Stator with multiple connections

Abstract

A stator for an electric motor, particularly as a drive for a power tool, the stator comprising a stator laminar core having at least one first pole tooth and at least one second pole tooth, each for receiving and holding at least one coil conductor, and further comprising at least one first contact rail and at least one second contact rail, respectively, for electrically contacting the coil conductor. Each contact rail includes at least one first connecting element and at least one second connecting element, wherein the first connecting element is positioned in a first plane and the second connecting element is positioned in a second plane.

Description

[0001] The present invention relates to a stator for an electric motor, particularly as a drive for a power tool, the stator comprising a stator lamination core having at least one first pole tooth and at least one second pole tooth for receiving and holding at least one coil wire, and further comprising at least one first contact rail and at least one second contact rail for electrically contacting the coil wire in each case.

[0002] The present invention further relates to an electric motor having a stator.

[0003] The present invention also relates to a power tool having a stator.

[0004] The prior art discloses electric motors, which are particularly used as drives for power tools. These electric motors essentially consist of a stator and a rotor, the rotor of which can rotate relative to the stator to generate torque.

[0005] Electric motors (such as brushless DC motors) are typically located inside the housing of a power tool. The mounting space inside the power tool housing is often very small, leaving only a small volume available for the advantageous or desired positioning of structural components (and especially electric motors).

[0006] Power tools can be further constructed in an extremely wide variety of embodiments, such as hammer drills, chisels, grinders, saws, and lamps. The internal mounting spaces of these different power tools can also be constructed in very different ways. The advantageous or desired positioning or arrangement of a standardized electric motor in all these different power tool housings can lead to numerous modifications or design alterations to the electric motor and / or the corresponding power tool housing.

[0007] Therefore, the purpose of this invention is to solve the above-mentioned problems.

[0008] This objective is achieved through the subject matter of independent patent claims 1, 4 and 5.

[0009] Other advantageous embodiments of the subject matter of the invention can be found in the corresponding dependent patent claims.

[0010] This objective is achieved in particular by a stator for an electric motor, which is particularly used as a drive for a power tool, the stator comprising a stator lamination core having at least one first pole tooth and at least one second pole tooth for receiving and holding at least one coil wire, and further comprising at least one first contact rail and at least one second contact rail for electrically contacting the coil wire in each case.

[0011] According to the present invention, each contact rail includes at least one first connecting element and at least one second connecting element, wherein the first connecting element is positioned in a first plane and the second connecting element is positioned in a second plane.

[0012] According to an advantageous embodiment, the first plane and the second plane can be configured as two intersecting planes.

[0013] According to another advantageous embodiment, the first plane and the second plane can be arranged substantially orthogonally to each other.

[0014] According to another advantageous embodiment, the first connecting element and / or the second connecting element can be configured for material bonding, form-fitting, and / or press-fitting connections with the power cable.

[0015] According to another advantageous embodiment, the first connecting element and / or the second connecting element can be configured for welding, brazing, screwing and / or plugging into a power cable.

[0016] According to another advantageous embodiment, the first connecting element and / or the second connecting element can be configured as a socket.

[0017] This objective is further achieved by an electric motor with a stator.

[0018] This objective is also achieved through a power tool with a stator.

[0019] Further advantages can be obtained from the description of the following figures. Different exemplary embodiments of the invention are shown in the figures.

[0020] The accompanying drawings, description, and claims include many combinations of features. Those skilled in the art will also be able to consider these features individually and combine them to produce other useful combinations.

[0021] In the attached diagram:

[0022] Figure 1 A schematic side view of a power tool according to an exemplary embodiment of the present invention is shown;

[0023] Figure 2 A front view of an electric motor with a stator and rotor is shown;

[0024] Figure 3 A perspective view of the stator according to an exemplary embodiment is shown;

[0025] Figure 4 A perspective view of a contact rail having a first connecting element and a second connecting element according to an exemplary embodiment is shown;

[0026] Figure 5 Another perspective view of a stator having multiple power cables according to a first exemplary embodiment is shown;

[0027] Figure 6 A top view of a stator having multiple power cables according to a second exemplary embodiment is shown; and

[0028] Figure 7 Another top view of a stator having multiple power cables according to a third exemplary embodiment is shown. Detailed Implementation

[0029] Figure 1 A power tool 1 according to an exemplary embodiment is shown. The power tool 1 is configured as a power drill powered by a rechargeable battery.

[0030] According to alternative exemplary embodiments, power tools can also be configured in the form of saws, grinders, hammer drills, etc.

[0031] The power tool 1, which is configured as a power drill, basically includes a housing 2, a handle 3, tool accessories 4, and a power supply device 5.

[0032] The housing 2 has a front end 2a, a rear end 2b, an upper end 2c, and a lower end 2d.

[0033] Tool accessory 4 is positioned at the front end 2a of housing 2. Tool accessory 4 is used to receive and hold the tool. The tool is not shown in the accompanying drawings.

[0034] In this exemplary embodiment, the tool can be configured in the form of a drill bit. The first end 3a of the handle 3 is positioned at the lower end 2d of the housing 2. An interface 6 is provided at the second end 3b of the handle 3.

[0035] like Figure 1 As shown, the handle 3 has a start switch 8, which can be used to adjust the power tool 1 to the start or stop state.

[0036] The power supply device 5 can be detachably fastened to the interface 6. In this exemplary embodiment, the power supply device 5 is configured as a rechargeable battery. The power supply device 5 is used to supply electrical energy to the power tool.

[0037] According to an alternative exemplary embodiment, the power supply device 5 can also be configured as a cable for connecting the power tool 1 to an AC power source (plug and socket). The power supply device 5 configured as a cable is not shown in the accompanying drawings.

[0038] Inside the housing 2 are positioned an electric motor 9, a transmission device 10, a drive shaft 11, and a control device 12, which serve as the drive unit.

[0039] The electric motor 9, transmission 10, drive shaft 11 and tool accessory 4 are arranged relative to each other inside the housing 2 such that the torque generated in the electric motor 9 can be transmitted to the transmission 10, drive shaft 11, and ultimately to the tool accessory 4 or the tool.

[0040] The control device 12 is connected to the start switch 8, the rechargeable battery interface 6 and the electric motor 9 via the corresponding line L.

[0041] The power supply device 5, configured as a rechargeable battery, can be detachably connected to the power tool 1 to supply electrical energy to the power tool 1. The rechargeable battery 5 basically includes a rechargeable battery housing 20, a plurality of energy storage cells 13, a rechargeable battery interface 14, and a control device 15.

[0042] The energy storage cell 13 can also be referred to as a rechargeable battery cell, and it is arranged inside the rechargeable battery casing 20.

[0043] The rechargeable battery housing 20 generally includes a cover element 20a, four side walls 20b, and a base element 20c.

[0044] The rechargeable battery interface 14 is arranged on the outside of the cover element 20a and is used to electrically or electronically and mechanically connect the rechargeable battery 5 to the power tool 1 or the charging device.

[0045] The charging device is used to charge the rechargeable battery 5 and is not shown in the accompanying drawings.

[0046] For electrical or electronic connection purposes, the rechargeable battery interface 14 has positive contacts, negative contacts, and communication contacts. The positive and negative contacts are used to generate a circuit when the rechargeable battery 5 is connected to the power tool 1 or a charging device. The communication contacts are used to send and receive data and information in the form of electrical signals.

[0047] As an alternative or additional option, the rechargeable battery 5 may also include a device for radio communication (e.g., Bluetooth) or wireless communication.

[0048] The energy storage cell 13 is used to receive, store, and retransmit electrical energy. The energy storage cell 13 has a cylindrical shape and is based on lithium-ion technology. Each energy storage cell 13 includes a contact device at one end for transmitting electrical energy. Each contact device is connected to the control device 15 of the rechargeable battery 5 via a corresponding line.

[0049] As an alternative, the energy storage cell 13 can also be based on another suitable technology.

[0050] The cylindrical shape of the energy storage cell 13 is also optional, allowing for the selection of any other suitable shape or geometry. Therefore, in particular, the energy storage cell 13 can also be constructed as a pouch cell.

[0051] Additionally, the rechargeable battery 5 may include both cylindrical energy storage cells 13 and pouch cells. Specifically, the rechargeable battery 5 may also include only a single cylindrical energy storage cell 13 and a single pouch cell.

[0052] The control device 15 regulates and controls various functions of the rechargeable battery 5. These functions include, in particular, controlling the reception of electrical energy into and from the energy storage cell 13. Furthermore, the control device 15 controls the amount of electrical energy to be received or delivered by the energy storage cell 13.

[0053] The electric motor 9 is configured as a brushless electric motor and essentially comprises a stator 16 and a rotor 17, see [link to documentation]. Figure 2 The rotor 17 is rotatably positioned inside the stator 16 about the central axis R.

[0054] Figures 3 to 7 A stator 16 according to an exemplary embodiment is shown. The stator 16 substantially includes a stator laminar core 22 having six radially inwardly pointing pole teeth 19. The stator laminar core 22 substantially consists of a plurality of irregularly shaped laminations stacked one on top of the other.

[0055] In their respective configurations, the two pole teeth 19 are positioned relative to each other. According to alternative embodiments, more or fewer than six pole teeth 19 may also be provided. Each pole tooth 19 is used to receive a coil wire 21 for forming a coil 24. The coil 24 is correspondingly connected to a power supply device 5 via a control device 12 to apply voltage to the coil 24. In other words, the coil 24 is energized. The coil 24 is used to generate an alternating magnetic field through which the rotor 17 rotates about the central axis R.

[0056] The stator laminated iron core 22 has a winding support 23 at its first end 22a, which is positioned above or at the first end 22a along the direction of arrow A. The winding support 23 is essentially used to support the coil conductor 21 around the pole teeth 19. As shown, the free end 21a of the coil conductor 21 exits from the winding support 23 at the first end 22a of the stator laminated iron core 22.

[0057] The first, second, and third contact rails 25 are further positioned along arrow direction A. The first, second, and third contact rails 25 have substantially the same configuration here.

[0058] Figure 4 A contact rail 25 according to a first exemplary embodiment is shown. The contact rail 25 has a substantially elongated, curved base 26. The arc or radius of the curved base 26 is selected such that the base 26 can be positioned at the arc of the stator lamination core 22. In particular, as in Figure 3 As can be seen, the base 26 of the contact rail 25 is located in the corresponding curved recess 27 of the winding support 23 and follows the shape of the stator lamination core 22.

[0059] A first clamping element 28a is disposed at a first end 26a of the base 26. The first clamping element 28a is used to receive and hold the coil wire 21 of the coil 24. A first connecting element 30 is disposed at a second end 26b of the base 26. The first connecting element 30 is connected to the second end 26b of the base 26 via the first end 30a. A first end 32a of a connecting element 32 is mounted at the second end 30b of the first connecting element 30. A first end 31a of a second connecting element 31 is mounted at the second end 32b of the connecting element 32. According to a first exemplary embodiment, the connecting element 32 is configured as a rod having a right angle (= 90°). Due to the right-angle configuration of the connecting element 32, the first connecting element 30 is positioned in a first plane E1, and the second connecting element 31 is positioned in a second plane E2. The first plane E1 and the second plane E2 are configured as two intersecting planes and are arranged substantially orthogonally relative to each other. As a result, the first connecting element 30 and the second connecting element 31 are arranged accordingly orthogonally relative to each other.

[0060] As an alternative, the first plane E1 and the second plane E2 are arranged at a straight angle or an acute angle relative to each other, that is, at an angle greater than or less than 90° relative to each other.

[0061] The second clamping element 28b is further disposed on the first connecting element 30. For example, in Figure 3 As can be seen, the second clamping element 28b protrudes downward from the second connecting element 28b in the opposite direction to arrow A. Like the first clamping element 28a, the second clamping element 28b also serves to receive and hold the coil wire of the coil 24. The first clamping element 28a is used to receive and hold the first coil wire 21 of the first coil 24, and the second clamping element 28b is further used to receive and hold the second coil wire 21 of the second coil 24. The first coil and the second coil 24 are arranged opposite each other, see [reference needed]. Figure 7 .

[0062] As in Figure 4 It can be seen particularly clearly that the first clamping element 28a and the second clamping element 28b are in the form of bent metal sheets, and the end 21a of the winding wire 21 is inserted into the bent metal sheet and clamped by bending the metal sheet.

[0063] According to an alternative embodiment, the first clamping element 28a and the second clamping element 28b may each be configured as a straight metal sheet, to which the end 21a of the winding wire 21 is welded.

[0064] According to a first exemplary embodiment, the first connecting element 30 and the second connecting element 31 are each configured as a through hole having an internal thread 33. The internal thread 33 is used to releasably connect the contact rail 25 to the power cables 34a, 34b, 34c, see [link to example]. Figures 5 to 7 .like Figures 5 to 7 As shown, screws 35 are screwed into each through hole to releasably fasten power cables 34a, 34b, 34c to contact rail 25.

[0065] Power cables 34a, 34b, and 34c are used to supply electrical energy from power supply unit 5 to contact rail 25 and ultimately to coil 24.

[0066] According to an alternative embodiment, at least one connecting element 30, 31 may be configured such that power cables 34a, 34b, 34c may be soldered, brazed, or simply plugged into contact rail 25. For a suitable plugged connection, connecting elements 30, 31 may be configured as sockets, and the ends of power cables 34a, 34b, 34c may be configured as plugs corresponding to the sockets.

[0067] Figure 5 The stator 16 is shown, wherein a first power cable 34a is connected to a second connecting element 31 of a first contact rail 25, a second power cable 34b is connected to a second connecting element 31 of a second contact rail 25, and a third power cable 34c is connected to a second connecting element 33 of a third contact rail 25. Thus, the three power cables 34a, 34b, and 34c are connected to the stator 16 radially, such that the power cables 34a, 34b, and 34c extend axially (=along direction A). The first connecting element 30 of the respective contact rail 25 is not occupied here.

[0068] Figure 6 The stator 16 is shown, wherein a first power cable 34a is connected to a second connecting element 31 of a first contact rail 25, a second power cable 34b is connected to a second connecting element 31 of a second contact rail 25, and a third power cable 34c is connected to a second connecting element 31 of a third contact rail 25. Thus, three power cables 34a, 34b, and 34c are connected to the stator 16 radially; however, in the first portion, the respective power cables 34a, 34b, and 34c extend tangentially relative to the stator lamination core 22. After the first portion, the power cables 34a, 34b, and 34c then extend radially. The first connecting element 30 of the respective contact rail 25 is also unoccupied.

[0069] Figure 7The stator 16 is shown, wherein a first power cable 34a is connected to a first connecting element 30 of a first contact rail 25, a second power cable 34b is connected to a first connecting element 30 of a second contact rail 25, and a third power cable 34c is connected to a first connecting element 30 of a third contact rail 25. Thus, the three power cables 34a, 34b, and 34c are connected to the stator 16 axially, such that the corresponding power cables 34a, 34b, and 34c extend radially. The second connecting element 31 of the corresponding contact rail 25 is not occupied here.

[0070] Figure Labels

[0071] 1 Power Tools

[0072] 2 shells

[0073] 2a Front end of the shell

[0074] Rear end of 2b housing

[0075] The upper end of the 2c housing

[0076] The lower end of the 2D shell

[0077] 3-handle

[0078] The first end of the 3a handle

[0079] The second end of the 3b handle

[0080] 4 Tools and Accessories

[0081] 5 Power Supply Unit

[0082] 6 interfaces

[0083] 8 Start Switch

[0084] 9 electric motors

[0085] 10 Transmission Device

[0086] 11 drive shafts

[0087] 12 control devices

[0088] 13 energy storage cells

[0089] 14 rechargeable battery ports

[0090] 15 Control Devices

[0091] 16 stators

[0092] 17 rotors

[0093] 19-pole teeth

[0094] 20 Rechargeable Battery Case

[0095] 21 coil wires

[0096] 21a coil wire end

[0097] 22 stator laminated iron core

[0098] The first end of the 22a stator laminated iron core

[0099] 23 Winding Support

[0100] 24 coils

[0101] 25 contact rail

[0102] 26. Base of contact rail

[0103] The first end of the 26a matrix

[0104] The second end of the 26b matrix

[0105] 27. Recess on the winding support

[0106] 28a First clamping element

[0107] 28b Second clamping element

[0108] 30 First connecting element

[0109] 30a First end of the first connecting element

[0110] 30b The second end of the first connecting element

[0111] 31 Second connecting element

[0112] 31a First end of the second connecting element

[0113] 31b Second end of the second connecting element

[0114] 32 connecting elements

[0115] The first end of the 32a connecting element

[0116] The second end of the 32b connecting element

[0117] 33 Internal Thread

[0118] 34a First Power Cable

[0119] 34b Second Power Cable

[0120] 34c third power cable

[0121] 35 screws

[0122] R center axis

[0123] E1 First Plane

[0124] E2 Second Plane.

Claims

1. A stator (16) for an electric motor (9), particularly as a drive for a power tool (1), the stator comprising a stator lamination core (22) having at least one first pole tooth and at least one second pole tooth (19) for receiving and holding at least one coil wire (21), and further comprising at least one first contact rail and at least one second contact rail (25) for electrically contacting the coil wire (21) in each case. Its features are, Each contact rail (25) includes at least one first connecting element and at least one second connecting element (30, 31), wherein the first connecting element (30) is positioned in a first plane (E1) and the second connecting element (31) is positioned in a second plane (E2).

2. The stator (16) as described in claim 1. Its features are, The first plane and the second plane (E1, E2) are constructed as two intersecting planes.

3. The stator (16) as described in claim 1 or 2. Its features are, The first plane and the second plane (E1, E2) are arranged substantially orthogonally to each other.

4. The stator (16) as described in at least one of claims 1 to 3. Its features are, The first connecting element and / or the second connecting element (30, 31) are configured for material bonding, form-fitting and / or press-fitting connections with power cables (34a, 34b, 34c).

5. The stator (16) as described in at least one of claims 1 to 4. Its features are, The first connecting element and / or the second connecting element (30, 31) are configured for welding, brazing, screw fixing and / or plugging into power cables (34a, 34b, 34c).

6. The stator (16) as described in at least one of claims 1 to 5. Its features are, The first connecting element and / or the second connecting element (30, 31) are configured as a socket.

7. An electric motor having a stator (16) as described in at least one of claims 1 to 6.

8. A power tool having a stator (16) as described in at least one of claims 1 to 6.

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