Stator assembly

Abstract

The invention relates to a stator assembly for an electric machine, comprising: a stator comprising a stator core (1) on which a stator winding (11) is arranged; the invention relates to a stator (1) for a motor vehicle, comprising a stator winding (11), a connection module (15) for electrically connecting winding wire ends (13) of the stator winding (11), the connection module (15) being arranged on an end face of the stator, characterized in that the connection module (15) comprises a one-piece electrical terminal conductor (21) which is at least partially embedded in a body (17) made of an electrically insulating material, the terminal conductors (21) each form a terminal contact (27), to which an external power supply and / or control device of the stator assembly can be connected, and a winding contact (29), which is electrically conductively connected to the winding wire end (13).

Description

Technical Field

[0001] The invention relates to a stator assembly for an electric machine, in particular an electric motor. Background Art

[0002] Electric motors can be used in vehicles, for example commercial vehicles. Vehicles can have a drive as an alternative to an internal combustion engine powered by fossil fuels in order to reduce CO2 emissions. Such an electric drive can be powered, for example, by a fuel cell or a battery. One field of application of electric motors in vehicles is the cooling of the drive, the battery or the electronic devices. The electric motor drives a blower which cools the components. For such applications, compact dimensions (also in the axial direction) and high power are desired.

[0003] The stator assembly is part of an electric machine, such as an electric motor. The stator assembly is the stationary part of the electric motor. The part of the electric motor that rotates therein is called the rotor. The stator has a stator winding, through which a time-varying magnetic field is induced by means of a time-varying current. When operating with three AC voltages that are phase-shifted by 120 degrees, a phase branch is provided in the stator winding for each AC voltage.

[0004] In the manufacture of an exemplary conventional stator assembly, each phase branch of the stator winding is wound with a continuous wire along three stator teeth on one side of the stator core in one working process to form a pole. Then, the wire is guided to the opposite side and wound along three stator teeth on the other side staggered by 180 degrees to form another pole. The wire is guided between the tooth groups by the annular area of ​​the end plate on the end face of the stator core. The annular area has a laying channel for the wires between the poles on three stepped planes. Each plane is only provided with wires for one phase and provides enough air gaps for the crossed wires of other phases so as to achieve the required insulation between the wires on the annular area. The wiring is implemented on the annular area extending inward behind the winding on the iron stator core and is accompanied by a larger inner diameter and therefore a large amount of material consumption for the iron stator core. In addition, compared with the water core used for heat dissipation, the thermal performance of the wiring is very poor.

[0005] US 10,763,723 B2 shows a motor, which includes a rotatable rotor, a stator facing the rotor, a busbar electrically connected to the stator, a busbar carrier for holding the busbar, and a terminal block having a first end electrically connected to the busbar. The terminal block has a connecting terminal electrically connected to a drive device at a second end, and a seal fixed to the drive device and arranged between the busbar and the connecting terminal. The sealing section includes a through hole, and the terminal block is pressed into the through hole.

[0006] DE 10 2004 037 639 B4 discloses an electric motor which can be operated with a star point connection, wherein the connection of the star point is realized by means of the same winding machine as the tooth winding of the polyphase winding. Summary of the invention

[0007] An object of the present invention is to provide a stator assembly having compact dimensions.

[0008] The object is achieved by a stator assembly for an electric motor, which comprises a stator, the stator comprising a stator core and a connection module, a stator winding is arranged on the stator core, and the connection module is used to electrically connect the winding wire ends of the stator winding. The connection module is arranged on the end face of the stator. The connection module comprises an integral electrical terminal conductor, which is at least partially embedded in a body made of an electrically insulating material, wherein the terminal conductors respectively constitute a terminal contact and a winding contact, an external power supply device and / or a control device of the stator assembly can be connected to the terminal contacts, and the winding contacts are electrically conductively connected to the winding wire ends.

[0009] Such a stator assembly is advantageously provided for an electric motor. In this stator assembly, a stator winding having a plurality of winding wires and its connection are separated and arranged in different components. A connection module enables the connection to be decoupled from the stator winding, since the stator winding and the connection are arranged in separate components. During the manufacture of the stator, only the stator winding is applied. No switching wire guides are provided between the different poles. However, the connection of the winding wire ends is achieved by a connection module which is manufactured separately and then mounted, to which the winding wire ends of the stator winding are connected.

[0010] The wiring module is a functional component, by means of which the wiring of the stator winding is provided. It has a conductor embedded in an electrically insulating material. The conductor is advantageously completely surrounded by the material except for its contacts, so that only the contacts are accessible. The conductor is advantageously metallic. The conductor is constructed in one piece. The conductor can be formed, for example, by a metal plate. Alternatively, the contacts can be welded to the conductor at the end or connected in a material-locked manner in other ways to form an integral conductor. The electrically insulating material of the body in which the conductor is at least partially embedded is, for example, plastic or a plastic mixture. The body insulates the conductors from each other and holds the conductors in their position. The body composed of an electrically insulating material can advantageously be a casting, such as an injection molding, or an injection molding body. The injection molding body stipulates that the conductor is first positioned in a pre-injected carrier part and oriented relative to each other. In another step, the injection molding body material is directly applied to the carrier part and the conductor, and the carrier part and the conductor are at least partially embedded in the injection molding body material. In the above-mentioned embedded form, a material-locked connection is generated between the body and the conductor.

[0011] Embedding can also be achieved by alternative means of inserting the conductor into the body. Such a body can be, for example, two-piece, and the conductor is positioned in a cavity between mutually engaging parts of the body to be at least partially embedded therein. The terminal contacts and the winding contacts are accessible outside the body.

[0012] The conductor comprises a terminal conductor, the end region of which is configured as a terminal contact for an external power supply and / or a control device on the one hand and as a winding contact to which the winding wire ends of the stator winding are connected on the other hand. The combination of the terminal contact for the external power supply and / or the control device and the winding contact in the terminal conductor as a lead frame reduces the manufacturing effort.

[0013] The connection module provides terminal contacts for an external power supply and / or control device of the stator assembly, which are directly connected to the terminal contacts. Compared with conventional assemblies (in which the terminal contacts are provided as separate components), manufacturing is simplified and terminal resistance is reduced.

[0014] A narrow design with minimal axial extension is achieved by means of a terminal module mounted on the end face of the stator. In this packaging, the easy-to-manufacture terminal module replaces the wire guides in conventional, non-automatically manufactured winding concepts, in which the winding wires are guided through grooves in the end plates between the poles. In addition to the advantages of modularity, the stator assembly also enables faster and automated production suitable for mass production.

[0015] Advantageously, the terminal module comprises an integral electrical connection conductor as a further conductor, which is at least partially embedded in the insulating material of the body and forms two winding contacts, which are electrically conductively connected to the winding wire ends. The electrical connection of the two winding wire ends is achieved with these connection conductors, for example for connecting two opposite poles.

[0016] In one embodiment, the winding wires of the stator winding are contacted for each pole via a connection module, so that each pole of the stator has two winding wire ends. The poles of the same branch are electrically connected through the connection module.

[0017] In one embodiment, three terminal contacts are provided, which are phase terminal contacts for three phase branches, so that the stator can be operated with a three-phase alternating current.

[0018] In the case of a star circuit, the three branches of the stator winding are connected to one another in the form of a star. This union is called a star point or neutral point. In one embodiment, the connection module comprises an integral electrical star point conductor as a conductor, which is at least partially embedded in the casting material and forms three winding contacts, which are electrically conductively connected to the ends of the winding wires so that the connection forms a star point. Alternatively, the three branches are connected as a delta circuit.

[0019] The combination of terminal conductors, connecting conductors and star point conductors forms a connection in which the stator winding can be connected externally via terminal contacts and has a plurality of poles and a star point.

[0020] The conductor at least partially embedded in the insulating material, whether it is a terminal conductor, a connecting conductor or a star point conductor, has an end region in which at least one side is exposed for contacting so as to form a terminal contact or a winding contact. The other side is embedded in the material so that the contact portion is constructed to be flat and stable. Alternatively, the entire end region extends from the body composed of the insulating material. The exposed end region can be electrically contacted by a suitable force-locking, shape-locking or material-locking connection. If only one side of the end region is exposed, soldering or welding is particularly suitable. The end region extending completely from the material can be constructed as a cutting contact or a pin contact. The latter is particularly suitable for terminal contacts. The terminal contact is advantageously constructed as a pin-shaped rolled or bent plate section that extends from the casting material. Alternatively, the terminal contact is constructed as a contact piece in a socket in the casting material. The socket is a gap in a body composed of an insulating material, and a contact piece is arranged on its wall. The winding contact can be constructed as a cutting contact, a clamping contact, a soldering contact or a welding contact. The cutting contacts can be designed similarly to insulation displacement connectors (IDC). Different contact types can also be provided for the winding contacts in the same terminal module.

[0021] The conductor is advantageously designed as a stamped bent part, which can be manufactured simply. The conductor is stamped from a metal sheet and then bent into its shape. This can include bending, with which the end region of the conductor is guided onto the upper side of the terminal module, or rolling, which serves to form a pin-shaped terminal contact that protrudes from the terminal module. The conductor or at least a section of the conductor can be designed as a stamped sheet metal part, wherein the sheet is bent into its shape only when it is inserted into the body.

[0022] Advantageously, the terminal module comprises a fixing mechanism formed by an insulating material as an integral part of the body. The fixing mechanism forms a force-locking or form-locking connection with the stator. This connection can be formed in particular with an end disc of a stator formed by an insulating material. The end disc has an end shield and is arranged on the end face of the stator core. The end disc holds the coils of the stator winding in their position between the boundaries of the winding space. In one embodiment, the fixing mechanism comprises a clip or a convex point, which can be clamped onto the end disc, and the convex point is embedded in the corresponding gap of the stator. The prefabricated terminal module can be easily mounted on the end shield, in which the convex point on the terminal module is embedded in the preset gap on the end shield on the stator core. The orientation of the terminal module and the stator relative to each other is also advantageously preset by the fixing mechanism. Alternatively or additionally, a coding mechanism, such as an orientation groove on the stator core, can also be provided for this purpose.

[0023] In one embodiment, the terminal module has a basic shape defined by a ring-shaped body made of insulating material, in which the terminal conductors or connecting conductors or star point conductors extend essentially in the shape of circular arcs between the contacts. The contacts are conductor areas and / or material-free areas that extend from the body and are accessible for contacting.

[0024] In one embodiment, the winding contacts project radially into an inner region enclosed by the terminal module and provided for the rotor, or are arranged on the upper side of the end face of the terminal module so that the winding wire ends are guided to the end face of the terminal module for contacting.

[0025] Advantageously, the terminal contacts protrude from a base on the upper side of the end face of the terminal block, so that the power supply and control are carried out via the end face, which results in a compact design.

[0026] In one embodiment, the body comprises a main body and a bottom, the main body having a groove for inserting a conductor in a group with terminal conductors, connecting conductors and star point conductors or for inserting a section of the conductor, and the bottom closing the groove. Such a groove can extend in an arc shape. The retention of the conductor can be improved by a convex point-shaped retaining mechanism extending from the side wall of the groove into the interior of the groove. The conductor is retained by the retaining mechanism in a force-locking and / or form-locking manner.

[0027] The inserted conductor or the inserted section is embedded between the main body and the bottom. In one embodiment, the terminal contact is cast in the main body and is connected to the section of the terminal conductor inserted into the groove by material bonding to form an integral terminal conductor.

[0028] The base can be designed as a glued-on film or as a ring made of insulating injection molding material, which is clamped or glued to the body. The latter embodiment is thicker than the film and requires more axial installation space.

[0029] Regardless of whether it is a film or a ring, the embodiment of the base with a continuous bottom surface not only prevents the conductor from falling out, but also serves as an insulator for the copper winding of the stator when the terminal module is placed on the stator in the installed state. The base with a discontinuous bottom surface, i.e., with a notch in the base, essentially serves as a catch for the conductor. The actual insulation from the winding of the stator is achieved by the subsequent casting of the stator and the terminal module. In the case of a continuous bottom surface, the casting material is not absolutely necessary for this purpose. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Some embodiments are described in detail below with the aid of the accompanying drawings. In the accompanying drawings:

[0031] Figure 1 shows a three-dimensional view of one embodiment of a stator assembly,

[0032] Figure 2 shows a top view of an embodiment of a stator,

[0033] Figure 3 A winding schematic diagram showing an embodiment of a stator winding and its connection,

[0034] Figure 4 An embodiment of a wiring module is shown.

[0035] Figure 5 Another embodiment of a wiring module is shown.

[0036] Figure 6 Another embodiment of the wiring module is shown.

[0037] Figure 7 Shows Figure 6 Part of the embodiment,

[0038] Figure 8 FIG. 2 shows a partial view of another embodiment of a wiring module.

[0039] Fig. 9 Another embodiment of the wiring module is shown.

[0040] Fig.10 An embodiment of the subject is shown, and

[0041] Fig.11 An exploded view of the junction module is shown.

[0042] In the figures, identical or functionally identical components are provided with the same reference symbols. DETAILED DESCRIPTION

[0043] Figure 1An embodiment of a stator assembly is shown in a three-dimensional view. The stator assembly comprises a stator core 1 with a laminated core, in which stator teeth 3 projecting outwards are formed circumferentially. An end disc 5 is arranged on the end face of the stator core 1, the contour of which at least substantially corresponds to the contour of the stator core 1. The end disc 5 forms an end shield 7 on the stator teeth 3. The end disc 5 can be designed in multiple parts. These end shields 7 have inner and outer winding space boundaries 9, between which the coils of the stator winding 11 extending on the stator teeth 3 are held and radially supported.

[0044] The stator winding 11 comprises a plurality of winding wires, which are each wound in a coil-shaped manner on one or more stator teeth 3. The winding wire ends 13 of the winding wires are electrically connected to one another via a connection module 15. The connection module 15 is attached to the stator and forms a positive or non-positive connection with the stator. For example, the connection module is clamped, clamped or glued.

[0045] The junction module 15 includes conductors 21, 23, 25 (in Figure 1 These conductors are at least partially embedded in a body 17 made of insulating material (not shown). The contour of the annular body 17 corresponds to the contour of the stator, so that there is enough space inside the ring for the rotor. Figure 1 In the schematic diagram in FIG. 1 , for the sake of clarity, the winding wire ends 13 connected to the conductors 21 , 23 , 25 are not shown.

[0046] External control and power supply of the stator assembly is achieved through the terminal contacts 27 of the wiring module 15. In this embodiment, the terminal contacts 27 are phase terminal contacts to which three phases of the AC power supply can be applied. The terminal contacts 27 are configured as pin contacts extending from the base 19 in the axial direction.

[0047] When producing such a stator assembly, winding and connection are decoupled, since the winding wire is first wound on the stator teeth 3. Only then is the winding wire end 13 connected by means of the connection module 15, in that the winding wire end 13 is electrically connected to the winding contact 29 of the connection module 15. As a result, the winding process is faster, since it is not necessary to switch between different poles during winding.

[0048] After the connection module has been mounted on the stator, the components are cast in order to achieve a permanent connection and to protect the components, in particular the stator winding 11. However, in the event of a defect, one of the components can be replaced beforehand.

[0049] By means of the connection module 15 which is attached to one of the end plates 5 at the end face, a narrow design with a minimal axial longitudinal extension is achieved, which results in a compact packaging.

[0050] Figure 2A top view of the stator is shown and the course of the conductors and the position of the contacts in the terminal module 15 are schematically shown. Further features of the terminal module 15 are shown in FIG. Figure 2 Not shown.

[0051] The stator is designed for three phase branches and comprises 18 stator teeth 3 in this embodiment, wherein three adjacent stator teeth 3 are provided for one of the six poles in total. Two poles of the same phase branch are arranged opposite each other. The poles of the three phase branches can be distinguished by their hatching, wherein no hatching is provided for one phase branch. A winding wire extends over three stator teeth 3 per pole. Each pole has two winding wire ends 13, which are electrically conductively connected to the winding contacts 29 of the connection module 15.

[0052] End shields 7 consisting of end discs 5 are arranged on the stator teeth 3 for guiding and holding the stator winding 11. These end shields 7 have winding space boundaries 9, which protrude in the axial direction as flanges on the outside and are hollow cylindrical axial projections 33 on the inside. In addition to stabilizing and holding the stator winding 11, the projections 33 have another function. These projections are designed so that the protrusions on the underside of the terminal module 15 can engage in their recesses and form a connection between the stator and the terminal module 15. The terminal module 15 is placed on the end shield 7 of the stator as a prefabricated lead frame ring. Only two protrusions are required to orient and reliably connect the terminal module 15. However, more protrusions can be provided to increase the stability of the connection.

[0053] The electrical connection in the terminal module 15 is realized by metallic, one-piece conductors 21, 23, 25, which are at least partially embedded in an insulating material (in the Figure 2 The directions of these conductors 21, 23, 25 and their contacts 27, 29 are schematically shown in Figure 2 Shown in.

[0054] The connection module 15 comprises three integral terminal conductors 21 as lead frames, which have winding contacts 29 at one end and pin-shaped phase terminal contacts as terminal contacts 27 at the other end. For each phase, the terminal conductor 21 extends from the terminal contact 27 to one of the poles of the phase branch. The other pole of the phase branch is contacted by an integral connecting conductor 23 as a lead frame, to which the winding wire ends 13 of the two poles are connected. The remaining winding wire ends 13 of different phase branches are connected to each other to form a star point by a star point conductor 25 as a lead frame. The winding wire ends 13 and the winding contacts 29 are arranged on one of the outer stator teeth 3 of each pole. The conductors 21, 23, 25 for contacting the pole usually extend all the way to one of the outer stator teeth without crossing other stator teeth of the same pole.

[0055] Figure 3 An exemplary winding scheme of an embodiment of the stator winding 11 and the electrical coupling by the connection module 15 are schematically shown. The brackets respectively show the winding sections for one pole. The branch of the U phase extends on two poles on the first, second and third stator teeth Z1, Z2, Z3 and on the tenth, eleventh and twelfth stator teeth Z10, Z11, Z12. The terminal conductor connected to the winding wire end U1 of the first stator tooth Z1 also constitutes the phase terminal contact R. A connecting conductor connects the winding wire ends of the third and tenth stator teeth Z3, Z10. The branch of the V phase extends on two poles on the fourth, fifth and sixth stator teeth Z4, Z5, Z6 and on the thirteenth, fourteenth and fifteenth stator teeth Z13, Z14, Z15. The terminal conductor connected to the winding wire end V1 of the fourth stator tooth Z4 also constitutes the phase terminal contact S. A connecting conductor connects the winding wire ends on the sixth and thirteenth stator teeth Z6, Z13. The branch of the W phase extends over two poles on the seventh, eighth and ninth stator teeth Z7, Z8, Z9 and on the sixteenth, seventeenth and eighteenth stator teeth Z16, Z17, Z18. The terminal conductor connected to the winding wire end W1 of the sixteenth stator tooth Z16 also forms the phase terminal contact T. A connecting conductor connects the winding wire ends of the seventh and eighteenth stator teeth Z7, Z18. A star point conductor connects the winding wire ends U2, V2, W2 on the ninth, twelfth and fifth stator teeth Z9, Z12, Z15 to form the star point of the connection.

[0056] Figure 4 The embodiment of an annular terminal module 15 is shown, in which a terminal conductor 21, a connecting conductor 23 and a star point conductor 25 are embedded in a body 17 of insulating material, except for their end regions. The conductors 21, 23, 25 are held in their position by the material and are insulated from the other conductors. The conductors 21, 23, 25 are already connected. Figure 2The terminal module 15 as described extends so that the pole and phase contact of the phase branch are electrically connected. As the wiring module 15 of the lead frame ring, it includes three terminal conductors 21 as the lead frame, that is, there is a terminal conductor for each phase. On the end of the terminal conductor 21, the terminal contact 27 is configured as a phase contact, which extends axially from the base 19 formed by the insulating material on the upper side of the ring as a plug-in contact. The other ends of the terminal conductor 21 extend radially from the body 17 into the ring interior as the end of the connecting conductor 23 and the end of the star conductor 25 and form a winding contact 29, which is configured as a hook or S-shaped so that the winding wire end 13 can be hung and maintained by the elastic deformation of the hook or S-shaped winding contact 29. Reliable connection can be realized by optional soldering or bonding. Nevertheless, the subsequent pouring of the entire assembly is finally fixedly connected and protects the stator together with its stator winding 11 and the wiring module 15.

[0057] The conductors 21, 23, 25 are stamped and bent parts, the basic shape of which is stamped from a metal sheet and then deformed. The deformation basically involves forming the winding contact 29 (which is configured as a wire terminal for the winding wire end 13) and the terminal contact 27. The winding contact 29 or the terminal contact 27 can also be soldered or welded as an alternative to form an integral conductor.

[0058] The terminal contact 27 is a hollow cylindrical deformed plate area with a circular, elliptical or polygonal contour. In the terminal conductor 21, the terminal contact 27 is arranged at one end and the winding contact 29 is arranged at the other end. The terminal conductor 21 is composed of a stamped and bent metal sheet. The stamped part that has not yet been deformed is designed so that the particularly rectangular area forming the terminal contact 29 is a component of the one-piece stamped part.

[0059] The conductors 21, 23, 25 extend in an arc shape and are radially offset to prevent short circuits. The conductors 21, 23, 25 extend at least partially in different planes, so that the section extending radially inward to the winding contact 29 crosses the other conductors 21, 23, 25, but does not contact the other conductors 21, 23, 25. Alternatively, the section crossing the other conductors 21, 23, 25 can be an arc-shaped run.

[0060] During the production of the terminal module 15, the conductors 21, 23, 25 are held in their subsequent position by the pre-injected carrier part at a distance from each other after stamping and forming and then injection-molded. The formed injection-molded body 17 fits onto the end cap 7 of the stator, onto which it is attached.

[0061] The above explanations, in particular with respect to the conductors 21 , 23 , 25 , also apply to the following exemplary embodiment, the description of which focuses on the differences from this exemplary embodiment.

[0062] Figure 5 A further embodiment of an annular terminal module 15 is shown, which differs from the previous embodiment in terms of the winding contacts 29. The winding contacts 29 are designed as pliers-shaped cutting contacts in this embodiment. The winding wire ends 17 are inserted axially into the cutting contacts that extend into the interior of the ring.

[0063] Figure 6 A further exemplary embodiment of an annular terminal module 15 is shown, which differs from the preceding exemplary embodiments with regard to the winding contacts 29 and the terminal contacts 27 . Figure 7 Shown in detail Figure 6 The embodiment of the present invention has a section of a winding contact 29 .

[0064] In this exemplary embodiment, the terminal contact 27 is designed as a socket 31 in an axially protruding base 19 in the body 17 made of insulating material. The terminal contact 29 is the end region of the terminal conductor 21, which extends into the socket 31 as a contact piece, where it is positioned on the socket wall and can be contacted by external plug contacts.

[0065] The winding contact 29 is positioned on the upper side of the connection module 15 and protrudes axially from the cast body 17. The winding contact is positioned adjacent to the stator tooth 3, at which the winding wire end 13 is to be electrically connected to the winding contact 29. Since the winding contact 29 is arranged on the upper side, in this embodiment, the radially offset conductors 21, 23, 25 do not cross. Since the conductors 21, 23, 25 are radially offset, the winding contact 29 constructed at their ends is also radially offset. For contacting, the winding wire end 13 is radially guided to the upper side of the connection module 15 and inserted into the cutting contact as the winding contact 29. No star point conductor is provided.

[0066] Figure 8 A part of another embodiment of the wiring module 15 is shown. In this embodiment, the contacting of the winding wire end 13 is also realized on the upper side of the wiring module 15, that is, by fixing and welding the winding wire end 13 on the exposed conductor end as the winding contact 29. The wiring module 15 has an L-shaped groove 35, which has arms arranged at right angles to each other. One arm extends along the conductor end, which is accessible at the bottom of the groove. The other arm extends radially toward the inside of the ring. In order to contact, the winding wire end 19 is inserted into the groove 35 so that it follows the groove direction and is welded at the conductor end. Each winding wire end 13 to be contacted is welded on the winding contact 29 provided for this purpose of the lead frame geometry of the wiring module 15. Alternatively, an interface similar to IDC is also possible.

[0067] In this embodiment, it can also be seen that hollow cylindrical projections 33 are provided on the end cap 7, which guide and hold the winding wires from the coils on the stator teeth to the coils on the stator teeth. The protrusions 37 engage in the projections on the underside of the terminal module 15 in order to connect the terminal module 15 and the stator.

[0068] Fig. 9 A further embodiment of a ring-shaped terminal module 15 is shown in a three-dimensional view obliquely from above, in which the terminal conductors 21 and the star point conductor 25 are at least partially embedded in the body 17 of the terminal module. Optionally, the connecting conductors 23 can also be at least partially embedded. The connection is similar or identical to the previously described embodiments.

[0069] In this embodiment, the body 17 is constructed in two parts and has a body 41 and a bottom 43. The segments 61 of the terminal conductor 21 and the star point conductor 25 are inserted into the body 41. The body 41 is closed on the bottom by the bottom 43 to at least partially embed the conductors. The body 41 can be an injection-molded component made of plastic or other insulating materials, and the bottom 43 can be a film made of insulating material, for example a polytetrafluoroethylene film, which is glued to the bottom side 53 of the body 41 and covers the inserted conductors.

[0070] In this exemplary embodiment, the winding contact 29 is designed as a rectangular plate which projects through a slot 49 on the upper side from the body 41. The connection of the winding wire ends can be achieved, for example, by soldering or ultrasonic welding.

[0071] The terminal contact 27 is a metal pin which projects from a base 19 which is formed on the upper side 51 of the body 41. The base 19 is an integral component of the body 41. The terminal contact 27 is cast in the base 19 of the body 41.

[0072] Fig.10 Shows Fig. 9 A three-dimensional view of the main body 41 viewed obliquely from below.

[0073] The body 41 can be an injection-molded component made of plastic, which has a circular arc-shaped groove 47 on its structured bottom side 53, in which the section 61 of the terminal conductor 21, the connecting conductor 23 and the star point conductor 25 is arranged. The groove 47 receives the conductor ( Fig.10 The grooves 47 do not cross each other, so that the conductors are insulated from each other. The slots 49 in the grooves 47 extending all the way to the upper side 51 are provided for the winding contacts 29 designed as plates, so that the winding contacts 29 extend onto the surface 51 when the conductors are inserted.

[0074] Based on air and creepage distance, groove 47 has radial distance between each other, which advantageously corresponds to the required insulation coordination. In addition, groove 47 has convex points on its side walls as a retaining mechanism, which clamps the conductor of the plate strip and therefore keeps it in its position. These convex points are advantageously configured as semicircular or hemispherical protrusions, which extend into the center of the groove from at least one opposite side wall of the groove. This shape can be well realized with injection molding technology. The convex points can only be applied on one or two opposite side walls of the groove. In the case mentioned later, these convex points can be arranged relatively or staggered from each other. In an embodiment with convex points on a side wall, the opposite side wall has a semicircular or hemispherical depression, so that a local narrow curve is produced in the groove direction. The number of convex points can be varied, and at least three convex points are advantageously set for a conductor. When inserting the conductor, these conductors overcome slight resistance and are pressed into the groove 47 by the convex points, wherein the conductor and / or the convex points are deformed, and the conductor is thus maintained and retained in its position.

[0075] The cast metal pins of the terminal contacts 27 extend as far as the underside 53 .

[0076] The connection lugs projecting downward at the outer edge of the main body 41 are designed as clips 55 , so that a subsequent terminal module 15 can be placed on the stator and mechanically connected by a snap connection.

[0077] Fig.11 An exploded view of the wiring module 15 is shown, which has a terminal contact 27 as a phase terminal contact, a body 41, three sections 61 of the connecting conductor 21, a star conductor 25 and a bottom 43.

[0078] The terminal contact 27 is cast in the base 19 of the body 41. The cross-sectional widening in the central region of the terminal contact 27 ensures a secure hold during the casting of the terminal contact 27. The terminal contact 27 has a connecting slot on the underside.

[0079] The sections 61 of the terminal conductor 21 are each designed as a one-piece sheet metal strip. The rectangular widening of the sheet metal strip forms a sheet metal strip as a winding contact 29 .

[0080] The sheet metal strip extends perpendicularly to the upper side 51 of the body 41 and is inserted into the groove 47 in a bent manner. The sheet metal strip can be pre-bent or bent only when inserted. The sheet metal strip is inserted so that its winding contact 29 extends through the slot 49 and the sheet metal strip engages in the lower connecting slot of the terminal contact 27. The electrically conductive and materially bonded connection between the section 61 of the terminal conductor 21 and the terminal contact 27 is achieved, for example, by soldering, so that the one-piece terminal contact 21 is formed by the sheet metal section 61 and the pin-shaped terminal contact 27.

[0081] The bottom 43 is then fixed to the underside 53 of the body 41. The bottom 43 covers the strips inserted into the grooves 47 so that they are embedded and cannot fall out.

[0082] The polytetrafluoroethylene film as the bottom 43 has a continuous surface and provides sufficient insulation against the copper windings on the stator even without a casting compound when the terminal module 15 is mounted on the stator. Nevertheless, this effect can also be supported by casting the terminal module 15 on the stator.

[0083] Such a multi-part body 17 can also have more than two parts. The winding contact 29 can be designed in an alternative manner, for example as explained in conjunction with the preceding exemplary embodiments.

[0084] The features mentioned above and in the claims and which can be seen in the drawings can be implemented advantageously both individually and in different combinations. The invention is not limited to the described embodiments but can be modified in many ways within the capabilities of a person skilled in the art.

[0085] Reference numerals

[0086] 1 stator core

[0087] 3. Z1 ... Z18 stator teeth

[0088] 5-end tray

[0089] 7 End shield

[0090] 9 Winding space boundary

[0091] 11 Stator winding

[0092] 13. Ends of U1, U2, V1, V2, W1, W2 winding wires

[0093] 15 Wiring Module

[0094] 17 body

[0095] 19 Base

[0096] 21 terminal conductor

[0097] 23 Connecting conductors

[0098] 25 Star point conductor

[0099] 27 terminal contacts

[0100] 29 winding contacts

[0101] 31 sockets

[0102] 33 protrusions

[0103] 35 Grooves

[0104] 37 convex points

[0105] 41 Main Body

[0106] 43 bottom

[0107] 47 Grooves

[0108] 49 Gap

[0109] 51 upper side

[0110] 53 lower side

[0111] 55 Clip

[0112] Sector 61

[0113] R, S, T phase terminal contacts

Claims

1. A stator assembly for an electric motor, comprising: A stator, the stator comprising a stator core (1), on which a stator winding (11) is arranged; A connection module (15) for electrically connecting winding wire ends (13) of the stator winding (11), wherein: The wiring module (15) is arranged on the end surface of the stator. It is characterized in that The wiring module (15) comprises an integrated electrical terminal conductor (21), which is at least partially embedded in a body (17) made of an electrically insulating material, wherein the terminal conductor (21) respectively constitutes a terminal contact (27) and a winding contact (29), to which an external power supply device and / or a control device of the stator component can be connected, and the winding contact is conductively connected to a winding wire end (13).

2. The stator assembly according to claim 1, It is characterized in that The terminal module (15) comprises one or more integral electrical connection conductors (23), each of which is at least partially embedded in a body (17) made of an electrically insulating material and forms two winding contacts (29) which are electrically conductively connected to the winding wire ends (13).

3. The stator assembly according to claim 1 or 2, It is characterized in that Each pole of the stator comprises two winding wire ends (13).

4. A stator assembly according to any one of the preceding claims, It is characterized in that Three terminal contacts (13) are provided, which are phase terminal contacts (R, S, T).

5. A stator assembly according to any one of the preceding claims, It is characterized in that The connection module (15) comprises an integral star point conductor (25), which is at least partially embedded in a body (17) made of an electrically insulating material and forms three winding contacts (29), which are electrically conductively connected to winding wire ends (29) so that the connection forms a star point.

6. The stator assembly according to claim 5, It is characterized in that A conductor embedded in a body (17) made of electrically insulating material and in a group comprising a terminal conductor (21), a connecting conductor (23) and a star point conductor (25) has an end region exposed at least on one side, the end region being configured as a terminal contact (27) or a winding contact (29), wherein the winding contact (29) protrudes radially into an inner region enclosed by a terminal module (15) or is arranged on an upper side (51) of an end face of the terminal module (15).

7. The stator assembly according to claim 5 or 6, It is characterized in that The conductors in the group comprising the terminal conductor (21), the connecting conductor (23) and the star point conductor (25) are designed as a stamped bent part or a stamped sheet metal part or at least partially as a stamped sheet metal part.

8. A stator assembly according to any one of the preceding claims, It is characterized in that The body (17) has fastening means, in particular clips (55) or lugs, made of the electrically insulating material and forming a non-positive and / or positive connection with the stator.

9. A stator assembly according to any one of the preceding claims, It is characterized in that The insulating material is an injection molding compound, an injection molding compound or a casting compound.

10. The stator assembly according to any one of claims 5 to 9, It is characterized in that The body (17) comprises a main body (41) having a groove (47) for inserting a conductor in a group having a terminal conductor (21), a connecting conductor (23) and a star point conductor (25) or for inserting a segment (61) of the conductor, and a bottom at least partially closing the groove (47).

11. The stator assembly according to claim 10, It is characterized in that The terminal contact (27) is cast in the body (41) and is connected to a section (61) of the terminal conductor (21) in a materially bonded manner.

12. A stator assembly according to any one of the preceding claims, It is characterized in that At least one winding contact (29) is designed as a cutting contact, a clamping contact, a soldering contact or a welding contact.

13. A stator assembly according to any one of the preceding claims, It is characterized in that The terminal contact (27) is designed as a rolled or bent hollow cylindrical sheet metal section which projects from the insulating material, or the terminal contact (27) is designed as a contact lug in a socket (31) in the insulating material.

14. A stator assembly according to any one of claims 6 to 13, It is characterized in that The terminal module (15) has a ring-shaped basic shape, in which the terminal conductor (21) or the connecting conductor (23) or the star point conductor (25) extends in the shape of a circular arc.

15. A stator assembly according to any one of the preceding claims, It is characterized in that The terminal contacts (27) protrude from a base (17) on the upper side of the end face of the terminal module (15).

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