# US 12,224,639 B2 · Rotor for an externally excited synchronous machine

> Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt

- Number: US 12,224,639 B2
- Document ID: US12224639B2
- Status: Granted
- Kind: B2
- Application number: 17/895,856
- Filed: 2022-08-25
- Published: 2023-03-02
- Granted: 2025-02-11
- Earliest claimed: 2021-08-26
- Assignees: Audi AG
- Applicants: Audi AG
- Inventors: Martin Gerngroß; Lars Wetterau
- Web page: https://patentgrep.com/patent/US12224639B2

## CPC

- H02K 3/527: {applicable to rotors only}
- H02K 3/18: Windings for salient poles
- H02K 3/522: {for generally annular cores with salient poles}
- Y02T 10/64: Electric machine technologies in electromobility
- H02K: DYNAMO-ELECTRIC MACHINES (dynamo-electric relays H01H53/00; conversion of DC or AC input power into surge output power {H03K3/53})
- Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION

## Abstract

A star disc has integrated current busbars for the interconnecting of rotor windings. A rotor may comprise the star disc, and a method may comprise producing the rotor.

## Claims

### Claim 1

A star disc for a rotor of an externally excited synchronous machine, comprising:
a surface of the star disc that is formed of plastic, in which current busbars are embedded,
the current busbars connecting in electrically conductive manner a pole shoe or a groove of the star disc to an adjacent pole shoe or an adjacent groove of the star disc, and
the current busbars extending to a radially outward free end of a respective pole of the star disc opposite a base end of the pole and including, at their two ends respectively, a contacting element to receive a winding wire protruding from the surface of the star disc.

### Claim 2 (depends on 1)

The star disc according to claim 1, wherein the current busbars are embedded by injection molding in the star disc.

### Claim 3 (depends on 1)

The star disc according to claim 1, wherein the poles of the star disc comprise support structures for guiding and bracing of a winding wire.

### Claim 4 (depends on 1)

The star disc according to claim 1, wherein at least one current busbar leads from the pole shoe of at least one pole to a yoke of the star disc adjacent to the pole.

### Claim 5 (depends on 1)

The star disc according to claim 1, wherein at least one current busbar leads from the pole shoe of at least one pole to the pole shoe of a pole of the star disc which is clockwise adjacent to the pole.

### Claim 6 (depends on 1)

The star disc according to claim 1, wherein at least one current busbar leads from the foot of at least one pole to the foot of a clockwise adjacent pole of the star disc.

### Claim 7 (depends on 1)

The star disc according to claim 1, wherein the current busbars are arranged such that they allow a winding of all poles with the same direction of rotation and at the same time make possible parallel current directions in the grooves of the star disc.

### Claim 8

A rotor of an externally excited synchronous machine, comprising:
two star discs, which are arranged on a rotor axis at opposite end faces of a laminated stack of the rotor,
wherein at least one of the two star discs is a star disc including:
a surface of the star disc that is formed of plastic, in which current busbars are embedded,
the current busbars connecting in electrically conductive manner a pole shoe or a groove of the star disc to an adjacent pole shoe or an adjacent groove of the star disc, and
the current busbars extending to a radially outward free end of a respective pole of the star disc opposite a base end of the pole and including, at their two ends respectively, a contacting element to receive a winding wire protruding from the surface of the star disc.

### Claim 9

A method for producing a rotor of an externally excited synchronous machine, comprising:
arranging two star discs at opposite end faces of a laminated stack of the rotor, and
winding the poles of the star discs and the laminated stacks with a winding wire to form a trapezoidally orthocyclic winding,
wherein at least one of the two star discs is a star disc including:
a surface of the star disc that is formed of plastic, in which current busbars are embedded;
the current busbars connecting in electrically conductive manner a pole shoe or a groove of the star disc to an adjacent pole shoe or an adjacent groove of the star disc, and
the current busbars extending to a radially outward free end of a respective pole of the star disc opposite a base end of the pole and including, at their two ends respectively, a contacting element to receive a winding wire protruding from the surface of the star disc.

### Claim 10 (depends on 9)

The method according to claim 9, in which multiple poles of the rotor are wound at the same time and in the same winding direction.