Electric motor, braking device, and vehicle

Abstract

An electric drive for an electrohydraulic brake system, having a housing and a stator-rotor unit received by the housing. The stator-rotor unit has a stator with an arrangement of a plurality of magnetizable, pole-forming stator teeth. The stator teeth are subdivided into separate tooth pairs inserted into the housing. Each of the tooth pairs is wrapped with its own common metal wire forming a part of the coil, the two wire ends of which are electrically contacted with a separate housing insert made of plastic, which is joined to the housing and thereby covers the stator-rotor unit. The individual stator teeth are braced against one another in the housing while lying on one another and are braced against the housing.

Claims

1. An electric drive for use in an electrohydraulic brake system, comprising: a housing; a stator-rotor unit received by the housing, that comprises: a stator comprising: an arrangement of a plurality of magnetizable, pole-forming stator teeth; separate tooth pairs into which the stator teeth are subdivided and inserted into the housing; wherein each of the tooth pairs is wrapped with a respective common metal wire forming a part of a coil; a separate housing insert made of plastic which is joined to the housing and covers the stator-rotor unit; two wire ends of each of the tooth pairs are contacted with the separate housing insert made of plastic; wherein individual stator teeth are wound and are braced against one another in the housing while lying on one another and are braced against the housing, wherein the separate housing insert made of plastic encloses a contact arrangement of at least two spaced-apart, electrically conducting contact elements for electrical supply of at least two phases of the coil of the stator, wherein the contact elements are circumferentially arranged and insulated from one other by the plastic of the separate housing insert made of plastic, wherein the individual stator teeth are overmolded with a coil carrier made of plastic with formation of a first end panel, which, in an installed position of the stator, faces a rotor, and overmolded with the formation of a second end panel, which faces away from the rotor in the installed position, wherein an associated wire winding belonging to the coil is enclosed between the first end panel and the second end panel, wherein at least one pin-shaped anchoring section made of plastic is integrally formed on each of the individual coil carriers on a side of each respective second panel and extends in a longitudinal direction of the electric drive through an associated opening in the separate housing insert made of plastic beyond an end face of the separate housing insert made of plastic facing away from the stator-rotor unit and engages behind the end face.

2. The electric drive as claimed in claim 1, wherein the associated wire windings have a gradation between respective first and second panels.

3. The electric drive as claimed in claim 1, wherein each of the at least one plastic anchoring sections are caulked with the separate housing insert made of plastic.

4. The electric drive as claimed in claim 1, wherein the contact elements have first contact sections for external contacting of the stator with a plug and second contact sections for internal contacting of the stator with respective contact elements.

5. The electric drive as claimed in claim 4, wherein the first contact sections and the second contact sections protrude in a longitudinal direction of the electric drive from an end face of the separate housing insert made of plastic facing away from the stator-rotor unit.

6. The electric drive as claimed in claim 1, wherein individual wire ends of the tooth pairs are routed in a longitudinal direction of the electric drive through associated openings in the separate housing insert made of plastic beyond an end face of the separate housing insert made of plastic facing away from the stator-rotor unit and electrically contacted with the separate housing insert made of plastic.

7. The electric drive as claimed in claim 1, wherein the contact arrangement has three spaced-apart, electrically conducting contact elements for electrical supply of three phases of the coil.

8. The electric drive as claimed in claim 1, further comprising: an annular arrangement with twelve stator teeth which form a total of six tooth pairs.

9. The electric drive as claimed in claim 1, wherein the housing is a deep-drawn metal sheet.

10. The electric drive as claimed in claim 1, wherein the electric drive is arranged in an electrohydraulic brake system.

11. The use of an electric drive as claimed in claim 1 the stator-rotor unit displaces a piston of a cylinder-piston arrangement in order to generate a brake pressure.

12. The electric drive as claimed in claim 1, wherein respective wire ends of the tooth pairs are arranged at different radial positions in the separate housing insert made of plastic.

13. The electric drive as claimed in claim 1, wherein a circumferentially outer surface of each second panel directly faces a circumferentially inner surface of the housing.

14. A brake system comprising: an electric drive comprising: a housing; a stator-rotor unit received by the housing, that comprises: a stator comprising: an arrangement of a plurality of magnetizable, pole-forming stator teeth; separate tooth pairs into which the stator teeth are subdivided and inserted into the housing; wherein each of the tooth pairs is wrapped with a respective common metal wire forming a part of a coil; a separate housing insert made of plastic which is joined to the housing and covers the stator-rotor unit; two wire ends of each of the tooth pairs are contacted with the separate housing insert made of plastic; wherein individual stator teeth are each wound and braced against one another in the housing while lying on one another and are braced against the housing, wherein the separate housing insert made of plastic encloses a contact arrangement of at least two spaced-apart, electrically conducting contact elements for electrical supply of at least two phases of the coil of the stator, wherein the contact elements are circumferentially arranged and insulated from one other by the plastic of the separate housing insert made of plastic, wherein the individual stator teeth are overmolded with a coil carrier made of plastic with formation of a first end panel, which, in an installed position of the stator, faces a rotor, and overmolded with the formation of a second end panel, which faces away from the rotor in the installed position, wherein an associated wire winding belonging to the coil is enclosed between the first end panel and the second end panel, wherein at least one pin-shaped anchoring section made of plastic is integrally formed on each of the individual coil carriers on a side of each respective second panel and extends in a longitudinal direction of the electric drive through an associated opening in the separate housing insert made of plastic beyond an end face of the separate housing insert made of plastic facing away from the stator-rotor unit and engages behind the end face.

15. A vehicle comprising: a brake system of an electric drive comprising: a housing; a stator-rotor unit received by the housing, that comprises: a stator comprising: an arrangement of a plurality of magnetizable, pole-forming stator teeth; separate tooth pairs into which the stator teeth are subdivided and inserted into the housing; wherein each of the tooth pairs is wrapped with a respective common metal wire forming a part of a coil; a separate housing insert made of plastic which is joined to the housing and covers the stator-rotor unit; two wire ends of each of the tooth pairs are contacted with the separate housing insert made of plastic; wherein individual stator teeth are each wound and are braced against one another in the housing while lying on one another and are braced against the housing, wherein the separate housing insert made of plastic encloses a contact arrangement of at least two spaced-apart, electrically conducting contact elements for electrical supply of at least two phases of the coil of the stator, wherein the contact elements are circumferentially arranged and insulated from one other by the plastic of the separate housing insert made of plastic, wherein the individual stator teeth are overmolded with a coil carrier made of plastic with formation of a first end panel, which, in an installed position of the stator, faces a rotor, and overmolded with the formation of each second a panel, which faces away from the rotor in the installed position, wherein an associated wire winding belonging to the coil is enclosed between the first end panel and the second end panel, wherein at least one pin-shaped anchoring section made of plastic is integrally formed on each of the individual coil carriers on a side of each respective second panel and extends in a longitudinal direction of the electric drive through an associated opening in the separate housing insert made of plastic beyond an end face of the separate housing insert made of plastic facing away from the stator-rotor unit and engages behind the end face.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Further advantageous developments of the present invention will emerge from the dependent claims and from the following description of preferred embodiments. In the drawings:

(2) FIG. 1 is a perspective illustration of an electric drive;

(3) FIG. 2 is an exploded illustration of the electric drive shown in FIG. 1;

(4) FIGS. 3A and 3B are a perspective illustration of an arrangement of two stator teeth forming a tooth pair;

(5) FIG. 4 is a perspective illustration of a coil of the electric drive shown in FIG. 1,

(6) FIG. 5 is a perspective illustration of a rotor of the electric drive shown in FIG. 1,

(7) FIG. 6 is a further perspective illustration of the housing insert shown in FIG. 1 together with the coil shown in FIG. 4,

(8) FIG. 7 is an enlarged perspective illustration of an internal contacting of the coil shown in FIG. 4,

(9) FIG. 8 is an enlarged perspective illustration of a connection between the housing insert shown in FIG. 1 and the coil shown in FIG. 4,

(10) FIGS. 9A and 9B show two further perspective views of the housing insert; and

(11) FIGS. 10A-10F show three contact elements of the housing insert with unbent and bent first and second contact sections.

DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENTS

(12) The proposed electric drive 2 is intended for use in an electrohydraulic brake system. The electric drive 2 is designed as an electronically commutated, three-phase (phases U, V, W) direct current motor in the form of an internal rotor. The electric drive 2 comprises a housing 4, which is formed, for example, from a deep-drawn metal sheet and which can be attached to a housing of the electrohydraulic brake system via a flange 6. In the housing 4 there is installed a stator-rotor unit 18, 26 that drives a ball screwnot shown herefor displacing a piston of a cylinder-piston arrangement in order to generate a brake pressure.

(13) In connection with an application other than the one proposed here, the electric drive proposed in the context of this description of the figures can also be operated as an electronically commutated alternating current motor.

(14) A separate, plastic-encapsulated housing insert 8 is also joined to the housing 4, through a central opening of which insert there extends a section 10 of a tube 28 of a rotor 26, in which the ball screw is arranged (cf. FIG. 1). In this context, separate means that the housing insert 8 is not part of the stator 18.

(15) The housing insert 8 encloses a contact arrangement 22 of three spaced-apart, electrically conducting contact elements KE.sub.U, KE.sub.V, KE.sub.W (cf. FIG. 2 in conjunction with FIGS. 10A-10F), which are electrically insulated from one another by the plastic of the housing insert 8. Each of the contact elements KE.sub.U, KE.sub.V, KE.sub.W has a partially circular base section BA on which a single, first contact section U.sub.I, V.sub.I, W.sub.I and a total of four second contact sections U.sub.II, V.sub.II, W.sub.II are integrally formed (cf. FIGS. 10A-10F).

(16) Both the first contact sections U.sub.I, V.sub.I, W.sub.I and the second contact sections U.sub.II, V.sub.II, W.sub.II protrude from an end face of the housing insert 8 facing away from the stator-rotor unit 18, 26. Furthermore, individual wire ends D.sub.B, D.sub.E of a coil 20 of a stator 18 are routed through associated openings in the housing insert 8 to the outside through the housing insert 8, so that these wire ends also protrude from the end face. Here, a wire end means either a wire beginning D.sub.B (B=beginning) or a wire end D.sub.E (E=end) of a wire winding DW.sub.U, DW.sub.V, DW.sub.W of the coil 20. In the exemplary embodiment, a total of 6 wire windings form the coil 20. These wire ends are contacted with the respectively assigned second contact sections U.sub.II, V.sub.II, W.sub.II. The wire ends can be connected to the respective contact sections U.sub.II, V.sub.II, W.sub.II in an integrally bonded manner by resistance welding (cf. connection 14 in FIG. 1 or FIG. 6).

(17) The first contact sections U.sub.I, V.sub.I, W.sub.I serve for externally contacting the stator 18 with a plug. By contrast, the second contact sections U.sub.II, V.sub.II, W.sub.II serve for internally contacting the stator 18 with the three contact elements KE.sub.1, KE.sub.2, KE.sub.3 (cf. FIG. 2 in conjunction with FIGS. 10A-10F), each of which is assigned to one of three phases U, V, W of the coil 20.

(18) The contact sections U.sub.II, V.sub.II, W.sub.II are assigned in pairs to a coil section, that is to say to a beginning of a wire winding DW.sub.U and to an end of a wire winding DW.sub.V, DW.sub.W adjacent thereto, with the coil section belonging to one of the phases U, V, W of the coil 20. The mutually opposite pairs of the contact sections U.sub.II, V.sub.II, W.sub.II each contact a coil section belonging to the same phase U, V or W (cf. FIGS. 10A-10F). The division of the contact elements KE.sub.U, KE.sub.V, KE.sub.W can be such that the spacing between the mutually assigned contact sections U.sub.II, V.sub.II, W.sub.II differs (cf. FIGS. 10A-10F). In principle, however, this spacing can also be identical, provided that the wire ends D.sub.B, D.sub.E of the coil 20 are routed away accordingly.

(19) FIG. 2 and FIG. 7 in conjunction with FIGS. 10A-10F illustrate that two adjacent contact sections of the total of four second contact sections U.sub.II, V.sub.II, W.sub.II, which are provided for each contact element KE.sub.U, KE.sub.V, KE.sub.W and which, as such, are integrally formed on the base section BA via an assigned web section SA, connect a wire beginning D.sub.B of one of the wire windings DW.sub.U, DW.sub.V, DW.sub.W to a wire end D.sub.E of an adjacent wire winding DW.sub.U, DW.sub.V, DW.sub.W. These two adjacent wire windings DW.sub.U, DW.sub.V, DW.sub.W belong to one of the three phases U, V, W (cf. FIG. 4).

(20) Furthermore, individual pin-like anchoring sections 16, made of plastic, of the stator 18 also protrude from the end face and are integrally formed on the stator 18 and extend through the housing insert 8 through associated openings in the housing insert 8. These plastic anchoring sections 16 are caulked with the housing insert 8 in a form-fitting manner, for example by what is known as hot caulking.

(21) To stiffen the housing 4, it is possible, in the region of the flange 6, for bulge regions that are evenly spaced apart from one another to be provided in the housing sheet metal, in each of which regions a bulge oriented radially inward is formed. In the region of the respective bulges, a fastening hole is also formed in the flange in order to be able to attach the housing 4 to the housing of the electrohydraulic brake system.

(22) The stator 18 is joined to the housing 4 in a clamped manner. The permanently magnetized rotor 26 enclosed by the stator 18 comprises a tube 28, which is press-connected to a hub 30. The hub 30 carries an arrangement of a plurality of permanent magnets 32 in the form of shell magnets, which interact as such with the coil 20. The tube 28 is also laser-welded at one of its two ends to a bearing bush 36, which as such extends through an angular-contact ball bearing 34 which functions as a fixed bearing and via which the tube 28 is received in the region of one end of the housing 4. The tube 28 is also received by a ball bearing 38, which functions as a floating bearing and is received in a centering manner by the housing insert 8. The housing insert 8 presses against the ball bearing 38 or its outer ring via, for example, an annular spring element 24for example in the form of a corrugated springwhich is enclosed as such by the housing insert 8. The spring element 24 can be connected to the housing insert 8 in an integrally bonded manner by being correspondingly concomitantly encapsulated during the plastic encapsulation of the housing insert 8. Furthermore, the housing insert 8 covers the stator-rotor unit 18, 26 in the sense of a shield or housing and bearing shield.

(23) In summary, the housing insert 8 combines the following functions: receiving and centering of the floating bearing 38; bracing of the floating bearing 38; internal and external contacting of the coil 20; form-fitting connection with the stator 18; and covering of the stator-rotor unit 18, 26.

(24) The integration of all these functions in the separate housing insert 8 is associated with a reduction in manufacturing costs and simplified assembly of such an electric drive 2. In addition, there is a very compact design of the electric drive 2.

(25) The proposed housing insert 8 also reduces the length tolerances to be taken into account in the longitudinal direction X-X of the electric drive 2 (reduction of a length tolerance chain).

(26) In addition, the integration of the contact arrangement 22 in the housing insert 8 results in a very compact or very tight arrangement of the individual wire windings DW.sub.U, DW.sub.V, DW.sub.W, forming the coil 20, in the housing 4 (compact or tight packaging), because a plastic encapsulation which encloses a sectionfor example an end section of the stator 18and which as such encompasses the contact arrangement is dispensed with.

(27) The stator 18, which is arranged clamped in the housing 4, comprises, for example, an annular arrangement of a total of twelve magnetizable, pole-forming stator teeth SZ.sub.1, SZ.sub.2 . . . SZ.sub.11, SZ.sub.12. These stator teeth SZ.sub.1, SZ.sub.2 . . . SZ.sub.11, SZ.sub.12 are subdivided into separate tooth pairs SZ.sub.1 & SZ.sub.2, SZ.sub.3 & SZ.sub.4 . . . SZ.sub.11 & SZ.sub.12, with each of the tooth pairs SZ.sub.1 & SZ.sub.2, SZ.sub.3 & SZ.sub.4 . . . SZ.sub.11 & SZ.sub.12 being wrapped with its own common metal wire forming a part of the coil 20 (cf. FIG. 3 and FIG. 4). The two wire ends D.sub.B, D.sub.E of the respective tooth pairs (FIG. 3) are electrically contacted with the housing insert 8 described above.

(28) The individual stator teeth SZ.sub.1, SZ.sub.2 . . . SZ.sub.11, SZ.sub.12 are composed of individual sheet metal layers to form a laminated core. The individual laminated cores are held together by an embossing produced by a punch in a longitudinal extent X-X of the laminated core. The embossing extends over the entire longitudinal extent X-X of the respective laminated core, so that a form fit is created between the individual sheet metal layers that holds the sheet metal layers together.

(29) The individual stator teeth SZ.sub.1, SZ.sub.2 . . . SZ.sub.11, SZ.sub.12 are overmolded with a coil carrier made of plastic with the formation of a first panel P.sub.i (i=inner) in the region of the first end face of the stator tooth and overmolded with the formation of a second panel P.sub.o (o=outer) in the region of the second end face of the stator tooth. The first end panel P.sub.i faces the rotor 26 in an installed position of the stator 18, whereas the second end panel P.sub.o faces away from the rotor 26 in the installed position of the stator 18. Therefore, the first panel P.sub.i can also be referred to as the inner panel, and the second panel P.sub.o can also be referred to as the outer panel. The wire winding DW.sub.U, DW.sub.V, DW.sub.W assigned to the respective stator tooth and belonging to the coil 20 is enclosed between the panel P.sub.i and the panel P.sub.o. The coil carrier can be injection-molded in such a way that it either completely or only partially envelops the respective stator tooth (cf., for example, FIG. 3).

(30) FIG. 3 illustrates an arrangement of two stator teeth SZ.sub.1, SZ.sub.2 which form a tooth pair and which are arranged opposite one another for joint wrapping with a metal wire in such a way that initially the outer ends in the use position of the tooth pairor the second end facesare opposite one another.

(31) Wrapping occurs here in such a way that in relation to one of the two teethhere SZ.sub.1the wrapping is counterclockwise, whereas in relation to the other toothhere SZ.sub.2the wrapping is clockwise. Furthermore, the wrapping is such that between the respective first and second panel P.sub.i, P.sub.o a gradation S in the wire winding DW.sub.U, DW.sub.V, DW.sub.W is formed, with the outer wire winding section facing the panel P.sub.o being tighter in relation to that situated to the inside thereof, or inner wire winding section. For this reason, the panel P.sub.o is also designed to be longer than the panel P.sub.i. After the wrapping, the two stator teeth SZ.sub.1, SZ.sub.2 are pivoted relative to one another (cf. arrow representation in FIG. 3) in order to finally be able to be inserted into the housing 4 according to the illustration in FIG. 4. Accordingly, in the embodiment described, to be understood by way of example, a total of six tooth pairs SZ.sub.1 & SZ.sub.2, SZ.sub.3 & SZ.sub.4 . . . SZ.sub.11 & SZ.sub.12 are inserted into the housing 4 one after the other. The individual stator teeth SZ.sub.1, SZ.sub.2 . . . SZ.sub.11, SZ.sub.12 are braced against one another in the housing 4 while lying on one another and are braced against the housing 4.

(32) Integrally formed on the individual coil carriers on the side of the respective panel P.sub.o is a pin-like anchoring section 16, also called anchoring dome, which is encapsulated with the coil carrier, protrudes from the panel P.sub.o in a longitudinal direction X-X of the electric drive 2 and as it were constitutes an extension of the panel P.sub.o(cf. FIG. 7 and FIG. 8). This anchoring section 16 extendsas already described abovethrough an associated opening in the housing insert 8 beyond an end face of the housing insert 8 facing away from the stator-rotor unit 18, 26, which end face has the anchoring section 16 engaging behind it for the purpose of a form fit. Reference is made at this point to the previously mentioned hot caulking of the individual anchoring sections 16, by which a nonreleasable form fit between the housing insert 8 and the stator 18 is brought about.

(33) The individual wire ends D.sub.B, D.sub.E of the tooth pairs SZ.sub.1 & SZ.sub.2, SZ.sub.3 & SZ.sub.4 . . . SZ.sub.11 & SZ.sub.12 are routed in the longitudinal direction X-X of the electric drive 2 through associated openings in the housing insert 8 beyond the end face of the housing insert 8 facing away from the stator-rotor unit 18, 26 and electrically contacted with the housing insert 8 via respectively assigned contact sections U.sub.II, V.sub.II, W.sub.II. The contact is such that in each case a wire beginning D.sub.B of one of the wire windings DW.sub.U, DW.sub.V, DW.sub.W is connected to a wire end D.sub.E of an adjacent wire winding DW.sub.U, DW.sub.V, DW.sub.W by the contact arrangement 22 enclosed by the housing insert 8, specifically via one of the contact elements KE.sub.U, KE.sub.V, KE.sub.W. These respectively adjacent and interconnected wire windings DW.sub.U, DW.sub.V, DW.sub.W belong to one of the three phases U, V, W.

(34) The proposed coil design also contributes to a very compact or very tight arrangement of the individual wire windings DW.sub.U, DW.sub.V, DW.sub.W forming the coil 20 (compact or tight packaging). In conjunction with the proposed housing insert 8, the result is a very compact electric drive 2, which can also be easily produced and assembled. The electric drive 2 can also be produced inexpensively.

(35) Although exemplary embodiments have been discussed in the above description, it should be noted that numerous modifications are possible. Furthermore, it should be noted that the exemplary embodiments are merely examples which are not intended to limit the scope of protection, the applications and the design in any way. Instead, the above description gives a person skilled in the art a guideline for the implementation of at least one exemplary embodiment, with it being possible for various changes to be made, especially with regard to the function and arrangement of the component parts described, without departing from the scope of protection resulting from the claims and combinations of features equivalent thereto.

(36) Thus, while there have shown and described and pointed out fundamental novel features of the invention as applied to a preferred embodiment thereof, it will be understood that various omissions and substitutions and changes in the form and details of the devices illustrated, and in their operation, may be made by those skilled in the art without departing from the spirit of the invention. For example, it is expressly intended that all combinations of those elements and/or method steps which perform substantially the same function in substantially the same way to achieve the same results are within the scope of the invention. Moreover, it should be recognized that structures and/or elements and/or method steps shown and/or described in connection with any disclosed form or embodiment of the invention may be incorporated in any other disclosed or described or suggested form or embodiment as a general matter of design choice. It is the intention, therefore, to be limited only as indicated by the scope of the claims appended hereto.