High-voltage interface and method for producing contact element

Abstract

The invention relates to a high-voltage connection (10) for producing an electrical connection between a stator (25) having a stator-side busbar (26) and a housing-side joining part (30) of a high-voltage electronic component (35) by means of a contact element (8). In order to functionally improve and / or simplify the high-voltage connection (10) in terms of production, the contact element (8) has a helical tolerance compensation structure (38) which is designed and arranged in such a way that not only tolerances along the longitudinal axis (36) of the contact element (8) can be compensated, but also tolerances along the longitudinal axis (36) of the contact element (8) can be compensated. An inclined position of the engagement part (30) relative to the contact element (8) can also be compensated.

Description

Technical Field

[0001] The invention relates to a high-voltage interface for establishing an electrical connection between a stator having a stator-side busbar and a housing-side connection piece of a high-voltage electronic component by means of a contact element. The invention also relates to a method for producing a contact element for such a high-voltage interface. Background Art

[0002] From German laid-open patent document DE 10 2019 207 438 A1, an electrically supported turbocharger is known, which has a seal housing, a stator package of an electric motor coupled to the turbocharger, which is connected to the seal housing, and an electronics housing of the electric motor, which is connected to the stator package. From European patent document EP 3 641 068 B1, a plug connector with a coupling plug and a coupling socket is known, wherein the coupling socket comprises an annular socket part and a lamellar rotor cage arranged at least partially inside the annular socket part. Summary of the invention

[0003] The object of the present invention is to functionally improve or to simplify in terms of production a high-voltage interface for producing an electrical connection between a stator having stator-side busbars and a housing-side connection part of a high-voltage electronic component by means of contact elements.

[0004] The task is solved in the following way in a high-voltage interface for establishing an electrical connection between a stator with a stator-side busbar and a coupling piece on the housing side of a high-voltage electronic device by means of a contact element, wherein the contact element has a spiral tolerance compensation structure, which is implemented and arranged so that not only the tolerance along the longitudinal axis of the contact element can be compensated, but also the tilted position of the coupling piece relative to the contact element can be compensated. Here, higher production costs are intentionally borne when manufacturing the contact element. The spiral tolerance compensation structure can be processed into the contact element in different ways. The spiral tolerance compensation structure is constructed in a substantially cylindrical shell shape at least on its ends that are separated from each other. Between the ends of the tolerance compensation structure that are separated from each other, the spiral tolerance compensation structure can have a reduced or also increased diameter. At least when the contact element is not subjected to load, the spiral tolerance compensation structure can have a substantially constant diameter along its longitudinal axis. In the state of bearing load, especially in the installed state, the configuration of the spiral tolerance compensation structure can be changed so that the desired tolerance compensation can be achieved. This significantly simplifies the assembly of the high-voltage interface. The intentionally permitted configuration change of the tolerance compensation structure is caused on the one hand by the spiral configuration. In addition, the contact element is formed by the following material at least in the region of the spiral tolerance compensation structure, and the material can be elastically deformed in a limited manner. The spiral for establishing the spiral tolerance compensation structure can include a spiral cut (Helixschnitt) in the tolerance compensation structure of a substantially cylindrical shell shape. But the spiral can also include more than one spiral cut. The tolerance compensation capability can be improved thereby. But the configuration of the tolerance compensation structure with multiple spiral cuts is also more expensive in manufacturing. The electrical connection is referred to as a high-voltage interface, and the electrical connection can be operated by an alternating voltage of thirty volts to one thousand volts or by a direct voltage of sixty volts to one thousand five hundred volts. High safety requirements, especially in terms of touch protection, are guaranteed here.

[0005] A preferred embodiment of the high-voltage connection is characterized in that the helical tolerance compensation structure is formed from an elastically deformable material. The elastic deformability simplifies the manufacture of the contact element with the helical tolerance compensation structure. In addition, the establishment of the desired tolerance compensation function is simplified by the elastically deformable material. Of course, the material forming the helical tolerance compensation structure cannot be elastically deformed indefinitely. The elastic deformation plays a role mainly within the scope of the desired tolerance compensation function. The material forming the contact element with the helical tolerance compensation structure remains deformed during the manufacture of the contact element.

[0006] Another preferred embodiment of the high-voltage connection is characterized in that the tolerance compensation structure is formed by an electrically conductive sheet material, which has a spiral shape. The electrically conductive sheet material is preferably a metal sheet material, which, in addition to its electrically conductive material properties, can be processed relatively easily in order to produce the tolerance compensation structure in the contact element in the desired configuration.

[0007] Another preferred embodiment of the high-voltage interface is characterized in that the contact element with the tolerance compensation structure has the configuration of a straight cylinder. In the area of ​​the spiral tolerance compensation structure, the contact element has the configuration of a straight cylindrical shell, into which the spiral tolerance compensation structure is introduced by corresponding processing. This simplifies the stable conductive connection of the contact element to the busbar on the stator side and to the joint on the housing side of the high-voltage electronic device. Here, it is intentionally allowed that when the contact element is assembled, the configuration of the straight cylinder of the contact element with the tolerance compensation structure is changed within the framework of the desired tolerance compensation function. The conductive connection of the contact element to the busbar is preferably achieved by material locking. The conductive connection of the contact element with the tolerance compensation structure to the joint on the housing side of the high-voltage electronic device is preferably achieved by means of a screw connection. In addition, the following advantages are provided: the existing tolerance is automatically compensated in a simple manner when the contact element is assembled.

[0008] Another preferred embodiment of the high-voltage connection is characterized in that the contact element with the tolerance compensation structure has the configuration of a circular ring at the end facing the connection piece, the circular ring having a through hole. This makes it possible to realize a screw connection for the conductive connection to the connection piece with simple structural and production measures.

[0009] Another preferred embodiment of the high voltage interface is characterized in that the contact element with the tolerance compensation structure is electrically conductively connected to the busbar through a multifunctional sleeve on the end away from the joint. The multifunctional sleeve basically has the configuration of a straight cylindrical shell. The multifunctional sleeve is preferably connected to the contact element in one piece. But it is also possible that the multifunctional sleeve is connected to the contact element in another way, such as material locking. The conductive connection of the multifunctional sleeve to the busbar is preferably realized in a material locking manner. However, according to the embodiment, the multifunctional sleeve can also be connected to the busbar in another way, such as force locking, shape locking or also in one piece. The multifunctional sleeve is additionally implemented in addition to its conductive function on the high voltage interface. The other function preferably includes at least one sealing function. In addition, the multifunctional sleeve is also advantageously used to position the tolerance compensation structure constructed on the contact element relative to the joint so that the conductive connection between the end of the contact element facing the joint and the joint is preferably manufactured by means of bolts.

[0010] Another preferred embodiment of the high-voltage interface is characterized in that the multifunctional sleeve has an axial bearing section for the inner seal, wherein the bearing section for the inner seal has an outer diameter greater than the tolerance compensation structure. The inner seal is preferably an internal single seal. Between the tolerance compensation structure and the bearing section for the inner seal, a conical guide section is preferably provided on the contact element, which simplifies the assembly of the inner seal. The tolerance compensation structure is advantageously arranged inside the support column, which preferably completely surrounds the tolerance compensation structure in the assembled state of the contact element. The support column is preferably formed of an electrically insulating material. The support column reliably prevents the tolerance compensation structure deformed during assembly from contacting with conductive parts, especially housing parts. The inner seal is preferably combined with an outer seal, which is preferably implemented as an external integrated seal for multiple, especially all contact elements.

[0011] Another preferred embodiment of the high-voltage connection is characterized in that the multifunctional sleeve has a receiving space for a plug seal at its end facing the busbar. The plug seal is fastened in the free end of the multifunctional sleeve, for example, by means of a fastening plug. By the combination of inner seal, outer seal and plug seal, a very convenient sealing concept is provided, by which the contact element can not only be protected from moisture in the assembled state, but also by which the required air tightness of the high-voltage connection is ensured.

[0012] The invention also relates to a contact element for the above-mentioned high voltage interface. The contact element is processed individually.

[0013] In a method for producing a contact element for the above-mentioned high-voltage connection, the above-mentioned object is alternatively or additionally achieved by introducing a helical tolerance compensation structure into the contact element by laser processing, water jet processing or mechanical processing.

[0014] The invention optionally also relates to an electrically driven air supply device for supplying air to a fuel cell system via at least one of the above-mentioned high-pressure connections. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Further advantages, features and details of the invention emerge from the following description, in which various exemplary embodiments are described in detail with reference to the drawings.

[0016] The accompanying drawings show:

[0017] Figure 1 Longitudinal section through a high-voltage connection for producing an electrical connection between a stator and a connection piece on the housing side of an air supply device;

[0018] Figure 2A perspective view of an air supply device having a housing, the housing comprising a high-pressure connection having three contact elements;

[0019] Figure 3 a perspective view of a contact element which is electrically conductively connected at one end to an end of a busbar;

[0020] Figure 4 Figure 3 A three-dimensional illustration of a contact element in a non-loaded or unassembled state;

[0021] Figure 5 Figure 4 A contact element in which the contact element is in a loaded state, which loaded state may occur, for example, in an assembled state;

[0022] Figure 6 A perspective view of a contact unit fixed to a thermostatic sleeve, the contact unit having three contact elements;

[0023] Figure 7 Figure 6 A perspective view of the contact unit in FIG. 1 as viewed from the rear side;

[0024] Figure 8 a perspective view of a joining unit having three support columns for three contact elements; and

[0025] Fig. 9 A perspective view of a combined plug unit with a plug seal. DETAILED DESCRIPTION

[0026] exist Figure 2 The air supply device 1 is shown in perspective in FIG. The air supply device 1 is also called an air compressor and is used in a mobile fuel cell system to provide compressed air. The mobile fuel cell system is in turn used in a vehicle equipped with a fuel cell system to provide electrical energy, which is converted into drive energy for the vehicle, for example, by an electric motor.

[0027] The air supply device 1 comprises a multi-part housing 2 having an air connection 3, via which the air is supplied, and an air connection 4, via which the compressed air is discharged. To compress the air, the air supply device 1 comprises, for example, a compressor wheel which can rotate inside a compressor volute.

[0028] The compressor wheel is driven by an electric motor, optionally with assistance from a turbine wheel, which is arranged in housing 2. The electric motor comprises a rotor which can rotate within a stator.

[0029] The stator of the electric motor comprises a current coupling device 5, through which a three-phase alternating current is supplied to the stator. The current coupling device 5 is connected to a control coupling device 6 via a connecting device, which comprises three elongated contact elements 7, 8, 9. The contact elements 7, 8, 9 are used to establish a high-voltage interface 10 between the stator and the high-voltage electronics.

[0030] The high-voltage electronics include a converter. The control connection device 6 is combined, for example, with a cable outlet which, as indicated by the three output cables shown, is connected to a separately arranged and Figure 2 However, the inverter can also be integrated into the housing 2 of the air supply device 1.

[0031] exist Figure 1 8 shows a high-pressure connection 10 in a longitudinal section through the contact element 8. The housing 2 of the air supply device comprises two housing bodies 11, 12. In addition, the housing body 11 is used to receive an electric drive for the air supply device. The housing body 12 is used, for example, to rotatably receive an impeller, in particular a compressor impeller. The compressor impeller is driven by the electric drive in the air supply device.

[0032] Depend on Figure 1 , 6 The overview of Figures 1 and 7 shows that a total of three contact elements 7, 8, 9 in the electrical contact unit 14 are each connected to a busbar 26. The electrical contact unit 14 is mounted on a temperature control sleeve 24, which surrounds the stator component 20 in the housing body 11 and has a stator component 20 at Figure 1 25 . Since the temperature control jacket 24 is mainly used to cool the stator 25 , it is also referred to as cooling jacket 24 .

[0033] The stator 25 includes a stator winding and a coil head, from which the stator wires originate. Figure 1 2 , in a manner not visible in the section shown in FIG. 2 , the busbar 26 is electrically conductively bonded to its radially inner end. The contact element 8 electrically conductively connects the busbar 26 to a bonding piece 30 of a high-voltage electronic component 35, which is likewise only designated by a reference numeral. The high-voltage electronic component 35 comprises a current converter.

[0034] exist Figure 3 Only the busbar 26 together with the contact element 8 fixed thereto is shown in perspective. Figure 3 At the upper end of the busbar 26 in the embodiment, the contact element 8 is connected to the busbar 26 by a material connection. Figure 3 A crimping sleeve 45 is formed on the lower end of the busbar 26 in FIG. The crimping sleeve 45 is used for electrical connection of a stator conductor (not shown).

[0035] The contact element 8 has a multifunctional sleeve 16 at its end facing the busbar 26. The multifunctional sleeve 16 is provided with a Figure 3 The left end in FIG. 1 is electrically conductively connected to the busbar 26 in a materially bonded manner, preferably by welding.

[0036] exist Figure 4 As can be seen from the three-dimensional view of the contact element 8, Figure 3 On the right end in FIG. 1 , there is an annular disk 28 with a through hole 29 . At the same end, the contact element 8 has a first conical section 41 . The second conical section 42 is formed by the contact element 8 between the helical tolerance compensation structure 38 and the multifunctional sleeve 16 .

[0037] exist Figure 4 and 5 1, it is explained how the contact element 8 deforms in the region of the helical tolerance compensation structure 38 during assembly when a load acts on the contact element 8 having the tolerance compensation structure 38. Such loads occur, for example, when tolerances along the longitudinal axis 36 need to be compensated or when an inclined position of the coupling part 30 also needs to be compensated. Such tolerances cannot be avoided, depending on the type of production, or can only be avoided with increased effort.

[0038] exist Figure 3 , a view of the longitudinal axis 36 which is not visible there and is only used for illustration is shown. Figure 3 It can be seen in FIG. 8 that the contact element 8 is arranged with its longitudinal axis 36 perpendicular to the longitudinal extension of the busbar 26 .

[0039] exist Figure 1 As can be seen in FIG. 8 , the contact element 8 is Figure 1 The right end of the contact element 8 is fixed to the joint part 30 by means of a screw 31. The screw head of the screw 31 is arranged inside the tolerance compensation structure 38. The screw shank of the screw 31 is screwed into a corresponding threaded blind hole in the joint part 30. This ensures a stable and electrically conductive permanent connection between the contact element 8 and the joint part 30 in a simple manner.

[0040] The helical tolerance compensation structure 38 of the contact element 8 is arranged inside the support column 40. There is sufficient play between the support column 40 and the tolerance compensation structure 38 to enable movement and / or configuration changes of the contact element 8 in the region of the tolerance compensation structure 38. Such configuration changes are for example Figure 4 and 5 of the overview.

[0041] A plug seal 18, an inner seal 21 and an outer seal 22 are provided for sealing the high-pressure connection 10. The plug seal 18 is pressed into the receiving space 17 by means of a plug of a combined plug unit 23, which is provided for this purpose in the multifunctional sleeve 16. The plug of the combined plug unit 23 is used in particular to support the plug seal 18 in the receiving space 17 of the multifunctional sleeve 16 in such a way that the plug seal 18 cannot be deformed undesirably.

[0042] The multifunctional sleeve 16 has a radially outer bearing section 19 on which an inner seal 21 is arranged. The inner seal 21 is designed as an inner single seal and is arranged in an annular space which is delimited radially inwardly by the multifunctional sleeve 16. The annular space is delimited radially outwardly and in both axial directions by the electrical contact unit 14.

[0043] An outer seal 22 is arranged radially outside the inner seal 21. The outer seal 22 is designed as an outer integrated seal and is arranged in an annular space which is delimited radially on the inside by the electrical contact unit 14 and radially on the outside by the housing body 11.

[0044] The conical sections 41 and 42 enable a damage-free assembly of the inner seal 21 onto the multifunctional sleeve 16. The third conical section 43 enables a damage-free assembly of the plug seal 18 to the combined plug unit 23.

[0045] The sealing shoulder 27 in the housing body 11 ensures that the outer seal 22 remains in its desired position.

[0046] exist Figure 6 and 7 2 shows how the outer seal 22, which is designed as an outer integrated seal, is mounted together with the three contact elements 7, 8, 9 and the sensor connection point 48 on the electrical contact unit 14. The electrical contact unit 14 is in turn fastened to the temperature control sleeve 24. Furthermore, screw points are provided at which the electrical contact unit 14 is fastened to the housing 2.

[0047] exist Figure 8 , for example, shows a joining unit 50 which has a total of three support columns 40 for three contact elements.

[0048] exist Fig. 9 1 and 2 show in perspective the plug seal 18 combined with the combined plug unit 23. The combined plug seal 18 comprises a single plug seal for each contact element.

Claims

1. A high-voltage connection (10) for producing an electrical connection between a stator (25) having a stator-side busbar (26) and a housing-side connection (30) of a high-voltage electronic component (35) by means of a contact element (8), characterized in that: The contact element (8) has a helical tolerance compensation structure (38) which is designed and arranged in such a way that it can compensate not only for tolerances along a longitudinal axis (36) of the contact element (8) but also for an inclined position of the engagement part (30) relative to the contact element (8).

2. The high voltage interface according to claim 1, characterized in that: The helical tolerance compensation structure (38) is formed from an elastically deformable material.

3. A high voltage interface according to any one of the preceding claims, characterized in that The tolerance compensation structure (38) is formed by a conductive sheet material having a spiral shape.

4. A high voltage interface according to any one of the preceding claims, characterised in that The contact element (8) having the tolerance compensation structure (38) has the configuration of a right circular cylinder.

5. A high voltage interface according to any one of the preceding claims, characterised in that The contact element (8) having the tolerance compensation structure (38) has, at the end facing the engagement element (30), the configuration of a circular ring disk (28) having a through hole (29).

6. A high voltage interface according to any one of the preceding claims, characterised in that The contact element (8) having the tolerance compensation structure (38) is electrically conductively connected to the busbar (26) via a multifunctional sleeve (16) at the end facing away from the connection piece (30).

7. The high voltage interface according to claim 6, characterized in that: The multifunctional sleeve (16) has an axial bearing section (19) for an inner seal (21), wherein the bearing section (19) for the inner seal (21) has an outer diameter that is greater than the tolerance compensation structure (38).

8. The high voltage interface according to claim 6 or 7, characterized in that: The multifunctional sleeve (16) has a receiving space (17) for a plug seal (18) at the end of the multifunctional sleeve facing the busbar (26).

9. Contact element (7, 8, 9) for a high-voltage connection (10), the high-voltage connection being a high-voltage connection according to any of the preceding claims.

10. Method for producing a contact element (7, 8, 9) for a high-voltage connection (10) according to any one of claims 1 to 8, characterized in that A helical tolerance compensation structure (38) is machined into the contact element (7, 8, 9) by laser machining, water jet machining or mechanical machining.

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