Stator for an electrical machine, an electrical machine and method for producing a stator of this kind
Stator and method for producing a stator for an electrical machine, comprising a stator main body ( 34 ) which has radial stator teeth ( 14 ) for receiving coils ( 17 ) of an electrical winding and, on an end side of the stator main body ( 34 ), has an insulating lamination ( 40 ) with receiving pockets ( 46 ) for insulation-displacement terminal elements ( 70 ), wherein the coils ( 17 ) are wound by means of a winding wire which is inserted into the receiving pockets ( 46 ), wherein an interconnection plate ( 52 ) has annular conductors ( 84 ) on which in each case a plurality of insulation-displacement terminal elements ( 70 ) are arranged, which insulation-displacement terminal elements axially engage into the receiving pockets ( 46 ) in order to make electrical contact with the winding wire, wherein the interconnection plate ( 52 ) is manufactured from plastic and has annular grooves ( 59 ) which are open axially at the bottom and into which the annular conductors ( 84 ) are inserted.
1. A stator ( 10 ) for an electrical machine ( 12 ), the stator comprising a stator main body ( 34 ) which has radial stator teeth ( 14 ) for receiving coils ( 17 ) of an electrical winding ( 18 ) and, on an end side ( 39 ) of the stator main body ( 34 ), has an insulating lamination ( 40 ) with receiving pockets ( 46 ) for insulation-displacement elements ( 70 ), wherein the coils ( 17 ) are wound by means of a winding wire ( 22 ) which is inserted into the receiving pockets ( 46 ), wherein an interconnect plate ( 52 ) has annular conductors ( 84 ), each of the annular conductors ( 84 ) having thereon a plurality of insulation-displacement elements ( 70 ) arranged to engage axially in the receiving pockets ( 46 ) in order to make electrical contact with the winding wire ( 22 ), wherein the interconnect plate ( 52 ) is manufactured from plastic and has annular grooves ( 59 ) which are open axially downward and into which the annular conductors ( 84 ) are fitted, and
wherein axial centering pins ( 80 ) which engage in corresponding centering receptacles ( 81 ) in the interconnect plate ( 52 ) are molded onto the insulating lamination ( 40 ).
2. The stator ( 10 ) as claimed in claim 1 , characterized in that the annular conductors ( 84 ) are manufactured as punched and bent parts on which the insulation- displacement elements ( 70 ) are molded integrally, and respective phase connection pins ( 85 ) via which individual phases ( 26 ) of the electrical winding ( 18 ) are energized are molded on the annular conductors ( 84 ).
3. The stator ( 10 ) as claimed in claim 2 , characterized in that axial guide channels ( 106 ) through which the phase connection pins ( 85 ) project axially are molded onto an upper side ( 55 ) of the interconnect plate ( 52 ).
4. The stator ( 10 ) as claimed in claim 2 , characterized in that axial guide channels ( 106 ) through which the phase connection pins ( 85 ) project axially are molded onto an upper side ( 55 ) of the interconnect plate ( 52 ), wherein precisely three axial guide channels ( 106 ) extend in an axial direction ( 3 ) directly adjacent in a radial region of the closed carrier ring ( 53 ).
5. The stator ( 10 ) as claimed in claim 1 , characterized in that precisely three annular conductors ( 84 ) are arranged on different radii in the interconnect plate ( 52 ).
6. The stator ( 10 ) as claimed in claim 1 , characterized in that each annular conductor ( 84 ) is assigned precisely one phase ( 26 ) having precisely one phase connection pin ( 85 ).
7. The stator ( 10 ) as claimed in claim 1 , characterized in that the interconnect plate ( 52 ) forms a closed carrier ring ( 53 ), an outside diameter of which approximately corresponds to an outside diameter of the stator main body ( 34 ) and an inside diameter of which is larger than an inside diameter of the stator main body ( 34 ).
8. The stator ( 10 ) as claimed in claim 1 , characterized in that all of the coils ( 17 ) are continuously wound directly one after another with an uninterrupted winding wire ( 22 ) on stator teeth ( 14 ) which are directly adjacent in a circumferential direction ( 2 ).
9. The stator ( 10 ) as claimed in claim 1 , characterized in that an axially upper side ( 55 ) of the interconnect plate ( 52 ) has axially continuous installation openings ( 108 ) through which installation fingers ( 110 ) reach axially in order to lie directly against the insulation-displacement elements ( 70 ) in order to press said elements axially into the receiving pockets ( 46 ).
10. The stator ( 10 ) as claimed in claim 1 , characterized in that axial test bores ( 112 ) are formed on an upper side ( 55 ) of the interconnect plate ( 52 ) through which test electrodes can make direct contact with the conductors ( 84 ) in order to test the quality of the insulation-displacement connections.
11. The stator ( 10 ) as claimed in claim 1 , characterized in that the stator main body ( 34 ) is stacked from individual sheet-metal laminations ( 36 ) which have a closed yoke ring ( 38 ) and radial stator teeth ( 14 ) molded thereon.
12. The stator ( 10 ) as claimed in claim 1 , characterized in that the receiving pockets ( 46 ) have two radial walls ( 61 , 62 ) which extend in a circumferential direction ( 2 ) and in which a radial aperture ( 64 ) is formed as an axially upwardly open slot ( 63 ) into which the winding wire ( 22 ) is inserted, wherein the insulation-displacement elements ( 70 ) are wider in the circumferential direction ( 2 ) than in a radial direction ( 4 ) and, centrally with respect to the circumferential direction ( 2 ), form a fork ( 76 ) with cutting edges ( 71 ) which are pushed axially over the winding wire ( 22 ) in order to cut into the winding wire and thereby to form an electrical contact, wherein outer sides ( 77 ) of the insulation-displacement elements ( 70 ) are securely clamped in the receiving pockets ( 46 ).
13. A method for producing a stator ( 10 ) as claimed in claim 1 , the method comprising the following method steps:
axially fitting an insulating lamination ( 40 ) onto an end side ( 39 ) of the stator teeth ( 14 );
then winding coils ( 17 ) onto the stator teeth ( 14 ), wherein, after each winding of a coil ( 17 ), the winding wire ( 22 ) is guided radially through a receiving pocket ( 46 ) for an insulation-displacement element ( 70 ); and
axially fitting an interconnect plate ( 52 ) over the insulating lamination ( 40 ) onto the stator main body ( 34 ) in such a manner that installation fingers ( 110 ) through axial installation openings ( 108 ) in the interconnect plate ( 52 ) rest axially directly on the insulation-displacement elements ( 70 ) and press the latter into the receiving pockets ( 46 ) in order to make electrical contact with the winding wire ( 22 ).
14. The method as claimed in claim 13 , wherein axially fitting the interconnect plate includes:
pressing the insulation-displacement elements ( 70 ) axially downward until the interconnect plate ( 52 ) is pressed to a stop against the insulating mask ( 40 ) and is thus secured; and
removing the installation fingers ( 110 ) from the insulation-displacement elements ( 70 ), such that no axial forces act on the insulation-displacement connections;
wherein two installation fingers are used in particular simultaneously to press directly against precisely one insulation-displacement element, preferably against all of the insulation-displacement elements simultaneously.
15. The stator ( 10 ) as claimed in claim 1 , characterized in that precisely three annular conductors ( 84 ) are arranged on different radii in the interconnect plate ( 52 ), wherein the insulation-displacement elements ( 70 ) are molded thereon in such a manner that all of the insulation-displacement elements ( 70 ) of all of the conductors ( 84 ) are arranged on an identical radius which corresponds to the radius on which all of the receiving pockets ( 46 ) are arranged.
16. The stator ( 10 ) as claimed in claim 1 , characterized in that each annular conductor ( 84 ) is assigned precisely one phase ( 26 ) having precisely one phase connection pin ( 85 ), and the phases ( 26 ) are interconnected to form a star point circuit or a triangular circuit.
17. The stator ( 10 ) as claimed in claim 1 , wherein the centering receptacles ( 81 ) are designed as through holes ( 82 ) and the axial end ( 92 ) of the centering pins ( 80 ) is deformed by means of hot calking in order to form a form-fitting connection with the interconnect plate ( 52 ).
18. The stator ( 10 ) as claimed in claim 1 , characterized in that the interconnect plate ( 52 ) forms a closed carrier ring ( 53 ), an outside diameter of which approximately corresponds to an outside diameter of the stator main body ( 34 ) and an inside diameter of which is larger than an inside diameter of the stator main body ( 34 ), wherein the closed carrier ring ( 53 ) has an enlarged inside diameter ( 104 ) over a certain angular region in order to receive a rotational position sensor for the rotor in said region.
19. The stator ( 10 ) as claimed in claim 1 , characterized in that all of the coils ( 17 ) are continuously wound by needle winding directly one after another with an uninterrupted winding wire ( 22 ) on stator teeth ( 14 ) which are directly adjacent in a circumferential direction ( 2 ).
20. The stator ( 10 ) as claimed in claim 1 , characterized in that an axially upper side ( 55 ) of the interconnect plate ( 52 ) has axially continuous installation openings ( 108 ) through which installation fingers ( 110 ) reach axially in order to lie directly against shoulders ( 69 ) of the insulation-displacement elements ( 70 ) in order to press said elements axially into the receiving pockets ( 46 ).
21. The stator ( 10 ) as claimed in claim 1 , characterized in that axial test bores ( 112 ) are formed on an upper side ( 55 ) of the interconnect plate ( 52 ), with precisely one test bore ( 112 ) for each annular conductor ( 84 ) of three phases ( 26 ), through which test electrodes can make direct contact with the annular conductors ( 84 ) in order to test the quality of the insulation-displacement connections.
22. The stator ( 10 ) as claimed in claim 1 , characterized in that the stator main body ( 34 ) is stacked from individual sheet-metal laminations ( 36 ) which have a closed yoke ring ( 38 ) and radial stator teeth ( 14 ) molded thereon, wherein the individual sheet-metal laminations ( 36 ) are arranged rotated with respect to one another in a circumferential direction ( 2 ), and therefore the stator teeth ( 14 ) are formed in a skewed manner in the circumferential direction ( 2 ).
23. The stator ( 10 ) as claimed in claim 1 , characterized in that the receiving pockets ( 46 ) have two radial walls ( 61 , 62 ) which extend in a circumferential direction ( 2 ) and in which a radial aperture ( 64 ) is formed as an axially upwardly open slot ( 63 ) into which the winding wire ( 22 ) is inserted, wherein the insulation-displacement elements ( 70 ) are wider in the circumferential direction ( 2 ) than in a radial direction ( 4 ) and, centrally with respect to the circumferential direction ( 2 ), form a fork ( 76 ) with cutting edges ( 71 ) which are pushed axially over the winding wire ( 22 ) in order to cut into the winding wire and thereby to form an electrical contact, wherein outer sides ( 77 ) of the insulation-displacement elements ( 70 ) are securely clamped in the receiving pockets ( 46 ) by means of latching lugs ( 72 ).
24. An electrical machine ( 12 ) comprising
a cylindrical motor housing,
a stator ( 10 ) comprising a stator main body ( 34 ) which has radial stator teeth ( 14 ) for receiving coils ( 17 ) of an electrical winding ( 18 ) and, on an end side ( 39 ) of the stator main body ( 34 ), has an insulating lamination ( 40 ) with receiving pockets ( 46 ) for insulation-displacement elements ( 70 ), wherein the coils ( 17 ) are wound by means of a winding wire ( 22 ) which is inserted into the receiving pockets ( 46 ), wherein an interconnect plate ( 52 ) has annular conductors ( 84 ), each of the annular conductors ( 84 ) having thereon a plurality of insulation-displacement elements ( 70 ) arranged to engage axially in the receiving pockets ( 46 ) in order to make electrical contact with the winding wire ( 22 ), characterized in that the interconnect plate ( 52 ) is manufactured from plastic and has annular grooves ( 59 ) which are open axially downward and into which the annular conductors ( 84 ) are fitted, wherein the stator ( 10 ) is fitted into the cylindrical motor housing, and
a rotor mounted within the stator ( 10 )
wherein axial centering pins ( 80 ) which engage in corresponding centering receptacles ( 81 ) in the interconnect plate ( 52 ) are molded onto the insulating lamination ( 40 ).
25. The electrical machine as claimed in claim 24 , further comprising an electronic unit for activating the phases ( 26 ), the electronic unit being arranged axially above the interconnect plate ( 52 ).