Interconnection element for connection of stator coils

• US 10,256,692 B2
• Filed: 03/02/2015
• Issued: 04/09/2019
• Est. Priority Date: 03/24/2014
• Status: Active Grant

• Current Assignee: Valeo Equipements Electriques Moteur (Valeo SE)
• Original Assignee: Valeo Equipements Electriques Moteur (Valeo SE)
• Inventors: El Baraka, Khadija, Jugovic, Svetislav, Armiroli, Paul
• Primary Examiner(s): Phillips, Forrest M
• Application Number:
  US15/126,544
• Publication Number:
  US 20170085145A1
• Time in Patent Office: 1,499 Days
• Field of Search: 310 71
• CPC Class Codes: H02K 3/28 Layout of windings or of connections between windings windings for pole-changing H02K17/06, H02K17/14, H02K19/12, H02K19/32
• CPC Class Codes: H02K 3/522 for generally annular cores with salient poles

Abstract

An interconnection element (24) for connecting the stator coils of a polyphase rotary electric machine (2), including a plurality of conductive layers stacked axially, including the same number of solid base layers (26, 28, 30), and additional layers (32, 34, 36), each formed by a plurality of ring portions, each one of the ring portions not covering the entire perimeter of the stator, each one of the conductive layers having internal connection tabs (40) for connecting the coils and external connection tabs (48, 50) for connecting to connected electrical devices (4, 20), the number of base layers and additional layers being equal to the number of phases of the machine to which the interconnection element is added.

Claims

1. An interconnection element for connection of stator coils of a stator of a polyphase rotary electrical machine, the interconnection element comprising a plurality of axially stacked conductive layers including:

solid base layers, each formed by a solid ring; and

additional layers, each formed by at least two partial rings, each of the partial rings not covering all of a periphery of the stator;

a number of the solid base layers being equal to a number of the additional layers;

each of the conductive layers comprising inner connection lugs for connection of the stator coils, and outer connection lugs for connection to a connected electrical equipment;

the number of the base layers and the number of the additional layers being equal to a number of phases of the polyphase rotary electrical machine comprising the interconnection element.

2. The interconnection element according to claim 1, wherein the additional layers are formed by two half-rings.

3. The interconnection element according to claim 1, wherein the conductive layers are arranged axially above one a not her, without electrical contact with one another.

4. The interconnection element according to claim 1, wherein the inner connection lugs face towards an interior of the interconnection element, and wherein the outer connection lugs extend from an outer lateral wall of the conductive layers which form the interconnection element.

5. The interconnection element according to claim 1, wherein each conductive layer includes a number of the inner connection lugs which is equal to a number of stator coils per phase, wherein a number of outer connection lugs is independent from a number of stator coils, wherein each of the base layers includes a single outer connection lug, and wherein the additional layers include a plurality of the outer connection lugs, one per each of the partial rings.

6. The interconnection element according to claim 1, wherein the outer connection lugs associated with the additional layers are supported by one of ends of each of the partial rings.

7. The interconnection element according to claim 1, wherein all of the partial rings of each of the additional layers have an angular dimension which is smaller than an angular dimension of each of the base layers, such that a rupture area is formed between opposite ends of two partial rings of each of the additional layers.

8. The interconnection element according to claim 1, wherein each of the partial rings which forms part of one of the additional layers has a structure identical to a structure of the adjacent one of the partial rings, wherein the partial rings which are arranged axially above one another are offset angularly around a common axis of the rotary electrical machine and the interconnection element, such that the inner connection lugs do not overlap, and are distributed angularly regularly.

9. The interconnection element according to claim 8, wherein the angular offsetting with which the partial rings of the different additional layers are arranged relative to one another is equal to 360°

divided by a total number of inner connection lugs supported by the base layers.

10. The interconnection element according to claim 1, wherein the inner connection lugs of the additional layers are arranged angularly regularly, in the vicinity of the inner connection lugs of the base layers.

11. The interconnection element according to claim 1, wherein each of the inner connection lugs comprises a lateral extension which extends radially towards an interior of the interconnection element on a plane of the conductive layer which supports the inner connection lug, and a raised edge which extends at a free end of the lateral extension substantially perpendicularly thereto, and wherein the raised edges of the inner connection lugs are all oriented axially in the direction extending opposite the base layers.

12. The interconnection element according to claim 11, wherein each raised edge comprises an undulating part forming a groove which faces towards the conductive layers of the interconnection element, and is configured to receive connection wires of the stator coils.

13. A three-phase rotary electrical machine with twelve stator coils per phase, wherein the interconnection element according to claim 1 comprises six conductive layers including three base layers each having a solid annular profile and three additional layers each having a partial annular profile formed by two half-rings separated by two diametrically opposite rupture areas,

each of the base layers comprising twelve inner connection lugs for the connection of the stator coils, and each of the half-rings forming in pairs one of the additional layers comprising six inner connection lugs also for connection of the stator coils,

the inner connection lugs being arranged such that one of the inner connection lugs associated with one of the additional layers is arranged in the vicinity of one of the inner connection lugs associated with one of the base layers, and such that the successive connection lugs of each of the conductive layers are distributed angularly with a regular angular pitch of 30°

.

14. The three-phase rotary electrical machine according to claim 13, wherein six stator coils of a single phase are connected to the six inner connection lugs associated with one of the half-rings of one of the additional layers, and to six inner connection lugs associated with one of the base layers, whereas the six remaining stator coils of the same phase are connected to the six inner connection lugs associated with the opposite half-ring of the additional layer, and to the remaining six inner connection lugs associated with the base layer.

15. The interconnection element according to claim 2, wherein the conductive layers are arranged axially above one another, without electrical contact with one another.

16. The interconnection element according to claim 2, wherein the inner connection lugs face towards an interior of the interconnection element, and wherein the outer connection lugs extend from an outer lateral wall of the conductive layers which form the interconnection element.

17. The interconnection element according to claim 3, wherein the inner connection lugs face towards an interior of the interconnection element, and wherein the outer connection lugs extend from an outer lateral wall of the conductive layers which form the interconnection element.

18. The interconnection element according to claim 2, wherein each conductive layer includes a number of the inner connection lugs which is equal to the number of the stator coils per phase, wherein the number of the outer connection lugs is independent from the number of the stator coils, wherein the base layers each includes a single outer connection lug, and wherein the additional layers include a plurality of the outer connection lugs, one per each of the partial rings.

19. The interconnection element according to claim 3, wherein each conductive layer includes a number of the inner connection lugs which is equal to the number of the stator coils per phase, wherein the number of the outer connection lugs is independent from the number of the stator coils, wherein the base layers each includes a single outer connection lug, and wherein the additional layers include a plurality of the outer connection lugs, one per each of the partial rings.

20. The interconnection element according to claim 4, wherein each conductive layer includes a number of the inner connection lugs which is equal to the number of the stator coils per phase, wherein the number of the outer connection lugs is independent from the number of the stator coils, wherein the base layers each includes a single outer connection lug, and wherein the additional layers include a plurality of the outer connection lugs, one per each of the partial rings.