Electric motor for motor vehicle

Abstract

The invention relates to an electric motor (2) for a motor vehicle, comprising a motor housing (4), an electronics unit (8) arranged on an end face of the motor housing (4), a plurality of phase connections (42, 70, 121) being guided from the motor housing (4) into the electronics unit (8), a printed circuit board arrangement (34) of the electronics unit (8) as a control unit of the electric motor (2), and a wire harness terminal (12) for an electronics unit (8) of the wire harness (10), the wire harness terminal (12) being designed for plug-in contact with the wire harness (10).

Description

[0001] The present invention relates to an electric motor for a motor vehicle. The invention particularly relates to an improved concept for maintenance, service or repair work on the motor electronics and / or a wiring harness connected to the electric motor.

[0002] In modern motor vehicles, electric motors are used in various ways as (adjustable) drives for various actuating elements. Electric motors are used, for example, as window lifter drives, sunroof drives or seat adjustment drives, steering drives (EPS, Electrical Power Steering), brake drives, pump drives, cooler fan drives or transmission actuators. Furthermore, electric motors are used as (traction) drives, for example, for electrically powered or drivable vehicles with two, three or four wheels.

[0003] In particular, brushless electric motors as (three-phase) electric motors usually have a stator provided with a field winding or a stator winding, which is arranged coaxially with a rotor having one or more permanent magnets. Both the rotor and the stator are constructed, for example, as a laminated core, wherein the stator teeth carry the coils of the stator winding in the stator slots between them.

[0004] In brushless electric motors, the alternating current supplied to the stator winding is usually generated by a frequency converter (inverter). The converter is usually arranged on a printed circuit board together with associated control electronics and accommodated in an electronics compartment integrated into the motor housing.

[0005] The electronics compartment, for example, has a housing terminal area in the form of an electrical interface for electrically contacting the electronics. In this case, the interface is provided and designed for contacting the electronics with the vehicle on-board electrical system or a (vehicle) wiring harness. The interface, also referred to as wiring harness terminal below, has here current contacts for supplying power to the electric motor or the electronics and signal contacts for connecting the electronics to a signal or communication line, in particular a bus, for example a CAN bus.

[0006] The integrated design of the electric motor, in which the printed circuit board is integrated into the electronics compartment of the motor housing, makes maintenance, repair and service work on the internal printed circuit board difficult due to assembly restrictions.

[0007] The printed circuit board, for example, is usually fixed in the electronics compartment by means of screws at different points. In particular, the printed circuit board is also often contacted with the phase contacts of the stator winding by means of phase contact screws. Furthermore, the connection to the wiring harness is usually assembled from the inside of the motor. The signal connection (CAN connection) provided in the wiring harness is also connected directly to a plug connector (e.g. Erni) of the printed circuit board. Therefore, in order to remove the printed circuit board or the wiring harness, it is usually necessary to completely disassemble both components. It is therefore not possible to maintain or replace the wiring harness and / or the printed circuit board assembly in the installed state.

[0008] Therefore, any damage to the printed circuit board during transportation or operation will render the entire motor unit unusable. In such cases, the printed circuit board used as the motor control unit must be removed and replaced / reworked. Furthermore, due to design and assembly limitations, it is not possible to replace the wiring harness for different cable specifications.

[0009] Therefore, the object of the present invention is to provide an electric motor particularly suitable for motor vehicles, which is especially improved in terms of maintenance, repair, or service work. In particular, a concept for removing printed circuit board assemblies from the electric motor without interrupting internal connections will be given.

[0010] According to the invention, this objective is achieved by the features of claim 1. Advantageous designs and improvements are the subject of the dependent claims (sub-claims).

[0011] The electric motor according to the invention is provided for and is suitable for motor vehicles. The electric motor is preferably a drive or traction motor, wherein the motor vehicle is particularly an electric or driveable motor vehicle, such as an electric or hybrid vehicle having two, three, or four wheels.

[0012] In particular, brushless motors have a stator and a rotor. The stator is equipped with a multi-phase stator or rotating field winding, which has a number of phase contacts corresponding to the number of phases. For example, the rotating field winding is designed to be three-phase or six-phase. The stator and rotor are housed in the motor housing.

[0013] The electronic unit is located on the end side of the motor housing, wherein the phase contacts of the stator winding are guided from the motor housing to the electronic unit.

[0014] In this configuration, the electronic unit has a printed circuit board assembly that contacts the phase contacts as a control unit or (motor) control device (MCU; Electronic Control Unit, ECU). The printed circuit board assembly has a printed circuit board or circuit board serving as a circuit tray, equipped with converter or inverter circuitry and a controller. To supply power to the stator windings, the intermediate circuitry of the inverter circuitry can be connected to the DC circuitry of the vehicle's electrical system via a wiring harness. For this purpose, the electronic unit has wiring harness terminals for the corresponding wiring harnesses. In this configuration, the wiring harness specifically has two power lines (HV+, HV-) for power supply and at least one signal line for connection to a signal bus or vehicle bus, particularly the CAN bus (CAN: Controller Area Network).

[0015] According to the invention, the wire harness terminals are at least partially designed for insertion contact with the wire harness or wire harness plug. In this context, "at least partially designed for insertion contact" should be specifically understood to mean that at least one terminal of the wire harness plug, i.e., the current terminal for the power line and / or the signal terminal for the signal line / bus, is designed for insertion contact. Therefore, a particularly suitable motor is achieved.

[0016] Here and in the following text, the word “and / or” should be understood as meaning that the features associated with the conjunction can coexist or serve as alternatives to each other.

[0017] The electric motor concept according to the present invention enables the servicing of an electric motor having an integrated printed circuit board assembly and connected to a wiring harness for power supply and CAN communication. The plug connections of the wiring harness terminals simplify the servicing, maintenance, and repair of the electric motor electronics. The proposed concept can be realized through combinations of various types of plug connectors and wire connections within the printed circuit board for any type of electric motor, particularly for traction motors.

[0018] According to the present invention, the printed circuit board assembly and wiring harness terminals for power supply and CAN communication signals are connected to the motor assembly in such a manner that the corresponding assembly process is completely independent of other assembly processes and also independent of each other. The concept of the above-described assembly process transforms the entire assembly of the printed circuit board and wiring harness into a single functional unit.

[0019] The usability according to the invention is a combination of removal and replacement / reinstallation of printed circuit board assemblies and wiring harnesses used for motor assembly. Preferably, a completely independent assembly process is achieved, which optimizes the design for ease of maintenance. To remove the printed circuit board assembly from the motor or phase contacts, it is not necessary to remove all other assembly components not directly connected to the printed circuit board. Therefore, the concept according to the invention eliminates the dependence on other components not directly related to the printed circuit board or wiring harness assembly.

[0020] The plug connection improves the assembly process and facilitates access to printed circuit board assemblies and wiring harnesses at any point during operation. This ease of maintenance can also be applied to motors mounted on vehicles without removing the motor or motor housing from the assembly location.

[0021] The electric motor concept according to the invention specifically includes an assembly process for electronic units as sliding or sandwich press-fit assemblies, so that no further additional process is required to connect to the corresponding interface.

[0022] Furthermore, the motor concept according to the invention allows for modular design, enabling printed circuit board assembly modules and wiring harnesses to be packaged individually and independently, and sold separately from each other, so that the motor can be completed when it is considered a component to be maintained. Therefore, the same motor can be adapted to different current specifications by simply changing the cable specifications of the current terminals.

[0023] In a first embodiment of the invention, the electronic unit is designed for plug-in assembly. In this case, the electronic unit has a plug-in compartment integrally formed on the motor housing, i.e., integrally or monolithically formed. The plug-in compartment has a front or side plug-in opening for a plug-in bracket, in which a printed circuit board assembly is arranged. In this case, wire harness terminals are integrated into the plug-in bracket. In the assembled state, the plug-in bracket is inserted into the plug-in compartment along the insertion direction. This makes simple assembly and disassembly of the electronic unit possible.

[0024] In a suitable improvement, the insert bracket has an end flange for screw fastening to the insert compartment, wherein the wiring harness terminals are integrated into the flange. In the assembled state, the insert opening of the insert compartment is closed by the flange. Therefore, the flange is designed as a cover or cover plate.

[0025] In the preferred design, the phase contacts protruding into the electronic compartment are designed as vertically upward-projecting contact lugs. In this case, the phase contacts of the stator winding pass through the bottom of the motor side of the insert compartment. The phase contacts are distributed and staggered so that when the insert bracket is inserted along the insertion direction, each phase contact can make contact with the associated phase terminal of the insert bracket or printed circuit board without collision.

[0026] Here and below, the printed circuit board (phase) mating contacts used for stator-side phase contacts are specifically referred to as phase terminals. Phase contacts are connected to the stator windings, while phase terminals are connected to the printed circuit board assembly.

[0027] The phase contacts are distributed along the insertion direction and offset relative to each other in an offset direction lateral to the insertion direction. The insert-type bracket or printed circuit board assembly has multiple plug-and-socket shaped phase terminals that contact the printed circuit board assembly.

[0028] In this configuration, the phase terminals are, for example, substantially U-shaped or C-shaped and open in the insertion direction, allowing the contact lugs of the phase contacts to slide as they are inserted into the supports of the phase contacts, thereby achieving insert-type contact with the printed circuit board assembly. As a result, a particularly simple and cost-effective contact for the stator phases is achieved, where only the insert bracket is inserted into the insert compartment. The contact can be readily released by pulling out the insert bracket for maintenance, service, and repair work.

[0029] In the second embodiment, the electronic unit is designed for sandwich press-fit assembly. For this purpose, the electronic unit has an electronic compartment having a compartment bottom integrally formed on the motor housing and a cooling cover engaged thereto, wherein a printed circuit board assembly is arranged in an assembly space formed between the compartment bottom and the cooling cover. An upwardly projecting terminal assembly with wiring harness terminals is arranged on the upper side of the printed circuit board assembly facing the cooling cover.

[0030] In this configuration, the cooling cover has a window-shaped recess that, in the assembled state, at least partially passes through the terminal assembly, particularly the wiring harness terminals. Therefore, the wiring harness terminals are positioned on the upper side of the cooling cover and are thus particularly easy to access.

[0031] In a suitable improvement, the terminal assembly protrudes beyond the edge of the printed circuit board assembly. Therefore, the terminal assembly protrudes upwards from the edge of the printed circuit board assembly. In this case, the terminal assembly has phase terminals for contacting phase contacts on the underside of the protruding area facing the bottom of the compartment. Thus, the terminal assembly has wire harness terminals and contact points for phase contacts.

[0032] In this configuration, the phase contacts are designed, in particular, in the form of a plug and socket of a phase contact adapter, and are arranged axially aligned below the phase terminals. In an advantageous configuration, the phase terminals here have upwardly projecting contact pins or contacts that are inserted into or pressed into the plug or socket of the phase contact adapter.

[0033] In a preferred embodiment, the terminal assembly is held in a sandwich-like manner between the cooling cover and the contact socket of the phase contact adapter. In particular, the sandwich-like support ensures reliable and operatively reliable contact between the phase contacts and phase terminals.

[0034] In the third embodiment, the electronic unit has a bottom (base plate) disposed in the motor housing and a cooling module covering it. In this case, the cooling module has a plate-shaped mounting bracket with a lower mounting bracket side facing the bottom and an upper mounting bracket side facing away from the bottom. A printed circuit board assembly is arranged on the upper mounting bracket and is connected to the phase terminals on the lower mounting bracket via busbars integrated into the mounting bracket.

[0035] The phase contacts are located at the bottom, specifically aligned with the phase terminals. Phase terminals and phase contacts.

[0036] For example, the phase terminals are threaded together from the top of the bracket by phase contact screws. Therefore, the threaded contact of the phase terminals can be accessed from the outside.

[0037] In one conceivable design, the harness terminal has signal terminals and integrated current terminals integrated into the mounting bracket end, which contact the harness via phase contact screws.

[0038] The embodiments of the present invention will be further described below with reference to the accompanying drawings. Wherein:

[0039] Figure 1 A perspective view of the electric motor in the first embodiment is shown;

[0040] Figure 2 A perspective view of the insert bracket for the electric motor is shown;

[0041] Figure 3 An exploded perspective view of an insert bracket with a printed circuit board assembly is shown.

[0042] Figure 4 A perspective view of an insert-type bracket with a printed circuit board assembly is shown;

[0043] Figure 5 A perspective view of the insert compartment of the electric motor is shown;

[0044] Figure 6 A perspective view of the electric motor assembly is shown;

[0045] Figure 7 A perspective view of the electric motor in the second embodiment is shown;

[0046] Figure 8 A perspective view of the terminal assembly of the electric motor is shown;

[0047] Figure 9 A perspective view of the terminal assembly as seen from below is shown;

[0048] Figure 10 An exploded perspective view of the electronic unit of the electric motor is shown;

[0049] Figure 11 A perspective view of the electric motor assembly is shown;

[0050] Figure 12 A partial perspective view of the terminal assembly in its assembled state is shown;

[0051] Figure 13 A perspective view of the electric motor in the third embodiment is shown;

[0052] Figure 14 A perspective view of the mounting bracket for the motor's cooling module is shown;

[0053] Figure 15 A perspective view of the assembly bracket as seen from below is shown;

[0054] Figure 16 An exploded perspective view of the cooling module is shown;

[0055] Figure 17A perspective view of the electric motor assembly is shown, and

[0056] Figure 18 A perspective view of the phase contact screw is shown.

[0057] In all drawings, corresponding parts and dimensions always use the same reference labels.

[0058] Figure 1 Details of the electric motor 2, which is a traction drive for a motor vehicle that is electrically driven or capable of being driven, are shown below. (Refer to below) Figures 1 to 6 The electric motor 2, described in more detail, has a motor housing 4 in which a stator and a rotor (not shown in further detail) are arranged. The rotor is fixedly coupled to the motor shaft 6. Figure 5 The electronic unit 8 for operating the motor 2 is arranged on the end side of the motor housing 4.

[0059] The electronic unit 8 has a (first) electrical interface for supplying power to the motor phase or stator winding of the brushless motor 2, and another (second) electrical interface for connecting to the wiring harness 10 of the vehicle electrical system.

[0060] The harness-side interface is designed as harness terminal 12. Harness 10 has two connection contacts 14 with the vehicle batteries (KL30, KL31) and a connection contact 16 with the bus (COM), which connect to corresponding mating contacts 18, 20 of harness terminal 12. In this configuration, harness 10 and harness terminal 12 are designed for plug-in connections or plug-in contacts. In this embodiment, mating contacts 18, 20 are designed as plug-in sockets for the connection contacts 14, which are designed as plug-in contacts. Therefore, harness terminal 12 is designed as a hybrid terminal for power and signal connections of motor 2.

[0061] The electronic unit 8 has an insert-type compartment 22 integrally formed on the motor housing 4, i.e., formed as a single piece or integrally. The insert-type compartment 22 opens to one side through an insert-type opening 24. The insert-type compartment 22 has a compartment bottom 26 through which the axially oriented phase contacts 28 of the motor or stator winding are guided (…). Figure 5 ).

[0062] The electronic unit 8 has multiple upwardly projecting cooling ribs 30 on the housing side away from the bottom 26 of the compartment, which are indicated by reference numerals in the figure only as examples.

[0063] The electronic unit 8 also has an insert bracket (printed circuit board assembly bracket) 32 for the printed circuit board assembly 34 of the electronic unit 8 that can be inserted into the insert opening 24.

[0064] The printed circuit board assembly 34 has a printed circuit board 36 serving as a circuit bracket, which is equipped with multiple electronic components and parts. In particular, an inverter circuit for generating multiphase alternating current to power the stator windings and a controller as a control device are arranged on the printed circuit board 36. The power switches (power semiconductor switches) of the inverter circuit are arranged on the upper side 38 of the printed circuit board facing the cooling fins 30, while the six phase terminals 42 for the phase contacts 28 are arranged on the lower side 40 of the printed circuit board facing the bottom 26 of the compartment.

[0065] The insert bracket 32 ​​has an approximately rectangular retaining frame 44 for the printed circuit board assembly 34 and end flanges 46 oriented perpendicular to the plane of the frame. The insert bracket 32 ​​is specifically designed as an injection-molded part.

[0066] The wiring harness terminal 12 and mating contacts 18, 20 are integrated into the flange plate 46. The contacts 18, 20 are designed as injection-molded stamped meshes. In this case, the contacts 18, 20 are designed as upwardly curved contact lugs 48 on the printed circuit board side.

[0067] During assembly, the printed circuit board assembly 34 is inserted into the retaining frame 44 and screwed onto it, for example, by six fastening screws 50. In this case, upwardly oriented contact lugs 48 engage from below into corresponding openings in the printed circuit board 36 and contact the conductor tracks of the printed circuit board 36 at the upper side 38 of the printed circuit board, particularly by soldering.

[0068] Flange plate 46 serves as a cover or closure for insert opening 24. For this purpose, flange plate 46 has a circumferential flange collar that rests against the edge of insert opening 24 and is connected to it by six fastening screws 52. In the accompanying drawings, the fastening screws 52 are indicated by reference numerals only, by way of example.

[0069] On the rear side of the flange collar, that is, on the side of the flange plate 46 facing the inside of the insertion compartment 22, a circumferential sealing element 54 is provided, which safely and reliably seals the insertion opening 24 in the assembled state.

[0070] For example, such as Figure 5 As shown, the motor shaft 6 is engaged in at least segmented sections into the insert compartment 22 through a feedthrough opening at the bottom 26 of the compartment. At the shaft end, a sensor cap 55 with a sensor magnet is arranged on the motor shaft 6, wherein the printed circuit board assembly 34 has a corresponding magnetic field sensor, particularly a Hall sensor, to detect and monitor the orientation or position of the motor shaft 6 or the rotor during motor operation.

[0071] like Figure 5 As shown, in this embodiment, the six phase contacts 28, designed as contact lugs, are vertically guided into the electronic unit 8 through the bottom 26 of the compartment via the through contacts 56.

[0072] The phase contacts 28 are grouped into two sets of three, which are arranged on opposite long sides inside a generally cuboid compartment. The phase contacts 28 in each set are distributed along an insertion direction E perpendicular to the orientation of the flange plate 46 or the insertion opening 24 and a transverse (offset) direction perpendicular to its orientation. Phase contacts 28 arranged further rearward in the insertion direction E are specifically offset towards the centerline of the insertion compartment 22. Therefore, viewed from the insertion opening 24, the phase contacts 28 are not aligned, but rather arranged offset from each other or without overlap.

[0073] The phase terminals 42 of the printed circuit board assembly 34 are arranged complementaryly to the phase contacts 28. To stabilize the phase terminals 42, they are inserted into the retaining supports 58 of the retaining frame 44, which are integrally formed on the retaining frame 44.

[0074] The assembly of electronic unit 8 is as follows Figure 6 As shown. In this case, the insert bracket 32, which houses the printed circuit board assembly 34, is inserted into the insert opening 24 of the insert compartment 22 along the insertion direction E, and the flange collar 46 is fixed to the insert compartment 22. In this case, the phase contact 28, which is a male plug connector, is inserted into the phase terminal 42, which is a female plug socket. Finally, the wire harness 10 is inserted into the wire harness terminal 12.

[0075] In this case, the phase terminal 42 is, for example, substantially U-shaped or C-shaped and open in the insertion direction E, such that when the insertable compartment 22 is inserted into the support of the phase terminal 42, the contact lug of the phase contact 28 slides, thereby achieving insertable contact with the printed circuit board assembly 34.

[0076] therefore, Figures 1 to 6 The embodiment uses an insert bracket 32 ​​with mixed harness terminals 12 for current and signal to realize a sliding printed circuit board assembly 34.

[0077] The following reference Figures 7 to 12 The second embodiment of the electric motor 2 will be explained in more detail.

[0078] In this embodiment, the electronic unit 8 is designed for sandwich press-fit assembly. For this purpose, the electronic unit 8 has an electronic compartment having a compartment bottom 60 integrally formed on the motor housing and a cooling cover 62 engaged thereto, wherein the printed circuit board assembly 34 is arranged in the assembly space formed between the compartment bottom 60 and the cooling cover 62.

[0079] Figure 8 and Figure 9 The terminal assembly 64, which has wire harness terminals 12, shown separately, is arranged on the upper side 38 of the printed circuit board of the printed circuit board assembly 34 facing the cooling cover 62.

[0080] The terminal assembly 64, implemented as an injection-molded component, has a mating plate 66. The wire harness terminal 12 is integrally formed on the upper side of the mating plate, wherein mating contacts 18, 20 are guided as injection-molded stamped meshes to the lower side of the mating plate 66, and protrude generally vertically upward as welding lugs 67.

[0081] The wire harness terminal 12 is surrounded by an annular sealing element 68 disposed on the upper side of the bonding plate 66.

[0082] On the underside of the rectangular bonding plate 66, six phase terminals 70 are arranged in a row along one of the longer sides. In the figures, the phase terminals 70 are indicated by reference numerals only, by way of example. Each phase terminal 70 has an elongated contact surface from which a tapered contact pin 72 extends. In this case, the contact pin 72 is arranged at the edge of the bonding plate 66. Opposite to the contact pin 72, the phase terminal 70 has a vertically upward-curving contact leg 74 on its contact surface.

[0083] In the assembled state, the terminal assembly 64 is arranged on the upper side 38 of the printed circuit board of the printed circuit board assembly 34. In this case, the bonding plate 66 is inserted into the corresponding support of the printed circuit board 36 in the area of ​​the solder lug 67 and the contact leg 74, in particular the solder lug 67 is in solder contact with the printed circuit board 36. Half of the bonding plate 66 with the contact pin 72 protrudes beyond the edge of the printed circuit board 36. In other words, the bonding plate 66 or the terminal assembly 64 protrudes upward from the edge of the printed circuit board in segments.

[0084] Therefore, the mating contacts 18 and 20 of the wire harness terminal 12 are placed on the upper side 38 of the printed circuit board in an upward protruding manner.

[0085] like Figure 10 As shown, the cooling cover 62 has a window-shaped recess or feedthrough opening 76 for the wire harness terminal 12 and a plurality of cooling ribs 30. For assembling the electronic unit 8, the terminal assembly 64 is first arranged and secured to the printed circuit board assembly 34. The cooling cover 62 is then placed on the assemblies 34 and 64. In this case, the wire harness terminal 12 is guided through the recess 76, wherein a sealing element 68 circumferentially seals the recess 76. The assemblies 34 and 64, particularly the printed circuit board 36, are screwed onto the cooling cover 62 from the underside 40 of the printed circuit board by six fastening screws 78.

[0086] Cooling cap 62, housing components 34 and 64, is then placed on the compartment bottom 60. Six phase contacts 28 are connected via phase contact adapter 80 as through contacts passing through the compartment bottom 60 to six side-by-side plug sockets. In this configuration, the plug sockets or phase contacts 28 are arranged axially aligned with a row of contact pins 72 protruding from the terminal assembly 64 on the printed circuit board 36.

[0087] A sealing element 82 is provided between the cooling cover 62 and the bottom of the compartment 60, which surrounds the components 34 and 64 on the outer periphery.

[0088] To engage the cooling cover 62 with the compartment bottom 60, six upward-projecting spiral tabs 84 are integrally formed on the edge of the cooling cover. The spiral tabs 84—and thus the cooling cover 62—are fastened to the compartment bottom 60 or the motor housing 4 by fastening screws 86. In the accompanying drawings, the spiral tabs 84 and the fastening screws 86 are shown with reference numerals only by way of example.

[0089] During the tightening of the screws on the cooling cover 62, the contact pin 72 is inserted or pressed into the plug socket of the phase contact 28. For example... Figure 12 As shown, the terminal assembly 64 is held in a sandwich manner between the cooling cover 62 and the contact socket of the phase contact adapter 80.

[0090] therefore, Figures 7 to 12 The electric motor concept shown has a terminal assembly 64 with mixed terminals (power and signal) and interlayer phase contacts 28, 70 for press-in.

[0091] Figures 13 to 18 A third embodiment of the electric motor 2 is shown, which will be explained in more detail below.

[0092] In this embodiment, the electronic unit 8 has a base plate 88 inserted into the motor housing 4 and a cooling module 90 covering it. The base 88 is surrounded by a circumferential annular wall, which has a window-shaped recess or feedthrough opening 92 on one side.

[0093] In this embodiment, the wiring harness terminal 12 is designed as a signal terminal 12a and a current terminal 12b. In this case, the connection contact 14 of the wiring harness 10 is integrated into the bracket structure 94 and passes through the feedthrough opening 92, wherein the bracket structure 94 is fastened to the annular wall or the motor housing 4, particularly by screws.

[0094] Cooling module 90 has a plate-shaped mounting bracket 96, such as Figure 14 and Figure 15 As shown.

[0095] The mounting bracket 96 has a slotted support 98 with a central recess 100 for the sensor cap 55 to pass through the motor shaft 6. The approximately rectangular support 98 is surrounded on three sides by the support surface 102 of the printed circuit board assembly 34. Figure 14On the upper side 104 of the mounting bracket shown, the support 98 and the bearing surface 102 are surrounded by a circumferential sealing element 106. Eight upwardly projecting helical domes 108 for accommodating phase contact screws 110 are formed radially outward of the sealing element 106. In the drawings, the helical domes 108 and the phase contact screws 110 are provided with reference numerals only by way of example.

[0096] The injection-molded stamped mesh 112 is embedded or integrated into the assembly bracket 96, which connects and contacts the printed circuit board assembly 34 in the area of ​​the support surface 102 through an upwardly projecting contact portion.

[0097] exist Figure 15 As shown in more detail on the lower side 114 of the mounting bracket, the stamped mesh 112 has eight exposed contact surfaces 116, which are axially aligned with the helical dome 108. Each contact surface 116 has a feed opening for the shaft 118 of the phase contact screw 110. The contact surfaces 116 are surrounded by a circumferential sealing element 120 provided on the lower side 114 of the mounting bracket.

[0098] Signal terminal 12a is integrally formed on one side of the upper side 104 of the mounting bracket, wherein the mating contact 20 is designed as part of a stamped grid 112. On either side of signal terminal 12a are two phase domes 108 serving as current terminals 12b, wherein contact surfaces 116 arranged below them form mating contacts 18. The remaining six contact surfaces 116 form phase terminals 121.

[0099] Figure 16 The (pre)assembly of the cooling module 90 is shown. In this configuration, the sealing element 106 is placed on the upper side 104 of the mounting bracket. Subsequently, the printed circuit board assembly 34 rests on the support surface 102 and is connected to the contact portion of the stamped mesh 112. Afterward, a plate-shaped cooling body 122 with cooling ribs 30 is placed on the printed circuit board assembly 34 as a cover. From the lower side 114 of the mounting bracket, the mounting bracket 96 is engaged to the printed circuit board assembly 34 and the cooling body 122 by six distributed fastening screws 124. In the figures, the fastening screws 124 are indicated by reference numerals only for illustrative purposes.

[0100] The sealing element 106 seals the edge of the cooling cover 122 relative to the upper side 104 of the mounting bracket. In this case, the fastening points for the fastening screws 124 are arranged radially inside the sealing elements 106, 120.

[0101] Figure 17The assembly of the electronic unit 8 is shown. For this purpose, the (pre-assembled) cooling module 90 is placed on the base plate 88 or in a support formed by a circumferential annular wall, into which the annular sealing element 120 is inserted. Six phase contacts 28 pass through the base plate 88 as spiral tabs, wherein the assembly bracket 95 of the cooling module 90 rests on the base 88 in such a way that the contact surface 116 rests on the spiral tabs of the phase contacts 28.

[0102] The cooling module 90 is then fastened to the motor housing 4 from the upper side 104 of the mounting bracket on the end side by eight circumferentially distributed fastening screws 126. In the accompanying drawings, the fastening screws 126 are provided with reference numerals only for illustrative purposes.

[0103] Subsequently, the connecting contact 14 is inserted through the feedthrough opening 92, such that it is positioned below the contact surface 116 or the mating contact 18. In this case, the connecting contact 14 has a threaded hole for the phase contact screw 110. In this case, the bracket structure 94 is screwed onto the motor housing 4.

[0104] Next, insert the phase contact screw 110 into the spiral dome 108. Figure 18 The phase contact screw 110, shown in more detail, has a shaft 118 with a screw head 128. A plate-shaped clamping head 130 is provided around the screw head 128, which protrudes radially upward around the screw head 128 where a tool engagement 132 is provided. A sealing ring 134 is provided on the underside of the clamping head 130.

[0105] Phase contact screws 110 are screwed into the corresponding threaded holes of connecting contact 14 and phase contact 28, thereby ensuring safer contact with contact surface 116 or mating contact 18 and phase terminal 121. Finally, cover cap 136 is placed on the end side of screw dome 108. In the accompanying drawings, cover cap 136 is provided with reference numerals only by way of example.

[0106] Therefore, the third embodiment of the motor 2 has a cooling body module 90, which has a cooling body 122 and an integrated assembly housing for the bus 112 and the CAN terminal 12a.

[0107] Each of the three embodiments described above improves the maintainability of the printed circuit board assembly 34 and wiring harness 10 at any desired point in operation or lifespan.

[0108] The claimed utility model is not limited to the embodiments described above. Instead, those skilled in the art can derive other variations of the utility model within the scope of the disclosed claims without departing from the subject matter of the claimed utility model. Furthermore, within the scope of the disclosed claims, all individual features described in conjunction with the various embodiments can be combined in other ways without departing from the subject matter of the claimed utility model.

[0109] List of reference numerals

[0110] 2 electric motors

[0111] 4 Motor housing

[0112] 6 motor shafts

[0113] 8 electronic units

[0114] 10 wire harness

[0115] 12 wire harness terminals

[0116] 12a signal terminal

[0117] 12b current terminal

[0118] 14 and 16 are connected to the contact point

[0119] 18, 20 mating contacts

[0120] 22 Insert-type compartments

[0121] 24 Insertion Opening

[0122] 26 compartment bottom

[0123] 28-phase contacts

[0124] 30 cooling ribs

[0125] 32 Insert-type bracket

[0126] 34 Printed Circuit Board Assembly

[0127] 36 Printed Circuit Boards

[0128] 38 Printed Circuit Board Top Side

[0129] 40 Printed Circuit Board Underside

[0130] 42-phase terminals

[0131] 44 Keep the frame

[0132] 46 flange plate

[0133] 48 Contact lugs

[0134] 50 fastening screws

[0135] 52 Fastening Screws

[0136] 54 Sealing Elements

[0137] 55 sensor cap

[0138] 56 through contacts

[0139] 58. Maintain support

[0140] 60 compartment bottom

[0141] 62 Cooling Cover

[0142] 64-terminal assembly

[0143] 66 joint plate

[0144] 67 Welded Lug

[0145] 68 sealing elements

[0146] 70-phase terminals

[0147] 72 contact needle

[0148] 74 contact legs

[0149] 76 grooves

[0150] 78 Fastening Screws

[0151] 80-phase contact adapter

[0152] 82 sealing element

[0153] 84 spiral convex plate

[0154] 86 fastening screws

[0155] 88 base plate

[0156] 90 Cooling Module

[0157] 92 Feedthrough Opening

[0158] 94 bracket structure

[0159] 96 Assembly Bracket

[0160] 98 supports

[0161] 100 grooves

[0162] 102 Support Surface

[0163] 104 Assembly bracket upper side

[0164] 106 sealing element

[0165] 108 Spiral Domes

[0166] 110 phase contact screw

[0167] 112 stamped mesh

[0168] 114 Assembly bracket underside

[0169] 116 contact surface

[0170] 118 axis

[0171] 120 sealing element

[0172] 121-phase terminal

[0173] 122 cooling body

[0174] 124 fastening screw

[0175] 126 fastening screw

[0176] 128 screw head

[0177] 130 clamping head

[0178] 132 Tool Support

[0179] 134 sealing ring

[0180] 136 Covering Cap

[0181] E Insertion direction

Claims

1. An electric motor (2) for a motor vehicle, the electric motor comprising: - Motor housing (4). - An electronic unit (8) is provided on the end side of the motor housing (4), wherein, Multiple phase terminals (42, 70, 121) are guided from the motor housing (4) into the electronic unit (8). - The printed circuit board assembly (34) of the electronic unit (8) serving as the control unit of the electric motor (2), and - The wire harness terminal (12) of the electronic unit (8) for the wire harness (10). - wherein the wire harness terminal (12) is at least partially designed for insert contact with the wire harness (10).

2. The electric motor (2) according to claim 1. Its features are, - The electronic unit (8) has an insertable compartment (22) integrally formed on the motor housing (4). -The printed circuit board assembly (34) is arranged in an insert bracket (32), - The wire harness terminal (12) is integrated into the insert bracket (32), and - The insert bracket (32) is inserted into the insert compartment (22) along the insertion direction (E).

3. The electric motor (2) according to claim 2. Its features are, - The insert bracket (32) has an end flange (46) for screw fastening to the insert compartment (22), and - The wire harness terminal (12) is integrated into the flange plate (46).

4. The electric motor (2) according to claim 2 or 3. Its features are, - The phase contact (28) is guided through the bottom (26) of the insert compartment (22) as a vertically upward protruding contact lug. -The phase contacts (28) are arranged along the insertion direction (E). - The phase contacts (28) are arranged offset relative to each other in an offset direction transverse to the insertion direction (E), and - The insert bracket (32) has a plurality of phase terminals (42) that contact the printed circuit board assembly (34), which correspond to the number of phase contacts (28) and are arranged on the insert bracket (32) in such a way that each phase terminal (42) inserts into contact with the associated phase contact (28) when inserted along the insertion direction (E).

5. The electric motor (2) according to claim 1. Its features are, - The electronic unit (8) has an electronic compartment having a compartment bottom (60) integrally formed on the motor housing (4) and a cooling cover (62) joined thereto. - An upwardly projecting terminal assembly (64) having the wire harness terminal (12) is arranged on the upper side (38) of the printed circuit board assembly (34) facing the cooling cover (62), and - The terminal assembly (64) passes through the window-shaped recess (76) of the cooling cover (62) at least in segments.

6. The electric motor (2) according to claim 5. Its features are, The terminal assembly (64) protrudes from the edge of the printed circuit board assembly (34), wherein the terminal assembly (64) has a phase terminal (70) for contacting the phase contact (28) on the underside of the protruding area facing the bottom of the compartment (60).

7. The electric motor (2) according to claim 6. Its features are, The phase terminal (70) has an upwardly protruding contact pin (72) that is pressed into a corresponding contact socket of the phase contact adapter (80) connected to the phase contact (28).

8. The electric motor (2) according to claim 7. Its features are, The terminal assembly (64) is held in a sandwich manner between the cooling cover (62) and the contact socket of the phase contact adapter (80).

9. The electric motor (2) according to claim 1. Its features are, - The electronic unit (8) has a bottom (88) disposed in the motor housing (4) and a cooling module (90) covering it. - The cooling module (90) has a plate-shaped mounting bracket (96) having a lower mounting bracket side (114) facing the bottom (88) and an upper mounting bracket side (104) facing away from the bottom (88), and - The printed circuit board assembly (44) is arranged on the upper side (104) of the mounting bracket and is connected to the phase terminal (121) on the lower side (114) of the mounting bracket via a busbar (112) integrated into the mounting bracket (96).

10. The electric motor (2) according to claim 9. Its features are, The wiring harness terminal (12) has a signal terminal (12a) integrated into the end side of the mounting bracket (96) and an integrated current terminal (12b), which are in contact with the wiring harness (10) via a phase contact screw (110).

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