Method for electrically coupling electric motor to power electronics, electric machine and motor vehicle

Abstract

The invention relates to a method for electrically coupling an electric motor (1) for an electric machine (2) of a motor vehicle (3) to power electronics (4) of the electric machine (2). According to the method, components of the electric motor (2) are arranged in such a way that a contact lever (9) of the electric motor (1) is held on a stator winding (17) of a stator (8) of the electric motor (1) via a support device (6) on a first housing component (5) of the electric motor (2) and via a contact bridge (10) on a second housing component (12) of the electric motor (2). The invention further relates to an electric machine (2) for driving a motor vehicle (3) and to a motor vehicle (3) having an electric drive system (21).

Description

Technical Field

[0001] This invention relates to a method for electrically coupling an electric motor for use in a motor vehicle to power electronic equipment of the motor. The invention further relates to a motor having an electric motor and power electronic equipment, and a motor vehicle having an electric drive system for driving the motor vehicle. Background Technology

[0002] An electric motor for driving a motor vehicle is known, comprising an electric motor with a stator and a rotor, and power electronics for selectively supplying power to the stator. For electrical coupling of the stator, the stator has multiple contact rods that are electrically and mechanically coupled to the busbars of the power electronics. Conventional motors are known, for example, from document 2020 / 0412208A1.

[0003] Document 102019205781A1 discloses an electric motor in which busbars of power electronics each have blind holes with internal threads, which are aligned with through guide portions of contact rods of an electric motor. The contact rods are each secured to the busbars via a threaded member. Therefore, the contact rods are arranged at right angles to the busbars. To facilitate the placement of the contact rods at the busbars, each busbar is held at a corresponding housing component by a retaining device, wherein one or more sealing devices are arranged between the retaining device and the corresponding housing component.

[0004] Document WO2023 / 179816A1 discloses a method for electrically coupling an electric motor to a power electronics device of the motor. Here, flexible electrical conductors are temporarily fastened to housing components via retaining elements, and are detached from the respective retaining elements after the housing components are joined together to establish electrical coupling between the power electronics device and the electric motor.

[0005] Known methods for electrically coupling an electric motor to its power electronics have the following drawbacks: the arrangement and alignment of the contact rods relative to the busbars are sometimes very complex and time-consuming. Automation of this process is almost impossible or only very difficult. Furthermore, undesirable vibrations may occur at the contact rods or busbars during motor operation. Summary of the Invention

[0006] Therefore, the object of the present invention is to eliminate, or at least partially eliminate, the disadvantages described above in motors used to drive motor vehicles. In particular, the object of the present invention is to provide a method for electrically coupling an electric motor for a motor vehicle to power electronic equipment of the motor, an electric motor for driving a motor vehicle, and a motor vehicle having an electric drive system that reduces vibration and / or simplifies assembly in a simple and cost-effective manner using contact rods or busbars.

[0007] The aforementioned task is solved according to the present invention. Therefore, the task is solved by the method according to the present invention for electrically coupling an electric motor for a motor vehicle to a power electronic device of the motor, by the electric motor according to the present invention for driving a motor vehicle, and by a motor vehicle having an electric drive system according to the present invention for driving a motor vehicle. Other features and details of the invention are derived from the remaining embodiments, description, and drawings. Herein, the features and details described in connection with the method according to the invention are of course also applicable to the electric motor according to the invention and the motor vehicle according to the invention, and vice versa, so that the disclosure of various aspects of the invention can always be cross-referenced.

[0008] According to a first aspect of the invention, the task is solved by a method for electrically coupling an electric motor for a motor vehicle to power electronic equipment of the motor. The method includes: -Provide the first housing component for the motor. - The support device is arranged in the receiving portion of the first housing component in such a way that the support device is held in the receiving portion. - Provides a stator for an electric motor, the stator having a plurality of contact rods for electrically coupling the stator to power electronic equipment. The stator is arranged in the first housing component such that the contact rod passes through and is supported by the support device at the first housing component. - The contact bridge is positioned at the second housing component of the motor to establish electrical coupling between the contact rod and the busbar of the power electronics. - The first housing component and the second housing component are assembled in such a way that the contact rod at least partially extends into the contact bridge, and - The power electronics are arranged at the second housing component such that the busbar extends at least partially into the contact bridge.

[0009] First, a first housing component of the motor is provided. This first housing component is configured to house the stator of the electric motor. For this purpose, the first housing component preferably has a stator receiving portion for form-fittingly accommodating the stator or a portion thereof. To fully accommodate the stator, one or more additional housing components are preferably also provided, which are coaxially arranged and interconnected to form the motor housing of the electric motor. The first housing component preferably has a first end face that, during motor assembly, can make sealing contact with a second end face of a second housing component.

[0010] The first housing component has a receiving portion in which a support device is arranged, for example, by a linear engagement movement parallel to the longitudinal axis of the motor, particularly toward the power electronics device in its installed state or toward the stator in its installed state. The support device is preferably form-fitted into the receiving portion to prevent relative movement of the support device with respect to the receiving portion in the circumferential and / or radial directions. The support device is preferably arranged in the receiving portion along the engagement direction such that further movement of the support device in the engagement direction is form-fitted into the first housing component. For this purpose, the support device preferably has an end stop that contacts the first housing component at the end of the engagement process. The support device has an internal through-guide for guiding the contact rod through. The support device is preferably made of plastic.

[0011] Additionally, a stator is provided. The stator preferably has a stator base in which a plurality of stator slots are arranged parallel to the longitudinal axis of the stator base. The stator base is preferably formed of a plurality of sheet metal plates arranged coaxially with each other, and these sheet metal plates are preferably electrically insulated, for example, using varnish. A stator winding is arranged in the stator slots, and the stator winding is preferably formed by hairpins. The hairpins are preferably formed of copper and further preferably have electrically insulating portions. The hairpins can be configured, for example, as U-shaped leads or I-shaped leads. Alternatively, the stator windings can also be produced by wound continuous wire (e.g., round wire). The winding heads of the stator windings are preferably arranged at two base end sides of the stator base. A plurality of contact rods are arranged at the base end sides facing the power electronic devices, and these contact rods extend along the longitudinal direction of the electric motor and are electrically coupled to the stator windings. The stator can be electrically coupled to the power electronic devices via the contact rods. The stator preferably has one contact rod for each phase.

[0012] The stator is arranged in the first housing component. Here, the contact rod is guided through a support device. The contact rod is now supported directly or indirectly at the first housing component via the support device. Within the scope of the invention, direct support is understood as the contact rod directly contacting and being supported at the support device through direct contact. Within the scope of the invention, indirect support is understood as at least one intermediate element arranged between the contact rod and the support device, such that the contact rod is supported at the support device via said at least one intermediate element.

[0013] Additionally, a second housing component is provided, configured to house power electronics. Within the scope of this invention, power electronics are understood as electronic components of an electric motor configured to supply power to the stator of an electric motor. The power electronics may, for example, have a pulse inverter, particularly with an AC module, etc. For electrical coupling with the electric motor (e.g., with the contact rods of the stator), the power electronics have buses. Preferably, the power electronics have one bus for each phase. The second housing component is configured to be directly or indirectly joined to the first housing component.

[0014] A contact bridge is arranged at the second housing component to establish electrical coupling between the stator contact rod and the busbar of the power electronics equipment. The contact bridge can be fixed to the second housing component, for example, by clips, threaded fittings, brazing, welding, etc. The contact bridge has a first opening for introducing the contact rod. On the opposite side, the contact bridge has a second opening for introducing the busbar. Therefore, direct electrical coupling can be established between the busbar and the contact rod. One or more circuit boards are preferably arranged inside the contact bridge to further improve the electrical coupling between the busbar and the contact rod. More preferably, the contact bridge has widenings at the first and / or second openings to facilitate the introduction of the contact rod or busbar into the contact bridge. The contact bridge preferably has a ramp inside, which causes the contact rod and / or busbar to move towards the wall of the contact bridge when introduced into it. Therefore, both electrical and mechanical coupling between the busbar and the contact rod can be improved. The contact bridge is preferably constructed such that different electrical phases are electrically insulated from each other. The housing of the contact bridge is preferably made of plastic.

[0015] The first housing component and the second housing component are assembled such that the end region of the contact rod is introduced into the first opening of the contact bridge and, at the end of the assembly process, is positioned inside the contact bridge or extends from the second opening of the contact bridge. This prepares for electrical coupling between the contact rod and the busbar, or, in the case of a correspondingly constructed contact bridge, electrical coupling between the contact rod and the contact bridge can already be established. After assembly, the first housing component directly or indirectly contacts the second housing component, for example, via one or more sealing devices and preferably circumferentially. The first housing component is preferably fastened to the second housing component, for example, via threads.

[0016] Furthermore, the power electronics are arranged at the second housing component such that the end region of the bus is introduced into the second opening of the contact bridge, and at the end of the engagement process, is disposed inside the contact bridge or extends from the first opening of the contact bridge. The power electronics are preferably arranged such that the bus is directly electrically coupled to the contact rod, particularly through direct contact with the contact rod. Additionally, the bus can be configured to be electrically coupled to the contact bridge. Finally, a threaded member is preferably screwed into the contact bridge, via which the contact rod and the bus are secured to each other. Preferably, one threaded member is screwed into the contact bridge for each pair of bus and contact rod. The threaded member may already be included in the clamping body of the contact bridge and connected to the clamping plate during engagement. This threaded member is preferably constructed as a headless thread and is tightened after the bus is introduced to press the clamping plate downwards.

[0017] The method for electrically coupling an electric motor for use in motor vehicles to the power electronics of the motor according to the present invention has the following advantages over conventional methods: it enables the electrical coupling between the stator and the power electronics to be established using simple means and in a cost-effective manner. Electrical coupling can be established in a particularly simple manner when assembling housing components via busbars and contact rods and contact bridges supported by support devices, thus eliminating the need for complex engagement movements and alignment processes of individual conductors. Furthermore, by using support devices and contact bridges, vibration of the contact rods can be avoided during motor operation, thereby improving the durability of the motor.

[0018] According to a preferred improvement of the invention, in one method, the stator is arranged in such a way that the power electronics are arranged in a first housing component and in a second housing component that the contact rods and busbars form a common overlapping area in the axial direction within the contact bridge. The contact rods preferably contact the busbars in the overlapping area, thereby establishing a direct electrical coupling between the contact rods and the busbars. The contact rods and busbars preferably have the same width in the overlapping area and are arranged in a covering manner within the overlapping area, thereby providing a particularly advantageous electrical coupling. This has the advantage of establishing reliable electrical coupling between the contact rods and the busbars using simple means and at a cost-effective manner.

[0019] According to the invention, it is preferred that the support device is arranged at the first housing member such that the locking protrusion of the support device engages with the first housing member and holds the support device at the first housing member, and / or the support device is secured at the first housing member after being arranged there, by means of a fastening device separately constructed from the support device. The locking protrusion is preferably arranged on the side of the support device facing the longitudinal axis of the motor and / or on the side of the support device opposite to the longitudinal axis. The locking protrusion is preferably constructed such that, upon reaching the assembly end position of the support device, it engages from behind the wall of the first housing member in the area of ​​the receiving portion, for example, by spring-loaded engagement of the wall of the first housing member from behind. For this purpose, the support device preferably has an inclined portion at the locking protrusion, which ensures easy bending of the locking protrusion in conjunction with the wall of the receiving portion when the support device is pushed into the receiving portion. As a fastening device separately constructed from the support device, threaded parts, pins, clips, rivets, adhesives, etc., can be used, for example. According to the present invention, the support device can also be fixed to the first housing component by welding. In this case, it is preferable that the support device has a weldable metal. This has the advantage of ensuring reliable fixing of the support device to the first housing component using simple means and at a reasonable cost.

[0020] More preferably, a support device with an internal clamping mechanism is used, wherein the contact rod is introduced into the support device such that the clamping mechanism holds the contact rod. The clamping mechanism may, for example, have a spring (e.g., an elastic plastic bow-shaped portion / or ramp), which engages with the contact rod, the sleeve connected to the contact rod, etc., as it guides the contact rod through the support device. Thus, by arranging the stator in a relative terminal position relative to the first housing component, the contact rod can be clamped at the support device via the clamping mechanism. This has the advantages of ensuring easy assembly of the stator at the first housing component using simple means and at a reasonable cost. Furthermore, the clamping mechanism can further reduce vibration of the contact rod during motor operation.

[0021] In a particularly preferred embodiment of the invention, one method involves injection molding the contact rod portion with plastic to form a plastic sleeve, which is arranged inside a support device such that the contact rod is supported at the support device via the plastic sleeve. When using a support device with an internal clamping device, it is preferable that the plastic sleeve is clamped by the clamping device in the assembly end position. The plastic sleeve is preferably formed such that it surrounds a plurality (preferably all) of the contact rods. Furthermore, the plastic sleeve can form-fit the defined spacing between the contact rods relative to each other and prevent contact between adjacent contact rods. This has the advantages of further improving motor assembly using simple means and in a cost-effective manner, and further reducing vibration of the contact rods during motor operation.

[0022] The contact rod is preferably electrically and mechanically coupled to the stator winding via brazing or fusion welding. This is preferably done before the stator is arranged at the first housing component. Here, the contact rod is preferably directed to and connected to the free end of the stator winding's hairpin or to the wire end of the retaining winding or round wire winding. The free end of the hairpin is preferably located in the winding head of the stator winding. This has the advantage of further improving the assembly of the motor using simple means and at a cost-effective manner.

[0023] According to a preferred embodiment of the invention, a contact bridge with an upper contact element is used, wherein the contact rod and busbar are arranged below the upper contact element. Alternatively or additionally preferred, a contact bridge with a lower contact element is used, wherein the contact rod and busbar are arranged above the lower contact element. The upper and / or lower contact elements are preferably constructed as electrical conductors, such as those made of copper. The upper contact element is preferably electrically coupled to the lower contact element. Electrical coupling can be achieved, for example, through direct or indirect contact between the upper and lower contact elements. The upper contact element can also be integrally constructed with the lower contact element. The upper and / or lower contact elements have inclined portions at one or both end regions to facilitate engagement of the contact rod or busbar into the contact bridge. The inclined portions can be constructed, for example, straight and / or curved. According to the invention, the transition region between the end regions and the intermediate regions can have curved edges or radii. This has the following advantages: it allows for further improvement of motor assembly and electrical coupling between the contact rod and the busbar using simple means and at a reasonable cost.

[0024] The contact rod and busbar are particularly preferably fastened to the contact bridge via a threaded fastener. For this purpose, the second housing component preferably has a through-guide through which an assembly tool can be guided for tightening the threaded fastener. Preferably, the busbar and contact rod are pressed together by tightening the threaded fastener, for example, in conjunction with the upper and / or lower contact elements. The threaded fastener can, for example, be screwed into the lower contact element. The threaded fastener is preferably guided through a through-hole in the upper contact element. This has the advantages of further improving the assembly of the motor and the electrical coupling between the contact rod and the busbar using simple means and in a cost-effective manner.

[0025] According to a second aspect of the invention, the task is solved by an electric motor for driving a motor vehicle. The motor has an electric motor and power electronics electrically coupled to the electric motor. According to the invention, the electrical coupling between the electric motor and the power electronics is established by a method according to the invention. Accordingly, the motor has a contact bridge arranged in a second housing component, into which a busbar of the power electronics is introduced from one side, and contact rods of the stator of the electric motor are introduced into the contact bridge from the opposite side and are mechanically and electrically coupled to each other via the contact bridge. Furthermore, the contact rods are supported at a first housing component of the motor via a support device. The first and second housing components are mechanically connected components of the motor housing. According to the invention, the housing may have additional housing components.

[0026] In the electric motor for driving a motor vehicle according to the invention, all the advantages described with respect to the method of electrically coupling the electric motor of the motor for a motor vehicle with the power electronics of the motor according to the first aspect of the invention are obtained. Accordingly, the motor according to the invention has the following advantages over conventional motors: it provides electrical coupling between the stator and the power electronics in a simple and cost-effective manner. Electrical coupling can be established in a particularly simple manner when assembling the housing components via busbars and contact rods supported by support devices and contact bridges, thereby eliminating the need for complex engagement movements and alignment processes of individual conductors. Furthermore, by using support devices and contact bridges, vibration of the contact rods can be avoided during motor operation, thereby improving the durability of the motor.

[0027] According to a third aspect of the invention, the task is accomplished by a motor vehicle. This motor vehicle has an electric drive system for driving the motor vehicle. According to the invention, the electric drive system for driving the motor vehicle has a motor according to the invention. Furthermore, the electric drive system preferably has a traction battery for supplying electrical energy to the motor.

[0028] In the motor vehicle according to the invention, all the advantages described with respect to the method for electrically coupling an electric motor for a motor vehicle to power electronics equipment according to the first aspect of the invention and to the motor for driving a motor vehicle according to the second aspect of the invention are obtained. Accordingly, the motor vehicle according to the invention has the following advantages over conventional motor vehicles: it provides electrical coupling between the stator and power electronics equipment using simple means and in a cost-effective manner. Electrical coupling can be established in a particularly simple manner when assembling housing components via busbars and contact rods and contact bridges supported by support devices, thereby eliminating the need for complex engagement movements and alignment processes of individual conductors. Furthermore, by using support devices and contact bridges, vibration of the contact rods can be avoided during motor operation, thereby improving the durability of the motor. Attached Figure Description

[0029] The following description, with reference to the accompanying drawings, explains in more detail the electric motor for driving a motor vehicle according to the invention, the motor vehicle according to the invention, and the method according to the invention for electrically coupling the electric motor for the motor vehicle to the power electronic equipment of the motor. Specifically: Figure 1 A cross-sectional view schematically shows a segment of the motor according to a preferred first embodiment of the present invention. Figure 2 Suggested schematically in perspective view Figure 1 The motor section in the middle, Figure 3 schematically shown from a top-down perspective view Figure 1 The motor section in the middle, Figure 4 Schematally shown from a perspective top view below. Figure 3 The motor section in the middle, Figure 5 A preferred embodiment of the motor vehicle according to the present invention is schematically shown in a side view, and Figure 6 A preferred embodiment of the method according to the invention is illustrated schematically in flowchart form. Detailed Implementation

[0030] exist Figures 1 to 6 In the figure, components with the same function and mode of operation are respectively marked with the same reference numeral.

[0031] exist Figure 1 The diagram schematically depicts a cross-section of a preferred first embodiment of the motor 2 according to the present invention. The motor 2 includes an electric motor 1 and power electronics 4. The electric motor 1 has a stator 8 with stator windings 17 formed by hairpins and a rotor (not shown). The stator 8 is partially disposed within a first housing component 5.

[0032] To electrically couple the electric motor 1 to the power electronics 4, the electric motor 1 has a plurality of contact rods 9 arranged one after the other in this view, such that the rear contact rod 9 is shielded by the front contact rod 9. The contact rods 9 are electrically and mechanically coupled to the free hairpin ends of the stator winding 17, for example by brazing. The contact rods 9 have a common plastic sleeve 16 in a region, which is, for example, injection-molded into the contact rod 9 and completely surrounds the contact rod 9.

[0033] The support device 6 is arranged in the receiving portion 7 of the first housing component 5 and is held in the receiving portion 7 by the locking protrusion 14 of the support device 6 and the end stop 22 of the support device 6. The contact rod 9 is guided through the support device 6. A clamping device 15 is constructed in the support device 6, which clamps the plastic sleeve 16 and thus holds the contact rod 9.

[0034] The power electronics 4 of the motor 2 is arranged in the second housing component 12. In order to electrically couple the power electronics 4 to the electric motor 1, the power electronics 4 has a plurality of busbars 11, which are arranged front to back in this view, so that the rear busbar 11 is blocked by the front busbar 11.

[0035] The contact bridge 10 is disposed in the second housing component 12 and is preferably fastened (e.g., pressed in, glued, tightened, etc.) at the second housing component 12. The contact bridge 10 has a housing in which an upper contact element 18 and a lower contact element 19 are disposed. The upper contact element 18 and the lower contact element 19 are bent away from each other at their two end regions to facilitate the assembly of the busbar 11 and the contact rod 9 at the contact bridge 10.

[0036] Busbar 11 is introduced into contact bridge 10 from one side, and contact rod 9 is introduced into contact bridge 10 from the opposite side, such that busbar 11 and contact rod 9 form a common overlap area 13, which is arranged between upper contact element 18 and lower contact element 19. Furthermore, busbar 11 and contact rod 9 are clamped together via contact bridge 10. Therefore, busbar 11 and contact rod 9 are electrically and mechanically coupled via contact bridge 10. Vibration of contact rod 9 can be damped during operation of motor 2 via support device 6.

[0037] Figure 2 Suggested schematically in perspective view Figure 1The view shows a section of motor 2. In this view, the support device 6 arranged in the receiving portion 7 can be clearly seen. The end stop 22 and the locking protrusion 14 engage with the walls of the first housing member 5 (in which the receiving portion 7 is constructed) on both sides, thereby holding the support device 6 in the receiving portion 7. Furthermore, in this detailed view, it can be clearly seen that the plastic sleeve 16 completely surrounds the plurality or all of the contact rods 9 and is clamped in the clamping device 15 of the support device 6. Additionally, the connection from the stator winding 17 to the contact rods 9 can also be clearly seen.

[0038] exist Figure 3 The diagram is schematically shown from a top perspective view. Figure 1 The view shows a section of motor 2. The upper contact elements 18 of the contact bridge 10 are visible in this view. These upper contact elements are pressed against the contact rod 9, which in turn presses the contact rod 9 against the busbar 11, and the busbar 11 is pressed against the lower contact elements 19, which are not visible in this view (see [reference]). Figure 4 To generate the clamping force, the contact bridge 10 has a central threaded part 20 for each pair of contact rods 9 and busbars 11. It can also be seen how the clamping device 15 of the support device 6 acts from above onto the plastic sleeve 16 of the contact rods 9.

[0039] Figure 4 Schematally shown from a perspective top view below. Figure 3 The view shows a section of motor 2. The lower contact elements 19 of the contact bridge 10 are visible in this view, pressed against the busbar 11. Furthermore, it is clearly shown how the clamping device 15 of the support device 6 acts from below onto the plastic sleeve 16 of the contact rod 9.

[0040] exist Figure 5 A preferred embodiment of the motor vehicle 3 according to the present invention is schematically depicted in a side view. The motor vehicle 3 has an electric drive system 21, which includes an electric motor 2 according to the present invention for driving the motor vehicle 3 and a traction battery 23 for operating the electric motor 2.

[0041] Figure 6A preferred embodiment of the method according to the invention for electrically coupling an electric motor 1 for an electric motor 2 for a motor vehicle 3 to a power electronics device 4 of the motor 2 is illustrated schematically in a flowchart. In a first method step 100, a first housing component 5 of the motor 2 is provided. The first housing component 5 has a wall portion in which a receiving portion 7 is constructed. In a second method step 200, a support device 6 is pushed into the receiving portion 7 until a plurality of end stops 22 of the support device 6 act on one side of the wall portion of the first housing component 5, and thus form-fits to prevent the support device 6 from being pushed further into the receiving portion 7, and a plurality of locking protrusions 14 of the support device 6 engage from the rear opposite sides of the wall portion of the receiving portion 7, thereby form-fitting to prevent the support device 6 from being withdrawn from the receiving portion 7. Thus, the support device 6 is held in the receiving portion 7.

[0042] In the third method measure 300, a stator 8 of the electric motor 1 is provided. The stator 8 has a plurality of contact rods 9 configured to electrically couple the stator 8 or the stator winding 17 of the stator to the power electronics 4 of the motor 2. The contact rods 9 are preferably brazed to the free hairpin ends of the hairpins forming the stator winding 17. In the fourth method measure 400, the stator 8 is arranged in a first housing member 5. Here, the rod ends of the contact rods 9 are guided through a support device 6. A plastic sleeve 16 surrounding the contact rods 9 is introduced into the support device 6 and clamped by a clamping device 15 of the support device 6, thereby supporting the contact rods 9 at the first housing member 5 via the support device 6.

[0043] In the fifth method measure 500, the contact bridge 10 is arranged in the second housing component 12 of the motor 2, and preferably fixed therein. In the sixth method measure 600, the first housing component 5 and the second housing component 12 are joined, preferably with a linear engagement movement. The joining is preferably performed such that the first housing component 5 directly contacts the second housing component 12. Preferably, a sealing device is additionally arranged between the first housing component 5 and the second housing component 12. During joining, the contact rod 9 is introduced into the contact bridge 10, and preferably terminates inside the contact bridge 10. In the seventh method measure 700, the power electronics 4 is arranged in the second housing component 12. Here, the bus 11 is introduced into the contact bridge 10 from the opposite side, and preferably terminates inside the contact bridge 10. By tightening the threaded part 2ß of the contact bridge 10, the contact rod 9 can be clamped to the bus 11, thereby providing mechanical and electrical coupling.

[0044] List of reference numerals in the attached diagram: 1 electric motor 2 motors 3 motor vehicles 4 Power Electronic Devices 5 First casing component 6 support devices 7. Reception 8 stators 9 contact rods 10 contact bridges 11 busbars 12 Second housing component 13 overlapping regions 14 locking protrusions 15 clamping devices 16 Plastic Sleeve 17 stator windings 18 Upper contact elements 19 Lower contact element 20 threaded parts 21 Electric Drive System 22 End stop section 23 Traction Battery 100 First Methods and Measures 200 Second Methods and Measures 300 Third Methods and Measures 400 Fourth Methods and Measures 500 Fifth Methods and Measures 600 Sixth Method and Measures 700 Seventh Method and Measures.

Claims

1. A method for electrically coupling an electric motor (1) of an electric motor (2) for a motor vehicle (3) to a power electronic device (4) of the motor (2), the method comprising: - Provides a first housing component (5) for the motor (2), - The support device (6) is arranged in the receiving portion (7) of the first housing component (5) such that the support device (6) is held in the receiving portion (7). - Provides a stator (8) for the electric motor (1), the stator having a plurality of contact rods (9) for electrically coupling the stator (8) to the power electronic device (4), - The stator (8) is arranged in the first housing component (5) such that the contact rod (9) passes through the support device (6) and is supported at the first housing component (5) via the support device (6). - A contact bridge (10) is arranged at the second housing component (12) of the motor (2) to establish electrical coupling between the contact rod (9) and the bus (11) of the power electronics (4). - The first housing component (5) and the second housing component (12) are assembled in such a way that the contact rod (9) at least partially extends into the contact bridge (10), and The power electronics (4) is arranged at the second housing component (12) such that the busbar (11) extends at least partially into the contact bridge (10).

2. The method according to claim 1, characterized in that, The stator (8) is arranged at the first housing component (5) and the power electronics (4) is arranged at the second housing component (12) such that the contact rod (9) and the busbar (11) form a common overlapping area (13) in the axial direction inside the contact bridge (10).

3. The method according to claim 1 or 2, characterized in that, The support device (6) is arranged at the first housing component (5) such that the locking protrusion (14) of the support device (6) engages with the first housing component (5) and holds the support device (6) at the first housing component (5), and / or the support device (6) is secured at the first housing component (5) after being arranged at the first housing component (5) by a fastening device separately constructed from the support device (6).

4. The method according to any one of the preceding claims, characterized in that, A support device (6) with a clamping device (15) inside is used, wherein the contact rod (9) is introduced into the support device (6) such that the clamping device (15) clamps the contact rod (9).

5. The method according to any one of the preceding claims, characterized in that, The contact rod (9) is partially encapsulated in plastic by injection molding to form a plastic sleeve (16), wherein the plastic sleeve (16) is arranged inside the support device (6) such that the contact rod (9) is supported at the support device (6) via the plastic sleeve (16).

6. The method according to any one of the preceding claims, characterized in that, The contact rod (9) is electrically and mechanically coupled to the stator winding (17) of the stator (8) via a brazing or fusion welding process.

7. The method according to any one of the preceding claims, characterized in that, A contact bridge (10) with an upper contact element (18) is used, wherein the contact rod (9) and the busbar (11) are arranged below the upper contact element (18), and / or a contact bridge (10) with a lower contact element (19) is used, wherein the contact rod (9) and the busbar (11) are arranged above the lower contact element (19).

8. The method according to any one of the preceding claims, characterized in that, The contact rod (9) and the busbar (11) are fastened to the contact bridge (10) via a threaded part (20).

9. A motor (2) for driving a motor vehicle (3), the motor having an electric motor (1) and a power electronic device (4) electrically coupled to the electric motor (1), characterized in that, The electric motor (1) and the power electronic device (4) are electrically coupled by means of the method according to any one of the preceding claims.

10. A motor vehicle (3) having an electric drive system (21) for driving the motor vehicle (3), characterized in that, The electric drive system (21) for driving the motor vehicle (3) has a motor (2) according to claim 9.

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