ELECTRIC MOTOR HAVING AN INTERCONNECTION UNIT AND METHOD FOR MANUFACTURING AN ELECTRIC MOTOR HAVING AN INTERCONNECTION UNIT

Abstract

An electric motor includes a rotor and a stator having a plurality of coils; each coil having two coil terminals; the coils being interconnected with the aid of an interconnection unit including a carrier part for holding a plurality of interconnection elements set apart from each other; each of the interconnection elements having two contacting regions set apart from each other and a connecting region joined to the contacting regions; the contacting regions of the interconnection elements being connected to one of the coil terminals at a connecting point; the region covered by the connecting region of one of the interconnection elements in the circumferential and radial directions overlapping a region covered by the connecting region of another interconnection element in the circumferential and radial directions; the first interconnection elements being manufactured identically.

Claims

1-15. (canceled)

16. An electric motor, comprising: a rotor rotatable about an axis of rotation; and a stator including a plurality of coils and a plurality of stator segments, each coil including two coil terminals, each stator segment including a single coil, the coils being interconnected by an interconnection unit including a carrier part adapted to hold a plurality of interconnection elements set apart from each other, the interconnection elements including at least three first interconnection elements, each first interconnection elements including two contacting regions set apart from each other and a connecting region joined to the contacting regions, the contacting regions of each first interconnection element being connected to one of the coil terminals at a connecting point, a region covered by the connecting region of one of the first interconnection elements in circumferential and radial directions overlapping a region covered by the connecting region of another of the first interconnection elements in the circumferential and radial directions; wherein the first interconnection elements are identical.

17. The electric motor according to claim 16, wherein the electric motor is arranged as a permanent-magnet synchronous motor.

18. The electric motor according to claim 16, wherein the coils are connected by a star connection.

19. The electric motor according to claim 16, wherein the carrier part is arranged as substantially annular carrier part, is formed of an insulating material, and/or is adapted to hold at least four interconnection elements set apart from each other.

20. The electric motor according to claim 16, wherein the interconnection unit is positioned at an axial end of the stator and/or concentrically to the axis of rotation.

21. The electric motor according to claim 16, wherein the first interconnection elements include exactly two contacting regions.

22. The electric motor according to claim 16, wherein the connecting region is arranged between the contacting regions.

23. The electric motor according to claim 16, wherein the contacting regions of each first interconnection element are electrically connected and/or integrally connected by laser welding to one of the coil terminals at the connecting point.

24. The electric motor according to claim 16, wherein regions covered by the connecting regions of the first interconnection elements in an axial direction are identical and/or regions covered by the connecting regions of the first interconnection elements in the radial direction are identical.

25. The electric motor according to claim 16, wherein the contacting regions of each first interconnection element are shaped such that respective connecting points have substantially the same radial position at an outer circumference of the carrier part and/or have the same axial position.

26. The electric motor according to claim 16, wherein the connecting region of each first interconnection element has an approximately rectangular cross section, having a dimension in an axial direction less than a dimension in the radial direction, at least one connecting region of one of the first interconnection elements includes two axial steps, and/or all of the connecting regions of the first interconnection elements include two axial steps.

27. The electric motor according to claim 16, wherein each first interconnection element includes a first attachment region for form-locked and/or integral connection to the carrier part, each first attachment region includes a first through-recess in an axial direction, the carrier part includes a plurality of rivet pins extending in an axial direction, a first rivet pin adapted to pass through each of the first recesses, free ends of the first rivet pins adapted to be deformed into rivet heads by ultrasonic welding, each first interconnection element including a second attachment region for form-locked and/or integral connection to the carrier part, each second attachment region including a second through-recess in the axial direction, a second rivet pin adapted to pass through each of the second recesses, and/or free ends of the second rivet pins adapted to be deformed into rivet heads by ultrasonic welding.

28. The electric motor according to claim 27, wherein the first attachment regions of each first interconnection element have the same first radial position and/or the same first axial position, and/or the second attachment regions of each first interconnection element have the same second radial position and/or the same second axial position, the first radial position and the second radial position being different, the first axial position and the second axial position being different.

29. The electric motor according to claim 16, wherein the region covered by one of the first interconnection elements in the circumferential and radial directions overlaps two regions covered by two other first interconnection elements in the circumferential and radial directions.

30. The electric motor according to claim 16, wherein a second interconnection element is provided having three and/or exactly three contacting regions, each contacting regions of the second interconnection element being connected to, electrically connected to, and/or integrally connected by laser welding to one of the coil terminals, the second interconnection element having two and/or exactly two attachment regions for form-locked and/or integral connection to the carrier part, each attachment region having a through-recess in the axial direction, a third rivet pin adapted to pass through each of the recesses, free ends of the third rivet pins adapted to be deformed into rivet heads by ultrasonic welding.

31. The electric motor according to claim 30, wherein the region covered by the second interconnection element in the radial direction and the region covered by at least one of and/or all of the first interconnection elements in the radial direction are identical and/or the region covered by the second interconnection element in the circumferential and radial directions and the region covered by at least one and/or two of the first interconnection elements in the circumferential and radial directions overlap.

32. The electric motor according to claim 16, wherein a plurality and/or exactly three third interconnection elements are provided, each third interconnection element having a first contacting region and a second contacting region that are different, the first contacting region of a third interconnection element being connected to, electrically connected to, and/or integrally connected by laser welding to one of the coil terminals, each third interconnection element having a first and a second attachment region for form-locked and/or integral connection to the carrier part, each attachment region having a through-recess in the axial direction, a fourth rivet pin adapted to pass through each recess, free ends of the fourth rivet pins adapted to be deformed into rivet heads by ultrasonic welding, each third interconnection element having a third attachment region for form-locked and/or integral connection to the carrier part, the third attachment region bordering on the first contacting region of the respective, third interconnection element, the third attachment region having a through-recess in the axial direction, through which a fifth rivet pin is passable, free ends of the fifth rivet pins adapted to be deformed into rivet heads by ultrasonic welding, the third interconnection elements being identical.

33. The electric motor according to claim 16, wherein the carrier part includes a plurality of guide regions at an outer circumference adapted to guide the coil terminals in an axial direction, each contacting region connected to a coil terminal being assigned a guide region, a shape of the guide region being substantially identical to a shape of the respectively assigned contacting region.

34. The electric motor according to claim 16, wherein at least one of the first interconnection elements is surrounded by an insulating part made of an injection molded insulating material, the surrounded first interconnection element and the surrounding insulating part are joined on two sides in a form-locked manner in the circumferential direction and/or joined on two sides in a form-locked manner in the axial direction and/or joined on one side in a form-locked manner in the radial direction.

35. The electric motor according to claim 16, wherein in the circumferential direction, only every second of the first interconnection elements is surrounded by a respective insulating part.

36. The electric motor according to claim 16, wherein the coil terminals are integrally connected by laser welding to the contacting regions of the first interconnection elements and/or to contacting regions of second interconnection elements and/or to a contacting regions of third interconnection elements, the contacting regions having a V-shaped notch adapted to receive a coil terminal.

37. A method for manufacturing an electric motor as recited in claim 16, comprising: providing a substantially annular carrier part made of an insulating material and/or an injection molded material; positioning a plurality of identical first interconnection elements on the carrier part in a circumferential direction, each first interconnection element including two and/or exactly two contacting regions, the first interconnection elements being positioned such that a region covered by one of the first interconnection elements in circumferential and radial directions overlaps a region covered by an adjacent first interconnection element in the circumferential and radial directions, the first interconnection elements being positioned so as to be spaced apart from each other; joining the first interconnection elements to the carrier part in a form-locked and/or integral manner to form an interconnection unit; connecting, electrically connecting, and or integrally connecting by laser welding each of the contacting regions of the first interconnection elements to a coil terminal of one of a plurality of coils having two coil terminals and being positioned on a stator of the electric motor to interconnect the coils to form a multiphase winding.

38. The method according to claim 37, wherein in the positioning step, the first interconnection elements are positioned such that in the circumferential direction only every second of the first interconnection elements is surrounded by an insulating part made of an injection molded insulating material, the surrounded, first interconnection element and the surrounding insulating part being joined on two sides in the circumferential direction in a form-locked manner and/or joined on two sides in the axial direction in a form-locked manner and/or joined on one side in the radial direction in a form-locked manner.

39. The method according to claim 37, wherein in the position step, a second interconnection element is positioned on the carrier part, the second interconnection element including three and/or exactly three contacting regions, and, in the joining step, the second interconnection element is joined to the carrier part in a form-locked and/or integral manner to form the interconnection unit, and, in the connecting step, each of the contacting regions of the second interconnection element is connected to, electrically connected to, and or integrally connected by laser welding to one of the coil terminals.

40. The method according to claim 37, wherein, in the position step, three and/or exactly three third interconnection elements are positioned on the carrier part, each third interconnection element having two different contacting regions, in the joining step, the third interconnection elements are joined to the carrier part in a form-locked and/or integral manner to form the interconnection unit, and, in the connecting step, one of the two contacting regions of the third interconnection elements is connected to, electrically connected to, and/or integrally connected by laser welding to one of the coil terminals.

41. The method according to claim 37, wherein in the connecting step, the stator, including the coils and the interconnection unit connected to the coil terminals, is encapsulated by potting compound.

42. The method according to claim 41, wherein contacting regions of third interconnection elements that are not connected to a coil terminal remain free of the potting compound.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0064] A perspective view of a first example embodiment of an interconnection unit situated on a stator of an electric motor is shown in FIG. 1.

[0065] A side view of the stator and the interconnection unit of FIG. 1 is shown in FIG. 2A.

[0066] A top view of the stator and the interconnection unit of FIG. 1 is shown in FIG. 2B.

[0067] A perspective view of a first interconnection element of the interconnection unit of FIG. 1 is shown in FIG. 3A.

[0068] A side view of the first interconnection element of FIG. 3A is shown in FIG. 3B.

[0069] A projection in the axial direction onto a plane of the first interconnection element of FIGS. 3A and 3B is shown in FIG. 3C, the plane being perpendicular to the axis of rotation.

[0070] A perspective view of a second interconnection element of the interconnection unit of FIG. 1 is shown in FIG. 4.

[0071] A perspective view of a third interconnection element of the interconnection unit of FIG. 1 is shown in FIG. 5A.

[0072] A top view of the third interconnection element of FIG. 5A is shown in FIG. 5B.

[0073] A perspective view of the carrier part of the interconnection unit of FIG. 1, including the second interconnection element of FIG. 4 situated on top of it, is shown in FIG. 6.

[0074] A perspective view of the first interconnection element of FIG. 3A, including an insulating part slid on, is shown in FIG. 7A.

[0075] A perspective view of two first interconnection elements is shown in FIG. 7B.

[0076] A projection in the axial direction onto a plane of the two first interconnection elements of FIG. 7B is shown in FIG. 7C, the plane being perpendicular to the axis of rotation.

[0077] A perspective view of the carrier part of the interconnection unit of FIG. 1, including interconnection elements situated on it, is shown in FIG. 8.

[0078] A perspective view of an insulating part of a second example embodiment of the interconnection unit is shown in FIG. 9A.

[0079] A perspective view of a first interconnection element of the interconnection unit is shown in FIG. 9B.

[0080] A perspective view of the insulating part of FIG. 9A, together with the first interconnection element of FIG. 9B, is shown in FIG. 9C.

[0081] A perspective view of the insulating part, the first interconnection element of FIG. 9C and a further first interconnection element are shown in FIG. 9D.

[0082] A perspective view of an interconnection unit of the second example embodiment is shown in FIG. 10.

DETAILED DESCRIPTION

[0083] Exemplary embodiments of the present invention are explained below in light of the attached drawing, where identical reference numerals are used for parts having the same function and are not described again with each figure.

[0084] FIG. 1 shows a perspective view of a first example embodiment of an interconnection unit 1, which is situated on an axial end of a stator 2 of an electric motor. Stator 2 of the electric motor is made up of individual stator segments 3. In the exemplary embodiment shown, stator 2 has twelve stator segments 3. In this instance, the number twelve is only illustrative; other numbers of stator segments are also possible. In this exemplary embodiment, stator segments 3 are, for example, constructed as stamp-packaged, sheet-metal packs.

[0085] Stator segments 3 are interconnected in such a manner, that they form a substantially cylindrical stator 2. A rotor, which is pivoted about an axis of rotation D, is positioned in the interior of stator 3. The rotor and stator 2 are positioned concentrically to axis of rotation D. The rotor, for example, includes permanent magnets, and the electric motor is, for example, arranged as a permanent-magnet synchronous motor.

[0086] Each stator segment 3 has a stator tooth, about which, in each instance, a coil 4 is wound. The coil is made up of insulated winding wire. The two ends of the winding wire are bare and form the two coil terminals 5, 6. In FIG. 1, coils 4 are only illustrated schematically. For example, insulating paper 7 for electrical insulation is situated between coils 4 and stator segments 3.

[0087] FIG. 2A shows a side view of the arrangement illustrated in FIG. 1. Direction A, which extends parallelly to axis of rotation D, is referred to as an axial direction. FIG. 2B shows a top view of the arrangement illustrated in FIG. 1. As shown, radial direction R is defined as starting out from axis of rotation D. Thus, radial direction R extends perpendicularly to axial direction A. Circumferential direction U extends along the circumference of stator 2 and is shown in FIG. 2B, as well.

[0088] With the aid of interconnection unit 1, individual coils 4 are interconnected to form a multiphase winding. In the present exemplary embodiment, the twelve coils 4 are interconnected by a star connection; a three-phase winding being formed. Therefore, four individual coils 4 are assigned to each phase. Within one phase, the four coils 4 are connected in series with the aid of interconnection unit 1. All three phases are interconnected, in turn, at the star point. For a more effective overview, the individual elements of interconnection unit 1 are explained in the following figures.

[0089] Interconnection unit 1 includes a plurality of interconnection elements 30, 40, 50 for interconnecting the coil terminals, as well as a carrier part 60 for holding interconnection elements 30, 40, 50. In order to interconnect the twelve coils 4 shown in this exemplary embodiment, using a star connection, to form a three-phase winding, nine first interconnection elements 30 and one second interconnection element 40 are necessary. If n denotes the number of phases and z denotes the number of stator segments 3 and, accordingly, the number of coils 4, then (z-n) first interconnection elements 30 and one second interconnection element 40 are necessary for a star connection. Thus, second interconnection element 40 is only necessary for interconnection by a star connection. For other types of interconnection, such as a delta connection, it may be omitted.

[0090] FIG. 3A shows a perspective view of a first interconnection element 30. First interconnection element 30 is made of sheet metal, e.g., sheet steel or sheet copper, and it is, for example, fabricated as a stamped and bent part. In the present exemplary embodiment, first interconnection element 30 includes a first contacting region 31 and a second contacting region 32. The two contacting regions 31, 32 are set apart from each other. A connecting region 33 is situated between the two contacting regions 31, 32. Connecting region 33 joins the two contacting regions 31, 32. Contacting regions 31, 32 are used for connecting first interconnection element 30 electrically and mechanically to coil terminals 5, 6. In this context, each contacting region 31, 32 is connected to a coil terminal 5, 6. Contacting regions 31, 32 have a V-shaped notch 301 for receiving a coil terminal 5, 6 in the form of a winding wire.

[0091] In addition to contacting regions 31, 32, first interconnection element 30 includes a first attachment region 34 and a second attachment region 35. Attachment regions 34, 35 are used for attaching first interconnection element 30 to carrier part 60. In the present exemplary embodiment, attachment regions 34, 35 each include a through-recess 36, 37 in the form of a cylindrical hole. Alternatively, half-open recesses in the form of, e.g., an axially extending groove are also possible.

[0092] FIG. 3B shows a side view of the first interconnection element 30 from FIG. 3A. In the present exemplary embodiment, the first interconnection element includes a first step 37 and a second step 38. These steps 37, 38 are, for example, produced by bending. Due to these steps 37, 38, first and second attachment regions 34, 35 have different axial positions.

[0093] FIG. 3C shows a perpendicular projection of first interconnection element 30 from FIG. 3A onto a plane perpendicular to the axis of rotation. Thus, steps 38, 39 from FIG. 3B are not visible. In this instance, hatched region B1 shows the region covered by connecting region 33 in the circumferential and radial directions.

[0094] FIG. 4 shows a perspective view of a second interconnection element 40. Second interconnection element 40 is made of sheet metal, e.g., sheet steel or sheet copper, and it is, for example, fabricated as a stamped and bent part. In the present exemplary embodiment, second interconnection element 40 includes a first contacting region 41, a second contacting region 42 and a third contacting region 43. The three contacting regions 41, 42, 43 are set apart from each other. A connecting region 44 is situated between first contacting region 41 and third contacting region 43. Second contacting region 42 is also situated on connecting region 44. Thus, connecting region 44 interconnects the three contacting regions 41, 42, 43. Contacting regions 41, 42, 43 are used for connecting second interconnection element 40 electrically and mechanically to coil terminals 5, 6. In this context, each contacting region 41, 42, 43 is connected to a coil terminal 5, 6. Contacting regions 41, 42, 43 have a V-shaped notch 401 for receiving a coil terminal 5, 6 in the form of a winding wire. In the case of the interconnection of three phases by a star connection, second interconnection element 40 forms the star point, at which the three phases are interconnected.

[0095] In addition to contacting regions 41, 42, 43, second interconnection element 40 includes a first attachment region 45 and a second attachment region 46. Attachment regions 45, 46 are used for attaching second interconnection element 40 to carrier part 60. In the present exemplary embodiment, attachment regions 45, 46 each include a through-recess 47 in the form of a cylindrical hole. Alternatively, half-open recesses in the form of, e.g., an axially extending groove are also possible.

[0096] FIG. 5A shows a perspective view of a third interconnection element 50. Third interconnection element 50 is made of sheet metal, e.g., sheet steel or sheet copper, and it is, for example, fabricated as a stamped and bent part. In the present exemplary embodiment, third interconnection element 50 includes a first contacting region 51 and a second contacting region 52. The two contacting regions 51, 52 are set apart from each other. First contacting region 51 is used for connecting third interconnection element 50 to a coil terminal 5, 6 electrically and mechanically and includes a V-shaped notch 501 for this. Second contacting region 52 is used for connecting third interconnection element 50 electrically and mechanically to a phase conductor. Thus, third interconnection elements 50 form the connections of the electric motor to phases U, V, W. Therefore, in the case of a three-phase winding, three third interconnection elements 50 are needed. The connection between third interconnection elements 50 and the phase conductors may be accomplished directly or indirectly, using a screw 80 having a corresponding nut 81. In principle, a direct connection between the phase conductors and coil terminals 5, 6 may also be produced, which means that third interconnection elements 50 may be omitted. However, third interconnection elements 50 simplify the manufacturing method of the electric motor and provide for simple connection of the phase conductors to the electric motor. In the present exemplary embodiment, second contacting region 52 includes a through-recess. A screw 80, which is used as a terminal for a cable lug of the phase conductor, is passed through this recess. A nut 81 is used for attaching the cable lug to the third interconnection element.

[0097] In addition to contacting regions 51, 52, third interconnection element 50 includes a first attachment region 53, a second attachment region 54 and a third attachment region 55. Attachment regions 53, 54, 55 are used for attaching third interconnection element 50 to carrier part 60. In the present exemplary embodiment, attachment regions 53, 54, 55 include half-open recesses 56, 57 in the form of axially extending grooves. As an alternative, closed recesses, e.g., in the form of cylindrical holes, are also possible.

[0098] FIG. 6 shows carrier part 60, including a second interconnection element 40 supported on it. Carrier part 60 is substantially annular, and in this exemplary embodiment, it is manufactured as a plastic injection-molded part. It is, for example, produced in one piece. As shown in FIG. 1, carrier part 60 is positioned concentrically to axis of rotation D, on an axial end of stator 2. Carrier part 60 includes axial projections 61, 62, 63, 64, 65 in the form of rivet pins. In this exemplary embodiment, projections 61, 62, 63, 64, 65 are cylindrical, but other shapes are also possible. Rivet pins 61, 62, 63, 64, 65 are, for example, produced to be complementary to corresponding recesses 36, 37, 47, 56, 57, in order to provide a rigid mechanical connection between carrier part 60 and interconnection element 30, 40, 50.

[0099] Carrier part 60 includes first rivet pins 61 and second rivet pins 62 for holding first interconnection element 30. Carrier part 60, for example, includes third rivet pins 63 for holding second interconnection element 40. Carrier part 60, for example, has fourth rivet pins 64 and fifth rivet pins 65 for holding third interconnection elements 50.

[0100] The first, third and fourth rivet pins are, for example, situated close to the inner circumference of carrier part 60, while the second and fifth rivet pins are situated close to the outer circumference of carrier part 60.

[0101] Carrier part 60 includes a plurality of guide regions 66 distributed on its outer circumference. Each guide region 66 includes a V-shaped notch and is used for guiding coil terminals 5, 6 in the axial direction during the establishment of the electrical connection between coil terminals 5, 6 and contacting regions 31, 32, 41, 42, 43, 51. For this purpose, the position of a guide region 64 in the radial and circumferential directions is substantially identical to the position of a corresponding contacting region 31, 32, 41, 42, 43, 51. A guide region 66 is situated axially below a contacting region 31, 32, 41, 42, 43, 51. In this context, the V-shaped notch of guide region 66 is offset slightly in the radial direction, for example, 0.5 mm, towards the inner circumferential side, so that effective contacting between coil terminal 5, 6 and contacting region 31, 32, 41, 42, 43, 51 is ensured.

[0102] During the manufacturing method, coil terminals 5, 6 are initially bent in such a manner, that they point radially outwards. Interconnection unit 1 is subsequently placed on stator 2, and then, coil terminals 5, 6 are bent into position in such a manner, that they point axially upwards and touch corresponding contacting regions 31, 32, 41, 42, 43, 51. In this connection, guide regions 66 support the operation of contacting, so that coil terminals 5, 6 are oriented substantially parallelly to axial direction A.

[0103] The starting point in the method for manufacturing interconnection unit 1 is the carrier part 60 made of insulating material. In the present exemplary embodiment, this is made of plastic with the aid of an injection molding method. After that, as shown in FIG. 6, second interconnection element 40 is positioned on carrier part 60. Through-recesses 47 of attachment regions 45, 46 of second interconnection element 40 are used as a holding device, which means that it is possible for third rivet pins 63 to be passed through recesses 47.

[0104] In a subsequent manufacturing step, first interconnection elements 30 are positioned on carrier part 60, namely, in such a manner, that the region B1, B2 covered by connecting region 33 of one of the first interconnection elements 30 in the circumferential and radial direction overlaps, in each instance, a region B1, B2 covered by the connecting region 33 of another of the first interconnection elements 30 in the circumferential and radial directions. In other words, the first interconnection elements are at least partially stacked one on top of the other in the circumferential direction, so that a more compact configuration is rendered possible.

[0105] Through-recesses 36, 37 of attachment regions 34, 35 of first interconnection elements 30 are used for holding first interconnection elements 30, which means that it is possible to pass first and second rivet pins 61, 62 through recesses 36, 37. Since one recess 36 of the two recesses 36, 37 of a first interconnection element 30 is situated radially further inside than the recess 37, stable support is provided. In particular, tilting of first interconnection elements 30 is prevented. In other words, first attachment regions 34 have a radial position, which is different from the radial position of second attachment regions 35. First and second rivet pins 61, 62 and first interconnection elements 30 are positioned and shaped in such a manner, that the positioned, first interconnection elements 30 do not touch each other. Thus, they are positioned so as to be spaced apart from each other. Due to this, in principle, no further electrical insulation is necessary, since in a final manufacturing step, the stator is normally encapsulated by potting compound, which is used as insulating material.

[0106] It is considered advantageous that the electrical insulation between first interconnection elements 30 may also be provided by prefabricated insulating parts. To this end, for example, plastic insulating parts 70 are produced with the aid of an injection molding method. FIG. 7A shows an insulating part 70, which partially surrounds a first interconnection element. In this exemplary embodiment, insulating part 70 is shaped in such a manner, that it may be slid onto first interconnection element 30 in the radial direction. In this context, first interconnection element 30 is partially surrounded by insulating part 70 in the circumferential direction in such a manner, that displacement of insulating part 70 and first interconnection element 30 relative to each other in this direction is not possible. Thus, a bilateral, form-locked connection in the circumferential direction is present. In addition, first interconnection element 30 is partially surrounded by insulating part 70 in the axial direction in such a manner, that displacement of insulating part 70 and first interconnection element 30 relative to each other in this direction is not possible. Thus, a bilateral, form-locked connection in the axial direction is present. First interconnection element 30 is connected to insulating part 70 in the radial direction in a form-locked manner on only one side, which means that displacement relative to each other is possible.

[0107] If insulating parts 70 are used for electrical insulation, then it is possible for only every second of the first interconnection elements 30 to be surrounded by an insulating part 70 in the circumferential direction, as described above. FIG. 7B shows the first interconnection element 30A having a slid-on insulating part 70 of FIG. 7A, and in addition, a further, first interconnection element 30B, which is merely placed on insulating part 70. Subsequently, a first interconnection element 30 surrounded by an insulating part 70 is positioned again on this further, first interconnection element 30B.

[0108] FIG. 7C shows a perpendicular projection of the two first interconnection elements 30A, 30B of FIG. 7BA onto a plane perpendicular to the axis of rotation. In this instance, as in FIG. 3C, hatched region B1 shows the region covered by connecting region 33 of a first interconnection element 30 in the circumferential and radial directions. In a manner analogous to that, hatched region B2 indicates the region covered by connecting region 33 of the other, first interconnection element 30B in the circumferential and radial directions. These two regions overlap partially. In this exemplary embodiment, the regions covered by the two connecting regions 33 in the radial direction are identical. However, it is also possible for these to be different.

[0109] FIG. 8 shows carrier part 60 and second interconnection element 40 of FIG. 6, including the nine first interconnection elements 30 positioned on it, as well as the insulating parts 70 situated between them. In this exemplary embodiment, since only every second interconnection element 30 is surrounded by an insulating part 70, only five insulating parts 70 are necessary. In addition, a third interconnection element 50, which is held by two fourth rivet pins 64 and one fifth rivet pin 65 of carrier part 60, is also shown in FIG. 8. A square-headed bolt 80 having a corresponding nut 81 is used for contacting third interconnection element 50 with the phase conductor. The head of the bolt is situated axially below the through-recess of second attachment region 52, so that hexagonal nut 81 is accessible from above. This allows simple contacting of the phase conductor with third interconnection element 50 with the aid of, e.g., cable lugs. In this exemplary embodiment, in addition to the third interconnection element 50 shown, two further, third interconnection elements 50 are used, which are positioned next to and counterclockwise from shown, third interconnection element 50 in the circumferential direction. All three third interconnection elements 50 are shown in FIG. 1.

[0110] After all interconnection elements 30, 40, 50 are positioned on carrier part 60, they are joined to carrier part 60. To this end, in the present exemplary embodiment, the free ends of rivet pins 61, 62, 63, 64, 65 are deformed into rivet heads in such a manner, that the diameter of the rivet heads in the plane perpendicular to the axis of rotation is greater than the diameter of the corresponding recesses. The deformation may be produced, for example, with the aid of ultrasonic welding or hot crimping or hot stamping. If, during the deformation, only the rivet pin is deformed without an integral connection between the carrier part and the interconnection elements being formed in the process, then a form-locked connection is produced. However, it is also possible that, alternatively or additionally, an integral connection between the carrier part and the interconnection elements is produced. After interconnection elements 30, 40, 50 are joined to carrier part 60, coil terminals 5, 6 are connected to corresponding contacting regions 31, 32, 41, 42, 51 of interconnection elements 30, 40, 50, in order to produce an electrical connection. To this end, the bare ends of the wire of the coils are inserted into V-shaped notches 301, 401, 501 of contacting regions 31, 32, 41, 42, 51, and an integral connection between the wire and the interconnection element is produced. In this exemplary embodiment, this is accomplished with the aid of laser welding. However, other methods are also possible.

[0111] After coils 4 of the electric motor are interconnected in this manner with the aid of interconnection unit 1 to form a multiphase winding, stator 2, together with the interconnection unit 1 situated on an axial end of the stator, are encapsulated by potting compound in order to fix them in position mechanically. If no insulating parts 70 are used, this potting compound is used as electrical insulation between interconnection elements 30, 40, 50.

[0112] If three third interconnection elements 50 are used, as shown in the present exemplary embodiment, then, during the encapsulation, care must be taken that the second attachment regions 54 of third interconnection elements 50 remain free of potting compound. In order to ensure that third interconnection elements 50 are sufficiently surrounded by the potting compound and that rigid support is attained, third interconnection elements 50 include, for example, anchor regions 58, which point axially from the third attachment region in the direction of stator 2. For more effective anchoring in the potting compound, anchor region 58 includes, for example, an undercut 59.

[0113] FIG. 9B alternatively shows a first interconnection element 90 for a second exemplary embodiment of an interconnection unit 1. This first interconnection element 90 also includes a first contacting region 91 and a second contacting region 92. Contacting regions 91, 92 each include a catch arm 93, by which a specific coil terminal 5, 6 may be captured and held in a friction-locked manner, in particular, pinched between the catch arms. In addition, coil terminals 5, 6 are, for example, connected to the catch arms in an integral manner with the aid of contact welding. Catch arms 93 are open in a V-shape; the catch arms forming the arms of the V. Rapid and not very complex electrical connection of coil terminals 5, 6 to contacting regions 91, 92 is provided with the aid of catch arms 93, in that when interconnection unit 1 is rotated relative to stator 2, coil terminals 5, 6 are captured in the inner region spanned by contacting region 91, 92, that is, in particular, in the inner region spanned by the V of V-shaped catch arm 93. Thus, specific contacting region 91, 92 guides respective coil terminal 5, 6 into the connecting position at the inner tip of the V. As soon as the rotation is finished, joining by contact welding is carried out. To this end, the specific arms of contacting region 91, 92, that is, catch arms 93, are pressed together by suitably bending them, until coil terminal 5, 6 is held by friction, in particular, clamped, by catch arms 93 of contacting region 91, 92. Contact welding is then carried out, so that the electrical connection between coil terminal 5, 6 and contacting region 91, 92 may be produced without tin solder.

[0114] As also in the case of the first exemplary embodiment, connecting region 94 of first interconnection element 90 of the second exemplary embodiment has two axial steps 95, 96.

[0115] However, in contrast to the first exemplary embodiment, this first interconnection element 90 has only one attachment region 97. The attachment region includes a through-recess 98.

[0116] FIG. 9A shows an insulating part 99, which is slid onto first interconnection element 90. FIG. 9C shows first interconnection element 90 having insulating part 99 slid on.

[0117] FIG. 9D shows first interconnection element 90A having a slid-on insulating part 99 from FIG. 9C, and, in addition, a further, first interconnection element 90B, which is positioned on insulating part 99. In this context, the regions covered by the two connecting regions 94 of the two, first interconnection elements 90A, 90B overlap in the circumferential and radial directions.

[0118] FIG. 10 shows interconnection unit 100 of the second exemplary embodiment. As in the case of the first exemplary embodiment, interconnection unit 100 includes a carrier part 101 for holding the nine first interconnection elements 90, second interconnection element 102 and the three third interconnection elements 103.

[0119] As in the first exemplary embodiment, second interconnection element 102 has three contacting regions 104. As in the first exemplary embodiment, second interconnection element 102 includes two attachment regions 105, of which only one is visible due to the perspective view.

[0120] As in the first exemplary embodiment, third interconnection element 103 includes a first contacting region 106 for contacting with a coil terminal 5, 6 and a second contacting region 107 for contacting with a phase conductor. In contrast to the first exemplary embodiment, third interconnection element 103 has only one attachment region 108.

[0121] In the second exemplary embodiment, the form-locked connection between interconnection elements 90, 102, 103 and carrier part 101 is also obtained by deforming rivet pins of the carrier part into rivet heads; the rivet pins being able to be passed through recesses in the respective attachment regions.

[0122] In the second exemplary embodiment, the positioning of interconnection elements 90, 102, 103 on carrier part 101 is accomplished, in that carrier part 101 has a circumferential annular groove for receiving interconnection elements 90, 102, 103. At its outer circumference, carrier part 101 additionally includes recesses 109 in the groove wall, through which, in each instance, contacting regions 91, 92, 104, 106 may be passed. This also contributes to the exact positioning of the components.

[0123] In the two exemplary embodiments, in each instance, all of the first interconnection elements 30, 90 are manufactured identically, that is, are identical parts. Likewise, in each instance, third interconnection elements 50, 103 are also manufactured identically, that is, are also identical parts. An advantage of this is that the parts may be manufactured at lower cost. However, it is also possible for first interconnection elements 30, 90 and/or third interconnection elements 50, 103 to be manufactured differently.

[0124] In the two exemplary embodiments, both the regions covered by connecting regions 33, 94 of first interconnection elements 30, 90 in the axial direction and the regions covered by connecting regions 33, 94 of first interconnection elements 30, 90 in the radial direction are identical. However, it is also possible for these regions to be different.

LIST OF REFERENCE NUMERALS

[0125] 1 interconnection unit

[0126] 2 stator

[0127] 3 stator segment

[0128] 4 coil

[0129] 5 first coil terminal

[0130] 6 second coil terminal

[0131] 7 insulating paper

[0132] 30 first interconnection element

[0133] 31 first contacting region of a first interconnection element

[0134] 32 second contacting region of a first interconnection element

[0135] 33 connecting region of a first interconnection element

[0136] 34 first attachment region of a first interconnection element

[0137] 35 second attachment region of a first interconnection element

[0138] 36 first through-recess in a first interconnection element

[0139] 37 second through-recess in a first interconnection element

[0140] 38 first step of a first interconnection element

[0141] 39 second step of a first interconnection element

[0142] 301 V-shaped notch

[0143] 40 second interconnection element

[0144] 41 first contacting region of the second interconnection element

[0145] 42 second contacting region of the second interconnection element

[0146] 43 third contacting region of the second interconnection element

[0147] 44 connecting region of the second interconnection element

[0148] 45 first attachment region of the second interconnection element

[0149] 46 second attachment region of the second interconnection element

[0150] 47 through-recess in the second interconnection element

[0151] 401 V-shaped notch

[0152] 50 third interconnection element

[0153] 51 first contacting region of a third interconnection element

[0154] 52 second contacting region of a third interconnection element

[0155] 53 first attachment region of a third interconnection element

[0156] 54 second attachment region of a third interconnection element

[0157] 55 third attachment region of a third interconnection element

[0158] 56 through-recess in a third interconnection element

[0159] 57 through-recess in a third interconnection element

[0160] 58 anchor region of a third interconnection element

[0161] 60 carrier part

[0162] 61 first rivet pin

[0163] 62 second rivet pin

[0164] 63 third rivet pin

[0165] 64 fourth rivet pin

[0166] 65 fifth rivet pin

[0167] 66 guide region

[0168] 70 insulating part

[0169] 80 screw

[0170] 81 nut

[0171] 90 first interconnection element

[0172] 91 first contacting region of a first interconnection element

[0173] 92 second contacting region of a first interconnection element

[0174] 93 catch arm

[0175] 94 connecting region of a first interconnection element

[0176] 95 axial step

[0177] 96 axial step

[0178] 97 attachment region of a first interconnection element

[0179] 98 through-recess in a first interconnection element

[0180] 99 insulating part

[0181] 100 interconnection unit

[0182] 101 carrier part

[0183] 102 second interconnection element

[0184] 103 third interconnection element

[0185] 104 contacting region of a second interconnection element

[0186] 105 attachment region of a second interconnection element

[0187] 106 first contacting region of a third interconnection element

[0188] 107 second contacting region of a third interconnection element

[0189] 108 attachment region of a third interconnection element