Electronically commutated motors

Abstract

For an electronically commutated electric machine having a rotor with an associated rotor shaft (182) and a stator (150) having a plurality (215) of stator segments (216, 217, 218) arranged in a ring shape, wherein each stator segment (216 - 218) is provided with an associated single winding (299) having two wire ends (231 - 254) accordingly, and wherein the wire ends (231 - 254) of the associated single winding (299) are interconnected via an interconnecting device (280) at an axial end (201) of the stator (150) to form an electric machine winding, the interconnecting device (280) for interconnecting the wire ends (231 - 254) to form the electric machine winding (157) has at least two ring-segment-shaped interconnecting elements (281 - 286), the interconnecting elements being arranged between an inner diameter (D I ) and an outer diameter (D A ) of the stator (150) and having contact elements (292) configured as radial extensions (287) for electrical contact of the wire ends (231 - 254), wherein the contact elements (292) are configured to receive the respective wire ends (231 - 254) in a radial direction (204) of the stator (150).

Description

Technical Field

[0001] The invention relates to an electronically commutated motor having a rotor with an associated rotor shaft and a stator with a plurality of stator segments arranged in an annular shape, wherein each stator segment is provided with an associated single winding, each with two conductor ends, and wherein the conductor ends of the associated single windings are interconnected at axial ends of the stator via an interconnection device to form a motor winding. Background Art

[0002] Such an electronically commutated electric machine with a rotor and a stator is known from the prior art. In this case, the stator is designed as a segmented stator and has a plurality of stator segments arranged in an annular shape. To form an annular stator, the stator segments are connected to one another in a holding device or directly in a stator housing via a tongue-and-groove connection in the circumferential direction of the stator. Each stator segment is provided with an associated single winding, wherein all the single windings are interconnected via an interconnection device to form a motor winding. Summary of the invention

[0003] The invention provides an electronically commutated motor with a rotor having an associated rotor shaft and a stator having a plurality of stator segments arranged in an annular shape. Each stator segment is provided with an associated single winding, each having two wire ends. The wire ends of the associated single windings are interconnected at the axial ends of the stator via an interconnection device to form a motor winding. The interconnection device has at least two interconnection elements in the form of ring segments for interconnecting the wire ends to form a motor winding, which are arranged between the inner diameter and the outer diameter of the stator and have contact elements configured as axial extensions for electrical contacting of the wire ends. The contact elements are configured to accommodate the respective wire ends in the radial direction of the stator.

[0004] The invention thus makes it possible to provide an electronically commutated motor for which a simple and uncomplicated contacting of the individual conductor ends with the motor winding is possible by means of an interconnection element arranged between the inner diameter and the outer diameter of the stator and having a contact element designed as an axial extension. Thus, a rapid assembly of the electronically commutated motor according to the invention is possible.

[0005] At least two interconnecting elements preferably at least partially have a first diameter and / or a second diameter, wherein the second diameter is smaller than the first diameter. A space-saving arrangement of the interconnecting elements and thus a relatively small axial space requirement can thus be enabled.

[0006] Preferably, at least two interconnecting elements are arranged such that the contact elements are arranged equidistantly relative to the rotor axis on a common diameter. This makes it possible to simply and uncomplicatedly fasten the individual contact elements, preferably by laser welding.

[0007] At least one first interconnection element preferably has a first diameter and at least one second interconnection element has a second diameter, wherein the second diameter is smaller than the first diameter, and wherein the common diameter is smaller than the first diameter and larger than the second diameter. Thus, the common diameter for contacting the individual conductor ends can be matched in a simple manner.

[0008] According to one embodiment, the contact elements of the at least one first interconnection element are arranged on the inner periphery of the at least one first interconnection element, and the contact elements of the at least one second interconnection element are arranged on the outer periphery of the at least one second interconnection element. An arrangement of the contact elements between the inner diameter and the outer diameter of the stator is thus made possible in a simple and uncomplicated manner, wherein a relatively close arrangement of the interconnection elements is made possible.

[0009] Preferably, the contact element is designed as a welding fork, which has two legs for receiving the conductor end in the radial direction of the stator, which together form a receiving portion, wherein the corresponding conductor end can be arranged in the receiving portion. Thus, stable and reliable contact of the conductor end is possible.

[0010] The contact element is preferably arranged perpendicularly to the corresponding interconnection element on the corresponding interconnection element, thereby making simple and uncomplicated contacting possible.

[0011] The interconnection device is preferably assigned a retaining element which is designed to fasten the interconnection device to an axial end of the stator. A reliable and robust arrangement of the interconnection device on the stator is thus made possible.

[0012] According to one embodiment, at least two interconnection elements are arranged on the bottom side facing the motor and / or on the opposite top side of the holding element. Thus, a space-saving arrangement can be provided.

[0013] Preferably, at least one interconnection element is arranged on the bottom surface and at least one interconnection element is arranged on the top surface of the retaining element, wherein the at least one interconnection element arranged on the bottom surface has a connecting pin for connecting to the at least one interconnection element arranged on the top surface, and wherein the at least one interconnection element arranged on the top surface has a receptacle for receiving the connecting pin. Thus, it is possible in a simple manner to connect at least two interconnection elements to an individually adaptable motor topology and / or interconnection type.

[0014] At least two interconnecting elements preferably each have a coupling element that is connected to an external counter coupling element, wherein the coupling element has a pin that can be arranged in a connection receptacle assigned to the interconnecting element for connection to the respective interconnecting element. This makes it possible to connect the interconnection device to the external coupling element in a simple and uncomplicated manner.

[0015] According to one embodiment, the pin is associated with the additional element, wherein the additional element is preferably connected to the plug contact of the connection element via a copper strand. This makes it possible to connect the pin to the connection element in an alternative manner, wherein the additional element with the copper strand can be designed as a preassembled component and thus makes simple and rapid assembly possible.

[0016] Preferably, the connection elements assigned to at least two interconnecting elements are arranged in a common plug body which is constructed integrally with the retaining element. This makes it possible to provide compact connection elements, thereby making it possible to freely displace the plug contacts axially in the plug body and thus to achieve user-specific matching.

[0017] Preferably, the connecting pin is fastened in the receptacle and / or the pin is fastened in the connecting receptacle by laser welding. Thus, a safe and reliable connection can be constructed.

[0018] At least two interconnection elements preferably have copper guides for interconnecting the wire ends. Suitable interconnection elements can thus be provided in a simple manner in order to enable a desired motor topology and / or interconnection.

[0019] Preferably, at least two interconnection elements have at least one plane on which the copper guide is arranged. Thus, any desired motor topologies and / or interconnections can be made possible in a relatively small installation space.

[0020] According to one embodiment, at least two interconnection elements are each designed as stamped parts. This makes it possible to produce the interconnection elements in a simple and cost-effective manner, wherein relatively few bending processes are necessary and thus reduced material consumption can be achieved.

[0021] Preferably, the conductor ends of the individual windings are fixed to the contact elements of the corresponding interconnection elements via a laser welded connection. This makes an advantageous and reliable connection possible, in which additional or subsequent tinning and / or silvering can be dispensed with. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] The present invention is further explained in the following description with reference to the embodiments shown in the accompanying drawings.

[0023] Figure 1 shows a schematic view of an electronically commutated motor with rotor and stator,

[0024] Figure 2 Shows the interconnection device Figure 1 A perspective view of the stator,

[0025] Figure 3 Shows the direction Figure 2 A top view of the interconnection device,

[0026] Figure 4 Shows passing through Figure 2 and Figure 3 A longitudinal section of an interconnection device,

[0027] Figure 5 Shows passing through Figure 4 A schematic view of a longitudinal section of an interconnection device,

[0028] Figure 6 Shown is a cutout (Ausschnitt) with Figures 1 to 5 A perspective view of the stator of the interconnection device,

[0029] Figure 7 Shows Figure 6 An enlarged view of a cut portion of

[0030] Figure 8 shows a perspective view of two interconnection elements assigned to an interconnection device before assembly,

[0031] Fig. 9 Shown after assembly Figure 8 A perspective view of two interconnected elements,

[0032] Fig.10 A schematic diagram of an alternative interconnection device with a retaining element and an interconnection element according to another embodiment is shown with a cut-away portion. Figure 1 , Figure 2 and Figure 6 A perspective view of the stator,

[0033] Fig.11 Shows the Fig.10 A perspective view of the holding elements of the interconnecting elements,

[0034] Fig.12 Shows Fig.10 An enlarged view of a cut portion of

[0035] Fig.13 A perspective view showing a connecting unit connecting an interconnecting element with a coupling element, and

[0036] Fig.14 Shows the direction Fig.13 A perspective top view of a connecting unit. DETAILED DESCRIPTION

[0037] Figure 1 An electric motor 100 is shown which is designed as an inner rotor motor with an inner rotor 180 having a rotor shaft 182 and with a segmented outer stator 150. The outer stator 150 schematically has a segmented stator core 153 which is at least partially provided with a plastic sheath 155 which is preferably designed as a plurality of insulators and on which a stator winding 157 is arranged. The segmented outer stator 150 is referred to below only as "stator 150" for the sake of simplicity. Preferably, the invention takes into account stators with an outer diameter of less than 70 mm, but can also be used with any other outer diameter.

[0038] It should be noted that the motor 100 is Figure 1 100 is shown only schematically, since the structure and functionality of suitable electric motors are sufficiently known from the prior art, so that a detailed description of the electric motor 100 is omitted here for the sake of brevity and simplification of the description. It should also be pointed out that the electric motor 100 is shown as an inner rotor motor only by way of example and not to limit the invention. It should also be pointed out that the image of the outer stator is also of exemplary character and that the invention can also be used, for example, in the case of an annular inner stator.

[0039] Figure 2 Shows Figure 1 The stator 150 is constructed as a segmented external stator. The stator 150 has a first axial end 201 and an opposite second axial end 202, which define an axial direction 203 of the stator 150. In addition, the stator 150 has a radial direction 204 oriented perpendicular to the axial direction 203. According to one embodiment, the stator 150 is constructed from a plurality 215 of at least substantially identical stator segments 216-218 (illustrated twelve stator segments 216-218), which are preferably arranged in an annular manner, wherein only three stator segments 216-218 are numbered. The stator segments 216-218 are preferably constructed in such a way that they can be spliced ​​in an annular manner, wherein the stator segments 216-218 adjacent in the circumferential direction of the stator 150 are preferably connected to each other in a form-fitting manner or fixed to each other via suitable tongue-and-groove connections. However, it should be pointed out that the illustration of twelve stator segments 216 - 218 has only an exemplary character and is not to be understood as a limitation of the present invention, which can be used in the case of any number of stator segments.

[0040] The stator segments 216-218 preferably have an associated stator segment core 298, which is respectively provided with an insulator 210. Arranged on the respectively associated insulator 210 are individual windings 299 assigned to the stator segments 216-218. A plurality of individual windings 299 are preferably designed to be interconnected to form a motor winding 157. These individual windings 299 are preferably connected relative to the respective stator segment core 298 by Figure 1 The plastic sheathing 155 is electrically insulated or by a correspondingly associated insulating body 210, which preferably comprises plastic. However, the insulating body 210 can also comprise any other suitable electrically insulating material.

[0041] According to one embodiment, all the individual windings 299 are interconnected at the axial end 210 of the stator 150 via an interconnection device 280 to form the motor winding 157. Preferably, the interconnection device 280 has at least two interconnection elements 281-286 in the form of ring segments. As shown in the diagram, preferably six interconnection elements 281-286 are provided, which interconnect the wire ends 231-254 assigned to the individual windings 299 to form the motor winding 157. In this case, the individual windings 299 are preferably at least approximately all of the same length or are at least approximately identically constructed within a predetermined manufacturing tolerance. In addition, the individual windings 299 can be separated from each other by plastic walls.

[0042] At least two and in the illustrated embodiment six interconnecting elements 281 - 286 in the form of ring segments are arranged according to the invention on the inner diameter D of the stator 150 . I With outer diameter D A Preferably, the interconnecting elements 281-286 are arranged between the inner region of the stator teeth and the outer region of the stator teeth. For the electrical contact of the conductor ends 231-254, the interconnecting elements 281-286 preferably have at least one contact element 292 designed as an axial extension 287. For the sake of clarity and simplification of the drawings, only one contact element 292 is numbered. Preferably, the contact element 292 is designed to accommodate the corresponding conductor end 231-254 in the radial direction 204 of the stator 150.

[0043] The contact element 292 is preferably designed as a welding fork, which is arranged in the radial direction 204 of the stator 150 for accommodating the wire ends 231-254. In this case, the contact element 292 designed as a welding fork preferably has two legs 222, 223, which together form a receiving portion 224, wherein the corresponding wire end 231-254 can be arranged in the receiving portion 224. By way of example, an undercut is assigned to the groove 224, wherein the wire ends 251-256 can be arranged in the undercut accordingly. Preferably, the contact element 292 is arranged perpendicularly to the corresponding interconnection element 281-283 on the corresponding interconnection element 281-283. In order to make contact, the wire ends 231-254 are preferably stripped of insulation in the region of the contact element 292. In this case, the welding fork can also be designed in the manner of a cross-clamping element, which, when arranged in the receptacle 224 , strips the insulation of the respective conductor end 231 - 254 .

[0044] The interconnecting elements 281-283 are preferably configured as stamped parts. Preferably, the interconnecting elements 281-283 are configured as sheet metal stampings. Here, the interconnecting elements 281-283 are preferably made of copper with an optional coating. Preferably, the interconnecting elements 281-283 are made of a copper alloy, in particular of CuSn0.15. Optionally, the surface of the interconnecting elements 281-283 can be tinned here. In addition, the wire ends 231-254 of the single winding 299 are preferably fixed on the corresponding contact elements 292 via non-contact contact, preferably via laser welding connection. Preferably, laser welding is performed in the axial direction 203 of the stator 150, wherein the laser beam is preferably emitted from the first axial end 201 to the corresponding contact element 292. Here, laser welding provides an advantageous connection because additional / subsequent tinning and / or silvering can be eliminated because laser welding does not require coated interconnecting elements. In addition, laser welding requires less processing time than resistance welding.

[0045] Furthermore, the interconnection device 280 is preferably assigned a retaining element 270, which is fastened to the first axial end 201 of the stator 150. The retaining element 270 is preferably designed to fix the interconnection device 280 to the axial end 201 of the stator 150. Preferably, the retaining element 270 has a base body 271, which is preferably arranged on the first end 201 of the stator 150. Preferably, the retaining element 270 is designed as an injection molded part, in particular as an injection molded plate.

[0046] According to one embodiment, the interconnecting elements 281-286 are arranged on the bottom surface 276 facing the motor 100 and / or the top surface 275 of the holding element 270. For example, the interconnecting elements ( Figure 4 412, 413) can have a connecting section 261 for connecting to the interconnecting elements 281-286 arranged on the top surface 275. Here, the connecting section 261 extends from the bottom surface 276 in the direction of the axial end 201 into the groove 263 configured as a through-piece that passes through the retaining element 270. Preferably, the interconnecting element 285 arranged on the top surface 275 also has a connecting section 262. As illustrated, the two connecting sections 261, 262 are configured in the axial direction 203. Here, the two connecting sections 261, 262 are preferably arranged side by side with each other, particularly preferably parallel to each other. Preferably, the two connecting sections 261, 262 are connected to each other via a welding connection 260, in particular by laser welding.

[0047] On the bottom surface 276 and / or the top surface 275, a plurality of interconnection elements 281-286 can also be arranged one above the other in the axial direction 203 of the stator 150. In addition, the interconnection elements 281-286 preferably have copper guides for interconnecting the wire ends 231-254. In this case, the interconnection elements 281-286 preferably have at least one plane on which the copper guides are arranged. Thus, the desired motor topology and / or interconnection form can be made possible simply and easily.

[0048] Furthermore, the interconnecting elements 281-286 preferably have coupling elements 265, 266, 267, respectively, which can be connected to an external counterpart coupling element. The coupling elements 265, 266, 267 are preferably arranged vertically or in the axial direction 203 of the stator 150. It should be pointed out that the illustrated vertical arrangement of the coupling elements 265-267 has only exemplary features and is not to be regarded as a limitation of the invention. Therefore, the coupling elements 265-267 can also be arranged in any other direction, for example in the radial direction 204 of the stator 150.

[0049] The holding element 270 preferably has a receiving element 272, 273, 274 in which the connecting elements 265, 266, 267 are accommodated in order to accommodate the connecting elements 265-267. For this purpose, the receiving elements 272-274 preferably have a receiving portion 212 accordingly. Here, the receiving elements 272-274 are preferably constructed in one piece with the holding element 270, but can also be arranged there via a releasable connection. The three connecting elements 265, 266, 267 are shown in a diagrammatic illustration, which are respectively constructed as a motor phase of the motor circuit. Here, the individual interconnection elements 281-286 are interconnected with each other according to the desired interconnection.

[0050] The interconnecting elements 281-286 are preferably fixed in position on the retaining element 270 via a fixing element 294. The fixing element 294 is preferably configured as a rivet, in particular a hot rivet. Here, the fixing element 294 is preferably fastened to the base body 271 by hot pressing. For fastening to the fixing element 294, the interconnecting elements 281-286 preferably have an eyelet 295. Preferably, the eyelet 295 is arranged in the middle along the longitudinal extension of the interconnecting elements 281-286. For the clarity of the drawings, the eyelet 295 is arranged in the middle. Figure 2 Accordingly, only the eyelets 295 and the fixing elements 294 are numbered.

[0051] Figure 3 Shows the Figure 2 The stator 150 of the interconnection device 280. Here, Figure 3 An exemplary arrangement of interconnecting elements 281-286 is shown, in which these are arranged such that the contact elements 292 are arranged at least substantially equidistantly relative to the rotor shaft 182 on a common diameter D2. Preferably, at least one, illustrated three, first interconnecting elements 281, 282, 283 have a first diameter D3 and preferably at least one, illustrated three, second interconnecting elements 284, 285, 286 have a second diameter D1. Preferably, the second diameter D1 is smaller than the first diameter D3 and the common diameter D2 is preferably smaller than the first diameter D3 and larger than the second diameter D1. Preferably, the contact elements 331, 334, 335, 338, 339, 342 of the first interconnection elements 281-283 are arranged on the inner periphery 351 of the respective first interconnection elements 281-283 and the contact elements 332, 333, 336, 337, 340, 341 of the second interconnection elements 284-286 are arranged on the outer periphery 352 of the respective second interconnection elements 284-286.

[0052] Schematically and by way of example, each interconnection element 281-286 preferably has two contact elements 331-342. Here, the interconnection element 281 schematically has contact elements 331, 334 for accommodating the conductor ends 231, 238 on its inner periphery 351. The interconnection element 282 schematically has contact elements 335, 338 for accommodating the conductor ends 239, 246 on its inner periphery 351. In addition, the interconnection element 283 schematically has contact elements 339, 342 for accommodating the conductor ends 247, 254 on its inner periphery 351. Preferably, the interconnection element 284 schematically has contact elements 332, 333 for accommodating the conductor ends 234, 237 on its outer periphery 352. The interconnection element 285 schematically has contact elements 336, 337 for accommodating the conductor ends 242, 245 on its outer periphery 352. Furthermore, the interconnection element 286 has, as illustrated, contact elements 340 , 341 on its outer circumference 352 for receiving the wire ends 250 , 253 .

[0053] In addition, the interconnection device 280 is assigned an interconnection element ( Figure 4 411-413), the interconnection element is arranged on the bottom surface 276 of the holding element 270. Here, to the interconnection element ( Figure 4 411) is assigned, for example, contact elements 312, 315, 317, 322, which are configured to receive wire ends 283, 240, 243, 252. Figure 4 412) are assigned contact elements 311, 313, 318, 320, which are configured to accommodate wire ends 232, 235, 244, 249. Preferably, the interconnection element ( Figure 4 413 ) are assigned contact elements 314 , 316 , 319 , 321 , which are designed to receive conductor ends 236 , 241 , 248 , 251 .

[0054] Figure 4 Shows the Figure 2 The holding element 270 of its base body 271 is shown and the arrangement of the interconnection elements 281, 284 on the upper side 275 of the base body 271 and the arrangement of the interconnection elements 411, 412, 413 on the lower side 276 of the base body 271 are shown. As should be pointed out below, the interconnection elements can also be arranged only on the upper side 275 or the lower side 276. Preferably, the base body 271 for grasping the contact elements 311, 312, 313, 314 has a groove.

[0055] Figure 5 Shows a Figure 22 . An alternative retaining element 270 of a base body 271 of the present invention is provided, which diagrammatically has a first interconnecting element 513 with a first diameter D3 and a second interconnecting element 511 with a second diameter D1 on its top surface 275. In addition, the base body 271 has recesses 519, 520 on its bottom surface 276 for accommodating the interconnecting elements 512, 514. Preferably, the interconnecting element 512 arranged in the receptacle 519 has the second diameter D1, and the interconnecting element 514 arranged in the receptacle 520 has the first diameter D3. As will be noted below, the interconnecting elements 512, 514 can also have any other diameters.

[0056] Figure 6 The diagram with the cutout portion 610 is shown. Figure 2 and Figure 3 Here, the cutout 610 shows an exemplary connection 620 of the interconnection element 286 to the coupling element 265 and a connection 625 of the interconnection element 286 to the interconnection element 412 arranged on the bottom surface 275. Here, the connections 620, 625 represent by way of example the connection of the interconnection element to the corresponding coupling element 265-267 and the connection between the interconnection elements on the top surface and the bottom surface of the retaining element 270.

[0057] Figure 7 Shows Figure 6 610 and shows an exemplary connection 620 between the interconnecting element 286 and the coupling element 265. In addition, Figure 6 Exemplary connections 625 between interconnect elements 286, 412 on the top and bottom surfaces are shown.

[0058] At least one interconnection element 412 arranged on the bottom surface 276 preferably has a connection pin 721 for connecting to at least one interconnection element 286 arranged on the top surface 275. For this purpose, at least one interconnection element 286 arranged on the top surface 275 preferably has a receptacle 716 for accommodating the connection pin 721. In this case, the connection pin 721 is preferably fastened in the receptacle 716 by laser welding. Preferably, the connection pin 721 and the receptacle 716 are configured as a connection 625. As will be noted below, the connection 625 can also connect a plurality of interconnection elements to one another according to the desired motor topology and / or interconnection method.

[0059] Furthermore, the interconnecting element 286 preferably has a connecting element 265 for connecting to an external counter-connecting element, as described above. According to the illustrated embodiment, the connecting element 265 has a pin 712, which can be arranged in a connecting receptacle 715 assigned to the interconnecting element 286 for forming a connection 620 or connecting to the corresponding interconnecting element 286. The pin 712 is preferably fastened in the connecting receptacle 715 by laser welding. The pin 712 is preferably connected to the connecting element 265 via a connecting section 711 or is arranged integrally on the connecting element.

[0060] Preferably, the pin 712 and / or the connecting pin 721 are connected in one piece with the connecting element 265 or the interconnecting element 286 and are molded in particular by stamping. It should be noted that the connecting element 265 can also be designed in one piece with the interconnecting element 286. It should also be noted that the interconnection device 280 can have a connection 620 and / or 625.

[0061] Figure 8 The interconnection element 412 with the pin 712 and the interconnection element 412 with the pin 712 are shown. Figure 7 The interconnecting element 286 of the connection receiving portion 715 of the connection 625. As will be noted below, the interconnecting element 412 and the pin 712 for constructing the connection 625 are also for the Figure 7 4 and 5. The design of the connection 620 between the interconnecting element 412 and the coupling element 265 is representative. Here, the pin 721 and the connection receptacle 715 are illustrated as having an exemplary rectangular shape, wherein the two connection partners have the same cross section. However, the pin 721 and the connection receptacle 715 can also have any other shape, for example an oval shape. In addition, the pin 712 can have embossing, edge rounding and / or introduction chamfering.

[0062] Fig. 9 The interconnection element 412 with the pin 712 and the interconnection element 412 with the pin 712 are shown after the pin 712 is arranged in the connection receiving portion 715. Figure 7 and Figure 8 The pin 712 and the connection receptacle 715 are designed in such a way that the pin 712 can be arranged in the connection receptacle 715 without loss of force or with play. Preferably, the pin 712 protrudes in the direction of the first end 201 before the laser welding process when arranged in the connection receptacle 715. Preferably, the pin 712 protrudes from the connection receptacle 715 by 0 to 1.0 mm. After the laser welding process, a melting zone for mechanical and electrical connection is formed on the end of the exemplary interconnecting element 286 facing the first end 201.

[0063] Fig.10 The interconnection device 910 is shown Figure 2 , Figure 3 and Figure 6 According to another embodiment, at least two, illustrated three, interconnection elements 957, 962, 963 are assigned to the stator 150. Here, the interconnection elements 957, 962, 963 preferably partially have a first diameter D3 and partially have a second diameter D1. Preferably, the interconnection elements 957, 962, 963 are arranged at an inner diameter D3 of the stator 150 or of the retaining element 270. I With outer diameter D A2 Here, the outer diameter D A2 It is defined by a sunken receiving area 997 with a reduced height. Here, the interconnecting elements 957, 962, 963 each have a section 958 with a first diameter D3 and a section 959 with a second diameter D1. A transition section 960 is formed between the sections 958 and 959, which connects the two sections 958, 959 to each other.

[0064] Preferably, the sections 958, 959 each have two contact elements 945-956. However, it should be noted that the sections 958, 959 can also have more or less than two contact elements. The number of contact elements per section and / or per interconnection element can also vary. In addition, the interconnection elements 957, 962, 963 can be arranged in a receptacle formed in the holding element 270 for secure arrangement.

[0065] By way of illustration and example, interconnection element 957 has contact elements 945, 947 on its section 958 for receiving wire ends 931, 933 and contact elements 950, 952 are arranged on its section 959 for receiving wire ends 936, 938. In addition, interconnection element 962 has contact elements 949, 951 on its section 958 for receiving wire ends 935, 937 and contact elements 954, 956 are arranged on its section 959 for receiving wire ends 940, 942. In addition, interconnection element 963 has contact elements 953, 955 on its section 958 for receiving wire ends 939, 941 and contact elements 946, 948 are arranged on its section 959 for receiving wire ends 932, 934. In this case, the contact elements 945 - 956 are designed in the axial direction 203 of the stator 150 as axial expansions for radially accommodating the conductor ends 931 - 942 at the respective interconnection elements 957 , 962 , 963 .

[0066] Preferably, interconnecting elements 957, 962, 963 are each assigned preferably radial expansion elements 965, 966, 967, which each have a receptacle 970 for arranging pins 969. Explanatory elements 965, 966, 967 are illustrated as being radially outwardly configured, but may also be radially inwardly configured.

[0067] In addition, the base body 271 of the retaining element 270 preferably has a plug-in body 920 for arranging the connecting elements assigned to the corresponding interconnecting elements 957, 962, 963. Preferably, the plug-in body 920 has a cylindrical base body 921, which preferably has three receiving areas 922, 923, 924 for arranging the counterpart connecting parts of the corresponding connecting elements. However, it should be pointed out that the plug-in body 920 can also have less than three receiving areas or more than three receiving areas. Preferably, the plug-in body 920 is connected to the retaining element 270 or the base body 271 in one piece. Here, the plug-in body 920 is preferably arranged in the receiving area 997.

[0068] also, Fig.10 Shows further Fig.12 The cutout portion 990 is described in FIG.

[0069] Fig.11 Shows the Fig.10 The inner diameter D is preferably 240 mm. I In connection with the peripheral web 999, a section 959 with a second diameter D1 preferably rests on the peripheral web. Fig.11 The preferably L-shaped expansion elements 965 , 966 , 967 are shown. Preferably, the expansion element 965 arranged at the illustrated radially inner section 959 preferably projects beyond the corresponding illustrated radially outer section 958 of the interconnection element 962 .

[0070] Fig.12 Shows Fig.10 990, which shows the arrangement of the wire ends 936-939 in the contact elements 950-953. Fig.12 The contact elements 950 - 953 are shown preferably configured in the axial direction 203 at the top side of the respective interconnection element 957 , 962 , 963 facing the first axial end 201 .

[0071] according to Figures 10 to 12In the embodiment shown in FIG. 1 , the contact elements 950-953 are arranged directly on the corresponding interconnection elements 957, 962, 963 and have the same diameter as the corresponding sections 958, 959. In addition, the contact elements 950-953 can also be arranged offset relative to the corresponding interconnection elements in the radial direction 204, such as, for example, in Figures 2 to 4 In the embodiment of the present invention, the corresponding sections 958, 959 have a common diameter. In addition, the contact elements 950-953 of the sections 958, 959 can also have a common diameter, as in Figures 2 to 4 As in the implementation method of .

[0072] Fig.13 An exemplary connection unit 1030 is shown for connecting the respective interconnection elements 957, 962, 963 with the coupling element 265 or 1025. Illustratively, the connection unit 1030 at the interconnection element 957 is shown representatively for the interconnection elements 957, 962, 963.

[0073] Preferably, an additional element 1011 is provided, to which a pin 712 or 969 is assigned. As described above, the pin 969 can be arranged in the receptacle 970 of the expansion element 965. Here, the pin 969 and the receptacle 970 are preferably connected to each other by laser welding. Preferably, the additional element 1011 is arranged at the bottom surface 276 of the holding element 270 and extends through the groove. In addition, the additional element 1011 preferably has a fastening geometry 1022, which is designed to fasten the additional element 1011 in the groove of the holding element 270.

[0074] The additional element 1011 preferably has a connection surface 1021, which is used to connect to an electrical connection element, for example a copper strand 1012. Preferably, the copper strand 1012 is welded to the connection surface 1021 of the additional element 1011 with its first connection section 1013, preferably by resistance welding. The copper strand 1012 preferably connects the additional element 1011 to the connecting element 1025. The connecting element 1025 also preferably has a connection surface 1021 for welding the copper strand 1012, similar to the additional element 1011, wherein the copper strand 1012 is welded to the connection surface 1021 of the connecting element 1025 with its second connection section 1014.

[0075] Preferably, the connecting element 1025 has a preferably rectangular base body 1020, which is designed to be arranged in the receiving areas 922, 923, 924 of the plug body 920. The pin 969 or the additional element 1011 is thus connected to the plug contact 1020 of the connecting element 1025 via the copper strand 1012. Preferably, the three connecting elements 1025 are arranged in a common plug body 920, which is formed integrally with the retaining element 270.

[0076] Fig.14 Shows Fig.12 The connecting unit 1030 of FIG. 1 is shown, and the connecting surface 1021 of the additional element 1011 and the connecting element 1020 is shown, which has connecting sections 1013, 1014 of the exemplary copper litz wire 1012. In addition, Fig.14 An exemplary fastening geometry 1022 of the additional element 1011 is shown.

[0077] As will be noted below, the copper strands 1012 are preferably connected to the additional element 1011 and the connecting element 1020 by resistance welding. Thus, the connection between the additional element 1011 and the connecting element 1020 can be assembled as a preassembled component by means of the copper strands 1011. This ensures simple assembly, since the accessibility of the welding points is simple and uncomplicated.

[0078] At the same time or afterwards, the interconnection device 280 or 910 can be assembled. Subsequently, the pre-assembled part is connected to the interconnection device 910 or to the individual interconnection elements 957, 962, 963 and fastened by laser welding. Here, preferably, the wire ends 931-942 are connected to the contact elements 950-953 and the additional element 1011 is connected to the contact elements 950-953 preferably by laser welding. Preferably, the laser welding of the wire ends 931-942 at the contact elements 950-953 and the additional element 1011 at the contact elements 950-953 is carried out in a common laser welding process. Thus, a neutral cycle time can be made possible.

[0079] In the case of laser welding, the individual contact partners are heated by melting in such a way that the joint gap between two contact partners is filled. Preferably, the contact elements 950-953 and the additional element 1011 are arranged in such a way that the contact is made perpendicular to the rotor shaft 182 by laser welding. Optionally, a shielding (Versiegelung) of the electronically commutated electric machine 100 can be realized. In this case, preferably the entire stator 150 can be shielded or "recast (ummolden)", for example, in order to protect the electric machine 100 in wet rotor applications and / or in thermally and / or mechanically loaded applications.

Claims

1. An electronically commutated electric machine (100) having a rotor (180) with an associated rotor shaft (182) and a stator (150) with a plurality of stator segments (216, 217, 218) arranged in an annular manner, wherein: Each stator segment (216-218) is provided with an associated single winding (299) respectively having two wire ends (231-254), and wherein the wire ends (231-254) of the associated single winding (299) are interconnected at an axial end (201) of the stator (150) via an interconnection device (280) to form a motor winding (157), characterized in that the interconnection device (280) for interconnecting the wire ends (231-254) to form the motor winding (157) has at least two interconnection elements (281-286) in the form of ring segments, which are arranged at an inner diameter (D I ) and outer diameter (D A , D A2 ) and has a contact element (292) configured as an axial expansion portion (287) for electrical contact of the wire ends (231-254; 931-942), wherein the contact element (292) is configured to accommodate the corresponding wire ends (231-254; 931-942) in the radial direction (204) of the stator (150).

2. The electronically commutated motor according to claim 1, characterized in that: The at least two interconnected elements (957, 962, 963) at least partially have a first diameter (D3) and / or a second diameter (D1), wherein the second diameter (D1) is smaller than the first diameter (D3).

3. The electronically commutated motor according to claim 2, characterized in that: The at least two interconnecting elements (281-286) are arranged such that the contact elements (292) are arranged equidistantly relative to the rotor shaft (182) on a common diameter (D2).

4. The electronically commutated motor according to claim 3, characterized in that: At least one first interconnecting element (281-283) has a first diameter (D3) and at least one second interconnecting element (284-286) has a second diameter (D1), wherein the second diameter (D1) is smaller than the first diameter (D3), and wherein the common diameter (D2) is smaller than the first diameter (D3) and larger than the second diameter (D1).

5. The electronically commutated motor according to claim 4, characterized in that: The contact elements (331, 334, 335, 338, 339, 342) of the at least one first interconnecting element (281-283) are arranged on the inner periphery (351) of the at least one first interconnecting element (281-283), and the contact elements (332, 333, 336, 337, 340, 341) of the at least one second interconnecting element (284-286) are arranged on the outer periphery (352) of the at least one second interconnecting element (284-286).

6. The electronically commutated motor according to any one of claims 1 to 5, characterized in that: The contact element (292) is configured as a welding fork, which has two legs (222, 223) respectively for accommodating a wire end (231-254) in a radial direction (203) of the stator (150), which are jointly configured as a receiving portion (224), wherein the corresponding wire end (231-254) can be arranged in the receiving portion (224).

7. The electronically commutated motor according to claim 6, characterized in that: The contact element (292) is arranged on the corresponding interconnection element (281-283) perpendicularly to the corresponding interconnection element (281-283).

8. The electronically commutated motor according to claim 1, characterized in that: A retaining element (270) is assigned to the interconnection device (280) and is designed to fasten the interconnection device (280) to an axial end (201) of the stator (150).

9. The electronically commutated motor according to claim 8, characterized in that: The at least two interconnecting elements (281-286; 411-413; 511-514) are arranged on a bottom surface (276) facing the motor (100) and / or on an opposite top surface (275) of the retaining element (270).

10. The electronically commutated motor according to claim 9, characterized in that: At least one interconnecting element (412) is arranged on the bottom surface (276) and at least one interconnecting element (286) is arranged on the top surface (275) of the retaining element (270), wherein the at least one interconnecting element (412) arranged on the bottom surface (276) has a connecting pin (721) for connecting to the at least one interconnecting element (286) arranged on the top surface (275), and wherein the at least one interconnecting element (286) arranged on the top surface (275) has a receiving portion (716) for receiving the connecting pin (721).

11. The electronically commutated motor according to any one of claims 8 to 10, characterized in that: The at least two interconnecting elements (281-286) respectively have connecting elements (265, 266, 267), which are connected to an external matching connecting element, wherein the connecting elements (265-267) have a pin (712) which can be arranged in a connecting receptacle (715) assigned to the interconnecting element (286) for connection with the corresponding interconnecting element (286).

12. The electronically commutated motor according to claim 11, characterized in that: The pin (712; 969) is associated with an additional element (1011), wherein the additional element (1011) is connected to a plug contact (1020) of the connection element (265, 1025) via a copper litz wire (1012).

13. The electronically commutated motor according to claim 12, characterized in that: The connecting elements (1025) assigned to the at least two interconnecting elements (931-942) are arranged in a common plug-in body (920) which is formed integrally with the retaining element (270).

14. The electronically commutated motor according to claim 10, characterized in that: The connecting pin (721) is fastened in the receptacle (716) and / or the pin (712; 969) is fastened in the connecting receptacle (715; 970) by laser welding.

15. The electronically commutated motor according to any one of claims 1 to 5, characterized in that At least two interconnection elements (281-286) for interconnecting the wire ends (231-254) have copper guides.

16. The electronically commutated motor according to claim 15, characterized in that: At least two interconnection elements (281-286) have at least one plane on which the copper guides are arranged.

17. An electronically commutated motor according to any one of claims 1 to 5, characterized in that The at least two interconnecting elements (281-286; 411-413; 511-514) are respectively configured as stamped parts.

18. An electronically commutated motor according to any one of claims 1 to 5, characterized in that The wire ends (231-254) of the single winding (299) are fixed to the contact elements (292) of the corresponding interconnection elements (281-286) via laser welding connections.

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