 electric axial flux 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 when viewed in the circumferential direction.
  • the stator body can be formed from a stator lamination package with several laminated electrical lamination layers.
  • the stator body can also be formed from a pressed soft magnetic material, such as the so-called SMC material (Soft Magnetic Compound).
  • the rotor of an electric axial flux machine can be designed at least in part as a laminated rotor.
  • a laminated rotor is designed in a layered manner in the radial direction.
  • the rotor of an axial flux machine can alternatively also have a rotor carrier which is accordingly coated with magnetic sheets and/or SMC Material and is equipped with magnetic elements designed as permanent magnets.
  • the rotor does not have any other magnetically conductive materials besides the permanent magnets.
  • the 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 rotationally fixedly coupled.
  • the electric axial flow machine can also have a control device.
  • a control device as can be used in the present invention serves in particular for the electronic control and/or regulation of one or more technical systems of the electric axial flow 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 that 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 units, which are arranged in particular spatially separated from one another in the motor vehicle. Control units are also referred to as electronic control units (ECUs) or electronic control modules (ECMs) and preferably have electronic microcontrollers for carrying out computing operations for processing data, particularly preferably using 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. In particular, it is also possible to network the control units with one another via 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 different components which control or regulate a current to the electrical machine, preferably including the peripheral components required for this purpose, such as cooling elements or power supplies.
  • the power electronics contains one or more power electronic components which are designed to control or regulate a current. This is particularly preferably one or more power switches, e.g.
  • 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 flux machine is particularly intended for use within a drive train of a hybrid or fully electric motor vehicle.
  • the electric machine is dimensioned such that vehicle speeds greater than 50 km/h, preferably greater than 80 km/h and in particular greater than 100 km/h can be achieved.
  • the electric motor particularly preferably has an output greater than 50 kW, preferably greater than 100 kW and in particular greater than 250 kW.
  • the electric machine provides operating speeds greater than 5,000 rpm, particularly preferably greater than 10,000 rpm, very particularly preferably greater than 12,500 rpm.
  • the electric machine most preferably has operating speeds between 5,000-15,000 rpm, extremely preferably between 7,500-13,000 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, wherein the electric axial flux machine and the transmission form a structural unit.
  • the electric axial flux machine and the transmission are arranged in a common drive train housing.
  • the electric axial flux machine it would of course also be possible for the electric axial flux machine to have a motor housing and the transmission to have a transmission housing, wherein 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 provided 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 surrounded 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.
  • At least one of the openings preferably a plurality of the openings, particularly preferably all openings each have a base from which a dome extends axially in the direction of the rivet lug, which engages in a rivet head of the rivet lug.
  • the advantage of this embodiment is that the rivet head of the rivet lug is shaped after the rivet connection has been made in such a way that the pressure in the area of the flanks of the mandrel is increased.
  • the mandrel preferably has a V-shaped contour.
  • the stator yoke is formed from a plurality of axially stacked stator laminations.
  • the advantage of a stator arrangement in which the stator yoke is formed from a plurality of axially stacked stator laminations is that this leads to a higher magnetic efficiency of the machine.
  • the losses due to eddy currents and hysteresis can be minimized because the laminations are able to conduct and distribute the magnetic energy more efficiently.
  • the use of stacked laminations is cost-effective and enables the stator arrangement to be manufactured more easily.
  • the openings and the respective undercuts are formed by punching out the corresponding stator sheets.
  • the advantage of a stator arrangement in which the openings and the respective undercuts are formed by punching out the corresponding stator sheets is, among other things, that this contributes to cost-efficient production. Instead of producing the openings and undercuts separately, they can punched directly into the stator laminations, saving time and material. In addition, this leads to greater accuracy and precision of the stator assembly, as the punching enables uniform and consistent shaping.
  • the stator yoke is formed from a solid material and the undercuts of the openings are formed by an additional sheet attached to the stator yoke.
  • a significant advantage of such a stator arrangement is that if the stator yoke is formed from a solid material and the undercuts of the openings are formed by an additional sheet attached to the stator yoke, this leads to greater stability and rigidity of the stator yoke.
  • the stator yoke can have a higher mechanical strength, which leads to improved stability of the entire machine.
  • the additional sheet enables the undercuts to be produced more easily, since it can be produced separately and then attached to the stator yoke.
  • the additional sheet can, for example, be attached to the stator yoke in a material-to-material manner using a welding process, in particular using a laser welding process. It is also possible to form cooling channels from the thin sheet metal to cool the stator.
  • the invention can also be further developed in such a way that a fluid can flow through the openings during operation of the axial flow machine.
  • the advantage of this design is that it enables effective cooling of the machine. Flowing a fluid such as oil, air or water through the openings enables efficient heat dissipation from the area of the stator yoke, which leads to improved performance and efficiency. In addition, this can help to extend the service life of the machine by preventing overheating and thermal damage.
  • axial flow machine in particular for a drive train of a motor vehicle, comprising a stator arrangement according to one of claims 1-6.
  • the object of the invention can further be achieved by a method for producing a stator arrangement for an electric axial flow machine comprising the following steps:
  • stator with a disk-shaped stator yoke from which a plurality of stator teeth extend axially and openings extending axially into the stator yoke, each with an undercut
  • a stamping tool is used to form the rivet connections, which is placed on the side of the stator holder facing away from the opening and is subjected to force in the axial direction, so that at least one of the rivet lugs is axially displaced into the respective opening of the stator yoke and plastically deformed.
  • the invention can also be advantageously designed such that the punch tool has a mandrel extending axially therefrom, which can bring about an improved formation of the rivet connection.
  • Figure 1 shows an axial flow machine in I-design in a schematic axial section
  • Figure 2 shows a stator arrangement of an axial flow machine in an exploded view
  • Figure 3 shows a stator arrangement of an axial flow machine in a perspective view
  • Figure 4 shows four different designs of a stator arrangement, each in a schematic sectional view
  • Figure 5 shows a first embodiment of a stator arrangement in a view before assembly of the stator holder and formation of the rivet connection and a view after assembly of the stator holder and formation of the rivet connection
  • Figure 6 shows a second embodiment of a stator arrangement in a view before assembly of the stator holder and formation of the rivet connection and a view after assembly of the stator holder and formation of the rivet connection
  • Figure 7 shows a third embodiment of a stator arrangement in a view before assembly of the stator holder and formation of the rivet connection and a view after assembly of the stator holder and formation of the rivet connection
  • Figure 8 shows a motor vehicle with an electric drive train in a schematic representation.
  • Figure 1 shows an axial flux 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 flux machine 2.
  • the axial flux machine 2 can be used in particular for a drive train 43 of a motor vehicle 44, as is also outlined in Figure 8.
  • 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.
  • the stator holder 4 has rivet lugs 7 extending out of the stator holder 4 in the axial direction, which each engage in an opening 9 having an undercut 8 and extending axially into the stator yoke 5 and rest against the undercut 8, so that the stator 3 is fixed axially and radially to the stator holder 4 via the rivet connections 10 formed. This can also be clearly seen when looking at Figures 4-7.
  • At least one of the openings 9, preferably a majority of the openings 9, particularly preferably all of the openings 9 each have a base 11 from which a dome 12 extends axially in the direction of the rivet projection 7, which engages in a rivet head 13 of the rivet projection 7.
  • stator yoke 5 is formed from a plurality of axially stacked stator sheets 14, wherein the openings 9 and the respective undercuts 8 are formed by punchings in the corresponding stator sheets 14.
  • FIGs 5-7 show embodiments of the stator 3 in which the stator yoke 5 is formed from a solid material.
  • the undercuts 8 of the openings 9 are formed by an additional sheet 15 attached to the stator yoke 5. It is also clear from Figures 5-7 that a fluid can flow through the openings 9 during operation of the axial flow machine 2, which can in particular improve the cooling of the stator yoke 5 during operation of the axial flow machine 2.
  • the stator arrangement 1 for the electric axial flux machine 2 can be manufactured as follows:
  • a stator 3 is provided with a disk-shaped stator yoke 5, from which a plurality of stator teeth 6 extend axially, and which have openings 9 extending axially into the stator yoke 5, each with an undercut 8. Furthermore, a stator receptacle 4 is provided, which has rivet lugs 7 extending in the axial direction from the stator receptacle 4.
  • the rivet lugs 7 are inserted into the openings 9 of the stator yoke 5 and subsequently rivet connections 10 are formed by deforming one of the rivet lugs 7 in the respectively associated opening 9, so that the stator 3 is fixed radially and axially in the stator holder 4.
  • a stamping tool 16 is used, which is placed on the side 17 of the stator holder 4 facing away from the opening 9 and is subjected to force in the axial direction, so that at least one of the rivet projections 7 is axially displaced into the respective opening 9 of the stator yoke 5 and plastically deformed.
  • the stamping tool 16 can have a mandrel 18 extending axially from it, which leads to the design of the rivet connection shown in Figure 4 d.
  • the flanks of the tip of the mandrel 18 can be used to specifically reinforce the hole bearing or the pressing.

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

Abstract

L'invention concerne un ensemble stator (1) conçu pour une machine électrique à flux axial (2) comprenant un stator (3) et un logement de stator (4) relié au stator (3), ce stator (3) comprenant une culasse de stator (5) en forme de disque, à partir de laquelle une pluralité de dents de stator (6) s'étendent axialement, le logement de stator (4) comportant des structures saillantes formant rivet (7) qui s'étendant dans la direction axiale hors du logement de stator (4), qui s'engagent respectivement dans une ouverture (9) présentant une contre-dépouille (8), s'étendant axialement dans la culasse de stator (5) et s'appliquent contre la contre-dépouille (8), de sorte que le stator (3) soit fixé axialement et radialement sur le logement de stator (4) par l'intermédiaire des liaisons rivetées (10) formées.
PCT/DE2024/100527 2023-06-14 2024-06-14 Ensemble stator, machine à flux axial et procédé de fabrication d'une machine à flux axial Pending WO2024255969A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
CN202480033377.9A CN121312042A (zh) 2023-06-14 2024-06-14 定子组件、轴向通量型机器以及用于生产轴向通量型机器的方法

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102023115496.6 2023-06-14
DE102023115496.6A DE102023115496A1 (de) 2023-06-14 2023-06-14 Statoranordnung, Axialflussmaschine und Verfahren zur Herstellung einer Axialflussmaschine

Publications (1)

Publication Number Publication Date
WO2024255969A1 true WO2024255969A1 (fr) 2024-12-19

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Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/DE2024/100527 Pending WO2024255969A1 (fr) 2023-06-14 2024-06-14 Ensemble stator, machine à flux axial et procédé de fabrication d'une machine à flux axial

Country Status (3)

Country Link
CN (1) CN121312042A (fr)
DE (1) DE102023115496A1 (fr)
WO (1) WO2024255969A1 (fr)

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS5657639U (fr) * 1979-10-11 1981-05-18
US20120086303A1 (en) * 2010-10-12 2012-04-12 Industrial Technology Research Institute Reinforcement structure for disc motor
US20130069467A1 (en) * 2010-03-22 2013-03-21 Regal Beloit Corporation Axial flux electric machine and methods of assembling the same
US9577478B2 (en) * 2013-05-29 2017-02-21 Regal Beloit America, Inc. Axial flux motor with stator pre-load
WO2022073549A1 (fr) * 2020-10-07 2022-04-14 Schaeffler Technologies AG & Co. KG Stator pour moteur à flux axial ayant une liaison par emboîtement et par friction et un moteur à flux axial en agencement en i et refroidissement direct en ligne

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE29705501U1 (de) * 1997-03-26 1998-07-30 Intrasys GmbH Innovative Transport-Systeme, 80339 München Stator für einen Linear-Motor oder Linear-Generator
AT522711A1 (de) * 2019-07-09 2021-01-15 Miba Sinter Austria Gmbh Stator für eine Axialflussmaschine

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS5657639U (fr) * 1979-10-11 1981-05-18
US20130069467A1 (en) * 2010-03-22 2013-03-21 Regal Beloit Corporation Axial flux electric machine and methods of assembling the same
US20120086303A1 (en) * 2010-10-12 2012-04-12 Industrial Technology Research Institute Reinforcement structure for disc motor
US9577478B2 (en) * 2013-05-29 2017-02-21 Regal Beloit America, Inc. Axial flux motor with stator pre-load
WO2022073549A1 (fr) * 2020-10-07 2022-04-14 Schaeffler Technologies AG & Co. KG Stator pour moteur à flux axial ayant une liaison par emboîtement et par friction et un moteur à flux axial en agencement en i et refroidissement direct en ligne

Also Published As

Publication number Publication date
DE102023115496A1 (de) 2024-12-19
CN121312042A (zh) 2026-01-09

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