Stator for electric motor

Abstract

The invention relates to a stator (1) for an electric motor, comprising: a stator base body (2) having radially inwardly directed stator teeth (9) and stator windings (11) arranged on the stator teeth; an insulating ring (4) arranged on an end face (3) of the stator base body (2); and a contact adapter (5) which can be fitted onto the insulating ring and which has a contact element (7) for connecting a winding end (12) of the contact stator winding (11), the contact adapter (5) having an engagement opening (14) and the insulating ring (4) having a tongue pair corresponding to the engagement opening, the tongue pair having a centering tongue (15) and a parallel spring tongue (16), the spring tongue, together with the centering tongue (15), is accommodated in the engagement opening (14) of the contact adapter (5) in the engaged state of the contact adapter (5).

Description

Technical Field

[0001] The invention relates to a stator for an electric motor, the stator comprising: a stator base body with a stator winding arranged on radially inwardly directed stator teeth; an insulating ring arranged on the end side of the stator base body; and a contact adapter with a plug slot for a contact element for connecting and contacting a winding end of the stator winding. The invention also relates to an electric motor having such a stator. Background Art

[0002] An electric motor, in particular a brushless electric motor, as an alternating current motor has a stator having a stator base body, for example, in the form of a stator laminated core, with a number of stator teeth, for example arranged in a star shape, which carry a rotating field winding in the form of individual stator coils, which in turn are wound from insulated wires. The coils are assigned with their coil ends to the individual branches or phases and are interconnected with one another in a predetermined manner by means of contact elements.

[0003] In the case of a brushless electric motor as a three-phase AC motor, the stator assembly has three phases and therefore at least three phase conductors or phase windings, which are each charged with current in a phase-staggered manner in order to generate a rotating magnetic field, in which a rotor, which is usually provided with permanent magnets, rotates about an axis of rotation, which also represents the central (stator) axis. The phase ends of the phase windings are led to the motor electronics for controlling the electric motor. The coils of the rotating field winding are interconnected with each other or with the aid of the phase ends in a specific manner. The type of interconnection is determined by the winding scheme of the rotating field winding, wherein star connection or delta connection of the phase windings is common as a winding scheme.

[0004] An insulating ring is mounted on the end side of the stator base body. An insulating ring can also be arranged at the axially opposite end side of the stator base body. The insulating ring has, for example, cap-shaped, insulating coil bodies or winding bodies corresponding to the number of stator teeth, which surround the respective stator teeth, especially while exposing the tooth surface on the pole shoe side. The coil body has, for example, groove-shaped recesses or wire grooves for guiding the winding wire and / or side walls for preventing the wound coil from loosening from the stator teeth (radially). For example, only a specific axial section of the respective winding body can be formed on the respective insulating ring, and this section complements the corresponding section of another insulating ring leading to the winding body.

[0005] Typically, at least one of the insulating rings comprises a so-called tip, which protrudes axially from the stator base body as a segmented, annular wall. The tip enables the winding wire or coil wire to be guided circumferentially behind the stator teeth from stator tooth to stator tooth during the winding process, so that the winding wire does not collide with the winding tool.

[0006] The contacting of the wire ends or phase ends during the interconnection of the rotating field windings can be carried out by means of insulation piercing contacts as contact elements. These contact elements can be accommodated in the plug-in slots of an annular contact adapter and simultaneously make insulation piercing contact, the contact adapter being placed onto an insulating ring guiding the winding wire or coil wire and in particular surrounding the insulating ring on three sides. The insulation piercing contacts can be used, for example, to contact a conductor rail-shaped connecting contact as a phase connection and make it electrically conductive to the motor electronics.

[0007] The problem here is often that the centering or orientation of the contact adapter is not sufficient. The centering or orientation of the contact adapter is particularly important in order to position the connection contact as accurately as possible for its contact with the phase connection. Centering pins on the insulating ring are conceivable in order to orient the contact adapter as reliably as possible when it is engaged with the insulating ring.

[0008] However, establishing the required positioning tolerances of these centering pins is undesirably complex, wherein tolerances of the individual centering pins can lead to undesired play of the contact adapter at the (mechanical) interface with the insulating ring and thus to higher positioning tolerances of the connecting contacts. Summary of the invention

[0009] The object of the present invention is to describe a particularly suitable stator for an electric motor. In particular, reliable centering of the contact adapter and / or compensation of existing tolerances should be possible at the interface between the contact adapter and the end-side insulating ring of the stator. In addition, an electric motor having such a stator should be described.

[0010] The stated object is achieved with respect to the stator by means of the features of claim 1 and with respect to the electric motor by means of the features of claim 11. Advantageous embodiments and developments of the invention are the subject matter of the dependent claims.

[0011] The stator of an electric motor for an electric drive, in particular as a component or regulating element of a motor vehicle, comprises a stator base body and an insulating ring arranged on the end side of the stator base body or mounted on the stator base body at the end side, and a contact adapter mounted or mounted on the insulating ring, the contact adapter having a certain number of axially oriented plug slots for contact elements. The stator base body has a certain number of stator teeth, which point radially inwardly to a central axis, which in turn represents the axis of rotation of the rotor and thus of the electric motor. Coils of a stator winding or a rotating field winding are arranged on the stator teeth. Contact elements, which are embodied as insulation piercing contacts in a suitable manner, are provided and designed for connecting and contacting winding ends of the stator winding.

[0012] The contact adapter has at least one, preferably only one, engagement opening, with which the axially oriented tongue pair of the insulating ring preferably corresponds and / or is aligned. The engagement opening extends tangentially or azimuthally, i.e., in the circumferential direction of the contact adapter, also referred to below as the stator or the stator base body of the stator, and is locally limited. The engagement opening is arranged in a suitable manner in the region of a boundary edge or transition edge between an annular base plate or chassis of the contact adapter and a preferably circumferential edge web formed on the base plate, which at least partially axially covers the insulating ring on the circumferential side. For example, the azimuth extension or arc length of the engagement opening is in the order of 1 / 30 of the (circular) circumference of the contact adapter.

[0013] The insulating ring has an axial centering tongue corresponding to the engagement opening of the contact adapter, in particular aligned with the engagement opening, and an axial spring tongue parallel to the centering tongue, which is received together with the centering tongue in the engagement state of the contact adapter in the engagement opening of the contact adapter or passes through the engagement opening. Preferably, the tongue width of the centering tongue, also referred to below as the centering pin, in the circumferential direction of the insulating ring is in particular 2 to 3 times greater than the tongue width of the spring tongue, also referred to below as the spring pin. Due to the tongue width of the centering tongue, in particular compared to the spring tongue, the centering tongue is particularly stable in an appropriate manner.

[0014] In an advantageous embodiment, the centering tongue of the insulating ring has an axially extending positioning edge and an entry edge adjoining the positioning edge in the axial direction and at an inclined angle to the spring tongue.

[0015] The inclination angle of the positioning edge relative to the axial extension is expediently between 30° and 60°, preferably (45±5)°.

[0016] Preferably, only the positioning edges of the centering tongues or centering pins on the insulating ring have exact tolerances, wherein the contact adapter is oriented in a suitable manner on this positioning edge when the contact adapter is placed or pressed onto the insulating ring. Expediently, the contact adapter has a number of axially extending engagement tongues which, in the state engaged with the insulating ring or during the process of pressing the contact adapter onto the insulating ring, latch with engagement elements arranged on the insulating ring, in particular radially oriented ones.

[0017] In an advantageous embodiment, the spring tongue (spring pin) of the insulating ring has an axially extending engagement edge and a sliding edge connected to the engagement edge in the axial direction and inclined at an angle of attack relative to the centering tongue. In a suitable manner, the angle of attack relative to the axially extending engagement edge is between 50° and 70°, preferably (60±5)°.

[0018] Advantageously, a free space is formed between the centering tongue of the insulating ring and the spring tongue, into which the spring tongue springs or can spring when introduced into the engagement opening of the contact adapter. It is particularly advantageous if the spacing between the centering tongue of the insulating ring and the spring tongue is smaller than the tongue width of the centering tongue. Additionally or alternatively, the spacing between the centering tongue of the insulating ring and the spring tongue is greater than or equal to the tongue width of the spring tongue. Additionally or alternatively, the axial tongue length of the centering tongue is at least slightly greater than the axial tongue length of the spring tongue of the insulating ring.

[0019] The spring tongues of the insulating ring bring about the necessary tolerance compensation on the one hand and eliminate all play from the interface between the contact adapter and the insulating ring on the other hand. As a result, the positioning tolerances of the connection contacts can be significantly reduced. In addition, the component costs are reduced and the positioning tolerances of the connection contacts are increased. It is particularly advantageous if the centering tongues of the insulating ring center the contact adapter in its given position in the following manner or during the following period, i.e., the centering tongues on the insulating ring side penetrate into the engagement opening on the contact adapter side. The spring tongues of the insulating ring, which preferably lag behind the centering tongues, can be deflected toward the centering tongues by spring elasticity when penetrating into the engagement opening of the contact adapter due to their lower stability compared to the centering tongues. As a result, manufacturing tolerances, in particular manufacturing tolerances of the centering tongues of the insulating ring and / or the spring tongues and / or the engagement opening of the contact adapter, are reliably compensated. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The embodiments of the present invention are explained in detail below with reference to the accompanying drawings.

[0021] Figure 1 A perspective view of a stator is shown, which has a wound stator base body and a contact adapter with an insulation piercing contact in a plug slot and a tongue pair (centering tongue and spring tongue) of a joining opening and an insulating ring received in the joining opening;

[0022] Figure 2 An exploded view of a portion of a stator is shown, in which the contact adapter is located above the insulating ring, in which the engagement opening on the adapter side and the tongue pair on the insulating ring side formed by the centering tongue and the spring tongue can be seen;

[0023] Figure 3 A perspective view of a stator base body is shown, wherein a contact adapter is placed onto an insulating ring;

[0024] Figure 4a and Figure 4b Along Figure 3 The sectional view along the line IV-IV in FIG. 1 shows the tongue pair of the insulating ring when entering the engagement opening or when being placed in the engagement opening of the contact adapter;

[0025] Figure 5a to Figure 5d The tongue pair on the insulating ring side is shown in the following positioning: entry positioning of the centering tongue into the engagement opening on the adapter side, abutment positioning of the centering tongue at the opening edge of the engagement opening, abutment positioning of the spring tongue at another opening edge of the engagement opening, or the spring tongue is ejected into the engagement opening of the contact adapter.

[0026] In all figures, corresponding parts and dimensions are provided with the same reference symbols. DETAILED DESCRIPTION

[0027] Figure 1 A stator 1, also referred to below as a stator subassembly, is shown, which is provided for an electric motor of an electric drive, in particular as a subassembly or adjusting element of a motor vehicle. The stator or stator subassembly 1 has a stator base body 2 and an insulating ring 4 arranged on or placed on an end face 3 of the stator base body, and a contact adapter 5 placed on the insulating ring 4, the contact adapter 5 having a number (four in the exemplary embodiment) of plug slots 6 for contact elements 7 oriented in the axial direction A. A further insulating ring 8 is arranged on the stator base body 2 on the opposite end face.

[0028] The central axis D of the stator 1 shown is also the rotation axis of the rotor (not shown), which is designed, for example, as a rotor lamination stack in which permanent magnets are accommodated. In the case of an electric motor designed as an inner rotor, the rotor is accommodated in a cylindrical space surrounded by the stator base body 2 and the contact adapter 5 and the insulating ring 4, with the formation of a gap.

[0029] The stator base body 2 has a number of stator teeth 9 pointing inwards in a radial direction R toward a central axis D. Coils 10 of a stator winding or rotating field winding 11 are arranged on the stator teeth 9. Contact elements 7 designed as insulation piercing contacts are provided for contacting winding ends or coil ends 12 of the stator winding 11. It can be seen that the individual winding ends 12 are guided along the outer circumference of the insulating ring 4 in the circumferential direction U of the stator base body 2 and are guided at corresponding positions via recesses 13 of the contact adapter 5 on the upper side of the contact adapter to the plug slot 6 in order to make contact there with the contact elements 7, preferably using insulation piercing technology. Three or, in the exemplary embodiment, four phase connections of the motor electronics are contacted by means of the contact elements 7 in a manner and method not shown in detail (clamping) in order to selectively energize the stator winding 11 in terms of phases.

[0030] The contact adapter 5 has a joint opening 14, to which the axially oriented tongue pairs 15, 16 of the insulating ring 4 correspond. The joint opening 14 extends in the peripheral direction U of the contact adapter 5 and is locally limited. The joint opening 14 is arranged in the region of a transition edge 17 between the annular base plate 5a of the contact adapter 5 and a surrounding edge web 5b of the contact adapter 5 formed on the base plate 5a. The edge web 5b and the base plate 5a and preferably the further radially inner edge web 5c cover the insulating ring 4 at least partially on three sides in the axial direction A. The length of the joint opening 14 on the peripheral side is, for example, 1 / 30 of the (circular) circumference of the contact adapter 5.

[0031] As combined Figure 2 and Figure 3 It can be seen that the contact adapter 5 has a number of axially extending engagement tongues 18 which are spaced apart in the circumferential direction U. When the contact adapter 5 is fitted or pressed onto the insulating ring 4, these engagement tongues latch with corresponding engagement elements or latching elements 19 of the insulating ring 4 to produce a releasable engagement connection, for example.

[0032] Figure 4a and Figure 4b The partial section of the joint opening 14 of the contact adapter 5 shows the tongue pair 15, 16 when entering the joint opening 14 of the contact adapter 5 from the underside or rear side of the annular base plate 5a of the contact adapter or in the final position. In this final position, the lateral shoulder sections 20 of the tongue pair 15, 16 abut against the joint opening 14 at the opening edge or plate section 21 of the contact adapter 5 located on both sides of the narrow side of the joint opening.

[0033] The insulating ring 4 has an axial centering tongue 15, which is also referred to as a centering pin in the following text, and an axial spring tongue 16, which is also referred to as a spring pin in the following text and is parallel to the centering tongue. They form a tongue pair 15, 16. It is also possible to provide more than one (for example, two) centering tongues 15 and / or more than one (for example, two) spring tongues 16. In the engaged state of the contact adapter 5 and the insulating ring 4, the spring tongue 16 is connected together with the centering tongue 15 or behind the centering tongue 15 ( Figure 5b ) through the engagement opening 14 of the contact adapter 5. Here, the centering tongue 15 orients the contact adapter 5 into a predetermined position of the contact adapter.

[0034] The spring tongue 16 is used on the one hand to compensate for (manufacturing) tolerances. In addition, the spring tongue 16 can also eliminate existing mechanical play of the (mechanical) interface between the contact adapter 5 and the insulating ring 4. For this purpose, the spring tongue 16 is retracted or deflected into the free space 22. The free space 22 is provided on the basis of the (azimuthal) spacing provided between the centering tongue 15 and the spring tongue 16 in the peripheral direction U and is provided for this purpose in the axial direction A extending parallel to the centering tongue 15.

[0035] Figure 5a to Figure 5d The (mechanical) interface between the insulating ring 4 and the contact adapter 5 is shown in the region of the joining opening 14 and thus of the tongue pairs 15 , 16 corresponding thereto.

[0036] The centering tongue 15 of the insulating ring 4 has an axially extending positioning edge 15a and an entry edge 15b connected to the positioning edge in the axial direction A and inclined or at an angle of attack in the direction of the spring tongue 16. In the present embodiment, the inclination angle α relative to the axial extension of the positioning edge 15a is about 45°.

[0037] like Figure 5a As shown, when the contact adapter 5 is put on the insulating ring 4, the opening edge 14a of the engagement opening 14 contacts the corresponding entry edge 15b of the centering tongue 15, and slides along the entry edge 15b of the centering tongue 15 in the direction of the arrow shown when the contact adapter 5 is further put on or pressed onto the insulating ring 4. In this case, the engagement opening 14 and thus the contact adapter 5 are automatically oriented at the centering tongue 15 in the direction of the intended positioning of the contact adapter 5 relative to the insulating ring 4 and thus relative to the stator base body 2.

[0038] like Figure 5b It can be seen that when the contact adapter 5 is further pressed onto the insulating ring 4 , the contact adapter 5 is subsequently aligned at the positioning edge 15 a of the centering tongue 15 , which has a tolerance that is as exact or precise as possible on or at the insulating ring 4 in a suitable manner.

[0039] Figure 5c and Figure 5d It can also be seen that the spring tongue 16 of the insulating ring 4 has an axially extending engagement edge 16a and a sliding edge 16b connected to the engagement edge in the axial direction A and inclined at an angle of attack ß relative to the centering tongue 15. The angle of attack ß relative to the axial extension of the engagement edge 16a is approximately 60°. In the present embodiment, the axial tongue length L2 of the spring tongue 16 is less than the axial tongue length L1 of the centering tongue 15.

[0040] like Figure 5c and Figure 5dAs shown, when the contact adapter 5 is pressed onto the insulating ring 4, the spring tongue 16 first slides with its sliding edge 16b along the corresponding opening edge 14b of the joining opening 14. If it is necessary to compensate for tolerances or eliminate play at the mechanical interface, the spring tongue 16 springs into the free space 22 provided between it and the centering tongue 15. The spacing or clear width a between the centering tongue 15 and the spring tongue 16 of the insulating ring 4, which forms the free space 22, is smaller than the tongue width b1 of the centering tongue 15.

[0041] In this embodiment, the spacing a between the centering tongue 15 and the spring tongue 16 of the insulating ring 4 is greater than the tongue width b2 of the spring tongue 16. The tongue width b1 of the centering tongue 15, viewed in the peripheral direction U of the insulating ring 4, is in particular two (2) to three (3) times greater than the tongue width b2 of the spring tongue 16. The centering tongue 15 is thus designed to be more stable than the spring tongue 16, which is moreover sufficiently elastic to be deflected, in particular, into the free space 22 when the contact adapter 5 is joined to the insulating ring 4.

[0042] In summary, the invention relates to a stator or a stator assembly 1 for an electric motor, the stator comprising: a stator base body 2 with stator teeth 9 and stator windings 11 arranged on the stator teeth; an insulating ring 4 arranged on the stator base body 2 at the end; and a contact adapter 5 which can be put on or pressed onto the insulating ring, the contact adapter having a joining opening 14, wherein the insulating ring 4 has a pair of tongues 15, 16 corresponding to the joining opening 14, and when the contact adapter 5 is put on the insulating ring 4, the pair of tongues is received in the joining opening 14 of the contact adapter 5 or passes through the joining opening 14 in the joined state of the contact adapter 5. In this case, the centering tongues 15 of the insulating ring 4 center the contact adapter 5 in its intended position, while the centering tongues 15 on the insulating ring side penetrate into the joining opening 16 on the contact adapter side.

[0043] The spring tongue 16 of the insulating ring 4, which preferably lags behind the centering tongue 15, can bounce towards the centering tongue 15 when penetrating into the engagement opening 14 of the contact adapter 5 due to its lower stability compared to the centering tongue 15, so as to reliably compensate for manufacturing tolerances, in particular manufacturing tolerances of the centering tongue 15 of the insulating ring 4 and / or the spring tongue 16 and / or the engagement opening 14 of the contact adapter 5.

[0044] The present invention is not limited to the above-described embodiments. On the contrary, those skilled in the art can also derive other variants of the present invention from this without departing from the subject matter of the present invention. In addition, in particular, all the individual features described in conjunction with the embodiments can also be combined with each other in other ways without departing from the subject matter of the present invention.

[0045] Reference numerals list

[0046] 1. Stator / Stator structure components

[0047] 2. Stator base

[0048] 3. End side

[0049] 4 Insulation ring

[0050] 5-contact adapter

[0051] 5a base plate

[0052] 5b, 5c edge tabs

[0053] 6 Plug slots

[0054] 7Contact element / insulation piercing contact

[0055] 8 Insulation ring

[0056] 9 stator teeth

[0057] 10 coils

[0058] 11 Stator winding / rotating field winding

[0059] 12 Winding end / coil end

[0060] 13 recesses

[0061] 14Joint opening

[0062] 14a, 14b opening edge

[0063] 15 Centering tongue

[0064] 15a Positioning edge

[0065] 15b Entering edge

[0066] 16 Spring tongue

[0067] 16a Joining edge

[0068] 16b sliding edge

[0069] 17 Transition edge

[0070] 18 Engagement tongue

[0071] 19 Engagement element / locking element

[0072] 20 Shoulder section

[0073] 21 Plate section / opening edge

[0074] 22 Free Space

[0075] A Axial direction

[0076] D (rotation) axis

[0077] L1, L2 tongue length

[0078] R radial direction

[0079] U Peripheral direction

[0080] a Spacing / Clear Width

[0081] b1, b2 tongue width

[0082] α Tilt angle

[0083] ß Angle of attack

Claims

1. A stator (1) for an electric motor, the stator having - a stator base body (2) having stator teeth (9) pointing radially inwards towards a central axis (D), the stator teeth having stator windings (11) arranged on the stator teeth, - an insulating ring (4) arranged on the end side (3) of the stator base body (2), and - a contact adapter (5) which is or can be placed onto the insulating ring (4), the contact adapter having a number of axially oriented plug-in slots (6) for contact elements (7), in particular insulation piercing contacts, which are used for connecting and contacting the winding ends (12) of the stator winding (11), - in, The contact adapter (5) has a tangentially or azimuthally extending engagement opening (14), - wherein the insulating ring (4) has at least one axial centering tongue (15) corresponding to the engagement opening (14) of the contact adapter (5) and an axial spring tongue (16) parallel to the centering tongue, wherein the spring tongue is received in the engagement opening (14) of the contact adapter (5) together with the centering tongue (15) in the engagement state of the contact adapter (5).

2. The stator (1) according to claim 1, It is characterized in that The engagement opening (14) is arranged in the region of a transition edge (17) between an annular base plate (5a) of the contact adapter (5) and an axial or axially extending edge web (5b) formed onto the base plate (5a), the edge web at least partially covering the insulating ring (4) on the circumferential side.

3. The stator (1) according to claim 1 or 2, It is characterized in that The contact adapter (5) has a number of axially extending engagement tongues (18) which, in the engaged state, latch with, in particular radially oriented engagement elements (19) of the insulating ring (4).

4. The stator (1) according to any one of claims 1 to 3, It is characterized in that A free space (22) is formed between the centering tongue (15) and the spring tongue (16) of the insulating ring (4), into which the spring tongue (16) springs when introduced into the engagement opening (14) of the contact adapter (5).

5. The stator (1) according to any one of claims 1 to 4, It is characterized in that The centering tongue (15) of the insulating ring (4) has an axially extending positioning edge (15a) and an entry edge (15b) connected to the positioning edge in the axial direction (A) and forming an inclined angle (α) relative to the spring tongue (13).

6. The stator (1) according to claim 5, It is characterized in that The inclination angle (α) of the positioning edge (15a) relative to the axial extension is between 30° and 60°, preferably (45±5)°.

7. The stator (1) according to any one of claims 1 to 6, It is characterized in that The spring tongue (16) of the insulating ring (4) has an axially extending engagement edge (16a) and a sliding edge (16b) connected to the engagement edge in the axial direction (A) and inclined at an attack angle (ß) relative to the centering tongue (15).

8. The stator (1) according to claim 7, It is characterized in that The angle of attack (ß) of the axially extending joining edge (16a) is between 50° and 70°, preferably (60±5)°.

9. The stator (1) according to any one of claims 1 to 8, It is characterized in that - the tongue width (b1) of the centering tongue (15) in the peripheral direction (U) of the insulating ring (4) is in particular 2 to 3 times greater than the tongue width (b2) of the spring tongue (16), and / or - The centering tongue (15) of the insulating ring (4) guides the contact adapter into its given position when penetrating into the engagement opening (14) of the contact adapter (2), and the spring tongue (16) of the insulating ring (4) which preferably lags behind the centering tongue (15) when penetrating into the engagement opening (14) of the contact adapter (5) springs toward the centering tongue (15) in order to compensate for manufacturing tolerances, in particular manufacturing tolerances of the centering tongue (15) and / or the spring tongue (16) of the insulating ring (4) and / or the engagement opening (14) of the contact adapter (5).

10. The stator (1) according to any one of claims 1 to 9, It is characterized in that - the distance (a) between the centering tongue (15) and the spring tongue (16) of the insulating ring (4) is smaller than the tongue width (b1) of the centering tongue (15), and / or - the distance (a) between the centering tongue (15) and the spring tongue (16) of the insulating ring (4) is greater than or equal to the tongue width (b2) of the spring tongue (16), and / or - The axial tongue length (L1) of the centering tongue (15) is at least slightly greater than the axial tongue length (L2) of the spring tongue (16) of the insulating ring (4).

11. An electric motor having a stator (1) according to any one of claims 1 to 10.

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