Flexible connector system for connecting a high-voltage motor to a printed circuit board of an integrated electronic system of a vehicle.

Abstract

Integrated electronic system for a vehicle, including: a case (30), a circuit board (32) attached to the housing (30), at least one electrical circuit board connection (34) which is attached to and extends from the circuit board (32), an electric motor (23) with windings (41), wherein the electric motor (23) is a three-phase AC motor with a rated current of about 50 amperes, at least one electrical motor connection (36) connected to the electrical circuit board connection (34), a body (24) associated with the housing (30) and generally adjacent to the circuit board (32), wherein the body (24) has at least one through-opening (28), wherein the at least one electrical motor connection (36) fits together with the at least one electrical circuit connection (34) within the at least one opening (28), and a flexible conductor (40) designed as a braided mesh-like conductor, wherein the flexible conductor (40) is electrically connected between the windings (41) and the at least one electrical motor connection (36) through the opening (28) in the body (24) in order to allow movement of the at least one electrical motor connection (36) with respect to different axes (42, 44), in conjunction with the at least one electrical circuit board connection (34).

Description

Area

[0001] The invention relates generally to a flexible connector system, and in particular to a flexible connector system for high-current AC motor applications, which reduces or eliminates tolerance problems between terminals associated with the motor and terminals mounted on a circuit board. background

[0002] With reference to Fig. Figure 1 shows a cross-section, generally designated by reference numeral 10, of a conventional integrated electronic system with a three-phase brushless DC motor 12. The system 10 includes a flexible connector 14, which establishes an electrical connection between the motor 12 and a connector 15 on a printed circuit board (PCB) 17. The flexible connector compensates for tolerances in the electrical connection with the connector 15; however, this system 10 has a lower current rating and uses a small-diameter conductor and therefore cannot be used in conjunction with high-current (50 ampere) AC motors for use in a vehicle. Furthermore, the flexible connector 14 has very limited movement to compensate for tolerances.

[0003] Additionally, the terminals 16 on the conventional brushless DC motor 12 are part of the motor winding 18, which simplifies connecting motor winding leads to the female terminal 19. Such a configuration cannot be used for high-current AC motors, as these motors require stronger, i.e., thicker, wire (or line) windings, and the motor connection point is located on the motor housing, not near the motor winding.

[0004] Accordingly, there is a need for a flexible connector system for electrically connecting terminals assigned to high-current motors to fixed terminals on a circuit board of an integrated electronic system of a vehicle.

[0005] From DE 20 2010 006 891 U1, a device fan is known which has a housing. An air duct is provided in the housing, in which a fan wheel is arranged. An electronically commutated drive motor is associated with the fan wheel. The housing is provided with flange-like sections which, together with the outer surface of the air duct, define cavities. Each cavity has at least one mounting opening. An electronic arrangement is arranged in one of the cavities, which includes components for commutation of the drive motor. A roof-like mechanical protective element covers at least part of the electronic arrangement and is detachably connected to the housing. The roof-like protective element has two roof slopes connected by a ridge. A gable is provided on each roof slope, in which an opening is provided that is aligned with the mounting openings.

[0006] From WO 00 / 39910 A1, an electric motor is known that is designed for mounting on a printed circuit board. The electric motor has a rotor and a stator with several coils and stator laminations. The stator laminations extend from the coils to the rotor. The motor is further provided with contact springs. The contact springs are electrically connected to one winding end of each coil. The contact springs are designed such that, after mounting, they bear against electrical conductors of the printed circuit board under spring tension.

[0007] From DE 198 49 267 A1, an electrical connector is known. It connects at least one stator winding of an electric motor to a circuit board of a controller. A plug soldered to the circuit board is inserted, when assembled, into a socket connected to the windings. The plug has a second solder contact to the circuit board via a flexible connection.

[0008] An electric motor is known from DE 196 16 077 A1. It has two independent excitation windings on a multi-armed stator. A central opening accommodates a permanent magnetized rotor. The rotor, with at least one pole pair, is arranged axially on a rotor shaft. Two opposing arms form a pair of arms. The opposing arms are bent such that they generate magnetic force vectors that are orthogonal to each other.

[0009] US patent 2010 / 0170294 A1 discloses an integrated electric compressor. It comprises an air conditioning compressor, a motor, a control board, and a housing. The control board contains a switching element on a first board that pulses the voltage to the motor. A control circuit on a second, spaced-away board controls the switching element. The IGBT and diode of the switching element are implemented as a bare chip.

[0010] A hybrid vehicle is known from US Patent 5,343,970 A. It has two or more drive wheels that receive torque from an output shaft. A drive unit delivers torque via a controllable torque transmission. This unit receives torque from a combustion engine and an electric motor via two input shafts. The electric motor can operate as a generator and is coupled to a battery. A controller manages the combustion engine, electric motor, and torque transmission. The speed ratios within the transmission are fixed.

[0011] US Patent 2011 / 0316373 A1 discloses a vibration-resistant inverter connection plate. It comprises an electrical conductor with an inverter connection, a motor connection, and a braided conductor. The motor connection is a long, plate-shaped terminal. The entire periphery of this terminal is enclosed in a housing.

[0012] A brake fluid pressure regulating device is known from EP 0 921 048 A2. It has an electric motor mounted on one side of the housing and an electronics box arranged on the other side. Conductors extend from the electronics box through openings in the housing. The conductors have plug-in pins at their motor-side ends. The plug-in pins are inserted into receiving sleeves of the electric motor. The motor-side plug-in sleeves and plug-in pins are interlocked. Summary

[0013] It is an object of the present invention to fulfill the aforementioned need. In accordance with the principles of one embodiment, this object is achieved by an integrated electronic system for a vehicle, comprising a housing, a circuit board attached to the housing, at least one electrical circuit board connection attached to and extending from the circuit board, and an electric motor with windings. The electric motor is a three-phase AC motor with a rated current of approximately 50 amperes. At least one electrical motor connection is connected to the electrical circuit board connection.A body is associated with the housing and generally adjoins the circuit board, the body having at least one through-opening, wherein the at least one electrical motor connection aligns with the at least one electrical circuit connection within the at least one opening. A flexible conductor, designed as a braided mesh-like conductor, is electrically connected between the windings and the at least one electrical motor connection through the opening in the body, thus allowing movement or displacement of the at least one electrical motor connection with respect to different axes, while coupled with the at least one electrical circuit board connection.

[0014] In accordance with a further aspect of the embodiment, a method for electrically connecting a motor to a circuit board of an integrated electronic system for a vehicle is provided. The motor is a three-phase AC motor with a rated current of approximately 50 amperes. The circuit board comprises at least one electrical circuit board terminal, which is attached to and extends from the circuit board. The method provides at least one flexible conductor, configured as a braided mesh-like conductor, which is electrically connected between windings of the motor and an electrical motor terminal. A body is provided, which generally adjoins the circuit board, and the body has at least one through-hole.The electrical motor connection is repositioned or moved relative to the fixed electrical circuit board connection for alignment. The electrical motor connection is then connected to the fixed electrical circuit board connection, the connecting step comprising connecting the electrical motor connection to the electrical circuit board connection within the opening.

[0015] Further tasks, features and properties of the embodiments as well as the methods of operation and the functions of the corresponding structural elements, the combination of parts and economic efficiency with regard to manufacturing become more apparent when considering the following detailed description and the attached claims with reference to the accompanying drawing figures, which all form part of this description. Brief description of the drawings

[0016] The invention will be better understood by the following detailed description of the preferred embodiments thereof in conjunction with the accompanying drawings, wherein the same reference numerals refer to the same parts, wherein: Fig. 1 is a cross-section of a conventional integrated electronic system with a three-phase brushless motor and a flexible connector. Fig. 2 a section view of a part of an integrated electronic system comprising an AC electric motor with a flexible connector system, in accordance with an embodiment. Fig. 3 an exploded view of the section of the integrated electronics system made of Fig. 2 is. Detailed description of exemplary embodiments

[0017] The following description of the preferred embodiment(s) is merely exemplary and is not intended to limit the invention, its application or uses in any way.

[0018] With reference to Fig. Figure 2 shows a section of an integrated vehicle electronics system, generally designated by reference numeral 10'. System 10' can, for example, be an electric clutch actuation system. System 10' comprises an AC electric motor assembly, generally designated by reference numeral 12', which, in accordance with one embodiment and generally designated by reference numeral 20, has a flexible connector system. The motor assembly 12' includes a motor 23, which is preferably a three-phase high-current (such as 50 ampere) AC motor. The motor assembly 12' with the flexible connector system 20 is also suitable for other applications with a three-phase high-current AC motor with integrated electronic systems, such as electric power steering, electric oil pumps, and electronically limited-slip differential systems.

[0019] The motor assembly 12' comprises a body 24 which accommodates a rotatable shaft 26 of the electric motor 23. The body 24 is associated with a housing 30 of the electronic system 10'. A printed circuit board (PCB) 32 is attached to the housing 30 of the electronic system and generally abuts the body 24. The PCB 32 comprises at least one male electrical circuit board connector 34, which is fixed to or attached to the PCB 32 and extends from it into the opening 28 of the body 24. Fig. 1) In the embodiment shown, three terminals 34 are provided, however, depending on the application, more or fewer may be provided.

[0020] The flexible connector system 20 comprises at least one female electrical motor terminal 36, which is arranged to receive the male terminal 34 through an opening 28 in the body 24. In this embodiment, three female terminals 36 are provided, each terminal 36 corresponding to a male terminal 34. Each female terminal 36 is connected to a flexible braided mesh-like conductor or wire 40, which is electrically connected directly or indirectly to windings 41 of the motor 23. Due to the flexible braided mesh-like wire 40, each female terminal 36 can be displaced, or "float," along a first axis 42 (for example, the X-axis) and a second axis 44 (for example, the Y-axis) within the corresponding opening 28, thus aligning the female terminal 36 with respect to the corresponding male terminal 34.During assembly, the female terminal 36 receives (i.e., is connected to) an associated male terminal 34, and due to the ability of each female terminal 36 to shift along each axis 42, 44, tolerances of the fixed male terminal 34 in the X and Y directions can be compensated for. This "floating" in the X and Y directions is necessary for the assembly process when a "blind" (i.e., in some way automated) assembly of the motor 23 with the integrated electronic system 10' is performed. Additionally, the "floating" of the female terminal 36 also provides stress relief for the solder joints on the male terminal 34.

[0021] The braided, mesh-like wire 40 enables applications for a high-current AC motor and provides the flexibility for the connected female terminal 36. The rated current of the wire 40 and the female terminal 36 is specifically selected to be substantially equal to the rated current of the motor 23. Although the female terminal 36 is connected to the wire 40 in this embodiment, it is preferred that the wire 40 be connectable to a male connector 34, with the PCB 32 comprising a suitable fixed or attached female terminal 36.

[0022] The preceding preferred embodiments were presented and described for the purposes of illustrating the structural and functional principles of the present invention, as well as for illustrating the methods of applying the preferred embodiments, whereby modifications are possible without departing from such principles. For this reason, this invention encompasses all modifications that fall within the scope of the following claims.

Claims

[1] Integrated electronic system for a vehicle, comprising: a case (30), a circuit board (32) attached to the housing (30), at least one electrical circuit board connection (34) which is attached to and extends from the circuit board (32), an electric motor (23) with windings (41), wherein the electric motor (23) is a three-phase AC motor with a rated current of about 50 amperes, at least one electrical motor connection (36) connected to the electrical circuit board connection (34), a body (24) associated with the housing (30) and generally adjacent to the circuit board (32), wherein the body (24) has at least one through-opening (28), wherein the at least one electrical motor connection (36) fits together with the at least one electrical circuit connection (34) within the at least one opening (28), and a flexible conductor (40) designed as a braided mesh-like conductor, wherein the flexible conductor (40) is electrically connected between the windings (41) and the at least one electrical motor connection (36) through the opening (28) in the body (24) in order to allow movement of the at least one electrical motor connection (36) with respect to different axes (42, 44), in conjunction with the at least one electrical circuit board connection (34). [2] System according to claim 1, wherein the at least one electrical circuit board connection (34) is a male connection and the at least one electrical motor connection (36) is a female connection. [3] System according to claim 1 or 2, wherein three electrical motor connections (36) are provided, each of which corresponds to an associated electrical circuit board connection (34). [4] Method for electrically connecting a motor (23) to a circuit board (32) of an integrated electronic system for a vehicle, wherein the motor (23) is a three-phase AC motor with a rated current of about 50 amperes, and wherein the circuit board (32) comprises at least one electrical circuit board connector (34) which is attached to and extends from the circuit board (32), the method comprising the following steps: Providing at least one flexible cable (40) which is designed as a braided mesh-like cable and is electrically connected between windings (41) of the motor (23) and an electrical motor connection (36), Providing a body (24) which generally adjoins the circuit board (32), wherein the body (24) has at least one through-opening (28), Relocating the electrical motor connection (36) with respect to the fixed electrical circuit connection (34) for alignment therewith, and Connecting the electrical motor terminal (36) to the attached electrical circuit board terminal (34), wherein the connecting step comprises connecting the electrical motor terminal (36) to the electrical circuit board terminal (34) within the opening (28). [5] Method according to claim 4, wherein the step of providing the at least one flexible conductor (40) which is connected to the electrical connection comprises selecting the flexible conductor (40) and the electrical motor connection (36) to have a rated current which is substantially equal to the rated current of the motor (23). [6] Method according to claim 4 or 5, wherein the at least one electrical circuit board connection (34) is a male connection and the at least one electrical motor connection (36) is a female connection.

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