STATOR OF AN ELECTRIC MOTOR

Abstract

A stator of an electric motor has stator teeth that carry coils of a multi-phase stator winding. A connection element has insert pockets with contact elements inserted therein each with at least one insulation displacement contact as a connection point for a wire portion of coils joined to one another. A contact apparatus is mounted on the connection element and has a contact housing with a connection socket with phase plug connectors corresponding to the number of phases. The contact apparatus has busbars which correspond to the number of phases and which each have a first and a second bar end. The first bar ends are flexibly or movably in contact with one of the phase plug connectors each and the second bar ends are each inserted or can each be inserted in a contact slot of one of the contact elements to form a terminal connection.

Claims

1-10. (canceled)

11. A stator of an electric motor, the stator comprising: a plurality of stator teeth each carrying coils of a multi-phase stator winding; an interconnection element having a plurality of insert pockets with contact elements inserted therein, each with at least one insulation displacement contact forming an interconnection point for a wire portion of coils connected to one another; a contact device mounted, at least in part, on said interconnection element, and having a contact housing with a connection socket having a number of phase connectors corresponding to a number of phases; said contact device having a number of busbars corresponding to the number of phases, and each of said busbars having a first bar end and a second bar end; said first bar ends being flexibly or movably in contact with one each of said phase connectors; and said second bar ends being inserted or insertable into a respective one of said contact slots of one of said contact elements with clamping contact.

12. The stator according to claim 11, wherein said contact housing is formed with a plurality of radially directed recesses on an outer circumference thereof, each of recesses exposing one of said second bar ends.

13. The stator according to claim 11, wherein each of said first bar ends is contacted with a flexible conductor at said phase connectors.

14. The stator according to claim 11, wherein each of said phase connectors has a flexurally elastic contact lug against which said first bar ends bear resiliently.

15. The stator according to claim 11, wherein said busbars are overmolded as insert parts by said contact housing.

16. The stator according to claim 11, wherein said busbars are joined in grooves of said contact housing.

17. The stator according to claim 11, wherein said contact housing has, on an underside facing said interconnection element, a plurality of axially projecting support surfaces for axial support of said contact device on said interconnection element.

18. The stator according to claim 11, wherein said insulation displacement contact of said contact element includes a first insulation displacement contact and a second insulation displacement contact spaced apart from said first insulation displacement contact.

19. An electric motor, comprising: a pot-shaped motor housing having an end face; an end shield closing said end face; and a stator according to claim 11 inserted in said motor housing.

20. The electric motor according to claim 19, configured as a motor for an anti-lock braking system of a motor vehicle.

21. A contact device for a stator with a plurality of stator teeth carrying phase-selectively connected coils of a multi-phase stator winding, and with an interconnection element having a plurality of insert pockets with contact elements inserted therein, each with at least one insulation displacement contact forming an interconnection point for a wire portion of coils connected to one another, the contact device comprising: a contact housing with a connection socket having a number of phase connectors corresponding to a number of phases, said contact housing being configured to be fitted, or being fitted, on the interconnection element; a number of busbars corresponding to the number of phases, each of said busbar having first bar end and a second bar ends; said first bar ends being flexibly or movably in contact with a respective one of said phase connectors; and said second bar ends being configured for insertion, or being inserted, into a respective contact slot of the contact elements with clamping contact.

Description

[0037] In the following, exemplary embodiments of the invention are explained in more detail with reference to a drawing, which show:

[0038] FIG. 1 in perspective view, an electric motor with a motor housing and with an end shield,

[0039] FIG. 2 in perspective view, the electric motor without end shield,

[0040] FIG. 3 in plan view, the electric motor according to FIG. 2,

[0041] FIG. 4 in perspective view, a stator of the electric motor, with a stator winding and with an annular interconnection element and with a ring-sector-shaped contact device,

[0042] FIG. 5 in perspective view, a first exemplary embodiment of the contact device, looking at an upper side,

[0043] FIG. 6 in perspective view, the first exemplary embodiment of the contact device, looking at a bottom side,

[0044] FIG. 7 in perspective view, a detail of the interconnection element and the first exemplary embodiment of the contact device in a partially disassembled state,

[0045] FIG. 8 in perspective view, a second exemplary embodiment of the contact device, looking at a bottom side,

[0046] FIG. 9 a sectional view of the second exemplary embodiment of the contact device along the line of section IX-IX according to FIG. 8,

[0047] FIG. 10 in perspective view, a third exemplary embodiment of the contact device, looking at a bottom side, and

[0048] FIG. 11 in front view, a contact element of the interconnection element.

[0049] Corresponding parts and dimensions are always provided with the same reference signs in all figures.

[0050] FIGS. 1 to 4 show a brushless electric motor 2. The electric motor 2 is embodied, for example, as a brake motor for an anti-lock braking system (ABS) of a motor vehicle not shown in greater detail.

[0051] The electric motor 2 has a pole pot as motor housing 4, which is closed at the end face by means of an end shield 6. The end shield 6 has a central recess for a motor shaft (rotor shaft) 8. A bearing seat 10 for a rolling bearing 11 is suitably provided in the region of this recess. Opposite the bearing seat 10, a bearing seat 12 is formed in the bottom of the motor housing 4 (FIG. 3, FIG. 4), in which a second rolling bearing 13 (FIG. 3) is inserted. The motor shaft 8 is rotatably mounted about a motor axis by means of the rolling bearings 11, 13. The end shield 6 has a feed-through opening 14 radially on the outside, which is penetrated by a connection bushing 16 of a stator 18 (FIG. 2).

[0052] The motor shaft 8 has a magnetic encoder 20 fixed to the shaft end for conjoint rotation. The magnetic encoder 20 is designed, for example, as a magnetic dipole encoder in the form of a magnetic cap. In the installed state of the electric motor 2, the magnetic encoder 20 is expediently arranged in the vicinity of a magnetic sensor or Hall sensor so that, during operation of the electric motor 2, its motor speed and/or rotor position can be monitored by the alternating magnetic field of the rotating magnetic encoder 20.

[0053] As can be seen comparatively clearly in FIG. 2 and in FIG. 3, the electric motor 2 is embodied as an internal rotor motor with the stator 18 on the radially outer side and a rotor 22 joined fixedly to the motor shaft 8. In the assembled state, the rotor 22 is rotatably mounted inside the stationary stator 18 so as to be rotatable about the axis of rotation of the motor along an axial direction A. The rotor 22 is formed (in a manner not shown in greater detail) by a laminated core in which permanent magnets 24 are inserted to generate an excitation field. The permanent magnets 24 are provided with reference signs in the figures merely by way of example.

[0054] The stator 18 has a stator laminated core, not described in further detail, with a circumferential stator yoke, from which a number of stator teeth 26 (FIG. 4) extend radially inward. The stator laminated core is provided with a stator winding 28 for generating a magnetic rotating field.

[0055] In the exemplary embodiment shown, the stator 18 has a three-phase stator winding 28, which is wound in the form of (stator) coils 30 onto the stator teeth 26. The coils 30, which are provided with reference signs merely by way of example, are phase-selectively connected to one another to form phase strings or phase windings. In this embodiment, the stator laminated core has an approximately star-shaped arrangement with twelve inwardly directed stator teeth 26, wherein one phase winding per phase of the stator winding 28 is wound around two adjacent stator teeth 26 in each case and around the two stator teeth 26 arranged diametrically opposite hereto in the stator laminated core to form a magnetic pole.

[0056] An electric current flows through the three phase windings during operation of the electric motor 2 and thus forms six magnetic pole regions of the stator 18. For guiding, routing and interconnecting the phase windings on the stator teeth 26, the stator 18 has two routing or interconnection rings as interconnection elements 32. The interconnection elements 32 are each fitted axially here on one of the end faces of the stator laminated core. In the figures, only the interconnection element 32 facing the end shield 6 is shown and marked with a reference sign.

[0057] The annular interconnection elements 32, which are made from an insulating plastic material, each have an annular body 34, on which twelve half-sleeve-like coil formers 36 are integrally formed on the stator lamination side in the form of pole-shoe-like receptacles for the stator teeth 26 (FIG. 7). Once fitted in place, the stator teeth 26 are thus substantially surrounded by the insulating coil formers 36 of the interconnection elements 32 in such a way that only the pole-shoe-side ends of the stator teeth 26 are exposed (FIG. 4).

[0058] The coils 30 or phase windings are wound onto the coil formers 36 of the interconnection elements 32 around the stator teeth 26 with an insulated copper wire (coil wire, winding wire). In order to prevent the coils 30 from detaching from the coil formers 36 in the wound state, each coil former 36 has an inner flange on the radially inner side with respect to the stator laminated core and an outer flange offset radially outwardly with respect thereto as delimiting side walls.

[0059] The upper, i.e., end-shield-side, interconnection element 32 shown in the figures has a segmented, circular ring-like wall as termination 38. As can be seen in particular in FIG. 7, the termination 38 protrudes axially beyond the stator laminated core along the axial direction A in the assembled state. During the winding of the coils 30, the coil wires or winding wires are wound through the termination 38 circumferentially behind the stator teeth 26 to form the magnetic poles.

[0060] To form the phase strands or phase winding, the coils 30 are electrically interconnected at their coil ends and/or a wire portion (coil portion) arranged in between. For this purpose, the interconnection element 32 has six insert pockets 40 distributed around the circumference, which are integrally formed in one part, i.e., in one piece or monolithically, on the ring body 34. The insert pockets 40 are designed in particular as insert pocket pairs, which each have two tangentially running insert slots 42 open axially on one side. The insert pockets 40 each have two radially directed slots 44 through which the wire portions of the coils 30 are guided.

[0061] A metal contact element 46 is inserted or pressed as a clamping connector into each of the insert pockets 40. The contact element 46 shown individually in FIG. 11 has two insulation displacement contacts 48 as interconnection points for the coil portions seated in the slots 44. The contact element 46 is thus embodied as a pair of insulation displacement contacts or as a double insulation displacement contact plug (double IDC). In the assembled state, the insulation displacement contacts 48 are inserted into one each of the insert slots 42 of the insert pockets 40.

[0062] The insulation displacement contacts 48 are arranged at a distance from each other and are provided on the same side of the contact element 46. On the axially opposite side of the contact element 46, two clamping or contact slots 50 are provided, which are accessible from there and which are arranged axially in alignment with the insulation displacement contacts 48. In the clamped contacted state of the coils, the contact slots 50 are arranged at least in some portions radially aligned with the slots 44. The insert pockets 40 and the contact elements 46 are provided with reference signs in the figures merely by way of example.

[0063] As can be seen in FIGS. 1 to 4, in the assembled state of the stator 18 a contact device 52 is placed axially on the end-shield-side interconnection element 32. The contact device 52 is designed as a customer-specific interface of the stator 18 or the electric motor 2. The contact device 52 is explained in greater detail below, in particular with reference to FIGS. 5 to 10.

[0064] The contact device 52, which is shown individually in FIG. 5, for example, is of ring-sector-shaped design, and has a contact housing (contact carrier) 54 with the connection socket 16 formed integrally thereon, in particular in one piece. The ring-sector-shaped contact device 52 extends here, for example, over an angular range of about 120°. The connection box 16 here has three integrated phase connectors 56 for electrically conductive connection, i.e., for connection or contacting of the stator winding 28 (FIG. 7).

[0065] The phase connectors 56 are designed here as latchable or clippable plug receptacles or plug sockets for a customer-specific power source or for a customer-specific connector or plug. The phase connectors 56 furthermore each have a contact lug 58, and busbars 60a, 60b, 60c are guided one to each of said contact lugs and electrically conductively contact the latter.

[0066] The busbars 60a, 60b, 60c are each embodied as an approximately L-shaped stamped-and-bent part. The busbars 60a, 60b, 60c each have a first bar end 62a, 62b, 62c and a second bar end 64a, 64b, 64c, which substantially form the free ends of the corresponding L-leg. The bar ends 62a, 62b, 62c are here flexibly or movably contacted to the phase connector 56 or to the contact lug 58 thereof, wherein the bar ends 64a, 64b, 64c, which are in particular radially oriented or aligned, are each inserted or can be inserted with clamping contact into a contact slot 50 of one of the contact elements 46 (see for example FIG. 7).

[0067] The contact housing 54 has a number of radially directed and tangentially extending recesses 66 on its outer circumference. As can be seen, for example, from FIGS. 6, 8 and 10, the recesses 66 substantially expose the bar ends 64a, 64b, 64c. As can be seen in particular from FIGS. 2 to 4, the contact slots 50 of the contact elements 46 of the interconnection element 32 are also at least partially accessible through the recesses 66 when the contact device 52 is fitted in place. The recesses 66 are thus embodied as windows of the contact housing 54, which allow engagement of a press-in tool during the course of an assembly process.

[0068] In the following, a first exemplary embodiment of the contact device 52 is explained in greater detail with reference to FIG. 6 and FIG. 7.

[0069] In this embodiment, the busbars 60a, 60b, 60c are embodied as insert parts, and are overmolded by the material of the contact housing 54 in such a way that only the bar ends 62a, 62b, 62c and 64a, 64b, 64c are exposed. In this case, the contact housing 54 is made of an electrically non-conductive plastic.

[0070] In this exemplary embodiment, a flexible conductor 68 in the form of a stranded wire is arranged between the bar ends 62a, 62b, 62c and the associated contact lugs 58.

[0071] On an underside (inner side) facing the interconnection element 32, the contact housing 54 has four axially projecting support surfaces 70 as functional or contact surfaces for axial support of the contact device 52 on the interconnection element 32. The support surfaces 70 are distributed here along an arc in the region of the outer circumference of the contact housing 54.

[0072] The support surfaces 70 are suitable and designed for limiting the joining path when the contact device 52 is fitted axially on the interconnection element 32. The support surfaces 70 are embodied as locally reinforced material thicknesses or wall thicknesses of the contact housing 54. The support surfaces 70 specifically define the press-fit depth of the bar ends 64a, 64b, 64c into the contact slots 50 of the contact elements 46, wherein the support surfaces 70 of the contact device 52 are supported on corresponding contours of the interconnection element 32.

[0073] The second exemplary embodiment of the contact device 52 shown in FIG. 8 and in FIG. 9 differs from the embodiment described above basically in that the busbars 60a, 60b, 60c are not embodied as insert parts, and in that the contact lugs 58′ of the phase connectors 56 are bent axially (around).

[0074] For joining the busbars 60a, 60b, 60c to the contact housing 54, the latter has three grooves or gaps 72 into which the busbars 60a, 60b, 60c are inserted in a form-fitting and/or frictionally engaged manner. In addition or alternatively, it is possible, for example, that the busbars 60a, 60b, 60c are glued into the grooves 72 in an integrally bonded manner by means of an adhesive.

[0075] In this embodiment, the bar ends 62a, 62b, 62c each have an approximately hook-shaped or arcuate bar extension 74a, 74b, 74c. As can be seen comparatively clearly in particular on the basis of the sectional view of FIG. 9, the bar extensions 74a, 74b, 74c are each in electrically conductive contact with the corresponding associated contact lug 58′, wherein in FIG. 9 only the phase connector 56 connected to the busbar 60a is shown as an example.

[0076] In this exemplary embodiment, the contact lug 58′ is designed in a flexurally elastic manner as a spring hook or spring lug or spring leg of the phase connector 56, to which the bar ends 62a, 62b, 62c are resiliently or floatingly contacted.

[0077] In FIG. 10, a third exemplary embodiment of the contact device 52 is shown. As in the exemplary embodiment described above, the bus bars 60a, 60b, 60c are inserted into grooves 72 of the contact housing 54, wherein the side walls of the grooves 72 in this case each have at least one joining extension pair 76. In particular, the grooves 72 of the busbars 60a and 60c each have one joining extension pair 76 and the groove 72 of the busbar 60b has two joining extension pairs 76.

[0078] The joining extensions pairs 76 have two axially directed extensions which, after insertion of the busbars 60a, 60b, 60c into the grooves 72, are deformed or re-shaped in such a way that the busbars 60a, 60b, 60c are held in a form-fitting and/or frictionally engaged manner in the grooves 72. The joining extension pairs 76 are formed in this case, in particular, by means of caulking.

[0079] The claimed invention is not limited to the exemplary embodiments described above. Rather, other variants of the invention can also be derived therefrom by a person skilled in the art within the scope of the disclosed claims, without departing from the subject matter of the claimed invention. In particular, all individual features described in conjunction with the various exemplary embodiments can also be combined in other ways within the scope of the disclosed claims, without departing from the subject matter of the claimed invention.

LIST OF REFERENCE SIGNS

[0080] 2 electric motor [0081] 4 motor housing [0082] 6 end shield [0083] 8 motor shaft [0084] 10 bearing seat [0085] 11 rolling bearing [0086] 12 bearing seat [0087] 13 rolling bearing [0088] 14 feed-through opening [0089] 16 connection socket [0090] 18 stator [0091] 20 magnetic encoder [0092] 22 rotor [0093] 24 permanent magnet [0094] 26 stator tooth [0095] 28 stator winding [0096] 30 coil [0097] 32 connection element [0098] 34 annular body [0099] 36 coil former [0100] 38 termination [0101] 40 insert pocket [0102] 42 insert slot [0103] 44 slot [0104] 46 contact element [0105] 48 insulation displacement contact [0106] 50 contact slot [0107] 52 contact device [0108] 54 contact housing [0109] 56 phase connector [0110] 58, 58′ contact lug [0111] 60a, 60b, 60c busbar [0112] 62a, 62b, 62c bar end [0113] 64a, 64b, 64c bar end [0114] 66 recess [0115] 68 conductor [0116] 70 support surface [0117] 72 groove [0118] 74a, 74b, 74c bar extension [0119] 76 joining extension pair [0120] A axial direction