Electric machine with a connection unit and method for producing an electric machine with a connection unit

Abstract

The invention relates to an electric machine, in particular a permanent-magnet synchronous machine, comprising a stator and a rotor which is arranged so as to be rotatable about an axis of rotation, the stator having a plurality of coils, each coil having two coil connection terminals, in particular wherein the stator has a plurality of stator segments, each stator segment having exactly one coil, the coils being connected to one another by means of a connection unit, in particular in a star-shaped manner, the connection unit comprising a carrier part, in particular a substantially annular carrier part, in particular a carrier part consisting of an insulating material, for accommodating a plurality of, in particular at least four, connection elements which are spaced apart from one another, in particular wherein the connection unit is arranged, in particular concentrically with the axis of rotation, at an axial end of the stator, wherein in particular at least three first connection elements are provided, wherein each first connection element The elements each have two, in particular exactly two, contact areas spaced apart from one another, and a connection area connected to the contact areas, in particular such that the connection area is arranged between the contact areas, wherein the contact area of ​​each first terminal element, in particular all the contact areas, are respectively connected to one of the coil terminals at a connection point, in particular electrically connected, in particular connected in a materially bonded manner by means of laser welding, wherein an area covered by the connection area of ​​one of the first terminal elements in a circumferential direction and in a radial direction respectively overlaps an area covered by the connection area of ​​another first terminal element in a circumferential direction and in a radial direction, wherein an area covered by the connection area of ​​the first terminal elements in an axial direction is identical and an area covered by the connection area of ​​the first terminal elements in a radial direction is identical.

Description

Technical Field

[0001] The invention relates to an electric machine having a terminal unit and a method for producing the electric machine. Background Art

[0002] As is known, electric machines have a stator on which a multi-phase winding is arranged. In this case, the winding comprises, for example, a plurality of coils connected to one another. Stators are also known which consist of wound individual teeth, so that in the case of individual teeth each stator tooth receives a single tooth winding. In this case, each single tooth winding forms a coil, which is made of winding wire. The free ends of the winding wire form the two coil terminals of the coil, which usually have to be connected to one another with one or both axial ends of the stator in order to form a multi-phase winding. Star connection and delta connection are known in this regard.

[0003] The invention is particularly suitable for synchronous machines whose stators are composed of individual stator tooth segments, wherein each stator tooth segment has a coil, i.e., a single-tooth winding. The synchronous machine has in particular a three-phase winding with phases U, V and W, wherein each phase is preferably assigned a coil group. The coil group in turn comprises a plurality of individual coils, wherein the coils are electrically connected to one another by means of a wiring unit according to the invention. Thus, one coil connection end of a coil is connected to another coil connection end of another coil by means of a wiring element of the wiring unit. The coil groups connected in this way are preferably connected to one another in a star connection.

[0004] Different types of connection of coil terminals are known from the prior art.

[0005] A stator unit and an electric machine are known from DE 11 2013 005 061 T5, in which a busbar unit is arranged on the upper side of the stator.

[0006] DE 10 2012 024 581 A1 discloses an electric machine having a connecting ring, in which conductor sections are inserted into concentrically extending radially spaced-apart grooves.

[0007] DE 10 2012 020 329 A1 discloses an electric machine having a terminal ring, in which electrical conductions, in particular in the form of punched and bent parts, are inserted into concentrically extending, radially spaced-apart grooves.

[0008] DE 10 328 720 A1 discloses an electric motor having an annular carrier and conductor tracks arranged in the carrier for electrical connection of coils and winding tracks. Here, the conductor tracks are staggered vertically in a radial direction and are installed in the carrier staggered relative to each other in the circumferential direction.

[0009] DE 10 2014 201 637 A1 discloses an electric machine having a carrier component, in which the winding ends are connected by means of a multi-part busbar.

[0010] EP 27 529 73 A1 discloses an electric motor having a terminal ring, in which arc-shaped busbars are accommodated in two annular grooves of the terminal ring.

[0011] DE 10 2016 204 935 A1 discloses an electric machine having a terminal block, in which conductor elements are used for connecting windings, wherein the conductor elements are injection-molded with plastic for insulation.

[0012] DE 10 2015 200 093 A1 discloses a terminal block for a stator of an electric machine, wherein the terminal block has conductor elements which can be connected to an electrical winding. Summary of the invention

[0013] The object of the present invention is therefore to improve an electric machine having a terminal unit and a method for producing the electric machine, wherein the manufacturing complexity during production is reduced and the electric machine can be produced more simply, more cost-effectively and more stably.

[0014] The invention is distinguished in that the electric machine, in particular a permanent-magnet synchronous machine, has a stator and a rotor arranged so as to be rotatable about an axis of rotation, the stator having a plurality of coils, each coil having two coil terminals, in particular the stator having a plurality of stator segments, each stator segment having exactly one coil, the coils being connected to one another by means of a connection unit, in particular in a star-shaped manner, the connection unit comprising a carrier part, in particular a substantially annular carrier part, in particular a carrier part consisting of an insulating material, for accommodating a plurality of, in particular at least four, connection elements spaced apart from one another, in particular the connection unit is arranged, in particular concentrically with the axis of rotation, at an axial end of the stator. wherein at least three first terminal elements are provided, wherein each first terminal element has two, in particular exactly two, contact regions spaced apart from one another and a connection region connected to the contact regions, in particular such that the connection region is arranged between the contact regions, wherein the contact regions of each first terminal element, in particular all the contact regions, are respectively connected to one of the coil terminals at a connection point, in particular electrically, in particular in a materially bonded manner by means of laser welding, wherein an area covered by the connection region of one of the first terminal elements in the circumferential direction and in the radial direction respectively overlaps an area covered by the connection region of another first terminal element in the circumferential direction and in the radial direction.

[0015] The expressions "circumferential direction", "radial direction" and "axial direction" refer to directions with reference to the axis of rotation of the rotor. Thus, an axial direction denotes a direction parallel to the axis of rotation, while a radial direction denotes a direction perpendicular to the axis of rotation and radially outward from the axis of rotation or radially inward with reference to the axis of rotation. A circumferential direction is to be understood as a direction which runs along the circumference of a closed curve, in particular a circle, which runs perpendicularly and in particular concentrically to the axis of rotation. The term is therefore not limited to the circumference, but can also be used for the circumference of, for example, an ellipse or a polygon.

[0016] The expression "substantially annular carrier part" is therefore to be understood as meaning that the carrier part is designed in the form of a plate, i.e. has a continuous opening in the middle and has an extension in the axial direction that is smaller than the diameter of the carrier part in a plane perpendicular to the axis of rotation. The exact extension of the inner and outer contours does not have to correspond to a circular ring. Other shapes, such as polygonal shapes, are also conceivable. It is also possible for the shape to deviate from the ideal circle, for which purpose, for example, there are notches at the outer or inner circumference.

[0017] Plastic is preferably used as the insulating material for the carrier part. The carrier part is produced in particular by means of a plastic injection molding method. However, other materials can also be used which have electrically insulating properties, ie insulating materials.

[0018] The carrier element receives the terminal elements and is thus responsible for the spatial arrangement of the terminal elements relative to one another. The terminal elements are spaced apart from one another so that they do not touch one another and therefore do not have direct contact with one another.

[0019] Instead of laser welding, brazing, ultrasonic welding or resistance welding can also be carried out.

[0020] The terminal element is made of an electrically conductive material, preferably of metal or metal sheet, in particular of copper sheet. The terminal element is preferably implemented in one piece and / or is preferably implemented as a punched / bent part. Production can be carried out by means of water jet cutting or laser cutting.

[0021] A “connection point” is understood to be a location at which an electrical connection exists between the terminal element and the coil connection.

[0022] A "region" is understood to be a specific part of a component that fulfills a specific function. For example, the connection region of a first terminal element connects two contact regions. The contact region is used to connect the terminal element to the coil terminal.

[0023] If the component is designed in one piece, the exact boundaries between the individual regions cannot always be precisely defined. Such regions of a component should not be confused with a "covered region" of the component in a direction.

[0024] Each first terminal element received on the carrier is arranged above or below at least one other first terminal element in the axial direction. Therefore, the first terminal elements are partially stacked on top of each other in the axial direction, but do not touch each other. Here, the area of ​​the connection region that is covered in the circumferential and radial directions is a surface that is generated by projecting the corresponding connection region parallel to the axial direction onto a projection plane that is perpendicular to the rotation axis. Therefore, the projection surfaces of the connection regions of the two corresponding first terminal elements that are generated in this way overlap in the projection plane.

[0025] This has the advantage that a compact design of the terminal unit can be achieved.

[0026] According to the present invention, the areas covered by the connecting regions of the first connecting elements in the axial direction are identical, and the areas covered by the connecting regions of the first connecting elements in the radial direction are identical.

[0027] The advantage is that the structural space in the axial direction and the radial direction can be saved, so that a compact structural form of the terminal unit in the axial direction can be achieved.

[0028] In an advantageous embodiment, the contact region of each first connecting element is shaped in such a way that the respective connection locations, in particular on the outer circumference of the carrier part, have essentially the same radial position and / or have the same axial position.

[0029] This has the advantage that the contact region can be easily connected to the coil connection. This allows automated assembly. Advantageously, the connection point is arranged on the outer circumference of the carrier part so that it can be easily accessed.

[0030] In an advantageous embodiment, the connection region of each first terminal element has an, in particular, approximately rectangular, cross section, the extent of which in the axial direction is smaller than its extent in the radial direction.

[0031] This has the advantage that construction space in the axial direction can be saved.

[0032] At least one connection region of one of the first terminal elements has two axial steps, in particular wherein all connection regions of the first terminal elements have two axial steps.

[0033] This has the advantage that the stacking of parts of the first terminal element is simplified. Instead of discrete steps in the connection area, an inclination of the connection area extending in the axial direction, in particular constantly, can also be achieved, so that the two contact areas have different axial positions and can be partially stacked.

[0034] In an advantageous embodiment, the region covered by one of the first terminal elements in the circumferential direction and in the radial direction overlaps with two regions covered by the other two first terminal elements in the circumferential direction and in the radial direction.

[0035] The advantage is that a more compact structural form of the terminal unit can be achieved. Therefore, this construction can be understood as that three first terminal elements are arranged axially one above the other in a certain circumferential and radial region.

[0036] In an advantageous embodiment, at least one of the first terminal elements is surrounded by an insulating part formed of an insulating material, in particular produced by means of an injection molding method, in such a way that the surrounded first terminal element and the surrounding insulating part are connected in a form-locking manner on both sides in the circumferential direction and / or in a form-locking manner on both sides in the axial direction and / or in a form-locking manner on one side in the radial direction, in particular, only every other first terminal element in the circumferential direction is surrounded by the corresponding insulating part in the above-mentioned manner.

[0037] This has the advantage that sufficient electrical insulation of the first terminal elements from one another can be easily achieved. With the aid of prefabricated insulating parts, smaller distances between the first terminal elements can be achieved while at the same time ensuring corresponding creepage distances for sufficient electrical insulation. Alternatively, the first terminal elements can be subsequently overmolded with insulating material. However, this method is more difficult to implement and more expensive.

[0038] In an advantageous design, the carrier part has a plurality of guide areas on its outer circumference, which are used to guide the coil terminals in an axial direction, wherein a guide area is respectively assigned to each contact area connected to the coil terminals, and in particular wherein the shape of the guide area is substantially identical to the shape of the correspondingly assigned contact area.

[0039] This has the advantage that in the method for producing an electric machine, the step of connecting the coil terminal to the connection unit can be carried out more reliably. By guiding the coil terminal, it is ensured that the coil terminal is substantially parallel to the axis of rotation. The coil terminal can advantageously be tightened in the guide area, so that the method step of producing a material-locking connection between the contact area and the coil terminal is easier. This makes automated production possible.

[0040] In an advantageous design, each first terminal element has a first fixing area for being connected to the carrier in a form-fitting and / or materially sealed manner, in particular, each first fixing area has a first notch extending through the carrier in an axial direction, and the carrier has a plurality of rivet pins extending in the axial direction, in particular, each first notch can be penetrated by a first rivet pin, in particular, the free end of the first rivet pin is deformed into a rivet head, in particular by means of ultrasonic welding.

[0041] This has the advantage that a reliable and stable, in particular inseparable, connection of the terminal element to the carrier part can be achieved, thereby preventing it from being lost. Instead of ultrasonic welding, hot welding or hot stamping can also be implemented.

[0042] The notch can be designed, for example, in particular as a cylindrical hole. A hole is an example of a closed notch. However, open notches are also conceivable, which do not form a closed curve in a plane perpendicular to the axis of rotation. For example, a groove in the axial direction also forms such a notch. It is only important that the notch extends through in the axial direction and is suitable for supporting a positive and / or materially connected connection with the carrier part.

[0043] A rivet pin is understood to be a protrusion in the axial direction, which is shaped so that it can be passed through the recess of the first terminal element in the axial direction. In the exemplary case of a cylindrical hole as the recess, the rivet pin is designed as a cylindrical protrusion in the axial direction. The free end of the rivet pin is deformed into a rivet head to produce a positive and / or materially bonded connection. For example, a mushroom-shaped rivet head or a disk-shaped rivet head is suitable for achieving a positive connection. The diameter of the rivet head in a plane perpendicular to the axis of rotation is selected to be larger than the diameter of the corresponding recess in the same plane.

[0044] In an advantageous embodiment, each first terminal element has a second fixing region for connection to the carrier part in a form-fitting and / or material-locking manner, in particular, each second fixing region has a second notch extending through the carrier part in an axial direction, wherein each second notch can be penetrated by a second rivet pin, wherein the free end of the second rivet pin is deformed into a rivet head in particular by means of ultrasonic welding.

[0045] This has the advantage that the first terminal element can be fixed better and more stably in space on the carrier part, so that a movement of the terminal element relative to the carrier part is prevented.

[0046] In an advantageous embodiment, the first fixing region of each first terminal element has respectively the same first radial position and / or the same first axial position, and / or the second fixing region of each first terminal element has respectively the same second radial position and / or the same second axial position, in particular wherein the first radial position and the second radial position are different, in particular wherein the first axial position and the second axial position are different.

[0047] The advantage is that the spatial fixation of the first terminal element on the carrier is further improved, and the terminal element is prevented from tilting relative to the carrier.

[0048] In an advantageous embodiment, a second terminal element is provided which has three, in particular exactly three, contact areas, wherein each of the three contact areas of the second terminal element is respectively connected to one of the coil terminals, in particular electrically connected, in particular connected in a material-locked manner by means of laser welding.

[0049] The advantage is that a coil connection in a star connection circuit can be realized. In this case, the second terminal element is used as a star connection element for connecting three different coil terminals. For a delta connection, the second terminal element can be omitted.

[0050] In an advantageous embodiment, the second terminal element has two, in particular exactly two, fixing regions for being connected to the carrier part in a form-fitting and / or materially sealed manner, in particular wherein each fixing region has a respective notch extending through in the axial direction, each respective notch being passable by a third rivet pin, in particular wherein the free end of the third rivet pin is deformed into a rivet head, in particular by means of ultrasonic welding.

[0051] This has the advantage that a better and more stable spatial fixation of the second terminal element on the carrier part can be achieved, so that a movement of the terminal element relative to the carrier part is prevented.

[0052] In an advantageous embodiment, the area covered by the second terminal element in the radial direction is identical to the area covered by at least one of the first terminal elements, in particular by all of the first terminal elements, in the radial direction.

[0053] This has the advantage that structural space in the radial direction can be saved, so that a compact structural form of the terminal unit in the radial direction can be achieved.

[0054] In an advantageous embodiment, a region covered by the second terminal element in the circumferential direction and in the radial direction overlaps a region covered by at least one of the first terminal elements, in particular by two of the first terminal elements, in the circumferential direction and in the radial direction.

[0055] This has the advantage that a compact design of the terminal unit can be achieved.

[0056] In an advantageous embodiment, a plurality of, in particular exactly three, third terminal elements are provided, each of which has a first contact region and a second contact region, the first contact region and the second contact region of the third terminal elements being in particular embodied differently, wherein the first contact region of the third terminal elements is each connected to one of the coil terminals, in particular electrically connected, in particular connected in a material-locked manner by means of laser welding.

[0057] This has the advantage that in particular three phase conductors can be connected to the motor in a simple manner. The third terminal element is electrically connected to the coil via the first contact region, which is to be connected to the phase in question. The second contact region is then suitable for connecting the third terminal element to the phase conductor in order to thereby produce an electrical connection between the phase conductor and the coil. The connection is achieved, for example, in that the terminal ends of the phase conductor are fixed to the second fixing region by means of a screw and a nut.

[0058] In an advantageous embodiment, each third terminal element comprises a first fixing region and a second fixing region for being connected to the carrier part in a form-fitting and / or materially locking manner, in particular wherein each of the two fixing regions has a respective notch extending through in the axial direction, each respective notch being passable by a fourth rivet pin, in particular wherein the free end of the fourth rivet pin is deformed into a rivet head, in particular by means of ultrasonic welding.

[0059] This has the advantage that a better and more stable spatial fixation of the third terminal element on the carrier part can be achieved, so that a movement of the terminal element relative to the carrier part is prevented.

[0060] In an advantageous embodiment, each third terminal element has a third fixing region for being connected to the carrier part in a form-fitting and / or materially bonded manner, wherein the third fixing region is adjacent to the first contact region of the respective third terminal element, in particular wherein the third fixing region has a through-cut notch in the axial direction through which a fifth rivet pin can be passed, in particular wherein the free end of the fifth rivet pin is deformed into a rivet head, in particular by means of ultrasonic welding.

[0061] This has the advantage that the spatial fixation of the third connecting element on the carrier part is further improved.

[0062] In an advantageous embodiment, the first connecting elements are designed identically and / or the third connecting elements are designed identically.

[0063] This has the advantage that fewer different terminal elements need to be produced and the manufacturing complexity is thus reduced. The terminal unit can be produced from one type of first terminal element and / or one type of third terminal element. This facilitates the automated production of the first terminal element, for example when it is machined as a punched and bent part.

[0064] In an advantageous embodiment, the coil terminal is connected to a contact area of ​​the first terminal element and / or to a contact area of ​​the second terminal element and / or to a corresponding contact area of ​​the third terminal element in a material-locked manner by means of laser welding, in particular wherein the contact area to be connected has a V-shaped groove for accommodating the coil terminal, in particular wherein the radius of the arc section is at most as large as the radius of the winding wire.

[0065] This has the advantage that contacting can be carried out quickly by means of laser welding, so that no significant heating of the first terminal element occurs. The welding point can thus approach parts made of insulating material, in particular plastic, without damaging and / or deforming them due to heating. In particular, the contact region can thus be arranged in close spatial proximity, ie adjacent to, the fastening region, so that a more compact design can be achieved.

[0066] The V-shaped notch has the advantage that a safe and reliable electrical connection can always be established for winding wires of different diameters. The wire is always symmetrical about the symmetry axis of the notch and thus the contact area is connected at least at two locations. Thus, one type of contact area can be used for different wire diameters.

[0067] The method according to the invention for producing an electric machine is distinguished by the following steps, which are particularly linked to one another:

[0068] i) providing an in particular substantially annular carrier part which is formed from an insulating material, in particular wherein the carrier part is produced by means of an injection molding method,

[0069] ii) arranging a plurality of first terminal elements in a circumferential direction on a carrier part, wherein each of the first terminal elements has two, in particular exactly two, contact regions, and the first terminal elements are arranged such that a region covered by one of the first terminal elements in a circumferential direction and in a radial direction overlaps a region covered by an adjacent first terminal element in a circumferential direction and in a radial direction, wherein the first terminal elements are arranged spaced apart from one another, in particular wherein each first terminal element has a connection region connected to the contact region, in particular wherein the first terminal elements are arranged such that a region covered by a connection region of the first terminal elements in an axial direction is identical and a region covered by a connection region of the first terminal elements in a radial direction is identical,

[0070] iii) connecting the first terminal element to the carrier part, in particular in a form-fitting and / or materially bonding manner, to form a terminal unit,

[0071] iv) connecting each contact area of ​​the first terminal element to a corresponding coil terminal of one of the coils, in particular electrically, in particular by means of laser welding, in order to connect the coils into a multi-phase winding, wherein the coils each have two coil terminals and are arranged on the stator of the electric machine.

[0072] This has the advantage that a compact design of the terminal unit can be achieved.

[0073] In an advantageous design, in particular in step ii), the first terminal elements are arranged such that only every other first terminal element in the circumferential direction is surrounded by an insulating part made of insulating material, in particular produced by means of an injection molding method, wherein the surrounded first terminal element and the surrounding insulating part are connected in a form-locking manner on both sides in the circumferential direction and / or in a form-locking manner on both sides in the axial direction and / or in a form-locking manner on one side in the radial direction.

[0074] This has the advantage that sufficient electrical insulation of the first terminal elements from one another can be easily achieved. With the aid of prefabricated insulating parts, a smaller distance between the first terminal elements can be achieved while at the same time ensuring a corresponding creepage distance for sufficient electrical insulation. Alternatively, the first terminal elements can also be overmolded with insulating material afterwards. However, this method is more difficult to implement and more expensive.

[0075] In an advantageous embodiment, in particular in step ii), a second terminal element is arranged on the carrier part, wherein the second terminal element has three, in particular exactly three, contact regions.

[0076] In particular, in step iii), the second terminal element is connected to the carrier part in order to form the terminal unit, in particular in a form-fitting and / or materially bonded manner.

[0077] In particular, in step iv), each contact region of the second terminal element is connected to one of the coil terminals, in particular electrically, in particular by means of a material bond, by means of laser welding.

[0078] Its advantage is that the coil can be connected in a star point circuit. Here, the second terminal element is used as a star point element to connect three different coil terminals.

[0079] In an advantageous embodiment, in particular in step ii), three, in particular exactly three, third terminal elements are arranged on a carrier part, wherein each of the third terminal elements has two, in particular different contact areas, wherein in particular in step iii), in order to form a terminal unit, the third terminal element is connected to the carrier part, in particular in a form-locking and / or material-locking manner, and wherein in particular in step iv), one of the two contact areas of the third terminal element is connected to one of the corresponding coil terminals, in particular electrically, in particular in a material-locking manner by means of laser welding.

[0080] The advantage is that a simple connection of in particular three phase conductors to the motor can be achieved. The third terminal element is connected with one of its contact regions to the coil that is to be connected to the corresponding phase. The coil is then simply connected to the phase conductor, for example via a terminal connection.

[0081] In an advantageous embodiment, in particular after step iv), the stator with the coil and the terminal unit connected to the coil terminals is filled with a filling material, in particular so that contact regions of the third terminal elements which are not connected to the coil terminals remain free of filling material.

[0082] This has the advantage that a stable mechanical fixation of the terminal unit on the stator can be achieved.

[0083] For a person skilled in the art, further meaningful combinations of the features of the description and / or the drawings may emerge, in particular on the basis of the formulation of the technical problem and / or by a comparison with the prior art. BRIEF DESCRIPTION OF THE DRAWINGS

[0084] The present invention is further explained with the aid of the accompanying drawings.

[0085] exist Figure 1 A first embodiment of a terminal unit according to the invention in which an electric machine is arranged on a stator is shown in a perspective view.

[0086] exist Figure 2A The side view shows Figure 1 A first embodiment of a stator and a terminal unit.

[0087] exist Figure 2B The top view shows Figure 1 A first embodiment of a stator and a terminal unit.

[0088] exist Figure 3A The perspective view shows Figure 1 A first terminal element of a first embodiment of a terminal unit.

[0089] exist Figure 3B The side view shows Figure 3A The first wiring element.

[0090] exist Figure 3C It is shown in Figure 3A and 3B A projection of the first terminal element along the axial direction onto a plane perpendicular to the axis of rotation.

[0091] exist Figure 4 The perspective view shows Figure 1 The second terminal element of the first embodiment of the terminal unit.

[0092] exist Figure 5A The perspective view shows Figure 1 The third terminal element of the first embodiment of the terminal unit.

[0093] exist Figure 5B The top view shows Figure 5A The third wiring element.

[0094] exist Figure 6 The perspective view shows Figure 1 The first embodiment of the wiring unit of the carrier member and the wiring unit arranged on the carrier member Figure 4 The second wiring element.

[0095] exist Fig. 7A The perspective view shows Figure 3A The first wiring element and the push-fit insulating member.

[0096] exist Figure 7B Two first terminal elements are shown in a perspective view.

[0097] exist Figure 7C It is shown in Figure 7B The projections of the two first terminal elements along the axial direction onto a plane perpendicular to the rotation axis.

[0098] exist Figure 8 The perspective view shows Figure 1 A first embodiment of a terminal unit comprises a carrier part and terminal elements arranged thereon.

[0099] exist Fig.9A 0 shows an insulating part of a second specific embodiment of a terminal unit in a perspective view.

[0100] exist Fig. 9B 0 shows a first terminal element of a second specific embodiment of a terminal unit in a perspective view.

[0101] exist Fig. 9C The perspective view shows Fig.9A Insulation parts and Fig. 9B The first wiring element.

[0102] exist Fig.9D The perspective view shows Fig. 9C The insulating member and the first wiring element, and the further first wiring element.

[0103] exist Fig.10 FIG. 4 shows a wiring unit according to a second embodiment in a perspective view. DETAILED DESCRIPTION

[0104] Exemplary embodiments of the present invention are explained below with reference to the drawings, wherein the same reference numerals are used for components having the same function and a repeated description is omitted in each drawing.

[0105] Figure 1 A first embodiment of a terminal unit 1 is shown in a perspective view, which is arranged at the axial end of a stator 2 of an electric machine according to the invention (not shown in further detail). The stator 2 of the electric machine is composed of individual stator segments 3. In the exemplary embodiment shown, the stator 2 has twelve stator segments 3. The number of twelve is merely exemplary; other numbers of stator segments are also conceivable. In this exemplary embodiment, the stator segments 3 are preferably designed as stacked laminations.

[0106] The stator segments 3 are connected to one another so that they form a substantially cylindrical stator 2. A rotor (not shown) is arranged inside the stator 3 and is rotatably supported about an axis of rotation D. The rotor and the stator 2 are arranged concentrically to the axis of rotation D. The rotor preferably has permanent magnets, and the motor is preferably designed as a permanent-magnet synchronous motor.

[0107] Each stator segment 3 has stator teeth, around which a coil 4 is wound. The coil is formed by a winding wire, which is insulated. The two ends of the winding wire are stripped of insulation and form two coil terminals 5, 6. Figure 1 The coil 4 is only schematically shown in FIG. 1 . For example, an insulating paper 7 is provided between the coil 4 and the stator segment 3 for electrical insulation.

[0108] Figure 2A Shown in side view Figure 1 A direction A extending parallel to the rotation axis D represents the axial direction. Figure 2B The top view shows Figure 1 As shown, a radial direction R is defined from the rotation axis D. Therefore, the radial direction R extends perpendicularly to the axial direction A. The circumferential direction U extends along the periphery of the stator 2 and also in Figure 2B The circumferential direction U is shown in .

[0109] The individual coils 4 are connected to form a multi-phase winding by means of a connection unit 1. In this exemplary embodiment, twelve coils 4 are connected to one another in a star connection, thereby forming a three-phase winding. Thus, four individual coils 4 are assigned to each phase. Within one phase, four coils 4 are connected in series by means of a connection unit 1. All three phases are in turn connected to one another at the star point. For a better overview, the individual elements of the connection unit 1 are explained in the following figure.

[0110] The connection unit 1 according to the present invention comprises: a plurality of connection elements 30, 40, 50 for connecting the coil terminals; and a carrier member 60 for receiving the connection elements 30, 40, 50. In order to connect the twelve coils 4 shown in this embodiment in a star connection into a three-phase winding, nine first connection elements 30 and one second connection element 40 are required. If n represents the number of phases, and z represents the number of stator segments 3 and correspondingly represents the number of coils 4, then for the star connection, (z-n) first connection elements 30 and one second connection element 40 are required. Therefore, the second connection element 40 is only required for the connection in a star connection. For other types of connection, such as a delta connection, the second connection element can be omitted.

[0111] Figure 3A The first terminal element 30 is shown in a perspective view. The first terminal element 30 is formed of a metal sheet (preferably a steel sheet or a copper sheet) and is preferably made into a punched and bent part. In the present embodiment, the first terminal element 30 includes a first contact area 31 and a second contact area 32. The two contact areas 31, 32 are spaced apart from each other. A connection area 33 is arranged between the two contact areas 31, 32. The connection area 33 connects the two contact areas 31, 32. The contact areas 31, 32 are used for the electrical and mechanical connection of the first terminal element 30 with the coil terminals 5, 6. Here, the contact areas 31, 32 are respectively connected to the corresponding coil terminals 5, 6. The contact areas 31, 32 have a V-shaped notch 301 for receiving the coil terminals 5, 6 in the form of winding wires.

[0112] In addition to the contact regions 31, 32, the first terminal element 30 comprises a first fixing region 34 and a second fixing region 35. The fixing regions 34, 35 are used to fix the first terminal element 30 on the carrier 60. In the present embodiment, the fixing regions 34, 35 each have a through-going notch 36, 37 in the form of a cylindrical hole. Alternatively, a half-open notch in the form of a groove extending in the axial direction, for example, can also be implemented.

[0113] Figure 3B Shown in side view Figure 3A The first terminal element 30 is provided. In the present embodiment, the first terminal element has a first step 37 and a second step 38. The steps 37 and 38 are preferably made by bending. Due to the steps 37 and 38, the first fixing area 34 and the second fixing area 35 have different axial positions.

[0114] Figure 3C Shows Figure 3A The vertical projection of the first terminal element 30 onto a plane perpendicular to the axis of rotation. Figure 3BThe steps 38, 39 are shown in this case by the hatching B1 which shows the area covered by the connecting region 33 in the circumferential direction and in the radial direction.

[0115] Figure 4 The second terminal element 40 is shown in a perspective view. The second terminal element 40 is formed by a metal sheet, preferably a steel sheet or a copper sheet, and is preferably made into a punched and bent part. In the present embodiment, the second terminal element 40 includes a first contact area 41, a second contact area 42 and a third contact area 43. The three contact areas 41, 42, 43 are spaced apart from each other. A connection area 44 is arranged between the first contact area 41 and the third contact area 43. The second contact area 42 is also arranged at the connection area 44. Therefore, the connection area 44 connects the three contact areas 41, 42, 43 to each other. The contact areas 41, 42, 43 are used for the electrical and mechanical connection of the second terminal element 40 with the coil terminals 5, 6. Here, the contact areas 41, 42, 43 are each connected to the corresponding coil terminals 5, 6. The contact areas 41, 42, 43 have a V-shaped notch 401 for receiving the coil terminals in the form of winding wires. When the three phases are connected in a star connection, second terminal element 40 forms a star point at which the three phases are connected to one another.

[0116] In addition to the contact regions 41, 42, 43, the second terminal element 40 comprises a first fixing region 45 and a second fixing region 46. The fixing regions 45, 46 are used to fix the second terminal element 40 on the carrier 60. In the present embodiment, the fixing regions 45, 46 each have a through-going notch 47 in the form of a cylindrical hole. Alternatively, a half-open notch, for example in the form of an axially extending groove, can also be implemented.

[0117] Figure 5AThe third terminal element 50 is shown in a perspective view. The third terminal element 50 is made of a metal sheet, preferably a steel sheet or a copper sheet, and is preferably made into a punched and bent part. In this embodiment, the third terminal element 50 includes a first contact area 51 and a second contact area 52. The two contact areas 51 and 52 are spaced apart from each other. The first contact area 51 is used for the electrical and mechanical connection of the third terminal element 50 with the coil terminals 5 and 6, and has a V-shaped notch 501 for this purpose. The second contact area 52 is used for the electrical and mechanical connection of the third terminal element 50 with the phase conductor. Therefore, the third terminal element 50 forms a connection between the motor and the phases U, V, and W. Therefore, three third terminal elements 50 are required in the case of a three-phase winding. The connection between the third terminal element 50 and the phase conductor can be achieved directly or indirectly through a screw 80 and an associated nut 81. In principle, a direct connection between the phase conductor and the coil terminals 5 and 6 can also be established, so that the third terminal element 50 can be omitted. However, the third terminal element 50 simplifies the manufacturing process of the motor and causes a simpler connection of the phase conductor to the motor. In the present exemplary embodiment, the second contact region 52 has a through-going recess. A screw 80 is passed through the recess and serves as a connection for a terminal of a phase conductor. A nut 81 is used to fix the terminal to the third terminal element.

[0118] In addition to the contact areas 51, 52, the third terminal element 50 includes a first fixing area 53, a second fixing area 54 and a third fixing area 55. The fixing areas 53, 54, 55 are used to fix the third terminal element 50 on the carrier 60. In the present embodiment, the fixing areas 53, 54, 55 have half-open notches 56, 57 in the form of axially extending grooves. Alternatively, a closed notch, for example in the form of a cylindrical hole, can also be implemented. Figure 6 The carrier part 60 is shown, which has the second terminal element 40 fixed thereon. The carrier part 60 is designed essentially in annular shape and is designed as a plastic injection molded part in the present exemplary embodiment. The carrier part 60 is preferably designed in one piece. The carrier part 60 is arranged concentrically with respect to the rotation axis D at an axial end of the stator 2, such as at Figure 1 . The carrier part 60 has axial projections 61, 62, 63, 64, 65 in the form of rivet pins. In the present exemplary embodiment, the projections 61, 62, 63, 64, 65 are cylindrical, but other shapes are also conceivable. The rivet pins 61, 62, 63, 64, 65 are preferably designed to complement the corresponding notches 36, 37, 47, 56, 57 in order to achieve a stable mechanical connection between the carrier part 60 and the terminal elements 30, 40, 50.

[0119] The carrier 60 has a first rivet pin 61 and a second rivet pin 62 for fixing the first terminal element 30. Preferably, the carrier 60 has a third rivet pin 63 for fixing the second terminal element 40. Preferably, the carrier 60 has a fourth rivet pin 64 and a fifth rivet pin 65 for fixing the third terminal element 50.

[0120] The first, third and fourth rivet pins are advantageously arranged close to the inner periphery of the carrier member 60 , whereas the second and fifth rivet pins are arranged close to the outer periphery of the carrier member 60 .

[0121] On the outer periphery of the carrier part 60, the carrier part has a plurality of guide areas 66 distributed thereon. Each guide area 66 has a V-shaped notch and is used to guide the coil terminals 5, 6 in the axial direction when establishing an electrical connection between the coil terminals 5, 6 and the contact areas 31, 32, 41, 42, 43, 51. For this purpose, the position of the guide area 64 in the radial direction and the circumferential direction is substantially the same as the position of the corresponding contact areas 31, 32, 41, 42, 43, 51. The guide area 66 is arranged axially below the contact areas 31, 32, 41, 42, 43, 51. Here, the V-shaped notch of the guide area 66 is slightly offset toward the inner circumference in the radial direction, for example, by 0.5 mm, thereby ensuring good contact between the coil terminals 5, 6 and the contact areas 31, 32, 41, 42, 43, 51. During the manufacturing process, the coil terminals 5, 6 are first bent so that they point radially outward. The connection unit 1 is then placed on the stator 2, and the coil terminals 5, 6 are then bent at appropriate positions so that they point upward in the axial direction and contact the corresponding contact areas 31, 32, 41, 42, 43, 51. In this case, the guide area 66 supports the contact process so that the coil terminals 5, 6 are oriented substantially parallel to the axial direction A.

[0122] In the method for producing the terminal unit 1, the starting point is a carrier part 60 made of insulating material. In the present exemplary embodiment, the carrier part is made of plastic by means of an injection molding method. Figure 6 As shown in FIG. 1 , second terminal element 40 is arranged on carrier part 60 . For fixing, through-going recesses 47 of fixing regions 45 , 46 of second terminal element 40 are used so that third rivet pins 63 can pass through recesses 47 .

[0123] In the next production step, first terminal elements 30 are arranged on carrier part 60, that is, so that regions B1, B2 covered in the circumferential and radial directions by connecting region 33 of one of first terminal elements 30 overlap with regions B1, B2 covered in the circumferential and radial directions by connecting region 33 of another first terminal element 30. In other words, the first terminal elements overlap one another in the circumferential direction at least partially in the axial direction, thereby achieving a more compact construction.

[0124] In order to fix the first terminal element 30, the through notches 36, 37 of the fixing regions 34, 35 of the first terminal element 30 are used so that the first rivet pin 61 and the second rivet pin 62 can pass through the notches 36, 37. Since the notch 36 of the two notches 36, 37 of the first terminal element 30 is arranged radially further inward than the other notch 37, stable holding can be achieved. In particular, tilting of the first terminal element 30 is avoided. In other words, the radial position of the first fixing region 34 is different from the radial position of the second fixing region 35.

[0125] The first rivet pin 61 and the second rivet pin 62 as well as the first terminal element 30 are arranged and shaped in such a way that the first terminal elements 30 placed thereon do not touch one another. They are therefore arranged spaced apart from one another. In principle, no further electrical insulation is therefore necessary, since the stator is usually cast with a filler as an insulating material in the last processing step.

[0126] Advantageously, electrical insulation can also be provided between first terminal elements 30 by means of a prefabricated insulating part. For this purpose, insulating part 70 is produced from plastic, for example, by means of an injection molding method. Fig. 7A An insulating member 70 is shown, which partially surrounds the first terminal element. In the present embodiment, the insulating member 70 is shaped so that it can be pushed onto the first terminal element 30 in the radial direction. Here, the first terminal element 30 is partially surrounded by the insulating member 70 in the circumferential direction, so that the insulating member 70 and the first terminal element 30 cannot move relative to each other in this direction. Therefore, there is a form-locking connection on both sides in the circumferential direction. In addition, the first terminal element 30 is partially surrounded by the insulating member 70 in the axial direction, so that the insulating member 70 and the first terminal element 30 cannot move relative to each other in this direction. Therefore, there is a form-locking connection on both sides in the axial direction. The first terminal element 30 is connected to the insulating member 70 in a form-locking manner on only one side in the radial direction, so that it can move relative to each other.

[0127] If the insulating element 70 is used for electrical insulation, it may be advantageous if, in the circumferential direction, only every other first terminal element 30 is surrounded by the insulating element 70 as described above. Figure 7B Shows that there is Fig. 7A70, and additionally shows another first terminal element 30B, which is simply placed on the insulating element 70. Then, the first terminal element 30 surrounded by the insulating element 70 is then arranged on the other first terminal element 30B.

[0128] Figure 7C Shows Figure 7B The vertical projection of the two first terminal elements 30A, 30B of A onto a plane perpendicular to the axis of rotation. The insulating element 70 is not shown here. The shaded area B1 is as shown in Figure 3C 3 shows the area covered by the connection area 33 of the first wiring element 30 in the circumferential direction and the radial direction. Similarly, the shaded area B2 shows the area covered by the connection area 33 of the other first wiring element 30B in the circumferential direction and the radial direction. The two areas partially overlap. In the present embodiment, the areas covered by the two connection areas 33 in the radial direction are the same. However, it is also possible that they are different.

[0129] Figure 8 Shows Figure 6 The carrier member 60 and the second wiring element 40 are arranged on the nine first wiring elements 30 and the insulating member 70 arranged therebetween. Since only every other second wiring element 30 is surrounded by the insulating member 70, only five insulating members 70 are required in this embodiment. Figure 8 Also shown is a third terminal element 50, which is fixed by two fourth rivet pins 64 and a fifth rivet pin 65 of the carrier part 60. In order to make contact between the third terminal element 50 and the phase conductor, a square head screw 80 and an associated nut 81 are used. The head of the screw is arranged axially below the through-cut notch of the second fixing area 52, so that the hexagonal nut 81 is accessible from above. In this way, it is possible to achieve a simple contact between the phase conductor and the third terminal element 50, for example by means of a terminal. In the present embodiment, in addition to the third terminal element 50 shown, two other third terminal elements 50 are used, which are placed counterclockwise in the circumferential direction next to the third terminal element 50 shown. Figure 1 All three third terminal elements 50 are shown in FIG.

[0130] After all the terminal elements 30, 40, 50 have been arranged on the carrier part 60, they are connected to the carrier part 60. To this end, in the present example, the free ends of the rivet pins 61, 62, 63, 64, 65 are deformed into rivet heads so that the diameter of the rivet heads in a plane perpendicular to the axis of rotation is greater than the diameter of the corresponding notch. The deformation can be achieved, for example, by means of ultrasonic welding, hot welding or hot stamping. If only the rivet pins are deformed during the deformation without a material-locking connection between the carrier part and the terminal element being established, a positive connection is established. However, it is also conceivable to establish a material-locking connection between the carrier part and the terminal element as an alternative or in addition.

[0131] After the connection elements 30, 40, 50 are connected to the carrier 60, the coil terminals 5, 6 are connected to the corresponding contact areas 31, 32, 41, 42, 51 of the connection elements 30, 40, 50 to establish an electrical connection. For this purpose, the wire ends of the coils, stripped of insulation, are placed in the V-shaped notches 301, 401, 501 of the contact areas 31, 32, 41, 42, 51, and a material connection is established between the wire and the connection element. In the present embodiment, this is achieved by means of laser welding. However, other methods can also be implemented.

[0132] After the coils 4 of the electric machine have been connected in this way to form a multi-phase winding by means of the connection unit 1, the stator 2 together with the connection unit 1 arranged at the axial end of the stator is cast with a filler for mechanical fixing. If no insulating element 70 is used, the filler serves as an electrical insulator between the connection elements 30, 40, 50.

[0133] If three third terminal elements 50 are used as shown in the present embodiment, care must be taken during casting to keep second fixing region 54 of third terminal element 50 free of filler. In order to ensure that third terminal element 50 is fully surrounded by the filler and to achieve stable fixing, third terminal element 50 advantageously has an anchoring region 58 which points axially from the third fixing region in the direction of stator 2. For better anchoring in the filler, anchoring region 58 advantageously has a recessed portion 59.

[0134] Alternatively, for the second embodiment of the wiring unit 1, Fig. 9B The first terminal element 90 is shown. The first terminal element 90 also has a first contact area 91 and a second contact area 92. The contact areas 91, 92 each include a catch arm 93, by which the corresponding coil terminal 5, 6 can be caught and held in a force-locking manner, in particular the coil terminal can be clamped between the catch arms. In addition, the coil terminal 5, 6 is preferably connected to the catch arm in a material-locking manner by means of contact welding. The catch arm 93 is open in a V-shape, wherein the catch arm forms the side of the V.

[0135] By means of the catch arms 93, a quick and less complex electrical connection of the coil terminals 5, 6 to the contact regions 91, 92 can be achieved in the following manner: during a relative rotation of the connection unit 1 relative to the stator 2, the coil terminals 5, 6 are caught in the inner region covered by the contact regions 91, 92, i.e., in particular, in the inner region covered by the V of the V-shaped catch arms 93. As a result, the respective contact regions 91, 92 are penetrated by the respective coil terminals 5, 6 until the connection position at the inner top of the V. Once the rotation is completed, the contact welding connection is performed. For this purpose, the respective edges of the contact regions 91, 92, i.e., the catch arms 93, are first pressed in the following manner: the edges are bent accordingly until the coil terminals 5, 6 are held, in particular, clamped, by the catch arms 93 of the contact regions 91, 92 in a force-locking manner. Contact welding is then performed so that the electrical connection between the coil terminals 5, 6 and the contact regions 91, 92 can be performed without solder.

[0136] As in the first exemplary embodiment, connecting region 94 of first connecting element 90 of the second exemplary embodiment has two axial steps 95 , 96 .

[0137] However, in contrast to the first exemplary embodiment, first terminal element 90 has only one fastening region 97 . The fastening region has a continuous recess 98 .

[0138] Fig.9A An insulating element 99 is shown which is pushed onto the first terminal element 90 . Fig. 9C A first terminal element 90 is shown, which has a push-on insulating part 99 .

[0139] Fig.9D Shows Fig. 9C The first terminal element 90A is shown with an insulating member 99 pushed on, and another first terminal element 90B arranged on the insulating member 99 is additionally shown. Here, the areas covered by the two connecting areas 94 of the two first terminal elements 90A, 90B overlap in the circumferential and radial directions.

[0140] Fig.10 A second embodiment of the wiring unit 100 is shown. As in the first embodiment, the wiring unit 100 has a carrier 101 for fixing nine first wiring elements 90 , a second wiring element 102 and three third wiring elements 103 .

[0141] As in the first exemplary embodiment, second terminal element 102 has three contact regions 104. As in the first exemplary embodiment, second terminal element 102 has two fastening regions 105, of which only one is visible due to the perspective view.

[0142] As in the first exemplary embodiment, third terminal element 103 has a first contact region 106 for contacting coil terminals 5 , 6 and a second contact region 107 for contacting a phase conductor. In contrast to the first exemplary embodiment, third terminal element 103 has only one fastening region 108 .

[0143] In the second exemplary embodiment, the form-fitting connection between terminal elements 90 , 102 , 103 and carrier part 101 is likewise achieved by deformation of rivet pins of the carrier part into rivet heads, which rivet pins can be passed through recesses in the corresponding fastening regions.

[0144] In the second embodiment, the terminal elements 90, 102, 103 are positioned on the carrier 101 in the following manner: the carrier 101 has a circumferential annular groove to accommodate the terminal elements 90, 102, 103. In addition, the carrier 101 has a notch 109 in the groove wall on its outer circumference, through which the contact areas 91, 92, 104, 106 can be respectively passed. This also helps to accurately position the component.

[0145] In both embodiments, all first terminal elements 30, 90 are designed to be identical, i.e., identical components. Third terminal elements 50, 103 are also designed to be identical, i.e., identical components. This has the advantage that the components can be manufactured more efficiently. However, it is also possible that first terminal elements 30, 90 and / or third terminal elements 50, 103 are designed differently.

[0146] In both exemplary embodiments, the area covered by connecting region 33 , 94 of first connecting elements 30 , 90 in the axial direction and the area covered by connecting region 33 , 94 of first connecting elements 30 , 90 in the radial direction are identical. However, it is also possible that these areas are different.

[0147] Reference numerals list

[0148] 1 Wiring unit

[0149] 2 Stator

[0150] 3 Stator section

[0151] 4 Coils

[0152] 5 First coil terminal

[0153] 6 Second coil terminal

[0154] 7 Insulation Paper

[0155] 30 First wiring element

[0156] 31 First contact region of first terminal element

[0157] 32 Second contact region of first terminal element

[0158] 33 Connection area of ​​first terminal element

[0159] 34 First fixing region of first terminal element

[0160] 35 Second fixing region of first terminal element

[0161] 36 First continuous recess in the first terminal element

[0162] 37 Second continuous recess in the first terminal element

[0163] 38 First step of first terminal element

[0164] 39 Second step of first terminal element

[0165] 301 V-notch

[0166] 40 Second wiring element

[0167] 41 First contact region of second terminal element

[0168] 42 Second contact region of second terminal element

[0169] 43 Third contact region of second terminal element

[0170] 44 Connection area for second terminal element

[0171] 45 First fixing region of second terminal element

[0172] 46 Second fixing region of second terminal element

[0173] 47 Through-cut recess in second terminal element

[0174] 401 V-notch

[0175] 50 Third wiring element

[0176] 51 First contact region of the third wiring element

[0177] 52 Second contact region of the third terminal element

[0178] 53 First fixing region of third terminal element

[0179] 54 Second fixing region of the third terminal element

[0180] 55 Third fixing region of third terminal element

[0181] 56 Through-cut recess in third terminal element

[0182] 57 Through-cut recess in third terminal element

[0183] 58 Anchoring area of ​​the third wiring element

[0184] 60 Carrier parts

[0185] 61 First rivet pin

[0186] 62 Second rivet pin

[0187] 63 Third rivet pin

[0188] 64 Fourth rivet pin

[0189] 65 Fifth rivet pin

[0190] 66 Boot Area

[0191] 70 Insulation

[0192] 80 Screw

[0193] 81 Nut

[0194] 90 First wiring element

[0195] 91 First contact region of first terminal element

[0196] 92 Second contact region of the first terminal element

[0197] 93 Capture Arm

[0198] 94 Connection area of ​​first terminal element

[0199] 95 Axial Step

[0200] 96 Axial steps

[0201] 97 Fastening area of ​​first terminal element

[0202] 98 Through-cut recess in first terminal element

[0203] 99 Insulation

[0204] 100 Junction Units

[0205] 101 Carrier parts

[0206] 102 Second wiring element

[0207] 103 Third wiring element

[0208] 104 Contact region of second terminal element

[0209] 105 Fixing area of ​​second terminal element

[0210] 106 First contact region of third wiring element

[0211] 107 Second contact region of third terminal element

[0212] 108 Fixing area of ​​third wiring element

Claims

1. An electric machine having a stator (2) and a rotor arranged so as to be rotatable about a rotation axis (D), in, The stator (2) has a plurality of coils (4). Each coil (4) has two coil terminals (5, 6). The coils are connected to each other by means of a connection unit (1, 100). The wiring unit (1, 100) comprises a carrier (60, 101) for accommodating a plurality of wiring elements (30, 40, 50, 90, 102, 103) spaced apart from each other. At least three first wiring elements (30, 90) are provided. Each first terminal element (30, 90) has two contact regions (31, 32, 91, 92) spaced apart from each other and a connection region (33, 94) connected to the contact regions (31, 32, 91, 92), such that the connection region (33, 94) is arranged between the contact regions (31, 32, 91, 92), The contact area (31, 32, 91, 92) of each first terminal element (30, 90) is electrically connected to one of the coil terminals (5, 6) at a connection point (20). wherein an area (B1, B2) covered by a connection area (33, 94) of one of the first wiring elements (30, 90) in a circumferential direction (U) and a radial direction (R) overlaps with an area (B1, B2) covered by a connection area (33, 94) of the other first wiring element (30, 90) in a circumferential direction (U) and a radial direction (R), respectively; It is characterized in that The areas covered by the connection areas (33, 94) of the first terminal elements (30, 90) in the axial direction are identical, The areas covered by the connecting regions (33, 94) of the first terminal elements (30, 90) in the radial direction are identical.

2. The motor according to claim 1, characterized in that The contact region (31, 32, 91, 92) of each first terminal element is shaped so that the corresponding connection locations (20) have essentially the same radial position and / or the same axial position on the outer circumference of the carrier part.

3. The motor according to claim 1 or 2, characterized in that: The connection region (33, 94) of each first terminal element (30, 90) has an approximately rectangular cross section, the extension of which in the axial direction is smaller than its extension in the radial direction, and / or At least one connection region (33, 94) of one of the first terminal elements (30, 90) has two axial steps (38, 39, 95, 96), and all connection regions (33, 94) of the first terminal elements (30, 90) have two axial steps (38, 39, 95, 96).

4. The motor according to claim 1 or 2, characterized in that: The area (B1, B2) covered by one of the first terminal elements (30, 90) in the circumferential direction and in the radial direction overlaps with two areas (B1, B2) covered by the other two first terminal elements (30, 90) in the circumferential direction and in the radial direction.

5. The motor according to claim 1 or 2, characterized in that: At least one of the first terminal elements (30, 90) is surrounded by an insulating part (70, 99) formed of an insulating material in such a way that the surrounded first terminal element (30, 90) and the surrounding insulating part (70, 99) are connected in a positive-locking manner on both sides in a circumferential direction (U) and / or in a positive-locking manner on both sides in an axial direction (A) and / or in a positive-locking manner on one side in a radial direction (R), In the circumferential direction (U), only every other first terminal element (30, 90) is surrounded by a corresponding insulating part (70, 99) in the above-described manner.

6. The motor according to claim 1 or 2, characterized in that: The carrier part (60) has a plurality of guide areas (66) on its outer circumference, the guide areas being used to guide the coil terminals (5, 6) in an axial direction (A). A guide region (64) is respectively assigned to each contact region (31, 32, 41, 42, 43, 51) connected to the coil terminals (5, 6). The shape of the guide area (66) is substantially identical to the shape of the correspondingly assigned contact area (31, 32, 41, 42, 43, 51).

7. The motor according to claim 1 or 2, characterized in that: Each first terminal element (30, 90) has a first fixing area (34, 97) for connecting to a carrier part (60, 101) in a form-locking and / or material-locking manner, each first fixing area (34, 97) has a first notch (36, 98) extending in the axial direction, the carrier part (60, 101) has a plurality of rivet pins (61, 62, 63, 64, 65) extending in the axial direction, each first notch (36, 98) is penetrated by a first rivet pin (61), and a free end of the first rivet pin (61) is deformed into a rivet head by means of ultrasonic welding.

8. The motor according to claim 7, characterized in that Each first terminal element (30) has a second fixing region (35) for connecting to a carrier part (60) in a form-fitting and / or material-locking manner. Each second fixing area (35) has a second notch (37) extending through in the axial direction. Each second notch (37) is penetrated by a second rivet pin (62). The free end of the second rivet pin (62) is deformed into a rivet head by ultrasonic welding.

9. The motor according to claim 8, characterized in that The first fixing region (34, 97) of each first terminal element (30, 90) has the same first radial position and / or the same first axial position, and / or The second fixing region (35) of each first terminal element (30) has the same second radial position and / or the same second axial position. The first radial position and the second radial position are different, and the first axial position and the second axial position are different.

10. The motor according to claim 1 or 2, characterized in that: A second terminal element (40, 105) is provided, which has three contact areas (41, 42, 43, 104), wherein each of the three contact areas (41, 42, 43, 104) of the second terminal element (40, 102) is electrically connected to one of the coil terminals (5, 6), the electrical connection being achieved in a material-locking manner by means of laser welding, The second terminal element (40, 105) has two fixing areas (45, 46, 105) for connecting to the carrier part (60, 101) in a form-fitting and / or material-locking manner. Each fixing area (45, 46, 105) has a notch (47) extending through in the axial direction, and each notch (47) is penetrated by a third rivet pin (63). The free end of the third rivet pin (63) is deformed into a rivet head by ultrasonic welding.

11. The motor according to claim 10, characterized in that The area covered by the second terminal element (40, 102) in the radial direction is the same as the area covered by at least one of the first terminal elements (30, 90) in the radial direction (R), and / or The area covered by the second terminal element (40, 102) in the circumferential direction (U) and the radial direction (R) overlaps with the area covered by at least one of the first terminal elements (30, 90) in the circumferential direction (U) and the radial direction (R).

12. The motor according to claim 1 or 2, characterized in that: A plurality of third terminal elements (50, 103) are provided, each of which has a first contact region (51, 106) and a second contact region (52, 107), the first contact region and the second contact region of the third terminal elements being implemented differently, wherein the first contact region (51, 106) of the third terminal elements (50, 103) is each electrically connected to one of the coil terminals (5, 6), the electrical connection being achieved in a material-locked manner by means of laser welding, Each third terminal element (50) has a first fixing region and a second fixing region (53, 54) for connecting to a carrier part (60) in a form-fitting and / or material-locking manner. Each of the two fixing areas (53, 54) has a notch (56) extending through in the axial direction, each notch (56) is penetrated by a fourth rivet pin (64), and the free end of the fourth rivet pin (64) is deformed into a rivet head by means of ultrasonic welding. Each third terminal element (50) has a third fixing region (55) for being connected to the carrier part (60) in a form-fitting and / or materially bonded manner, wherein the third fixing region (55) adjoins the first contact region (51) of the respective third terminal element (50), The third fixing region (55) has a through-cut notch (57) in the axial direction, through which a fifth rivet pin (65) passes, and the free end of the fifth rivet pin (65) is deformed into a rivet head by means of ultrasonic welding.

13. The motor according to claim 1 or 2, characterized in that: The first terminal elements (30, 90) are of identical construction, and / or the third terminal elements (50, 103) are of identical construction, and / or The coil terminals (5, 6) are connected to the contact areas (31, 32) of the first terminal element (30) and / or to the contact areas (41, 42, 43) of the second terminal element (40) and / or to the corresponding contact areas (51) of the third terminal element (50) by means of laser welding in a material-locked manner, the contact areas (31, 32, 41, 42, 43, 51) to be connected having V-shaped notches (301, 401, 501) for accommodating the coil terminals (5, 6), the radius of the circular arc section being at most as large as the radius of the winding wire.

14. The motor according to claim 1, characterized in that The motor is a permanent magnet synchronous motor, The stator (2) has a plurality of stator segments (3), each stator segment (3) having exactly one coil (4). The coils are connected to each other in a star connection by means of a connection unit (1, 100). The carrier part (60, 101) is a substantially annular carrier part (60, 101) made of insulating material. The wiring unit (1, 100) is arranged concentrically with the rotation axis (D) at an axial end of the stator (2).

15. A method for manufacturing an electric machine according to any one of claims 1 to 14, the method comprising the following steps: i) providing a carrier member (60, 101), the carrier member being formed of an insulating material, ii) arranging a plurality of first terminal elements (30, 90) on a carrier part (60, 101) along a circumferential direction (U), wherein: The first terminal elements (30, 90) each have two contact areas (31, 32, 91, 92), and the first terminal elements (30, 90) are arranged so that an area (B1, B2) covered by one of the first terminal elements (30) in a circumferential direction (U) and a radial direction (R) overlaps an area (B1, B2) covered by an adjacent first terminal element (30, 90) in a circumferential direction (U) and a radial direction (R), wherein the first terminal elements (30, 90) are arranged spaced apart from one another, each first terminal element (30, 90) having a connection area (33, 94) connected to the contact areas (31, 32, 91, 92), and the first terminal elements (30, 90) are arranged so that an area covered by the connection areas (33, 94) of the first terminal elements (30, 90) in an axial direction is the same, and an area covered by the connection areas (33, 94) of the first terminal elements (30, 90) in a radial direction is the same, iii) connecting the first wiring element (30, 90) to the carrier (60, 101) to form a wiring unit (1, 100), iv) electrically connecting each contact area (31, 32, 91, 92) of the first terminal element (30, 90) to a corresponding coil terminal (5, 6) of one of a plurality of coils (4) to connect the coils (4) into a multi-phase winding, wherein each coil has two coil terminals (5, 6) and is arranged on a stator (2) of the motor.

16. The method according to claim 15, characterized in that In step ii), the first terminal elements (30, 90) are arranged such that only every other first terminal element (30, 90) in the circumferential direction (U) is surrounded by an insulating part (70, 99) made of an insulating material, wherein the surrounded first terminal elements (30, 90) and the surrounding insulating part (70, 99) are connected in a form-fitting manner on both sides in the circumferential direction (U) and / or in a form-fitting manner on both sides in the axial direction (A) and / or in a form-fitting manner on one side in the radial direction (R), and / or, In step ii), a second terminal element (40, 102) is arranged on a carrier part (60, 101), wherein the second terminal element (40, 102) has three contact regions (41, 42, 43, 104), In step iii), in order to form a wiring unit (1, 100), the second wiring element (40, 102) is connected to the carrier (60, 101), wherein, in step iv), each contact region (41, 42, 43, 104) of the second terminal element is electrically connected to one of the coil terminals (5, 6), and / or In step ii), three third terminal elements (50, 103) are arranged on a carrier part (60, 101), wherein the third terminal elements (50, 103) each have two contact regions (51, 52, 106, 107), In step iii), in order to form a wiring unit (1, 100), the third wiring element (50, 103) is connected to the carrier part (60, 101), wherein in step iv) one of the two contact regions (51, 52, 106, 107) of the third terminal element (50, 103) is connected to one of the corresponding coil terminals (5, 6), and / or After step iv), the stator (2) having the coil (4) and the terminal unit (1) connected to the coil terminals (5, 6) are filled with filler so that the contact areas (52) of the third terminal elements (50) not connected to the coil terminals (5, 6) remain free of filler.

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