Stator for electric machine, electric machine having stator and method for producing stator

By arranging the conductor elements radially outside the stator base of the motor and adopting an annular arrangement, the problem of high axial structure height of the motor is solved, and the reduction of the axial structure height and the improvement of application flexibility are achieved.

CN120150409APending Publication Date: 2025-06-13ROBERT BOSCH GMBH
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Patent Information

Application Number
CN202411827203.8
Authority / Receiving Office
CN · China
Patent Type
Applications(China)
Current Assignee / Owner
Priority Date
2023-12-12
Filing Date
2024-12-12
Publication Date
2025-06-13

AI Technical Summary

Technical Problem

In the prior art, the axial structure of the motor is high, and the arrangement of the coupling equipment requires a large axial structure space, which limits the application scenarios of the motor.

Method used

By arranging the conductor elements radially outside the stator base and overlapping the electrical winding in the axial direction, an annular arrangement is adopted to reduce the height of the axial structure. At the same time, the coupling arrangement structure is constructed using a plastic carrier and a curved stamping member to ensure the mechanical positioning and electrical contact of the conductor elements.

Benefits of technology

It significantly reduces the axial structure height of the motor, reduces the requirements for axial structure space, improves the application flexibility of the motor, and reduces manufacturing costs.

✦ Generated by Eureka AI based on patent content.

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Abstract

The invention relates to a stator (10), in particular for an electric machine (12), to an electric machine (12), and to a method for producing a stator (10), comprising a stator base body (13), which has a yoke region (14) from which stator teeth (16) extend inwards in a radial direction (7), an electric winding (42) being arranged on the stator teeth (16), a wire end (44) of the electrical winding (40) is electrically connected to a conductor element (54) of the connection arrangement (50), the conductor element (54) extending radially outside the stator base body (13) in the circumferential direction (9).
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Description

Field of the Invention

[0001] The present invention relates to a stator for an electric machine, an electric machine having a stator, and a method for manufacturing a stator according to the type of independent claims. Background Art

[0002] DE 102015200086 A1 describes a method for manufacturing a stator, in which a single-tooth coil with an uninterrupted winding wire is continuously wound around a plurality of stator teeth. Here, the connecting wires between the individual coils are clamped circumferentially between the axial protrusions of an insulating cover. In order to electrically connect the single-tooth coils, these single-tooth coils are electrically connected to a conductor element at the connecting wires. The conductor element has connection pins at the ends for electrical evaluation. At the other ends, welding hooks are formed at the conductor element, which surround and are welded to the tangential connecting wires of the coil. In an embodiment, the conductor elements are combined into a connection plate, which is arranged axially directly above the electrical coil. This connection plate requires axial structural space in the electric machine that is not available in all applications. In addition, for the contact of the connecting wires, a large free space must be provided for the positioning of the welding tongs during assembly. These disadvantages should be eliminated by the embodiments according to the present invention. Summary of the Invention

[0003] Advantages of the present invention.

[0004] In contrast, the device according to the present invention and the method according to the present invention having the features of the independent claims have the advantage that, by arranging the conductor elements of the connection device radially outside the stator body and axially overlapping the electrical winding, the overall axial structural height of the electric machine can be significantly reduced. By arranging the connection device annularly around the stator body, although a larger radial structural space for the stator is required, this does not represent a major limitation for specific applications if the axial structural length of the electric machine can be significantly reduced thereby.

[0005] Advantageous improvements and refinements of the embodiments predefined in the independent claims can be achieved by the measures listed in the dependent claims. Particularly advantageous is that the conductor elements of the connection arrangement do not project axially beyond the electrical winding or do not project axially beyond the insulating cover. The electrical winding wound around the insulating cover forms so-called winding heads at the two axial ends of the stator body, the axial structural height of which is predefined by the active components of the electric machine. If the connection arrangement is now arranged axially in the region of the winding heads and / or the stator body, then no additional axial structural space that has not been predefined by the active components is required.

[0006] The connection arrangement is arranged annularly outside the outer diameter of the stator body, wherein the circumferential angle of the connection arrangement is in particular at least 180°. Here, a plurality of individual conductor bars are arranged annularly in the connection arrangement, and the circumferential angles of these conductor bars at least partially overlap each other. Thus, the entire connection arrangement preferably extends over an entire angular range of approximately 180° to 270°.

[0007] Advantageously, the stator body is inserted axially into the stator housing, and the stator housing also extends axially over two winding heads. In order to now enable electrical contact between the winding wire ends and the connection arrangement arranged radially outside the stator housing, radial through-holes are provided in the cylindrical wall of the stator housing, and the wire ends are guided radially through the radial through-holes in the axial regions of the insulating cover and / or the winding heads. For example, exactly three radial through-holes with a spacing of approximately 120° can be arranged. In this embodiment, the stator housing used in a conventional EC motor can be adapted to the connection device arranged radially outside the stator housing with very low cost.

[0008] The conductor bars of the connection arrangement can be very inexpensively stamped and bent into stamped and bent parts, and contact elements are constructed at these conductor bars, and the contact elements can be directly electrically connected to the wire ends of the electrical coils. Such an electrical connection can be manufactured by means of thermal stacking or soldering or welding, in particular laser welding. The contact process can be actually carried out without structural space limitations through the exposed positions of the contact elements radially outside the stator body.

[0009] The conductor elements can be punched out from a metal sheet as strips, so that their cross-sections are approximately rectangularly configured. These strips are arranged annularly around the stator body, wherein the longer sides of the cross-sections can be respectively oriented in the axial direction or in the radial direction. Here, the annular conductor bars are then stacked on top of each other in the axial direction or arranged side by side in the radial direction.

[0010] For this purpose, the connection arrangement has an annular carrier made of plastic, and the annular carrier receives the conductor elements. Here, the stamped and bent parts can be pressed or clamped into the prefabricated plastic carrier. Alternatively, the stamped and bent parts can also be injection-molded and encapsulated with the plastic of the annular carrier member. Thereby, the conductor elements are reliably insulated from each other and mechanically firmly positioned.

[0011] Particularly advantageously, holding elements are integrally formed at the annular plastic carrier, which extend radially inwards from the plastic ring towards the stator body. These holding elements can be supported at the insulating cover and / or directly at the stator body and optionally latched there, whereby the connection arrangement is reliably mechanically fixed relative to the stator body. For example, three holding elements can be integrally formed as radial projections distributed on the periphery, which can also serve as guides for the radially outwardly guided wire ends.

[0012] Here, the radial projections of the holding elements preferably penetrate the radial penetration part of the stator housing radially, wherein the radially inner end of the radial projection can be clamped, for example, at the insulating cover or at the stator body or at the inner side of the stator housing wall. An insulating plate can also be arranged between the winding head and the bearing cover, and the holding elements of the connection arrangement can also be fastened to this insulating plate. The wire ends of the electrical winding can be guided radially outwards from the insulating cover and radially outwards through the radial projections of the holding elements to the annular plastic carrier. For this purpose, receiving portions can be formed in the radial projections, and the wire ends are inserted axially from above into these receiving portions. The wire ends are then led radially until they reach the contact elements of the conductor elements, which project axially and / or radially from the plastic carrier in particular. The contact elements can have, for example, contact forks, and the wire ends are placed in these contact forks and can then be firmly electrically contacted therein.

[0013] In order to accurately position the connection arrangement relative to the stator body, preferably arcuate guide tabs are constructed at the radially inner ends of the axial projections of the holding elements, which extend along the inner side of the stator housing in the circumferential direction. These arcuate guide tabs can be very easily clamped radially between the upper insulating cover and the inner side of the stator housing wall. Latching elements can be constructed at the arcuate guide tabs, for example, which cooperate with mating latching elements at the insulating cover and / or the stator body. In particular, the latching elements can be pressed axially into corresponding receiving elements at the outer periphery of the insulating cover or the stator body. Here, the latching elements can preferably be integrally formed with the arcuate guide tabs and with the axial projections of the holding elements and with the annular plastic carrier. The arcuate guide tabs can also be connected to each other in the circumferential direction, so that they extend integrally within the stator housing over most of the periphery or as a closed ring.

[0014] In a plastic carrier of the connection arrangement, preferably three or four individual conductor elements are arranged, which connect the single-tooth coils to form a star circuit or a delta circuit of the electric machine. Here, preferably exactly three electrical phases are configured, which, for example, include exactly two or three or four or six single-tooth coils. At the annular plastic carrier, a connection plug is configured here, and the plug-in contacts of the electrical conductor elements are arranged in the connection plug. Here, the connection plug can be brought into contact with a corresponding pin, which is connected to the control electronics via an electrical connection line. The pin can be inserted into the connection plug axially from above, axially from below, or in a radial direction or in a tangential direction here.

[0015] In an alternative embodiment, the stator housing is not arranged radially within the conductor elements in the axial region of the connection arrangement, but rather radially outside the conductor elements. For this purpose, the stator housing has a radial widening in the axial region of the connection arrangement, which surrounds the entire connection arrangement over the entire circumference. Thereby, the connection arrangement is particularly well protected by the metal stator housing. In this embodiment, the plastic carrier is also directly fixed to the stator base or the insulating cover by means of radial retaining elements, wherein no radial penetrations through the stator housing are required here.

[0016] The stator is preferably used in an electric machine, which is configured, for example, as an electronically commutated EC motor. The stator consists in particular of individual T-shaped stator segments, which are joined to form a closed stator ring after winding. A rotor is arranged radially within the stator, which is supported in the stator housing by means of a bearing cover. Here, the connection arrangement does not extend axially beyond the bearing cover in particular, so that the stator housing can be directly flange-connected to the transmission housing, for example. Here, the rotor shaft protrudes through the bearing cover, for example, and protrudes into the transmission housing with an output element. The electrical winding of the stator consists of single-tooth coils, which are controlled by the control electronics of the electric machine. For this purpose, the single-tooth coils are connected to the electronics unit via the conductor elements and their plug-in contacts. The electronics unit is preferably axially positioned above the electrical winding here. Each stator segment preferably has a single insulating cover. Here, the first insulating shell, for example, is placed on the stator segment axially from above and the second insulating shell axially from below. Here, the insulating cover covers the stator teeth on the one hand and protrudes radially beyond the stator teeth into the yoke region. In the yoke region, an axial projection is configured at the insulating cover, through which, for example, the wire ends of the single-tooth coils are bent radially outwards. When winding the stator teeth, for example, multiple single-tooth coils, in particular 2 or 3 or 4, are continuously wound by means of an uninterrupted winding wire (or double winding), wherein in particular two wire ends led out at a single retaining element form the start and / or end of a single electrical phase.

[0017] According to the manufacturing method according to the present invention, first, an electric winding is wound around a stator tooth, wherein the free wire ends of the coil project axially upward. In order to construct the connection arrangement, a plastic carrier with a holding element is placed on the stator base such that the conductor element is arranged radially outside the outer circumference of the stator base. Thereafter, the free wire ends are placed in the guide of the holding element and electrically connected to the contact element of the conductor element. Since the contact element is freely accessible, it is very advantageous to construct the electrical contact by means of thermal stacking (thermal embossing) or by means of welding in the following manner, i.e., for example, a welding tong heats the contact element to connect it to the wire end.

[0018] Here, after the connection arrangement has been connected to the stator base, the stator base can be inserted axially into the stator housing, or as an alternative, the wound stator base can first be inserted into the stator housing, and only then the connection arrangement is connected to the stator base. Here, in particular, the arcuate guide element of the holding element can then be clamped radially between the inner wall of the stator housing and the insulating cover and / or the stator base. The holding element is then directly connected to the stator base, or indirectly connected to the stator base through the insulating cover and / or through an insulating plate fastened via a winding head. Description of the Drawings

[0019] Embodiments of the present invention are shown in the drawings and explained in more detail in the following description.

[0020] Wherein:

[0021] Figure 1 A first embodiment of an electric machine according to the present invention is schematically shown.

[0022] Figure 2 Another embodiment of the electric machine according to the present invention is shown without the stator housing.

[0023] Figure 3 And Figure 4 Shows Figure 2 Two further partial views of an embodiment according to

[0024] Figure 5 And shows a further embodiment of an electric machine with a stator according to the present invention. Detailed Description of the Invention

[0025] In Figure 1A cross-section of an electric machine 10 is shown, as the electric machine is used, for example, in a brake unit of a motor vehicle. The electric machine 10 has a stator 10, in which a stator core 13 is inserted into a stator housing 11, and the stator core carries an electric winding 42. Here, the electric winding 42 with winding heads 46 projects axially beyond the stator core 13 at both ends. The stator core 13 is inserted into a cylindrical wall 15 of the stator housing 11. In the axial region of one of the two winding heads 46, the wire ends 44 of the electric winding 42 are led out radially from the stator housing 11 and are electrically connected there to a connection arrangement 50. The connection arrangement 50 has a plastic carrier 52 into which a plurality of conductor elements 54 are inserted. Here, the plastic carrier 52 with the conductor elements 54 extends within a circumferential angle 92 that preferably exceeds 180° around the stator core 13 and in particular also around the stator housing 11. The wire ends 44 are electrically connected to contact elements 57 of the conductor elements 54, wherein the conductor elements 54 are configured as plug-in contacts 65 for a connection plug 66 arranged at the plastic carrier 52. The electric winding 42 is connected, for example, in a star circuit or a delta circuit to three electrical phases U, V, W. An electrical line 68 leads from the connection plug 66 to control electronics 20 arranged in an electronics housing 24. The control electronics 20 has, for example, an electronic circuit board 23 on which electronic component elements 25 are arranged, and the electronic component elements are used for the electronic commenting of the electric winding 42. In this embodiment, the stator housing 11 and the annular connection arrangement 50 are arranged within a housing 80 of the electric machine 10, and the electric machine is a component of a brake unit. The electronics housing 24 is arranged here axially above the stator core 13 opposite the connection arrangement 54. A rotor 70, not shown in more detail, is arranged in the stator core 13 by means of rotor bearings 71, 69, wherein a first rotor bearing 71 is arranged in a bearing cover 72 that closes the axially open stator housing 11. A second rotor bearing 69 is arranged axially opposite at the bottom 78 of the stator housing 11, and the second rotor bearing receives a rotor shaft 74. The stator housing 11 is flange-connected axially to a transmission housing 22 by means of a stator flange 17 on the axial side of the bearing cover 72, and the transmission housing can be configured, for example, as a hydraulic block for a hydraulic pump. Optionally, on the axially opposite sides, the rotor shaft 72 can project axially through the second rotor bearing 69 and extend up to the control electronics 20. Here, a signal transmitter 81 can be arranged, for example, on the rotor shaft 74, and the signal transmitter interacts with a rotor position sensing device 82, which is a component of the control electronics 20 and is arranged in particular on the electronic circuit board 23. The housing 80 of the electric machine 12 can be configured integrally with the electronics housing 24, wherein the electronic circuit board 23 can be inserted into the electronics housing 24 and can then be sealed and closed by an electronics cover 27.The electronic circuit board 23 has an electrical connection to the stator housing 11, in particular for forming the ground contact 28.

[0026] Figure 2 A further embodiment is shown, in which the coupling arrangement 54 is arranged in the axial region of the stator body 13 and / or of the winding head 46. An embodiment is also conceivable in which the plastic carrier 52 is arranged entirely within the axial extent of the stator body 13. In this embodiment, the stator housing 11 is not shown in order to better see the fixing of the coupling arrangement 50 at the stator body 13. In a variant not shown, the stator housing 11 can have a radial widening in the axial region of the coupling arrangement 50, such that the coupling arrangement 50 arranged radially outside the stator body 13 is arranged radially within the radial widening of the stator housing 11 and is surrounded by the radial widening over the entire circumference. The stator body 13 has a radially outer yoke region 14, from which the stator teeth 14 extend inwards in the radial direction 7. An insulating cover 30 is arranged on the stator teeth 14, which electrically insulates the electrical winding 42 from the stator body 13. The insulating cover 30 has guide elements 32 in the axial region of the winding head 46, between which the winding wires 41 are guided between different single-tooth coils 40 of the electrical winding 42. Here, a plurality of single-tooth coils 40 can also be continuously wound by means of an uninterrupted winding wire 41. The wire ends 44 of the electrical winding 42 can also be fixed in the guide elements 32 of the insulating cover 30 and bent radially outwards towards the coupling arrangement 50. A holding element 58 is formed on the plastic body 52, which extends inwards in the radial direction 7 and bears on the insulating cover 30 and / or the stator body 13. For this purpose, an arcuate guide tab 60 is formed on the holding element 58, on which a clamping or latching element 62 is preferably arranged, by means of which the coupling arrangement 50 is firmly fixed to the stator body 13. The latching element 60 is, for example, inserted into a mating latching element 63 on the insulating cover 30 here. The arcuate guide tab 60 is preferably arranged radially within the cylindrical wall 15 of the stator housing 11, wherein the arcuate guide element 60 and / or the latching element 62 clamp the holding element 58 between the cylindrical wall 15 and the insulating cover 30 and / or the stator body 13. The wire ends 44 are received here in the receiving portion 59 of the holding element 58 and are guided radially through the radial penetration 18 in the wall 15 of the stator housing 11. In Figure 2 , a contact element 57 is formed at the free end of the conductor element 54, at which the wire ends 44 can be electrically contacted, for example by means of thermoprinting (thermal stacking) or by means of a welding connection 97. In particular, the contact element 57 is formed as a contact fork 98, into which the wire ends 44 are inserted and clamped or pressed in, or are materially bonded to the contact fork. In Figure 2In the embodiment, exactly six wire ends 44 are guided radially outwards to the conductor elements 54, wherein the connection plug 66 has exactly three phases U, V, W for energizing the single-tooth coils 40, in particular twelve single-tooth coils. The rotor 70 is supported in the stator 10 by means of rotor bearings 71, 69, wherein the rotor shaft 74 projects axially through the first rotor bearing 71 in the axial direction 8. On the rotor shaft 74 protruding from the stator housing 11, for example, a drive worm is arranged as the output element 76, which meshes with a corresponding drive mechanism element arranged in the drive mechanism housing 22.

[0027] In Figure 3 is shown a ring-shaped connection arrangement 50 from Figure 2 with an axially open plastic carrier 52. Here, the conductor elements 54 are axially inserted into the shell-shaped plastic carrier 52. The conductor elements 54 are here configured as stamped bends 56, wherein the strips 55 extend within a specific circumferential angle 92 around the stator base 13. The strips 55 are here, for example, arranged axially one above the other and electrically insulated from one another. The contact elements 57 project here axially from the strips 55 and then bend radially towards the insulating cover 30 in the radial direction 7. Preferably, the contact elements 57 are arranged in the circumferential region of the holding element 58, such that the wire ends 44 are directly guided to the contact elements 57 in the receiving part 59 of the holding element 58 and are electrically contacted at this contact element. The receiving part 59 is here, for example, configured as a radial groove in an arcuate guiding element 60. The holding element 58 is configured as a radial projection 99, which extends radially inwards towards the insulating cover 30. Then the arcuate guiding element 60 is arranged radially inside the radial projection 99, where a locking element 62 extends axially downwards from this arcuate guiding element. In this embodiment, one of the conductor elements 54 is configured as a star connection point 94, which electrically connects all phases U, V, W to one another. The three other conductor elements 54 each have a plug-in contact part 65 of the connection plug 66 at their free ends opposite the contact elements 57. The connection plug 66 is here, for example, configured as a tangential projection 67 at the plastic carrier 52, wherein the pins of the electrical connection line 68 can here, for example, be inserted axially into the connection plug 66. The plug-in contact part 65 can here be configured as a spring contact part projecting axially, into which the pins of the electrical connection line 68 can be clamped. If the conductor elements 54 are clamped or inserted into the shell-shaped plastic carrier 52, then the plastic carrier 52 can thereafter be closed, if necessary, with a cover made of plastic. The plastic carrier 52 extends here within a circumferential angle 92 of more than 180°, preferably more than 270°.

[0028] In Figure 4 is shown without the plastic carrier 52 according to Figure 2The conductor element 54 of the embodiment in the embodiment can be precisely identified in order to identify the geometric arrangement of the conductor element. Figure 3 , the conductor elements 54 are arranged one above the other at an axial spacing and all overlap with an axial region of the insulating cover 30 and / or the stator base body 13. The annular strip 55 of the conductor element 54 here has a rectangular cross section 53, the dimension 48 of which is greater in the radial direction 7 than its dimension 49 in the axial direction 8. The contact element 57 of the conductor element 54 protrudes from the annular strip 55 in the axial direction 8 toward the first rotor bearing 71. Here, the conductor element 54 does not extend beyond the bearing cover 72, not shown, in the axial direction 8, so that the electric machine 10 can be optimally shortened in the axial direction 8 by the connecting arrangement structure 50, which is arranged annularly around the stator base body 13 and overlaps with the insulating cover 30 and / or the stator base body 13 in the axial direction. In this embodiment, all the wire ends 44 are arranged at the same insulating cover 30 at the axial ends of the stator base body 13. In an alternative embodiment, the conductor element 54 can also be injection-coated as an insert by the plastic carrier 52, as shown by way of example in Figure 5 This is shown in .

[0029] exist Figure 5 In the embodiment of the present invention, the stator housing 11 is designed as an axially open pot which is closed by a bearing cover 72. A first rotor bearing 71 is fastened in the bearing cover 72, through which a rotor shaft 74 protrudes axially from the stator housing 11. An output element 76 is arranged at the free end of the rotor shaft 74, which cooperates with a corresponding transmission component in the transmission housing 22. The stator housing 11 has a radial penetration 18 through the cylindrical wall 15 in the circumferential region in which the retaining element 58 of the plastic carrier 52 is arranged. As a result, the retaining element 58 can be extended radially into the stator housing 11 as far as the insulating cover 30. Therefore, the wire end 44 of the electrical winding 42 is also guided through the radial penetration 18 by means of the radial projection 99 of the retaining element 58. The arc-shaped guide element 60 formed at the radially inner end of the retaining element 58 then extends along the inner side of the cylindrical wall 15 in the circumferential direction 9 beyond the tangential extension of the radial penetration 18. The holding element 58 has a cover 61 which covers the radial penetration 18 in the cylindrical wall 15. The connection arrangement 50 is designed here as an injection-molded component, wherein the bent punched part 56 of the conductor element 54 is injection-molded over the entire circumference of the connection arrangement 50. Here, the contact element 57 protrudes axially from the plastic carrier 52 in order to make electrical contact with the line end 44. Likewise, the plug-in contact 65 of the conductor element 54 emerges from the injection-molded plastic so that it can be contacted in the connection plug 66 with the pins of the electrical connection line 68 of the control electronics 20.

[0030] It should be noted that various combination possibilities between the individual features are feasible for the embodiments shown in the drawings and the description. Thus, for example, the plastic ring 52 of the connection arrangement 50 can have other contours, in particular be configured angularly or circularly. The number and geometry of the conductor elements 54 and their contact elements 57 can be adapted to the number of the single-tooth coils 40. Thus, the conductor bars 55 can also be arranged side by side radially, wherein their axial extent 49 is then greater than their radial extent 48. Likewise, the configuration of the holding element 58 and the insulating cover 30 and in particular their mechanical connection to the stator body 13 can vary. The stator 10 is preferably assembled from individual T-shaped stator segments, each of which has a radially outer yoke region 14, from which the stator teeth 16 extend radially inward in the radial direction 7. The stator body 13 is assembled from laminations stacked axially one above the other, which are preferably stamped. An insulating cover 30 is placed on each stator segment, and the single-tooth coils 40 are wound onto this insulating cover. The invention is particularly suitable for the rotational drive of components in a motor vehicle or for the adjustment of components in the motor vehicle, but is not limited to this application.

Claims

1. A stator (10), in particular for an electric machine (12), comprising a stator base body (13), the stator base body having a yoke region (14), from which stator teeth (16) extend inwardly in a radial direction (7), wherein: An electrical winding (42) is arranged on the stator tooth (16), wherein a wire end (44) of the electrical winding (40) is electrically connected to a conductor element (54) of a connecting arrangement (50), wherein the conductor element (54) extends radially outside the stator base body (13) in a circumferential direction (9).

2. The stator (10) according to claim 1, characterized in that: The electrical winding (42) protrudes axially beyond the stator base body (13) and forms a winding head (46) of the stator (10), and the conductor element (54) is arranged overlapping the winding head (46) and / or the stator base body (13) in an axial direction (8).

3. The stator (10) according to claim 1 or 2, characterized in that: The connection arrangement (50) with the conductor elements (54) extends in the form of a ring segment over an angular range (92) of more than 180°, in particular approximately 270°, around the stator base body (13).

4. A stator (10) according to any one of the preceding claims, characterized in that The connection arrangement (50) with the conductor element (54) is arranged radially outside a stator housing (11) made of metal, into which the stator base body (13) is inserted axially, wherein in particular a radial penetration (18) is formed in the stator housing (11), through which the wire ends (44) of the electrical winding (42) are led radially to the conductor element (54).

5. The stator (10) according to any one of the preceding claims, characterized in that The conductor element (54) is designed as a bent stamped part (56), and the wire end (44) is electrically connected to the conductor element (54) radially outside the stator base body (13), in particular by means of thermal stacking or by means of a welded connection (97).

6. A stator (10) according to any one of the preceding claims, characterised in that The conductor elements (54) are designed as sheet metal strips (55) with a rectangular cross section (53), wherein the sheet metal strips (55) are arranged one above the other in an axial direction (8) or one beside the other in a radial direction (7) in the coupling arrangement (50).

7. A stator (10) according to any one of the preceding claims, characterised in that The connection arrangement (50) has an annular plastic carrier (52) into which the conductor element (54) is inserted, in particular is injection-coated with the plastic carrier (54).

8. A stator (10) according to any one of the preceding claims, characterised in that A radially inwardly projecting retaining element (58) is integrally formed on the annular plastic carrier (52) and fixes the coupling arrangement (50) to the stator base body (13).

9. A stator (10) according to any one of the preceding claims, characterised in that An insulating cover (30) is arranged on the stator base body (13), which protrudes beyond the stator base body (13) in the axial direction, and a single-tooth coil (40) is wound onto the insulating cover (30) as the electrical winding (42), wherein the wire end (44) is inserted into a receiving portion (59) of the retaining element (58), and the wire end (44) is guided radially outward from the insulating cover (30) through the radial penetration (18) in the stator housing (11) by means of the retaining element (58) to the conductor element (54).

10. The stator (10) according to any one of the preceding claims, characterized in that The retaining element (58) has an arc-shaped guide web (60) which extends radially in the stator housing (11) in a circumferential direction (9) and in particular a latching element (62) is formed on the guide web (60) which fastens the plastic carrier (52) to the insulating cover (30).

11. The stator (10) according to any one of the preceding claims, characterized in that The conductor elements (54), in particular exactly three or four conductor elements, form a delta connection or a star connection and a connecting plug (66) is formed on the plastic carrier (52) radially outside the stator base body (13) for making a preferably three-phase electrical connection (68) to control electronics (20).

12. The stator (10) according to any one of the preceding claims, characterized in that The stator housing (11) has a radial widening (91) in the axial region of the plastic carrier (52), so that the plastic carrier (52) is received in the radial widening (91) and is arranged radially within a circumferential wall (15) of the stator housing (11).

13. An electric machine (12) having a stator (10) according to any one of the preceding claims, wherein: The rotor (70) is supported in the stator (10) by means of a bearing cover (72), which axially closes the stator housing (11), and the connection arrangement (50) is connected to control electronics (20) via the connection plug (66), by means of which the single-tooth coil (40) can be electronically commutated, and in particular the rotor shaft (74) of the rotor (70) extends axially outward through the bearing cover (72) with an output element (76), and a gear housing (22) for receiving the output element (76) is flange-connected to the stator housing (11).

14. Method for producing a stator (10), in particular a stator according to any of the preceding claims, characterized in that The following method steps: - winding the stator base body (13) with a single-tooth coil (40), wherein a plurality of free wire ends (44) protrude from the single-tooth coil (40) in the axial direction (8), - placing the connection arrangement (50) axially onto the wound stator base body (13) in such a way that the radially inwardly projecting retaining elements (58) of the plastic carrier (52) are fastened to the stator base body (13), - bending the wire ends (44) projecting axially upwards radially outwards and electrically contacting the free wire ends (44) with the conductor element (54), in particular by means of thermal stacking or welding, The stator base body (13) is preferably axially joined into a stator housing (11) made of metal before or after the connection of the coupling arrangement (50) to the stator base body (13).

Citation Information

Patent Citations

  • Circuit board for a stator of an electrical machine and method for producing such

    DE102015200086A1