Electric machine, in particular for motor vehicle, and method for producing such electric machine

Abstract

The invention relates to an electric machine having at least one winding (12), by means of which a magnetic field can be generated, and having a sensor device (22), by means of which the magnetic field can be detected, the sensor device (22) comprising at least one printed circuit board (24), the at least one printed circuit board has a plurality of printed circuit board regions (26) which are at least partially spaced apart from one another in the circumferential direction (36) of the electric machine, between which a respective length region (L) of the winding (12) is arranged. The sensor device (22) comprises sensor elements (28) which are held on a printed circuit board (24) and by means of which a magnetic field can be detected, at least two of the sensor elements (28) differing from one another in terms of their measurement principles for detecting the magnetic field.

Description

TECHNICAL FIELD

[0001] The invention relates to an electric machine, in particular for a motor vehicle, according to the preamble of patent claim 1. The invention also relates to a method for producing such an electric machine according to the preamble of patent claim 9. BACKGROUND

[0002] DE 10 2016 005 232 A1 discloses a rotor position sensor for an electric machine. DE 10 2013 225 141 A1 discloses a position sensor device for detecting an angular orientation of a rotor. DE 10 2013 020 985 A1 discloses an electric machine for a vehicle. DE 10 2012 009 906 A1 discloses an electric machine. DE 10 2008 042 912 A1 discloses a sensor device for detecting a rotational position of a rotating member. DE 10 2007 060 241 A1 discloses an electric machine having a sensor device for detecting a rotor position. Furthermore, DE 10 2007 028 482 A1 discloses a sensor assembly. DE 10 2005 004 322 A1 discloses rotor position detection by means of a Hall sensor and a magnetic flux guiding element. Furthermore, DE 103 31 505 A1 discloses a sensor assembly for determining a position angle of an electric machine.

[0003] DE 10 2021 131 178 A1 discloses an electric machine in a housing having a stator and a rotor, with one or more point field detectors for detecting stray fluxes within the housing. To this end, the point field detectors are arranged within the housing and can also be arranged on the rotor or the stator.

[0004] EP 2 214 296 A1 describes an electric machine assembly in an electric machine housing having an electric machine housing opening into which a sensor housing can be engaged and can be arranged. The sensor housing contains one or more Hall effect sensors, which protrude out of the sensor housing and, when the sensor housing is inserted, are positioned in the middle region of the teeth of the electric machine stator by means of slots in the electric machine housing opening. SUMMARY

[0005] It is an object of the invention to provide an electric machine, in particular for a motor vehicle, and a method for producing such an electric machine, so that the magnetic field of the electric machine can be detected in a particularly advantageous manner.

[0006] This object is achieved by the electric machine having the features of patent claim 1 and the method having the features of patent claim 9. Advantageous design solutions with suitable refinements of the invention are given in the remaining claims.

[0007] The first aspect of the application relates to an electric machine, in particular for a motor vehicle. This means, for example, that a motor vehicle, simply also referred to as a vehicle and configured, for example, as a car, in particular a passenger car, has an electric machine in its fully manufactured state and can be driven by means of the electric machine, in particular purely electrically. The electric machine has at least one winding by means of which a magnetic field can be generated, in particular for driving a rotor of the electric machine. This means, for example, that the electric machine in its fully manufactured state has a rotor which can be driven by the magnetic field. For example, the electric machine in its fully manufactured state has a stator and a rotor, wherein the rotor can be driven by the stator so as to be able to rotate relative to the stator about a machine rotational axis of the electric machine. In particular, the rotor can be driven by means of the magnetic field so as to rotate relative to the stator about the machine rotational axis. In particular, it is conceivable that the winding is a winding of the stator and is therefore also referred to as a stator winding. For example, the electric machine can provide a drive torque for driving the motor vehicle by means of its rotor. The electric machine has a sensor device by means of which a magnetic field can be detected. In particular, a quantity characterizing the magnetic field, i.e. a quantity describing or indicating the magnetic field, for example a magnetic flux of the magnetic field, also referred to as a magnetic flux, can be detected by means of the sensor device. For example, a stray flux of the electric machine, also referred to as a magnetic stray flux, can be realized by means of the sensor device, wherein the stray flux describes or is a part of the magnetic flux. Thus, for example, a stray flux measurement can be carried out by means of the sensor device, wherein the measurement, i.e. the detection, is carried out by means of the sensor device. In other words, for example, the sensor device can measure, i.e. detect, the magnetic flux and / or the stray flux of the magnetic field, so as to measure the magnetic field. For example, since the magnetic field can be used to drive the rotor, the magnetic field is also referred to as a rotor magnetic field. In particular, the magnetic field, in particular the magnetic flux and / or the stray flux, can be measured by means of the sensor device, so that the detection or measurement of the magnetic field is also referred to as a magnetic field measurement or a rotor magnetic field measurement.

[0008] To enable the detection, i.e., measurement of magnetic fields and thus, for example, magnetic flux and / or stray flux, in a particularly advantageous manner, according to the invention, the sensor device has a circuit board, also referred to as a printed circuit board, and has a plurality of circuit board regions that are at least partially, particularly completely, spaced apart from each other in the circumferential direction of the motor, with corresponding length regions of the windings arranged therebetween. The circumferential direction of the motor, as well as the circumferential directions of the stator and rotor, extends about the motor's axis of rotation. Since the circuit board regions are at least partially spaced apart from each other, corresponding through-holes are arranged between the circuit board regions in the circumferential direction of the motor, and these through-holes are continuous, particularly in the axial direction of the motor, which coincides with the motor's axis of rotation. The length regions of the windings pass through the through-holes, particularly in the axial direction of the motor, with their radial direction perpendicular to the axial direction of the motor. In particular, the circuit board regions are arranged in the circumferential direction of the motor between the length regions of the windings, such that, when viewed in the circumferential direction of the motor, the length regions and the circuit board regions are arranged alternately. Furthermore, according to the invention, the sensor device has a sensor element held on the circuit board, by means of which the magnetic field or dimension can be detected separately. Therefore, for example, magnetic flux and / or stray flux can be measured, i.e., detected, by means of sensor elements. For example, the corresponding sensor elements are or include at least one or exactly one magnetic field sensor and / or magnetic flux sensor, by which magnetic fields, particularly magnetic flux and / or stray flux, can be measured, i.e. detected. Specifically, the number of sensor elements is at least ten. The number of sensor elements is preferably greater than ten, particularly greater than or equal to one hundred. At least one or exactly one sensor element can be provided for each board area. Furthermore, it is conceivable, for example, that the number of sensor elements is greater than the number of board areas; for example, it is conceivable, particularly in each case, that one of the sensor elements is arranged in one board area, particularly precisely in one board area, such that, for example, at least or precisely all or several board areas have no sensor elements. In other words, for example, it is arranged such that no sensor elements are arranged in at least one or exactly one board area or several board areas.

[0009] To achieve a particularly advantageous structure in terms of weight, structural space, and cost of the motor, thereby enabling the detection of magnetic fields in a manner favorable to weight, cost, and structural space, according to the invention, the circuit board region is configured as teeth, also referred to as lugs or pointed teeth. The teeth project inwardly from the base region of the circuit board shared by the teeth in the radial direction of the motor, which extends perpendicular to the axial direction of the motor. In this configuration, the teeth are held on and together with each other in the base region, particularly in such a way that the teeth and base region are integrally formed, i.e., formed as a single piece. This should be understood in particular as not consisting of components constructed separately and connected to each other, but preferably, the teeth and base region are formed as a single piece, thus constructed as an integral unit or formed integrally. In other words, preferably, the teeth and base region are formed as an integrally manufactured unit, thus formed as a single piece, and therefore integrally manufactured. The corresponding teeth terminate inwardly in the radial direction of the motor at their respective free ends, which are opposite, for example, annular base regions. Thus, the circuit board is configured as a comb, therefore constructed in the form of a comb, with its pointed teeth being teeth. In this way, the cost, structural space, and weight economy of the circuit board and thus the sensor device as a whole can be shown, and the time and cost-effective assembly of the circuit board can also be shown.

[0010] To enable the measurement, i.e., detection of magnetic fields and thus, for example, magnetic flux and / or stray flux, in a particularly advantageous and accurate manner, according to the invention, at least two sensor elements are configured to differ from each other in their measurement principles for detecting the magnetic field. Thus, for example, at least one or exactly the first of the sensor elements belongs to a first sensor type, by which the magnetic field and thus, for example, magnetic flux and / or stray flux, can be detected according to or based on a first measurement principle. Furthermore, for example, at least one or exactly the second of the sensor elements belongs to a second sensor type different from the first sensor type, by which the magnetic field, thus, for example, magnetic flux and / or stray flux, can be detected according to or based on a second measurement principle different from the first measurement principle. In this case, the first and second measurement principles differ from each other, thus allowing for particularly accurate detection of the magnetic field. Since magnetic flux can be detected, for example, by means of a corresponding sensor element, the corresponding sensor element is, for example, or includes, specifically, a so-called flux sensor by which magnetic flux can be detected.

[0011] The first sensor type, or the corresponding sensor element belonging to the first sensor type, is or includes, for example, a 3D Hall sensor, by means of which magnetic fields, particularly magnetic flux and / or stray flux, can be detected with particularly high resolution. The second sensor type, or the corresponding sensor element belonging to the second sensor type, is, for example, a Hall switch.

[0012] For example, regarding the detection of magnetic fields, particularly magnetic flux and / or stray flux, the first sensor element has very high measurement accuracy for measuring the amplitude of the magnetic field, particularly the magnetic flux. As a result, the rotor temperature, also known as the rotor temperature, can be inferred particularly accurately or directly, for example. In other words, because at least two sensor elements differ from each other in their measurement principles for detecting magnetic fields, particularly magnetic flux and / or stray flux, the present invention makes it possible to determine the rotor temperature particularly accurately, i.e., at least based on the magnetic field, particularly the magnetic flux and / or stray flux, detected by means of the first sensor element. For example, regarding the detection of magnetic fields, particularly the magnetic flux and / or stray flux, and regarding the determination of rotor temperature, the first sensor element can have a measurement accuracy of, for example, 0.1% per Kelvin. In particular, for example, the present invention makes it possible to detect the amplitude of the magnetic field, particularly the magnetic flux and / or stray flux, particularly accurately by means of the first sensor element, so that the rotor temperature can be determined particularly accurately, for example, based on the detected amplitude, especially because the rotor temperature can be inferred particularly directly, for example, based on the detected amplitude.

[0013] This invention also enables a particularly economical structure for the motor, as it can be manufactured with low material costs. Furthermore, cost-effective assembly is possible because, for example, for detecting, and particularly for measuring, magnetic fields, such as magnetic flux and / or stray flux, there is no need for specially designed rotating parts that would otherwise require assembly. Moreover, an economical design in terms of structural space and weight is possible for the motor, since the magnetic field can be detected and measured using only a small number of components.

[0014] In particular, it is conceivable that a sensor device has multiple circuit boards, namely the aforementioned circuit board and at least one or more additional circuit boards, wherein previous and subsequent statements about the first circuit board can also be readily transferred to the corresponding additional circuit boards, and vice versa.

[0015] Therefore, for example, magnetic fields, particularly magnetic flux and / or stray flux, can be detected in a simple, redundant, and accurate manner using a circuit board and corresponding sensor elements mounted thereon. For example, by detecting or measuring the magnetic field or magnetic flux, faults in a current sensor system can be identified at an early stage. Thus, emergency operation of a motor can be achieved, for example, in emergency operation, the motor can be operated, particularly controlled or regulated, based on the detected magnetic field, particularly based on the magnetic flux and / or stray flux.

[0016] It has been shown that if the arrangement of sensor elements and / or sensor elements belonging to the first sensor type, especially the spatial arrangement, is, for example, six, depending on the pole-slot ratio, it is particularly advantageous to achieve a particularly advantageous flux position signal, thereby enabling the particularly advantageous detection of magnetic fields and thus, for example, magnetic flux and / or stray flux.

[0017] Another embodiment is characterized in that at least one or exactly one of the sensor elements, particularly the first sensor element, i.e., a sensor element belonging to a first sensor type, is configured to detect both the magnetic field and at least one or exactly one measurement parameter, which is different from the magnetic field and is attached to the magnetic field setting. Therefore, particularly advantageous operation of the motor can be ensured in a particularly simple, space-saving, and weight-saving manner.

[0018] To achieve particularly advantageous operation of the motor, it has proven especially advantageous if the measured parameter is the motor's temperature. Therefore, at least one or exactly one sensor element is or includes, for example, exactly one or at least one magnetic field sensor, particularly a flux sensor simply called a flux sensor, for detecting the magnetic field, particularly magnetic flux and / or stray flux, and at least one or exactly one sensor element is or particularly precisely includes a temperature sensor by means of which the temperature can be detected, i.e., measured. Very preferably, the temperature is the stator temperature, also called the stator temperature, thereby allowing the motor to be operated particularly advantageously, especially controlled or regulated, for example, according to the detected, i.e., measured temperature.

[0019] To achieve particularly advantageous operation of the motor in a particularly economical manner, in another embodiment of the invention, the remaining sensor elements attached to at least one or exactly one sensor element are configured to detect only the magnetic field with respect to the measured parameters and the magnetic field. As a result, the remaining sensor elements can be cost-effective in terms of weight, structural space, and cost.

[0020] Since at least one or exactly one sensor element is configured to both detect the magnetic field and for this purpose detect the measurement parameter, at least one or exactly one sensor element can, for example, perform a primary measurement, wherein the magnetic field and the measurement parameter are measured, i.e., detected, by at least one or exactly one sensor element. Therefore, at least one or exactly one sensor element has a first function and an additional second function, also referred to as an auxiliary function. The first function includes measurement, i.e., detecting the magnetic field, and the second function includes measurement, i.e., detecting the measurement parameter.

[0021] In order to detect, i.e. measure, magnetic fields, especially magnetic flux and / or stray flux, with particular precision and thus advantage, in one embodiment of the invention, a corresponding one of the sensor elements is positioned, in particular, precisely on the corresponding circuit board area.

[0022] Another embodiment is characterized in that the base region is formed in a circular or segmental shape on its side facing away from the teeth and outward in the radial direction of the motor. As a result, a particularly space-saving design allows the circuit board and thus the sensor device to be shown as a whole on the outer circumference, making the circuit board and thus the sensor device particularly advantageous to mount. Therefore, magnetic fields, especially magnetic flux and / or stray flux, can be detected, i.e., measured, particularly well.

[0023] In another particularly advantageous embodiment of the invention, the circuit board is inserted from the outside to the inside of the length region in the radial direction of the motor. As a result, the circuit board and sensor device can be assembled in a particularly time- and cost-effective manner, and consequently, the motor can be manufactured in a particularly time- and cost-effective manner. Therefore, the magnetic field, especially magnetic flux and / or stray flux, can be detected, i.e., measured, in a particularly economical manner.

[0024] In another embodiment of the invention, each sensor element is at least partially embedded in a circuit board. In this way, a particularly space-saving structure for the sensor device can be demonstrated, enabling particularly good detection of magnetic fields, especially magnetic flux and / or stray flux.

[0025] In another embodiment of the invention, the circuit board is manufactured using an injection molding process. In other words, the circuit board is preferably manufactured by injection molding. In this way, potentially complex geometries of the circuit board can be produced in a particularly economical manner as needed, allowing the circuit board to be advantageously arranged, especially relative to the windings. Therefore, it is particularly advantageous to measure, i.e., detect, magnetic fields.

[0026] In order to manufacture the circuit board in a particularly cost-effective manner, in another embodiment of the invention, the circuit board is manufactured by laser direct patterning (LDS).

[0027] In another particularly advantageous embodiment of the invention, the motor has a laminated core that carries the windings, which is specifically constructed separately from the windings.

[0028] In this case, it has proven particularly advantageous if the corresponding laminated segments of the laminated core are adjacent to the circuit board on both sides of the motor's circumferential direction. As a result, the circuit board is integrated into the laminated core in a particularly space-saving manner, especially in the axial direction of the motor, allowing for a particularly space-saving structure. Specifically, the circuit board is constructed in a precisely fitted form with the laminated segments (also called stator metal plates), such that, for example, in the production of the motor, i.e., in the method used to manufacture the motor, the circuit board can be placed directly on or bonded to the laminated core, for example, before and / or after the windings are introduced or arranged in or on the laminated core. Therefore, the circuit board can be arranged with a particularly precise fit between the laminated core and the winding head. Thus, very precise positioning of all sensor elements can be ensured. In particular, excessive offset can be avoided, allowing for particularly accurate measurement of the magnetic field.

[0029] For example, the circuit board is thus configured to mate with the stator yoke (also called the stator yoke) and / or the electrodes of the motor, so that the circuit board and therefore the sensor device can be advantageously integrated into the motor. For example, the circuit board, particularly in the axial direction of the motor, is arranged directly between the stator yoke and the winding head of the winding, thereby demonstrating a particularly advantageous arrangement of the circuit board and the sensor device. Therefore, magnetic fields can be detected, i.e., measured, particularly well.

[0030] For example, the stator yoke is a laminated core. The winding head is formed, for example, by the length region of the winding, because the length region and therefore the winding head protrude from the stator or laminated core respectively in the axial direction of the motor. In particular, the length region of the winding and therefore the winding head protrudes from the axial end side of the stator yoke or laminated core in the axial direction of the motor.

[0031] Another embodiment is characterized in that, when viewed in the axial direction of the motor, the corresponding laminated sections and circuit boards are arranged at least partially at the same height. As a result, particularly when viewed in the axial direction of the motor, a particularly space-saving structure can be shown, and the circuit board, and therefore the sensor device, can be advantageously integrated into the motor, making it possible to detect magnetic fields particularly well.

[0032] Furthermore, preferably, the corresponding laminated sections and circuit boards are arranged flush with each other, particularly on the respective axial end sides facing the winding head, resulting in a structure that is particularly space-saving. Therefore, magnetic fields can be detected with particular advantage.

[0033] For example, the circuit board at least partially overlaps the laminate core, particularly at least primarily, and therefore at least half or completely, in a first direction extending parallel to or coinciding with the motor's axial direction. In this case, for example, the circuit board is arranged in a second direction opposite to the first direction, extending parallel to or coinciding with the motor's axial direction, and opposite to the first direction, completely not overlapping the laminate core. Therefore, magnetic fields can be detected particularly advantageously by a sensor device, and the sensor device can be installed particularly simply, thus being time- and cost-effective.

[0034] In order to detect magnetic fields with particular accuracy and thus with particular advantage, the first sensor element and / or the second sensor element may be configured to have a magnetic sensor constructed for detecting magnetic fields, which is an anisotropic magnetoresistive sensor, and therefore an AMR sensor.

[0035] Finally, it has proven particularly advantageous if the sensor device is configured to determine at least one rotational position of the motor rotor, also known as angular azimuth or angular position, and / or the amplitude of the magnetic field and / or one or more of the aforementioned temperatures of the motor, based on a detected magnetic field or parameters. Since the rotor can rotate relative to the stator about the machine's axis of rotation, it can rotate relative to the stator to several different rotational or angular positions. In this case, for example, based on the magnetic field, at least one or more rotational or angular positions can be detected by means of the sensor device. In particular, for example, the higher the accuracy (also known as angular accuracy) of determining at least one rotational position, the greater the number of sensor elements. Background of the Invention: In particular, motors preferably configured as rotating magnetic field motors can be particularly advantageously operated, especially regulated, based on rotational positions (also known as rotor positions). Typically, determining rotor position by means of magnetic field sensors is very inaccurate or requires a particularly large number of sensors that must be individually mounted in precise locations, which can result in a very expensive manufacturing process. The present invention now makes it possible to assemble circuit boards and sensor devices in a time- and cost-effective and particularly accurate manner, enabling the detection of magnetic fields and, for example, at least one subsequent rotational position in a precise and cost-effective manner. Amplitude, also known as flux amplitude or rotor flux amplitude, can be used as highly advantageous additional information to determine, in particular, and very specifically, temperature, for example, based on amplitude, especially from amplitude, where temperature is, for example, the temperature of the rotor, also called rotor temperature. Furthermore, for example, based on amplitude, particularly advantageous condition monitoring of the motor can be achieved. Moreover, the present invention makes it possible to identify rotor demagnetization or partial demagnetization, as well as bearing damage and other damage, at an early stage, thereby enabling particularly advantageous operation of the motor.

[0036] A second aspect of the invention relates to a method for manufacturing an electric motor, particularly according to a first aspect of the invention. In the method according to the second aspect of the invention, the electric motor is equipped with at least one winding by means of which a magnetic field can be generated, and is equipped with at least one sensor device by means of which the magnetic field can be detected.

[0037] To enable the detection of magnetic fields, particularly magnetic flux and / or stray flux, in a particularly advantageous manner, the second aspect of the invention provides a sensor device made of a circuit board having multiple circuit board regions that are at least partially, and particularly completely, spaced apart from each other in the circumferential direction of the motor, with corresponding length regions of windings arranged between these circuit board regions. Furthermore, the sensor device is made of sensor elements held on the circuit board, by means of which the magnetic field, particularly magnetic flux and / or stray flux, can be detected. In this case, at least two or exactly two of the sensor elements are different from each other in their measurement principles for detecting the magnetic field. The advantageous and beneficial designs of the first aspect of the invention should be considered as advantageous and beneficial designs of the second aspect of the invention, and vice versa.

[0038] A third aspect is also disclosed, relating to a method for operating a motor according to the first aspect of the invention. The advantages and advantageous designs of the first and second aspects of the invention should be regarded as advantages and advantageous designs of the third aspect, and vice versa.

[0039] Other advantages, features, and details of the invention will become apparent from the following description of preferred embodiments and with reference to the accompanying drawings. Without departing from the scope of the invention, the features and combinations thereof mentioned in the specification, as well as the features and combinations thereof mentioned in the description of the drawings and / or shown individually in the drawings, may be used not only in their respective combinations, but also in other combinations or individually. Attached Figure Description

[0040] In the drawings: Figure 1 A schematic perspective view of the stator of an electric motor, particularly an electric motor for motor vehicles, is shown. Figure 2 Details of a schematic perspective view of a first embodiment of a sensor device circuit board for an electric motor are shown; Figure 3 A schematic plan view of a second embodiment of the circuit board is shown; Figure 4 A schematic plan view of a third embodiment of the circuit board is shown; and Figure 5 A schematic diagram of a sensor element held on a circuit board is shown.

[0041] In the figure, the same or functionally identical elements have the same reference numerals. Detailed Implementation

[0042] Figure 1 A schematic perspective view of an electric motor, particularly the stator 10 of a motor vehicle, is shown. This means that a motor vehicle, simply also referred to as a vehicle and constructed, for example, as an automobile, particularly a passenger car, has an electric motor in its fully manufactured state and can be driven, particularly by means of the motor, in pure electric drive. The motor is preferably a high-voltage component, with a voltage, particularly the electrical operating voltage or nominal voltage, preferably greater than 50 volts, particularly greater than 60 volts, and very preferably several hundred volts. In its fully manufactured state, the motor has a stator 10 and a rotor (not shown), which can be driven by the stator 10 and thus can rotate relative to the stator 10 about the machine rotation axis of the motor, the axial direction of which coincides with the machine rotation axis. In particular, the motor, extending radially perpendicular to the axial direction of the motor, can provide driving torque for driving the motor vehicle through its rotor.

[0043] The motor, particularly the stator 10, has at least one winding 12 through which a magnetic field can be generated, particularly having a magnetic flux simply referred to as magnetic flux or magnetic flux quantity. Most preferably, the winding 12 is designed according to a hairpin technique, also known as a hairpin winding. Since the winding 12 is a winding of the stator 10, the winding 12 is also referred to as the stator winding. The stator 10 and the motor have a laminated core 14 on which the winding 12 is held. Therefore, the winding 12 is carried by the laminated core 14. The axial direction of the motor and the axial direction of the stator 10 are... Figure 1 The double arrow 16 is used to indicate this. For example, the laminated core 14 is formed by multiple laminated segments that are constructed separately from each other and connected together, specifically compressed together. From Figure 1 It can be seen that, in the axial direction of the motor and therefore the laminated core 14, and therefore on the first axial end side AS1 of the laminated core 14, a corresponding length region L of the winding 12 protrudes from the laminated core 14, particularly from the axial end side AS1 of the laminated core 14, thereby forming at least one winding head 18 of the winding 12 arranged on the axial end side AS1. For example, the laminated core 14 also has a second axial end side AS2, which faces away from the first axial end side AS1 of the laminated core 14 in the axial direction of the motor. In this case, for example, it can be imagined that on the second axial end side AS2, a second length region L2 of the winding 12 protrudes from the laminated core 14 in the axial direction of the motor and therefore in the axial direction of the stator 10 of the laminated core 14, particularly from the axial end side AS2 of the laminated core 14, thereby, for example, forming a second winding head 20 of the winding 12.

[0044] The motor also has a sensor device 22, by means of which the magnetic field of the motor, particularly magnetic flux and / or stray flux, particularly magnetic field, can be detected.

[0045] In order to particularly advantageously detect magnetic fields, especially magnetic flux and / or stray flux, i.e., to be able to measure them, the sensor device 22 has at least one circuit board 24, which is preferably constructed separately from the laminate core 14 and is connected to the laminate core 14, for example, at least indirectly, and especially directly.

[0046] Figure 2 A first embodiment of the sensor device 22, having a circuit board 24, is shown in detail in a schematic perspective view. Figure 2 As can be seen particularly clearly, circuit board 24 has circuit board regions 26 that are at least partially (in this example completely) spaced apart from each other in the circumferential direction of the motor and thus the stator 10, which extends about the motor's rotation axis, with length regions L arranged between these circuit board regions. Conversely, circuit board regions 26 are arranged in the circumferential direction of the motor and therefore also between the length regions L of the stator 10.

[0047] The sensor device 22 also has sensor elements 28 held on and thus carried by the circuit board 24, particularly in such a way that each sensor element 28 is at least partially embedded in the circuit board 24. Therefore, the circuit board 24 is equipped with sensor elements 28. Magnetic fields, particularly magnetic flux and / or stray flux, can be measured, i.e., detected, by means of the sensor elements 28. Thus, for example, in a method for operating a motor, the magnetic field, particularly magnetic flux and / or stray flux, is detected, i.e., measured, by means of the sensor elements 28. For example, the sensor elements 28, and therefore the sensor device 22, provide at least one signal, particularly an electrical signal, that characterizes the magnetic field detected by the sensor elements 28, i.e., the measured magnetic field.

[0048] from Figure 2 It can be seen that a corresponding one of the sensor elements 28 is held, in particular, precisely held, on the corresponding circuit board area 26. Therefore, the sensor elements 28 are arranged, for example, within a length region L. For example, in... Figure 2 In the first embodiment of the sensor device 22 shown, a sensor element 28 is provided for each circuit board area 26, specifically exactly one sensor element.

[0049] The circuit board region 26 is configured as teeth or pointed teeth that protrude inward from the base region 30 of the circuit board 24, which is shared by the teeth, in the radial direction of the motor and thus in the radial direction of the stator 10, and in the radial direction of the motor, and thus in the radial direction of the stator 10, terminates inward at the corresponding free end E of the corresponding tooth opposite to the base region 30. Therefore, the circuit board 24 is configured as a comb, in this case, the circuit board 24 is configured as a comb bent about the axis of rotation of the machine. Therefore, the circuit board 24 can be assembled in a particularly time-saving and economical manner, such that in the method for manufacturing the motor, the circuit board 24 is inserted from the outside to the inside of the length region L in the radial direction of the motor, and thus in the radial direction of the stator 10. The radial directions of the motor and stator 10 extend perpendicular to the axial directions of the motor and stator 10, and... Figure 1 and Figure 2 The axis of the motor, and therefore the axis of the stator 10, is indicated by double arrow 32. Figure 1 The dotted line 34 indicates that the circumferential direction of the motor and the circumferential direction of the stator 10 extend axially and are indicated by double arrows 36.

[0050] from Figure 2 It can be seen that the base region 30 is constructed in a circular shape on its opposite side (circuit board region 26) and on the radially outward side 35 of the motor. From Figure 1 As can be seen, in the circumferential direction of the motor, and therefore in the circumferential direction of the stator 10, the corresponding laminated segments forming the laminated core 14 are adjacent to the circuit board 24 on both sides. The first of the laminated segments 38 adjacent to the circuit board 24 in the circumferential direction and the second of the laminated segments directly adjacent to the circuit board 24 in the circumferential direction are marked 40. When viewed in the axial direction of the motor, the corresponding laminated segments 38, 40 and the circuit board 24 are at least partially, and in particular at least completely, arranged on the same horizontal plane. In this case, the corresponding laminated segments 38, 40 and the circuit board 24 are arranged flush with each other on the axial end side AS1. In this case, the circuit board 24 is at least partially, and in particular at least primarily, and therefore at least more than half or completely covered by the laminated core 14 in the first direction indicated by arrow 42, i.e., overlapping, wherein the first direction indicated by arrow 42 is parallel to or coincides with the axial direction of the motor. In the second direction, opposite to the first direction as indicated by arrow 44, the circuit board 24 is arranged so as not to overlap with the laminated core 14 at all, and thus does not overlap with the laminated core 14. This second direction extends parallel to or coincides with the axial direction and is opposite to the first direction. Therefore, the circuit board 24 is arranged in the axial direction of the motor between at least one length region of the winding head 18 and the laminated core 14, thereby enabling particularly advantageous detection of magnetic fields, especially magnetic flux and / or stray flux. Specifically, the sensor element 28 is arranged along the axial direction between at least one length region of the winding head 18 and the laminated core 14.

[0051] To enable particularly precise detection of magnetic fields, especially magnetic flux and / or stray flux, at least one (in this example, multiple) of the sensor elements 28 is configured to measure, specifically, the magnetic field, particularly magnetic flux and / or stray flux, using a first measurement principle, i.e., according to or based on a first measurement principle. At least one, or exactly one, of the sensor elements 28 (in this example, multiple) is configured to measure, specifically, the magnetic field, particularly magnetic flux and / or stray flux, using a second measurement principle different from the first measurement principle, i.e., according to or based on a second measurement principle. This means that the first sensor element 28 and the second sensor element 28 differ from each other in the measurement principle used for detecting the magnetic field. For example, the corresponding first sensor element 28 is or includes at least one first magnetic field sensor of a first sensor type, and is therefore a sensor of the first sensor type. Furthermore, the corresponding second sensor element 28 is or includes at least one second magnetic field sensor of a second sensor type different from the first sensor type, and is therefore a sensor of the second sensor type different from the first sensor type. In this case, the corresponding first magnetic field sensor is configured to measure the magnetic field according to the first measurement principle, and the corresponding second magnetic field sensor is configured to measure, i.e., detect the magnetic field according to the second measurement principle.

[0052] Furthermore, at least one or exactly one of the sensor elements is configured as a multi-functional sensor. The multi-functional sensor is, for example, one of the first sensor elements 28 or one of the second sensor elements 28. The multi-functional sensor is configured to detect both the magnetic field and at least one additional measurement parameter, different from the magnetic field, attached to the magnetic field setting. In the embodiment shown in the figures, the additional measurement parameter is the temperature of the motor, particularly the temperature of the stator 10, such that this temperature is also referred to as the stator temperature. In this case, the multi-functional sensor includes, for example, a magnetic field sensor of the first or second sensor type, and additionally, the multi-functional sensor includes at least one additional sensor by means of which the additional measurement parameter can be detected. In the embodiment shown in the figures, the additional sensor is a temperature sensor by means of which the temperature can be detected. The multi-functional sensor in Figure 5 The diagram is shown and labeled 46.

[0053] Preferably, the remaining sensor elements 28 of the sensor device 22, which are attached to at least one or exactly one multifunctional sensor 46, are configured to detect only the magnetic field with respect to the measured parameters and the magnetic field, such that the measured parameters, i.e., temperature, cannot be detected, for example, by means of the remaining sensor elements 28.

[0054] It has been found that it is particularly advantageous if the sensor device 22 is configured to determine at least one rotational position of the rotor, particularly several rotational positions, especially relative to the stator 10, and / or the amplitude of the magnetic field, i.e., determination, based on the detected magnetic field. The corresponding rotational position is also referred to as the rotor position and can be used, for example, for operation based on the determined rotational position, particularly for adjusting the motor. The greater the number of sensor elements 28, the higher the accuracy of determining the rotor's rotational position. Therefore, particularly precise adjustment of the motor can be ensured.

[0055] Preferably, at least one laminated segment of the laminated core 14 and the circuit board 24, individually, are structurally identical, i.e., identical, particularly in terms of their respective outer contours, and therefore their shapes on the outer periphery. Preferably, the number of sensor elements 28 is in the range of 10 to 100. Preferably, the number of first sensor elements 28 is equal to the number of second sensor elements. Very preferably, the circuit board 24 is manufactured by injection molding and / or by laser direct patterning, and therefore by laser direct patterning (LDS). Since the circuit board 24 is preferably configured as a laminated segment of the laminated core 14, the circuit board 24 can be introduced into the manufacturing winding 12, for example, configured as a hairpin winding, in a time-saving and economical manner, particularly in such a way that, in this case, the comb-shaped circuit board 24 is inserted from the outside to the inside of the length region L of the winding 12 in the radial direction of the motor, and therefore in the radial direction of the stator 10.

[0056] By detecting magnetic fields, particularly magnetic flux and / or stray flux, bearing damage can be detected, for example, and position signals can be detected redundantly, for example. Furthermore, variations in the motor can be compensated for, for example, by aging, temperature, or other damage. Compared to traditional solutions, moving parts or couplings are no longer required, thus avoiding them and providing exceptionally high robustness.

[0057] Figure 3 A schematic plan view illustrates a second embodiment of the sensor device 22 with circuit board 24. It can be seen that the sensor element 28 is not arranged on each circuit board region 26, but rather the sensor element 28 is arranged on the first circuit board region 26, and the second circuit board region 26 has no sensor element 28. This is achieved in such a way that a corresponding one of the sensor elements 28 is arranged particularly precisely on the corresponding first circuit board region 26. For example, the first circuit board region 26 and the second circuit board region 26 are arranged alternately to each other in the circumferential direction of the motor extending about the machine's rotation axis. Alternatively or additionally, the first sensor element and the second sensor element may be arranged alternately to each other when extending about the machine's rotation axis in the circumferential direction of the motor and stator 10.

[0058] from Figure 3 It can also be seen that the sensor device 22 has a connecting element 48, which is, for example, fixed to the circuit board 24. For example, the sensor device 22 can provide the aforementioned signal via the connecting element 48. For example, a line can be connected to the connecting element 48, particularly an electrical connection, so that the signal can be transmitted from the sensor device 22 to the line or the line, for example, via the connecting element 48. For example, the signal can be directed to an electronic computing device via the line, which can, for example, operate a motor according to the signal, particularly adjust or control the motor.

[0059] In particular, by using the first sensor element 28 and the second sensor element 28, particularly high measurement accuracy can be achieved, especially with regard to magnetic flux and / or rotational position. For example, the first sensor element 28 and the second sensor element 28 are geometrically distributed on different teeth. For example, a six-phase system is suitable so that saturation and harmonics in the signal can trigger each other. Thus, for example, when viewed in the circumferential direction of the motor, the six sensor elements 28 are arranged to be electrically offset from each other by 30 degrees. Advantageously, the mechanical arrangement, i.e., spatial arrangement, of the sensor elements 28 is based on the ratio of the grooves and poles of the motor. If the motor, particularly the stator 10, has, for example, 48 grooves and 8 poles, then the sensor elements 28 are offset from each other, for example, by 7.5 degrees in the circumferential direction of the motor. Thus, for example, when viewed in the circumferential direction of the motor, the distance between adjacent sensor elements 28 is 7.5 degrees, especially when viewed in pairs. For example, in Figure 4 This is the case in the third embodiment of the sensor device 22 and the third embodiment of the circuit board 24 shown. In the second embodiment, it is conceivable that when viewed in the circumferential direction of the motor, the sensor elements 28 are arranged in pairs, offset from each other by 15 degrees, that is, spaced apart from each other, so that a mechanical offset of 15 degrees is set between the sensor elements 28. It is conceivable that when viewed in the circumferential direction of the motor, the sensor elements 28 are spaced apart from each other by 15 degrees, especially when viewed in pairs, wherein, for example, when viewed electrically, the sensor elements 28 are offset from each other by 30 degrees.

[0060] Figure 5 The magnetic field sensor of the multi-functional sensor 46, marked 50, belongs to, for example, the first sensor type and is configured as, for example, a 3D Hall sensor in this case. The temperature sensor of the multi-functional sensor 46... Figure 5 Marked as 52. The magnetic field sensor 50 and the temperature sensor 52 form a structural unit.

[0061] List of reference signs

Claims

1. An electric motor having at least one winding (12) and a sensor device (22), capable of generating a magnetic field by means of said at least one winding, and capable of detecting said magnetic field by means of said sensor device. Its features are, The sensor device (22) includes: - At least one circuit board (24), the at least one circuit board having a plurality of circuit board regions (26) at least partially spaced apart from each other in the circumferential direction (36) of the motor, and corresponding length regions (L) of the winding (12) arranged between the circuit board regions. The circuit board region (26) is configured as teeth, the teeth protruding inward from the base region (30) of the circuit board (24) shared by the teeth along the radial direction (32) of the motor, and terminating inward along the radial direction (32) of the motor at the corresponding free end (E) of the corresponding tooth opposite to the base region (30); and - Sensor elements (28) held on the circuit board (24) are capable of detecting the magnetic field by means of the sensor elements, wherein at least two of the sensor elements (28) are different from each other in terms of their measurement principle for detecting the magnetic field.

2. The motor according to claim 1, Its features are, At least one or exactly one of the sensor elements (28) is configured to detect both the magnetic field and at least one or exactly one measurement parameter that is attached to the magnetic field and is different from the magnetic field.

3. The motor according to claim 2, Its features are, The measured parameter is the temperature of the motor.

4. The motor according to claim 2 or 3, Its features are, The remaining sensor elements (28) of the sensor device (22), which are attached to at least one or exactly one sensor element (46), are configured to detect only the magnetic field with respect to the measurement parameters and the magnetic field.

5. The motor according to any one of the preceding claims, Its features are, The corresponding sensor element (28) is held on one of the corresponding ones in the circuit board area (26).

6. The motor according to any one of the preceding claims, Its features are, The base region (30) is formed in a circular or segmental shape on its back tooth and outward side (35) in the radial direction (32) of the motor.

7. The motor according to any one of the preceding claims, Its features are, The circuit board (24) is inserted from the outside to the inside of the length region (L) in the radial direction (32) of the motor.

8. A motor vehicle having at least one motor according to any one of the preceding claims.

9. A method for manufacturing an electric motor, wherein the electric motor is equipped with at least one winding (12) and at least one sensor device (22), wherein a magnetic field can be generated by means of the at least one winding, and the magnetic field can be detected by means of the at least one sensor device. Its features are, The sensor device (22) is made of the following: - A circuit board (24) having a plurality of circuit board regions (26) at least partially spaced apart from each other in the circumferential direction (36) of the motor, wherein a corresponding length region (L) of the winding (12) is arranged between the circuit board regions. The circuit board region (26) is configured as teeth, the teeth protruding inward from the base region (30) of the circuit board (24) shared by the teeth along the radial direction (32) of the motor, and terminating inward along the radial direction (32) of the motor at the corresponding free end (E) of the corresponding tooth opposite to the base region (30); and - Sensor elements (28) held on the circuit board (24) are capable of detecting the magnetic field by means of the sensor elements, wherein at least two of the sensor elements (28) are different from each other in terms of their measurement principle for detecting the magnetic field.

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