Sensor holder, system consisting of sensor holder and temperature sensor, electric machine and method for fastening system

Abstract

The invention relates to a sensor holder (12) for a temperature sensor (14) of an electric machine (32), comprising: a sensor receiving section (16) having a cavity (20) and an opening (22), such that the temperature sensor (14) can be arranged in the cavity (20) through the opening (22); and a fastening section (18) which is adjacent to the sensor receiving section (16) and is directly connected to the sensor receiving section (16), said fastening section having a through-opening (26) with a closed edge such that the sensor holder (12) can be inserted onto a conductor end (28) of the stator winding (30), the sensor receiving section (16) and the fastening section (18) being made of an elastic material. The invention further relates to a system (10) consisting of the sensor holder (12) and the temperature sensor (14), to an electric machine (32) having the system (10), and to a method for fastening the system (10) to a conductor end (28) of a stator winding (30).

Description

Technical Field

[0001] The invention relates to a sensor holder for a temperature sensor of an electric machine, wherein the sensor holder is made of an elastic material so that the sensor holder can be plugged onto a conductor end of a winding head and can be guided through a bending region of the conductor end. The subject matter of the invention further includes a system consisting of a sensor holder according to the invention and a temperature sensor arranged in the sensor holder. The invention further relates to an electric machine having a system according to the invention. The invention further relates to a method for fastening a system according to the invention. Background Art

[0002] Sensor holders for temperature sensors and for arrangement at the conductor ends of stator windings are generally known. For example, EP 3537579 B1 describes an insulating ring with such a sensor holder, which has a pocket in which the temperature sensor is arranged. The sensor holder also has a conductor guide into which the conductor ends of the stator windings are guided and pressed against the temperature sensor. The sensor holder is designed in such a way that only the distal conductor ends are pressed against the temperature sensor and therefore only the temperature can be measured there. Summary of the invention

[0003] The object of the present invention is to provide a sensor holder for a temperature sensor of an electric machine which can be placed in an easy manner on a conductor of a stator winding close to a winding head of the stator winding.

[0004] This object is achieved by the subject matter of the independent claims. Preferred developments of the invention are the subject matter of the dependent claims, the following description and the drawings. In this context, each feature can represent an aspect of the invention both individually and in combination, unless something to the contrary is clearly evident from the description.

[0005] In a first aspect, the present invention relates to a sensor bracket for a temperature sensor of an electric motor, the sensor bracket comprising: a sensor receiving section having a cavity and an opening, so that the temperature sensor can be arranged in the cavity through the opening; and a fastening section adjacent to the sensor receiving section and directly connected to the sensor receiving section, the fastening section having a through opening with closed edges, so that the sensor bracket can be inserted onto the conductor end of a stator winding, wherein the sensor receiving section and the fastening section are made of elastic material.

[0006] In other words, according to the first aspect of the present invention, a sensor bracket for a temperature sensor of an electric motor is provided. The sensor bracket includes a sensor receiving section and a fastening section. The sensor receiving section has a cavity and an opening, so that the temperature sensor can be inserted into the cavity of the sensor receiving section through the opening and arranged therein. The fastening section is constructed adjacent to the sensor receiving section. In other words, the fastening section and the sensor receiving section are firmly or inseparablely connected to each other. The fastening section has a through opening with closed edges. Therefore, the conductor end of the stator winding can be embedded in the fastening opening, so that the sensor bracket can be inserted and fixed on the conductor end of the stator winding. The sensor receiving section and the fastening section are composed of elastic or flexible materials. In this way, the sensor bracket can be directly inserted on the conductor end and pushed into a corresponding position on the conductor end along the longitudinal direction of the conductor end. Due to the elastic construction scheme of the sensor bracket, any bending of the conductor end can be overcome, so that the temperature sensor can be positioned as close as possible to the winding head of the stator winding to detect the maximum temperature of the stator or stator winding.

[0007] A preferred development of the invention is that the elastic material is a silicone-containing and / or silicone-like material. In other words, the elastic material contains silicone at least in sections and / or in parts. Silicone-containing materials can have an increased and lasting flexibility. Therefore, such materials are particularly suitable for the sensor holder in order to fix the sensor holder directly or immediately to the conductor end. Any subsequent heat treatment for fixing the sensor holder to the conductor end can thus be omitted.

[0008] It is particularly preferably provided that the silicone-containing material is a non-gassing material. In other words, it is provided that, in particular at elevated temperatures, i.e. temperatures within the operating range of the electric machine, the silicone-containing material does not release vapors which could damage other components of the electric machine. Thus, not only is a sensor holder provided which can be particularly conveniently plugged onto a conductor end, but also an operationally safe sensor holder is provided.

[0009] In an advantageous development of the invention, it is provided that the fastening section and the sensor receiving section are formed integrally with one another. In other words, it is provided that the fastening section and the sensor receiving section are formed integrally with one another during the manufacturing process. The sensor holder can thus be manufactured in an injection molding process. In other words, the elastic material is poured into an injection mold and then removed from the injection mold. The sensor holder can thus be manufactured particularly cost-effectively.

[0010] It is conceivable that the fastening section and the sensor receiving section consist of two different elastic materials. It can be advantageous if the sensor receiving section has an increased rigidity relative to the fastening section for arranging the temperature sensor.

[0011] Advantageously, provision is made for both the fastening section and the sensor receiving section to consist of the same elastic material. This has advantages during production. Furthermore, if the fastening section and the sensor receiving section consist of the same material, material-related and / or production-related interfaces can be reduced. Furthermore, since only one material is used, costs can be reduced.

[0012] In a preferred embodiment of the present invention, it is provided that the sensor receiving section and the fastening section are arranged parallel and / or side by side with respect to the longitudinal direction of the sensor holder. In other words, the sensor holder has a longitudinal direction. With respect to this longitudinal direction, the sensor receiving section and the fastening section are arranged parallel to each other. Likewise, the longitudinal direction of the cavity in the sensor receiving section and the longitudinal direction of the edge-closed through-opening in the fastening section are parallel to the longitudinal direction of the sensor holder. In this way, the sensor holder can be plugged onto the conductor end of the stator winding, wherein the temperature sensor is thus also oriented parallel to the longitudinal direction or longitudinal direction of the conductor end. Since the temperature sensor is oriented with respect to the direction of the conductor end, a space-saving arrangement and / or orientation of the temperature sensor in the sensor holder can therefore be achieved.

[0013] An advantageous development of the invention is that the length of the sensor receiving section in the longitudinal direction of the sensor holder is longer than the length of the fastening section in the longitudinal direction of the sensor holder. In this way, a particularly flexible sensor holder is provided, since the fastening section is designed just long enough to ensure the necessary fastening on the conductor end of the stator winding and to provide the greatest possible flexibility, so that in particular bending of the conductor is overcome when the sensor holder is moved on the conductor end in the longitudinal direction of the conductor end. The required and necessary fastening of the temperature sensor can be achieved by means of a longer sensor receiving section.

[0014] According to a preferred design of the present invention, it is provided that the fastening section is constructed parallel to the sensor head section of the sensor receiving section and / or is constructed at the height of the sensor head section relative to the sensor receiving section. In other words, the sensor receiving section has a sensor head section, which is constructed in the cavity on the side facing away from the opening. Therefore, the temperature sensor is inserted into the cavity of the sensor receiving section through the opening with the sensor head at the front. The fastening section is constructed at the height of the sensor head section. In this way, the temperature sensor can be held and / or pressed to the conductor end of the stator winding, so that the temperature of the stator winding can be reliably detected by the temperature sensor.

[0015] The temperature sensor is not directly adjacent to the electrical conductor, but is separated from it by an intermediate wall, ie the wall of the fastening section and the sensor receiving section.

[0016] In an advantageous improvement of the present invention, it is provided that the through-opening has a rectangular cross section and at least one protrusion is respectively constructed on the inner side of the through-opening facing the sensor receiving section and / or on the inner side of the through-opening in the region of two opposite lateral sections of the fastening section. Therefore, the cross section of the through-opening is preferably adapted to the outer contour of the conductor end of the stator winding. A protrusion is constructed on the inner side of the through-opening facing the sensor receiving section. The protrusion acts as a clamping element and / or a fixing element, so that the sensor holder is securely fastened to the conductor end of the stator winding. It is also conceivable and advantageously provided that the two lateral sections of the fastening section connected to the sensor receiving section each have a protrusion on their inner side. The positioning of the sensor holder on the conductor end and the clamping of the sensor holder on the conductor end can be achieved by means of the protrusion.

[0017] In a second aspect, the invention relates to a system comprising a sensor holder according to the invention and a temperature sensor arranged in the sensor holder, wherein the temperature sensor is inserted into a cavity through an opening of the sensor receiving section and is fixed therein in a materially bonded manner.

[0018] According to a second aspect of the present invention, it is therefore provided that a temperature sensor is arranged in the sensor holder. The temperature sensor is preferably inserted into the cavity with the sensor head at the front through the opening. The wiring of the temperature sensor is led out of the opening. The temperature sensor is arranged in the cavity in a material-locked manner. Due to the material-locked connection of the temperature sensor in the cavity, the temperature sensor is arranged inseparably in the sensor holder. In addition, due to the material-locked connection of the temperature sensor in the cavity, a better heat transfer from the temperature to be detected through the intermediate wall and the material-locked connection to the sensor head of the temperature sensor can be achieved. The material-locked fixing part is preferably a permanently elastic casting part, which particularly preferably also has a silicone-containing material.

[0019] In a third aspect, the invention relates to an electric machine having a stator with a stator winding, wherein the stator winding has at least one conductor end and the system according to the invention is plugged onto the conductor end, wherein the conductor end engages in an edge-closed through-opening of a fastening section.

[0020] According to a third aspect of the invention, an electric machine is provided, which has a stator, wherein the stator comprises a stator winding. At the end side of the stator, the stator winding has a winding head. The system according to the invention is plugged onto the conductor end of the stator winding in order to measure the temperature close to the winding head.

[0021] In a fourth aspect, the invention relates to a method of fastening a system according to the invention to a stator winding, wherein:

[0022] - providing a stator having a stator winding, wherein the stator winding has a winding head with a conductor end,

[0023] The system is plugged onto the conductor end, wherein the conductor end is inserted into the through-opening of the fastening section and the system is moved in the longitudinal direction of the conductor into the end position.

[0024] In other words, according to the fourth aspect of the present invention, a method for fastening a system to a stator winding is provided. It is provided that in a first step, a stator having a stator winding is provided, wherein the stator winding has a winding head at the end side of the stator. The winding head includes a conductor end. A system consisting of a sensor holder and a temperature sensor arranged in the sensor holder is inserted onto the conductor end. Here, the conductor end is embedded in the through-opening of the fastening section, and the system is moved into a final position along the longitudinal direction of the conductor of the stator winding. The final position is preferably constructed with a distance from the distal end of the conductor end. Therefore, the stator is first manufactured, and then the stator winding is arranged in the stator, and the winding head is preferably constructed by twisting the winding head. Preferably, before the stator winding is connected, the temperature sensor is pushed onto the winding head of the conductor of the stator winding, preferably onto the neutral conductor. Therefore, a method is provided, by which the system, in particular the sensor holder, can be easily arranged on the electrical conductor or easily arranged on the conductor end of the stator winding.

[0025] Finally, an advantageous development of the invention is that after the winding head of the stator winding is formed, the system is plugged onto the conductor end, wherein the conductor end of the stator winding has a bend in at least one region, which has an angle α of 90°≤α≤160°, preferably 95°≤α≤150°, particularly preferably 100°≤α≤140° relative to the longitudinal axis of the conductor end, and the sensor holder is guided along the conductor through the region of the bend. In other words, the stator winding is constructed, wherein the conductor end has at least one bend region. The conductor is bent at an angle α of 90°≤α≤160° relative to the longitudinal axis of the conductor end. The system or the sensor holder is guided through this bend section of the conductor.

[0026] It should be noted that all features described above and below with respect to an aspect of the invention are equally applicable to any other aspect of the invention. In particular, all features of the sensor support and / or the system and / or the motor and / or the method can also be features of the motor vehicle. This also applies in reverse. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Other features and advantages of the invention can be derived from the dependent claims and the following examples. The examples are not restrictive but can be understood as examples. The examples should enable a person skilled in the art to implement the invention. The applicant reserves the right to make single and / or multiple features of the features disclosed in the examples the subject of claims or to incorporate these features into existing claims. The examples are explained in more detail with reference to the drawings.

[0028] in:

[0029] Figure 1 shows a longitudinal cross-sectional view of a system including a sensor holder and a temperature sensor;

[0030] Figure 2 An isometric view of the system is shown;

[0031] Figure 3 A detailed view showing the system inserted on the conductor end of the stator winding;

[0032] Figure 4 A detailed view of the electric machine in the area of ​​the plugged-in system is shown;

[0033] Figure 5 A method for plugging the system onto the conductor end of a stator winding is shown. DETAILED DESCRIPTION

[0034] Figure 1 A longitudinal sectional view of a system 10 is shown, which comprises a sensor holder 12 and a temperature sensor 14. The sensor holder 12 comprises a sensor receiving section 16 and a fastening section 18. The sensor receiving section 16 has a cavity 20 and an opening 22. The temperature sensor 14 is guided into the cavity 20 of the sensor receiving section 16 through the opening 22. The fastening section 18 is constructed directly adjacent to the sensor receiving section 16. It is provided that the sensor receiving section 16 and the fastening section 18 are arranged parallel and / or side by side with respect to a longitudinal direction 24 of the sensor holder 12. In other words, the sensor holder 12 has a longitudinal direction 24. With respect to this longitudinal direction 24, the sensor receiving section 16 and the fastening section 18 are arranged parallel to each other.

[0035] The fastening section 18 has a through opening 26 that is closed at the edges. Both the longitudinal direction of the cavity 20 and the longitudinal direction of the through opening 26 are parallel to the longitudinal direction 24 of the sensor holder 12. In this way, the sensor holder 12 can be plugged onto the conductor end 28 of the stator winding 30 and the temperature sensor 14 is thus oriented parallel to the longitudinal direction or longitudinal extension of the conductor end 28.

[0036] The sensor receiving section 16 and the fastening section 18 are made of an elastic or flexible material. In this way, the sensor holder 12 can be plugged directly onto the conductor end 28 and pushed onto the conductor end 28 in the longitudinal direction thereof into a corresponding position. Due to the elastic design of the sensor holder 12, any bending of the conductor end 28 can be overcome, so that the temperature sensor 14 can be positioned as close as possible to the winding head in order to detect the maximum temperature of the stator winding 30. Due to the elastic design of the sensor holder 12, in the final position of the sensor holder 12 on the conductor end 28, no final heat treatment of conceivable fixing means, such as, for example, a plugged-in shrink tube, is required. Thus, a sensor holder 12 for a temperature sensor 14 is provided, which can be easily placed on a conductor of a stator winding 30.

[0037] In the present embodiment, the elastic material is a silicone-containing material that does not release gases. In other words, the elastic material contains silicone at least in sections and / or in parts. Silicone-containing materials can have an increased and lasting flexibility. Therefore, such materials are particularly suitable for the sensor holder 12 in order to fix the sensor holder 12 directly or immediately on the conductor end 28. Since the elastic material is designed to not release gases, no harmful vapors are released at elevated temperatures of the motor 32, i.e., at temperatures within the operating range of the motor 32. Therefore, not only a sensor holder 12 that can be particularly comfortably plugged onto the conductor end 28 is provided, but also a sensor holder 12 that is safe in operation is provided.

[0038] The fastening section 18 and the sensor receiving section 16 are formed integrally with one another. In other words, it is provided that the fastening section 18 and the sensor receiving section 16 are formed integrally with one another during the manufacturing process. The sensor holder 12 can thus preferably be manufactured in an injection molding process. In other words, the elastic material is cast into an injection mold and then removed from the injection mold. The sensor holder 12 can thus be manufactured particularly cost-effectively.

[0039] The length of the sensor receiving section 16 in the longitudinal direction 24 of the sensor holder 12 is longer than the length of the fastening section 18 in the longitudinal direction 24 of the sensor holder 12. In this way, a particularly flexible sensor holder 12 is provided, since the fastening section 18 is designed just long enough to ensure the necessary fastening on the conductor end 28 of the stator winding 30 and to provide a maximum degree of flexibility, so that in particular bending of the conductor 28 is overcome when the sensor holder 12 is moved at the conductor end 28 in the longitudinal direction of the conductor end. The required and necessary fastening of the temperature sensor 14 can be achieved by the longer sensor receiving section 16.

[0040] Figure 2The system 10 is shown in an isometric view. The through-opening 26 with closed edges has a rectangular cross section, wherein at least one projection 36 is respectively formed on the inner side of the through-opening 26 facing the sensor receiving section 16 and on the inner side of the through-opening 26 in the region of two opposite lateral sections 34 of the fastening section 18. The cross section of the through-opening 26 is therefore preferably adapted to the outer contour of the conductor end 28 of the stator winding 30. The projection 36 is formed on the inner side of the through-opening 26 facing the sensor receiving section 16. The projection 36 acts as a clamping element and / or fixing element, so that the sensor holder 12 can be securely fastened to the conductor end 28 of the stator winding 30. It is also provided that the two lateral sections 34 of the fastening section 18 connected to the sensor receiving section 16 each have a projection 36 on their inner side. The positioning of the sensor holder 12 on the conductor end 28 and the pressing of the sensor holder 12 on the conductor end 28 can be achieved by means of these projections 36.

[0041] Figure 3 A detailed view of the system 10 inserted on the conductor end 28 of the stator winding 30 is shown. Starting from the distal end 38 of the conductor end 28 of the stator winding 30, the system 10 including the sensor holder 12 with the temperature sensor 14 arranged and cast therein is inserted onto the conductor end 28 and is pushed along the longitudinal extension of the conductor end 28 into the end position. Starting from the distal end 38, the conductor end 28 has two curved and mutually spaced sections relative to the longitudinal axis of the conductor end 28. In the corresponding area, the conductor is designed to be curved at an angle α of 110°. The system 10 is pushed along the insertion path 40 on the conductor until it reaches the end position.

[0042] exist Figure 4 Detailed view of the electric machine 32 in the region of the inserted system 10 is shown in FIG. After the system 10 has been inserted via the distal end 38 onto the conductor end 28 and has been pushed into the final position on the electrical conductor, the winding heads of the stator winding 30 are cast. The system 10 at least partially extends into the casting 42. This ensures that the system 10 is permanently positioned in the final position. In addition, the thermal connection of the temperature sensor 14 to the winding heads can be improved.

[0043] Figure 5 A method of plugging the system 10 onto the conductor ends 28 of the stator windings 30 is shown.

[0044] In a first step 100 , a stator having a stator winding 30 is provided, wherein the stator winding 30 has a winding head with a conductor end 28 .

[0045] In a second step 110 , starting from the distal end 38 of the conductor end 28 , the system 10 is plugged onto the conductor end 28 , wherein the conductor end 28 is inserted into the through-opening 26 of the fastening section 18 .

[0046] In a third step 120 , the system 10 is moved along the longitudinal direction or longitudinal extension of the conductor or conductor end 28 into a final position close to the winding head.

Claims

1. A sensor bracket (12) for a temperature sensor (14) of an electric motor (32), the sensor bracket comprising: A sensor receiving section (16) having a cavity (20) and an opening (22), so that a temperature sensor (14) can be arranged in the cavity (20) through the opening (22); as well as a fastening section (18) adjacent to the sensor receiving section (16) and directly connected to the sensor receiving section (16), the fastening section having a through-opening (26) with closed edges, so that the sensor holder (12) can be plugged onto a conductor end (28) of a stator winding (30), The sensor receiving section (16) and the fastening section (18) are made of elastic material.

2. The sensor bracket (12) according to claim 1, characterized in that The elastic material is a silicone-containing material.

3. The sensor holder (12) according to any one of the preceding claims, characterized in that The fastening section (18) and the sensor receiving section (16) are formed integrally with one another.

4. The sensor holder (12) according to any one of the preceding claims, characterized in that The sensor receiving section (16) and the fastening section (18) are arranged parallel and / or next to each other with respect to a longitudinal direction (24) of the sensor holder (12).

5. The sensor holder (12) according to any one of the preceding claims, characterized in that The length of the sensor receiving section (16) along the longitudinal direction (24) of the sensor bracket (12) is longer than the length of the fastening section (18) along the longitudinal direction (24) of the sensor bracket (12).

6. The sensor holder (12) according to any one of the preceding claims, characterized in that The fastening section (18) is designed parallel to a sensor head section of the sensor receiving section (16) and / or is designed at a height relative to the sensor head section of the sensor receiving section (16).

7. The sensor holder (12) according to any one of the preceding claims, characterized in that The through-opening (26) has a rectangular cross-section and is provided with at least one projection (36) on the inner side of the through-opening (26) facing the sensor receiving section (16) and / or on the inner side of the through-opening (26) in the region of two opposite lateral sections (34) of the fastening section (18).

8. A system (10) comprising a sensor holder (12) according to any one of the preceding claims and a temperature sensor (14) arranged in the sensor holder (12), wherein: The temperature sensor (14) is inserted into the cavity (20) through an opening (22) of the sensor receiving section (16) and is fixed therein in a materially bonded manner.

9. An electric machine (32) having a stator with a stator winding (30), wherein: The stator winding (30) has at least one conductor end (28), and the system (10) according to claim 8 is plugged onto the conductor end (28), wherein the conductor end (28) engages in a through-opening (26) of the fastening section (18) that is closed at the edge.

10. A method for fastening a system (10) according to claim 8 to a stator winding (30), wherein: - providing a stator having a stator winding (30), wherein the stator winding (30) has a winding head with a conductor end (28), - plugging the system (10) onto the conductor end (28), wherein the conductor end (28) is inserted into a through-opening (26) of the fastening section (18) and the system (10) is moved into a final position along the longitudinal direction of the conductor.

11. The method according to claim 10, characterized in that After forming the winding head of the stator winding (30), the system (10) is inserted into the conductor end (28). The conductor end (30) of the stator winding (30) has a bend in at least one region, which has an angle α of 90°≤α≤160° relative to the longitudinal axis of the conductor end (28), and the sensor holder (12) is guided along the conductor through the region of the bend.

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