Connection element, stator, rotor, method for producing stator, method for producing rotor, and kit

Abstract

The invention relates to a connection element (1), in particular for electrically contacting two mutually spaced contact elements (2), comprising a first conductor end (3) and a second conductor end (4). The connection element (1) has an insulation (5) between the first conductor end (3) and the second conductor end (4), the insulation (5) being made of a flat insulation element (6) which at least partially surrounds the connection element (1) and has a first edge (7) extending in the longitudinal extension of the connection element (1) and a second edge (8) extending in the longitudinal extension of the connection element (1). The first edge (7) is fixed relative to the second edge (8) of the flat insulating element (6) by means of a bonding connection and / or a form-fitting connection such that the wiring element (1) is surrounded by the flat insulating element (6) in a tubular manner.

Description

Technical Field

[0001] The invention relates to a terminal element, in particular for electrically contacting two contact elements spaced apart from one another, the terminal element comprising a first conductor end and a second conductor end, wherein the terminal element has an insulating element between its first conductor end and its second conductor end. The invention also relates to a stator, a rotor, a method for producing a stator, a method for producing a rotor and a kit. Background Art

[0002] Electric motors are increasingly used to drive motor vehicles in order to create an alternative to fossil fuel-intensive internal combustion engines. Considerable efforts have been made to improve the suitability of electric drives for everyday use and also to be able to provide users with the driving comfort to which they are accustomed.

[0003] A detailed description of the electric drive can be found in the article by Erik Schneider, Frank Fickl, Bernd Cebulski and Jens Liebold in the German automobile magazine ATZ, issue 63, 05 / 20 6, pages 360 to 365, entitled: Hochintegrativ und Flexibel Elektrische Antriebseinheit für E-Fahrzeuge [Highly integrated and flexible electric drive unit for electric vehicles]. The article describes a drive unit for an axle of a vehicle, which comprises an electric motor, which is arranged concentrically and coaxially with a bevel gear differential, wherein a switchable 2-speed planetary gear set is arranged in the drive train between the electric motor and the bevel gear differential and is also positioned coaxially with the electric motor or the bevel gear differential or the spur gear differential. The drive unit is very compact and, due to the switchable 2-speed planetary gear set, achieves a good compromise between gradeability, acceleration and energy consumption. Such drive units are also known as electric axles.

[0004] In addition to purely electrically operated drive trains, hybrid drive trains are also known. Such drive trains of hybrid vehicles usually include a combination of an internal combustion engine and an electric motor and enable, for example, a purely electric operating mode in urban areas while allowing both sufficient range and usability, in particular when driving off-road. In addition, in certain operating situations, drive can also be provided simultaneously by the internal combustion engine and the electric motor.

[0005] In addition to being used in electric vehicles, electric machines are also used, for example, as automation electric motors or industrial motors. Industrial motors in particular are very diverse, with varying numbers and requirements. One way to master this diversity is to use common geometries, such as laminates, in order to then differentiate the product into types with their properties by connecting the individual coils.

[0006] In order to develop electric machines, in particular for the above-mentioned hybrid motor vehicles or all-electric motor vehicles or also for wheel hub drives, fundamentally different winding technologies for the stators of electric machines are known.

[0007] For the electrical insulation in multi-phase windings, the dielectric strength of the individual coils of a phase as well as the dielectric strength of the connecting wires between the coils within a phase and between the phases, for example when implementing a star / delta configuration, must be ensured. The electrical insulation of the winding heads is usually achieved using so-called phase separators, wherein these are designed as flat insulating materials with defined 2D or 2.5D cuts (embossing / curvature). When wiring the windings or winding ends on one of the winding heads, so-called surrounding insulation elements are used, which are intended to prevent electrical contact between the connection elements on the winding heads or in the winding heads of other coils of the same phase or other phases.

[0008] However, it is often not possible or only possible with great effort to automate the process of wiring or insulating the electrical conductors intended for wiring. An example is the relatively complex automation of the axial splicing of a pipe system to a flexible connecting wire. Even alternative insulating bandages can only be automated to a limited extent due to the accessibility of the splicing / insulation points. Summary of the invention

[0009] The object of the present invention is therefore to provide a terminal element, in particular for electrically contacting two contact elements spaced apart from one another, which terminal element can be provided with an insulation piece in a simple, automated manner. Another object of the present invention is to provide a stator with an improved terminal element and a rotor with an improved terminal element. The object of the present invention is also to provide an optimized process for producing a stator and for producing a rotor. Finally, the object of the present invention is also to provide a kit for producing an insulation piece for a terminal element for electrically contacting two contact elements spaced apart from one another.

[0010] This object is achieved by a terminal element, which is particularly used to make electrical contact with two contact elements spaced apart from each other, the terminal element comprising a first conductor end and a second conductor end, wherein the terminal element has an insulating part between its first conductor end and its second conductor end, wherein the insulating part is made of a flat insulating element which at least partially surrounds the terminal element, the flat insulating element having a first edge extending in the longitudinal extension of the terminal element and a second edge extending in the longitudinal extension of the terminal element, wherein the first edge is fixed relative to the second edge of the flat insulating element by means of a bonding connection and / or a form-fitting connection, so that the terminal element is surrounded by the flat insulating element in a tubular manner.

[0011] This has the advantage that the terminal elements can be produced in a highly automated manner. Preferably, the flat insulating element uses a material similar to or even identical to that provided for the phase separators of the coils in the winding head. This means that one material can be used for the insulation of the entire winding, which saves costs in material supply and logistics as well as in product development and material qualification. Typically, the thickness of the material is thinner than the tubes used previously, which is why a more compact winding head can be produced, since the wiring of the jumper wires is easier and the associated space requirements are also smaller.

[0012] The layer thickness of the flat insulating material can also be flexibly adjusted based on the selected degree of overlap in the outer region. By using flat insulating materials, it is also possible to further increase the insulating properties of the material by subsequently applying secondary insulation, for example by drip irrigation or impregnation. This is usually not possible when using tubes.

[0013] The terminal element can be formed by one terminal wire or by a plurality of terminal wires. It is also conceivable that the terminal element consists of a wire harness, wherein the individual terminal wires are arranged, for example, in a twisted manner. In particular, the terminal element is designed to be flexible. In order to fix the wires before the actual electrical contact is made, it can be advantageous to fix them with the help of cable connectors. This is usually combined with a cost-effective welding process of thermocompression welding or resistance welding. In particular in the case of a large number of parallel conductors of the terminal wire, contact elements such as cable connectors, welding sleeves or similar elements are preferably used.

[0014] The flat insulating element preferably has a foil-like shape. For example, the flat insulating element can be designed as an insulating paper or an insulating fabric. In principle, of course, the flat insulating element can also be formed from an electrically insulating plastic film. The flat insulating element can be provided as a flat and / or horizontal blank. Preferably, the flat insulating element has a rectangular shape. Of course, in principle, any other flat shape is also conceivable.

[0015] According to the invention, a first edge of a flat insulating element is fixed relative to a second edge by means of a bonding connection and / or a form-fitting connection. For example, the form-fitting connection can be achieved by folding over the edges. The use of an adhesive is particularly advantageous for the bonding connection. It is particularly advantageous if at least one of the edges is already provided with an adhesive strip, so that the application of adhesive during the production of the insulating part of the terminal element can be avoided. From a process point of view, combining these processes in sequence can also bring advantages, for example by temporary fixing by means of a form-fitting connection, followed by additional fixing in the process chain by secondary insulation by means of a bonding connection.

[0016] For fixing by means of a positive connection, it is useful to adapt the geometry of the edges to one another, so that the edges of the flat insulating element can be prevented from being removed in the form of self-hammering. The principle is based on a receiving contour and a penetration contour on opposite sides, similar to the key lock principle. The receiving contour can be designed in different ways, for example by means of an undercut in the side profile, as well as a perforation or a recess.

[0017] According to an advantageous embodiment of the invention, it can be provided that the bonding connection is produced by means of an adhesive which is formed as a strip on the first edge and which extends at least partially over the longitudinal extension of the terminal element and / or that the bonding connection is produced by means of an adhesive which is formed as a strip on the second edge and which extends at least partially over the longitudinal extension of the terminal element. This embodiment has the advantage that a particularly secure and simple material-bonded connection can be achieved.

[0018] The adhesive may be applied in strips. This may be accomplished, for example, by a plurality of bonding points, continuous or discontinuous bonding lines arranged in a strip. The strip may be straight, zigzag or wavy.

[0019] The object of the invention is also achieved by a stator with a stator winding for an electric machine, wherein at least one terminal element according to one of claims 1 to 2 is used for the electrical connection of the stator winding. The design of the stator with the terminal element makes the winding head on the product side more compact, thereby reducing material and logistics costs. In terms of process, automation of the wiring and insulation processes can be achieved, thereby saving costs in mass production. This means that the customer's product flexibility is maintained and cost potential can be realized both in product design and production.

[0020] Furthermore, the object of the invention can also be achieved by a rotor of an electric machine having a rotor winding, wherein at least one terminal element according to one of claims 1 to 2 is used for the electrical connection of the rotor winding. The advantageous effect of this embodiment is based on the fact that even for wound rotors, such as wound rotors of DC motors, the connection must be carried out in a small installation space. The presented solution is particularly suitable for this purpose due to its good installation properties.

[0021] In addition, the object of the present invention is also achieved by a method for producing a stator of an electric motor, the method comprising the following steps:

[0022] Provide stator,

[0023] Provide stator winding,

[0024] providing a terminal element for electrically contacting two mutually spaced contact elements of the stator winding,

[0025] providing a flat insulating element having a first edge extending in the longitudinal extension of the terminal element and a second edge extending in the longitudinal extension of the terminal element,

[0026] a) establishing electrical contact between two mutually spaced contact elements of the stator winding by means of a terminal element,

[0027] b) Insert the terminal element into the flat insulating element,

[0028] c) folding the flat insulating element so that the terminal element is surrounded by the flat insulating element in a tubular manner,

[0029] d) Fixing the first edge of the flat insulation element relative to the second edge by means of a bonding connection and / or a form-fitting connection.

[0030] In terms of product properties, this has the particular effect of producing a structurally compact but flexible insulating part for the connection, which is particularly suitable for automation due to the defined process sequence.

[0031] In addition, the object of the present invention can also be achieved by a method for producing a rotor of an electric motor, the method comprising the following steps:

[0032] Provide rotor,

[0033] Provide rotor winding,

[0034] providing a terminal element for electrically contacting two mutually spaced contact elements of the rotor winding,

[0035] providing a flat insulating element having a first edge extending in the longitudinal extension of the terminal element and a second edge extending in the longitudinal extension of the terminal element,

[0036] a) establishing an electrical contact between two mutually spaced contact elements of the rotor winding by means of a terminal element,

[0037] b) Insert the terminal element into the flat insulating element,

[0038] c) folding the flat insulating element so that the terminal element is surrounded by the flat insulating element in a tubular manner,

[0039] d) Fixing the first edge of the flat insulation element relative to the second edge by means of a bonding connection and / or a form-fitting connection.

[0040] In an equally preferred embodiment of the invention, it can also be provided that, before the terminal element is inserted into the flat insulating element, the flat insulating element is preformed into a profile with a V-shaped or U-shaped cross section. This can help to ensure that the conductor is centered around the center of the flat insulating element, in particular in the case of large conductor cross sections or a large number of parallel sub-conductors. This simplifies the winding step and ensures an increased positional accuracy of the contact element and an increased process capability of the assembly.

[0041] The invention can also be further developed advantageously in such a way that the flat insulating element is preformed by means of a die which has a channel open on one side in cross section, in particular a V-shaped or U-shaped channel, into which the flat insulating element is inserted. This has the advantage that, depending on the specific contour of the terminal element, individual guiding properties of the flat insulating element can be developed in order to achieve optimal centering for a given product contour.

[0042] According to another preferred embodiment of the subject matter of the invention, it can be provided that the flat insulating element is sucked in and / or held in the channel by means of negative pressure. This can be used to prevent relative movement in the plane of the flat insulating element when the contact element is combined with the flat insulating element.

[0043] Finally, the invention can also advantageously be designed such that the channel has two channel wings which are movable relative to one another.

[0044] Finally, the object of the invention is also achieved by a kit for producing an insulating part of a terminal element for making electrical contact between two contact elements spaced apart from each other, the kit comprising:

[0045] a plurality of terminal elements, each terminal element being used to electrically contact two contact elements spaced apart from each other, each terminal element having a first conductor end and a second conductor end,

[0046] a plurality of flat insulating elements having a first edge with a first adhesive strip extending in the longitudinal extension of the terminal element and a second edge extending in the longitudinal extension of the terminal element,

[0047] A mold having a channel which is open on one side in cross section, in particular a V-shaped or U-shaped channel, into which the flat insulating element can be inserted.

[0048] This offers the advantage that all elements required for assembly, wiring and insulation are available in a particularly easy-to-assemble and convenient manner.

[0049] For example, a kit can be a packaging unit. In addition, a kit can be designed as a compilation of separate storage containers, which are used to store the individual components or corresponding component groups of the kit. BRIEF DESCRIPTION OF THE DRAWINGS

[0050] Without limiting the general concept of the invention, the invention is explained in more detail below with reference to the accompanying drawings.

[0051] In the attached picture:

[0052] Figure 1 The top view shows the connection element in two different manufacturing states.

[0053] Figure 2 A detailed view of a terminal element is shown in a perspective view,

[0054] Figure 3 shows a cross-sectional view of a wiring element,

[0055] Figure 4 A terminal element is shown in a top view with an adhesive strip applied to a flat insulating element,

[0056] Figure 5 A stator with terminal elements in a plan view showing the winding heads,

[0057] Figure 6 A first embodiment of a mold for producing a terminal element in two different production states of the terminal element is shown in cross-sectional views, respectively.

[0058] Figure 7 A second embodiment of a mold for producing a wiring element in two different manufacturing states of the wiring element is shown in cross-sectional views, respectively.

[0059] Figure 8 The kit is shown in a schematic block diagram. DETAILED DESCRIPTION

[0060] Figure 1A terminal element 1 is shown, which serves in particular to make electrical contact with two contact elements 2 which are spaced apart from one another, since these are present in particular in winding ends of stator windings or rotor windings in electrical machines.

[0061] The terminal element 1 has a first conductor end 3 and a second conductor end 4, wherein the terminal element 1 has an insulating part 5 between its first conductor end 3 and its second conductor end 4. The insulating part 5 is made of a flat insulating element 6 which at least partially surrounds the terminal element 1 and has a first edge 7 extending in the longitudinal extension of the terminal element 1 and a second edge 8 extending in the longitudinal extension of the terminal element 1. The first edge 7 is fixed relative to the second edge 8 of the flat insulating element 6 by means of a bonding connection and / or a form-fitting connection, so that the terminal element 1 is surrounded by the flat insulating element 6 in a tubular manner, which can be achieved by bonding. Figure 1 and Figures 2 to 3 Come together to understand easily.

[0062] Figure 1 The right-hand figure of shows a terminal element 1 which is inserted into a flat insulating element 6 and which is formed in this example as a terminal wire with a round conductor cross section. Figure 1 The left figure of FIG. 1 shows the closed assembled state of the flat insulating element 6, for example Figure 3 as shown in .

[0063] from Figure 4 It can be seen that the bonding connection is produced with the aid of an adhesive 9 which is formed as a strip on the first edge 7, which extends at least partially over the longitudinal extension of the terminal element 1, and which is formed as a strip extending at least partially at the second edge 8. This can be formed, for example, as an adhesive strip on the flat insulating element 6.

[0064] Figure 5 A stator 10 of an electric machine 11 with a stator winding 12 is shown, wherein, as shown in FIG. Figures 1 to 4 As is known, the connection element 1 is used for the electrical connection of the stator winding 12. Even though it is not shown in the figure, it is of course also possible that the rotor of the electric machine 11 with the rotor winding also uses at least one connection element 1 for the electrical connection of the rotor winding, such as Figures 1 to 4 shown.

[0065] The method for producing the stator 10 of the electric machine 11 is explained in more detail below; the method comprises the following steps:

[0066] First, a stator 10 and a stator winding 12 are provided. Furthermore, a terminal element 1 is provided for electrically contacting two mutually spaced contact elements 2 of the stator winding 12. A flat insulating element 6 is also provided, which has a first edge 7 extending in the longitudinal extension of the terminal element 1 and a second edge 8 extending in the longitudinal extension of the terminal element 1.

[0067] Then, an electrical contact is established by means of the terminal element 1 between two contact elements 2 of the stator winding 12 which are spaced apart from each other and which are connected at a position which is close to the terminal element 1. Figure 5 In the design example shown in , two winding ends of the winding head of the stator winding are shown. The insulating paper is provided with an adhesive strip, punched and embossed into a flat insulating element 6, and then fed to the insulating point on the terminal element 1, whereby, for example, the wire bundle of the terminal element 1 only needs to be positioned above the insulating paper.

[0068] In this state, the terminal element 1 is then inserted into the flat insulating element 6 and the flat insulating element 6 is folded over so that the terminal element 1 is surrounded in a tubular manner by the flat insulating element 6. Finally, the first edge 7 is fixed relative to the second edge 8 of the flat insulating element 6 by means of a bonding connection and / or a form-fitting connection.

[0069] from Figure 6 It can be seen that before the terminal element 1 is inserted into the flat insulating element 6, the flat insulating element 6 is preformed into a profile with a V-shaped or U-shaped cross section. The preforming of the flat insulating element 6 is carried out with the aid of a mold 13, which has a channel 14 open on one side in the cross section, in particular a V-shaped or U-shaped channel 14, into which the flat insulating element 6 is inserted. The flat insulating element 6 can be sucked into the channel 14 and / or held, for example, by means of negative pressure. Figure 7 In a further exemplary embodiment of a mould 13 shown in FIG, the channel 14 has two channel wings 15 , 16 which are movable relative to one another and which can be pivoted towards one another after insertion of the terminal element 1 .

[0070] Thus, the flat insulating element 6, which is designed as insulating paper, for example, is transformed from a flat shape into a V-shape or a U-shape and finally into a closed shape by means of the mold 13. The electrical insulation of the terminal element 1 is produced by closing the insulating points of the terminal element 1. By bonding the connection with the adhesive 9 in the insulating paper, a permanent connection is produced, wherein the terminal element 1 insulated in this way can still be laid and impregnated with resin, for example, after the insulation assembly.

[0071] at last, Figure 8A kit 20 is shown for producing an insulating part of a terminal element 1 for making electrical contact between two mutually spaced contact elements 2. The kit comprises: a plurality of terminal elements 1, each for making electrical contact between two mutually spaced contact elements 2, each having a first wire end 3 and a second wire end 4; and a plurality of flat insulating elements 6, the flat insulating elements having a first edge 7 extending in the longitudinal extension of the terminal element 1 and having a first adhesive strip 17, and a second edge 8 extending in the longitudinal extension of the terminal element 1. Finally, the kit 20 also contains a mold 13, which has a channel 14 open on one side in cross section, in particular a V-shaped or U-shaped channel 14, into which the flat insulating elements 6 can be inserted. In particular, the above-described method for producing an insulating part of a terminal element 1 on a stator 10 can be carried out with the kit 20, whereby the kit 20 provides the necessary components and tools to the technician in a very convenient manner.

[0072] The present invention is not limited to the embodiments shown in the accompanying drawings. Therefore, the above description should not be regarded as limiting, but rather as illustrative. The attached claims should be understood to mean that the stated features exist in at least one embodiment of the present invention. This does not exclude the existence of other features. Where the claims and the above description define a "first" feature and a "second" feature, such naming is used to distinguish between two features of the same type without defining the order of precedence.

[0073] Reference numerals list

[0074] 1 Wiring components

[0075] 2 Contact elements

[0076] 3 Wire end

[0077] 4 Wire ends

[0078] 5 Insulation

[0079] 6 Flat insulating element

[0080] 7 Edge

[0081] 8 Edge

[0082] 9 Adhesives

[0083] 10 Stator

[0084] 11 Motor

[0085] 12 Stator winding

[0086] 13. Mould

[0087] 14 channels

[0088] 15 Channel wing

[0089] 16 channels

[0090] 17 Adhesive Strips

[0091] 20 Kits.

Claims

1. A terminal element (1), which is used in particular for electrically contacting two contact elements (2) spaced apart from one another, The wiring element comprises a first wire end (3) and a second wire end (4), wherein: The wiring element (1) has an insulating member (5) between a first wire end (3) of the wiring element and a second wire end (4) of the wiring element. It is characterized in that The insulating member (5) is made of a flat insulating element (6) which at least partially surrounds the terminal element (1). The flat insulating element has a first edge (7) extending in the longitudinal extension of the terminal element (1) and a second edge (8) extending in the longitudinal extension of the terminal element (1), The first edge (7) is fixed relative to the second edge (8) of the flat insulating element (6) by means of a bonding connection and / or a form-fitting connection, so that the terminal element (1) is surrounded by the flat insulating element (6) in a tubular manner.

2. The wiring element according to claim 1, It is characterized in that The bonding connection is produced by means of an adhesive (9) which is formed as a strip on the first edge (7) and which extends at least partially over the longitudinal extension of the terminal element (1). and / or The bonding connection is produced by means of an adhesive (9) which is formed as a strip on the second edge (8) and which extends at least partially over the longitudinal extension of the terminal element (1).

3. A stator (10) of an electric motor (11), the stator having a stator winding (12), characterized in that: At least one terminal element (1) according to one of claims 1 to 2 is used for the electrical connection of the stator winding (12).

4. A rotor of an electric motor (11), the rotor having a rotor winding, characterized in that: At least one terminal element (1) according to one of claims 1 to 2 is used for the electrical connection of the rotor winding.

5. A method for producing a stator (10) for an electric machine (11), the method comprising the following steps: Providing a stator (10), providing a stator winding (12), providing a terminal element (1) for electrically contacting two mutually spaced contact elements (2) of the stator winding (12), providing a flat insulating element (6) having a first edge (7) extending in the longitudinal extension of the terminal element (1) and a second edge (8) extending in the longitudinal extension of the terminal element (1), a) establishing electrical contact between the two contact elements (2) of the stator winding (12) which are spaced apart from one another by means of the terminal element (1), b) inserting the terminal element (1) into the flat insulating element (6), c) folding the flat insulating element (6) so that the terminal element (1) is surrounded by the flat insulating element (6) in a tubular manner, d) fixing the first edge (7) of the flat insulating element (6) relative to the second edge (8) by means of a bonding connection and / or a form-fitting connection.

6. A method for producing a rotor for an electric machine (11), the method comprising the following steps: Provide rotor, Provide rotor winding, providing a terminal element (1) for electrically contacting two mutually spaced contact elements (2) of the rotor winding, providing a flat insulating element (6) having a first edge (7) extending in the longitudinal extension of the terminal element (1) and a second edge (8) extending in the longitudinal extension of the terminal element (1), a) establishing electrical contact between the two contact elements (2) of the rotor winding which are spaced apart from one another by means of the terminal element (1), b) inserting the terminal element (1) into the flat insulating element (6), c) folding the flat insulating element (6) so that the terminal element (1) is surrounded by the flat insulating element (6) in a tubular manner, d) fixing the first edge (7) of the flat insulating element (6) relative to the second edge (8) by means of a bonding connection and / or a form-fitting connection.

7. The method according to claim 5 or 6, It is characterized in that Before the terminal element (1) is inserted into the flat insulating element (6), the flat insulating element (6) is preformed into a profile having a V-shaped or U-shaped cross section.

8. The method according to any one of claims 5 to 7, It is characterized in that The flat insulating element (6) is preformed by means of a mold (13) which has a channel (14) open on one side in cross section, in particular a V-shaped or U-shaped channel (14), into which the flat insulating element (6) is inserted.

9. The method according to claim 8, It is characterized in that The flat insulating element (6) is sucked into the channel (14) and / or held by means of negative pressure.

10. The method according to any one of claims 5 to 9, It is characterized in that The channel (14) has two channel wings (15, 16) which are movable relative to each other.

11. A kit (20) for producing an insulating part of a terminal element (1) for making electrical contact between two contact elements (2) spaced apart from each other, the kit comprising: A plurality of terminal elements (1), each terminal element being used to electrically contact two contact elements (2) spaced apart from each other, each terminal element having a first conductor end (3) and a second conductor end (4), a plurality of flat insulating elements (6) having a first edge (7) with a first adhesive strip (17) extending in the longitudinal extension of the terminal element (1) and a second edge (8) extending in the longitudinal extension of the terminal element (1), A mold (13) having a channel (14) which is open on one side in cross section, in particular a V-shaped or U-shaped channel (14), into which the flat insulating element (6) can be inserted.

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