Electric motor contact rail

Abstract

Contact rail (10) for the electrical supply of at least one coil winding (20) of an electric motor, wherein the contact rail has at least one contact area (11) for contacting at least one wire section (21) of the coil winding, at least one power connection (12A;12B) and a joint arrangement (13) comprising a first integral joint (14, 15) connecting the contact area and the electrical connection, wherein the joint arrangement comprises a second integral joint (16) connecting the contact area and the electrical connection, wherein a joint axis (A1) of the first joint and a joint axis (A2) of the second joint enclose a non-zero angle with each other, wherein the first and / or second joint comprises at least two, in particular opposing, bends (14, 15) and / or the joint arrangement comprises a third integral joint (17) connecting the contact area and the electrical connection.;

Description

[0001] The present invention relates to a contact rail for the electrical supply of at least one coil winding of an electric motor, a stator and an electric motor with the contact rail, and a method for connecting at least one coil winding of a stator using the contact rail.

[0002] Electric motor stators typically have multiple coil windings that are alternately supplied with current to generate a moving magnetic field.

[0003] For this purpose, the coil windings are contacted by means of busbars (“lead frames”) according to internal company practice, which in turn can be connected to printed circuit boards, in particular via press-in contacts.

[0004] The documents US 2009 / 0 108 688 A1 and DE 10 2010 017 516 A1 relate to contact rails and essentially each show a contact rail for the electrical supply of at least one coil winding of an electric motor, wherein the contact rail has at least one contact region for contacting at least one wire section of the coil winding, at least one power connection and a joint arrangement with a first integrally formed joint which connects the contact region and the power connection to one another.

[0005] The object of the present invention is to improve electric motors, in particular their design, assembly, reliability, stability and / or performance.

[0006] This object is achieved by a contact rail having the features of claim 1. Claims 8, 11, and 12 protect a stator and an electric motor having one or more contact rails described herein, as well as a method for connecting one or more coil windings of a stator using a contact rail described herein. The subclaims relate to advantageous developments.

[0007] According to one embodiment of the present invention, one or more contact rails, by means of which (each) one or more coil windings of an electric motor are electrically supplied or which are provided, in particular configured, or used for this purpose, have (each) at least one contact region which contacts one or more wire sections of the (respective) coil winding, in one embodiment directly and / or frictionally, positively and / or materially and / or electrically, or which are provided, in particular configured, or used for this purpose, at least one power connection, in particular for connecting the contact rail to a power supply, and a joint arrangement which has a first integrally formed joint which connects the contact region and the power connection to one another.If, in one embodiment, the contact rail has a plurality of contact areas, wherein a first of these contact areas contacts one or more wire sections of a first of the coil windings and one or more further of these contact areas (each) contacts one or more wire sections of a further of the coil windings or is provided, in particular set up, or used for this purpose, in particular in order to supply them with current in phase or together, then in a further development of this embodiment the joint arrangement is arranged between the power connection and at least two of these contact areas, in particular therefore between the power connection and the contact area closest to it.

[0008] By means of (at least) one joint, in one embodiment, assembly tolerances between the coil winding(s) or contacted wire sections on the one hand and a connection of the power connection on the other hand can be at least partially compensated and / or these two areas can be at least partially mechanically decoupled or a force, in particular bending and / or torsional moment transmission between the contact area and the power connection can be reduced and thus their (mechanical) load, in particular due to tensions and / or vibrations, can be reduced.

[0009] By means of an integrally formed joint, which in one embodiment has a one-piece joint or a joint without mutually sliding joint surfaces or an elastic (deformed) joint, in particular, the contact rail in one embodiment can advantageously be realized in a more compact and / or reliable manner and / or can be better mounted.

[0010] In one embodiment, the joint arrangement has a second integrally formed joint which connects the contact region and the power connection to one another, wherein in a further development (at least) one joint axis of the first joint and (at least) one joint axis, which in one embodiment is skewed thereto, of the second joint enclose an angle with one another which is different from zero and which in one embodiment is at least 30°, in particular at least 45°, preferably at least 60° and in one embodiment, at least substantially 90°.

[0011] In one embodiment, the joint arrangement has a third integrally formed joint which connects the contact region and the power connection to one another, wherein in a further development (at least one joint axis of the third joint and the (at least one) joint axis of the first joint as well as the (at least one) joint axis of the third joint and the (at least one) joint axis of the second joint each enclose an angle different from zero, in one embodiment are skew to one another, wherein in one embodiment the angle between the first and third joint axes and / or the angle between the second and third joint axes (in each case) is at least 30°, in particular at least 45°, preferably at least 60° and in one embodiment, at least substantially 90°.

[0012] As a result, in one embodiment, assembly tolerances between the coil winding(s) or contacted wire sections on the one hand and a connection of the power connection on the other hand can be at least partially compensated in a particularly advantageous manner and / or these two areas can be at least partially mechanically decoupled or a force, in particular bending and / or torsional moment transmission between the contact area and the power connection can be reduced and thus their (mechanical) load, in particular due to tensions and / or vibrations, can be reduced.

[0013] In the present case, a joint axis is understood, in particular in the usual way in the art, to be a degree of freedom of the joint or a movement possibility in which the joint opposes a movement or deformation with a resistance that is reduced compared to movements or deformations in other directions, preferably by at least 10%, in particular by at least 25%, in one embodiment by at least 50%.

[0014] In one embodiment, the first, second and / or third joint is a swivel joint, and its aforementioned joint axis is thus (in each case) a (preferred) swivel axis.

[0015] As a result, in one embodiment, assembly tolerances between the coil winding(s) or contacted wire sections on the one hand and a connection of the power connection on the other hand can be at least partially compensated in a particularly advantageous manner and / or these two areas can be at least partially mechanically decoupled or a force, in particular bending and / or torsional moment transmission between the contact area and the power connection can be reduced and thus their (mechanical) load, in particular due to tensions and / or vibrations, can be reduced.

[0016] In one embodiment, the first, second and / or third joint, in particular for this purpose or to realize a pivot joint, has at least one local bend, in particular two or more, in one embodiment, in particular consecutive or pairwise, opposing bends, wherein in one embodiment the or one or more of the bend(s) each amount to at least 60°, in particular at least 75°, preferably at least 85°. In a further development, at least one local bend of the first joint and at least one local bend of the second joint lie or run in planes which enclose an angle different from zero with one another, which angle in one embodiment amounts to at least 30°, in particular at least 45°, preferably at least 60° and in one embodiment, at least substantially 90°. Additionally or alternatively,In a further development, at least one local bend of the first joint and at least one local bend of the third joint run in planes that enclose an angle different from zero with one another, which angle is at least 30°, in particular at least 45°, preferably at least 60°, and in one embodiment, at least substantially 90°. Additionally or alternatively, in a further development, at least one local bend of the second joint and at least one local bend of the third joint lie or run in planes that enclose an angle different from zero with one another, which angle is at least 30°, in particular at least 45°, preferably at least 60°, and in one embodiment, at least substantially 90°.

[0017] Additionally or alternatively, in one embodiment, the first, second, and / or third joint, in particular for implementing a pivot joint, has at least one local material thinning, in particular at least one local wall thickness reduction and / or at least one local wall height reduction. In a further development, at least one local material thinning of the first joint and at least one local material thinning of the second joint are located in sections of the contact rail that enclose an angle different from zero with one another, which in one embodiment is at least 30°, in particular at least 45°, preferably at least 60°, and in one embodiment, at least substantially 90°.Additionally or alternatively, in a further development, at least one local material thinning of the first joint and at least one local material thinning of the third joint are located in sections of the contact rail which enclose an angle with one another which is different from zero, which in one embodiment is at least 30°, in particular at least 45°, preferably at least 60°, and in one embodiment is at least substantially 90°. Additionally or alternatively, in a further development, at least one local material thinning of the second joint and at least one local material thinning of the third joint are located in sections of the contact rail which enclose an angle with one another which is different from zero, which in one embodiment is at least 30°, in particular at least 45°, preferably at least 60°, and in one embodiment is at least substantially 90°.

[0018] In one embodiment, the first, second and / or third joint is thus designed as a band joint, in particular as a film joint or film hinge (local material thinning(s)) and / or by one or more arches (local bend(s)).

[0019] This allows the contact rail to be designed in a particularly compact and / or reliable manner and / or to be mounted advantageously.

[0020] In one embodiment, the contact rail and thus in particular its joint arrangement is formed in one piece together with the contact area and the power connection which it connects.

[0021] Additionally or alternatively, the contact rail is designed in a strip-like manner in one embodiment. In one embodiment, a wall or strip thickness, in particular a maximum, minimum and / or average, amounts to a maximum of 75%, in particular a maximum of 50%, in one embodiment a maximum of 25%, of a wall or strip height or width, in particular a maximum, minimum and / or average, and / or a wall or strip height or width, in particular a maximum, minimum and / or average, amounts to a maximum of 50%, in particular a maximum of 25%, in one embodiment a maximum of 10%, of a wall or strip or contact rail (total) length, in particular a maximum, minimum and / or average.

[0022] Additionally or alternatively, the contact rail, in particular the band-like contact rail, in particular its joint arrangement, is or will be deformed, in particular plastically bent, in one embodiment.

[0023] Additionally or alternatively, the contact rail in one embodiment may comprise metal, in particular copper or a copper alloy such as CuSn, in particular consist thereof.

[0024] As a result, the contact rail, in particular its joint arrangement, can be realized in a particularly light, compact, reliable and / or simple design, in particular in combination.

[0025] In one embodiment, the contact area has at least one, in particular closed, hook, which engages around the (respective) wire section(s), clamps it in one embodiment, or is provided, in particular configured or used, for this purpose.

[0026] This can improve contacting and / or assembly in one design.

[0027] Additionally or alternatively, the power connection has a press-in contact which is pressed into a circuit board, in particular in a form-fitting and / or friction-fitting manner, or is provided, in particular configured or used, for this purpose.

[0028] The present invention can be used with particular advantage in such press-in contacts, since they are particularly sensitive to mechanical stress.

[0029] Likewise, the power connection can also be a soldered or plug-in shoe contact in one embodiment and / or be accessible from the outside (of the stator) and, in one embodiment, can be connected to a plug or the like or be provided for this purpose, in particular, be configured or used. The present invention can also be used with particular advantage with such external power connections, since these generally require larger assembly tolerances.

[0030] In one embodiment, a potting material at least partially encloses the coil winding(s) and / or the contact area(s) of the contact rail(s). This advantageously protects and / or electrically insulates them.

[0031] In one embodiment, the joint assembly is then located outside of this encapsulated material. This can improve its mobility.

[0032] According to one embodiment of the present invention, one or more wire sections of one or more coil windings of a (stator of an) electric motor are contacted using the contact area(s) of the contact rail(s) and, in one embodiment, their press-in contact(s) are pressed into a circuit board.

[0033] In one embodiment, an elastic deformation of the first, second and / or third joint is at most 1 mm, in particular at most 0.75 mm, or the joint is provided for this purpose, in particular configured or used for this purpose.

[0034] Further advantages and features emerge from the subclaims and the exemplary embodiments. The following shows, partly schematically: Fig. 1: an electric motor with a stator with coil windings and a contact rail according to an embodiment of the present invention in a meridian section; Fig. 2: a contact rail according to a further embodiment of the present invention in a perspective view; Fig. 3: the contact rail of the Fig. 2 in a front view; Fig. 4: the contact rail of the Fig. 2 in a side view; and Fig. 5: the contact rail of the Fig. 2 in a top view.

[0035] Fig. 1 shows an electric motor with a rotor 30 and a stator with coil windings 20 and three contact rails according to an embodiment of the present invention, wherein in the meridian section of the Fig. 1 only one contact rail 10 is shown.

[0036] The one-piece, band-like contact rail 10 has a contact area in the form of a closed hook 11, which contacts a wire section 21 of one of the coil windings 20.

[0037] In a modification not shown, the hook 11 can also contact several parallel wire sections. Additionally or alternatively, further contact areas, in particular (closed) hooks, can contact wire sections of one or more other coil windings.

[0038] The contact rail 10 further comprises an externally accessible power connection 12A for insertion into a plug or the like (not shown).

[0039] In another version, which is in the Fig. 2-5, the contact rail 10 instead has a power connection in the form of a press-in contact 12B, which is pressed into a corresponding recess in a circuit board (not shown). The two versions of the Fig. 1 or Fig. 2-5 are essentially identical in construction and are therefore described together.

[0040] Finally, the contact rail 10 has a joint arrangement 13 with a first integrally formed joint, a second integrally formed joint and a third integrally formed joint, which connect the contact area or hook 11 and the power connection 12A or 12B to one another.

[0041] The three joints are each designed as band or swivel joints, with the first joint having several opposing local bends of approximately 90° each, of which Fig. 2 two consecutive opposite bends are identified by reference numerals 14 and 15, and one in Fig. 2 has the joint axis A1 shown.

[0042] The second joint has the local bend 16 of about 90° and a Fig. 2 drawn joint axis A2, which is on the skew, in Fig. 2 is essentially perpendicular to the joint axis A1 of the first joint or forms an angle of approximately 90° with it.

[0043] The third joint has several opposing local bends of about 90°, of which Fig. 2 a bend is indicated by the reference numeral 17, and one in Fig. 2, which is substantially perpendicular to the aforementioned skewed joint axes A1 and A2 of the first and second joints or forms an angle of approximately 90° with them.

[0044] It can be seen that the local bends of the first joint, in particular the above-mentioned local bends 14, 15, the local bend 16 of the second joint and the local bends of the third joint, in particular the above-mentioned local bend 17, lie or run in three essentially mutually perpendicular planes, namely the local bends of the first joint in the normal plane to A1, the local bend 16 of the second joint in the normal plane to A2 and the local bends of the third joint in the normal plane to A3.

[0045] The other two contact rails are designed in an analogous manner and their contact areas contact wire sections of other coil windings so that a rotating field can be generated through them.

[0046] The coil windings and contact areas of the contact rails are encased in potting material 40, with the joint arrangements being arranged outside the potting material, as shown in Fig. 1 indicated.

[0047] Although exemplary embodiments have been explained in the preceding description, it should be noted that numerous modifications are possible. Furthermore, it should be noted that the exemplary embodiments are merely examples and are not intended to limit the scope of protection, applications, or structure in any way. Rather, the preceding description provides the skilled person with a guide for implementing at least one exemplary embodiment, whereby various modifications, particularly with regard to the function and arrangement of the described components, can be made without departing from the scope of protection as it results from the claims and equivalent combinations of features. List of reference symbols 10 contact rail 11 hooks (contact area) 12A from externally accessible power connection 12B press-in contact (power connection) 13 Joint arrangement 14-17 local bending 20 coil windings 21 Wire section 30 rotors 40 Casting material A1-A3 joint axis

Claims

[1] Contact rail (10) for the electrical supply of at least one coil winding (20) of an electric motor, wherein the contact rail has at least one contact area (11) for contacting at least one wire section (21) of the coil winding, at least one current connection (12A;12B) and a joint arrangement (13) with a first integrally formed joint (14, 15) which connects the contact region and the power connection to one another, wherein the joint arrangement has a second integrally formed joint (16) which connects the contact region and the power connection to one another, wherein a joint axis (A1) of the first joint and a joint axis (A2) of the second joint enclose an angle different from zero with one another, wherein the first and / or second joint has at least two, in particular opposing, bends (14, 15) and / or the joint arrangement has a third integrally formed joint (17) which connects the contact region and the power connection to one another.; [2] Contact rail according to claim 1, wherein a joint axis (A3) of the third joint and the joint axis of the first joint as well as the joint axis of the third joint and the joint axis of the second joint each enclose an angle different from zero. [3] Contact rail according to one of the preceding claims, characterized by that it is formed in one piece and / or in a band-like manner and / or formed and / or comprises metal. [4] Contact rail according to one of the preceding claims, characterized by that the third joint has at least one local bend (14-17), in particular at least two opposing bends (14, 15). [5] Contact rail according to one of the preceding claims, characterized by that the first, second and / or third joint has at least one local material thinning, in particular local wall thickness and / or wall height reduction. [6] Contact rail according to one of the preceding claims, characterized by that the contact area has at least one hook (11) for contacting the wire section. [7] Contact rail according to one of the preceding claims, characterized by that the power connector has a press-in contact (12B) for pressing into a circuit board. [8] Stator for an electric motor, which has a plurality of coil windings (20) and at least one contact rail (10) according to one of the preceding claims, whose at least one contact region (11) contacts at least one wire section (21) of at least one of the coil windings. [9] Stator according to the preceding claim, characterized by that the power connection (12A; 12B) of the at least one contact rail is connected to a circuit board or is accessible from the outside. [10] Stator according to one of the two preceding claims, characterized bythat the joint arrangement (13) is arranged outside a casting material (40) which at least partially encloses the coil windings and / or the contact region of the at least one contact rail. [11] Electric motor with a stator having at least one contact rail according to one of the preceding claims. [12] Method for connecting at least one coil winding (20) of a stator using a contact rail (10) according to one of the preceding claims, characterized by that at least one wire section (21) of the coil winding is contacted by means of the contact area (11) of the contact rail.

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