Continuous stator winding wound on bobbins

• US 9,450,465 B2
• Filed: 08/27/2013
• Issued: 09/20/2016
• Est. Priority Date: 07/11/2013
• Status: Active Grant

• Current Assignee: Siemens AG
• Original Assignee: Siemens AG
• Inventors: Pawellek, Jrgen, Eckert, Rainer
• Primary Examiner(s): Lam, Thanh
• Application Number:
  US14/903,894
• Publication Number:
  US 20160156242A1
• Time in Patent Office: 1,120 Days
• Field of Search: 310/68.R, 310/71, 310/194, 310179-180, 310/184, 295/96, 295/98, 296/06
• US Class Current: 1/1
• CPC Class Codes: H02K 15/065 Windings consisting of complete sections, e.g. coils, waves windings for large electric machines other than those consisting of cables H02K15/063
• CPC Class Codes: H02K 15/066 inserted perpendicularly to the axis of the slots or inter-polar channels
• CPC Class Codes: H02K 2203/12 Machines characterised by the bobbins for supporting the windings
• 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 3/325 for windings on salient poles, such as claw-shaped poles
• CPC Class Codes: H02K 3/522 for generally annular cores with salient poles

Abstract

In a method for producing a stator winding of a stator, an auxiliary element is positioned with its central axis in alignment with a central axis of the stator. Bobbins are arranged on the auxiliary element in uniformly spaced-apart relationship around the central axis of the auxiliary element, and a circuit carrier is arranged on the auxiliary element radially inside the bobbins. Coils are formed by winding a conductor wire for each phase of the stator winding onto a corresponding one of the bobbins and routed via the circuit carrier to another one of the bobbins of this phase and wound thereon. Each of the bobbins is pivoted with the coils about a pivot so as to enable the bobbins to pivot up onto radially outwardly protruding stator teeth of the stator from radially outside.

Claims

1. A method for producing a stator winding of a stator, comprising:

positioning an auxiliary element relative to the stator such as to align a central axis of the auxiliary element with a central axis of the stator;

arranging bobbins on the auxiliary element at a radial distance from a central axis of the auxiliary element and in uniformly spaced-apart relationship around the central axis of the auxiliary element, when viewed tangentially around the central axis of the auxiliary element;

arranging a circuit carrier on the auxiliary element radially inside the bobbins;

winding a conductor wire for each phase of the stator winding onto a corresponding one of the bobbins to form coils of the stator winding;

routing the conductor wire of each phase via the circuit carrier to another one of the bobbins of said phase and winding the conductor wire onto the other one of the bobbins; and

pivoting each of the bobbins with the coils about a pivot axis that extends tangentially to the central axis of the auxiliary element and the central axis of the stator in vicinity of the circuit carrier so as to respectively pivot up the bobbins onto radially outwardly protruding stator teeth of the stator from radially outside.

2. The method of claim 1, wherein the bobbins are pivoted by at least 90°

about their pivot axes onto the stator teeth.

3. The method of claim 1, wherein the bobbins are pivoted by at least 180°

about their pivot axes onto the stator teeth.

4. The method of claim 1, wherein the conductor wire of the one phase is routed in the circuit carrier in a radially offset manner in relation to a conductor wire of another phase.

5. The method of claim 1, wherein the conductor wire of the one phase is routed in the circuit carrier in an axially offset manner in relation to a conductor wire of another phase.

6. The method of claim 1, further comprising providing the circuit carrier for each phase with a separate carrier section, arranging initially one of the carrier sections on the auxiliary element, and placing another one of the carrier sections on the one of the carrier sections only after the conductor wire for said phase has been wound to form the coils.

7. The method of claim 1, further comprising connecting each of the bobbins via a hinge to the circuit carrier.

8. The method of claim 1, further comprising forming each of the bobbins with a first bobbin flange and a second bobbin flange such, when pivoting up the bobbins onto the stator teeth, the first bobbin flange face a connecting structure of the stator that extends circumferentially around the central axis of the stator at a radial distance thereto, and the second bobbin flange faces away from the connecting structure, wherein the conductor wire is introduced through a lead-in groove into a winding region of the one of the bobbins which is delimited by the first and second bobbin flanges, with the lead-in groove extending non-axially with respect to the central axis of the stator and having a tangential component in at least one section, when pivoting up the bobbins onto the stator teeth.

9. The method of claim 8, wherein the first bobbin flange is smaller than the second bobbin flange.

10. The method of claim 1, further comprising pushing a stator yoke onto the stator teeth in axial relation to the central axis of the stator after the bobbins provided with the coils have been pivoted up onto the stator teeth.

11. A stator, comprising:

a plurality of stator teeth configured to protrude radially outward from a connecting structure that extends circumferentially around a central axis of the stator at a radial distance from the central axis;

bobbins arranged on the stator teeth at a radial distance from the central axis of the stator and, viewed tangentially around the central axis of the stator, in a uniformly spaced-apart relationship around the central axis of the stator;

a circuit carrier arranged at an axial end of the bobbins; and

a conductor wire wound onto each of the bobbins such as to form a coil of a stator winding of the stator,

wherein, for each phase, the conductor wire is routed via the circuit carrier from the bobbin to another one of the bobbins of the phase in an axially offset manner in the circuit carrier from phase to phase, and

wherein the circuit carrier has one carrier section per phase, said carrier sections being stacked on top of one another, viewed in a direction of the central axis of the stator.

12. The stator of claim 11, wherein each of the bobbins is connected to the circuit carrier via a hinge.

13. The stator of claim 11, wherein each of the bobbins has a first bobbin flange and a second bobbin flange, said first bobbin flange facing toward the connecting structure, said second bobbin flange facing away from the connecting structure and having a lead-in groove via which the conductor wire is introduced into a winding region of the bobbin, with the winding region being delimited by the first and second bobbin flanges, said lead-in groove configured to extend non-axially and to have a tangential component in at least one section.

14. The stator of claim 13, wherein the first bobbin flange is smaller than the second bobbin flange.

15. The stator of claim 11, further comprising a stator yoke push-fitted onto the stator teeth.