Electric motor stator

• US 7,936,099 B2
• Filed: 05/30/2006
• Issued: 05/03/2011
• Est. Priority Date: 07/28/2005
• Status: Active Grant

• Current Assignee: ThyssenKrupp Presta AG (Thyssenkrupp AG)
• Original Assignee: ThyssenKrupp Presta AG (Thyssenkrupp AG)
• Inventors: Battisti, Christoph, Staudemann, Christian
• Primary Examiner(s): Leung; Quyen
• Assistant Examiner(s): Mok; Alex W
• Application Number:
  US11/996,775
• Publication Number:
  US 20080231133A1
• Time in Patent Office: 1,799 Days
• Field of Search: 310/71, 310/208, 310/185, 310/180, 310/184, 310/198
• US Class Current: 310/71
• CPC Class Codes: H02K 11/33 Drive circuits, e.g. power electronics H02K11/38 takes precedence
• CPC Class Codes: H02K 2203/09 Machines characterised by wiring elements other than wires, e.g. bus rings, for connecting the winding terminations
• 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

The invention relates to a stator for an electronically switchable electric motor comprising a cylinder-shaped envelop and several poles, which are made of an ferromagnetic material and inwardly oriented in front of the cylinder axis (3), wherein said poles (P1 to P12) surround a cylindrical cavity for receiving the rotor (2), each pole (P1 to P12) is provided with a coil (L1 to L12) consisting of several wire windings in such a way that a magnetic armature is formed and the windings of coils (L1 to L12) are wound about the poles (P1 to P12) successively and without interruptions.

Claims

1. Stator for an electronically commutated electric motor, comprising:

a cylindrical shell having an engagement side and an opposite side, with a plurality of poles (P1 to P12) of ferromagnetic material extending inwardly toward the cylinder axis (3) of the shell,

the poles (P1 to P12) being spaced from each other in sequence around the shell and together encompassing a cylindrical cavity for housing a rotor (2) and wherein each pole (P1 to P12) is provided with a winding (L1 to L12) of a plurality of wire turns for developing a magnetic armature,

the wire turns of the windings (L1 to L12) being wound from only one start (6) to only one end (7) around the shell, without interruption, in a single pass, successively and in sequence from pole to pole around the shell and about the poles (P1 to P12) to form each winding around each respective pole,

a wire loop extending between each pair of adjacent poles around the shell and only at the engagement side of the shell, each wire loop forming a wire transition (11a to 11e) fixed at the engagement side of the shell,

a plurality of the wire transitions (11) being cut to form an electrical disconnection (S) and create two contact areas for the windings of the adjacent poles at the engagement end of the shell, and

a contact ring (10) having a plurality of stacked and mutually insulated flat conductor paths (U, V, W) of electrically conductive material, each conductor path extending partly around the engagement end of the shell, each conductor path having opposite ends with an electrical contact (9) at each end of each conductor path, each contact (9) being engaged with a respective wire transitions (11) or contact area of a wire transition (11) for wiring the windings at only the engagement side of the stator.

2. Stator as claimed in claim 1, wherein each pole (P1 to P12) receives at least two windings (L1 to L12) wound in the same direction and these windings form for one pole (P1 to P12) in each instance a winding bundle (L1 to L12).

3. Stator as claimed in claim 2, wherein the turns of the windings (L1 to L12) for each pole (P1 to P12) are developed as a bifilar winding.

4. Stator as claimed in claim 2, wherein the turns of the windings (L1 to L12) for each pole (P1 to P12) are developed as an interlaced winding.

5. Stator as claimed in claim 1, wherein the wire transitions (11a to 11e) are guided via insulating supports (8) disposed on the engagement side of the shell.

6. Stator as claimed in claim 1, wherein the electrical contacts (9) for an electrical power supply system takes place at the engagement side on the stator (1) on the winding start (6), on the winding end (7) and on at least one of the wire transitions (11a to 11e).

7. Stator as claimed in claim 6, wherein taps of the electrical contacts (9) form a multi-phase winding arrangement in Y-connection configuration.

8. Stator as claimed in claim 7, wherein three wire transitions (11a to 11e) are electrically contacted and joined together with a Y-point line (ST) to form a Y-point (ST).

9. Stator as claimed in claim 6, wherein each electrical contact (9) is a welding connection or a solder connection.

10. Stator as claimed in claim 1, wherein the stacked flat conductor paths each have winding terminals (U1, V1, W1) connected directly to a circuit board (20), which includes electronic activation circuitry (22) with wiring paths (21) as well as electrical terminals (23).

11. Componentry comprised of a stator (1) as claimed claim 1, assembled with a circuit board (20), which includes electronic activation circuitry (22) with wiring paths (21) and electrical terminals (23).

12. Stator as claimed in claim 1, for an electronically commutated electric motor for activating a power steering mechanism in motor automotive vehicles.

13. Stator as claimed in claim 1 wherein the contacts (9) are in the shape of hooks.

14. Method for assembling a stator for an electronically commutated electric motor, with a cylindrical shell having an engagement side and an opposite side, with a plurality of poles (P1 to P12) of ferromagnetic material extending inwardly toward the cylinder axis (3) of the shell, the poles (P1 to P12) being spaced from each other in sequence around the shell and together encompassing a cylindrical cavity for housing a rotor (2) and wherein each pole (P1 to P12) is provided with a winding (L1 to L12) with several wire turns for developing a magnetic armature, the method comprising:

winding turns of the windings (L1 to L12) without interruption successively about the poles (P1 to P12) from only one start (6) to only one end (7) around the shell, in a single pass and in sequence from pole to pole around the shell and about the poles (P1 to P12) to form each winding around each respective pole;

forming a wire loop extending between each pair of adjacent poles around the shell and only at the engagement side of the shell, each wire loop forming a wire transition (11a to 11e) fixed at the engagement side of the shell;

cutting a plurality of the wire transitions (11) to form an electrical disconnection (S) to create two contact areas for the windings of the adjacent poles at the engagement end of the shell;

engaging an electrically conductive contact ring (10) having a plurality of stacked mutually insulated flat conductor paths (U, V, W) each made of conductive material and each extending partly around the engagement end of the shell, each conductor path have opposite ends with an electrical contact (9) at each end of each conductor path; and

engaging the contacts (9) with respective wire transitions (11) or contact areas of the wire transitions (11) for wiring the windings at only the engagement side of the stator.

15. Method as claimed in claim 14 wherein the contacts (9) are in the shape of hooks.