Electric drive arrangement, braking device and vehicle

Abstract

This invention relates to an electric drive device (2) for use in an electro-hydraulic braking device, the electric drive device comprising: a housing (4); and stator-rotor units (8), (26) received by the housing (4) for moving a piston in a cylinder-piston assembly to generate braking pressure. Here, the stator-rotor units (18), (26) have a stator (18) having a plurality of magnetizable, pole-forming stator teeth SZ1, SZ2...SZ 11 SZ 12 The arrangement structure consists of stator teeth SZ1, SZ2...SZ 11 SZ 12 The teeth are divided into separate, inserted pairs SZ1 & SZ2, SZ3 & SZ4...SZ, which are inserted into the housing (4). 11 &SZ 12 Here, the teeth are SZ1 & SZ2, SZ3 & SZ4...SZ 11 &SZ 12 Each tooth pair is wound with its own and shared metal wire that forms part of the coil (20), the two wire ends D of the tooth pair A D E Electrical contact (20) is made of a separate housing insert (8) made of plastic, which engages with the housing (4) and covers the stator-rotor unit (18), (26). The individual stator teeth SZ1, SZ2...SZ 11 SZ 12 They are pressed against each other in a side-by-side manner within the housing (4) and pressed against the housing (4).

Description

Technical Field

[0001] The present invention relates to an electric drive device, a braking device having such an electric drive device, and a vehicle having such a braking device. Background Technology

[0002] The proposed electric drive device is configured for use in an electro-hydraulic braking device, wherein the electric drive device drives a ball screw drive, which in turn moves the piston of a cylinder-piston assembly to generate braking pressure.

[0003] Here, "vehicle" can be understood as any vehicle that must be supplied with liquid and / or gaseous fuel to operate, but particularly passenger cars and / or commercial vehicles. Furthermore, the vehicle may also be a partially electric or fully electric vehicle, but particularly passenger cars and / or commercial vehicles. Summary of the Invention

[0004] The object of this invention is to provide a compact electric drive device for electro-hydraulic braking equipment, which can also be manufactured and assembled as simply as possible. Furthermore, the electric drive device should be manufactured at the lowest possible cost.

[0005] This objective is achieved by an electric drive device having the features of claim 1. Furthermore, an application of such an electric drive device in an electro-hydraulic braking system for a vehicle is proposed and protection of this application is claimed (see claim 13). Furthermore, a braking system having such an electric drive device is proposed and protection of this braking system is claimed (see claim 14). Furthermore, a vehicle having such a braking system is protected (see claim 15). Advantageous embodiments of the invention are the subject of the dependent claims.

[0006] It is proposed that a coil frame made of plastic is injection molded on each stator tooth to form a first end-side panel and a second end-side panel, the first end-side panel facing the rotor at the stator mounting position, and the second end-side panel facing away from the rotor at the mounting position, wherein the corresponding wire windings belonging to the coil are surrounded between the first panel and the second panel.

[0007] According to one embodiment of the present invention, each wire winding has a ladder between its respective first panel and second panel.

[0008] According to another embodiment of the invention, a pin-shaped anchoring section made of plastic is formed on one side of the respective second panel on each coil frame. This anchoring section extends along the longitudinal direction of the electric drive unit through a corresponding opening in the housing insert until it exceeds the end face of the housing insert facing away from the stator-rotor unit. The anchoring section engages behind this end face to form-lock the housing insert to the stator. Here, these plastic anchoring sections can be inserted into the housing insert. Insertion is understood as establishing a force-locking and form-locking connection between the respective anchoring section and the housing insert, wherein the anchoring section undergoes plastic deformation. Therefore, it is not necessary to use additional, separate components to fix the housing insert relative to the stator. This also minimizes the longitudinal extension distance of the electric drive unit.

[0009] According to another embodiment of the invention, the housing insert surrounds a contact arrangement consisting of at least two spaced-apart, conductive contact elements for supplying power to at least two phases of the stator coils, wherein the contact elements are electrically insulated from each other using plastic.

[0010] Here, the contact element has a first contact section for external contact between the stator and the plug, and a second contact section for internal contact between the stator and the corresponding contact element. The first and second contact sections are also referred to as contact posts or contact plates.

[0011] According to another embodiment of the invention, the first contact segment and the second contact segment extend from the plastic portion of the housing insert from the end face of the housing insert opposite to the stator-rotor unit along the longitudinal direction of the electric drive device. This also minimizes the longitudinal extension distance of the electric drive device.

[0012] It is proposed that the ends of each tooth pair are guided along the longitudinal direction of the electric drive device through the corresponding openings in the housing insert until they exceed the end face of the housing insert opposite to the stator-rotor unit and make electrical contact with the housing insert.

[0013] In a particularly advantageous embodiment of the invention, the contact arrangement has three spaced-apart, conductive contact elements for three-phase power supply to the coil. Attached Figure Description

[0014] Other advantageous improvements to the invention are derived from the dependent claims and the following description of preferred embodiments. The figures show:

[0015] Figure 1 A perspective view of the proposed electric drive device is shown.

[0016] Figure 2 Show Figure 1 An exploded view of the electric drive device shown.

[0017] Figure 3 A perspective view showing the arrangement of the two stator teeth forming a tooth pair.

[0018] Figure 4 Show Figure 1 A perspective view of the coil of the electric drive device shown.

[0019] Figure 5 Show Figure 1 A perspective view of the rotor of the electric drive unit shown.

[0020] Figure 6 Show Figure 1 The housing insert shown together Figure 4 Another perspective view of the coil shown.

[0021] Figure 7 Show Figure 4 An enlarged perspective view of the internal contacts of the coil shown.

[0022] Figure 8 Shown in Figure 1 The housing insert shown is with Figure 4 An enlarged perspective view of the connections between the coils shown.

[0023] Figure 9 Two additional perspective views of the housing insert are shown.

[0024] Figure 10 The three contact elements of the housing insert are shown, having first and second contact sections that are not bent and bent. Detailed Implementation

[0025] The proposed electric drive unit 2 is configured for use in an electro-hydraulic braking device. The electric drive unit 2 is designed as an electronically commutated three-phase (U-phase, V-phase, W-phase) DC motor with an internal rotor configuration. The electric drive unit 2 includes a housing 4, which is formed, for example, from a deep-drawn sheet metal sheet and can be mounted onto the housing of the electro-hydraulic braking device via a flange 6. Stator-rotor units 18 and 26 are mounted in the housing 4, which drive a ball screw drive (not shown) to move the piston of a cylinder-piston assembly to generate braking pressure.

[0026] In connection with another application different from that presented herein, the electric drive device presented within the scope of the accompanying drawings can also operate as an electronically commutated AC motor.

[0027] Furthermore, a separate, plastic-overmolded / plastic-coated housing insert 8 engages with the housing 4, and a section 10 of the tube 28 of the rotor 26 extends through the central opening of this housing insert, in which the aforementioned ball screw drive is arranged (see [link]). Figure 1 "Separate" here means that the housing insert 8 is not part of the stator 18.

[0028] Here, the housing insert 8 surrounds three spaced-apart, conductive contact elements KE U KE V KE W The contact arrangement structure 22 (see) Figure 2 as well as Figure 10 The contact elements are electrically insulated from each other using the plastic of the housing insert 8. Here, the contact element KE U KE V KE W Each contact element has a partially circular / arc-shaped base segment BA, on which a single first contact segment U is formed. I V I W I And a total of four second contact segments U II V II W II (see Figure 10 ).

[0029] Here, not only the first contact segment U I V I W I Moreover, the second contact section U II V II W II All extend from the end face of the housing insert 8 away from the stator-rotor units 18, 26. Furthermore, the respective wire ends D of the coils 20 of the stator 18... A D E The wire is led out of the housing insert 8 through the corresponding opening, so that the wire end also protrudes from the end face. Here, the wire end is the wire winding DW of the coil 20. U DW V DW W The starting point of the line D A (A = starting point) or line end point D E (E = Endpoint). In this embodiment, a total of 6 wire windings form coil 20. The ends of these wires here connect with their respective second contact segments U. II V II W II Contact. The end of the wire can here make contact with the corresponding contact segment U. II VII W II Connected by resistance welding using a material-locking method (see...) Figure 1 or Figure 6 (Connecting part 14 in the middle).

[0030] First contact section U I V I W I It is used for external contact between the stator 18 and the plug. The second contact section U... II V II W II For internal contact between stator 18 and three contact elements KE1, KE2, and KE3 (see...) Figure 2 Together Figure 10 The three contact elements are respectively assigned to one of the three phases U, V, and W of the coil 20.

[0031] Contact section U II V II W II Here, the coil sections, that is, the wire windings DW, are allocated in pairs. U The starting point and the adjacent wire winding DW V DW W The endpoint, wherein this coil section belongs to one of the U-phase, V-phase, or W-phase of coil 20. Here, paired contact sections U are arranged opposite to each other. II V II W II Contact each coil section belonging to the same U-phase, V-phase, or W-phase (see...). Figure 10 Here, contact element KE U KE V KE W This can be distinguished as follows (Teilung): in the contact segments U that are related to each other. II V II W II The spacing between them is different (see Figure 10 However, if the wire end D of coil 20 A D E If they are guided away accordingly, then this spacing can also be basically the same.

[0032] Figure 2 and Figure 7 Together Figure 10 This indicates that, corresponding to each contact element KE U KE V KE W A total of four second contact segments U were set. II V II W II—These second contact segments themselves are formed on the base segment BA through corresponding splice segments SA—two adjacent second contact segments in the base segment DW will connect the wire winding DW U DW V DW W One of the line starting points D A The wire winding DW adjacent to this wire winding U DW V DW W The endpoint of the line D E Connection. These two adjacent wire windings DW U DW V DW W This belongs to one of the U-phase, V-phase, and W-phase (see [link]). Figure 4 ).

[0033] Furthermore, various pin-shaped anchoring segments 16 made of plastic from the stator 18 also extend from the end face. These anchoring segments are formed on the stator 18 and extend through corresponding openings in the housing insert 8. These plastic anchoring segments 16 are here, for example, filled into the housing insert 8 in a form-locking manner by so-called thermoforming.

[0034] To reinforce the housing 4, evenly spaced raised areas can be provided in the housing plate within the region of the flange 6, each of which has radially inwardly oriented raised portions. Furthermore, in the respective regions of the raised portions, fixing holes are formed in the flange to allow the housing 4 to be mounted on the housing of the electro-hydraulic braking device.

[0035] The stator 18 is press-fitted into the housing 4. The permanently magnetized rotor 26, surrounded by the stator 18, includes a tube 28, which is press-fitted into a bushing 30. Here, the bushing 30 carries an arrangement of a plurality of permanent magnets 32, each acting in conjunction with the coils 20 and configured as shell magnets. Furthermore, the tube 28 is laser-welded to one of its two ends to a bearing sleeve 36, which itself extends through an angular contact ball bearing 34 serving as a “fixed bearing,” by which the tube 28 is received in a region at one end of the housing 4. The tube 28 is also received by a ball bearing 38 serving as a “floating bearing,” which is centered and received by a housing insert 8. Here, the housing insert 8 is pressed against the ball bearing 38 or its outer ring portion by, for example, an annular spring element 24—for example, configured as a corrugated spring—which is itself surrounded by the housing insert 8. Here, the spring element 24 can be connected to the housing insert 8 in a locking manner, i.e., in the case of a plastic-coated housing insert 8, the spring element is correspondingly covered together. Furthermore, the housing insert 8 serves as a cover, or rather, a housing and bearing cover, covering the stator-rotor units 18 and 26.

[0036] In summary, housing insert 8 has the following functions:

[0037] • Reception and centering of floating bearing 38

[0038] Clamping of floating bearing 38

[0039] • The internal and external contacts of coil 20

[0040] • Form-fitting connection with stator 18, and

[0041] • Coverage of stator-rotor units 18 and 26.

[0042] Integrating all these functions into a single housing insert 8 results in reduced manufacturing costs and simplified assembly of the electric drive unit 2. Furthermore, it yields a very compact structural form for the electric drive unit 2.

[0043] Furthermore, the proposed housing insert 8 reduces the length tolerance to be considered in the longitudinal direction XX of the electric drive device 2 (reduction of the length tolerance chain).

[0044] Furthermore, integrating the contact arrangement structure 22 into the housing insert 8 causes the individual wire windings DW in the housing 4 to form the coil 20. U DW V DW W The very compact or very tight arrangement (compact or tight “encapsulation”) is due to the omission of the plastic overmolded portion that surrounds a section (e.g., the end section of stator 18) and itself contains the contact arrangement structure.

[0045] Here, the stator 18, which is compacted and arranged in the housing 4, exemplarily includes a total of twelve magnetizable stator teeth SZ1, SZ2...SZ1 that form poles. 11 SZ 12 The stator teeth are arranged in a ring shape. Here, these stator teeth SZ1, SZ2...SZ... 11 SZ 12 Divided into individual tooth pairs SZ1 & SZ2, SZ3 & SZ4...SZ 11 &SZ 12 Among them, the tooth pairs are SZ1 & SZ2, SZ3 & SZ4...SZ 11 &SZ 12 Each tooth pair is wound with its own and shared metal wire that forms part of coil 20 (see [link]). Figure 3 and Figure 4 Here, the two line ends D of the corresponding tooth pair A D E ( Figure 3It makes electrical contact with the previously described housing insert 8.

[0046] Each stator tooth SZ1, SZ2...SZ 11 SZ 12 Here, individual metal sheets are combined to form a laminated core. Each laminated core is then formed by embossing / tempering. The embossing itself is produced by means of a die along the longitudinal extension direction XX of the laminated core. Here, the embossing extends along the entire longitudinal extension XX of the respective laminated core, thereby forming a form-locking between the individual metal sheets, which holds the metal sheets together.

[0047] Here, in each stator tooth SZ1, SZ2...SZ 11 SZ 12 The upper injection molded coil frame is made of plastic to form a first panel P in the end region on the first end side of the stator teeth. i (i = inside), and a second panel P is formed in the end region on the second end side of the stator tooth. a (a = external). Panel P on this first end side i The stator 18 is mounted facing the rotor 26, while the second end panel P... a The stator 18 is mounted away from the rotor 26. Therefore, the first panel P i It can also be called the inner panel, while the second panel P a It can also be called the outer panel. Here, the wire winding DW, which belongs to coil 20, is assigned to the corresponding stator teeth. U DW V DW W Surrounded by panel P i With panel P a Between. The coil frame can be spray-formed such that it completely or only partially covers the corresponding stator teeth (see, for example, see...). Figure 3 ).

[0048] Figure 3 This describes the arrangement of two stator teeth SZ1 and SZ2 that form a tooth pair. These two stator teeth are arranged opposite each other in order to utilize a shared metal wire for winding, such that their outer ends—or the ends on the second end side—are opposite each other at their initial positions of use in the tooth pair.

[0049] This winding is such that for one of the two teeth—here, SZ1—it is wound counterclockwise, and for the other tooth—here, SZ2—it is wound clockwise. Furthermore, this winding ensures that on the corresponding first panel P... i With the second panel P a Between, online winding DW U DWV DW W Step S is formed in the middle, with the one facing the panel P. a The external winding section is thicker than the internal winding section. Therefore, panel P a It also forms a panel P i Long. After winding, the two stator teeth SZ1 and SZ2 deflect relative to each other (see...). Figure 3 (See the arrow diagram in the image) so that it can be inserted at the end according to... Figure 4 The housing 4 shown in the diagram. Therefore, in the described, exemplary embodiment, there are a total of six tooth pairs SZ1 & SZ2, SZ3 & SZ4...SZ 11 &SZ 12 They are inserted sequentially into housing 4. Here, each stator tooth SZ1, SZ2...SZ... 11 SZ 12 They are pressed against each other in a side-by-side manner within the housing 4 and pressed against the housing 4.

[0050] On each coil holder, on the corresponding panel P a On one side, a pin-shaped anchoring section 16—also called an anchoring protrusion—is formed to cover the coil frame. This anchoring section extends from panel P along the longitudinal direction XX of the electric drive device 2. a The section extends outwards and the anchoring section is part of the panel P to some extent. a The extension (see) Figure 7 and Figure 8 Here, as described above, the anchoring section 16 extends through the corresponding opening in the housing insert 8 until it exceeds the end face of the housing insert 8 facing away from the stator-rotor units 18, 26, to which the anchoring section 16 engages for form-locking. Reference can be made here to the heat-filled sections 16 mentioned above, which induce an irremovable form-locking between the housing insert 8 and the stator 18.

[0051] Tooth pairs SZ1 & SZ2, SZ3 & SZ4...SZ 11 &SZ 12 The ends of each line D A D E Along the longitudinal direction of the electric drive unit 2, XX is guided through the corresponding opening in the housing insert 8 until it exceeds the end face of the housing insert 8 facing away from the stator-rotor units 18, 26, and contacts the housing insert 8 through the corresponding contact segments U. II V II W II Electrical contact. Here, the contact causes the wire winding DW to... U DW V DWW One of the line starting points D A and the adjacent wire winding DW respectively U DW V DW W The endpoint of the line D E The connection is made by means of the contact arrangement structure 22 surrounded by the housing insert 8, or more precisely by the contact element KE. U KE V KE W One of the connections. These adjacent and interconnected wire windings DW U DW V DW W This belongs to one of the U-phase, V-phase, or W-phase.

[0052] The proposed coil design also helps to realize the individual wire windings DW that form coil 20. U DW V DW W A very compact or very tight arrangement (compact or tight "encapsulation"). Combined with the proposed housing insert 8, the result is a very compact electric drive unit 2, which can also be easily manufactured and installed. Furthermore, the electric drive unit 2 can be manufactured cost-effectively.

[0053] Although exemplary embodiments have been described in the foregoing description, it should be noted that numerous variations are possible. Furthermore, it should be noted that these exemplary embodiments are merely examples and should not be construed as limiting the scope, application, or structure of protection in any way. Rather, the foregoing description provides guidance to those skilled in the art for implementing at least one exemplary embodiment, wherein various changes can be made, particularly in relation to the function and arrangement of the said components, without departing from the scope of protection derived from the claims and the combination of such equivalent features.

Claims

1. An electric drive device (2) for use in an electro-hydraulic braking device, the electric drive device comprising: • Shell (4), and • The stator-rotor units (18, 26) received by the housing (4) are used to move the piston in the cylinder-piston assembly to generate braking pressure. Among them, the stator-rotor unit (18, 26) has a stator (18) which has multiple magnetizable stator teeth (SZ1, SZ2...SZ) forming poles. 11 SZ 12 The arrangement structure consists of stator teeth (SZ1, SZ2...SZ...). 11 SZ 12 The teeth are divided into individual, inserted pairs (SZ1 & SZ2, SZ3 & SZ4...SZ) into the housing (4). 11 &SZ 12 ), of which, tooth pairs (SZ1&SZ2, SZ3&SZ4...SZ 11 &SZ 12 Each tooth pair in the coil (20) is wound with its own and shared metal wire, which forms part of the coil (20), and the two ends of the wire of the tooth pair (D) A D E The stator (4) is electrically contacted with a separate housing insert (8) made of plastic, which engages with the housing (4) and covers the stator-rotor unit (18, 26). Among them, each stator tooth (SZ1, SZ2...SZ) 11 SZ 12 They are pressed against each other in a side-by-side manner within the housing (4) and pressed against the housing (4). Among them, in each stator tooth (SZ1, SZ2...SZ) 11 SZ 12 The coil frame, made of plastic, is injection molded onto the surface to form the first end side panel (P). i ; i = internal) and the second end side panel (P a ;a = external), the first end side panel faces the rotor (26) at the mounting position of the stator (18), while the second end side panel faces away from the rotor (26) at the mounting position, wherein the corresponding wire winding (DW) belonging to the coil (20) U DW V DW W ) surrounded by the first panel (P i ) and the second panel (P a )between, Among them, on each of the coil frames, on the corresponding second panel (P) a On one side of the device, a pin-shaped anchoring section (16) made of plastic is formed. This anchoring section extends along the longitudinal direction (XX) of the electric drive device (2) through the corresponding opening in the housing insert (8) until it exceeds the end face of the housing insert (8) away from the stator-rotor unit (18, 26). The anchoring section engages behind this end face, and The housing insert (8) surrounds at least two spaced-apart, conductive contact elements (KE) U KE V KE W A contact arrangement structure (22) consisting of contact elements (KE) is used for power supply of at least two phases (U, V, W) of the coils (20) of the stator (18), wherein the contact elements (KE) U KE V KE W The plastic of the housing insert (8) is electrically insulated from each other.

2. The electric drive device (2) according to claim 1, wherein, Each wire winding (DW) U DW V DW W ) in the corresponding first panel (P) i ) and the second panel (P a There are steps between them.

3. The electric drive device according to claim 1 or 2, wherein, Each plastic anchoring section (16) is filled into the housing insert (8).

4. The electric drive device according to claim 1 or 2, wherein, Contact element (KE) U KE V KE W ) has a first contact section (U) I V I W I ) and the second contact section (U) II V II W II The first contact section is used for external contact between the stator (18) and the plug, while the second contact section is used for external contact between the stator (18) and the corresponding contact element (KE). U KE V KE W (internal contact) 5. The electric drive device according to claim 4, wherein, First contact section (U) I V I W I ) and the second contact section (U) II V II W II The plastic portion of the housing insert (8) extends from the end face of the housing insert (8) away from the stator-rotor unit (18, 26) along the longitudinal direction (XX) of the electric drive unit (2).

6. The electric drive device according to claim 1 or 2, wherein, Tooth pairs (SZ1 & SZ2, SZ3 & SZ4...SZ) 11 &SZ 12 The ends of each line (D) A D E The device is guided along the longitudinal direction (XX) of the electric drive unit (2) through the corresponding opening in the housing insert (8) until it exceeds the end face of the housing insert (8) away from the stator-rotor unit (18, 26) and makes electrical contact with the housing insert (8).

7. The electric drive device according to claim 1 or 2, wherein, The contact arrangement structure (22) has three spaced-apart, conductive contact elements (KE). U KE V KE W ), used for the three-phase (U, V, W) power supply of coil (20).

8. The electric drive device according to claim 1 or 2, wherein, It is equipped with twelve stator teeth (SZ1, SZ2...SZ). 11 SZ 12 The twelve stator teeth form a ring-shaped arrangement, with a total of six tooth pairs (SZ1 & SZ2, SZ3 & SZ4...SZ...). 11 &SZ 12 ).

9. The electric drive device according to claim 1 or 2, wherein, The shell (4) is formed by deep drawing of metal sheet.

10. The use of an electric drive device in an electro-hydraulic braking device, said electric drive device being the electric drive device according to any one of claims 1 to 9.

11. A braking device having an electric drive device according to any one of claims 1 to 9.

12. A vehicle having a braking device according to claim 11.

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