Stator contact device, stator and motor

Abstract

The invention relates to a contact device (1) for a stator (2) of an electric machine, wherein the contact device (1) has a contact carrier (4) made of an electrically insulating material, which can be positioned on an upper side facing away from the stator (2), and at least on the upper side facing away from the stator (2), electrically conductive connecting wires (41) for connecting a plurality of coils (3) via coil wires (31), the electrically conductive connecting wires being arranged on the circumference of the stator (2). The contact device (1) also has a through-opening (5), through which the coil wires (31) of the coils (3) can be guided, so that at least one coil wire (31) can be connected to the connecting wire (41). The contact carrier (4) also has a fixing device (6) at the through-opening (5), which is designed so that at least one coil conductor (31) contacts a connecting conductor (41) at a contact surface (7) and the coil conductor (31) exerts a permanent force on the connecting conductor (41) at the contact surface (7) via a force acting perpendicularly to the respective conductor axis, whereby mutually parallel arranged sections of the coil conductor (31) and the connecting conductor (41) are pressed against each other at the common contact surface (7).

Description

Technical Field

[0001] The invention relates to a contact device of a stator of an electric motor, as well as a stator and an electric motor. Background Art

[0002] The electric motor has a three-phase stator, for example as a three-phase motor, and therefore at least three phase conductors or phase windings to which currents are applied in each case with a phase shift in order to generate a rotating magnetic field in which a rotor or armature, which is usually provided with permanent magnets, rotates. The phase ends of the phase windings are led to the motor electronics, so that the electric motor is controlled via the phase connection. The coils are connected to one another in a suitable manner via the coil ends of the phase windings. The manner of interconnecting the coil ends is determined by the winding pattern of the rotating field winding.

[0003] The contact device arranged on the stator end face is usually used to guide and interconnect the coil ends. For example, such a contact device has a wiring ring and a connecting ring which can be sealed thereon, and the coil ends to be interconnected are arranged between the wiring ring and the connecting ring.

[0004] For example, the contact device is designed as a modular component so that different contact devices are placed on the stator depending on the application and the required interconnections have been taken into account in order to connect different winding modes appropriately and flexibly in practice. In particular, in applications where rotating field windings are required to be connected with single or multiple redundancy, such modular contact devices have high space requirements.

[0005] The printed document EP 2 606 558 A1 discloses a contact arrangement in a stator of an electric machine, which has an annular contact carrier made of an electrically insulating material and a plurality of conducting paths for contacting the coils of the stator. The conducting paths are held on the contact carrier via shaped fastening elements.

[0006] Furthermore, a stator of an electric machine with a stator lamination stack is known from the printed document DE 10 2016 224 526 A1. An associated contact device comprises a wiring element arranged on the end face of the stator lamination stack and a connecting element for connecting the coil ends to the connected ones at the stator end face. The coil ends protrude vertically through the through openings in the wiring element and are each guided in a radially angled manner along the guide grooves of the wiring element. At the contact points of the guide grooves, the coil ends are contacted and axially fixed by contact elements coupled to the connecting element in an electrically conductive manner. Each of the guide grooves has a narrow point in the axial direction, which fixes the coil end guided in each case in the guide groove to prevent axial slipping out. Summary of the invention

[0007] The invention is based on the object of developing a contact arrangement for a stator of an electric machine.

[0008] The invention is reproduced by the features of the contact device, the stator and the electric machine defined by the invention.

[0009] The invention comprises a contact device for a stator of an electric machine, wherein the contact device has a contact carrier made of an electrically insulating material, which can be positioned facing away from the stator, and at least on the upper side facing away from the stator, for contacting the electrically conductive connecting wires of a plurality of coils via coil wires, the electrically conductive connecting wires being arranged on the circumference of the stator. The contact device furthermore has a through-opening, through which the coil wires of the coils can be guided, so that at least one coil wire can be connected to a connecting wire. In particular, a respective coil wire can be connected to a respective connecting wire. Furthermore, the contact carrier has a fixing device at the through-opening, which is designed so that at least one coil wire contacts the connecting wire at a contact surface, and the coil wire exerts a permanent force on the connecting wire at this contact surface via a force acting perpendicularly to the respective wire axis. It is thus possible that mutually parallel arrangement sections of the coil wire and the connecting wire, in particular mutually parallel arrangement ends of the coil wire and the connecting wire, are pressed against each other at a common contact surface.

[0010] The contact device according to the invention can preferably be used in the stator of an electric machine, such as a generator or an electric motor. For example, the application field is electric machines in the automotive field, or in general machine construction and in driving technology applications. For example, in servomotors, drive motors or auxiliary devices in vehicles.

[0011] In this case, the invention firstly considers that a contact carrier made of insulating material can be placed on the end face of the stator and connected to the stator housing. The contact carrier thus serves on the one hand to fasten the contact device to the stator and on the other hand to serve as a carrier for the conductive paths of the connecting wires. Due to the design of the contact carrier, the different conductive paths made of electrically insulating material are electrically insulated from one another on the contact carrier. Although the contact carrier is usually already constructed in a very complex manner, in principle, a single annular contact carrier on which the conductive paths of the connecting wires are arranged is also sufficient.

[0012] Via a contact device, the coils in the stator can be electrically connected via coil wires. The contact device comprises a usually annular contact carrier made of an electrically insulating material and a conductive path as a connecting wire for contacting the winding wires of the coils. The conductive path, the winding wires of the coils and the coil wires can have a circular, oval rectangular or even square cross section perpendicular to their wire axis.

[0013] In order to connect the coil wire of the coil to the connecting wire for electrical contacting, it is advantageous if these all have a similar type of rectangular or even square cross section at the connection point. The coil wire and the connecting wire thus contact each other at a flat and maximized contact surface.

[0014] In the region of this contact surface, the coil conductor is connected to the connecting conductor in an electrically conductive and preferably materially bonded manner. A suitable materially bonded connection of the coil conductor and the connecting conductor arranged with one another at the respective ends is, for example, a welded or soldered connection.

[0015] When wiring and connecting conductor ends, a contact carrier made of an electrically insulating material, preferably in a ring-shaped design, is primarily used as a positioning element. For this purpose, the coil conductors are pushed through these through-openings. The through-openings have fixing devices, which hold these connecting conductors at least by friction fit and / or material fit. In other words: the fixing devices are elastically deformable narrow passage points arranged in the through-openings. When the coil conductors are contacted by the connecting conductors of the contact device, for example by plug-in connection or by welding or soldering connection with material fit, the elastic properties of the narrow points lead to retention. In the case of a welded or soldered connection, the retention of the coil conductors has the result that the cable end is already fixed in place before the welding or soldering process, whereby the respective coil conductor and the respective connecting conductor are positioned relatively precisely to each other in order to produce a joined connection.

[0016] The coil wire exerts a permanent force action on the connecting wire at the contact surface and a secure electrical connection can already be produced, possibly without further retaining devices. In order to produce this force action, the contact carrier is equipped with a fixing device at the through-opening, which enables a specific positioning of the two wire ends relative to each other. The wire parts, in particular the wire ends, which are arranged parallel to each other, are therefore pressed against each other at the common contact surface by a force acting perpendicularly to the respective wire axis. This force action is present in particular during the joining process, so that a good electrical contact is produced, and is advantageously also designed so that this force action continues to be maintained after the wire ends have been connected.

[0017] A particular advantage is that simply because the coil conductor and the connecting conductor are pressed together, a reliable and permanent electrical contact is already present which is not affected by strains caused by tensile stresses.

[0018] In a preferred configuration of the invention, the contact carrier may be designed with fixing devices at the through-openings so that these fixing devices block the coil wires at least in one direction relative to axial movement. For assembly purposes, the coil wires of the coils are pushed through the through-openings. The fixing devices are preferably designed so that the coil wires are held by friction fit or material fit, at least opposite to the insertion direction. The insertion direction is the direction from the bottom surface of the contact carrier facing the coil to the upper side where the connecting wires are positioned. In this case, the elastically deformable narrow channel points are formed as fixing devices, which reliably offset the reverse movement of the corresponding wire ends. Before the coil wires are connected to the connecting wires of the contact device, for example by plug-in connection or by welding or soldering connection with material fit, the elastic properties of the narrow points already lead to a fixing effect.

[0019] The fixing device can advantageously be formed by retaining lugs. Thus, a plurality of elastically and / or plastically deformed retaining lugs form narrow spots whose opening width is smaller than the diameter of the coil wire. These narrow the cross section so that the fixing device fixes the corresponding wire end in place in the manner of a clamping mechanism. Due to the elastically or plastically deformable material, the opening width is widened only when the wire end passes through, and thus a retaining force perpendicular to the axial direction of the wire and / or an axial retaining force is generated at the same time. Suitable materials are plastic materials with corresponding elastic or plastic properties. In particular, the retaining lugs can also be made of the same material as the contact carrier.

[0020] In principle, it is also advantageous that a plurality of retaining lugs can be arranged in at least one through opening. In this case, these retaining lugs can be arranged in the channel plane and / or they can also be arranged staggered and / or offset in the axial direction of the channel opening by contacting the carrier. Under the overall influence of the retaining lugs, the retaining lugs are arranged so that they finally exert the permanent force of the coil wire on the connecting wire at the common contact surface. In its entirety, the retaining lugs can also prevent the reverse movement of the corresponding wire end opposite to the insertion direction. For square or rectangular wire cross sections, it is advantageous to start with four retaining lugs on four wire surfaces.

[0021] A force fit caused by static friction is usually formed between the fixing device and the conductor section passing through the through-opening. However, other fixing mechanisms are also conceivable, either alone or in combination with one another.

[0022] Therefore, in an advantageous embodiment of the invention, the retaining lug forms a positive connection with the coil wire. For this purpose, the wire section passing through the through-opening can have a suitable roughness or alternative structure on its surface, which in each case forms a positive fit with the retaining lug. Structurally advantageous are notches, grooves or teeth on the wire surface of the coil wire, in which the retaining lug can engage.

[0023] Alternatively or in combination, in a further advantageous embodiment of the invention, the retaining lug forms a material fit connection with the coil wire. For this purpose, a thermal connection process, such as welding or soldering, can be used. Due to the targeted heat input during the production of the electrical contact, sufficient heat can flow along the coil wire to the fixture for thermally melting or melting the latter and thus forming a stable material fit.

[0024] In a further advantageous embodiment of the invention, the fixing device can be arranged at the output side end of the through-opening in the insertion direction of the coil conductor. In this case, during the installation process, the conductor end is first introduced into the through-opening and is already guided at the output side end in a manner that is sufficiently stable for it to pass through the fixing device.

[0025] The through-opening can advantageously taper conically in the insertion direction of the coil conductor. The conical form of the through-opening leads to a larger opening on the input side, into which the conductor end of the coil conductor can be easily inserted, wherein the conductor end is guided to the output-side end during the installation process via the tapered conical length. In these through-openings, it is advantageous to arrange the fixture directly at the output-side end. The conductor end is thus introduced directly into the fixture.

[0026] A further aspect of the invention comprises a stator of an electric machine having a contact arrangement according to the invention.

[0027] A further aspect of the invention comprises an electric machine with a stator according to the invention.The above-described stator with the contact unit according to the invention may be an independent modular unit of an electric machine. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Exemplary embodiments of the invention are explained in more detail with reference to schematic diagrams, in which:

[0029] Figure 1 It is a prior art, showing a schematic diagram of a motor stator, wherein the contact device is mounted on the end surface.

[0030] Figure 2 shows a detailed view of the contact device in the area of ​​the contact point of the coil conductor and the connecting conductor,

[0031] Figure 3 shows a plan view of a section of the contact device,

[0032] Figure 4 Shown along Figure 3 The cross section of line AA,

[0033] Figure 5 shows a cross section of a segment of the contact device, and

[0034] Figure 6 yes Figure 5 Detailed view of the fixture.

[0035] Reference numerals list

[0036] 1 Contact device

[0037] 2 Stator

[0038] 3 Coils

[0039] 31 Coil wire

[0040] 4 Contact carrier

[0041] 41 Connecting wires

[0042] 5Through opening

[0043] 6 Fixing device

[0044] 61 Retaining lug

[0045] 7 Contact surface

[0046] 8 Output side

[0047] 9 Input side DETAILED DESCRIPTION

[0048] In all the figures, parts that correspond to each other are denoted by the same reference numerals.

[0049] exist Figure 1 In FIG. 4 , a stator 2 is diagrammatically shown with a contact device 1 arranged on an end face. The connecting contacts arranged on the upper side of the contact carrier 4 are assembled in a connector, which is to be connected to the electrical connection. The contact device 1 is Figure 2 Shown in partial detail.

[0050] Figure 2 Schematic detail view of the contact device 1 in the area of ​​the contact point of the coil conductor 31 and the connecting conductor 41 is shown. Figure 2, but are arranged in the direction of the arrows. The coil wire 31 and the connecting wire 41 have a rectangular cross-section that is perpendicular to their respective wire axes. Due to these rectangular cross-sections, the coil wire 31 and the connecting wire 41 contact each other at a common contact surface 7. The end of the coil wire 31 passes through a through opening in the contact carrier 4. A fixing device 6 with a retaining lug 61 is formed at the output side end of the through opening. In this case, there are four elastically deformable retaining lugs 61, each of which abuts against the surface of the rectangular coil wire 31. These retaining lugs 61 narrow the cross-section so that the fixing device 6 acts on the corresponding coil wire 31 in the manner of a clamping mechanism. In this case, the retaining lugs 61 are also made of the same material as the contact carrier 4.

[0051] During the assembly of the coil wires 31, these are pushed through the narrow point determined by the fixing device 6 and thus prestress the retaining lugs 61 as before. This produces a force effect, by which the coil wire 31 exerts a permanent force on the connecting wire 41 at the common contact surface 7. The coil wire 31 and the connecting wire 41 are already connected in an electrically conductive manner due to the contact pressure and are materially connected at least in sections or on the entire common contact surface 7, for example via a welded or soldered connection. For plug-in contact, the contact pressure between the coil wire 31 and the connecting wire 41 can also be used to produce a reliable electrical contact.

[0052] Figure 3 A plan view of a section of the contact device 1 is shown. Figure 4 Shown along Figure 3 The cross section of the line AA of FIG. The coil wire 31 and the connecting wire 41 are in contact with each other at a common contact surface 7. A joining connection can be achieved at this contact surface 7. The end of the coil wire 31 passes through the through-opening 5 in the contact carrier 4. The through-opening 5 has a larger opening width at the input side end 9 than at the output side end 8, and therefore tapers conically in the insertion direction of the coil wire 31. Due to the conical shape of the through-opening 5, the wire end of the coil wire 31 can be more easily introduced through the through-opening 5, wherein, during the installation process, the wire end is guided into the fixture 6 through the tapering tapered length to the output side end 8. The fixture 6 is arranged directly at the output side end 8 together with its retaining lug 61. The wire end of the corresponding coil wire 31 is therefore specifically guided through the fixture 6 until it is positioned on the connecting wire 41.

[0053] Figure 5 A segmented cross section of the contact device 1 is shown. Figure 6 Shows Figure 5Detailed view of the fixing device 6 of FIG. The retaining lugs 61 of the fixing device 6 arranged at the output-side end 8 are elastically deformed and pretensioned in the insertion direction by the pushed-in coil wire 31. These upwardly bent retaining lugs 61 counteract the reverse movement of the corresponding wire end of the coil wire 31. The elastic properties of the pinch point already lead to a fixing effect before the associated connecting wire 41 is materially connected to the coil wire 31 by a welding or soldering connection.

Claims

1. A contact device (1) for a stator (2) of an electric machine, wherein: The contact device (1) comprises a contact carrier (4) made of an electrically insulating material, which can be positioned on an upper side facing away from the stator (2), and at least on the upper side facing away from the stator (2), electrically conductive connecting wires (41) for contacting a plurality of coils (3) via coil wires (31), the electrically conductive connecting wires being arranged on the circumference of the stator (2), The contact device (1) further comprises a through opening (5), through which the coil wire (31) of the coil (3) can be guided so that at least one coil wire (31) can be connected to a connecting wire (41), each through opening (5) having an output side end (8), the output side end (8) facing the connecting wire (41), characterized in that the contact carrier (4) has a fixing device (6) at the output side end (8) of the through opening (5), wherein at the output side end (8) of the through opening (5), each fixing device (6) is an elastic member arranged in the through opening. The invention relates to a deformation narrow passage point, wherein the fixing device (6) is formed by a retaining lug (61), and the fixing device is designed so that when the wire is pushed through the narrow passage point, at least one retaining lug (61) is subjected to pretension, whereby at least one coil wire (31) contacts the connecting wire (41) at a contact surface (7), and the coil wire (31) exerts a permanent force on the connecting wire (41) at the contact surface (7) via a force acting perpendicularly to the corresponding wire axis, whereby the mutually parallel arranged parts of the coil wire (31) and the connecting wire (41) are pressed together at the common contact surface (7).

2. The contact device (1) according to claim 1, characterized in that The fixing means (6) are designed such that they block the coil wire (31) with respect to axial movement in at least one direction.

3. The contact device (1) according to claim 1, characterized in that A plurality of retaining lugs (61) are arranged in at least one through-opening (5).

4. The contact device (1) according to any one of claims 1 to 3, characterized in that The retaining lug (61) forms a positive connection with the coil conductor (31).

5. The contact device (1) according to any one of claims 1 to 3, characterized in that The retaining lug (61) forms a material-fitting connection with the coil conductor (31).

6. The contact device (1) according to claim 5, characterized in that The through opening (5) tapers in a conical shape along the insertion direction of the coil conductor (31).

7. A stator (2) of an electric machine, comprising a contact device (1) according to any one of claims 1 to 6.

8. An electric machine comprising a stator (2) according to claim 7.

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