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EP2789077A1 - Electrical machine with contact connectors - Google Patents

Electrical machine with contact connectors

Info

Publication number
EP2789077A1
EP2789077A1 EP12797912.8A EP12797912A EP2789077A1 EP 2789077 A1 EP2789077 A1 EP 2789077A1 EP 12797912 A EP12797912 A EP 12797912A EP 2789077 A1 EP2789077 A1 EP 2789077A1
Authority
EP
European Patent Office
Prior art keywords
electrical
connector
winding
electrical connector
contact
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.)
Withdrawn
Application number
EP12797912.8A
Other languages
German (de)
French (fr)
Inventor
Bertrand Vedy
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.)
Michelin Recherche et Technique SA Switzerland
Compagnie Generale des Etablissements Michelin SCA
Original Assignee
Michelin Recherche et Technique SA Switzerland
Compagnie Generale des Etablissements Michelin SCA
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 Michelin Recherche et Technique SA Switzerland, Compagnie Generale des Etablissements Michelin SCA filed Critical Michelin Recherche et Technique SA Switzerland
Publication of EP2789077A1 publication Critical patent/EP2789077A1/en
Withdrawn legal-status Critical Current

Links

Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K5/00—Casings; Enclosures; Supports
    • H02K5/04—Casings or enclosures characterised by the shape, form or construction thereof
    • H02K5/22—Auxiliary parts of casings not covered by groups H02K5/06-H02K5/20, e.g. shaped to form connection boxes or terminal boxes
    • H02K5/225—Terminal boxes or connection arrangements
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
    • H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K11/00—Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection
    • H02K11/0094—Structural association with other electrical or electronic devices
    • 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
    • H02K15/04—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings prior to their mounting into the machines
    • H02K15/043—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings prior to their mounting into the machines winding flat conductive wires or sheets
    • 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
    • H02K15/12—Impregnating, moulding insulation, heating or drying of windings, stators, rotors or machines
    • 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
    • H02K15/32—Manufacture of terminal arrangements; Connecting the terminals to external circuits
    • 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
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/46—Fastening of windings on the stator or rotor structure
    • H02K3/50—Fastening of winding heads, equalising connectors, or connections thereto
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K2203/00—Specific aspects not provided for in the other groups of this subclass relating to the windings
    • H02K2203/06—Machines characterised by the wiring leads, i.e. conducting wires for connecting the winding terminations
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49009—Dynamoelectric machine

Definitions

  • the present invention relates to electrical machines, in particular intended to be installed in road vehicles.
  • the present invention relates in particular to electrical stator winding machines.
  • This invention finds, for example, an example of application to permanent magnets in brushless electric machines.
  • An electric machine is a machine for converting between electrical energy and mechanical energy. This conversion can be done in both directions, depending on whether the machine operates as a generator or motor. There are different types of machines, whether DC machines or AC machines, in which there are synchronous or asynchronous machines. To perform this conversion, an electrical machine generally comprises a fixed part, called stator, and a rotatable part, called rotor.
  • Electrical machines can be installed in all kinds of systems, including a road vehicle, and more particularly in a wheel of a road vehicle.
  • one of the challenges of installing an electrical machine is based on the connection of the machine to external connections, in this case an electrical harness of the vehicle.
  • an electrical harness of the vehicle In the case of a permanent magnet machine without brushes, the connection on the side of the electrical machine takes place at the stator.
  • This crimp is embedded in a coating resin, as close as possible to the cooled surfaces of the electric machine, to ensure good thermal behavior of the assembly.
  • the present invention is therefore to provide an electric machine does not have these disadvantages.
  • the present invention aims to provide an electric machine such that disassembly is relatively easy, and it can adapt to different applications without requiring special adaptations.
  • the present invention relates to an electric machine with permanent magnets comprising a housing housing a stator winding at least two phase outputs, said electrical machine comprising
  • each electrical connector fixed on each phase output of the winding, a cover comprising at least two contactors and connected to an electric harness, each electrical connector having a contact surface intended to cooperate with a contact element,
  • each contactor of the cover is in contact with a contact surface of an electrical connector and the electrical machine is connected to the harness.
  • contactor and connector designate separate elements but of the same nature, namely contacts, or contactors, electrical.
  • a machine according to the invention has the advantage of requiring a single step of fixing electrical connectors on the phase outputs. Indeed, the second crimping step described in the state of the art is no longer necessary, since the electrical connection of the machine is performed by a simple contact of a bonnet contactor with a contacting surface an electrical connector installed on a phase output of the winding. Moreover, this connection by simple contact allows a better adaptability of the cover and the electric machine. Thus, it is possible to modify one of the elements without having to modify the other, as long as the geometry of the contact points remains the same. Such a solution therefore saves costs by not requiring specifically to manufacture machines for each application.
  • a machine according to the invention allows disassembly and easy access to the various elements.
  • Such a feature is particularly interesting in the case where an electric machine is installed on a wheel, because the wheel arch is a particularly difficult to access.
  • the attachment of the electrical connector to a phase output of the winding is included in the group comprising: crimping, welding, pinching son by a screw.
  • each electrical connector comprises:
  • the lower and upper part forming an angle substantially equal to 90 °, and the lower part, the upper part, the fixing element and the contact surface forming a single mechanical part.
  • the electrical connector is formed of a conductive metallic material, for example copper.
  • the machine further comprises at least one insulating part cooperating with each electrical connector to prevent contact of the upper part of the electrical connector with the winding or the carcass of the machine.
  • This piece is, for example, injected plastic.
  • the invention also relates to a method of manufacturing an electric machine, comprising the following steps:
  • an electrical connector is fixed, comprising a plane part extending in the axis of the electrical machine and supporting the fixing element to the winding,
  • the flat portion of the connector is folded so as to form a lower part of the connector supporting the fixing element, and an upper part of the connector having a contact surface.
  • the positioning of the electrical connector and its late folding can not interfere with the conformation of the chinions, necessary in the context of the manufacture of an electric machine.
  • the lower portion and the upper portion of the connector form an angle substantially equal to 90 °.
  • the method comprises the step, before or after the bending of the connector, to coat the coils and chinions with an impregnating resin.
  • the lower part of the connector is also embedded in a coating resin.
  • the method comprises the final step of installing a cover comprising three contact elements intended to be in contact respectively with each contact surface of an electrical connector.
  • the step of fixing an electrical connector on a winding phase is comprised in the group comprising: a crimping step, a soldering step, a pinching step of the wires by a screw.
  • the method comprises, prior to the folding step, the step of placing a conformation piece for isolating the upper part of the winding connector and the carcass of the electric machine.
  • FIG. 1 represents a view of an electrical machine comprising three electrical connectors without the cover
  • FIGS. 2a and 2b show two views of an electrical connector installed on a phase of a winding
  • FIG. 3 represents an example of a hood
  • FIG. 4 represents an external view of an electric machine comprising a cover shown in transparency
  • FIG. 5 represents a sectional view of an electric machine and its cover
  • Figure 6a shows an electrical connector before folding
  • Figure 6b shows a folding step
  • Figure 1 shows a brushless permanent magnet electric machine.
  • This machine is represented without its hood.
  • the machine comprises a casing 1, in which is installed a rotor 2 in the housing axis, surrounded by a stator winding 3.
  • This winding is three-phase, that is to say that the windings define three phases.
  • the machine has 3 identical connectors 4, each installed on an output of the winding.
  • each connector is shaped around an insulating part 5.
  • An electrical connector such as one of those shown in Figure 1 is, initially, a non-folded conductive metal part, as shown in Figure 6.
  • an unfolded connector is fixed on a phase output of the stator winding.
  • a fixing element 43 is crimped onto a phase output, for example comprising three wires, in order to establish a connection.
  • This crimping action is performed after the winding of the stator windings.
  • the connector is always in an unfolded state as shown in FIG. 6, and the flat portion 44 of the connector is situated in the axis of the casing 1, which appears in FIG. 1.
  • the plane portion 44 is then folded so as to form, as shown in FIGS. 2a and 2b, an upper portion 41 having a contacting surface 42, and a lower portion 45 that is not very visible on 2a, supporting the fixing element 43.
  • this folding is performed around an insulating part 5.
  • This piece for example injected plastic, prevents the upper portion 41 from coming into contact windings upon bending of the connector and isolates the contact of the housing.
  • the electrical machine comprises three connectors having three contacting surfaces on the surface of the stator winding. These three contacting surfaces are arranged so as to cooperate with three contactors 10 installed in a cover 11 as shown in FIG.
  • Figures 4 and 5 show this contacting: in Figure 4, the cover is shown in transparency , in order to allow the visualization of the contactors 10 and the connectors 4.
  • the cover 11 comprises sheaths 12, for passing electrical connections that will be connected on one side to the contactors 10, and the other to the system in which is installed the electric machine, for example a road vehicle.
  • one of the sheaths is arranged to receive the three power wires connected to the three contactors, and the other sheath is arranged to receive links used to carry out measurements, in particular thermal measurements or measurements of the position. solver. It should be noted that in FIG. 3, the power wires connecting the contactors 10 to the electrical harness are not shown.
  • the geometry of the electrical connectors allows their integration in a limited volume, thus ensuring good compactness to all.
  • the present invention allows the removal of a flexible multi-strand wire, thus decreasing the volume required for the connection.
  • only a crimping operation is necessary, which facilitates the connection and disconnection of the electric machine, and thus simplifies the maintenance of the electric machine.

Landscapes

  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Manufacture Of Motors, Generators (AREA)
  • Insulation, Fastening Of Motor, Generator Windings (AREA)
  • Motor Or Generator Frames (AREA)

Abstract

The invention relates to an electrical machine with permanent magnets comprising a housing containing a stator winding with at least two phase outputs, said electrical machine comprising at least one electrical connector fixed to each phase output of the winding, a cover comprising at least two contactors and connected to an electrical harness, each electrical connector having a contact surface intended to cooperate with a contact element, the machine being such that when the cover is installed on the housing, each contactor of the cover is in contact with a contact surface of an electrical connector and the electrical machine is connected to the electrical harness.

Description

Machine électrique avec connecteurs par contact Electric machine with contact connectors

DOMAINE DE L'INVENTION FIELD OF THE INVENTION

[0001] La présente invention concerne les machines électriques, notamment destinées à être installées dans des véhicules routiers.  The present invention relates to electrical machines, in particular intended to be installed in road vehicles.

[0002] La présente invention concerne notamment les machines électriques à bobinage statorique. Cette invention trouve, par exemple, un exemple d'application à aimants permanents dans les machines électriques sans balais. The present invention relates in particular to electrical stator winding machines. This invention finds, for example, an example of application to permanent magnets in brushless electric machines.

[0003] Une machine électrique est une machine permettant la conversion entre énergie électrique et énergie mécanique. Cette conversion peut se faire dans les deux sens, selon que la machine fonctionne en générateur ou en moteur. Il existe différents types de machines, que ce soit des machines à courant continu ou des machines à courant alternatif, au sein desquelles on trouve des machines synchrones ou asynchrones. Pour effectuer cette conversion, une machine électrique comprend généralement une partie fixe, nommée stator, et une partie mobile en rotation, nommée rotor.  An electric machine is a machine for converting between electrical energy and mechanical energy. This conversion can be done in both directions, depending on whether the machine operates as a generator or motor. There are different types of machines, whether DC machines or AC machines, in which there are synchronous or asynchronous machines. To perform this conversion, an electrical machine generally comprises a fixed part, called stator, and a rotatable part, called rotor.

[0004] Les machines électriques peuvent être installées dans toutes sortes de systèmes, notamment dans un véhicule routier, et plus particulièrement dans une roue d'un véhicule routier. Dans une telle configuration particulière, un des enjeux de l'installation d'une machine électrique repose sur la connexion de la machine aux connexions externes, en l'occurrence un faisceau électrique du véhicule. Dans le cas d'une machine à aimants permanents sans balais, le branchement du côté de la machine électrique s'effectue au niveau du stator. Electrical machines can be installed in all kinds of systems, including a road vehicle, and more particularly in a wheel of a road vehicle. In such a particular configuration, one of the challenges of installing an electrical machine is based on the connection of the machine to external connections, in this case an electrical harness of the vehicle. In the case of a permanent magnet machine without brushes, the connection on the side of the electrical machine takes place at the stator.

[0005] On connaît, dans l'état de la technique, une machine électrique dans laquelle la liaison électrique avec les éléments extérieurs est assurée par le sertissage des conducteurs de bobinage à fil multibrins souple relié à une broche d'un connecteur trois broches, chaque broche correspondant aux trois phases du bobinage.  It is known in the state of the art, an electrical machine in which the electrical connection with the outer elements is provided by the crimping of the flexible wire winding conductors connected to a pin of a three-pin connector, each pin corresponding to the three phases of the winding.

[0006] Ce sertissage est noyé dans une résine d'enrobage, le plus près possible des surfaces refroidies de la machine électrique, afin d'assurer un bon comportement thermique de l'ensemble. A l'autre extrémité du fil multibrins souple, il convient d'effectuer un deuxième sertissage, avec de fixer un contact du connecteur. This crimp is embedded in a coating resin, as close as possible to the cooled surfaces of the electric machine, to ensure good thermal behavior of the assembly. At the other end of the flexible multi-strand wire, it is necessary to perform a second crimping, with fixing a contact of the connector.

[0007] On constate ainsi que l'installation d'une machine électrique connectée de cette façon est relativement complexe. En effet, elle nécessite deux sertissages, chacun pour les trois phases du stator, ce qui signifie que six opérations de sertissage doivent être effectuées.  It is thus found that the installation of an electrical machine connected in this way is relatively complex. Indeed, it requires two crimps, each for the three phases of the stator, which means that six crimping operations must be performed.

FEU I LLE DE REM PLACEM ENT (RÈG LE 26) [0008] Par ailleurs, une telle installation peut poser des problèmes de fiabilité en cas de démontage ultérieur de la machine. En effet, lors d'un démontage, soit on décide de laisser le fil multibrins en place, et dans ce cas il convient d'être très précautionneux pour éviter tout endommagement, soit on décide de désolidariser le fil multibrins du côté connecteur, auquel cas il faut procéder ultérieurement à une nouvelle opération de sertissage lors du remontage. FIRE I LLE OF REM PLACEM ENT (RULE 26) Moreover, such an installation can cause reliability problems in case of subsequent disassembly of the machine. Indeed, during disassembly, it is decided to leave the multi-strand wire in place, and in this case it is necessary to be very cautious to avoid any damage, or it is decided to separate the multi-strand wire connector side, in which case a new crimping operation must be carried out subsequently during reassembly.

BREVE DESCRIPTION DE L'INVENTION BRIEF DESCRIPTION OF THE INVENTION

[0009] La présente invention vise donc à proposer une machine électrique ne présentant pas ces inconvénients. The present invention is therefore to provide an electric machine does not have these disadvantages.

[0010] De manière plus précise, la présente invention vise à proposer une machine électrique telle que le démontage soit relativement aisé, et qu'elle puisse s'adapter à différentes applications sans nécessiter d'adaptations particulières.  More specifically, the present invention aims to provide an electric machine such that disassembly is relatively easy, and it can adapt to different applications without requiring special adaptations.

[0011] Ainsi, la présente invention concerne une machine électrique à aimants permanents comportant un carter abritant un bobinage stator à au moins deux sorties de phase, ladite machine électrique comportant  Thus, the present invention relates to an electric machine with permanent magnets comprising a housing housing a stator winding at least two phase outputs, said electrical machine comprising

au moins un connecteur électrique fixé sur chaque sortie de phase du bobinage, un capot comportant au moins deux contacteurs et relié à un faisceau électrique, chaque connecteur électrique présentant une surface de contact destinée à coopérer avec un élément de contact,  at least one electrical connector fixed on each phase output of the winding, a cover comprising at least two contactors and connected to an electric harness, each electrical connector having a contact surface intended to cooperate with a contact element,

la machine étant telle que lorsque le capot est installé sur le carter, chaque contacteur du capot est en contact avec une surface de contact d'un connecteur électrique et la machine électrique est reliée au faisceau électrique.  the machine being such that when the cover is installed on the housing, each contactor of the cover is in contact with a contact surface of an electrical connector and the electrical machine is connected to the harness.

[0012] Par souci de clarification, on utilise dans la présente description deux termes différents, contacteur et connecteur, pour désigner des éléments distincts mais de même nature, à savoir des contacts, ou contacteurs, électriques.  For the sake of clarification, the present description uses two different terms, contactor and connector, to designate separate elements but of the same nature, namely contacts, or contactors, electrical.

[0013] Une machine selon l'invention présente l'avantage de nécessiter une seule étape de fixation de connecteurs électriques sur les sorties de phase. En effet, la deuxième étape de sertissage décrite dans l'état de la technique n'est plus nécessaire, puisque la connexion électrique de la machine est effectuée par une simple mise en contact d'un contacteur du capot avec une surface de mise en contact d'un connecteur électrique installé sur une sortie de phase du bobinage. [0014] Par ailleurs, cette connexion par simple mise en contact permet une meilleure adaptabilité du capot et de la machine électrique. Ainsi, il est possible de modifier l'un des éléments sans avoir à modifier l'autre, tant que la géométrie des points de contact reste la même. Une telle solution permet donc d'économiser des coûts en ne nécessitant pas de fabriquer spécifiquement des machines pour chaque application. A machine according to the invention has the advantage of requiring a single step of fixing electrical connectors on the phase outputs. Indeed, the second crimping step described in the state of the art is no longer necessary, since the electrical connection of the machine is performed by a simple contact of a bonnet contactor with a contacting surface an electrical connector installed on a phase output of the winding. Moreover, this connection by simple contact allows a better adaptability of the cover and the electric machine. Thus, it is possible to modify one of the elements without having to modify the other, as long as the geometry of the contact points remains the same. Such a solution therefore saves costs by not requiring specifically to manufacture machines for each application.

[0015] Par ailleurs, une machine selon l'invention permet un démontage et un accès aisé aux différents éléments. Une telle caractéristique est particulièrement intéressante dans le cas où une machine électrique est installée sur une roue, car le passage de roue est un endroit particulièrement difficile d'accès.  Furthermore, a machine according to the invention allows disassembly and easy access to the various elements. Such a feature is particularly interesting in the case where an electric machine is installed on a wheel, because the wheel arch is a particularly difficult to access.

[0016] La fixation du connecteur électrique à une sortie de phase du bobinage est comprise dans le groupe comprenant : un sertissage, une soudure, un pinçage des fils par une vis. The attachment of the electrical connector to a phase output of the winding is included in the group comprising: crimping, welding, pinching son by a screw.

[0017] Dans une réalisation particulière de l'invention, chaque connecteur électrique comprend :  In a particular embodiment of the invention, each electrical connector comprises:

- une partie inférieure supportant un élément de fixation au bobinage (qui peut être rapportée), et  a lower part supporting a fastening element to the winding (which can be attached), and

une partie supérieure supportant la surface de contact,  an upper part supporting the contact surface,

la partie inférieure et supérieure formant un angle sensiblement égal à 90°, et la partie inférieure, la partie supérieure, l'élément de fixation et la surface de contact formant une unique pièce mécanique.  the lower and upper part forming an angle substantially equal to 90 °, and the lower part, the upper part, the fixing element and the contact surface forming a single mechanical part.

Le connecteur électrique est formé dans un matériau métallique conducteur, par exemple du cuivre.  The electrical connector is formed of a conductive metallic material, for example copper.

[0018] De manière préférentielle, la machine comprend en outre au moins une pièce isolante coopérant avec chaque connecteur électrique afin d'empêcher tout contact de la partie supérieure du connecteur électrique avec le bobinage ou la carcasse de la machine. Cette pièce est, par exemple, en plastique injecté.  Preferably, the machine further comprises at least one insulating part cooperating with each electrical connector to prevent contact of the upper part of the electrical connector with the winding or the carcass of the machine. This piece is, for example, injected plastic.

[0019] L'invention concerne également un procédé de fabrication d'une machine électrique, comprenant les étapes suivantes :  The invention also relates to a method of manufacturing an electric machine, comprising the following steps:

on fixe, sur chaque sortie de phase d'un bobinage statorique, un connecteur électrique, comportant une partie plane s'étendant dans l'axe de la machine électrique et supportant l'élément de fixation au bobinage,  at each phase output of a stator winding, an electrical connector is fixed, comprising a plane part extending in the axis of the electrical machine and supporting the fixing element to the winding,

on installe le bobinage dans un fourreau et on conforme les chinions, on procède au pliage de la partie plane du connecteur, de manière à former une partie inférieure du connecteur supportant l'élément de fixation, et une partie supérieure du connecteur présentant une surface de contact. we install the winding in a sheath and we conform the chinions, the flat portion of the connector is folded so as to form a lower part of the connector supporting the fixing element, and an upper part of the connector having a contact surface.

[0020] Le positionnement du connecteur électrique et son pliage tardif permettent de ne pas gêner la conformation des chinions, nécessaire dans le cadre de la fabrication d'une machine électrique.  The positioning of the electrical connector and its late folding can not interfere with the conformation of the chinions, necessary in the context of the manufacture of an electric machine.

[0021] Dans une réalisation particulière de l'invention, à l'issue de l'étape de pliage, la partie inférieure et la partie supérieure du connecteur forment un angle sensiblement égal à 90°.  In a particular embodiment of the invention, at the end of the folding step, the lower portion and the upper portion of the connector form an angle substantially equal to 90 °.

[0022] Par ailleurs, dans une autre réalisation de l'invention, le procédé comprend l'étape, avant ou après le pliage du connecteur, d'enrober les bobinages et les chinions par une résine d'imprégnation. Dans ce cas, la partie inférieure du connecteur est elle aussi noyée dans une résine d'enrobage.  Furthermore, in another embodiment of the invention, the method comprises the step, before or after the bending of the connector, to coat the coils and chinions with an impregnating resin. In this case, the lower part of the connector is also embedded in a coating resin.

[0023] En outre, dans une autre réalisation de l'invention, le procédé comprend l'étape finale d'installer un capot comprenant trois éléments de contact destinés à être mis en contact respectivement avec chaque surface de contact d'un connecteur électrique. On constate ainsi que l'invention propose un procédé de fabrication relativement simple, puisque la connexion finale de la machine électrique est effectuée par une simple mise en contact d'un capot avec des éléments installés au préalable.  In addition, in another embodiment of the invention, the method comprises the final step of installing a cover comprising three contact elements intended to be in contact respectively with each contact surface of an electrical connector. It can thus be seen that the invention proposes a relatively simple manufacturing method, since the final connection of the electric machine is carried out simply by placing a cover in contact with elements previously installed.

[0024] Dans un exemple particulier de l'invention, l'étape de fixation d'un connecteur électrique sur une phase du bobinage est comprise dans le groupe comprenant : une étape de sertissage, une étape de soudure, une étape de pinçage des fils par une vis.  In a particular example of the invention, the step of fixing an electrical connector on a winding phase is comprised in the group comprising: a crimping step, a soldering step, a pinching step of the wires by a screw.

[0025] Dans une autre réalisation enfin, le procédé comprend, préalablement à l'étape de pliage, l'étape de placer une pièce de conformation destinée à isoler la partie supérieure du connecteur du bobinage et de la carcasse de la machine électrique.  In another embodiment, the method comprises, prior to the folding step, the step of placing a conformation piece for isolating the upper part of the winding connector and the carcass of the electric machine.

BREVE DESCRIPTION DES FIGURES BRIEF DESCRIPTION OF THE FIGURES

[0026] D'autres objectifs et avantages de l'invention apparaîtront clairement dans la description qui va suivre d'un mode de réalisation préféré mais non limitatif, illustré par les figures suivantes dans lesquelles : Other objects and advantages of the invention will become apparent from the following description of a preferred but nonlimiting embodiment, illustrated by the following figures in which:

• la figure 1 représente une vue d'une machine électrique comportant trois connecteurs électriques sans le capot, • les figures 2a et 2b montrent deux vues d'un connecteur électrique installé sur une phase d'un bobinage, FIG. 1 represents a view of an electrical machine comprising three electrical connectors without the cover, FIGS. 2a and 2b show two views of an electrical connector installed on a phase of a winding,

• la figure 3 représente un exemple de capot,  FIG. 3 represents an example of a hood,

• la figure 4 représente une vue extérieure d'une machine électrique comportant un capot montré en transparence, FIG. 4 represents an external view of an electric machine comprising a cover shown in transparency,

• la figure 5 représente une vue en coupe d'une machine électrique et son capot, et FIG. 5 represents a sectional view of an electric machine and its cover, and

• la figure 6a représente un connecteur électrique avant pliage, et la figure 6b montre une étape du pliage. • Figure 6a shows an electrical connector before folding, and Figure 6b shows a folding step.

DESCRIPTION DU MEILLEUR MODE DE REALISATION DE L'INVENTION DESCRIPTION OF THE BEST MODE OF CARRYING OUT THE INVENTION

[0027] Dans la description des figures, des éléments identiques d'une figure à l'autre porteront la même référence. In the description of the figures, identical elements from one figure to another will bear the same reference.

[0028] La figure 1 montre une machine électrique à aimants permanents sans balais. Cette machine est représentée sans son capot. La machine comporte un carter 1, dans lequel est installé un rotor 2 dans l'axe du carter, entouré par un bobinage statorique 3. Ce bobinage est triphasé, c'est-à-dire que les enroulements définissent trois phases. Sur l'exemple de la figure 1, la machine comporte 3 connecteurs identiques 4, installé chacun sur une sortie du bobinage. En outre, chaque connecteur est conformé autour d'une pièce isolante 5. [0028] Figure 1 shows a brushless permanent magnet electric machine. This machine is represented without its hood. The machine comprises a casing 1, in which is installed a rotor 2 in the housing axis, surrounded by a stator winding 3. This winding is three-phase, that is to say that the windings define three phases. In the example of Figure 1, the machine has 3 identical connectors 4, each installed on an output of the winding. In addition, each connector is shaped around an insulating part 5.

[0029] Un connecteur électrique tel qu'un de ceux représenté sur la figure 1 est, initialement, une pièce métallique conductrice non pliée, telle que montrée sur la figure 6. Lors de la fabrication de la machine électrique, un connecteur non plié est fixé sur une sortie de phase du bobinage statorique. A cet effet, un élément de fixation 43 est serti sur une sortie de phase, comportant par exemple trois fils, afin d'établir une connexion.  An electrical connector such as one of those shown in Figure 1 is, initially, a non-folded conductive metal part, as shown in Figure 6. During the manufacture of the electrical machine, an unfolded connector is fixed on a phase output of the stator winding. For this purpose, a fixing element 43 is crimped onto a phase output, for example comprising three wires, in order to establish a connection.

[0030] Cette action de sertissage est effectuée après l'enroulement des bobinages statoriques. A ce stade, le connecteur est toujours dans un état déplié tel que montré sur la figure 6, et la partie plane 44 du connecteur est situé dans l'axe du carter 1, qui apparaît sur la figure 1. Ceci permet de ne pas gêner l'étape suivante, qui consiste à conformer les chinions. Selon les réalisations, il est également possible, à ce stade du procédé de fabrication, d'enrober les bobinages et les chinions dans une résine d'imprégnation. [0031] On procède ensuite au pliage de la partie plane 44 de manière à former, ainsi que montré sur les figures 2a et 2b, une partie supérieure 41 comportant une surface de mise en contact 42, et une partie inférieure 45, peu visible sur la figure 2a, supportant l'élément de fixation 43. De manière préférentielle, ce pliage est effectué autour d'une pièce isolante 5. Cette pièce, par exemple en plastique injecté, permet d'éviter que la partie supérieure 41 ne vienne au contact des bobinages lors sur pliage du connecteur et isole le contact du carter. This crimping action is performed after the winding of the stator windings. At this stage, the connector is always in an unfolded state as shown in FIG. 6, and the flat portion 44 of the connector is situated in the axis of the casing 1, which appears in FIG. 1. This makes it possible not to interfere the next step, which is to conform the chinions. According to the embodiments, it is also possible, at this stage of the manufacturing process, to coat the coils and the chinions in an impregnating resin. The plane portion 44 is then folded so as to form, as shown in FIGS. 2a and 2b, an upper portion 41 having a contacting surface 42, and a lower portion 45 that is not very visible on 2a, supporting the fixing element 43. Preferably, this folding is performed around an insulating part 5. This piece, for example injected plastic, prevents the upper portion 41 from coming into contact windings upon bending of the connector and isolates the contact of the housing.

[0032] Ainsi, après installation des trois connecteurs et pliage comme précédemment décrit, la machine électrique comporte trois connecteurs offrant trois surfaces de mise en contact à la surface du bobinage statorique. Ces trois surfaces de mise en contact sont agencées de manière à pouvoir coopérer avec trois contacteurs 10 installé dans un capot 11 tel que montré en figure 3.  Thus, after installation of the three connectors and folding as described above, the electrical machine comprises three connectors having three contacting surfaces on the surface of the stator winding. These three contacting surfaces are arranged so as to cooperate with three contactors 10 installed in a cover 11 as shown in FIG.

[0033] Lors de la mise en place du capot 11, les trois contacteurs 10 viennent au contact des surfaces de mise en contact 42. Les figures 4 et 5 montrent cette mise en contact : sur la figure 4, le capot est représenté en transparence, afin de permettre la visualisation des contacteurs 10 et des connecteurs 4.  During the introduction of the cover 11, the three contactors 10 come into contact with the contacting surfaces 42. Figures 4 and 5 show this contacting: in Figure 4, the cover is shown in transparency , in order to allow the visualization of the contactors 10 and the connectors 4.

[0034] Le capot 11 comprend des gaines 12, permettant de faire passer des connexions électriques qui seront reliées d'un côté aux contacteurs 10, et de l'autre au système dans lequel est installée la machine électrique, par exemple un véhicule routier. Ainsi, dans un exemple, une des gaines est agencée pour recevoir les trois fils de puissance reliés aux trois contacteurs, et l'autre gaine est agencée pour recevoir des liaisons utilisées pour effectuer des mesures, notamment des mesures thermiques ou des mesures de positionnement du résolveur. Il est à noter que, sur la figure 3, les fils de puissance reliant les contacteurs 10 au faisceau électrique ne sont pas représentés.  The cover 11 comprises sheaths 12, for passing electrical connections that will be connected on one side to the contactors 10, and the other to the system in which is installed the electric machine, for example a road vehicle. Thus, in one example, one of the sheaths is arranged to receive the three power wires connected to the three contactors, and the other sheath is arranged to receive links used to carry out measurements, in particular thermal measurements or measurements of the position. solver. It should be noted that in FIG. 3, the power wires connecting the contactors 10 to the electrical harness are not shown.

[0035] On constate ici plusieurs avantages d'une machine électrique selon l'invention. En effet, une telle machine permet tout d'abord de réaliser un seul type de stator, quel que soit le choix de connexion adopté. Par conséquent, une telle machine offre une solution économique par rapport aux solutions existantes.  Here we see several advantages of an electric machine according to the invention. Indeed, such a machine makes it possible first of all to make a single type of stator, whatever the choice of connection adopted. Therefore, such a machine offers an economical solution compared to existing solutions.

[0036] En outre, la géométrie des connecteurs électriques permet leur intégration dans un volume limité, garantissant ainsi une bonne compacité à l'ensemble. En effet, la présente invention permet la suppression d'un fil multibrins souple, diminuant ainsi le volume nécessaire pour la connexion. Par ailleurs, seule une opération de sertissage est nécessaire, ce qui permet de faciliter la connexion et la déconnexion de la machine électrique, et donc de simplifier la maintenance de la machine électrique.  In addition, the geometry of the electrical connectors allows their integration in a limited volume, thus ensuring good compactness to all. Indeed, the present invention allows the removal of a flexible multi-strand wire, thus decreasing the volume required for the connection. Furthermore, only a crimping operation is necessary, which facilitates the connection and disconnection of the electric machine, and thus simplifies the maintenance of the electric machine.

Claims

REVENDICATIONS 1. Machine électrique à aimants permanents comportant un carter abritant un bobinage stator à au moins deux sorties de phase, ladite machine électrique comportant 1. Permanent magnet electric machine comprising a casing housing a stator winding with at least two phase outputs, said electric machine comprising au moins un connecteur électrique fixé sur chaque sortie de phase du bobinage, un capot comportant au moins deux contacteurs et relié à un faisceau électrique, chaque connecteur électrique présentant une surface de contact destinée à coopérer avec un élément de contact,  at least one electrical connector fixed on each phase output of the winding, a cover comprising at least two contactors and connected to an electric harness, each electrical connector having a contact surface intended to cooperate with a contact element, la machine étant telle que lorsque le capot est installé sur le carter, chaque contacteur du capot est en contact avec une surface de contact d'un connecteur électrique et la machine électrique est reliée au faisceau électrique.  the machine being such that when the cover is installed on the housing, each contactor of the cover is in contact with a contact surface of an electrical connector and the electrical machine is connected to the harness. Machine électrique selon la revendication 1, dans laquelle chaque connecteur électrique comprend : An electrical machine according to claim 1, wherein each electrical connector comprises: une partie inférieure supportant un élément de fixation au bobinage, et  a lower part supporting a fastening element to the winding, and une partie supérieure supportant la surface de contact,  an upper part supporting the contact surface, la partie inférieure et supérieure formant un angle sensiblement égal à 90°, et  the lower and upper part forming an angle substantially equal to 90 °, and la partie inférieure, la partie supérieure, l'élément de fixation et la surface de contact formant une unique pièce mécanique.  the lower part, the upper part, the fixing element and the contact surface forming a single mechanical part. Machine électrique selon la revendication 2, comprenant en outre au moins une pièce isolante coopérant avec chaque connecteur électrique afin d'empêcher tout contact de la partie supérieure du connecteur électrique avec le bobinage et le carter. An electrical machine according to claim 2, further comprising at least one insulating member cooperating with each electrical connector to prevent contact of the upper portion of the electrical connector with the winding and the housing. Machine électrique selon la revendication 3, dans laquelle la pièce isolante est une pièce en plastique injecté. An electrical machine according to claim 3, wherein the insulating member is an injected plastic part. Machine électrique selon l'une des revendications précédentes, dans laquelle la fixation du connecteur électrique à une sortie de phase du bobinage est comprise dans le groupe comprenant : un sertissage, une soudure, un pinçage des fils par une vis. Electrical machine according to one of the preceding claims, wherein the fixing of the electrical connector to a phase output of the winding is included in the group comprising: crimping, soldering, clamping son by a screw. 6. Machine électrique selon l'une des revendications précédentes, dans laquelle chaque connecteur électrique est en cuivre. 6. Electrical machine according to one of the preceding claims, wherein each electrical connector is copper. 7. Procédé de fabrication d'une machine électrique, comprenant les étapes suivantes : 7. A method of manufacturing an electric machine, comprising the following steps: on fixe, sur chaque sortie de phase d'un bobinage statorique, un connecteur électrique, comportant une partie plane s'étendant dans l'axe de la machine électrique et supportant l'élément de fixation au bobinage,  at each phase output of a stator winding, an electrical connector is fixed, comprising a plane part extending in the axis of the electrical machine and supporting the fixing element to the winding, on installe le bobinage dans un fourreau et on conforme les chinions,  we install the winding in a sheath and we conform the chinions, on procède au pliage de la partie plane du connecteur, de manière à former une partie inférieure du connecteur supportant l'élément de fixation, et une partie supérieure du connecteur présentant une surface de contact.  the flat portion of the connector is folded so as to form a lower part of the connector supporting the fixing element, and an upper part of the connector having a contact surface. 8. Procédé de fabrication selon la revendication 7, dans lequel à l'issue de l'étape de pliage, la partie inférieure et la partie supérieure du connecteur forment un angle sensiblement égal à 90°. 8. The manufacturing method according to claim 7, wherein at the end of the folding step, the lower part and the upper part of the connector form an angle substantially equal to 90 °. 9. Procédé de fabrication selon la revendication 7 ou 8, comprenant en outre l'étape, avant ou après le pliage du connecteur, d'enrober les bobinages et les chinions par une résine d'imprégnation. 9. The manufacturing method according to claim 7 or 8, further comprising the step, before or after folding the connector, to coat the coils and chinions with an impregnating resin. 10. Procédé de fabrication selon l'une des revendications7 à 9, comprenant l'étape finale d'installer un capot comprenant trois éléments de contact destinés à être mis en contact respectivement avec chaque surface de contact d'un connecteur électrique et du carter. 10. The manufacturing method according to one of claims7 to 9, comprising the final step of installing a cover comprising three contact elements intended to be respectively in contact with each contact surface of an electrical connector and the housing. 11. Procédé de fabrication selon l'une des revendications 7 à 10 dans laquelle l'étape de fixation d'un connecteur électrique sur une phase du bobinage est comprise dans le groupe comprenant : une étape de sertissage, une étape de soudure, une étape de pinçage des fils par une vis. 11. The manufacturing method according to one of claims 7 to 10 wherein the step of fixing an electrical connector on a winding phase is included in the group comprising: a crimping step, a welding step, a step pinching the wires with a screw. 12. Procédé de fabrication selon l'une des revendications 7 à 11, comprenant l'étape, préalablement à l'étape de pliage, de placer une pièce de conformation destinée à isoler la partie supérieure du connecteur du bobinage de la machine électrique. 12. The manufacturing method according to one of claims 7 to 11, comprising the step, prior to the folding step, to place a shaping piece for isolating the upper part of the winding connector of the electric machine.
EP12797912.8A 2011-12-09 2012-12-06 Electrical machine with contact connectors Withdrawn EP2789077A1 (en)

Applications Claiming Priority (2)

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FR1161417A FR2984036B1 (en) 2011-12-09 2011-12-09 ELECTRICAL MACHINE WITH CONTACT CONNECTORS
PCT/EP2012/074631 WO2013083688A1 (en) 2011-12-09 2012-12-06 Electrical machine with contact connectors

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CN103975512A (en) 2014-08-06
CN103975512B (en) 2016-08-31
JP2015501125A (en) 2015-01-08
FR2984036B1 (en) 2014-08-08
US20140354086A1 (en) 2014-12-04
WO2013083688A1 (en) 2013-06-13

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