Arrangement having two welded parts, electric machine, and method for producing such arrangement and electric machine

Abstract

The invention relates to an electrical device (1) having a power input (2), a power output (3) and an electrical interface (4) arranged between the power input (2) and the power output (3), the interface (4) comprising a wire (5) as a first component (6) and a rail-like connecting element (7) welded to the wire (5) as a second component (8), one part (8) of the two parts rests against a shoulder (9) of the other part (6), and a weld seam (10) connecting the two parts (6, 8) extends from the shoulder (9) over the entire thickness (11) of the other part (8) resting against the shoulder (9). The invention also relates to an electrical machine (23) comprising such an apparatus (1), to a method for producing an electrical apparatus (1), and to a method for producing an electrical machine (23).

Description

Technical Field

[0001] The present invention relates to an electrical device having a power input, preferably an input connected to a power supply during operation; a power output, preferably in the form of an electrical consumer; and an electrical interface arranged between the power input and the power output, wherein the interface comprises a wire as a first component and a rail-shaped connecting element welded to the wire as a second component. The present invention also relates to an electric motor having such an electrical device. The present invention also relates to a method for producing such an electrical device and an electric motor. Background Art

[0002] Universal devices with corresponding interfaces are known from the prior art. For example, WO 2020 / 104701 A1 discloses an electrically conductive connecting component having a cap-shaped connecting region that can accommodate the free ends of at least two conductor bars. It is also known to weld certain sections in this connecting region to join the components together.

[0003] However, it has been found that the geometric design of the connected components means that welds cannot be applied across the entire thickness / depth of the components. This, in turn, means that during operation, due to typical loads, increased notch stresses may occur on these welds, which weaken the weld joint. Simple penetration welding, i.e. forming welds across the entire thickness of the components, is also generally not possible due to the risk that adjacent components will be damaged during the welding process. Summary of the Invention

[0004] It is therefore an object of the present invention to provide an electrical device having a welded interface whose fatigue strength is significantly increased, wherein the risk of damage to adjacent components during the welding process is at least significantly reduced.

[0005] According to the invention, this is achieved in that one of the two parts rests against a shoulder of the other part and the weld seam connecting the two parts extends from the shoulder over the entire thickness of the other part resting against the shoulder. The depth of the weld seam is therefore at least as great as the thickness of the other part.

[0006] Due to the design of the weld seam starting from the shoulder, the weld seam is designed so that the notch effect between the welded parts is significantly reduced. In addition, the shoulder provides a rear impact surface for the melting device, by which the heat beam is reflected or at least deflected, so that the parts located below / behind the shoulder are protected as much as possible from damage by the heat beam.

[0007] Further advantageous embodiments are claimed in the dependent claims and are explained in more detail below.

[0008] Therefore, it is also advantageous if the first component / wire is provided with a shoulder. Thus, a shoulder can be introduced in the wire in a relatively simple manner, which shoulder is relatively easy to form in the usual manner.

[0009] To further increase the strength of the welded joint, it is advantageous to introduce shoulders in one component in at least two lateral / spatial directions (in the transverse direction of one component, preferably the first component). Furthermore, it is advantageous to introduce shoulders in one component on three sides. Sides generally refer to the sides of a quadrilateral that are at right angles to one another.

[0010] Assembly is further simplified if a shoulder is introduced at an end region of a component.

[0011] It is also advantageous if the second part resting against the shoulder has a recess (preferably open towards one end of the second part) at least partially surrounding / accommodating the first part. This facilitates assembly and the application of the weld.

[0012] Furthermore, it is advantageous if the first component and the second component are aligned at an angle to one another, preferably perpendicularly to one another, via their mutually connected end regions.

[0013] The second component / connection element is also preferably a busbar, which is also connected to the power electronics or directly forms part of said power electronics.

[0014] Furthermore, the invention relates to an electric machine, which is preferably designed as an electric drive machine for a motor vehicle, having a stator; a rotor, which is mounted rotatably relative to the stator; and an electric device according to the invention according to at least one of the preceding embodiments, wherein the first component is part of a coil winding of the stator or rotor.

[0015] The invention also relates to a method for producing an electrical device having an electrical interface, which in turn has a wire as a first component and a rail-shaped connecting element as a second component, the method comprising the following steps: a) providing one of the two components with a shoulder, b) resting the other of the two components against the shoulder, and c) welding the two components together, wherein the weld extends from the shoulder over the entire thickness of the other component resting against the shoulder.

[0016] In this case, it has proven particularly advantageous if the components are joined together by laser welding. This enables the weld seam to be formed precisely.

[0017] The invention also relates to a method for producing an electric machine, in order to form an electrical device according to the method described above. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] The present invention will be described in more detail below with reference to the accompanying drawings.

[0019] In the attached figure:

[0020] Figure 1 shows a highly simplified illustration of an electrical device according to the invention according to a preferred exemplary embodiment, with an interface between two components connected to one another by welding according to the invention,

[0021] Figure 2 Shown Figure 1 A top view of the interface shown in

[0022] Figure 3 Shown according to Figure 1 Side view of the interface,

[0023] Figure 4 Shown with Figure 1 a simplified longitudinal cross-sectional view of an electric machine of an electrical device, and

[0024] Figure 5 A flow chart is shown which illustrates a method according to the invention for manufacturing an electrical device. DETAILED DESCRIPTION

[0025] The drawings are merely schematic in nature and are therefore intended only for the purpose of understanding the present invention. Identical elements are provided with the same reference numerals.

[0026] Figure 1 Firstly, an abstract representation of an electrical device 1 according to the invention (also called an electronic unit) is shown, in particular in the area of an interface 4 / connection point / coupling point implemented according to the invention, which will be explained in more detail below.

[0027] The electrical device 1 further comprises an (electrical) power input 2, shown schematically, and an (electrical) power output 3, also shown schematically. During operation, the power input 2 is electrically connected to a power source, such as a battery, in the usual manner. The power output 3 is connected to an electrical load or preferably directly forms the load. An interface 4 is arranged between the power input 2 and the power output 3.

[0028] Reference Figure 4 First, it should be noted that the electrical device 1 is preferably used in an electric motor 23. The power input 2 can then include control electronics, such as an inverter, etc. The power output 3 is preferably directly part of the stator 16 of the electric motor 23, more preferably the coil windings 18 arranged on the stator 16.

[0029] The electric machine 23 is also designed as an electric drive machine for a motor vehicle and, in addition to the stator 16, has a rotor 17 which is mounted rotatably relative to the stator 16. For the sake of completeness, it should be pointed out that, of course, according to other exemplary embodiments, the coil windings 18 can also be provided in the rotor 17. Thus, the power output 3 would then be the rotor 17 itself.

[0030] The coil winding 18 is connected to the first part 6 of the interface 4. In this regard, it should be noted that the wire 5 in this embodiment preferably directly forms the coil winding 18 and the first part 6 (in terms of material, it is a single piece). The part of the interface 4 that is also connected to the power input 2 is called the second part 8. The second part 8 is a rail-shaped connecting element 7 (also called a conductor rail).

[0031] Reference Figures 1 to 3 The welded connection realized according to the present invention can be seen in greater detail in the interface 4. The first component 6, in the form of a wire 5, has an end region 13. This end region 13 has a shoulder 9 formed according to the present invention. The shoulder 9 forms a stepped taper or a stepped recess in the diameter of the wire 5. This means that the shoulder 9 is formed / introduced perpendicularly to the longitudinal direction of the wire 5.

[0032] The shoulder 9 thus forms a bearing surface 19 directed towards one end side (seen in the longitudinal direction of the wire 5) against which the second component 8 / connecting element 7 rests. In principle, a plurality of shoulders 9 can also be formed offset in the longitudinal direction of the wire 5.

[0033] It can also be seen that the thickness 11 of the second component 8 is smaller than the longitudinal section 21 of the first component 6 , which extends from the shoulder 9 to the free end 20 of the first component 6 .

[0034] See also Figure 2 It is clear that the shoulder 9 is generally L-shaped and therefore surrounds the longitudinal section 21 of the first component 6 from two sides 12a, 12b. However, in other embodiments, it is also possible for the shoulder to additionally surround the third side 12c, or even completely surround all four sides 12a, 12b, 12c, 12d. Viewed in cross section of the first component 6, these sides 12a, 12b, 12c, 12d form the four sides of a rectangle, each of which is offset by 90 degrees from one another.

[0035] It can also be seen that the second part 8 has a recess 15 towards its end region 14 which is larger than the (rectangular) cross section of the longitudinal section 21. The second part 8 finally comes to rest against the longitudinal section 21 on the respective side 12a, 12b, the shoulder 9 also enclosing the respective side.

[0036] Reference Figure 2The weld seam 10 connecting the first component 6 to the second component 8 illustrated in the figure is introduced in the (previous) gap region 24 between the longitudinal section 21 and the recess 15 above the shoulder 9. Figure 1 As shown / indicated in , the weld seam 10 extends along its depth 25 over the entire thickness 11 of the second component 8 and thus extends from the shoulder 9 in the depth / thickness direction to a surface 22 of the second component 8 facing away from the shoulder 9 .

[0037] In this respect, it is advantageous to use laser welding to realize the weld seam 10 .

[0038] Then, Figure 5 Schematically relates to a production method according to the invention, wherein, Figures 1 to 4 The electrical device 1 is realized by a method in which, in step a), one of the two components, preferably the first component 6, is provided with a shoulder 9. The shoulder 9 can be produced, for example, by machining or shaping the end region 13. In a second step b), the other of the two components, in this case the second component 8, is then placed against the shoulder 9, and finally, in a third step c), the two components 6, 8 are welded together, wherein a weld seam 10 extends from the shoulder 9 over the entire thickness 11 of the other component 8 placed against the shoulder 9.

[0039] It goes without saying that the two components 6 , 8 can therefore also be interchanged in principle and that a second component 8 can thus be formed instead of the first component, i.e. the second component can in particular be provided with a shoulder 9 and the first component 6 can then be placed accordingly on this shoulder 9 and welded to the second component 8 .

[0040] The method is then used / applied analogously in the method for producing the electric machine 23 .

[0041] In other words, according to the present invention, an overlap is achieved by adding a shoulder 9 to one of the two parts 6, 8 to be welded (e.g., the wire 5). During welding, this overlap ensures that the laser beam does not penetrate into the underlying parts, thereby damaging them. The weld depth (depth 25) can then be increased to the full material thickness, and a weld root with a lower notch effect can be formed.

[0042] exist Figures 1 to 3 In a preferred exemplary embodiment of the present invention, the wire 5 is provided with a shoulder 9 against which the busbar to be welded (second component 8) rests. The shoulder 9 can rest against one side 12a of the wire 5, on all four sides 12a, 12b, 12c, 12d of the wire 5 or in all possible positions therebetween. Figures 1 to 3 An example is shown in which the wire 5 has shoulders 9 on both sides 12 a , 12 b .

[0043] The connecting gap (gap region 24) is then welded to the lower shoulder 9 of the wire 5 from above by means of a laser. Figures 1 to 3 This results in an L-shaped weld seam 10 .

[0044] Reference Signs List

[0045] 1 Electrical device

[0046] 2 Power input

[0047] 3 Power output unit

[0048] 4 interfaces

[0049] 5 Wire

[0050] 6 First component

[0051] 7 Connecting elements

[0052] 8 Second component

[0053] 9 Shoulders

[0054] 10 welds

[0055] 11thickness

[0056] 12a First side portion

[0057] 12b Second side

[0058] 12c Third side

[0059] 12d Fourth side

[0060] 13 End region of first component

[0061] 14 End region of the second component

[0062] 15 concavity

[0063] 16 stator

[0064] 17 rotor

[0065] 18 Coil winding

[0066] 19 Support surface

[0067] 20 end

[0068] 21 longitudinal segments

[0069] 22 Surface

[0070] 23 Motor

[0071] 24 Gap Area

[0072] 25 Depth

Claims

1. An electrical device (1), comprising: a power input portion (2); a power output portion (3); and an electrical interface (4), wherein the electrical interface is arranged between the power input portion (2) and the power output portion (3), wherein: The interface (4) has a wire (5) as a first component (6) and a rail-shaped connecting element (7) welded to the wire (5) as a second component (8), characterized in that one of the two components (8) rests against a shoulder (9) of the other component (6), and the weld (10) connecting the two components (6, 8) extends from the shoulder (9) over the entire thickness (11) of the other component (8) resting against the shoulder (9).

2. The device (1) according to claim 1, characterized in that The first component (6) is provided with the shoulder (9).

3. The device (1) according to claim 1 or 2, characterized in that The shoulder (9) is introduced into the one component (6) from at least two sides (12a, 12b).

4. The device (1) according to any one of claims 1 to 3, characterized in that The shoulder (9) is introduced at an end region (13) of the one component (6).

5. The device (1) according to any one of claims 1 to 4, characterized in that The second part (8) resting against the shoulder (9) has a recess (15) at least partially surrounding the first part (6).

6. The device (1) according to any one of claims 1 to 5, characterized in that The first component (6) and the second component (8) are aligned perpendicularly to each other via the interconnected end regions (13, 14) of the first component and the second component.

7. An electric motor (23) comprising: a stator (16); a rotor (17) rotatably mounted relative to the stator (16); and an electric device (1) according to any one of claims 1 to 6, wherein: The first component (6) is part of a coil winding (18) of the stator (16) or the rotor (17).

8. A method for producing an electrical device (1) having an electrical interface (4), the interface (4) in turn having a wire (5) as a first component (6) and a rail-shaped connecting element (7) as a second component (8), the method comprising the following steps: a) providing a shoulder (9) for one of the two components (6); b) placing the other of the two parts (8) against the shoulder (9); as well as c) Welding the two components (6, 8) together, wherein the weld seam (10) extends from the shoulder (9) over the entire thickness (11) of the further component (8) resting against the shoulder (9).

9. The method according to claim 8, characterized in that The components (6, 8) are connected to each other by means of laser welding.

10. A method for manufacturing an electric machine (23), wherein the electric device (1) is formed by the method according to claim 8 or 9.

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