Connector for electrically connecting electric motor and inverter and device comprising electric motor and inverter

Abstract

A connector (1) for electrically connecting an electric motor (15) and an inverter (14) comprises a plurality of conductors (2) wherein each conductor (2) is assigned to one phase of the electric motor (15) wherein the conductor (2) is S-shaped wherein one end section (3) of the conductor (2) is connectable to the inverter (14) and the other end section (4) of the conductor (2) is connectable to the electric motor (15). Furthermore, an arrangement is proposed, comprising an electric motor (15) and an inverter (14) electrically connected by a connector (1).

Description

Technical Field

[0001] The invention relates to a connector for electrically connecting an electric motor and an inverter, comprising a plurality of conductors, wherein each conductor is assigned to one phase of the electric motor. Background Art

[0002] Electric machines are increasingly used in electric and hybrid vehicles, primarily as electric motors that drive the wheels or axles.

[0003] Such electric motors are usually mechanically coupled to a gearbox for speed regulation. In addition, the electric motor is usually electrically coupled to an inverter, which generates an AC voltage from a DC voltage provided by a battery to operate the electric motor.

[0004] Traditionally, the motor and inverter are connected via busbars, where each phase of the electric motor requires a separate busbar. The busbars are typically made of copper, which is a relatively expensive material. Summary of the invention

[0005] The invention is therefore based on the problem of providing a connection between a motor and an inverter with a reduced copper requirement.

[0006] This problem is solved by a connector having the features of claim 1 .

[0007] According to the present invention, there is provided a connector having an S-shaped conductor, wherein one end section of the conductor is connectable to an inverter and the other end section of the conductor is connectable to an electric motor.

[0008] The invention has the advantage that no intermediate, separate or additional busbars are required. Instead, the motor and inverter are directly connected via the connection system of the invention, thereby reducing the amount of copper required and making the arrangement of the motor and inverter more compact compared to conventional designs.

[0009] Preferably, the S-shaped conductor comprises four or five bent sections, wherein the bending angle between two adjacent sections is at least approximately a right angle. An advantage of using an S-shaped conductor is that the required space is minimal.

[0010] The installation of the connector of the present invention is further simplified when the end section of each conductor extends through a bracket in which the conductors are arranged spaced apart from each other. By using this bracket, it is ensured that each conductor is kept in the correct position.

[0011] Preferably, the support is made by encapsulating the conductors with a plastic material, which electrically insulates the conductors from each other.

[0012] In a preferred embodiment of the connector of the present invention, the bracket includes a seal for each conductor. The seal prevents waste / fluid and air from intruding into the inverter. The seal is configured to cover the hole formed by the bracket and for the conductor to be inserted.

[0013] The fastening means, in particular a thread or a nut, is preferably provided on the inverter-side end section of the conductor.The thread of the nut can be used to connect the connector to the busbar by using a screw.

[0014] Preferably, the end section of the connector on the motor side has a fork shape, wherein an inclined central section is arranged between two outer fork sections. The fork shape of the end section allows the end section of the connector to be connected to a flat wire of the electric motor by welding.

[0015] According to an embodiment of the invention, the conductor has an end section on the inverter side of the conductor and an end section on the electric motor side of the conductor, the end section on the inverter side includes a fastening device, the end section on the electric motor side includes an inclined central section, the bracket forms a plate extending in a first plane, the fastening device and the inclined central section are located only on one side of the first plane. In one example, the fastening device can be a thread or a nut. The thread of the nut can be used to connect the connector to the busbar by using a screw.

[0016] According to an embodiment of the present invention, the conductor has an end section on the inverter side of the conductor and an end section on the motor side of the conductor, the end section on the inverter side includes a fastening device, the end section on the motor side includes an inclined central section, the bracket forms a plate extending in a first plane, the fastening device and the inclined central section are respectively located in a second plane and a third plane, the second plane and the third plane are parallel to each other and are positioned perpendicular to the first plane. In one example, the fastening device can be a thread or a nut. The thread of the nut can be used to connect the connector to the busbar by using a screw.

[0017] According to an embodiment of the present invention, the conductor has an end section on the inverter side of the conductor and an end section on the motor side of the conductor, the end section on the inverter side includes a fastening device, the end section on the motor side includes an inclined central section, the bracket forms a plate extending in a first plane, the fastening device is located on one side of the first plane, and the inclined central section is located on the other opposite side of the first plane. The fastening device and the inclined central section are respectively located in a second plane and a third plane, which are parallel to each other and are positioned perpendicular to the first plane. In one example, the fastening device can be a thread or a nut. The thread of the nut can be used to connect the connector to the busbar by using a screw.

[0018] The invention also relates to a device comprising an electric motor and an inverter electrically connected via the connector of the invention.

[0019] By means of the connector of the present invention, the electric motor and the inverter are directly connected without an intermediate bus bar, so that the amount of copper required is reduced compared to conventional connections between the electric motor and the inverter.

[0020] Preferably, the inverter-side end section of the conductor is connected to the inverter by means of a screw connection and / or the electric motor-side end section of the conductor is welded to a flat wire of the electric motor.

[0021] According to the present invention, the motor and the inverter can be accommodated in the center housing, wherein the connector closes and seals the opening of the center housing. In this case, the center housing does not need an additional cover.

[0022] According to an embodiment of the invention, in the assembled state, there is an additional sealing material between the bracket and the seal, and another additional sealing material between the seal and the conductor. Between the bracket and the seal, the additional material is located near the hole. This additional sealing material can be solid or liquid and can also prevent waste such as oil or cooling fluid from the electric motor from entering the inverter through the connector.

[0023] According to a preferred embodiment of the device according to the invention, at least a part of the connector is impregnated by immersion in a coating bath. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The present invention will be explained by preferred examples with reference to the accompanying drawings. The accompanying drawings are schematic diagrams and show:

[0025] Figure 1 is a perspective view of a connector of the present invention having a seal;

[0026] Figure 2 yes Figure 1 Another perspective view of the connector in FIG.

[0027] Figure 3 yes Figure 1 A side view of the connector in FIG.

[0028] Figure 4 is another view of the connector; and

[0029] Figure 5 It is a detail of a device comprising an electric motor and an inverter. DETAILED DESCRIPTION

[0030] Figures 1 to 4 Different views of a connector 1 are shown, the connector being configured to electrically connect an electric motor and an inverter. In this embodiment, the connector 1 comprises three conductors 2, whereby each conductor 2 is assigned to a phase of the electric motor.

[0031] One end section 3 of the S-shaped conductor 2 may be connected to an inverter, and the other end section 4 of the conductor 2 may be connected to an electric motor.

[0032] Figure 3 is a side view of the connector 1, showing that the conductors 2 are S-shaped and arranged in parallel. Each conductor 2 comprises five bent portions, wherein the bending angle between two adjacent portions is at least approximately a right angle.

[0033] The support 5 serves to fix all three conductors 2. Each end section 3 of a conductor 2 on the inverter side extends through a hole 6 in the support 5. In the support 5, the conductors 2 are arranged at a distance from one another.

[0034] The bracket 5 is made by encapsulating the conductors 2 with a plastic material. On the inverter side of the bracket 5, each conductor 2 is surrounded by a seal 7. The seal 7 prevents waste materials such as oil or cooling fluid from the electric motor from entering the inverter through the connector 1.

[0035] The seal 7 is also configured to cover the hole 6. Additional sealing material (not shown) may be added between the bracket 5 and the seal 7. This additional sealing material may be solid or liquid (not shown) and may also prevent waste materials such as oil or cooling fluid from the electric motor from entering the inverter through the connector 1.

[0036] Other additional sealing materials (not shown) may also be added between the seal 7 and the conductor 2 to prevent waste from the electric motor from entering the inverter.

[0037] Opposite to the seal 7 , the bracket 5 comprises a recess 8 having a circular hole, so that the bracket 5 can be mounted on the housing by screws.

[0038] The end section 3 of the conductor 2 on the inverter side is provided with a fastening means in the form of a nut 9, which is attached to the underside of the end section 3. The nut 9 can be welded or assembled to the end section 3, for example by press fitting. The nut 9 can be used to screw the conductor 2 together with the HV AC busbar of the inverter.

[0039] like Figure 1 It can be seen that the end section 4 of the conductor 2 on the electric motor side has a fork shape, wherein an inclined central section 10 is arranged between two outer fork parts 11, 12. This special shape of the end section 4 facilitates the positioning of the connector 1 relative to the flat wire of the electric motor, to which the end section 4 can be welded.

[0040] The connector 1 provides a compact interface between the electric motor and the inverter, and can be pre-assembled and then welded to the flat wires of the stator of the electric motor. The connector 1 can be attached to the drive end side as well as the non-drive end side of the electric motor. Compared with traditional designs, costs can be saved because the busbars are shorter and less copper is required.

[0041] Figure 5 Details of an arrangement comprising an electric motor and an inverter are shown. The connector 1 is arranged in a central housing 13 in which an inverter 14 and an electric motor 15 are accommodated. The electric motor 15 comprises a rotor surrounded by a stator with stator windings and a flat wire 16. In the mounted state, the end sections 4 of the conductors 2 are welded to the flat wire 16. Figure 5 The other end of the conductor 2, which is not visible, is connected to the inverter 14 via a screw.

[0042] Due to the compact shape of the connector 1 , the impregnation and immersion process of the electric motor 15 can be performed when the connector 1 is welded to the stator.

[0043] according to Figure 1 , Figure 2 , Figure 3 and Figure 4 In the embodiment disclosed in the invention, the support 5 forms a plate extending in the first plane. The nut 9 and the inclined central section 10 are located only on one side of the first plane ( Figure 3 ). In addition, the nut 9 and the inclined central section 10 are located in a second plane and a third plane, respectively. The second plane and the third plane are parallel to each other and are located perpendicular to the first plane.

[0044] However, in another embodiment not shown, the nut 9 may be located on one side of the first plane, and the inclined central section 10 may be located on the opposite side of the first plane. In addition, the nut 9 and the inclined central section 10 may be located in a second plane and a third plane, respectively, which are parallel to each other and are located perpendicular to the first plane.

[0045] Reference Symbols List

[0046] 1 Connector

[0047] 2 Conductors

[0048] 3 End section

[0049] 4 End section

[0050] 5 Bracket

[0051] 6 holes

[0052] 7 Seals

[0053] 8 Notch

[0054] 9 Nut

[0055] 10 Central section

[0056] 11 Fork-shaped part

[0057] 12 Fork-shaped part

[0058] 13 Center housing

[0059] 14 Inverter

[0060] 15 Electric motor

Claims

1. A connector (1) for electrically connecting an electric motor (15) and an inverter (14), comprising a plurality of conductors (2), wherein: Each conductor (2) is assigned to a phase of the electric motor (15), characterized in that the conductor (2) is S-shaped, wherein one end section (3) of the conductor (2) can be connected to the inverter (14) and the other end section (4) of the conductor (2) can be connected to the electric motor (15).

2. The connector according to claim 1, wherein: The S-shaped conductor (2) comprises four or five bent sections, wherein the bending angle between two adjacent sections is at least approximately a right angle.

3. The connector according to claim 1 or 2, wherein: An end section (3) of each conductor (2) extends through a support (5) in which the conductors (2) are arranged at a distance from one another.

4. The connector according to claim 3, wherein: The support (5) is made by encapsulating the conductor (2) with a plastic material.

5. The connector according to claim 3 or 4, wherein: The support (5) comprises a seal for each conductor (2).

6. A connector according to any one of the preceding claims, wherein: A fastening device, in particular a thread or a nut (9), is provided on the inverter-side end section (2) of the conductor (2).

7. A connector according to any one of the preceding claims, wherein: The motor-side end section (4) has a fork shape, wherein an inclined central section (10) is arranged between two outer fork-tip sections (10, 11).

8. The connector according to any one of claims 1 to 7, wherein: The conductor (2) has an end section (3) on the inverter side of the conductor (2) and an end section (4) on the electric motor side of the conductor, the one end section (3) comprising a fastening device (9), the one end section (4) comprising an inclined central section (10), the bracket forming a plate extending in a first plane, the fastening device and the inclined central section being located only on one side of the first plane.

9. The connector according to any one of claims 1 to 8, wherein: The conductor (2) has an end section (3) on the inverter side of the conductor (2) and an end section (4) on the electric motor side, the end section (3) on the inverter side including a fastening device (9), the end section (4) on the electric motor side including an inclined central section (10), the bracket forming a plate extending in a first plane, the fastening device and the inclined central section are respectively located in a second plane and a third plane, the second plane and the third plane are parallel to each other and are positioned perpendicular to the first plane.

10. A device comprising an electric motor (15) and an inverter (14), the electric motor (15) and the inverter (14) being electrically connected via a connector (1) according to any one of claims 1 to 9.

11. The device according to claim 10, wherein: The electric motor (15) and the inverter (14) are directly connected without an intermediate bus bar.

12. The device according to claim 10 or 11, wherein: The inverter-side end section (3) of the conductor (2) is connected to the inverter (14) by means of a screw connection, and / or the electric motor-side end section (4) of the conductor (2) is welded to a flat wire of a stator of the electric motor (15).

13. The device according to any one of claims 10 to 12, wherein: The motor (15) and the inverter (14) are accommodated in a central housing (13), wherein the connector (1) closes and seals an opening of the central housing (13).

14. The device according to any one of claims 10 to 13, wherein: At least a portion of the connector (1) is impregnated by immersion in a coating bath.

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