阅读说明：本技术 用于他励同步电机的转子的星形盘 (Star disk for rotor of separately excited synchronous machine ) 是由 P·乌尔曼 P·赫尔曼 M·戈恩格罗斯 于 2021-05-14 设计创作，主要内容包括：一种用于他励同步电机的转子的星形盘,其具有居中的盘体,多个接片从盘体出发径向地延伸,在所述多个接片的端部上分别设置有端板,使得在盘体与相应的端板之间形成绕线槽,该绕线槽通过形成槽底的接片界定并且侧向地通过形成槽侧面的盘体和形成槽侧面的端板界定,并且该绕线槽用于接纳围绕接片引导的、由在多层中缠绕的导线形成的导体线匝,其中,接片配设有沟槽,该沟槽沿缠绕方向延伸并且用于接纳各一个导线部段,其中,在接片的至少一侧上在槽侧面上设置有至少一个附加的沟槽。(A star disk for the rotor of a separately excited synchronous machine, having a central disk body, from which a plurality of webs extend radially, end plates being provided in each case at the ends of the plurality of webs, such that a winding slot is formed between the disk body and the respective end plate, which winding slot is delimited by webs forming the slot bottom and laterally by the disk body forming the slot side and the end plates forming the slot side, and which winding slot is intended to receive conductor turns, which are guided around the webs and formed by wires wound in a plurality of layers, wherein the webs are provided with grooves which extend in the winding direction and are intended to receive in each case one wire section, wherein at least one additional groove is provided on at least one side of the webs on the slot side.)

1. A star-shaped disk for a rotor (1) of a separately excited synchronous machine, having a central disk body (7a, 7b), from which a plurality of webs (8a, 8b) extend radially, end plates (9a, 9b) each being provided at the ends of the plurality of webs, so that a winding slot (11a, 11b) is formed between the disk body (7a, 7b) and the respective end plate (9a, 9b), which is delimited by the webs (8a, 8b) forming a slot base (14a, 14b) and is delimited laterally by the disk body (7a, 7b) forming a slot side (12a, 12b) and the end plates (9a, 9b) forming a slot side (13a, 13b), for receiving a conductor (5) which is guided around the webs (8a, 8b) and is formed by a wire wound in a plurality of layers, wherein the webs (8a, 8b) are provided with grooves (15a, 15b) which extend in the winding direction and are intended to receive in each case one conductor section,

it is characterized in that the preparation method is characterized in that,

at least one additional groove (16a, 16b, 17a, 17b) is provided on the groove flank (12a, 12b, 13a, 13b) on at least one side of the web (8a, 8 b).

2. The star-shaped disk of claim 1,

it is characterized in that the preparation method is characterized in that,

at least one additional groove (16a, 16b, 17a, 17b) is provided on each side of the webs (8a, 8b) on both groove flanks (12a, 12b, 13a, 13 b).

3. Star disc according to claim 1 or 2,

it is characterized in that the preparation method is characterized in that,

additional grooves (16a, 16b, 17a, 17b) are provided at the level of the immediately following layer of the conductor turn.

4. Star disc according to any of the previous claims,

it is characterized in that the preparation method is characterized in that,

an additional plurality of grooves (16a, 16b, 17a, 17b) are provided on one or both sides, respectively, which grooves are provided at different heights of the conductor turns.

5. The star disk of claim 4,

it is characterized in that the preparation method is characterized in that,

a plurality of grooves (16a, 16b, 17a, 17b) are provided at successive levels of the conductor turn.

6. Star disc according to claim 4 or 5,

it is characterized in that the preparation method is characterized in that,

a plurality of grooves (16a, 16b, 17a, 17b) is arranged at least one quarter of the height of the respective groove flank (12a, 12b, 13a, 13 b).

7. The star-shaped disk of claim 6,

it is characterized in that the preparation method is characterized in that,

a plurality of grooves (16a, 16b, 17a, 17b) extend on both groove flanks (12a, 12b, 13a, 13b) at the same height.

8. Star disc according to any of the previous claims,

it is characterized in that the preparation method is characterized in that,

at least the grooves (16a, 16b, 17a, 17b) extend on the webs (8a, 8b) or perpendicularly to the longitudinal axes of the webs or at an angle (a) of not equal to 90 DEG to the longitudinal axes of the webs, the angle being dimensioned such that the outlets of the grooves (16b, 17b) are offset from the inlets by the wire thickness of the conductor.

9. Star disc according to any of the previous claims,

it is characterized in that the preparation method is characterized in that,

the webs (8a, 8b) have a rectangular cross section, the edges of which are rounded at least on the winding groove side, wherein the grooves (15a, 15b) extend on the web outer side and at least over a part of both web sides.

10. Star disc according to any of the previous claims,

it is characterized in that the preparation method is characterized in that,

a slot (18) for introducing the conductor into the winding slot (11b) is formed in the disk body (7b), extends as far as the tab (8b) and opens into the plane of the groove (15b) on the tab side.

11. Star disc according to any of the previous claims,

it is characterized in that the preparation method is characterized in that,

the star plate is made of plastic.

12. Rotor comprising a rotor shaft (2) and a lamination stack (3) arranged thereon and two star-shaped discs (6) according to any of the preceding claims axially at the ends of the lamination stack (3), onto which conductor turns are wound.

13. The rotor as set forth in claim 12, wherein,

it is characterized in that the preparation method is characterized in that,

one of the star-shaped disks (6a) has a groove (15a) extending perpendicularly to the longitudinal axis of the web (8a), while the other star-shaped disk (6b) has a groove (15b) extending at an angle (α) different from 90 ° to the longitudinal axis.

14. A synchronous machine comprising a rotor (1) according to claim 12 or 13.

Technical Field

The invention relates to a star disk for a rotor of a separately excited synchronous machine, having a central disk body from which a plurality of webs extend radially, end plates being provided on the ends of the plurality of webs in each case, such that a winding groove is formed between the disk body and the respective end plate, which winding groove is delimited by the webs forming the bottom of the groove and laterally by the disk body and the end plates forming the sides of the groove, and which winding groove serves for receiving conductor turns, which are guided around the webs and formed by conductor wires wound in a plurality of layers, wherein the webs are provided with grooves which extend in the winding direction and serve for receiving in each case one conductor section.

Background

The electric machine is composed primarily of a stationary part, i.e. the stator, and a moving part, i.e. the rotor. The rotor itself usually comprises a rotor shaft on which a lamination stack consisting of a plurality of individual laminations is mounted. In separately excited synchronous machines, the rotor also has a number of conductor turns corresponding to the number of individual phases, wherein such synchronous machines are mostly three-phase machines. The conductor turns extend axially and are looped around at the rotor end, so that a corresponding turn structure is obtained. In order to wind the wires around at the two rotor ends, a so-called star disk is located at the end side of the lamination stack, on which star disk respective winding slots are formed, into which the respective wires are wound in a plurality of layers lying one above the other, so that the wires run from one star disk to the other, here through the lamination stack.

For this purpose, each of the star disks has a central disk body with which the star disk is mounted on the rotor shaft. Tabs extend radially outward from the disk body, the number of tabs corresponding to the number of poles of the rotor, wherein each tab is terminated by an end plate. The central disk body and the end plates each form a slot flank which delimits the respective winding slot radially inwardly and outwardly, while the webs or the web flanks remote from the lamination stack form the slot base.

In order to ensure a positionally fixed positioning of the conductor in the first layer wound onto the tab, in order to obtain a precise guidance of the conductor, it is known to provide the tab with grooves extending in the winding direction, wherein each groove is intended to receive an inserted conductor section. It is thus possible by means of this groove to fasten each conductor section to such an extent that it does not slide sideways and forms a defined first layer, which enables the winding of the other layers. However, if a plurality of layers are wound one on top of the other, it is not always possible to achieve an exact layer structure on all layers due to fluctuations in the wire diameter and possible manufacturing tolerances of the star disk.

Disclosure of Invention

It is therefore an object of the present invention to provide a relatively improved star disk.

In order to achieve this object, according to the invention, in a star disk of the type mentioned at the outset, at least one additional groove is provided on at least one side of the web on the groove flank.

The star disk according to the invention is provided with a groove section not only at the web, i.e. at the groove bottom, but also at least one of the two groove flanks in such a way that at least one additional groove, preferably of course also a plurality of additional grooves with a height offset, is provided at this groove flank. This makes it possible to achieve, in addition to guiding or supporting the wires or wire sections at the groove bottoms, an additional support in one or more further metal wire layers above the first metal wire layer, depending on the number of additional grooves. This ensures additional lateral guidance in the at least one, preferably several, further wire layers, since a defined winding geometry can also be achieved laterally with defined conductor guides, so that a better layer structure and thus a higher copper fill factor can be achieved, wherein the increased copper fill factor in turn leads to a higher efficiency of the electrical machine.

In this case, preferably not only on one side of the web, i.e. on one groove flank, but also on both groove flanks, i.e. on both sides of the web, at least one additional groove is provided, wherein at least one additional groove, preferably a plurality of additional grooves that are graduated in height, are provided on each groove flank, so that guidance can be achieved not only in one additional wire layer but also in a plurality of additional wire layers.

The additional groove on one or both groove sides is expediently arranged at the level of the immediately following layer of the conductor turn, i.e. directly adjoining the first winding plane on the web or in the groove portion of the web in terms of height. If only one additional groove is provided, it is also conceivable to provide this additional groove in a higher plane. Independently of this, the distance of this additional groove in height from the tab plane or from the tab groove section is of course selected as a function of the wire diameter, so that an exact positioning of the respective additional groove in the wire layer produced during winding is ensured.

As already indicated above, it is of course particularly expedient to provide a plurality of additional trenches offset in height on one or each groove flank, that is to say to arrange the trenches in different height positions, wherein these height positions of course correspond to the respective metal wire layer or metal wire plane. The additional grooves do not have to directly adjoin the web plane or the web groove sections, but can also be offset from one another in terms of height, wherein no direct sequence is necessary in the groove sequence of the additional grooves, but a corresponding offset of a plurality of metal wire layers can also be present there.

Preferably, however, a plurality of grooves are provided at successive heights of the conductor turns, so that each winding layer or winding plane following the first metal wire layer is guided laterally precisely on one side or preferably also on both sides.

The grooves are arranged at least one-fourth of the height of the respective slot flank, but preferably also at a greater height if the height of the entire winding structure requires this. Preferably, the groove extends at the same height on both groove sides, so that identical, symmetrical wire guides are obtained on both sides.

As described above, the wire is wound into the winding slot. In order to wind the winding groove over the entire width, the wire needs to be guided radially from the inside to the outside and back in order to wind the individual layers with conductor sections running parallel. In this case, a layer jump is necessarily required at each return/return (Umlauf), with which the conductor is shifted further radially outward or inward by the wire thickness or the wire diameter. This layer jump is usually achieved in a winding technique when looping around a star disk, while on another star disk there is a simple, non-jumping return. In order to limit layer jumps in the first layer, but at the same time to achieve a precise conductor guidance on the other star disk as well, a particularly advantageous development of the invention provides that at least the plurality of grooves extend on the web either perpendicularly to the longitudinal axis of the web or at an angle of not equal to 90 ° to the longitudinal axis of the web, the angle being dimensioned such that the outlet of the groove is offset from the inlet by the wire thickness of the conductor. That is to say, the two star disks are designed differently according to the invention with regard to the groove on the web. One of the star disks, on which no layer jump is formed, has a groove portion, wherein the groove extends perpendicular to the web longitudinal axis. In any case, of course, all the grooves run parallel, but are not angled here, but perpendicular to the longitudinal axis of the web. This makes it possible to achieve a guided winding without layer jumps. However, the other star disk is designed in its groove section exclusively for the layer jump specified. The grooves of the groove sections, which also extend parallel to one another here, form an angle of not equal to 90 ° with the longitudinal axis of the web. The angle is determined such that, viewed in the radial direction, the groove inlet and the groove outlet are arranged offset from one another by the wire thickness or the wire diameter. That is, the returned wire is staggered by exactly one wire thickness or wire diameter relative to the wire that was previously returned.

In principle, it is preferably provided that the web has a rectangular cross section, which is rounded at least at the edges on the winding groove side, wherein the groove extends over the web outer side and at least a part of the two web side surfaces. By means of such a rectangular web structure and the groove on the outside of the web, an approximately large-area conductor guide in the groove is achieved, which groove also extends at least partially over the two web sides on which the conductor is also guided. Furthermore, particularly when layer jumps are realized on the star disk by means of the groove sections, a very precise conductor guidance and thus a very stable layer structure can be realized, so that layer jumps occur over a relatively long winding distance, i.e. from the groove inlet on one web side over the groove length on the web outer side to the groove outlet on the other web side.

In a preferred embodiment of the invention, a groove is formed in the disk body, which groove guides the conductor into the winding groove, extends as far as the web and opens into the plane with the web-side groove. The first wire from the star plate must be forcibly inserted into the winding slot. According to the invention, the metal wire is now introduced through a groove formed in the disk body, which groove extends up to the tab and into the region of the groove portion. The groove opens into the plane of the groove with the first contact side, so that the conductor is guided into the recessed groove plane and then continues to be guided. This results in the lead-in conductor being led in at the start in such a way that the thickness of the metal line is reduced by approximately one. This now results in that the conductor can be wrapped in the second winding plane without problems at the first start and no "bulge" is formed in the turn which occurs when the wire protrudes approximately out of the plane of the groove at the start. This is also very advantageous for a precise layer structure.

The star disk itself is preferably made of plastic, i.e., the star disk is an injection molded part on which the corresponding geometry and in particular the groove can be formed by means of a corresponding injection mold.

In addition to the star disk itself, the invention also relates to a rotor comprising a rotor shaft and a lamination stack arranged on the rotor shaft and two star disks of the above-described type, which terminate the lamination stack axially, conductor turns being wound onto the star disks. Preferably, one star disk has a layer jump formed or defined by a groove portion, while the groove portion of the other star disk defines a simple, non-jumping return. That is to say, one of the star discs with a layer jump has grooves which extend at an angle of not 90 ° to the longitudinal axis, while the other star disc has grooves which extend perpendicularly to the longitudinal axis of the web.

Finally, the invention also relates to a synchronous machine comprising a rotor of the aforementioned type.

Drawings

Further advantages and details of the invention emerge from the examples of embodiment described below and from the figures. The figures show that:

figure 1 shows as a principle drawing a perspective view of a rotor according to the invention,

fig. 2 shows a partial view of the star plate of the first embodiment, showing tabs along with wire winding slots,

fig. 3 shows a perspective view of a portion of the star disk in fig. 2, wherein the groove portions on the radially outer groove side are shown,

fig. 4 shows a perspective view of a portion of the star disk in fig. 2, showing the groove portions on the radially inner groove side,

figure 5 shows a partial view of a star-shaped disc with obliquely extending grooves according to a second embodiment of the invention,

FIG. 6 shows a perspective view of a portion of the star disk of FIG. 5 showing the groove portions on the radially outer groove side, and

fig. 7 shows a perspective view of a portion of the star disk of fig. 5, showing the groove portions on the radially inwardly located groove sides.

Detailed Description

Fig. 1 shows a rotor 1 comprising a rotor shaft 2, on which a lamination stack/core 3 is arranged, which comprises a plurality of axially successive laminations. A set of individual (magnetic) poles 4 is formed on the stator lamination 3, to which poles corresponding conductor turns 5 are assigned, which can be excited by an excitation current in order to generate a magnetic field via the poles 4.

In order to be able to form these turns, the stator lamination 3 is provided on both axial sides with a respective star disk 6, wherein the conductor turns 5 are wound by the star disks 6 and are wound there into corresponding winding grooves. The star disk 6 is preferably made of plastic and is designed to achieve the most precise possible layer structure by means of a plurality of conductor layers wound one on top of the other.

Fig. 2 shows a partial view of a first star disk 6a according to the invention. The first star disk comprises a central disk body 7a, to which reference is also made to fig. 3 and 4, which has a central bore through which the rotor shaft 2 extends. A plurality of, in the example shown, six webs 8a project radially from the central disk body 7a, which webs are in turn provided with end-side end plates 9a, on which in turn magnetic flux-conducting metal elements 10a are arranged. The design is such that a winding groove 11a is formed, which is delimited or defined radially by a radially inner groove flank 12a formed by the disk body 7a and a radially outer groove flank 13a formed by the end plate 9a and by the webs 8a defining the groove base 14 a.

As shown in fig. 2 to 4, a plurality of grooves 15a are provided on the web 8a itself, which grooves all run parallel to one another. The tab 8a itself has an approximately rectangular cross section with rounded outer edges, wherein the groove 15a extends from the tab short side via the tab outer side to the other tab short side, as shown in particular in fig. 3 and 4.

However, the groove 15a does not extend only at the tab 8a itself. More specifically, referring to fig. 3 and 4, a plurality of additional grooves 16a are formed on the radially outer groove side 13a, i.e., the end plate 9a, and a plurality of additional grooves 17a are formed on the inner groove side 12a, i.e., the disc 7 a. The additional grooves 16a and 17a on each groove flank 12a and 13a are arranged at the same height, i.e. in the same winding plane, wherein the respective additional grooves 16a and 17a respectively adjoin one another in terms of height and are therefore spaced apart from one another in terms of height, i.e. ultimately at a defined spacing approximately corresponding to the wire thickness. The additional groove also runs curved in geometry similar to the groove 14 a. That is to say, the entire groove runs upwards through the additional grooves 16a, 17a on the groove flanks 12a, 13a, so that, in addition to the precise guidance and support of the wound-in wire section in the groove base 14a, i.e. in the groove 15a, a support is also formed, viewed in the radial direction, by the additional grooves 16a, 17a on the groove flanks 12a, 13a, so that the wire is thus guided and supported well not only in the first winding layer directly on the web 8a, but also in a plurality of further layers wound over the first winding layer. Although, for example, only a few grooves 16a are provided on the outer groove flank 13a, it is of course also conceivable to run these further upwards, i.e. to form more grooves 16 a.

This means that very precise conductor guidance and conductor support is achieved, which is suitable for very precise layer structures.

It can be seen that the groove 15a extends perpendicularly to the longitudinal axis of the tab 8 a. Thus, no layer jumps occur via this tab 8a, i.e. the conductor enters the respective groove 15a in one plane and again extends from the respective groove 15a in the same plane.

However, since the wire is guided radially outward and inward at a corresponding alternating frequency during the winding of the conductor turns 5, it is necessary to continue the guiding of the wire in the return position/winding-back position in a defined radially outward or inward manner, with a deviation of approximately one wire thickness. According to the invention, this is done by means of individual groove guides on the webs themselves, as shown in fig. 5 to 7.

These figures show a second embodiment of a star disk 6b with a disk body 7b and a web 8b which in turn has an end plate 9b comprising a magnetic flux-guiding metallic element 10 b. Thus, a winding groove 11b is also formed here, which is in turn delimited by a radially inner groove side 12b on the disk body 7b and a radially outer groove side 13b on the end plate 9 b.

Here too, a groove 14b is again provided on the web 8b itself, which groove is formed by a plurality of parallel grooves 15b, see fig. 5, which however extend at an angle α to the longitudinal web axis. That is, the respective groove inlets and groove outlets are offset from one another, as viewed in the radial direction, to be precise by the wire thickness or the wire diameter, so that the wire outlets are radially offset by more than one wire thickness than the wire inlets. In this way, a defined layer jump is achieved in the first layer, wherein, as shown in fig. 6 and 7, the groove 15b likewise extends here not only on the tab outer side but also on the tab short-side.

Here, referring to fig. 6 and 7, additional grooves 16b, 17b are also provided on the groove flanks 12b, 13b, respectively, similarly to the case in the embodiment of fig. 2 to 4. In other words, a precise wire guidance is also achieved here in the higher winding layer on both slot sides 12b, 13 b. Here, the additional grooves 16b, 17b also adjoin the level of the first groove plane, wherein here too further additional grooves 16b, 17b can be provided, which can therefore also run/run further up via the groove flanks.

Finally, fig. 5 shows a slot 18 which is formed on the tray body 7b and through which the wire is first introduced into the winding slot 11 b. The groove 18 leads to the groove bottom, i.e. to the groove 14b and into the groove 15b, so that the fed conductor approximately sinks and enters the groove plane. This results in that the conductor can be wrapped without problems by the next second and subsequent winding layers without "bulging" in the turns, which is detrimental to the layer structure.