STATOR FOR A POLYPHASE ELECTRIC MACHINE AND METHOD FOR MANUFACTURING SAME

• US 20100295390A1
• Filed: 03/30/2007
• Published: 11/25/2010
• Est. Priority Date: 03/31/2006
• Status: Active Grant

• Current Assignee: Seg Automotive Germany GMBH
• Original Assignee: Robert Bosch GmbH
• Inventors: Shendl, Alexander, Rau, Eberhard
• Granted Patent: US 8,344,580 B2
• Time in Patent Office: Days
• US Class Current: 310/62
• CPC Class Codes: H02K 1/165 Shape, form or location of the slots
• CPC Class Codes: H02K 3/12 arranged in slots
• CPC Class Codes: Y10T 29/49009 Dynamoelectric machine

Abstract

A stator (16) is proposed for a polyphase electric machine, having a core body (17), which is provided with slots (114), which are situated in the radial direction with respect to an axis of rotation of the electric machine on one side of the core body (17) parallel to the longitudinal axis of the core body (17), having a slot width (bn1, bn2) and a stator yoke (122) being provided on the opposite side, with two slots (114) each being separated from one another by a tooth (116) having a tooth width (bz1, bz2) and extending from a slot base (120) to a tooth head (118), these slots (114) being provided to receive at least one coil winding having a plurality of coils that is electrically connected in series and are manufactured from at least one continuous wire (124) without interruption, the ratio (bz2/hj) of the tooth width (bz2) to the yoke height (hj) at the tooth head (118) being between 0.3 and 0.8 and/or the ratio (bz2/bn2) of the tooth width (bz2) at the tooth head (118) to the slot width (bn2) at the tooth head (118) being between 0.3 and 3, and/or the ratio (mCu(slot)/mCu(total)) of the copper mass of the wire (124) in the slot (114) to the total copper mass of the wire (124) being between 0.43 and 0.55

Claims

1-19. -19. (canceled)

20. A stator for a polyphase electric machine, comprising:

a core body which, in a radial direction with respect to an axis of rotation of the electric machine, has slots with a slot width on one side of the core body parallel to a longitudinal axis of the core body and is provided on the opposite side with a stator yoke, two slots being respectively separated from one another by a tooth having a tooth width and extending from a slot base to a tooth head, the slots being provided with a plurality of coils connected electrically in series to receive at least one coil winding, the coil winding being manufactured from at least one continuous wire without interruption;

wherein at least one of (a) a ratio of the tooth width at the tooth head to the yoke height is between 0.3 and 0.8, (b) a ratio of the tooth width at the tooth head to the slot width at the tooth head is between 0.3 and 3, and (c) a ratio of a copper mass of the wire in the slot to a total copper mass of the wire is between 0.43 and 0.55.

21. The stator according to claim 20, wherein the ratio of tooth width at the tooth head to the yoke height is between 0.4 and 0.6.

22. The stator according to claim 20, wherein the ratio of the tooth width at the tooth head to the yoke height is between 0.4 and 0.5.

23. The stator according to claim 20, wherein the ratio of the tooth width at the tooth head to the slot width at the tooth head is between 0.5 and 2.5.

24. The stator according to claim 20, wherein the ratio of the tooth width at the tooth head to the slot width at the tooth head is between 0.7 and 1.6.

25. The stator according to claim 20, wherein the ratio of the copper mass of the wire in the slots to the total copper mass of the wire in the stator is between 0.45 and 0.53.

26. The stator according to claim 20, wherein the ratio of the copper mass of the wire in the slots to the total copper mass of the wire in the stator is between 0.47 and 0.51.

27. The stator according to claim 20, wherein the slot includes parallel flanks.

28. The stator according to claim 20, wherein the teeth have a comparable, approximately a same, width, in an area of the tooth head and in an area of the slot base.

29. The stator according to claim 20, wherein the wires have a winding head that protrudes axially beyond the slots and the winding head is impregnated, the impregnation of a wire of one phase in the winding head having at least one point of contact with all other phases through the impregnation, the point of contact being reinforced by impregnation.

30. The stator according to claim 20, wherein the slot width is substantially equal to the slot width at the tooth head.

31. The stator according to claim 20, wherein the slot width is greater than the width of the wire.

32. The stator according to claim 20, wherein the electric machine is a claw pole generator, the rotor being made up of two claw pole boards which are spaced an axial distance apart by a pole core.

33. The stator according to claim 32, wherein the winding heads are situated substantially in a radial cooling air stream of fans.

34. The stator according to claim 33, wherein the cooling air stream is created substantially by two fans which are connected axially to two end faces of the rotor and each has a common contact surface with the claw pole boards.

35. The stator according to claim 33, wherein a cooling air stream flows through an air gap separating the stator and rotor and thereby cools the wires situated in the slots.

36. A method for manufacturing a stator for a polyphase electric machine having a core body which, in a radial direction with respect to an axis of rotation of the electric machine, has slots with a slot width on one side of the core body parallel to a longitudinal axis of the core body and is provided on the opposite side with a stator yoke, two slots being respectively separated from one another by a tooth having a tooth width and extending from a slot base to a tooth head, the slots being provided with a plurality of coils connected electrically in series to receive at least one coil winding, the coil winding being manufactured from at least one continuous wire without interruption, at least one of (a) a ratio of the tooth width at the tooth head to the yoke height is between 0.3 and 0.8, (b) a ratio of the tooth width at the tooth head to the slot width at the tooth head is between 0.3 and 3, and (c) a ratio of a copper mass of the wire in the slot to a total copper mass of the wire is between 0.43 and 0.55, comprising:

joining the wires in the slots substantially in the radial direction.

37. The method according to claim 36, wherein the wires are secured in the slots by impregnation of their winding head.

38. The method according to claim 36, wherein the wires are round wires, are stamped in a mold, and are then introduced into the slots of the stator.