WO2010043321A2 - Stator of an electric machine and method for manufacturing a winding for a stator of an electric machine - Google Patents
Stator of an electric machine and method for manufacturing a winding for a stator of an electric machine Download PDFInfo
- Publication number
- WO2010043321A2 WO2010043321A2 PCT/EP2009/007161 EP2009007161W WO2010043321A2 WO 2010043321 A2 WO2010043321 A2 WO 2010043321A2 EP 2009007161 W EP2009007161 W EP 2009007161W WO 2010043321 A2 WO2010043321 A2 WO 2010043321A2
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- slots
- stator
- wire segments
- hairpin
- interconnected
- Prior art date
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Classifications
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
- H02K3/28—Layout of windings or of connections between windings
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
- H02K3/12—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors arranged in slots
Definitions
- the invention refers to a stator for an electric machine and to a method for manufacturing a winding for such a stator.
- Electric machines are key automotive components. Electric machines may be utilized as starting motors, as alternators driven by an engine to generate electricity and as electric drive motors in modern hybrid electric vehicles (HEVs).
- HEVs hybrid electric vehicles
- the efficiency of the electric machine is a major issue In hybrid electric vehicles and other applications. Since the electric machine has to be located 'under the hood' of the vehicle, Where space is limited, the size/dimensions of the electric machine must be as small as possible.
- Most electric machines include a stator formed from a lamination stack.
- Axial slots are formed in the stator in a circular arrangement around the stator with openings at the axial ends of the slots.
- a plurality of electric conductors typically in the form of copper wires, is positioned in the slots of the stator.
- slot-fill-ratio is typically defined as the ratio of the aggregate cross-sectional area of the bare copper conductors in a slot to the cross-sectional area of the slot itself.
- SFR slot-fill-ratio
- the large cross-sectional area of the copper wires helps reduce the phase resistance and consequently the resistance of the windings (i.e., power loss) for a given slot size, so that the efficiency of the machine is improved. Accordingly, more efficient electric machines can be built at a smaller size than in the past.
- Armature windings of most small and mid-sized electric machines are typically wound In many turns with single or multiple strands of round conductor wires.
- the SFR of the round wire machines can reach a maximum of 44% preventing the design of low loss (resistance), high efficiency electric machines. As discussed previously, this issue becomes even more critical when designing high efficiency machines for hybrid vehicles. Available space onboard hybrid vehicles is strictly limited, and therefore, boosting efficiency by increasing machine size becomes impractical.
- US 6,894,417 discloses an electric machine having multi-set rectangular copper hairpin windings.
- the electric machine comprises a stator having a plurality of partially closed stator slots.
- a first winding set and a second winding set are positioned in the stator slots.
- the first winding set and the second winding set are connected by adjacent leg ends.
- conductor layers in alternate slots alternate between different phases.
- the conductor layers in the remaining slots are all of the same phase.
- Hairpins having unequal length legs are used to implement the first embodiment.
- conductor layers tn atternate stots inctude one phase for the first winding set and another phase for the second winding set.
- the conductor layers in the remaining slots are all of the same phase.
- Hairpins having equal length legs are used to implement the second embodiment.
- a method for manufacturing a winding for a stator of an electric machine comprises the steps of inserting a multitude of wire segments having a rectangular cross-section into a multitude of slots arranged around the stator. Ends of the wire segments protruding from the slots are interconnected in a so called winding head.
- the wire segments are interconnected in a mixed lap and wave style, i.e. pairs of hairpin coils shaped from the wire segments are located in the same two of the slots in different layers and interconnected on one respective end of each hairpin coil in order to form a lap part.
- the respective other end of the hairpin coil is connected to a respective end of one hairpin coil of another pair located in two other slots In order to form a non-interlaced wave part.
- a Stator for an electric machine exhibits a multitude of slots arranged around the stator.
- a multitude of wire segments having a rectangular cross- section Is arranged in the slots. Ends of the wire segments protruding from the slots are interconnected in a winding head.
- the wire segments are interconnected in a mixed lap and wave style in such a manner that pairs of hairpin coils shaped from the wire segments are located in the same two of the slots in different layers and interconnected on one respective end of each hairpin coil thus forming a lap part.
- the respective other end of the hairpin coil is connected to a respective end of one hairpin coil of another pair located in two other slots thus forming a non-interlaced wave part.
- the wire head according to the invention may be more efficiently cooled because of the space between the wires, particularly when using active cooling technology.
- the reduced size of the winding head allows for more compact design of the electric machine so less space is required when arranging the electric machine in a vehicle. By combining lap and wave style more conductors or wire segments may be put in each slot so the size (cross-sectional area) of the conductors may be reduced.
- Coils shaped from the wire segments may be connected in series or in parallel so different winding turns and more flexible motor design may be achieved, i.e. electric machines with different size, power and torque requirements may be designed.
- the smaller conductor size cross-sectional area
- the wire segments have to be bent. Bending and twisting is easier and yields less risk of breaking the wire with smaller cross-sectional area. This makes the windings more reliable.
- the reduced cross-sectional area also yields a smaller skin effect which is particularly critical at high speed of the electric machine related to high current frequency. More jumpers, I.e. connections between two sets of windings may be needed with the inventive method and stator.
- the wire segments may be given a hairpin shape before insertion.
- all the hairpin coils may be inserted from one side into the slots.
- the hairpin coils may be shaped by interconnecting respective ends of two of the wire segments after Insertion into the slots.
- copper wire segments are used. Copper is a conductor with a very good electrical and heat conductivity. Thus the performance of the electric machine and heat dissipation may be improved.
- the ends of the wire segments may be interconnected by welding since welding is a very reliable connection technique.
- At least two sets of windings may be arranged in the stator in different layers of the slots.
- the stator may be applied in an electric machine for automotive use, particularly for a hybrid electric vehicle or a purely electric car.
- Fig. 1 is a schematic of a winding set in a stator
- Fig. 2 is a schematic of a second winding set in the stator of Fig. 1 .
- Fig. 3 is a schematic of a hairpin shaped coil.
- FIG. 1 a schematic of a stator 1 for an electric machine is shown.
- a multitude of slots 2.1 to 2.13 are provided for holding hairpin coils 3.1 to 3.4 shaped from wire segments.
- the slots 2.1 to 2.13 are arranged around the stator 1.
- the hairpin coils 3.1 to 3.4 are made from copper wire segments having a rectangular cross-section.
- One side of the hairpin coil 3.1 is put in slot 2.4, layer A, another side of the hairpin coil 3.1 is put in slot 2.10, layer B.
- Hairpin coil 3.2 is arranged in slot 2.4, layer C and slot 2.10, layer D.
- the ends of hairpin coils 3.1 and 3.2 from slot 2.4, layer C and slot 2.10, layer B are bent towards each other and interconnected, e.g. by welding thus a lap part of a winding set is formed.
- the other ends of hairpin coils 3.1 and 3.2 from slot 2.4, layer A and slot 2.10, layer D are bent outwards and connected to other hairpin coils, e.g. 3.5 thus forming a wave part of the winding set.
- Hairpin coils 3.3 and 3.4 are connected in the same way in slots 2.5 and 2.11. Thus the first winding set is formed.
- Figure 2 shows schematically a second winding set in the same stator 1 formed by hairpin coils 3.6 to 3.9 arranged in the same slots on top of the first winding set in layers E, F, G and H in the same manner as the first winding set.
- the winding sets may be interconnected.
- Figure 3 shows a hairpin coil 3.1 shaped from a wire segment with a rectangular cross- section.
- the wire segment may be given the hairpin shape shown before insertion into the slots 2.1 to 2.n although the lower ends have to be bent after insertion.
- the hairpin coil 3.1 may be shaped by interconnecting respective upper ends of two of the wire segments after insertion into tha slots. The upper ends may be bent before insertion.
- the exemplified hairpin coils 3.1 to 3.9 are only a fraction of the total number of hairpin coils 3.1 to 3.n arranged In the stator 1.
- the interconnection of the ends may be achieved by welding.
- the stator 1 may be applied in an electric machine for automotive use.
- the number of slots 2.1 to 2.n inside the lap part or Inside the wave part may differ from what is shown in figures 1 and 2.
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- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Windings For Motors And Generators (AREA)
- Manufacture Of Motors, Generators (AREA)
Abstract
In a stator for an electric machine and a method for manufacturing a winding for a stator of an electric machine having a multitude of wire segments of rectangular cross-section inserted into a multitude of slots arranged around the stator, wherein ends of the wire segments protruding from the slots are interconnected in a winding head, the wire segments are interconnected in a mixed lap and wave style in such a manner that pairs of hairpin coils formed from the wire segments are located in the same two of the slots in different layers and interconnected on one respective end of each hairpin coil in so as to form a lap part, the respective other end of the hairpin coil being connected to a respective end of one hairpin coil of another pair disposed in two other slots in order to form a non-interlaced wave part.
Description
Stator of an electric machine and method for manufacturing a winding for a stator of an electric machine
Background of the invention
1. Field of the Invention
The invention refers to a stator for an electric machine and to a method for manufacturing a winding for such a stator.
2. Description of the Background Art
Electric machines are key automotive components. Electric machines may be utilized as starting motors, as alternators driven by an engine to generate electricity and as electric drive motors in modern hybrid electric vehicles (HEVs).
The efficiency of the electric machine is a major issue In hybrid electric vehicles and other applications. Since the electric machine has to be located 'under the hood' of the vehicle, Where space is limited, the size/dimensions of the electric machine must be as small as possible.
Most electric machines include a stator formed from a lamination stack. Axial slots are formed in the stator in a circular arrangement around the stator with openings at the axial ends of the slots. A plurality of electric conductors, typically in the form of copper wires, is positioned in the slots of the stator.
One approach for reducing the size of the electric machine while maintaining or increasing efficiency is to increase the slot-fill-ratio of the electric machine. The term "slot- fill-ratio" (= SFR) is typically defined as the ratio of the aggregate cross-sectional area of the bare copper conductors in a slot to the cross-sectional area of the slot itself. With high SFR, the large cross-sectional area of the copper wires helps reduce the phase
resistance and consequently the resistance of the windings (i.e., power loss) for a given slot size, so that the efficiency of the machine is improved. Accordingly, more efficient electric machines can be built at a smaller size than in the past. Armature windings of most small and mid-sized electric machines are typically wound In many turns with single or multiple strands of round conductor wires. The SFR of the round wire machines can reach a maximum of 44% preventing the design of low loss (resistance), high efficiency electric machines. As discussed previously, this issue becomes even more critical when designing high efficiency machines for hybrid vehicles. Available space onboard hybrid vehicles is strictly limited, and therefore, boosting efficiency by increasing machine size becomes impractical.
One solution to increasing the SFR is to use rectangular wires in the stator slots in place of round wires. Use of rectangular wires in the stator slots can increase the slot-fill-ratio up to 70% over that of round wires, allowing the SFR of rectangular wire machines to reach near 75% or more.
US 6,894,417 discloses an electric machine having multi-set rectangular copper hairpin windings. The electric machine comprises a stator having a plurality of partially closed stator slots. A first winding set and a second winding set are positioned in the stator slots. The first winding set and the second winding set are connected by adjacent leg ends. According to a first embodiment, conductor layers in alternate slots alternate between different phases. The conductor layers in the remaining slots are all of the same phase. Hairpins having unequal length legs are used to implement the first embodiment. According to a second embodiment, conductor layers tn atternate stots inctude one phase for the first winding set and another phase for the second winding set. The conductor layers in the remaining slots are all of the same phase. Hairpins having equal length legs are used to implement the second embodiment.
Summary of the invention
It is an object of the present invention to provide an improved stator for an electric machine and an improved method for manufacturing a winding for such a stator,
A method for manufacturing a winding for a stator of an electric machine according to the invention comprises the steps of inserting a multitude of wire segments having a rectangular cross-section into a multitude of slots arranged around the stator. Ends of the wire segments protruding from the slots are interconnected in a so called winding head.
The wire segments are interconnected in a mixed lap and wave style, i.e. pairs of hairpin coils shaped from the wire segments are located in the same two of the slots in different layers and interconnected on one respective end of each hairpin coil in order to form a lap part. The respective other end of the hairpin coil is connected to a respective end of one hairpin coil of another pair located in two other slots In order to form a non-interlaced wave part.
A Stator for an electric machine according to the invention exhibits a multitude of slots arranged around the stator. A multitude of wire segments having a rectangular cross- section Is arranged in the slots. Ends of the wire segments protruding from the slots are interconnected in a winding head. The wire segments are interconnected in a mixed lap and wave style in such a manner that pairs of hairpin coils shaped from the wire segments are located in the same two of the slots in different layers and interconnected on one respective end of each hairpin coil thus forming a lap part. The respective other end of the hairpin coil is connected to a respective end of one hairpin coil of another pair located in two other slots thus forming a non-interlaced wave part.
Because of the better slot-fill-ratio of rectangular wires a smaller number of wire segments is needed compared to round wires. This allows for more space between the wire ends (n the winding head compared to round wires, where a huge number of wire ends are crowded in the winding head thus increasing its size while virtually not leaving any gaps between the wires. The wire head according to the invention may be more efficiently cooled because of the space between the wires, particularly when using active cooling technology. The reduced size of the winding head allows for more compact design of the electric machine so less space is required when arranging the electric machine in a vehicle. By combining lap and wave style more conductors or wire segments may be put in each slot so the size (cross-sectional area) of the conductors may be reduced. Coils shaped from the wire segments may be connected in series or in parallel so different winding turns and more flexible motor design may be achieved, i.e. electric machines with different size, power and torque requirements may be designed. The smaller conductor size (cross-sectional area) allows for using less energy when Interconnecting the wire ends, particularly by welding. Less energy means less heat thus the risk of damaging the wire insulation is reduced. In order to form the winding heads the wire segments have to be bent. Bending and twisting is easier and yields less risk of breaking the wire with smaller cross-sectional area. This makes the windings more
reliable. The reduced cross-sectional area also yields a smaller skin effect which is particularly critical at high speed of the electric machine related to high current frequency. More jumpers, I.e. connections between two sets of windings may be needed with the inventive method and stator.
In an advantageous embodiment the wire segments may be given a hairpin shape before insertion. Thus all the hairpin coils may be inserted from one side into the slots.
In another embodiment the hairpin coils may be shaped by interconnecting respective ends of two of the wire segments after Insertion into the slots.
In one embodiment of the invention copper wire segments are used. Copper is a conductor with a very good electrical and heat conductivity. Thus the performance of the electric machine and heat dissipation may be improved.
The ends of the wire segments may be interconnected by welding since welding is a very reliable connection technique.
In another embodiment of the Invention at least two sets of windings may be arranged in the stator in different layers of the slots.
The stator may be applied in an electric machine for automotive use, particularly for a hybrid electric vehicle or a purely electric car.
All features of the dependent claims may be combined.
Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of (he invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
The present invention will become more readily apparent from the detailed description given herein below with reference to the accompanying drawings which represent exemplary embodiments, and thus, do not limit the present invention.
Brief description of the drawings
Fig. 1 is a schematic of a winding set in a stator,
Fig. 2 is a schematic of a second winding set in the stator of Fig. 1 , and
Fig. 3 is a schematic of a hairpin shaped coil.
Description of preferred embodiments
In Figure 1 a schematic of a stator 1 for an electric machine is shown. In the stator 1 a multitude of slots 2.1 to 2.13 are provided for holding hairpin coils 3.1 to 3.4 shaped from wire segments. The slots 2.1 to 2.13 are arranged around the stator 1. In order to make the schematic more comprehensible the stator 1 is shown unrolled. More or less slots 2.1 to 2.n may be arranged in the stator 1 than shown in the figure. The hairpin coils 3.1 to 3.4 are made from copper wire segments having a rectangular cross-section. One side of the hairpin coil 3.1 is put in slot 2.4, layer A, another side of the hairpin coil 3.1 is put in slot 2.10, layer B. Hairpin coil 3.2 is arranged in slot 2.4, layer C and slot 2.10, layer D. The ends of hairpin coils 3.1 and 3.2 from slot 2.4, layer C and slot 2.10, layer B are bent towards each other and interconnected, e.g. by welding thus a lap part of a winding set is formed. The other ends of hairpin coils 3.1 and 3.2 from slot 2.4, layer A and slot 2.10, layer D are bent outwards and connected to other hairpin coils, e.g. 3.5 thus forming a wave part of the winding set. Hairpin coils 3.3 and 3.4 are connected in the same way in slots 2.5 and 2.11. Thus the first winding set is formed.
Figure 2 shows schematically a second winding set in the same stator 1 formed by hairpin coils 3.6 to 3.9 arranged in the same slots on top of the first winding set in layers E, F, G and H in the same manner as the first winding set. The winding sets may be interconnected.
Figure 3 shows a hairpin coil 3.1 shaped from a wire segment with a rectangular cross- section. The wire segment may be given the hairpin shape shown before insertion into the slots 2.1 to 2.n although the lower ends have to be bent after insertion. In another embodiment the hairpin coil 3.1 may be shaped by interconnecting respective upper ends of two of the wire segments after insertion into tha slots. The upper ends may be bent before insertion.
The exemplified hairpin coils 3.1 to 3.9 are only a fraction of the total number of hairpin coils 3.1 to 3.n arranged In the stator 1.
The interconnection of the ends may be achieved by welding.
The stator 1 may be applied in an electric machine for automotive use.
The number of slots 2.1 to 2.n inside the lap part or Inside the wave part may differ from what is shown in figures 1 and 2.
Claims
1. A method for manufacturing a winding for a stator of an electric machine comprising the steps of inserting a multitude of wire segments having a rectangular cross- section into a multitude of slots arranged around the stator and interconnecting ends of the wire segments protruding from the slots In a winding head in a mixed lap and wave style in such a way that pairs of hairpin coils shaped from the wire segments are located in the same two of the slots in different layers and interconnected on one respective end of each hairpin coil In order to form a lap part wherein the respective other end of the hairpin coil Is connected to a respective end of one hairpin coil of another pair located in two other slots in order to form a noninterlaced wave part.
2. The method according to claim 1, wherein the wire segments are given a hairpin shape before insertion.
3. The method according to claim 1 , wherein the hairpin coils are shaped by Interconnecting respective ends of the wire segments after Insertion into the slots.
4. The method according to claim 1 , wherein copper wire segments are used.
5. The method according to claim 1. wherein the ends of the wire segments are interconnected by welding.
6. The method according to claim 1, wherein at least two sets of windings are arranged in the stator in different layers of the slots.
7. A stator for an electric machine having a multitude of slots arranged around the stator, including a multitude of wire segments having a rectangular cross-section arranged in the slots and with ends of the wire segments protruding from the slots being interconnected in a winding head, the wire segments being interconnected in a mixed lap and wave style in such a way that pairs of hairpin coils formed from the wire segments are located in the same two of the slots in different layers and interconnected on one respective end of each hairpin coil so as to form a lap part wherein the respective other end of the hairpin coil is connected to a respective end of one hairpin coil of another pair located in two other slots thus forming a noninterlaced wave part.
8. The stator according to claim 7, wherein the wire segments comprise copper.
9. The stator according to claim 7, wherein the ends of the wire segments are connected by welding.
10. The stator according to claim 7, wherein at least two sets of windings are arranged in the stator in different layers of the slots.
11. An electric machine for automotive use, comprising a stator for an electric machine having a multitude of slots arranged around the stator, including a multitude of wire segments having a rectangular cross-section arranged in the slots and with ends of the wire segments protruding from the slots being interconnected in a winding head, the wire segments being interconnected in a mixed lap and wave style in such a way that pairs of hairpin coils formed from the wire segments are located in the same two of the slots in different layers and interconnected on one respective end of each hairpin coil so as to form a lap part wherein the respective other end of the hairpin coil Is connected to a respective end of one hairpin coil of another pair located in two other slots thus forming a non-interlaced wave part.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US19656208P | 2008-10-17 | 2008-10-17 | |
| US61/196,562 | 2008-10-17 |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| WO2010043321A2 true WO2010043321A2 (en) | 2010-04-22 |
| WO2010043321A3 WO2010043321A3 (en) | 2010-07-29 |
Family
ID=42035766
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/EP2009/007161 WO2010043321A2 (en) | 2008-10-17 | 2009-10-06 | Stator of an electric machine and method for manufacturing a winding for a stator of an electric machine |
Country Status (1)
| Country | Link |
|---|---|
| WO (1) | WO2010043321A2 (en) |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN111384806A (en) * | 2018-12-28 | 2020-07-07 | 台达电子工业股份有限公司 | motor stator |
| WO2022156815A1 (en) * | 2021-01-25 | 2022-07-28 | 中国第一汽车股份有限公司 | Contact pin winding type stator and electric motor |
Family Cites Families (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP0881744B1 (en) * | 1997-05-26 | 2005-07-20 | Denso Corporation | Alternator for vehicle |
| JP3384337B2 (en) * | 1998-09-07 | 2003-03-10 | 株式会社デンソー | Stator of vehicle alternator |
| FR2808935B1 (en) * | 2000-05-11 | 2002-06-28 | Valeo Equip Electr Moteur | STATOR OF ROTATING ELECTRIC MACHINE AND ALTERNATOR COMPRISING SUCH A STATOR |
| JP3832392B2 (en) * | 2002-06-25 | 2006-10-11 | 株式会社デンソー | Segment sequential joining stator coil of rotating electric machine and method for manufacturing the same |
-
2009
- 2009-10-06 WO PCT/EP2009/007161 patent/WO2010043321A2/en active Application Filing
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN111384806A (en) * | 2018-12-28 | 2020-07-07 | 台达电子工业股份有限公司 | motor stator |
| WO2022156815A1 (en) * | 2021-01-25 | 2022-07-28 | 中国第一汽车股份有限公司 | Contact pin winding type stator and electric motor |
Also Published As
| Publication number | Publication date |
|---|---|
| WO2010043321A3 (en) | 2010-07-29 |
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