WO2024255970A1 - Ensemble stator et procédé de production d'un logement de stator - Google Patents

Ensemble stator et procédé de production d'un logement de stator Download PDF

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Publication number
WO2024255970A1
WO2024255970A1 PCT/DE2024/100528 DE2024100528W WO2024255970A1 WO 2024255970 A1 WO2024255970 A1 WO 2024255970A1 DE 2024100528 W DE2024100528 W DE 2024100528W WO 2024255970 A1 WO2024255970 A1 WO 2024255970A1
Authority
WO
WIPO (PCT)
Prior art keywords
stator
contact
contact elements
holder
die
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/DE2024/100528
Other languages
German (de)
English (en)
Inventor
Christian Dinger
David SCHNÄDELBACH
Heiko Rosenfeld
Dirk Reimnitz
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 WO2024255970A1 publication Critical patent/WO2024255970A1/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
    • 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

Definitions

  • the present invention relates to a stator arrangement for an electrical 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.
  • the invention further relates to a method for producing a stator holder.
  • 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 axial 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. In addition to the shortened axial length, another advantage of the axial flux machine is its comparatively high torque density. The reason for this is the larger air gap area 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 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 receptacle has contact elements which are formed monolithically with the stator receptacle and protrude axially therefrom, against which the stator yoke axially rests, wherein the contact elements each have a first contact section and a second contact section spaced therefrom, wherein the contact sections rest against the stator yoke.
  • stator arrangement is that the stator holder with the monolithically formed contact elements enables a very stable and precise fastening of the stator.
  • manufacture of the stator arrangement can be simplified by the monolithic formation of the contact elements, which enables greater precision and cost efficiency.
  • an axial flux machine in an I-arrangement or an H-arrangement.
  • 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 designed accordingly with magnetic sheets and/or SMC material and with magnetic elements designed as permanent magnets.
  • the rotor does not have any other magnetically conductive materials in addition to the permanent magnets.
  • the Permanent magnets can also be housed in a rotor made entirely or partially from 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 Unit (ECU) or Electronic Control Module (ECM) and preferably have electronic microcontrollers for Carrying out arithmetic 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.
  • 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 intended in particular for use within a drive train of a hybrid or fully electric motor vehicle.
  • the electric machine is dimensioned such 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. It is further preferred that the electric machine provides operating speeds of more than 5,000 ll/min, particularly preferably more than 10,000 ll/min, very particularly preferably more than 12,500 ll/min.
  • the electric machine most preferably has operating speeds of between 5,000-15,000 ll/min, extremely preferably between 7,500-13,000 ll/min.
  • 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.
  • the contact elements extend in the radial direction on the stator holder at a distance from one another in the circumferential direction.
  • the advantage of this embodiment is that it allows a particularly mechanically stable contact to be formed between the contact elements and the stator yoke.
  • the contact elements are arranged equidistantly in the circumferential direction. It may also be preferred that the number of contact elements corresponds to the number of stator teeth. In this context, it is also preferable that each stator tooth is assigned a contact element.
  • the contact elements are arranged in radial alignment with one another.
  • several separate contact elements are aligned radially and spaced radially from one another. This allows the contact surface between the contact elements and the stator yoke to be reduced, which in turn means that, for example, a larger area on the stator yoke can be flowed over by a cooling fluid. This allows the cooling of the stator to be optimized.
  • a plurality of the contact elements are arranged on a common pitch circle.
  • the advantageous effect of this embodiment is based on the fact that it enables a uniform contact of the stator yoke on the contact elements to be achieved.
  • the contact sections of a contact element are spaced from one another by a concave or convex contour.
  • the invention can also be further developed in such a way that openings are provided in the stator yoke that extend into the stator yoke in the axial direction, with the contact sections each extending into a corresponding opening and resting in the corresponding opening in the circumferential direction and/or axial direction.
  • the advantage of this design is that it allows both a radial and circumferential fixing of the stator yoke relative to the stator holder.
  • the stator holder can be fixed axially relative to the stator yoke, for example by the contact sections abutting axially in the corresponding opening.
  • a channel through which a fluid can flow is formed between the stator yoke and one of the contact elements, which can improve the cooling of the stator.
  • the object of the invention can also be achieved by a method for producing a stator holder comprising the following steps:
  • the object of the invention can also be achieved by a method for producing a stator holder comprising the following steps:
  • Figure 1 shows an axial flow machine 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 three different embodiments of a stator holder in a perspective view
  • FIG. 5 shows a stator arrangement in a schematic sectional view
  • Figure 6 shows five different embodiments of stator arrangements, each in a schematic sectional view
  • Figure 7 shows an embodiment of a stator holder in a perspective view
  • Figure 8 shows a stator arrangement with the stator holder known from Figure 7 in a perspective axial section view
  • FIG 9 is a detailed view of a contact element of the stator holder known from Figure 7,
  • Figure 10 two embodiments of dies and punches for forming a stator holder in two schematic sectional views each
  • Figure 11 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.
  • such an axial flux machine 2 can be installed in a drive train 43 of a motor vehicle 44.
  • Figures 2-3 show a stator arrangement 1 for an electrical 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 contact elements 7 which are formed monolithically with the stator holder 4 and protrude axially therefrom, against which the stator yoke 5 rests axially.
  • the contact elements 7 each have a first contact section 8 and a second contact section 9 spaced apart therefrom, with the contact sections 8, 9 resting against the stator yoke 5, which can be clearly seen from a comparison with Figure 5.
  • the stator holder 4 is formed from a sheet metal. In principle, it would also be possible to form the stator holder 4 from a plastic.
  • the contact elements 7 themselves are formed using a forming process in such a way that they are manufactured very precisely in the area of the contact sections 8, 9.
  • the contact elements 7 extend in the circumferential direction at a distance from one another in the radial direction on the stator holder 4.
  • the contact elements 7 are thus essentially designed in a rod-like manner.
  • the radial alignment of the contact elements 7 allows the stator 3 to be supported in its radial extension. It is also possible to interrupt this radial extension of the contact elements 7 in order to reduce the forming volume. At least three contact elements 7 should be formed distributed over the circumference for mounting the stator yoke 5.
  • FIG. b of Figure 4 a corresponding alternative design of the contact elements 7 is shown, in which a plurality of the contact elements 7 are arranged in radial alignment with one another and are arranged on two partial circles 11.
  • FIG. c of Figure 4 a further design variant of the stator holder 4 is shown, in which the contact elements 7 are positioned on a total of three concentrically running partial circles 11.
  • openings 12 extending axially into the stator yoke 5 are provided in the stator yoke 5, with the contact sections 8,9 each extending into a corresponding opening 12 and rest in the corresponding opening 12 in the circumferential direction and/or axial direction. In this way, a channel 13 through which a fluid can flow can be formed between the stator yoke 5 and one of the contact elements 7.
  • the convex contour 10 of the contact element 7 engages in an opening 12 assigned to it.
  • FIGS 7-9 show an embodiment of the stator arrangement 1 in which the stator holder 4, which is designed as a housing cover, is stamped/pushed through on the back with a flat stamp 23 and the contact elements 7 are thus formed.
  • the stator yoke 5 serves as a die 20 for forming the contact elements 7 in a corresponding forming process.
  • the material of the stator holder 4 is pushed on during forming in order to achieve a corresponding volume compensation.
  • the opening 12 has a shoulder 15 on both sides in the circumferential direction.
  • the stator 3 later sits on the precise lateral flanks of the contact sections 8, 9.
  • the back of the stator holder 4, which is designed as a housing cover could be completely turned over in order to reduce the axial height of the axial flow machine.
  • the volume defined by the contour 10 in the middle area of the contact element 7 is thus located in the area of the opening 12 of the stator 3, which is designed as a cooling channel, and can be used as a compensation area during forming, for example by stamping the contact elements 7. This reduces the force during forming and, as a result, results in improvements in the overall flatness of the formed sheet metal component.
  • Figure 8 also shows the stator teeth 6 wound with the stator winding 14.
  • a first possible method for producing a stator holder 4 can now be explained in more detail, comprising the following steps: First, a die 20 is provided with a convex portion 21 which runs in cross-section between two parallel grooves 22, and a punch 23 with a concave portion 24 which runs in cross-section between two parallel webs 25.
  • stator holder 4 formed from a sheet metal is placed between the die 20 and the punch 23 and the punch 23 is displaced against the die 20 or vice versa.
  • FIG. 10 In illustration b of Figure 10, another method for producing a stator holder 4 is shown, which is designed as follows.
  • a die 20 with a groove 26 is provided, which has a shoulder 28 on each of its side walls 27 along its longitudinal extension, and a punch 23 is provided.
  • stator holder 4 formed from a sheet metal is positioned between the die 20 and the punch 23 and subsequently the punch 23 is displaced against the die 20 or vice versa.
  • the punch 23 is shaped in such a way that it pushes or stamps the material precisely against the die 20 in the side flanks.
  • the central recessed area (section 24 in Figure a, groove 26 in Figure) serves to compensate for stamping. Excess material can flow into the central area (section 24 in Figure a, groove 26 in Figure).

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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), le stator (3) comportant une culasse de stator (5) en forme de disque, à partir de laquelle s'étendent axialement une pluralité de dents de stator (6), le logement de stator (4) présentant des éléments d'appui (7) formés d'un seul tenant avec le logement de stator (4) et faisant saillie axialement par rapport à celui-ci, sur lesquels la culasse de stator (5) s'appuie axialement, les éléments d'appui (7) comportant respectivement une première partie d'appui (8) et une deuxième partie d'appui (9) espacée de celle-ci, les parties d'appui (8, 9) s'appuyant sur la culasse de stator (5).
PCT/DE2024/100528 2023-06-14 2024-06-14 Ensemble stator et procédé de production d'un logement de stator Pending WO2024255970A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102023115499.0 2023-06-14
DE102023115499.0A DE102023115499A1 (de) 2023-06-14 2023-06-14 Statoranordnung und Verfahren zur Herstellung einer Statoraufnahme

Publications (1)

Publication Number Publication Date
WO2024255970A1 true WO2024255970A1 (fr) 2024-12-19

Family

ID=91664084

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/DE2024/100528 Pending WO2024255970A1 (fr) 2023-06-14 2024-06-14 Ensemble stator et procédé de production d'un logement de stator

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DE (1) DE102023115499A1 (fr)
WO (1) WO2024255970A1 (fr)

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE4404659A1 (de) * 1994-02-14 1995-08-17 Boellhoff & Co Verfahren zum Herstellen einer Nietverbindung
WO2020135926A1 (fr) * 2018-12-24 2020-07-02 Robert Bosch Gmbh Procédé de découpage fin multi-couche pour la fabrication de pièces métalliques et dispositif de découpage fin pour la mise en œuvre d'un tel procédé
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 (3)

* 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
DD152075A1 (de) * 1980-07-15 1981-11-18 Dietrich Kirchhoff Verfahren und vorrichtung zur verformung von blechen,insbesondere praegesicken
AT522711A1 (de) * 2019-07-09 2021-01-15 Miba Sinter Austria Gmbh Stator für eine Axialflussmaschine

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE4404659A1 (de) * 1994-02-14 1995-08-17 Boellhoff & Co Verfahren zum Herstellen einer Nietverbindung
WO2020135926A1 (fr) * 2018-12-24 2020-07-02 Robert Bosch Gmbh Procédé de découpage fin multi-couche pour la fabrication de pièces métalliques et dispositif de découpage fin pour la mise en œuvre d'un tel procédé
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
DE102023115499A1 (de) 2024-12-19

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