Electric motor and method for manufacturing an electric motor

Abstract

electric motor comprising a stator (7) which is composed of at least stamped tooth segments (1), wherein the tooth segments (1) can be radially pushed together during manufacturing, wherein the tooth segments (1) have a groove (4) and tongue (3) for mutual positive locking in the circumferential direction, wherein the stator (7) formed from the radially pushed-together tooth segments (1) is held together by retaining parts (5) axially pushed onto the stator (7), where Each of the retaining parts (5) is designed as a ring with pins (6) which are inserted into holes in the tooth segments (1).

Description

[0001] The invention relates to an electric motor and a method for producing an electric motor.

[0002] EP 1 322 021 B1 discloses a stator in which the stator teeth are axially inserted into a hollow cylindrical annular body. Caps are attached to both ends, enclosing electrical connectors. The disadvantage is the large mass and therefore costly production of the motor.

[0003] A stator is also known from US 6 226 856 B1 in which the teeth of the stator are inserted axially into one another.

[0004] From US 6 359 355 B1 a stator is known in which the segments are brought together radially, but they are held by a surrounding “circular pattern 28”.

[0005] A support for a motor winding is known from US 4 999 532 A.

[0006] From US 2004 / 0068857 A1 a method for producing a core of a washing machine motor is known.

[0007] The invention is therefore based on the object of developing a device and a method, whereby the production of an electric motor and an associated series is to be simplified and environmental protection is to be improved.

[0008] According to the invention, the object is achieved by the features specified in claim 1.

[0009] Essential features of the invention in the electric motor are that it comprises a stator which is composed of at least punched tooth segments, wherein the tooth segments can be pushed together radially during manufacture and can be held together by axially pushed-on holding parts.

[0010] The advantage is that less mass is required for the stator package, in particular, there is no ring surrounding the tooth segments to shrink-fit them. This improves environmental protection. Furthermore, production is quick and easy, highly automated, and therefore cost-effective. The segments are simply pushed together radially, and then the retaining parts are attached axially.

[0011] Another advantage is that the stator package can be used as a pre-assembled unit in various housing systems, thus improving flexibility and modularity. Only one stator package needs to be kept in stock for several different housing types of the entire electric motor.

[0012] In this document, the stator package is also referred to as the stator for the sake of simplicity.

[0013] In an advantageous embodiment, the holding parts are positively connected to the toothed segments. This is advantageous because a significant portion of the holding force can be generated by a simple, axially attachable additional part.

[0014] According to the invention, the retaining parts are inserted into the holes of the toothed segments with pins. In particular, the pins are oriented axially. This is advantageous because the retaining part is easy to manufacture and, with simple fasteners, sufficiently stable stator components can be achieved.

[0015] In an advantageous embodiment, the toothed segments have a tongue and groove for mutual positive connection in the circumferential direction. This is advantageous because a positive connection in the circumferential direction can be created simply by shaping the toothed segments. Due to the pins of the retaining parts, theoretically only rotation of the toothed segments around the pins would be possible. However, since the tongue and groove are designed in such a way that they can be inserted into one another in the circumferential direction, radial movement is prevented. This is achieved by the arrangement of the tongue and groove positive connection on both sides in the circumferential direction.

[0016] In an advantageous embodiment, the holding parts comprise electrical connections for establishing the interconnection of the windings of the individual tooth segments. In particular, the holding parts comprise, for example, a plastic-encapsulated lead frame. This is advantageous in that the interconnection, i.e., the creation of the series or parallel connection, can be carried out particularly quickly and easily. The holding part can also be designed with plug contacts for electrically connecting cables. The tongues of the plug contacts are parts of the bent lead frame, i.e., a punched-bent lead frame instead of a lead frame.

[0017] In an advantageous embodiment, each toothed segment has an axially mounted end cap, in particular comprising grooves for wire guidance. This provides the advantage that the shape of the winding can be more easily influenced, thus allowing a high copper filling ratio to be achieved. This ensures high motor utilization and minimizes motor losses.

[0018] Essential features of the method for manufacturing an electric motor are that the toothed segments are pushed together radially during manufacturing and then pushed axially by holding parts, in particular for holding the segments together.

[0019] The advantage is that production is very quick and easy, making it cost-effective.

[0020] Further advantages arise from the subclaims.

[0021] The invention will now be explained in more detail with the aid of illustrations:

[0022] The motor according to the invention comprises a stator which consists of at least tooth segments.

[0023] In the Fig. 4 to 11 show the production of the finished wound tooth segment in sequence.

[0024] In the Fig. 1 to 3 show the assembly of the stator from the tooth segments.

[0025] The figures are described in more detail below: In the Fig. 4 shows a toothed segment 1. It has a groove 4 and a tongue 3, as well as a raised portion 8 created by the punching process. A hole is also provided for inserting pins 6.

[0026] In the Fig. 5 shows the insulating paper 9, which is pushed onto the tooth segment.

[0027] In the Fig. 6 shows the tooth segment 1 with the insulating paper 9 pushed on.

[0028] In the Fig. 7 shows an end cap 10 which has grooves 12 for the wire guide and a coil support 11 for securing the winding as well as recesses as wire guides 13.

[0029] In the Fig. 8 shows a tooth segment with end caps 10 pushed on.

[0030] In the Fig. 9 shows a tooth segment subsequently wound with the winding 14.

[0031] In the Fig. 10 shows the retaining part 5 with the pins 6. The pins 6 are shown projecting and oriented in the axial direction. The retaining part 5 is preferably made of plastic.

[0032] In the Fig. Figure 11 shows a section through the fully wound tooth segment 1. The winding 14 is surrounded by insulating paper 9.

[0033] In the Fig. Figure 1 shows punched, fully wound tooth segments 1, which are pushed together radially during the production of the stator. The respective groove 4 and tongue 3 of adjacent tooth segments meet, thus securing the radial connection between the two tooth segments.

[0034] In Fig. Figure 2 shows how the retaining parts 5 are pushed onto the axial end regions in the axial direction and are positively connected to the toothed segments with their pins 6. For this purpose, the pins 6 are inserted into holes 2 of the toothed segments.

[0035] The retaining parts 5 thus give the stator its cylindrical shape and hold it together. On the one hand, they limit the axial freedom of movement of the toothed segments 1, and on the other hand, they prevent radial movement of the toothed segments away from the pins 6, because the pins are inserted into the holes 2.

[0036] In the Fig.3 shows the stator with the holding parts 5 pushed on.

[0037] In further embodiments according to the invention, instead of the holding part 5 designed as a ring with pins, a differently shaped part provided with additional functions can also be used. The part can also be designed as a cap, for example. Furthermore, it can also be designed with electrical connections integrated into the holding part. A design with a lead frame that is plastic-encapsulated and thus produced as a holding part is particularly advantageous. The lead frame is designed in such a way that the circuitry can be created by punching the holding part. For this purpose, different areas are punched out of the holding part, thus providing the remaining lead frame for interconnection. List of reference symbols 1 tooth segment, punched packaged 2 holes 3 springs 4 grooves 5 Holding part 6 pin 7 Stator, complete 8 Survey 9 Insulating paper 10 End cap 11 Coil support 12 grooves 13 Wire guide 14 windings

Claims

[1] Electric motor comprising a stator (7) which is composed of at least punched tooth segments (1), wherein the tooth segments (1) can be pushed together radially during manufacture, wherein the tooth segments (1) have a groove (4) and a spring (3) for mutual positive connection in the circumferential direction, wherein the stator (7) formed from the radially pushed together tooth segments (1) is held together by holding parts (5) pushed axially onto the stator (7), where each of the holding parts (5) is designed as a ring with pins (6) which are inserted into holes in the tooth segments (1). [2] Electric motor according to claim 1, characterized by that the number of holding parts (5) is two. [3] Electric motor according to at least one of the preceding claims, characterized by that the holding parts (5) are positively connected to the tooth segments (1). [4] Electric motor according to at least one of the preceding claims, characterized by that the pins (6) are oriented in the axial direction. [5] Electric motor according to at least one of the preceding claims, characterized by that the holding parts (5) comprise electrical connections for establishing the interconnection of the windings (14) of the individual tooth segments (1), in particular for establishing the series or parallel connection. [6] Electric motor according to at least one of the preceding claims, characterized by that the holding parts (5) have a plastic-coated punched grid. [7] Electric motor according to at least one of the preceding claims, characterized by that each tooth segment (1) has an axially pushed-on end cap (10), in particular comprising grooves (12) for wire guidance (13). [8] Electric motor according to at least one of the preceding claims, characterized bythat the stator (7) can be used as a pre-completed stator package in at least two different housing systems, in particular to achieve a high degree of variance within a series of electric motors with as few parts as possible. [9] Method for producing an electric motor, comprising a stator (7) which is composed of at least punched tooth segments (1), characterized by , that - the tooth segments (1) are pushed together radially during production - groove (4) and tongue (3) of the toothed segments (1) are mutually positively connected in the circumferential direction, - then holding parts (5) are pushed axially onto the stator (7), whereby the stator (7) is held together in a shaping manner.

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