Method and device for manufacturing an electrical machine, electrical machine and group of electrical machines

The invention is in the field of mechanical engineering and production technology and relates in particular to a method for producing an electrical machine with laminated cores and electrical windings and an electrical machine.

Electrical machines, such as electric motors or generators, are usually designed with laminated cores and wound electrical coils. Since in order to generate magnetic fields from flexible conductors, electrical coils are wound around parts of the laminated core. This is not uncommon

Round wire used, d. H. a strand-shaped electrical conductor with a circular cross-section, which is usually wound in several layers, which are also referred to as windings, to form a coil. The cross section refers to a cut surface that is spatially aligned perpendicularly to the longitudinal direction of the electrical conductor, which is predetermined by the strand shape of the conductor, with the longitudinal direction being oriented essentially parallel to the strand. The space utilization of the space available for the coil by the material actually available as a conductor cross-section is limited and is usually between 30% and 55% of the ideal value at which the available space is used completely for conducting electricity could.

Various forms of electrical coils for such electrical machines have already been proposed in order to use economies of scale in the production of electrical machines. In order to reduce the costs for a rotor, a stator, laminated cores and other parts, it should be possible to produce coils in different variants.

So far, an individual requirement for an electrical machine, for example a power or torque class, has usually been implemented by changing or adapting the length or diameter of the electrical machine, so that the individual requirement is met. A performance adjustment can also be realized by adjusting the power electronics, in which case the hardware components of the machine are oversized in many cases, since they have to be designed for the highest current density that occurs and the associated heat dissipation requirements. Further individual requirements can relate, for example, to a heat class, a cooling system or a price of the electrical machine, with the price being able to be assigned to a price class in terms of its numerical value.

In some cases, to achieve the highest possible degree of filling of the space available for the electrical windings, already cast metallic coils have been proposed, which allow both a free design of the cross section of the conductor and a design of the outer shape of the winding. With a cast coil, the installation space, which extends outward orthogonally to the axis of rotation of the electrical machine, can be optimally utilized. With a constant amount of cross-section of the conductor along such a coil, the cross-sectional shape of the conductor can vary along the coil axis to optimize space utilization and heat distribution in the coil. This enables a higher degree of efficiency and a higher current density within the coil.

Against the background of the state of the art, the present invention is based on the object of creating a method for producing an electrical machine in which the design of the electrical machine is made possible in the simplest possible way in terms of an individual requirement.

The object is achieved with the features of the invention according to claim 1. The claims referring back to claim 1 relate to possible configurations of the method for producing an electrical machine. In addition, the invention relates to a device for producing an electrical machine according to patent claim 7 and to an electrical machine according to claim 8 or one of the claims based on it.

The claimed method is about the production of an electrical machine's, which has a laminated core and one or more windings, each surrounding a tooth of the laminated core. The method provides that, starting from a specified construction of the machine with a specified laminated core of the electrical machine to be produced, depending on one or more of the parameters maximum torque, maximum power, and minimum cooling power, which lead to a maximum value of a temporally average electrical Corresponding current density in the one or more winding/windings, as well as price range from a number of specified types, a type of winding is assigned, where In the case of the types, in particular a cast winding made of copper, a cast winding made of a copper alloy, a cast winding made of aluminum, a cast winding made of an aluminum alloy, a cast winding made of magnesium, a cast winding made of a conductive plastic, optionally one made of wire wound winding, an insulation system, the list from which the type of insulation system is selected includes insulation systems with thermal class 180°C, thermal class 250°C and thermal class 300°C, a cooling system with which the one or more winding/windings can be connected and is selected from the types of air cooling system, direct water cooling system, indirect water cooling system, or a sub-selection of these types.

An air cooling system is designed to supply the cooling structures, for example the cooling ducts or cooling vanes, with a flow of air which dissipates heat which can be generated in the windings during machine operation. The air cooling system can be constructed with the help of a fan, for example, and can also have other connecting elements, for example a tube and/or a hose, which direct the air flow generated by the fan to the cooling structures. The air heated in the cooling structures can be given off to a heat exchanger or to the environment, for example.

A water cooling system is designed to supply the cooling structures, for example the cooling channels or cooling vanes, with water in such a way that the water can flow through them and heat that can arise in the windings during machine operation is dissipated. A water cooling system can be constructed with the help of a pump, for example, and can also have other connecting elements, for example a tube and/or a hose, which direct the water flow generated by the pump to the cooling structures. The water heated in the cooling structures can be delivered to a heat exchanger, for example.

Direct water cooling is designed to supply water to the cooling structures in the windings, for example the cooling channels or cooling lugs.

Indirect water cooling is designed to supply water to other components, i.e. components that are different from the windings, for example a laminated core of the electrical machine or other parts of the electrical machine such as bearings or housings that are thermally connected to the windings, so that the heat that arrives there during machine operation can be dissipated.

The selection of the materials to be used can, for example, be carried out by a data processing system using a computer program or by a hard-wired automatic control for the winding after entering the parameters to be met in the electrical machine. It can be different, for example, in a database or in a simple memory device within a control device

Requirement parameters of the electrical machines each have to be assigned a material from which the electrical winding to be used is made.

In the method, by selecting a cost-effective winding, the most cost-effective machine can first be designed and a data processing device can be used to determine whether this machine meets the required electrical and mechanical requirements. If this is not the case, you can switch to the next higher-performance configuration of the winding and calculate this configuration with regard to the electrical and mechanical performance. In this way, each designed machine is checked against the existing requirements until all requirements are met, in which case the lowest possible cost for the machine is chosen. The individual windings selected in each case have the same geometric dimensions and differ only in the choice of material and, for example, also in the choice of the cross-sectional shape of the conductor. In addition to the cast coils, wound coils made of the materials mentioned can also be selected to meet special conditions. In addition, you can optionally choose from the cooling structures mentioned.

In one configuration of the method, it can be the case that the permissible mean electric current density over time in the one or more cast windings made of copper or a copper alloy is particularly preferred for a period of at least 1 minute, preferably at least 10 minutes, related to this at least 1 hour and in particular particularly preferably at least 1 day

- when connected to an air cooling system, has a maximum value greater than 10 A/mm2, preferably greater than 12 A/mm2,

- when connected to an indirect water cooling system, a maximum value greater than 20 A/mm2, preferably greater than als 24 A/mm2 and

- has a maximum value greater than 60 A/mm2 when connected to a direct water cooling system.

The electric current density indicates an electric current based on the cross-sectional area of ​​the electric conductor through which the electric current passes in the longitudinal direction of the electric conductor. In an electrical conductor with an electrical resistance, the power loss generated, i.e. the heat generation, is proportional to the square of the electrical current density. The electric current can be direct current or alternating current, for example. In the case of an alternating current, the electric current can be specified with the aid of an effective value known to a person skilled in the art. In the case of an electrical alternating current, the values ​​of the specified time-average electrical current densities relate to values ​​that are determined using the effective value of the electrical current.

The heat actually generated depends on the length of time with which the electrical current density occurs in the electrical conductor. Viewed over a period of time, a description of the generation of heat with an electric current density averaged over time can be helpful. The mean electric current density over time refers to a mean value over time of the electric current density over a period of time. The electrical current density is averaged over time over the period of time, for example 1 minute, 10 minutes, 1 hour or 1 day. For example, the electric current density can be mathematically integrated over this period of time and the result of the mathematical integration can be divided by the duration of the period.

Permissible electrical current density averaged over time means here that the value or level of the permitted electrical current density averaged over time does not lead to damage to the windings, the machine and/or parts of the machine, which contributes to the machine not reaching its intended service life or unacceptable hazards that are listed, for example, in the relevant technical standards known to those skilled in the art, arise.

The method can also be designed in such a way that the permissible mean electric current density over time in the one or more cast winding(s) made of aluminum or an aluminum alloy for the thermal class 180°C of the insulation system for a period of at least 1 minute, preferably at least 10 minutes,

more preferably at least 1 hour and particularly particularly preferably at least 1 day

- when connected to an air cooling system, has a maximum value greater than 6 A/mm2, preferably greater than 7 A/mm2,

- when connected to an indirect water cooling system, has a maximum value greater than 12 A/mm2, preferably greater than 14 A/mm2 and

- when connected to a direct water cooling system, has a maximum value greater than 35 A/mm2.

In one embodiment of the method, there is the possibility that the permissible mean electric current density over time in the one or more cast winding/windings made of aluminum or an aluminum alloy for the thermal class 250°C of the insulation system for a period related to this of at least 1 minute, preferably at least 10 minutes, particularly preferably at least 1 hour and in particular particularly preferably at least 1 day

- when connected to an air cooling system, has a maximum value greater than 7 A/mm2, preferably greater than 15 A/mm2,

- when connected to an indirect water cooling system, has a maximum value greater than 14 A/mm2, preferably greater than 25 A/mm2 and

- has a maximum value greater than 45 A/mm2 when connected to a direct water cooling system.

In one embodiment of the method, there is also the possibility that the permissible mean electric current density over time in the one or more cast windings/windings made of aluminum or an aluminum alloy for the thermal class 300°C of the insulation system for a period of time related to this at least 1 minute, preferably at least 10 minutes, particularly preferably at least 1 hour and in particular particularly preferably at least 1 day

- when connected to an air cooling system, has a maximum value greater than 8 A/mm2, preferably greater than 17 A/mm2,

- when connected to an indirect water cooling system, has a maximum value greater than 16 A/mm2, preferably greater than 30 A/mm2 and

- when connected to a direct water cooling system, has a maximum value greater than 56 A/mm2.

To produce an electrical machine according to the method described above, the invention can also relate to a device for producing an electrical machine with a laminated core and one or more windings, each of which is a tooth of the laminated core ts surrounded. In such a device, it can be provided that the device has a data processing unit with a memory device in which several different types of winding are stored that have the same external dimensions, and the data processing unit is set up to store one or more of the parameters Maximum torque, maximum power, and minimum cooling power, which correspond to a maximum value of a time-average electrical current density in the one or more cast winding/windings, as well as a price class and this/these, based on a specified construction of the machine with a assigned laminated core specified, one of the types stored in the storage device, the types in particular a cast copper winding, a cast copper alloy winding, a cast aluminum winding, a cast aluminum alloy winding a cast magnesium winding, a cast winding made of a conductive plastic, optionally a wire-wound winding, an insulation system, a list from which the type of insulation system is selected, insulation systems with thermal class 180°C, thermal class 250°C and thermal class 300°C, a cooling system to which the one or more winding(s) can be connected and is selected from the types of air cooling system, direct water cooling system, indirect water cooling system, or a sub-selection of these types include.

The invention also relates to an electrical machine with a laminated core and one or more windings, each of which surrounds a tooth of the laminated core, it also being provided that at least one, in particular several or all teeth of the laminated core each have a holding device for a deferred Have winding, the ben after pushing the winding on the tooth in a locked position can be brought and prevents displacement and / or movement of the winding on the tooth.

For this purpose, it can be provided, for example, that the holding device has a latch which can be slid or folded out of the contour of the respective tooth out of a recess in the tooth into a locking position.

The holding device serves to be able to slide prefabricated, in particular cast coils in a simple manner onto the sheet metal teeth of the laminated core of a machine, which coils can thus be fixed mechanically well. In addition, such a holding device should also be able to serve, for example, to hold an electrical winding that is to be optionally wound up, so that no structural adjustments to the laminated core are necessary for the positioning of an electrical coil, regardless of the type.

The invention also relates to an electrical machine with a laminated core and one or more windings, each of which surrounds a tooth of the laminated core, the electrical machine being characterized as an alternative or in addition to the holding device in that one or more of the windings are cast windings with cooling structures.

The cooling structures can be cooling channels or cooling vanes, for example. Cooling lugs can be cast on, for example, and channels can be introduced during casting or by post-processing, for example.

In addition, the property right application relates to a group of electrical machines, in particular generators and/or motors, which are equipped with laminated cores of identical construction, the machines being equipped with windings which each surround teeth of the laminated cores.

The object is achieved according to the invention in that at least two of the machines differ in terms of the type of winding.

The different windings can be selected from different cast windings and from wound windings that are wound from wire. In particular, all of the windings can also be cast windings, in which case they are used, for example, in FIG

5 th material or in other coil parameters differ from each other.

Typically, conductive castable materials are used.

The different windings can in particular be selected from the following types or a sub-selection of the following types: cast copper winding, cast winding from a first

10 Copper alloy, cast second copper alloy winding, cast aluminum winding, cast first aluminum alloy winding, cast second aluminum alloy winding, cast magnesium winding, cast conductive plastic winding, optional wire wound winding .

15 By using the same laminated cores, windings can be used that are suitable for different All electrical machines with different performance data have the same external shape. This results in a more cost-effective production of the laminated cores for a larger number of machines, with the performance requirements of the individual machines

20 can be met by concrete selection among the various windings available. The individual windings have the same external geometric shape, so that all windings can be applied to the same teeth of laminated cores, and the different windings differ, for example, in terms of the different material

25 choice. Groups of machines can thus be produced in which a first machine satisfies first performance requirements, while a second and/or further machine satisfies second performance requirements which differ from the first performance requirements.

Cooling structures can be present on or in the windings. This can

BO NEN be formed for example as cooling channels and / or cooling lugs.

patent claims

1. A method for producing an electrical machine (21, 22, 23) with a laminated core and one or more windings (4, 4'), each of which surrounds a tooth (2, 3) of the laminated core, characterized in that, Based on a specified construction of the machine with a specified laminated core of the electrical machine to be manufactured as a function of one or more of the parameters maximum torque, maximum power and minimum cooling power, which lead to a maximum value of a time-average electrical current density in one or more windings/ Windings correspond ponding, as well as price class from a number of specified Bauar th a type of winding (4, 4 ') is assigned, the Bauar th in particular a cast copper winding, a cast winding made of a copper alloy, a cast aluminum winding minium , a cast aluminum alloy winding, a cast magnesium winding, a cast Wic 180°C thermal class, 250°C thermal class and 300°C thermal class insulation systems from the list from which the insulation system design is selected, a cooling system , to which the one or more winding/windings can be connected and is selected from the types of air cooling system, direct water cooling system, indirect water cooling system, or a sub-selection of these types.

2. The method as claimed in claim 1, characterized in that the specified types of windings (4, 4') that are available for selection in order to be assigned to the electrical machine (21, 22, 13) each have the same geometric dimensions.

3. The method according to claim 1 or 2, characterized in that a cast winding is equipped with cooling structures, preferably in the form of cooling channels (27) or cooling lugs (28).

4. The method according to any one of claims 1 to 3, characterized in that the permissible time-average electric current density in the one or more cast winding / windings (4, 4 ') made of copper or a copper alloy for a and related to this time space of at least 1 minute, preferably at least 10 minutes, particularly preferably at least 1 hour and in particular particularly preferably at least 1 day

- when connected to an air cooling system, has a maximum value greater than 10 A/mm2, preferably greater than 12 A/mm2,

- when connected to an indirect water cooling system, has a maximum value greater than 20 A/mm2, preferably greater than 24 A/mm2 and

- when connected to a direct water cooling system, has a maximum value greater than 60 A/mm2.

5. The method according to any one of claims 1 to 4, characterized in that the permissible time-average electric current density in the one or more cast winding / windings (4, 4 ') made of aluminum or an aluminum alloy for the thermal class 180 ° C des Isolating system for and related to this period of at least 1 minute, preferably at least 10 minutes, more preferably at least 1 hour and particularly particularly preferably given to at least 1 day

- when connected to an air cooling system, has a maximum value greater than 6 A/mm2, preferably greater than 7 A/mm2,

- when connected to an indirect water cooling system, has a maximum value greater than 12 A/mm2, preferably greater than 14 A/mm2 and

- when connected to a direct water cooling system, has a maximum value greater than 35 A/mm2.

6. The method according to any one of claims 1 to 5, characterized in that the permissible time-average electric current density in the one or more cast winding / windings (4, 4 ') made of aluminum or an aluminum alloy for the thermal class 250 ° C des Isolating system for and related to this period of at least 1 minute, preferably at least 10 minutes, more preferably at least 1 hour and particularly particularly preferably given to at least 1 day

- when connected to an air cooling system, has a maximum value greater than 7 A/mm2, preferably greater than 15 A/mm2,

- when connected to an indirect water cooling system, has a maximum value greater than 14 A/mm2, preferably greater than 25 A/mm2 and

- when connected to a direct water cooling system, has a maximum value greater than 45 A/mm2.

7. The method according to any one of claims 1 to 6, characterized in that the permissible time-average electric current density in the one or more cast winding / windings (4, 4 ') made of aluminum or an aluminum alloy for the thermal class 300 ° C des Isolating system for and related to this period of at least 1 minute, preferably at least 10 minutes, more preferably at least 1 hour and particularly particularly preferably given to at least 1 day

- when connected to an air cooling system stem has a maximum value greater than 8 A/mm2, preferably greater than 17 A/mm2,

- when connected to an indirect water cooling system, has a maximum value greater than 16 A/mm2, preferably greater than 30 A/mm2 and

- when connected to a direct water cooling system, has a maximum value greater than 56 A/mm2.

8. Device for producing an electrical machine (21, 22, 23) with a laminated core and one or more windings (4, 4 '), each surrounding a tooth (2, 3) of the laminated core, characterized in that the device has a data processing unit (17) with a memory device (19) in which several different types of winding are stored which have the same external dimensions, and the data processing unit is set up to store one or more of the parameters maximum torque, maximum power and minimum cooling capacity, which corresponds to a maximum value of an electrical current density averaged over time in the one or more cast winding/windings, as well as a price class and this/these, based on a specified design of the machine with a specified laminated core, one of the in the storage device (19) to assign stored types, the types in particular e cast copper winding, a cast copper alloy winding, a cast aluminum winding, a cast aluminum alloy winding, a cast magnesium winding, a cast conductive plastic winding, an insulation system, with a list, from which the type of insulation system is selected from, includes insulation systems with thermal class 180°C, thermal class 250°C and thermal class 300°C, a cooling system with which the one or more winding/windings can be connected and selected from air cooling system, direct water cooling system, indirect water cooling system types, or a sub-selection of these types.

9. Electrical machine (21, 22, 23) with a laminated core and one or more windings (4, 4 '), each surrounding a tooth (2, 3) of Blechpa ketes, characterized in that at least one, in particular special several or all teeth (2, 3) of the laminated core each have a holding device for a deferred winding which

after the winding has been slid onto the tooth, it can be brought into a locked position and a displacement and/or movement of the winding (4, 4') on the tooth is prevented.

10. Electrical machine according to claim 9, characterized in that the holding device has a latch (24, 26) which can be pushed out or folded out of the contour of the respective tooth (3) into a blocking position.

11. Electrical machine according to claim 9 or 10, characterized in that a cast winding has cooling structures, preferably in the form of cooling channels (27) or cooling lugs (28).

12. Group with two or more electrical machines (21, 22, 23), in particular generators and/or motors, which are equipped with identical sheet metal packages, the machines (21, 22, 23) having windings (4, 4 ') which surround the respective teeth (2, 3) of the laminated cores, characterized in that at least two of the machines (21, 22, 23) differ in terms of the design of the windings, the differing windings (4, 4', 4") are selected in particular from different cast windings.

13. Group of electrical machines (21, 22, 13) according to claim 12, characterized in that the differing windings (4, 4') are selected from the following types or a sub-selection of the fol lowing types: cast copper winding, Cast winding made from a first copper alloy, cast winding made from a second copper alloy, cast aluminum winding, cast winding made from a first aluminum alloy, cast winding made from a second aluminum alloy, cast winding made from magnesium, cast winding made from a conductive plastic.

14. Group of electrical machines (21, 22, 13) according to claim 12, characterized in that the differing windings (4, 4') are selected from the following types: cast winding made of copper, cast winding made of a first copper alloy , cast winding made of a second copper alloy.

15. Group of electrical machines according to claim 12, characterized in that the differing windings (4, 4 ') are selected from the following types: cast aluminum winding, cast winding from a first aluminum alloy, ge cast winding from a second aluminum alloy.

16. Group of electrical machines according to claim 12, characterized in that the differing windings (4, 4') are selected from the following types:cast copper alloy winding, cast aluminum alloy winding.

17. Group of electrical machines according to one of claims 13, 15 or 16, characterized in that the differing windings (4, 4') have an insulation system, a list from which the type of insulation system is selected, insulation systems with the following thermal classes includes: thermal class 180°C, thermal class 250°C, thermal class 300°C.

18. Group of electrical machines according to one of claims 12 to 17, characterized in that the differing windings (4, 4') can be connected to a cooling system, the cooling system being selected from the following types: air cooling system, direct Water cooling system, indirect water cooling system.