WO2009083327A1

WO2009083327A1 - Electrical machine with a stator comprising a stator winding and associated method for the production thereof

Info

Publication number: WO2009083327A1
Application number: PCT/EP2008/065353
Authority: WO
Inventors: Gert Wolf
Original assignee: Robert Bosch Gmbh
Priority date: 2007-12-27
Filing date: 2008-11-12
Publication date: 2009-07-09
Also published as: DE102007063278A1

Abstract

The invention relates to an electrical machine, in particular an electrically excited claw pole generator (10) for a motor vehicle, with a stator (16) comprising a groove (15), and with a stator winding (18) made of conductor segments (60, 61, 61'; 60, 60', 61, 61 '). It is provided that at least two conductor segments (60, 60'; 61, 61', 61 ') located in directly adjoining grooves (15) in the circumferential direction and connecting identical groove layers are designed as a normal conductor segment (61; 60, 61) having an axial elongation (H1; H1') and as a raised conductor segment (61'; 60', 61') having a larger axial elongation (H2; H2') in comparison thereto. The invention further relates to a method for producing a stator winding for a corresponding electrical machine.

Description

description

Title Electric machine with a stator winding stator and associated manufacturing method

The invention relates to an electric machine according to the preamble of independent claim 1 and of an associated method for producing a stator winding of a corresponding electric machine according to the preamble of independent claim 1 1.

State of the art

Known stator windings of conductor segments for generators are made of U or V-shaped segments, which are inserted into a so-called setting tool and rotated in the circumferential direction. This precursor of conductor segments is inserted axially into a round stator core. In order to produce the winding profiles, the connecting portions of the individual conductor segments are bent toward one another and connected to each other, so that an electrical contact is made. This process is known, for example, from DE 698 16 263 T2. The stator winding is introduced into a laminated core and forms at least two winding heads. The conventional stator winding is regularly shaped and all conductor segments of the stator winding have the same axial extent. In addition, it is known to increase the overall winding head to improve the cooling of the stator.

Disclosure of the invention

The electric machine according to the invention with the features of independent claim 1 has the advantage that increased conductor segments are present, which have over adjacent normal conductor segments a greater axial extent. Due to the individual raised conductor segments, the cooling of a Laminated stacks of the stator and at the same time improves the flow noise of the electric machine, as increases with the larger axial extent of the conductor segments and at least one axial extent of a winding over the winding section of the conductor segment. A winding head section is to be understood as meaning the sections of the conductor segment which are involved in the formation of a winding head of the stator, that is to say lie outside the grooves of the laminated core.

In addition, the formation of elevated conductor segments requires a smaller copper insert than in a stator winding, in which all conductor segments are formed as conductor segments with greater axial extent. Under the connection of the same groove layers with circumferentially adjacent conductor segments is to be understood that the circumferentially adjacent conductor segments each connect the same radial groove layers in different, adjacent grooves. For example, the conductor segments lying in directly adjacent grooves each connect the radially outermost and the radially innermost groove layers. In particular, each conductor segment is composed of the following sections: a first connecting section, a first inclined section, a section inserted into a groove when the stand is mounted, a second inclined section, one

A bent portion, a third inclined portion, a second inboard portion, a fourth inclined portion and a second connecting portion. In this case, first winding head sections each consist of a second inclined section, a bending section and a third inclined section, and second winding head sections each composed of a first connecting section, a first inclined section, a fourth inclined section and a second connecting section. In addition to the normal outer conductor segments, each in the circumferential direction in directly adjacent grooves such as an elevated conductor segment, there are preferably also other, normal inner conductor segments.

According to the associated method for producing a stator winding of conductor segments for an electrical machine, in particular a stator winding for an aforementioned electric machine, a device for fixing and aligning raised portions of elevated conductor segments is used. The device fixes or straightens the increased portions during a Nutlagenweisen twisting in Umfangsgehchtung the later in a groove in-lying portions in the direction of attention and axial direction. The sections of the elevated conductor segments are in particular bending sections or connecting sections of the raised conductor segments. The stator winding thus produced is easy to cool, at the same time the flow noise of the electric machine is improved.

Furthermore, it is provided with advantage that the different axial extensions of the lying in Umfangsgehchtung in directly adjacent grooves conductor segments connecting the same groove layers, caused by different axial extensions of bending sections of the conductor segments, Thus, the first winding head portion of the elevated conductor segment, each of a second inclined portion, a bending portion and a third inclined portion of the conductor segment is formed, a greater axial extent or corresponding parts of the second winding head portion such as the first inclined portion and the first connecting portion.

It is particularly advantageous that the elevated conductor segments can be cooled by a radial flow of cooling air, since the further protruding, the winding head of the stator winding forming portions of the conductor segments can be aligned directly in the radial flow of cooling air. In this case, the cooling air flow is homogenized in an advantageous manner and at the same time significantly increases the cooling surface of the conductors forming the conductor segments. The radial cooling air flow is produced, for example, by a fan arranged axially next to the magnetically active part of a rotor on a shaft of the electric machine. This fan is designed in particular as a radial fan.

In an embodiment of the electric machine, the number of elevated conductor segments is less than or equal to 50% of the total number of conductor segments connecting the same radial groove layers. This total number results from the number of normal outer conductor segments and the increased outer conductor segments or, correspondingly, from the number of conductor segments with increased connection sections to the total number of conductor segments. The raised outer conductor segments and the normal outer Conductor segments form, for example, a regular pattern on the winding head.

Alternatively, it is advantageously provided that the different axial expansions of the conductor segments located in the circumferential direction in directly adjacent grooves, which connect the same groove layers, are produced by different axial expansions of connecting sections of the conductor segments. Also, by the different axial extent of the connecting portions, the cooling of the laminated core is advantageously increased while improving the flow noise of the electric machine. Thus, the second winding head portion of the raised conductor segment, each formed of a first connecting portion, a first inclined portion, a fourth inclined portion and a second connecting portion of the conductor segment, a larger axial extent.

The measures and refinements recited in the dependent claims, advantageous improvements of the electrical machine specified in the independent claim are possible.

Brief description of the drawings

The invention will be explained in more detail in an embodiment with reference to the accompanying drawings. Show it:

1 shows a longitudinal section through a Klauenpolgenerator designed as an alternator for motor vehicles,

2 shows a circuit diagram of a six-stranded alternator with downstream rectifier,

Figure 3 to 5 a first embodiment of a stator winding, their

Conductor segments and a stator with a winding cutout, wherein

3 shows a view of a section of a winding strand, Figure 4 is a perspective radial view of a section of all winding strands and

Figure 5 is a schematic side view of an inventive

Stand, where only a section of all winding strands is shown, concerns,

Figures 6 and 7 a second embodiment of a stator winding, its conductor segments and a winding cutout, wherein

Figure 6 is a view of a section of a winding strand and

Figure 7 is a perspective radial view of a section of all

Winding strands concerns, and

Figure 8 shows an interaction of the elevated conductor segments with axial

Protrusions in the end shields.

Embodiment (s) of the invention

FIG. 1 shows a section through an electrical machine designed as an alternator 10 for a motor vehicle. This has inter alia a two-part housing 13, which consists of a first bearing plate 13.1 and a second bearing plate 13.2. The bearing plate 13.1 and the bearing plate 13.2 take in a stand 16, with an annular laminated core 17, in which inwardly open and axially extending grooves 15 designed as a stator winding 18 winding is inserted. The stator winding 18 is formed by preferably a plurality of phase-forming winding strands 70, 71, 72, 73, 74, 75. The annular stator 16 surrounds with its radially inwardly directed surface an electromagnetically excited rotor 20, which is designed as a claw-pole rotor. The rotor 20 consists inter alia of Klauenpolplatinen 22 and 23, at the outer periphery extending in each case in the axial direction Claw pole fingers 24 and 25 are arranged. Both claw pole boards 22 and 23 are arranged in the rotor 20 such that their axially extending claw pole fingers 24, 25 alternate at the periphery of the rotor 20 as north and south poles. This results in magnetically required Klauenpolzwischenräume between the oppositely magnetized Klauenpolfingern 24 and 25, which extend slightly oblique to the machine axis because of tapering to its free ends towards Klauenpolfinger 24 and 25. For the following description of the invention, this course is simplified referred to as axial. The rotor 20 is rotatably supported in the respective end shields 13.1 and 13.2, respectively, by means of a shaft 27 and one respective rolling bearing 28 located on each side. It has two axial end faces, on each of which a fan 30 is attached. These fans 30 essentially consist of a plate-shaped or disk-shaped section, starting from the fan blades in a known manner. These fans 30 serve to allow an air exchange between the outside and the interior of the electric machine 10 via openings 40 in the end shields 13.1 and 13.2. For this purpose, the openings 40 are provided at the axial ends of the end shields 13.1 and 13.2, via which 30 cooling air is sucked into the interior of the electric machine 10 by means of the fan. This cooling air is accelerated radially outward by the rotation of the fans 30, so that they can pass through the cool air-permeable winding heads 45 on the drive side and 46 on the electronics side. This effect cools the windings. The cooling air takes after passing through the winding heads, or after the flow around this winding heads a path radially outward through openings not shown.

In Figure 1 on the right side there is a protective cap 47, which protects various components against environmental influences. Thus, this protective cap 47 covers, for example, a slip ring assembly 49, which supplies a field winding 51 with exciting current. Around this slip ring assembly 49 around a heat sink 53 is arranged, which acts as a positive heat sink here. As a so-called minus heat sink, the bearing plate acts 13.2. Between the bearing plate 13.2 and the heat sink 53, a connection plate 56 is arranged, which fixed in the bearing plate 13.2 minus diodes 58 and in this illustration not shown plus diodes of a rectifier 19 in the heat sink 53 in the form of a bridge circuit interconnects.

2 shows an AC generator 10 with six phase-forming winding strands 70, 71, 72, 73, 74, 75 illustrated by a circuit diagram. The totality of all winding strands 70, 71, 72, 73, 74, 75 forms the stator winding 18. The six winding strands 70, 71, 72, 73, 74, 75 are connected to two independent three-phase systems, each of the independent three-phase systems having a star connection, whose winding strands have an electrical phase shift of 120 ° at the star point. The star circuits are formed by the winding strands U1, V1, W1, 70, 71, 72 and U2, V2, W2, 73, 74, 75. The two independent three-phase systems are offset by an electrical angle of 30 °. Each of the two three-phase systems is connected to a separate B6 Brückenzleichhchter 19.1, 19.2, which are interconnected on the DC side. On the DC voltage side, a voltage regulator 26 is connected in parallel, which regulates the voltage of the generator by influencing the current through the exciter winding 51. The electrical system is shown schematically by the vehicle battery 31 and by vehicle consumers 32. The embodiment of the winding is not limited to this circuit example. Any number of strings, phase numbers and wiring types can be used.

FIG. 3 shows a section of a winding strand 70 as an exemplary embodiment of a winding constructed from conductor segments, which consists of five interconnected conductor segments 60, 61, 61 ^' . The illustrated winding is realized with four conductors in each groove 15 shown in Figure 5, with the narrow sides of the conductors facing each other and the broad sides of the conductors facing a groove wall. The conductors are arranged in the groove 15 in four radial groove layers 1, 2, 3, 4, wherein the radially outermost groove position is referred to as groove position 1 and the radially innermost groove position as 4.

Each conductor segment 60, 61, 61 ^' consists of at least one substantially axially aligned first connecting portion 60a, 61a, 61 ^' a, which is for contacting two radially adjacent connecting portions 60a, 61a, 61 ^' a, 6Oi, 61 i, 61 ^' i is used. This contacting can be done for example by welding, soldering or other methods of electrical contacting. The first connecting portion 60a, 61 a, 61 ^' a merges into a first inclined portion 60 b, 61 b, 61 ^' b, the first connecting portion 60 a, 61 a, 61 ^' a with a first axially aligned, in a groove 15 einliegen Section 60c, 61 c, 61 ^' c of the conductor segment 60, 61, 61 ^' connects. The in-slot, first section 60c, 61c, 61 ^' c merges into a second inclined section 6Od, 61d, 61 ^' d which merges into a bending section 6Oe, 61e, 61 ^' e. A third inclined portion passes from the bending portion 6of, 61 f, 61 ^'f and connects the bending portion 6 NC, 61 e, ^61' e with the inset in a second groove 15 portion 60g, 61 g, 61 ^'g. The second in the groove 15 inset portion 60g, 61 g, 61 ^'g is a fourth inclined portion 60h, 61 h, ^61' connected h opens into a second, substantially axially oriented connecting portion 6Oi, 61 i, 61 ^"\ In principle, it is also conceivable here for the conductor segment 60, 61, 61 ^{'to be constructed} from a plurality of turns, ie for a plurality of bending sections 6Oe, 61 e, 61 ^' e arranged on both axial sides of the laminated core 17. A conductor segment 60, 61, 61 ^' is usually divided into two radial layers, wherein the first connecting portion 60 a, 61 a, 61 ^' a, the first inclined portion 60 b, 61 b, 61 ^' b, the first straight, in the groove 15 inset portion 60 c, 61 c , 61 ^'c and the second inclined portion 6Od, 61 61 ^d' d are in the same radial layer. the third inclined portion 6of, 61 f, 61 ^'f, the second in the groove 15 inset portion 60g, 61 g, 61 ^' g, the fourth inclined section 60h, 61h, 61 ^' h and the second verb Induction section 6Oi, 61 i, 61 ^" lie in a second radial layer. The bending portion 6 NC, 61 e, 61 ^'e connects the sections of the two radial layers. The winding of a winding strand 70, 71, 72, 73, 74, 75 of a stator winding 18, which is given here by way of example, is made up of three different conductor segments 60, 61, 61 ^' : an inner normal conductor segment 60, which lies in the groove layers 2 and 3 , an outer normal conductor segment 61, with a first axial extension H1 on the bending portion side of the stator 16 between the bending portion 61 e and the axial end of the laminated core 17. The outer conductor segment 61, 61 ^' encloses an inner conductor segment 60 on the electronics side winding 46. The outer conductor segment 61, 61 ^' is located in the groove layers 1 and 4 a. A second outer raised conductor segment 61 ^' has a second axial Extension H2 on the bending portion side of the stator 16 between the bending portion 61 ^' e and the axial end of the laminated core 17.

The section of a winding of a winding strand 70 shown in FIG. 3 is connected as follows. The first outer conductor segment 61 with an axial extension H1 on the bending portion side of the stator 16 is located with a first straight portion 61 c in groove position 1, with its second straight portion 61 g in groove position 4 and is with its second connecting portion 61 i with the second connecting portion 6Oi of a first inner conductor segment 60 connected. The second connection portion 6Oi of the first inner conductor segment 60 is provided with a second straight groove-in portion 60g in the groove layer 3, with a first groove-inserted portion 60c in the groove layer 2 of the inner conductor segment 60 and a first connection portion 60a of the inner conductor segment 60 connected. The first connecting portion 60a of the first inner conductor segment 60 is connected to the second outer conductor segment 61 ^' , which has a greater axial extent H2 on the bending portion side of the stator 16, via the first connecting portion 61 ^' a, which in turn is connected to a first straight in a groove 15 inset portion 61 ^'c in slot position 1, a second straight portion ^61' g in the slot position 4 and a second connecting portion 61 ^"\ is connected. the second connecting portion 61 ^'g of the second outer conductor segment ^61' is connected to the second inner conductor segment 60 is connected via the second connecting portion 6Oi, which in turn is connected to a second straight groove portion 60g in groove position 3, a first straight portion 60c in the groove position 2, and a first connecting portion 60a by continuation of the illustrated scheme and Reiheschal tion of offset by a pole pitch conductor segments 60, 61, 61 ^' .

The sequence of outer normal conductor segments 61 of small axial extent H1 on the bending portion side of the stator 16 and outer conductor segments 61 ^'of large axial extent H2 on the bending portion side of the stator 16 can be arbitrarily selected here. By extending the axial extent of H2 on the bending portion side of the stator 16 of the outer conductor segment 61 ^'generally extend the second inclined portions ^61' d and the third inclined portions 61 ^'f. The sequence of inner and outer conductor segments 60, 61, 61 ^'forms a loop winding. The structure of the conductor segment winding is not limited to this example. It is also possible to construct a conductor segment winding with two approximately identical conductor segments lying next to one another in the radial direction, which then connect groove layers 1 and 2, or 3 and 4, and then form a wave winding accordingly.

4 shows a detail of a stator winding 18 for a stator 16 with ninety-six slots 15, six phase-forming winding phases U1, V1, W1, U2, V2, W2 70, 71, 72, 73, 74, 75 and an electrically excited rotor 20 sixteen Poles. The windings of all strands are designed according to FIG. They are not limited to this embodiment, for example it is also possible to produce a comparable stator winding 18 for a stator 16 with thirty-six slots 15, three phase-forming phase windings and an electrically excited rotor 20 with twelve poles.

The outer conductor segments 61 ^' having a larger axial extent H2 on the bending portion side of the stator 16 are distributed in this example to the various phase-forming winding strands 70, 71, 72, 73, 74, 75 such that every fifth outer conductor segment 61, 61 ^' is increased. This is due to the resulting approximately symmetrical division of the

Resistance increase due to the greater axial extent of the conductor segments on all winding strands 70, 71, 72, 73, 74, 75 advantageous.

FIG. 5 shows the section of the stator winding 18 shown in FIG. 4 in a laminated core 17. The drawn axial dimensions H1, H2 on the bending section side of the stator 16 are between the axial end of the laminated core 17 and the tip of the respective bending section 61e, 61 ^' e ,

The number of elevated outer conductor segments 61 ^' is less than or equal to 50% of the total number of normal outer conductor segments 61 and increased outer Conductor segments 61 ^' . Advantageously, the raised outer conductor segments 61 ^' and the normal outer conductor segments 61 are arranged to form a regular pattern on the electronics-side winding head 46. By the individual over the normal outer conductor segments 61 axially projecting outer conductor segments 61 ^' , the cooling of the laminated core and the flow noise of the generator can be improved in an advantageous manner. At the same time, the lengthening of individual conductor segments requires less use of copper than if the totality of all the winding segments were lengthened.

FIG. 6 shows a section of a winding strand as an embodiment of a winding made up of conductor segments, which consists of five interconnected conductor segments 60, 60 ^" , 61, 61 ^" . The illustrated winding is realized with four conductors in each groove 15, with the narrow sides of the conductors facing each other and the broad sides of the conductors facing a groove wall. The conductors are arranged in the groove 15 in four radial groove layers 1, 2, 3, 4, wherein the radially outermost groove position is referred to as groove position 1 and the radially innermost groove position as 4.

Each conductor segment 60, 60 ^" , 61, 61 ^" consists of at least one im

Substantially axially oriented first connecting portion 60a ^" , 61a, 61 ^" a for contacting two radially adjacent connecting portions 60a, 60 ^" a, 61 ^' a, 61 ^" a, 6Oi, 60 ^" i, 61 i, 61 ^" i is used , This contacting can be done for example by welding, soldering or other methods of electrical contacting. The first connecting portion 60a, 60 ^" a, 61a, 61 ^" a merges into a first inclined portion 60b, 60 ^" b, 61b, 61 ^" b of the first connecting portion 60a, 60 ^" a, 61a, 61 ^" a with a first axially aligned, in a groove 15 inlaid portion 60c, 60 ^" c, 61 c, 61 ^" c of the conductor segment 60, 60 ^" , 61, 61 ^" connects. The in-groove first section 60c, 60 ^" c, 61c, 61 ^" c merges into a second inclined section 6Od, 60 ^" d, 61d, 61 ^" d which merges into a bend section 6Oe, 60 ^" e, 61 e, 61 ^" e. From the bending portion, a third inclined portion 6Of, 60 ^" f, 61f, 61 ^" f passes and connects the bending portion 6Oe, 60 ^" e, 61e, 61 ^" e to the portion 60g, 60 ^" g inserted in a second groove 15 , 61 g, 61 ^" g. The second section 60g, 60 ^" g, 61g, 61 ^" g inserted in the groove 15 has a fourth one inclined portion 60h, 60 ^" h, 61 h, 61 ^" h, which opens into a second, substantially axially aligned connecting portion 6Oi, 60 ^" i, 61 i, 61 ^" i. In principle, it is also conceivable here that the conductor segment 60, 60 ^" , 61, 61 ^{" is} made up of several turns, ie a plurality of bending sections 6Oe, 60 ^" e, 61 e, 61 ^" e arranged on both axial sides of the laminated core 17. A conductor segment 60, 60 ^" , 61, 61 ^" is usually divided into two radial layers, the first connecting portion 60a, 60 ^" a, 61a, 61 ^" a, the first inclined portion 60b, 60 ^" b, 61b, 61st ^" b, the first straight section 60c, 60 ^" c, 61c, 61 ^" c inserted in the groove 15, and the second inclined section 6Od, 60 ^" d, 61d, 61 ^" d of a conductor segment 60, 60 ^" , 61, 61 ^" lie in the same radial layer. The third inclined portion 6Of, 60 ^" f, 61f, 61 ^" f, the second portion 60g, 60 ^" g, 61g, 61 ^" g inserted in the groove 15, the fourth inclined portion 60h, 60 ^" h, 61h , 61 ^" h and the second connecting portion 6Oi, 60 ^" i, 61 i, 61 ^" i of a conductor segment 60, 60 ^" , 61, 61 ^" lie in a second radial layer. The bending section 6Oe, 60 ^" e, 61 e, 61 ^" e connects the sections of the two radial layers of a conductor segment 60, 60 ^" , 61, 61 ^" . The winding of a winding strand 70 of a stator winding 18, which is given here as an example, is made up of four different conductor segments 60, 60 ^" , 61, 61 ^" . An inboard normal conductor segment 60 which rests in the groove layers 2 and 3 with a first axial extent H1 ^' on the connector portion side of the stator 16 between the connection portion 60a, 6Oi and the axial end of the lamination stack 17. An inner elevated conductor segment 60 ^". sandwiched in the groove layers 2 and 3, whose first connecting portion 60 ^" a has a greater axial extent H2 ^' on the connecting portion side of the stator 16 between the

^"Comprising a and the axial end of the laminated core. The second connecting portion 60 ^'connecting portion 60 i has a first axial dimension ^H1' on the connecting portion side of the stator 16 between the connecting portion ^60" i and the axial end of the laminated core 17.

An outer normal conductor segment 61, with a first axial extension H1 ^' on the connector portion side of the stator 16 between the connecting portion 61 a, 61 i and the axial end of the laminated core 17 and a first axial extension H1 on the bent portion side of the Stand 16 between the bending portion 61 e and the axial end of the laminated core 17th

An outer raised conductor segment 61 ^" having a second axial extent H2 ^' on the connecting portion side of the stator 16 between the connecting portion 61 ^" a and the axial end of the laminated core 17, with a first axial extent H1 ^' on the connecting portion side of the stator 16 between the connecting portion 61 ^" i and the axial end of the laminated core 17 and with a second axial extension H2 on the bending section side of the stator 16 between the bending section 61 ^" e and the axial end of the laminated core 17.

An outer conductor segment 61, 61 ^'61 ^"surrounds each having an inner conductor segment 60, ^60" on the electronics side winding head 46. The outer conductor segments 61, ^61', 61 ^"are located into the slot positions 1 and 4. FIG.

The section of a winding strand 70 shown in FIG. 6 is connected as follows. The first outer conductor segment 61 with an axial extension H1 on the bending portion side of the stator and an axial extension H1 ^' on the connecting portion side of the stator 16 is located with a second straight portion 61 g in groove 4, with its first straight portion in groove position 1 and with its first connecting portion 61 a connected to the first connecting portion 60a of a first inner conductor segment 60. The first connecting portion 60a of the first inner conductor segment is connected to a first straight in-slot portion 60c in the groove layer 2, a second in-slot portion 60g in the groove layer 3 of the inner conductor segment, and a second connecting portion 6Oi of the inner conductor segment 60 , The second connecting portion 6Oi of the first inner conductor segment 60 is connected to the second outer conductor segment 61 ^" having a larger axial extent H2 ^' on the connecting portion side of the stator 16 and a larger axial extent H2 on the bending portion side of the stator 16 via the second connecting portion 61 ^"i connected, which has an axial dimension H1 ^'on the connecting portion side of the stator sixteenth The second connection section 61 ^" i is in turn connected to a second straight section 61 ^" g in groove position 4, a first straight section, which engages in a groove 15 61 ^' c in the groove layer 1 and a first connecting portion 61 ^" a, wherein the first connecting portion 61 ^" a has an axial extent H2 ^' on the connecting portion side of the stator 16. The first connecting portion 61 ^"a of the second outer conductor segment ^61" is connected to the second inner conductor segment 60 ^'via the second connecting portion 60 ^"a having an axial dimension ^H2' on the connecting portion side of the stator sixteenth The connecting portion 60 ^" a is in turn connected to a first straight groove-engaging portion 60 ^" c in groove position 2, a second straight portion 60 ^" g in the groove position 3, and a second connecting portion 60 ^" i. The still missing portions of the winding strand U1 70 are obtained by continuing the illustrated scheme and the series connection of offset by a pole pitch conductor segments 60, 60 ^" , 61, 61 ^" .

The sequence of outer and inner conductor segments 60, 61 of small axial extension H1 ^' on the connecting portion side of the stator 16 and outer and inner conductor segments 60 ^" , 61 ^{" of} large axial extent H2 ^' on the connecting portion side of the stator 16 can be arbitrarily selected here. It is also possible beyond the embodiment, the first connecting portions 60 ^" a or the second connecting portion 60 ^" i or both connecting portions 60 ^" a, 60 ^" i of the inner conductor segment 60 ^" a with a larger axial extent H2 ^' on the connecting portion side of the stator 16, analogously, it is possible for the outer conductor segment 61 ^" , the first connection portion 61 ^" a or the second connection portion 61 ^" i or both

Connecting portion 61 ^" a, 61 ^" i with a larger axial extent H2 ^' on the connecting portion side of the stator 16 perform. Moreover, in the outer conductor segment 61, 61 ^{", it is} possible to realize the bending portion having a first axial extent H1 on the bending portion side of the stator 16 or a second axial extent H2 on the bending portion side of the stator 16.

By extending the axial extent H2 ^' on the connecting portion side of the stator 16 of the inner and outer conductor segments 60 ^" , 61 ^" , the first ones are usually elongated Connecting portions 60 ^" a, 61 ^" a. By the sequence of the inner and outer conductor segments 60, 60 ^" , 61, 61 ^" , a loop winding is formed. The structure of the conductor segment winding is not limited to this example. It is also possible to construct a conductor segment winding with two approximately identical conductor segments lying next to one another in the radial direction, which then connect groove layers 1 and 2, or 3 and 4, and then form a wave winding accordingly.

Fig. 7 shows a section of a stator winding 18 for a stator 16 with ninety-six slots 15, six phase-forming winding strands U1, V1, W1, U2, V2, W2 70, 71, 72, 73, 74, 75 and an electrically excited rotor 20 with sixteen Poles. The windings of all strands are designed according to FIG. They are not limited to this embodiment, for example it is also possible to produce a comparable stator winding 18 for a stator 16 with thirty-six slots 15, three phase-forming phase windings and an electrically excited rotor 20 with twelve poles.

The inner and outer conductor segments 60 ^" , 61 ^" with an axial extent H2 ^' on the connecting portion side of the stator 16 are distributed in this example on the various phase-forming winding strands 70, 71, 72, 73, 74, 75, that every fifth outer and inner conductor segment 60 ^" , 61 ^{" is} increased. This is due to the resulting approximately symmetrical distribution of resistance increase by the greater axial extent of the conductor segments on all winding strands 70, 71, 72, 73, 74, 75 advantageous.

Figure 8 shows a schematic side view of the stator 16 according to the invention in conjunction with a bearing plate 13, that in the axial direction projections 21, for example ribs, which serve to direct the cooling air flow. In particular, the cooling air flow is to be directed onto or around the elevated bending sections 61 ^' e, 61 ^" e, or connecting sections 60 ^" a, 61 ^" a in order to improve the cooling of the stator 16. At the same time, the projections serve as heat sink enlargement remove the bearing shield 13.1, 13.2 and so lower component temperatures of ball bearings and electronics Radius of the distance from groove position 1 is formed to the machine axis. The ribs preferably intervene alternately in the spaces formed by the increased bending portions 61 ^' e, 61 ^" e, and connecting portions 60 ^" a, 61 ^" a of the conductor segments, respectively, whereby the cooling of the machine is particularly improved.

In the production of conductor segments 60, 60 ^" , 61, 61 ^' , 61 ^" is based on a round or profile wire, which is first brought into a U or V-shaped preform. In this preform, the radial distances of the two later in the grooves 15 inlets 60c, 60g, 60 ^" c, 60 ^" g, 61 c, 61 g, 61 ^' c, 61 ^' g, 61 ^" c, 61 ^" g already given, however, these sections have no distance in Umfangsshchtung. This distance is produced by nutweisweiser twisting the sections 60c, 60g, 60 ^" c, 60 ^" g, 61 c, 61 g, 61 ^' c, 61 ^' g, 61 ^" c, 61 ^" g of the precursor of the conductor segment in the circumferential direction. The second precursor of the conductor segment obtained from this is inserted axially into a round laminated core 17. To complete the stator strands, the connecting portions 60a, 6Oi, 60 ^"a, ^60" i, 61 a, 61 i, 61 ^'a, 61 ϊ, 61 ^"a, ^61" i nutlagenweise be bent towards each other in the circumferential direction and then connected to each other so that an electrical contact between the respective connecting portions is formed. It is particularly advantageous for the transition from the first to the second precursor when the bending section 61 ^'s of the increased conductor segment ^61' or the raised connecting portions 60 ^"a, ^61" a by a groove in a not shown tool or by means of appropriate brackets in axial direction and / or held or guided in the circumferential direction.

LIST OF REFERENCE NUMBERS

1 first groove position (outermost groove position)

2 second groove position

3 third groove position

4 fourth groove position (innermost groove position)

10 alternator

13 two-part housing

13.1 first end shield

13.2 second end shield

14 teeth

15 groove

16 stands

17 annular laminated core

18 stator winding

19 rectifier

19.1, 19.2 B6 bridge rectifier

20 electrically excited runner

21 axially protruding from the bearing plate protrusions

22 claw pole board

23 claw pole board

24 Claw Wolfinger

25 claw-pole fingers

26 voltage regulator

27 wave

28 rolling bearings

30 fans

31 vehicle battery

32 vehicle consumers

40 openings in the end shields

45 drive-side, cool air-permeable winding head

46 Electron-side, cool air-permeable winding head

47 protective cap

49 slip ring assembly

51 excitation winding 53 rectifier heat sink

56 connection plate

58 negative diode

60 inner conductor segment 60 a first axially aligned portion of the inner conductor segment as a connecting portion

60b first inclined portion of the inner conductor segment

60c first axially aligned portion of the inner conductor segment, in-fitting 6Od second inclined portion of the inner conductor segment

6Oe bending section of the inner conductor segment

6Of third inclined portion of the inner conductor segment

60g second axially aligned portion of the inner conductor segment, in-slot 60h fourth inclined portion of the inner conductor segment

6Oi second axially aligned portion of the inner conductor segment as a connecting portion

60 ^" inner conductor segment with raised connection section

60 ^" a first axially aligned portion of the inner conductor segment with increased connection portion, as a connecting portion

60 ^" b first inclined portion of inner conductor segment with raised connection portion 60 ^" c first axially aligned portion of inner conductor segment with raised connection portion, in groove 60 ^" d second inclined portion of inner conductor segment with raised connection portion 60 ^" e bending portion of inner conductor segment with raised

connecting portion

60 ^" f third inclined portion of the inner conductor segment with increased connection portion

60 ^" g second axially aligned portion of the inner conductor segment with increased connection portion, in-slot 60 ^" h fourth inclined portion of the inner conductor segment with increased connection portion 60 ^" i second axially aligned portion of the inner conductor segment with increased connection portion, as a connecting portion 61 outer conductor segment

61 a first axially aligned portion of the outer conductor segment as a connecting portion

61 b first inclined portion of the outer conductor segment

61 c first axially aligned portion of the outer conductor segment, in-slot

61 d second inclined portion of the outer conductor segment 61 e bending portion of the outer conductor segment

61 f third inclined portion of the outer conductor segment

61 g second axially aligned portion of the outer

Conductor segment, in-slot

61 h fourth inclined portion of the outer conductor segment 61 i second axially aligned portion of the outer

Conductor segment as a connecting section

61 ^' outer conductor segment with axially increased bending portion

61 ^' a first axially aligned portion of the outer conductor segment with axially increased bending portion as a connecting portion 61 ^' b first inclined portion of the outer conductor segment with axially increased bending portion 61 ^' c first axially aligned portion of the outer conductor segment with axially increased bending portion, in-groove

61 ^' d second inclined portion of the outer conductor segment with axially increased bending portion

61 ^' e bending section of the outer conductor segment with axially increased

Bending portion 61 ^' f third inclined portion of the outer conductor segment with axially increased bending portion 61 ^' g second axially aligned portion of the outer

Conductor segment with axially increased bending portion, in groove 61 ^' h fourth inclined portion of the outer conductor segment with axially increased bending portion 61 ^" \ second axially aligned portion of the outer Conductor segment with axially increased bending portion as a connecting portion 61 ^" outer conductor segment with axially increased bending portion and elevated connection portion 61 ^" a first axially aligned portion of the outer conductor segment with axially increased bending portion and elevated connection portion as a connecting portion 61 ^" b first inclined portion of the outer conductor segment with axially increased bending portion and an elevated connecting portion 61 ^" c first axially aligned portion of the outer conductor segment with axially increased bending portion and raised connecting portion, in-fitting 61 ^" d second inclined portion of the outer conductor segment with axially increased bending portion and elevated

Connecting portion 61 ^" e bending portion of the outer conductor segment with axially increased

Bending section and elevated connecting section

61 ^" f third inclined portion of the outer conductor segment with axially increased bending portion and elevated connecting portion

61 ^" g second axially aligned portion of the outer

Conductor segment with axially increased bending portion and elevated connecting portion, in-slot

61 ^" h fourth inclined portion of the outer conductor segment with axially increased bending portion and elevated connecting portion

61 ^" i second axially aligned portion of the outer

Conductor segment with axially increased bending section and increased connecting section as connecting section 70,71, 72 winding strands U1, V1, W1 73,74,75 winding strands U2, V2, W2

H1 first axial extension of a bending section (61e) of the outer conductor segment (61)

H1 ^' first axial extent of a connecting portion (60a, 6Oi,

60 ^" i, 61 a, 61 i, 61 ^" i) ^"(H2 ^'second axial extension of a connecting portion 60 H2 second axial expansion of a bending portion ^(61' e) of the outer conductor segment (61 ^', ^61)" a,

61 ^" a)

Claims

claims

An electric machine, in particular an alternating current generator (10), preferably an electrically excited claw pole generator (10) for a motor vehicle, with a stator (16) having grooves (15) and with a stator winding (18) made of conductor segments (60, 61, 61 ^' ; 60, 60 ^" , 61, 61 ^" ), characterized in that at least two conductor segments (61, 61 ^' , 60, 60 ^" , 61, 61 ^" ) lying in the same direction in directly adjacent grooves (15) as a conductor segment (61; 60) having an axial extent (H1; H1 ^' )

61) and is formed as an enlarged conductor segment (61 ^' , 60 ^" , 61 ^" ) having a larger axial extent (H2, H2 ^' ).

2. Electrical machine according to claim 1, characterized in that the elevated portions of the conductor segments (61 ^' , 60 ^" , 61 ^" ) are cooled by a radial flow of cooling air.

3. Electrical machine according to one of the preceding claims, characterized in that the number of raised portions (61 ^' e; 60 ^" a, 61 ^" a, 61 ^" e) of the conductor segments (61 ^' , 60 ^" , 61 ^" ) is smaller or equal to 50% of the total number of normal sections (61 e, 60a, 61 a) of the conductor segments (60, 61) and raised sections (61 ^' e; 60 ^" a, 61 ^" a, 61 ^" e) of the conductor segments (61 ^' ; 60 ^" , 61 ^" ) within a winding head (45; 46).

4. Electrical machine according to one of the preceding claims, characterized in that the raised portions (61 ^' e; 60 ^" a, 61 ^" a, 61 ^" e) of the conductor segments (61 ^' , 60 ^" , 61 ^" ) and the normal sections (61 e, 60a, 61 a, 61 e) of the conductor segments (61, 60, 61) form a largely regular pattern on the winding head (45, 46).

5. Electrical machine according to one of the preceding claims, characterized in that the raised portions (61 ^' e; 60 ^" a, 61 ^" a, 61 ^" e) of the conductor segments (61 ^' , 60 ^" , 61 ^" ) at least partially have a different axial orientation than the portions (61 e, 60 a, 61 a, 61 e) of the normal conductor segments (61, 60, 61).

6. Electrical machine according to one of the preceding claims, characterized in that the orientation of the inclined

Sections (61 ^' d, 61 ^' f; 60 ^" b, 61 ^" b) of the raised conductor segments (61 ^' , 60 ^" , 61 ^" ) substantially follow the orientation of the inclined portions (61d, 61f, 60b, 61b) of FIG normal conductor segment (61, 60, 61) corresponds.

7. Electrical machine according to one of the preceding claims, characterized in that in the bearing plate (13.1, 13.2) axial projections exist which a cooling air flow to the raised portions (61 ^' e; 60 ^" a, 61 ^" a, 61 ^" e) of Conductor segments (61 ^' , 60 ^" , 61 ^" ) steers.

8. Electrical machine according to one of the preceding claims, characterized in that the different axial expansions (H1 ^' , H2 ^' ) on the connecting portion side of the stator (16) in the circumferential direction in directly adjacent grooves (15) lying conductor segments (60, 60 ^" ; 61, 61 ^" ), the same groove layers connect, by different axial expansions of

Connecting portions (60a, 6Oi, 60 ^" a, 60 ^" i; 61 a, 61 i, 61 ^" a, 61 ^" i) of the conductor segments (60, 60 ^" , 61, 61 ^" ) are formed.

9. Electrical machine according to one of claims 1 -7, characterized in that the different axial dimensions (H1,

H2) on the bending section side of the stator (16) of the circumferentially in directly adjacent grooves (15) lying conductor segments (61, 61 ^' ), the same groove layers connect, by different axial extensions of bending portions (61 e, 61 ^' e) of the conductor segments (61, 61 ^' ) arise.

10. Electrical machine according to claim 9, characterized in that over the bending portion 61 e of the normal conductor segment (61) projecting bending portion (61 ^' e) of the elevated conductor segment (61 ^' ) has a different axial orientation than the bending region (61 e) of the normal conductor segment (61) and is aligned radially in the cooling air flow.

1. A method for producing a stator winding of conductor segments for an electrical machine, in particular a stator winding for an electrical machine according to one of claims 1 to 10, characterized in that a device for fixing and alignment of raised portions (61 ^' e; 60 ^" a , 61 ^" a) is used by elevated conductor segments (61 ^' , 60 ^" , 61 ^" ) in the axial and / or circumferential direction during the production process, which has a greater axial extent (H2; H2 ^' ) than adjacent normal conductor segments (60, 61) ^. ) exhibit.