Electrical machine and method of manufacturing

FIELD: electricity.

SUBSTANCE: invention is related to the stator of electrical machine and the method of its manufacturing. The stator for electrical machine comprises the core having a variety of pole horns and a variety of windings made of electroconductive material at pole horns. At least a part of windings is made of a wire having a pair of free ends, which may be connected electrically to the network power source. The stator comprises two or more electric contacts having a flexible section, which may be moved in direction towards the core and away; the above contacts are connected electrically to the respective contacts of the power source. At least one of electrical contacts is formed by two free ends of the corresponding different wires and has a twisted shaped made by ends twisting along the initial line of the ends passing, at that at the base of each twisted part there is a loop for each electrical contact. The loop forms a dampening element for the respective twisted section.

EFFECT: improved reliability of the electrical machine.

21 cl, 20 dwg

 

The technical field

The present invention relates to a stator for an electric motor and method of manufacturing the electric motor winding, and the stator is preferably intended for use in an electric machine of a type that has a built-in electronic control circuit. More specifically, this invention relates to a method of manufacturing a stator of the electric motor.

Prior art

Rotating electric machine based includes a housing, a stator fixedly coupled to the housing, the rotor, for example, related to the type with permanent magnets, a closed casing and connected with the latter for rotation.

When the electric machine operates as a motor, the rotor is driven in rotation by the power of the stator through an electronic circuit or control circuit, which in this case is also located inside the enclosure.

The casing is then closed by a cover with contact output on its outer side for power electronic circuits and, consequently, of the electric motor. The electronic control circuit, which is installed on the corresponding plate, located between the stator and the cover.

The control circuit includes a power circuit and should therefore be equipped with a heat sink for pogloshena the heat generated by the electronic power components in the process.

At the same time, the Assembly should ensure effective electrical connection between an electronic circuit and an electric motor so as to ensure proper operation of the engine.

In the case of electric motors with integrated electronic circuit, the absorption of excess heat to achieve difficult, because it is difficult to perform an effective electrical connection between the electronic circuitry and the motor and a good thermal contact between the electronic circuit and the corresponding heat sink, in particular a lid.

The main problems are connected with the fact that due to the fact that the case must be closed with a lid, it is difficult when, essentially, a closed engine to perform all electrical and mechanical connections in an optimal way.

To ensure the closure Assembly, the decisions of the prior art provide at least one sliding contact, such as a connector, for example, which is easily subject to problems of reliability and efficiency, for example, related to vibration, wear of the contact or working temperature, between the engine and an electronic circuit, or between the electronic circuitry and the contact output.

In the first case, the electronic circuit are rigidly connected to the cover that is on, to optimize the heat exchange with the latter, and when the case is closed, the sliding contact connects the electronic circuit with the motor. In this case, therefore, the function of the heat sink is more of a priority compared to the reliability of connection between the electronic circuit and the engine.

In the second case, an electronic circuit effectively and rigidly connected with the engine, for example, by prepaymania, while the contact scheme with lid is not very efficient from the point of view of heat transfer due to inevitable tolerances on closing.

Thus, in the recent decision of the electronic circuit ineffective pressed against the heat sink, for example, taking into account the tolerances of the Assembly. In addition, as mentioned, uses a sliding contact with all the inherent limitations between the electronic circuitry and the contact output to the outside.

A brief statement of the substance of the invention

In this case, the main objective of the invention is to provide a stator for an electric motor, in particular an electric motor with electronic circuitry that is built into the housing, and a method of manufacturing a stator, which does not have the above disadvantages.

This invention has the task of creating a method of manufacturing an electric machine, which is more reliable compared with the decisions of this uravnenii in terms of the absorption of excess heat and electrical connections inside it.

An additional object of the invention is to propose a stator, in particular for an electric motor with integrated electronic circuit, in which excess heat generated by the circuit, is effectively absorbed.

Another additional object of the invention is to propose a stator for an electric machine with a reliable electric connection between the electric motor and an electronic circuit.

Another additional object of the invention is to propose an electric machine, having an effective connection between the contact pin and the engine.

The above objects and tasks, in fact, achieved with the help of a stator for an electric machine, which has the features described in the independent claim 1 of the formula of the invention and one or more dependent clauses.

Brief description of drawings

The invention is further explained in the description of the preferred variants of the embodiment with reference to the accompanying drawings, in which:

Fig.1 depicts a schematic General view of the rotating electrical machine containing the stator, in accordance with the invention;

Fig.2 depicts a schematic General view with some remote parts, for better illustration of other parts of the rotating electric machine of Fig.1;

Fig.3 is sabrejet schematic view in section of the machine from Fig.1 with some parts, removed to better illustrate other parts;

Fig.4 depicts another General view of the electric machine of Fig.1 with some remote parts, for better illustration of other parts;

Fig.5 depicts a schematic view diversity with some remote parts, for clarity, the electrical machine of Fig.1;

Fig.6A depicts a schematic General view of the first part of electric machine of Fig.1;

Fig.6b depicts a portion of Fig. 6A is another schematic General view;

Fig.6C depicts a portion of Fig.6A and 6b, in a schematic General view with some parts removed for clarity;

Fig.7 depicts a schematic General view of the second part of the electric machine of Fig.1;

Fig.8 depicts a stator of an electric machine with Fig.1 in a schematic General view and in accordance with an alternative embodiment;

Fig.9a and 9b depict, respectively, a General view and a top view of a stator of an electric machine with Fig.1, with some remote parts, for better illustration of other parts;

Fig.10A, 11a and 12A depict three of the top view of the stator of Fig. 9A, showing three successive stages of its production;

Fig.10b depicts the stator of Fig.10A cross-section along line X-X of Fig. 10A;

Fig.11b depicts the stator of Fig.10A cross-section along line XI-XI of Fig. 11a;

Phi is.12b depicts the stator of Fig.12A cross-section along line XII-XII of Fig. 12A;

Fig.13 and 14 depict the stator of Fig.9a in two views in cross-section, depicting the final two successive stages of its production.

Description of the preferred embodiments of the invention

In Fig.1 and 5 presents electric machine 1 manufactured by the method in accordance with this invention.

The machine 1 includes the electric motor of the closed type, that is, without any openings that provide access to its internal parts, to which this description is not limiting of the scope of the invention.

The machine 1 includes a housing 2 and a corresponding cover 2A, which together form a closed cavity 10, the stator or the stator unit 3 located in the housing; and a rotor or rotary unit 4, located in the housing and coupled with the latter for rotation.

With reference in particular to Fig.2 and 4, the stator 3 in the depicted example has three electrical contacts 5, 6, 7, and machine 1 includes an electronic circuit 8 to supply the electrical contacts 5, 6, 7. In more detail, the machine shown in particular in Fig.9a and 9b, contains twelve pole projections, four of which are wound around the first winding 100 is electrically series-connected with each other and supplied from the first electric contact 5, while the other four tabs of Namat the us second winding 200, also electrically connected with one another and supplied from the second electric contact 6, and the last four pole ledge wound third winding 300, is also electrically connected with one another and supplied from the third electric contact 7.

Scheme 8, mainly located in the housing 2, a contact pin 9 to power the circuit 8 externally accessible cavity 10.

Machine 1 also includes a heat sink to absorb heat generated, in particular, the electronic circuit 8.

In this solution, the function of heatsink performs a cover 2A, which, as will become more clear in the following description, supported in thermal contact with the electronic circuit 8.

With reference in particular to Fig.4, one can see that the machine 1 includes an elastic connection or means 11 connection acting between the stator 3 and the electronic circuit 8.

When the engine is closed, these tools 11 connections between the electronic circuit 8 and the stator 3 allow the electronic circuit 8 is not only closer to the stator 3, with which it is preferably rigidly fastened, as described further below, but close to the cover 2A.

As shown, the means 11 compounds contain many elastic clamping elements 12 or, more specifically, the springs in the Assembly machine press ELEH the throne circuit 8 to the heat sink, away from the stator 3.

Elastic means 11 compounds also contain flexible section 13 electrical contacts 5, 6, 7.

In other words, each of the electrical contacts 5, 6, 7 has at least one flexible section 13, in particular, closer to the stator 3, forming part of the elastic means 11 connections in order to maintain a reliable connection between the electronic circuit 8 and the electronic contacts 5, 6 and 7, while the scheme itself is pressed against the cover 2A.

The electronic circuit 8, in particular, is rigidly connected with the electronic contacts 5, 6, 7 on one end 14 of the respective flexible section 13.

On closer examination of the details associated with the flexible parts 13, where the reference position R means the axis of rotation of the engine, essentially parallel to the connection direction D along which meets the engine, flexible sections have a first branch 15 essentially transverse to the direction D (Fig.4).

Branch 15 defines some semblance of a spring suspension system, which allows flexible section 13 to move.

The electronic circuit 8, thus movable relative to the stator 3 in the direction of the latter and from him, in accordance with the expansion of the flat springs that are flat springs undergo elastic deformation so as to allow the flexible portions 13 of the electrical contacts 5, 6, 7 am in order to riservati movement of the electronic circuit 8 to the stator 3 and from him.

In practice, each electrical contact 5, 6, 7, which in the depicted example, takes the form of two wires that are located next to each other, is from the last winding 100, 200, 300 in the direction of the point at which, in essence, it is attached to the electronic circuit 8.

Each flexible section 13 also has a second branch 16 essentially parallel to the direction of the connection D and protruding in the direction of the electronic circuit 8.

As is shown in Fig.2, the end 14 of the flexible section 13 is defined by one end of the branch 16.

Each electrical contact 5, 6, 7 is connected with the electronic circuit 8 via the corresponding output 17, suitably provided on the electronic circuit 8. The ends 14 are soldered to corresponding terminals 17.

Position 35 in Fig.2, 5 and 8 show, in General, means to hold the ends 14 in position, suitable for the Assembly, as is more fully explained below.

With reference to Fig.2 and 5, this means 35 contains an element in the form of a plate 36 having many slots 37 into which you insert the flexible parts 13, in particular their second branch 16.

Machine 1 contains the means 38 for connecting element 36 with the stator 3 so as to hold them essentially in place during Assembly of the machine 1.

With reference to Fig.8, the tool 35 to hold the ends 14 in position, suitable for Assembly, made with the aid of the d distribution element 39, provided with slots 37, similar to the above sockets.

Distributing element 39 has an essentially circular cross section and has the shape of a truncated cone with curved side surfaces.

Distributing element 39 is located in the housing 2, not shown in Fig.8, and is connected to the stator 3 by using the above means 38 of the connection.

It should be noted that in this embodiment, the element 39 is made in such form, in order to keep the warm air that is generated inside the housing 2 and which moves by means of the rotor 4, in particular the fan 4A, in the area inside the element 39 in such a way as not to affect the electronic control circuit 8, or, more specifically, the power circuit 22, which forms part of the circuit 8 and described in more detail later.

In an alternative embodiment, the tool 35 is made with the help of 16 branches.

In this embodiment, the branches 16 themselves have a rigid structure, which effectively keeps them in position, essentially parallel to the axis D.

Mainly, two wires forming each electrical contact 5, 6, 7 twisted with each other, so that the electrical contacts 5, 6, 7 are tough enough to stay in place during Assembly of the engine 1. These are important advantages, the cat is who described below.

As for the elastic elements 12, it should be noted that the stator 3, which contains a metal core or section 18 with pole protrusions, covered by an insulating section 19, has many slots 20 for elastic elements 12.

Socket 20 formed in the insulating section 19 and preferably are tapered to facilitate the introduction of elastic elements 12.

In order to hold the elastic elements 12 in the correct position, thereby holding circuit 8 is pressed against the cover 2A, even in difficult operating conditions, which lead to heating of the machine 1, the slots 20 are tubular, that is, they are open on one side so that the elastic elements 12 located on the metal section 18.

Fig.6A, 6b and 6c, in particular, depict how the electric circuit 8 is set on the element 21 for installation, essentially in the form of a disc, and how elastic elements 12 between the stator 3 and the element 21.

The element 21 for installation has suitable mechanical properties to exert a pushing action on the cover 2A.

It should be noted that the electronic circuit 8 includes a circuit 22 of the power supply, which generates most of the heat that must be absorbed, and the signal circuit 23.

Scheme 22 food contains conductive paths 22A, for example, copper, which are essentially known e the Tronic power components 22b, such as MOS transistors (field-effect transistors with the structure of a metal-oxide-semiconductor), for example, necessary for the operation of the engine 1.

The signal circuit 23 includes a multilayer printed circuit Board 23a and many related passive email filtering and/or signal components 23b mounted on the printed circuit Board 23a.

Preferably, the electronic active power components 22b are mounted on the side opposite of passive electronic components 23b relative to the element 21 for installation.

In a preferred embodiment, the electronic power components 22b are mounted on the side opposite to the cover 2A relative to the element 21 for installation.

Preferably, the electronic power components 22b are mounted directly on the element 21 for installation.

It should be noted that the element 21 for installation also contains many elements 21A for separate mounting of passive electronic components 23b in such a manner as to hold them firmly in place.

It is important to note that this solution prevents the flow of high currents through the circuit Board, which can be damaged or destroyed during the passage of this type currents.

As shown in particular in Fig.6C, the circuit 22 of the power supply, in particular, tracks 22A are available through ELEH the UNT 21 to install so it can be brought into contact with the heat sink.

In practice, near circuit 22 of the power element 21 for installation has a pair of holes 24, which provide access to conductive paths 22A of the scheme 22.

As can be seen with reference in particular to Fig.7, the cover 2A, which, as indicated previously, is a heat sink for the electronic circuit 8 has its inner side a pair of projections 25, which are located essentially above the holes 24 so that they may come into contact with the power circuit 22, that is, with the conductive paths 22A.

Mainly, between conductive paths 22A circuit 22 of the power supply and the corresponding protrusion 25 machine 1 includes a thermally conductive, electrically insulating element 26 made, for example, from silpad®.

It should be noted that in order to give the element 26 to function correctly, the elastic elements 12 have corresponding dimensions, in order to press the power circuit 22 to the heat sink, providing a pre-set pressure.

For example, if you use silpad®, the pressure required for correct operation, is at least 1.5 kg per square centimeter.

Elastic elements 12 are designed and distributed in such a way as to optimize the clamping force applied to the element 21 for installation.

In particular, the elastic elements 12 developed the Ana for the application pushing force to the components of the circuit 22 power without hyperstatic structure.

In the depicted embodiments, the implementation of the elastic elements 12 are divided into two sets of three elements, and the elements in each set of three items located through the angular intervals of 120°. In a preferred embodiment, the elastic elements 12 exert a pushing force of about 60 kg.

In light of the above, when the cover is placed on the housing, the elastic elements 12 are pushing the electronic circuit 8 in the direction of the cover 2A is strong enough to ensure good heat transfer, while sections 13 can maintain optimum connection between the electronic circuit 8 and the windings of the stator.

With reference to Fig.3 and 7 for power supply machine 1 of the invention involves the provision of contact output 27 protruding from the cover 2A through a suitable opening 28.

Preferably, the opening 28 between the contact output 27 and the cover 2A is a gasket 29 which is pressed against the cover 2A of the elastic elements 12, thereby providing an effective seal in the area of the contact output when closed, the machine 1.

Below is a detailed description of the method of manufacturing a stator 3, illustrating, in particular, how are the electrical contacts 5, 6, 7.

Fig.9a and 9b depict the stator 3 after the electrical contacts 5, 6, 7 were from the otopleni. These drawings depict how the three electrical contacts 5, 6, 7 are in the direction of the stator 3 along lines parallel to each other and parallel to the axis of rotation of the rotor 4. Each of the electrical contacts 5, 6, 7 formed by twisting each other two wires that make up the electrical contact 5, 6, 7.

Fig.10A-14 depict successive working stages in the process which made the electrical contacts 5, 6, 7.

Fig.10A and 10b depict the initial situation before making a twisted electrical contacts 5, 6, 7. These two drawings depict the stator 3 in the configuration obtained in the previous stage of manufacture of the windings 100, 200, 300. More specifically, the drawing depicts six wires 110, 120; 210, 220; 310, 320, forming, in pairs, feeding the ends of the electric wires, from which it is made, each of the groups of windings 100, 200, 300.

In Fig.10A and 10b, showing the electric motor at 24 volts(while the engine 12 is twelve feeding ends instead of six) six wires 110, 120; 210, 220; 310, 320 there are on line, essentially radial stator 3.

In other words, six wires 110, 120; 210, 220; 310, 320 are arranged so that they lie in a first plane perpendicular to the axis of rotation R.

More specifically, wire 110, 120; 210, 220; 310, 320 are is accordance with a radial position on the half of the angular extent of the stator 3.

Wire 110, 120; 210, 220; 310, 320 located in the half plane bounded by a diameter D1, and includes the stator.

This half plane is the half plane that contains the electrical contacts 5, 6 and 7, with reference in particular to Fig.9b.

The length L of the wires 110, 120; 210, 220; 310, 320 is between about 35 mm and about 185 mm, so that the proper bend they form above the area of the flat spring, which allows electrical contacts 5, 6 and 7 move in accordance with the requirements.

The wires 110, 120; 210, 220; 310, 320 depends on the distance between the last coil windings 100, 200, 300, and, essentially, the position corresponding to the above conclusion 17.

Each wire 110, 120; 210, 220; 310, 320 generates the supply ends of the respective group of windings 100; 200; 300 and must be connected to the electronic circuit 8, which is located on an axis above the stator 3, as shown in Fig.5.

The stator 3 is located on the rotary drum T, which holds the stator 3 in the process step of manufacturing electrical contacts 5, 6, 7 and, preferably, also in the previous stage of manufacture of the windings 100, 200, 300. Still more preferably, the drum T has two hull nests, each of which is constructed in a suitable stator 3 and rotates around a horizontal axis located in Prohm is a duck between two massive nests thus, to allow rapid movement of the processed stator 3 from the place of manufacture of the windings 100, 200, 300 to the place of production of electrical contacts 5, 6, 7.

Starting from the configuration shown in Fig.10A-driven robot manipulator (not shown) pulls on one another radially spaced wires 110, 120; 210, 220; 310, 320 and positions them in such a way that the free ends of wires 14 110, 120; 210, 220; 310, 320 located in a pre-established angular position of the stator 3, as shown in Fig.11a.

In this configuration are formed in areas of flat springs each coil, that is, the branch 15.

The length L1 of the branches 15, preferably equal to between about 25 mm and about 60 mm, in such a way as to follow the movements of the electronic circuit by closing of the engine 1.

The length of the branches 15 depends on the distance between the last coil windings 100, 200, 300, and, essentially, the position corresponding to the above conclusion 17.

More specifically, the supply ends of the wires 110, 120; 210, 220; 310, 320 securely fasten in place using the clamping elements P that are installed on the drum T.

Additionally, the drum T contains three terminal 500, parallel to each other and along a line essentially parallel to the axis of rotation R. the Function of the rod 500 is to provide a reference position for positioning the supply to the CC of the wires 110, 120; 210, 220; 310, 320. Each pair of wires 110, 120; 210, 220; 310, 320 partially wound on the corresponding supporting element or cylindrical rod 500 so that the two wires of each pair intersect with each other around the rod 500 or near terminal 500, as shown in Fig.11a. In this configuration, the wire 110, 120; 210, 220; 310, 320 are arranged so that they lie in a plane essentially perpendicular to the axis of rotation R.

Next, the mobile cylinder M is placed on the stator 3 and the axis of rotation R. the Mobile head M may move along an axis parallel to the axis of rotation and along a line perpendicular to the axis of rotation R. In the case of the latter two types of movement of the mobile head M may move close to the metal ring of the stator core 3.

Mobile head "M" has three parallel support element or prong 600, each of which is constructed so that it was located, preferably, contacting or adhering to it, above the respective rod 500 in such a way as to form together with the rod 500 reference l-shaped structure 500, 600.

Further, driven robot manipulator (not shown) clamps one by one pair of wires 110, 120; 210, 220; 310, 320, prior to that, held clamping elements P, and clinches a couple of wires 110, 120; 210, 220; 310, 320 by pulling up until the neither will lie in the plane parallel to the axis of rotation R, and, hence, perpendicular to the first plane.

This completes the formation of the branches 16, parallel to the axis R and, at least partially, by the formation of the electrical contacts 5, 6 and 7.

This movement, therefore, makes each pair of wires 110, 120; 210, 220; 310, 320 be bent at right angles, and in the process of moving two wires 110, 120; 210, 220; 310, 320 each pair comprise corresponding first terminal 500, and then the corresponding prong 600 mobile head M until you reach the configuration shown in Fig.13.

In General, for the reference patterns enough to pass along a public profile that has at least one change of direction to allow each pair of conductors 110, 120; 210, 220; 310, 320 to remain at least partially wound on a corresponding support structure 500, 600 in the process of passing from the first plane to the second plane. The support structure 500, 600, preferably has a tubular shape and, more preferably, is limited to two straight and cylindrical sections 500, 600, to facilitate the pulling of wires 110, 120; 210, 220; 310, 320 the support structure 500, 600 in the process of passing from the first plane to the second plane.

Further, driven robot manipulator grips the ends 14, they are situated is close to each other, conductive wires 110, 120; 210, 220; 310, 320 each pair of cranks around the axis parallel to the axis of rotation R, so that twist the two wires with each other to make electrical contacts 5, 6, 7, shown in Fig.9a.

More specifically, the twisted portion of each electrical contact 5, 6, 7 are formed only in the contact section 14a of the ends 14, which pass from the support structure 500, 600 and which is formed above the second branch 16. The remaining part of the wire 110, 120; 210, 220; 310, 320, located between the support structure 500, 600 and corresponding windings 100, 200, 300, not subject to any perekruchivaem impact.

It should be noted that for each electrical contact 5, 6, 7 formed loop 40 at the base of the twisted part on the support elements 600.

Loop 40 makes electrical contact 5, 6, 7 elasticity along the axis R.

In a preferred embodiment of the invention the twisted plot of each electrical contact 5, 6, 7 has a length between 20 mm and 30 mm, preferably between 25 mm and 28 mm

Preferably, driven robot manipulator first locates all wires 110, 120; 210, 220; 310, 320 around the terminals 500, and then moves on to other actions.

Preferably, in addition to the step of bending wire pairs 110, 120; 210, 220; 310, 320 and the corresponding stage scruch the research was carried out one after the other without releasing controlled robot manipulator grip wire pairs.

Fig.14 clearly shows, as already mentioned, that the electrical contacts 5, 6, 7 form a second branch 16 of the flexible sections 13 and located above the corresponding teeth 600 mobile head M (which is reserved).

Mainly, the second branch 16 of each electrical contact has a corresponding loop 40.

Thus, under the prong 600 depicts a first branch 15 of each flexible section 13, and this branch is raised relative to the stator 3 and acts as a flat spring (since it acts on the stator 3 like a console).

The method of Assembly machine 1 includes the stages of preparation of the housing 2, the premises of the stator with the corresponding electrical contacts 5, 6, 7 in the housing 2, the location of the rotor 4 in the case 2, the coupling of the latter with the possibility of rotation and training of elastic elements 12 on the stator 3.

The element 21 for mounting electronic circuit 8 is then placed on the elastic elements 12 so that each of the ends 14 of the flexible sections 13 is located at an appropriate conclusion 17.

It should be noted that at this stage, the elastic elements 12 hold the electronic circuit 8 at a distance from the stator 3, further away from the stator than in an enclosed engine.

Thus, when the engine is closed, the elastic elements 12 are pushing the electronic circuit in the direction of the cover/heat sink 2A with the required strength.

p> The ends 14 of the electrical contacts 5, 6, 7 then soldered to corresponding terminals 17 to create a good reliable contact between the two parts.

Further, the method includes placing the cover 2A to the electronic circuit 8 and fastening it to the body 2.

At this stage, as indicated previously, the elastic elements 12 are pushed scheme 8 in the direction of the cover 2A, while soldered to the flexible parts 13 allow it to move in the direction of the stator 3 without affecting the electrical connection. Mainly, during this closing movement of the twisted portion of the flexible sections 13, that is, the electrical contacts 5, 6, 7, is not deformed, and thanks to the twisted structure, keeps a straight configuration, parallel to the axis of rotation R, while the first branch 15 of the flexible sections acts as a flat spring and absorbs the force at which the circuit 8 is approaching the stator 3.

Similarly, as already mentioned, the loops 40 are also shock-absorbing element of the twisted part.

Areas of flat springs make it possible compensation "gaps" of the Assembly, without exerting pressure on the material, primarily on the solders.

In practice, the motor can be assembled in a traditional way to install the rotor and associated supports, which are not described.

Elastic elements 12 are located in the stator, and when you enter electromachine, keep her away from the stator 3 and the housing 2.

Mainly, the ends 14 of the electrical contacts 5, 6, 7 are from the element 21 for installation through appropriately located holes 30 which provides the conductive paths on the side opposite to the stator 3 with respect to the element 21 for installation, with the above conclusions 17, to which is soldered the ends 14 of the electrical contacts 5, 6, 7.

The tool 35 supports the ends 14 of the electrical contacts 5, 6, 7 in a position suitable for insertion into corresponding holes 30.

The element 21 for installation, preferably made of cast in the form of a plastic material, and the conductive tracks of the electronic circuit 8 are in it, that is, the conductive paths are formed at the same time, when the element 21 for installation is molded in the shape.

This invention achieves its objectives and overcomes the above disadvantages known in the prior art.

The twisted structure of electrical contacts allows the wire to maintain the desired direction, even when the electronic circuit and the stator are moved relative to each other during Assembly of the electric machine. In fact, the twisted structure of the electrical contacts has a high resistance to bending, and this means that the only parts of the wires, who may be deformed during Assembly of the electric machine, are the flat spring located radially relative to the axis of rotation, or even a loop at the base of the twisted parts. It follows that the electrical contacts remain in place, and their electrical connection with the electronic circuitry durable and reliable.

Moreover, the above advantage is even more obvious, given the fact that the elastic elements cause the electronic circuit and the stator to move relative to each other during Assembly. Such movement however does not reduce the reliability of the connections, as twisted electrical contacts hard and have a resistance to bending caused by the movement.

It should also be noted that a rigid connection, for example using solder, between the stator and the electronic circuitry provides much greater contact reliability compared with solutions using the sliding contact of the prior art.

Moreover, the lands of the flat springs makes the engine completely reliable not only in terms of heat absorption, but also in relation to the electrical connections and the associated conductivity.

Industrial applicability

The solution is particularly advantageous for enclosed motors, which, although they have no openings that provide access to internal parts, can be with the gap in an optimal way.

1. Stator for electric machine (1), containing:
core (18) having many polar projections and a set of windings (100, 200, 300) made of electrically conductive material on the pole protrusions, and at least part of the windings (100, 200, 300) is made of wire(110, 120; 210, 220; 310, 320), having a pair of free ends (14), which can be electrically connected with the network power source; and
two or more electrical contacts (5, 6, 7), containing a flexible section (13) which can move in the direction of the core (18) and in the direction from the core (18) electrically connected to corresponding electrical contacts of the power source;
moreover, at least one of the electrical contacts (5, 6, 7) is formed by the two free ends (14) corresponding to different wires(110, 120; 210, 220; 310, 320) and has a twisted form, created by twisting the ends (14) along the initial line passing through the ends (14), and at the base of the curled portion formed loop (40) for each electrical contact (5, 6, 7) with the appropriate wires and the stator is characterized by the fact that the hinge (40) forms a cushioning element for the corresponding twisted plot.

2. The stator under item 1, in which the flexible sections (13) contain the first branch (15) essentially transverse to the axis of rotation (R) e-the historical machine, the first branch (15) forms a suspension of the flat spring, and a second branch (16) essentially parallel to the axis (R), and the second branch (16) contains a loop (40).

3. The stator under item 1 or 2, characterized in that the twisted electrical contact (5, 6, 7) is situated essentially in line with the axis of rotation (R) of the electric machine (1).

4. The stator under item 2, in which the twisted plot of each electrical contact (5, 6, 7) formed by the contact area (14a) of the free ends (14) and contact area (14a) forms the second branch of (16).

5. The stator under item 1, in which the twisted plot of each electrical contact (5, 6, 7) has a length in the range from 20 mm to 30 mm, preferably 25 mm to 28 mm

6. A method of manufacturing an electric rotating machine, comprising stages, which are:
prepare the core (18) having many polar projections and a set of windings (100, 200, 300) made of an electrically conductive material, each of the windings (100, 200, 300) has at least one corresponding conductor (110, 210, 310) and executed on a pole protrusions, and at least part of the windings (100, 200, 300) is made of wire having a free end (14), which can be electrically connected with the network power source;
characterized in that it further comprises the steps are:
place the conductors (10, 210, 310) in a plane essentially perpendicular to the axis of rotation (R) of the electric machine;
deform the conductors (110, 210, 310) to determine in the windings (100, 200, 300) of flexible section (13) which can move in the direction of the core (18) and the core (18), and the method further comprises the steps are stably connected to each other, at least two of the free end (14) of the various windings (100, 200, 300);
twisted United ends (14) with one another to form one electrical contact (5, 6, 7), stranded along the original line passing electrical contact (5, 6, 7), and at this stage curl:
- place the ends (14) next to each other and essentially on the same line relative to each other;
simultaneously clamp the ends (14); and
- keep the ends (14) together and turn them around an axis essentially parallel to the original axis passing through the ends (14), thereby to twist the ends (14) with each other, and the phase space of the ends (14) adjacent to each other are placed the ends (14) so that they were lying in the first plane, and before the step of twisting the ends (14) with each other have the ends (14) in the second plane essentially perpendicular to the first plane, thus to the electrical contact (5, 6, 7), obtained by twisting konzo is (14), located in the second plane,
moreover, the method comprises a stage on which to prepare the support structure (500, 600), and the stage ends (14) adjacent to each other have the ends (14) on opposite sides of the support structures (500, 600) so that subsequent twisting effect on the ends (14) caused twisting only the contact area (14a) of the ends (14), passing from the reference structure (500, 600), and at the stage of preparation of the support structures (500, 600) preparing the support structure (500, 600), which runs along the profile, which changes direction at least once, so that the ends (14) can always pass around their supporting structures (500, 600) during the passage of the ends (14) of the first plane to the second plane.

7. The method according to p. 6, characterized in that it contains a stage on which have conductors (110, 210, 310) in the half-plane bounded by the diameter (D1) of the core (18).

8. The method according to p. 6 or 7, characterized in that it contains a stage, which makes the conductors (110, 210, 310) with a length (L) between 35 mm and 185 mm

9. The method according to p. 6, characterized in that it contains a stage on which have conductors (110, 210, 310) radially relative to the core (18).

10. The method according to p. 6, characterized in that it contains a stage on which have conductors (110, 210, 310) according to the radial location on the half of the angular projection of the core (18).

11. The method according to p. 6, characterized in that at the stage of deformation is clamped conductors (110, 210, 310) and have conductors (110, 210, 310) so that the free ends (14) were located in a predefined angular position relative to the stator in order to obtain flexible areas (13).

12. The method according to p. 6, characterized in that it contains a stage on which form each flexible section (13) branch (15) preset length (L1), transverse to the axis of rotation (R).

13. The method according to p. 12, characterized in that the branch (15) has a length (L1) between 25 mm and 60 mm

14. The method according to any of paragraphs.11-13, characterized in that it contains the stage at which bend the conductors (110, 210, 310) as long as they will not be placed in the second plane, parallel to the axis of rotation (R), thus, to form for each conductor (110, 210, 310) of the second branch (16) parallel to the axis of rotation (R).

15. The method according to p. 14, characterized in that the second branch (16) has a length of between 20 mm and 30 mm

16. The method according to p. 6, characterized in that it contains the stage at which prepare the support structure (500, 600), and on the stage the location of the ends (14) adjacent to each other have the ends (14) with the opposite sides of the support structures (500, 600) so that subsequent twisting effect on the ends (14) caused the twisting that is are end portion (14a) of the ends (14), passing in the direction from the reference structure (500, 600).

17. The method according to p. 6, characterized in that at the stage of preparation of the support structures (500, 600) prepare the first supporting element (500), which is placed around the ends (14), despite the fact that they are located in the first plane, and prepare the second supporting element (600), which is placed around the ends (14), despite the fact that they are located in the second plane, and at the stage of preparation of the second support element (600) send the second supporting element (600) in the direction of the line, essentially, transverse to the first reference element (500), and, preferably, a second supporting element (600) in contact with the first supporting member (500).

18. The method according to p. 17, characterized in that at the stage of preparation of the first support element (500) prepare supporting the drum (Τ), with socket for stable positioning of the core (18), and the first supporting element (500) is in a preset position relative to the socket in the support drum (T).

19. The method according to p. 17 or 18, characterized in that at the stage of preparation of the second support element (600) prepare a flexible head (Μ), which stably supports the second supporting element (600), and the method further comprises a stage on which to impose a flexible head (M) in the core (18) and move the sliding head (M) is thus, the to the second supporting element (600) moved closer, preferably adjacent to the first reference element (500) for forming support structures (500, 600).

20. The method according to p. 17, wherein the steps of preparing first and second supporting elements (500, 600) contain the appropriate steps that prepare the supporting elements (500, 600) that have a direct, preferably, cylindrical in shape, thereby to form a tubular, essentially l-shaped support structure (500, 600).

21. The method according to p. 6, characterized in that on the stage the location of the ends (14) on opposite sides of the support structures (500, 600) perform the intersection of the ends (14) with each other so that the ends (14) were partially wound around the support structures (500, 600).



 

Same patents:

FIELD: engines and pumps.

SUBSTANCE: invention relates to perfection of borehole generators, particularly, to support and limitation of displacement of stator coils arranged in the engine housing. Borehole motor has tubular housing elongated in lengthwise direction, stator part arranged therein, stator coil winding looped back in the stator by end turn with tip. It comprises connector to connect at least one of coil windings and housing end abutting on stator part end to support the winding.

EFFECT: fastening of stator coils not coated with lacquer inside motor housing.

17 cl, 5 dwg

FIELD: electro-mechanical engineering.

SUBSTANCE: bandage of electric machine anchor winding is made in form of continuous solid coiling, coil to coil, in a layer of isolated wire of magnetic or non-magnetic material at whole axial length of bandage section of winding, which does not have other means of radial attachment. The bandage contains even number of wire layers with a lock of beginning and end of coiling on one of end sides. Below each single or double layer of wire, an insert ribbon is positioned which envelopes the anchor surface being bandaged in one layer and which is made of non electro-conductive reinforced material containing axially oriented direct threads rigid to stretching. Aforementioned insert ribbon is provided with collar stops on external surfaces along end edges. Collar stops are longitudinally reinforced with wire or non-metallic filaments rigid to stretching. Axial distance between their internal stopping surfaces is equal to axial size of surface being bandaged.

EFFECT: simplified construction, ensured maximal technically possible reduction of losses to vortex currents, ensured stable reliability.

4 cl, 8 dwg

FIELD: electric engineering and electro-mechanical industry, in particular, features of design of coils with salient poles for rectangular stators of salient-pole electric machine.

SUBSTANCE: in the coil for magnetic system of stator of salient-pole electric machine with rectangular poles, made by winding of flat rectangular cross-section bus onto narrow rib and containing elements of body and coil isolation with monolithic realization of working part of coil, in accordance to invention, on frontal parts of coil air gaps are provided between coils, expanding in wedge-like fashion in axial direction from the end of magnetic-duct of pole, in gaps between coils in longitudinal symmetry plane of coil distant inserts are installed made of solid isolating material with shape and dimensions, corresponding to gaps between coils in this plane, and with width substantially lesser than width of pole, connected by gluing to surfaces of adjacent coils, a packet of structural elements, consisting of frontal parts of coil rings and distant inserts between them, is fastened in longitudinal symmetry plane of the coil by bandage of non electro-conductive material, resistant to stretching, aforementioned inserts being of orthogonally symmetric H-like form with height of bar, equal to width of bus, and with common height, exceeding it by double bandage thickness, aforementioned bandage being positioned between shelves formed by aforementioned method. Due to such characteristic feature, all four sides of rectangular cross-section of each conductor within limits of frontal part of coil form surfaces, directly cooled by blowing air or liquid, correspondingly to scheme of theoretically full usage of external surface of conductors for their cooling.

EFFECT: increased efficiency of electric machine, increased density of current in windings, resulting in improved mass-dimensional characteristics of electric machine, decreased temperature of windings, and, thus, increased lifetime of isolation, allowing to use isolation of lesser heat resistance which is therefore cheaper or more technologically accessible.

8 cl, 10 dwg

FIELD: electrical and electromechanical engineering; rotors of large electrical machines such as turboalternators.

SUBSTANCE: proposed electrical machine rotor has heavy wound core whose winding coils are secured in end portions in radial direction by means of heavy metal banding rings fitted with one end on butt-end portions of core and with other end, on cylindrical surfaces of Z-section alignment rings; inner surface of alignment rings are joined with end portions of rotor shaft, two rows of slits being made in vicinity of mentioned rotor-shaft or banding-rind junction surfaces of each alignment ring uniformly and tangentially disposed over circumference of the latter in relatively staggered manner. One row of mentioned slits can be made in mentioned zones within alignment ring and other row, on rotor shaft surface jointed to alignment ring, for instance in the form of cooling ducts.

EFFECT: enhanced reliability due to additional reduction of alternate stress in zone where banding rings are fitted on rotor core.

1 cl, 2 dwg

The invention relates to the field of electrical and electric engineering, in particular to the construction of large electric machines, mainly turbogenerators and hydrogenerators, and more particularly to the fastening elements of the winding in the slots of the core

The invention relates to electrical machines, namely, devices for closure (closure) of the slots, and the system circuit filled with conductive rods or reels of the slots of the stator body of sheet steel electrical machines with end locks grooves, which consist respectively of the upper prismatic body, on the lower side of which has a surface that passes obliquely, and a lower prismatic body facing to the upper body, the surface of which is inclined relative to the bottom surface of the upper prismatic body in the opposite direction, and direct the jamming may be accomplished by relative displacement of both prismatic bodies

The invention relates to Electromechanical transducers mechanical energy into electrical energy to create a powerful pulse of energy sources intended for use in power systems large thermonuclear devices, lasers high power in other areas of technology

The invention relates to electrical engineering and can be used in transformers and electrical machines

The invention relates to the field of electrical engineering, namely electrical DC machines and can be used in the design of traction motors, ship crests electric motors, excavators and t

FIELD: electricity.

SUBSTANCE: in method for isolation of magnet core slots in micromotor stators all surface of the magnet core, excluding slots, is covered by a sealed dielectric shell made of elastic aggressive-resistant material, the magnet core is placed to a container filled with electrophoretic compound, two electrodes are led to butt ends of the magnet core and positive potential is supplied to the magnet core from a direct-current source and negative potential is supplied to the electrodes and electrophoretic precipitation of film-forming material is made; thereafter the magnet core is removed from electrophoretic compound, freed from the sealed dielectric shell and the film precipitated to the slot surface is subjected to thermal treatment during 4-5 min at temperature of 380-390°C.

EFFECT: obtaining higher adhesive and mechanical properties and reducing labour intensity.

2 dwg

FIELD: electricity.

SUBSTANCE: odd coils (1) and even coils (2) of a winding are arranged on cogs without crowns (3) of a stator with a back (4). Due to arrangement of even coils with external surfaces on an active length in the form of planes parallel to axes of their cogs, and odd coils - with external surfaces on an active length in the form of planes parallel to axes of the adjacent cogs, the electric machine stator winding is produced, making it possible to fully use a cog-to-cog space of the stator and to reduce capacity of losses in the stator winding at the same MMF, preserving at the same time the possibility of separate winding of coils and their subsequent installation on cogs, which increases manufacturability of stator winding manufacturing and increases repairability.

EFFECT: increased area of coils cross section and reduced capacity of losses in them with preservation of MMF, higher manufacturability of a stator winding.

2 dwg

FIELD: electricity.

SUBSTANCE: assembled stator comprises a stator core having the first end, the second end and multiple slots passing from the first end to the second end; multiple current-carrying cords comprising many separate insulated wires. Besides, at least one section of multiple current-carrying cords passes from the first end to the second end of one slot from the specified multitude of slots, at the same time the specified at least one section is twisted inside the specified one slot by the previously determined value to reduce the current circulating along the multitude of separate insulated wires on the specified at least one section to the minimum, and multiple current-carrying cords contain multiple pairs of current-carrying cords connected with a double star, besides, each pair of current-carrying cords corresponds to an AC phase connected to a stator, and has at least two current-carrying cords connected in parallel. Also the method to assemble such stator is proposed.

EFFECT: reduction of current circulating along multiple separate insulated wires on the section of each current-carrying cord arranged in a slot of a stator core to the minimum.

16 cl, 12 dwg

FIELD: engines and pumps.

SUBSTANCE: proposed device comprises housing 1 tetrahedron-like to part 2 and lower part 3 representing casing cut on its both sides, both said parts being separated by shoulder 4. Aforesaid housing has complex-shape inner space 5. The latter houses bolt 6 with spherical end face 7 interacting with inner surface 8 of bearing 9 representing a hollow bush. Additionally, proposed device incorporates frame 10 to interact, by its inner surface, with the housing outer surface and, by its outer surface, with the sides of groove 12 of the core.

EFFECT: ease of maintenance and mounting.

7 cl, 4 dwg

FIELD: electricity.

SUBSTANCE: invention is related to electric machine industry and is used in manufacture of submersible electric motors. Method of installation of pull-through winding of submersible motor stator includes installation of technological pins into stator slots, pulling of winding wire through to stator slot, its intermediate winding on drums and installation in the following slot. Technological pins are made with hinges on both ends. Prior to their installation in slot they are passed through draw plate attached to stator slot. Number of holes in draw plate is equal to number of wires in slot. To the end of winding wire with the help of cartridge end pin is fixed with hook for engaging of technological pin hinge. After end and technological pin wire is pulled through the slot, technological pin is disengaged, and wire is wound on receiving drum. Then drum is turned, wire with end pin is again fixed to technological pin from the other slot and pulled through the slot. Pin is disengaged, and wire is rewound to the other receiving drum. Process is repeated until coils are completely formed.

EFFECT: reduction of possibility of wire insulation damage in the process of winding installation, reduction of labour intensity of winding-insulating works.

2 cl, 3 dwg

FIELD: electrical engineering; direct-current brushless motor stator and its mechanical design.

SUBSTANCE: first alternative of proposed method for manufacturing DC brushless motor stator includes step-by-step formation of rear-yoke strip-shaped material by stamping silicon sheet steel, formation of stator rear yoke by helical placement of rear yoke material, formation of poles having rounded-off components on their outer circular surface using magnetic iron powder, connection of poles to rear yoke by inserting them into inner circular surface of rear yoke, covering of poles with insulating paper, this being followed by winding outer circular surfaces of poles covered with insulating paper. Another alternative of proposed method also includes step-by-step formation of strip-shaped rear-yoke material by stamping silicon sheet steel, formation of stator rear yoke by helical placement of rear yoke material, formation of poles having rounded-off components on their outer circular surface using magnetic iron powder, winding of formers, connection of formers to outer circular pole surfaces, and connection of poles to rear yoke by inserting poles into inner surface of rear yoke. Mechanical design of stator manufactured by one of proposed methods as well as mechanical design of DC brushless motor whose stator is manufactured using one of proposed methods are given in invention specification.

EFFECT: reduced cost, improved saturation and core loss characteristics.

13 cl, 23 dwg

FIELD: electrical engineering and specific features of the design of the motor stators and their manufacturing process.

SUBSTANCE: the motor stator assembly has a great number of yokes manufactured by superposition of a great number of steel plates having a preliminarily enclosed between the yokes and manufactured by molding of a magnetic material with the use of a mould, and a great number of frame bodies with a winding wound on them for generation of induced magnetism, and which are fitted on the outer parts of the poles, the mentioned poles contain: the guide section in the form of a round curve for accumulation of the magnetic flow, the neck section installed on which is the frame body connected to the rear surface of the guide section, and the connecting section formed on the rear surface of the neck section and joined to the yoke. The frame body has an inner wing attached to the outer part of the pole guide section, body connected to the inner wing and installed on the pole neck section for winding of the winding, and an outer wing projecting from each side of the body and covering the winding. Three modifications of the method for manufacture of the given stator of the electric motor are offered, they characterize both different features of manufacture of separate parts of the stator, in particular, with the use of the methods of the powder metallurgy, and the sequence of their assembly.

EFFECT: reduced expenditures connected with manufacture of the motor stator, and improved serviceability of the latter.

24 cl, 16 dwg

The invention relates to the field of electrical engineering

The invention relates to the field of electrical engineering and heavy engineering

The invention relates to electrical engineering, in particular to rotating electrical machines

FIELD: electricity.

SUBSTANCE: invention refers to the sphere of electric engineering and may be used to make a generator stator. The through pin (4) for magnetic stator core (1) of the generator is inserted into an opening (6) in plates (3) of the stator core used for tightening of the core components. The through pin (4) consists of at least two longitudinal members (9, 10) interconnected by at least one connecting element (11). Besides, the assembly method is described for the through pin (4) intended for plates (3) of the generator stator core.

EFFECT: reducing labour intensity of stator manufacture due to potential replacement of through pins located below the foundation bed level, and this replacement does not require special tools or lifting of the frame thus making such replacement easy and cost-effective.

12 cl, 7 dwg

FIELD: electricity.

SUBSTANCE: when the winding is heated up to the preset temperature before impregnation current pulses with an amplitude within the range of (10-50)A and a pulse length of (0.5-10)s are supplied to the winding. Pulse repetition frequency is in the range of (5-10)Hz. Simultaneously with supply of the above pulses the infrared oscillator is connected to the magnet core of the winding. At that the frequency of sound oscillations of the infrasound source are varied constantly and cyclically within the frequency band from 0.5 kHz up to 10 kHz and back. When impregnation is over the infrasound frequency generator is disconnected from the magnet core, the source of current pulses is disconnected from the winding, direct or alternating heating current is supplied to the winding and by means of this current the impregnated winding is heated up to the polymerisation temperature of the impregnating compound and then the winding is dried until the impregnating compound is hardened completely.

EFFECT: reduction of impregnation time per 1,8 times and increase in impregnation coefficient per 1,8 times with simultaneous triple reduction of impregnation coefficient spread for each winding.

2 dwg

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