Method for producing a stator of an electronically commutated DC motor

Abstract

A method for producing a stator (1) of an electronically commutated DC motor with a multi-phase stator (1) and an inner rotor, wherein the stator (1) has a closed return ring (2) and a plurality of inwardly directed stator poles (3) integral therewith, and an insulating body (4) with a connection means (5) for a winding wire (6) extending radially over the stator outer diameter, comprising the following method steps: - providing an assembly aid (34) for attaching the winding wires (6), - providing an insulated stator (1), - inserting the insulated stator (1) into the assembly aid (34), - inserting this arrangement into a winding device, - attaching a winding wire (6) to a stop point (35) of the assembly aid (34) arranged radially outside the stator (1),- joining the wire of a first phase around a first to an n-th pole of the stator (1) in succession, - guiding the wire to a second stop point of the assembly aid (34) and attaching the wire to this second stop point, - joining the same wire as a second phase without interruption around a first to an n-th further pole of the stator (1) in succession, - guiding the wire to a third stop point of the assembly aid (34) and attaching the wire to this third stop point, - uninterrupted joining of the same wire as a third phase around successively a first to an nth further pole of the stator (1), - guiding the wire to the first stop point and attaching it to it, - joining the wire receptacles (10) of the connecting means (5) in parallel arranged winding wire sections between the insulating body (4) and the stop points (35) of the assembly aid (34) at right angles to the wire extension, - sliding the connecting means (5) onto the guide (12) of the holding means (7), - joining the insulation displacement contacts (9), welding or soldering contacts into the receiving shafts (11), - severing the wire sections radially outside the connecting means (5), e.g. using a blade.

Description

[0001] The invention relates to a method for producing a stator of an electronically commutated DC motor with a multi-phase stator (1) and an inner rotor, wherein the stator (1) has a closed return ring (2) and a plurality of inwardly directed stator poles (3) integral therewith and an insulating body (4) with a connecting means (5) for a winding wire (6) extending radially over the stator outer diameter.

[0002] Electronically commutated DC motors with inward-facing poles are manufactured in different ways depending on the requirements. If short process times are to be achieved, a single-pole winding process is suitable, for example, in which the poles are wound economically in groups from the outside at the same time and then assembled and joined to form a stator. Each interface between the individual poles creates a magnetic resistance. The sum of these resistances reduces the overall efficiency of the DC motor. Therefore, this process is not used where high efficiency is required. Internal winding processes such as needle winding are better chosen for this purpose. A disadvantage of the needle winding process, however, is the relatively large installation space required for the winding needle itself, which must not only move between the poles but also be guided between wire guides when laying the winding wires.Furthermore, with needle winding, especially when connecting the winding wires to terminals, depending on the type of connection, it is necessary to join or lay the winding wire parallel to the axis. The wire must be secured axially so that it does not slip out of already laid sections, e.g. at deflection geometries. To prevent this, undercuts are usually provided on the deflection geometries. These geometries require significantly more complex injection molding tools with lateral sliders. The distances to the connection points must also be relatively large because this allows larger bending radii for the winding wire. If the bending radius is too small, the wire often cannot be guided over a terminal geometry without risking permanent bending deformation. This can lead to loose or loosening wire sections, which can then shorten the service life.

[0003] EP 1 722 464 A1 discloses a generic electronically commutated DC motor in which the wires are routed on the outside of the insulating body and connected to a contacting device (terminal block) radially adjacent to the insulating body. The winding is routed such that the winding wire is guided over a contacting element of the contacting device before or after winding all stator teeth assigned to a phase. The winding wire is routed on the outside of the insulating body in the area of ​​the return path. Since this is also the case in the area of ​​the contacting device, the contacting device extends very far radially outward, thereby significantly increasing the installation space.

[0004] EP 1 422 808 B1 discloses a resolver with a stator having a plurality of windings and an inner rotor, wherein the stator has a closed return ring and a plurality of inwardly directed stator poles integral therewith and an insulating body with a connecting means for a winding wire extending radially over the stator diameter, wherein the connecting means is mounted on a holding means integral with the insulating body.

[0005] DE 10 2012 214 088 A1 discloses an electronically commutated DC motor with a multi-phase stator, an inner rotor, and an insulating body with a connection element for a winding wire extending radially across the stator's outer diameter. The connection element is integral with the housing.

[0006] EP 1 191 665 A1 discloses a stator for electric motors in which a stator winding consisting of several winding phases is drawn into the stator slots of a stator core. The connecting means is integrally connected to the connecting plate.

[0007] From JP 2004 - 173 393 A, a stator is known in which a winding is wound around a stator core, a substrate arranged on the stator and connected to a lead wire, a rotor with a rotating shaft in the center, and the rotating shaft of the rotor, a bearing supporting the shaft, a mounting hole through which the lead wire passes, a bracket mounted on both sides of the stator, and a bushing with an insertion hole through which the lead wire is inserted and secured to the mounting hole. In the electric motor, the notch is provided in the mounting surface of the bracket so that the mounting hole is configured when the bracket is attached, and the bushing is formed from an elastic material along the insertion opening.A cut is provided in the socket and provided with a notch that snakes from the insertion hole to the surface of the socket. The lead wire is inserted from the notch into the insertion hole, and the socket is inserted into the notch. The gray-mounted, motor-cut end face of the bracket, mounted together with the bracket, presses the socket from both sides. It is characterized by being obtained by attaching the lead wire to the bracket.

[0008] US 2005 / 0 118 886 A1 discloses a motor comprising: at least one electrode wire wound around a coil of a stator to form a coil; at least one power line electrically connected to the lead wire to supply power to the lead wire; at least one connection terminal for connecting the lead wire to the power line; a terminal holding part provided on a part of the coil for placing the connection terminal; at least one terminal receiving opening in the terminal holding part provided to enable the connection terminal connected to the power line to be inserted and connected to the lead wire; and a fastening element for receiving the connection terminal connected to the power line therein and for fastening to the terminal holding part to keep the connection terminal mounted in the receiving opening of the terminal.

[0009] From US 2014 / 0 015 357 A1, an electrical connector assembly for providing an electrical connection with magnet wire terminals on electric motors with wire harnesses is known, comprising an adapter for connecting magnet wires to a wire harness. A first housing (10) of the adapter is attached to a motor housing (30) and has first terminals mounted in terminal receiving channels of the first housing and having insulation-displacing slots and mating portions, wherein the insulation-displacing slots are configured to receive magnet wires and the mating portions are configured to mate with the contacts of a matable connector attached to the wire harness. A second housing of the adapter has contact receiving channels with receiving portions configured to receive the mating parts of the first terminals and the receiving channels of the mating connector.

[0010] The object of the invention is to provide a generic DC motor with a compact design with small axial and radial dimensions, an optimal efficiency even when using a needle winding process and easy manufacturability.

[0011] This object is achieved according to the invention by the features of method claim 1.

[0012] The invention is characterized by a method for producing a stator of an electronically commutated DC motor with a multi-phase stator and an inner rotor, wherein the stator has a closed return ring and a plurality of inwardly directed stator poles integral therewith, and an insulating body with a connection means for a winding wire extending radially over the stator outer diameter, comprising the method steps: - providing an assembly aid for attaching the winding wires, - providing an insulated stator, - inserting the insulated stator into an assembly aid, - inserting this assembly into a winding device, - attaching a winding wire to a stop point of the assembly aid arranged radially outside the stator, - joining the wire of a first phase around a first to an nth pole of the stator in succession,- guiding the wire to a second stop point of the assembly aid and attaching the wire to this second stop point, - seamlessly joining the same wire as a second phase around a first to an nth further pole of the stator in succession, - guiding the wire to a third stop point of the assembly aid and attaching the wire to this third stop point, - seamlessly joining the same wire as a third phase around a first to an nth further pole of the stator in succession, - guiding the wire to the first stop point and attaching it to it, - joining the wire receptacles of the connecting means in parallel winding wire sections between the insulating body and the stop points of the assembly aid at right angles to the wire extension, - sliding the connecting means onto the guide of the holding means, - inserting the insulation displacement contacts into the receptacles,- Cutting the wire sections radially outside the connection means.,

[0013] The particular advantage of this method is that during the winding process, no connection needs to be made to the connecting element that will later be mounted on the holding element. This eliminates axial movements in the radially outer region of the stator, in which the connecting element is later secured. Once the stator has been wound and the wire sections directed radially outwards are still secured in the assembly aid, the connecting element is joined to the wire sections radially outside the holding element using an axis-parallel movement and then pushed onto the holding element and into its guide using a radial movement. The wire sections are not moved by this radial movement, but rather slide in the wire holders similar to a combing movement. The connection between the connecting element and the holding element can be designed to be force-fitting by slight over-pressing.By inserting the insulation displacement contacts into the receiving slots, the wires are stripped and electrically connected to the insulation displacement contacts.

[0014] A locking tab, which can be part of a housing cover, for example, locks the connection element in its position on the holding element after it has been installed.

[0015] Further developments of the invention are presented in the subclaims. The solution also includes the connection means not being one piece with the insulating body, but being mounted on a holding means that is one piece with the insulating body (4). This results in a number of advantages. Firstly, there is more space for the winding needle to fix the wire ends. Furthermore, the winding needle does not have to perform any axial movement for a joining movement with connection means such as insulation displacement contacts. For this reason, on the one hand, no retaining geometries such as hooks or undercuts are required. This means that the injection molding tool for the insulating body can be designed significantly simpler and without lateral sliders, making production more economical. Secondly, the radial installation space can be reduced, since space would also have to be provided for the axial movement.

[0016] The connecting element is designed to have slot-like wire receptacles. These are dimensioned so that the winding wire can be accommodated with virtually no play, yet without jamming. This flexibility is necessary to ensure reliable movement of the connecting element onto the retaining element.

[0017] The connector is further designed with recesses for insulation displacement contacts aligned at right angles to the wire receptacles. The insulation displacement contacts can also temporarily serve as a retaining or loss-preventing device for the connector during assembly.

[0018] It is advisable to provide a positive connection perpendicular to the joining direction between the connecting element and the retaining element. This ensures a secure mechanical connection in an axially parallel direction.

[0019] The positive connection is achieved by a guide in the retaining element and a corresponding and matching counter-contour on the connecting element. This connection can be designed as a slotted connection.

[0020] A particularly secure mechanical connection of the connecting element to the holding element, and thus to the insulating body, is achieved by locking the connection of the connecting element to the holding element with a locking device. This creates a positive connection both in the axially parallel and radial directions.

[0021] A very effective solution that limits the number of parts is to have the locking device on a housing cover that is necessary anyway.

[0022] The design of the mold for the insulating body can be significantly simplified by omitting axial retention geometries on the wire guide means of the insulating body.

[0023] According to a particularly preferred development of the invention, several wire guides are arranged in a ring region of the insulating body, which represents an axial projection of the return ring onto the insulating body, and are integral with the insulating body, for deflecting the winding wire. These wire guides are arranged in a 90° angle sector in which the connecting means is completely contained. These wire guides serve, in particular, to arrange the winding wire in a parallel arrangement as space-savingly and as optimally as possible, as a prerequisite for the installation of the connecting means.

[0024] Additional deflection means, which are provided radially outside this ring area on the holding means of the insulating body, also contribute significantly to the optimal arrangement of the winding wires.

[0025] It has been shown that a space-saving routing of the winding wire can be achieved, in particular, if the winding wire is guided axially inward around a wire guide means at least once, preferably at least twice, in the angular sector, in front of an already wound stator pole. This allows otherwise unused installation space to be used for the optimal arrangement of the winding wire.

[0026] This advantage is further exploited by laying the winding wire in a zigzag pattern around at least two wire guide means.

[0027] An embodiment of the invention is explained in more detail below with reference to the drawings. They show: Fig. 1 a stator in a first phase of an assembly process, Fig. 2 the stator in a second phase of the assembly process, Fig. 3 the stator in a third phase of the assembly process, Fig. 4 the wound stator in an axial view, Fig. 5 the wound stator in a plan view, Fig. 6 a sectional view of the wound stator, Fig. 7 an enlarged section E from Fig. 6, Fig. 8 a three-dimensional view of the wound stator, Fig. 9 a detailed view of a connecting element, Fig. 10 a side view of the connecting means, Fig. 11 a plan view of the connecting means, Fig. 12 a section BB through the connecting means from Fig. 11, Fig. 13 a section AA through the connecting means from Fig. 11, Fig. 14 an enlarged section G from Fig. 13, Fig. 15 a front view of an insulating body with a holding means, Fig. 16 an enlarged section of Fig. 15, Fig. 17 an exploded view and Fig. 18 an assembly aid.

[0028] Fig. Figure 1 shows a wound stator 1 in a first phase of an assembly process, with a closed return ring 2, an insulating body 4 with a holding means 7, a winding wire 6, which is wound around the individual radially inward-facing poles of the stator (not visible here) and guided between the individual poles in wire guide grooves 8 of the insulating body 4 on the circumference of the stator. The winding wire 6 is radially outwardly attached to a stop means 5 of an assembly aid 34 (see Fig. 18) is fixed.

[0029] Fig. 2 shows the stator 1 from Fig. 1 in a second phase of the assembly process, whereby wire holders 10 (see Fig. 5) of a connecting means 5 mesh with several wire sections of the winding wire 6 and the connecting means 5 is separated from the insulating body 4. The holding means 7 has a guide 12 (see Fig. 5) into which the connecting means 5 can be pushed with a counter contour 13, wherein the wires are arranged in the wire receptacles so as to be slidable along the wire extension direction.

[0030] Fig. 3 shows the stator 1 from the Fig. 1 and Fig. 2 in a third phase of the assembly process, in which the connecting element 5 is connected to the holding element 7. In this state, a positive connection exists in the axially parallel direction. The guide is dimensioned such that a frictional connection exists in the radial direction.

[0031] Fig. 4 shows the wound stator 1 in an axial view. Here, the stator poles 3 and the routing of the winding wire 6 can be seen. This is joined around wire guide means 15, whereby the wire is partially guided inward into a winding receiving area of ​​the stator 1 and back in order to route the wire to the desired position on the connecting means 5. Deflection means 31 are also provided for this purpose. The wire guide means 15, which serve to arrange the winding wires in the connecting area, are arranged in a 90° angular sector 30 in which the connecting means 5 is completely contained. The connecting means 5 is mounted on the insulating body 4 and has three insulation displacement contacts 9, which are joined axially (parallel to the motor axis 14) in receiving shafts 11 of the connecting means 5. The connecting means 5 is pushed approximately radially onto a holding means 7.The insulation displacement contacts 9 serve as a radial retaining device until final assembly. In the axial direction, there is a positive connection between the connecting element 5 and the retaining element 7.

[0032] Fig. Figure 5 shows a plan view of the wound stator 1, with the return ring 2, the insulating body 4, the connecting means 5, and the winding wire 6. The magnetically active part of the stator 1 consists of a stack of laminations. Several adjacent laminations of this stack are radially expanded at three points and form fastening eyes 16 (see also Fig. 4) for screwing to a housing. The insulating body 4 has a plurality of wire guide grooves 8 in which the winding wire 6 is laid on the outside circumference of the insulating body 4. Slot linings (not visible here) as part of the insulating body 4 protrude into slots of the stator 1. Also visible is the holding means 7, which is integral with the insulating body 4 and has the guide 12, onto which the connecting means 5 is pushed radially in a form-fitting manner, with the counter contour 13. The holding means further has support means 17, with which the holding means 7 is supported on the return ring 2. The connecting means 5 has guide means 18, which serve to guide a connection plug. To facilitate assembly, the guide means 18 are provided with insertion bevels. The guide means 18 project axially significantly further than the connecting means, which facilitates assembly of the connection plug.The connecting element 5 has slot-like wire receptacles 10, which are formed into the connecting element 5 at different depths, so that the wire sections of the winding wire 6 inserted therein are at different levels. As illustrated by dashed lines 19, the different levels are adapted to the axial position of the wire guide grooves 8. This geometric feature serves to install the winding wire 6 in the most space-saving manner possible.

[0033] On the opposite side of the stator 1, an insulating end plate 20 is mounted, which has no additional wire guide contours.

[0034] Fig. Figure 6 shows a sectional view of the wound stator 1, with the return path 2, the fastening eye 16, the stator poles 3, the insulating body 4, the insulating end plate 20, a plurality of stator coils 21, the connecting means 5, and the winding wire 6 received in the wire guide grooves 8 and in the wire receptacle 10 of the connecting means 5. The insulating body 4 and the insulating end plate 20 have slot linings 23. Furthermore, wire passages 22 are formed in the insulating body 4, through which the winding wire 6 is guided from the wire guide grooves 8 to the stator poles 3 and back, and from the wire guide means 15 to the stator poles 3 or to the connecting means 5. The support means 17 can absorb joining forces when inserting a connector.

[0035] The further details are shown more clearly in the enlarged detail E ( Fig. 7), with the insulating body 4, the return ring 2, the holding means 7, the connecting means 5, the wire guide means 15 and the winding wire 6. As can be clearly seen, two wires 6 are accommodated in the slot-like wire holder 10. This is a wire routed away from the connecting means 5 and a wire routed back to the connecting means. In the receiving shaft 11, the insulation displacement contact 9 is joined at right angles to the direction of wire extension. This contact serves to accommodate a contact tongue of a connector and is shaped accordingly. As cannot be seen, barbs of the insulation displacement contact 9 claw into the boundary surfaces of the receiving shaft 11. A stop means 24 is molded within the wire holder 10 and serves to determine the level at which the winding wires 6 cross the wire holder 10.Finally, the guide means 18 can be seen, which is provided with bevels 29 to facilitate the assembly of the connector plug.

[0036] Fig. Figure 8 shows a three-dimensional view of the wound stator 1, with the return ring 2, the insulating end plate 20, the insulating body 4, the stator poles 3, the winding wires 6, and the connecting means 5. The support means 17 of the holding means 7 and the guide 12, as well as the counter contour 13 of the connecting means 5, are clearly visible. Also shown are the stator coils 21, the fastening eyes 16, the wire receptacles 10, and the guide means 18.

[0037] Fig. Figure 9 shows an individual part of a connecting element 5, with the wire receptacles 10, the counter-contours 13, which resemble a slotted guide, and the guide elements 18, which are designed with different widths. The wire receptacles are provided with insertion bevels for easier wire installation. However, the slot width of the wire receptacle 10 is adapted to the wire thickness and is significantly smaller than a winding needle of a needle winding machine used to produce the winding.

[0038] Fig. 10 shows a side view of the connecting means 5, with the guide means 18 and a locking means 25, which serves to receive a housing cover section, by means of which the connecting means 5 is additionally fixed in a form-fitting manner in the axial direction.

[0039] Fig. 11 shows a plan view of the connecting means 5, with the locking means 25, the receiving shafts 11, the wire receptacles 10 and the guide means 18.

[0040] Fig. 12 shows a section BB through the connecting means 5 from Fig. 11, with the locking means 25, the stop means 24, the wire holder 10 and the receiving shaft 11.

[0041] Fig. 13 shows a section AA through the connecting means 5 from Fig. 11, with a receiving shaft 11 and a rib-like additional guide 26.

[0042] An enlarged section G from Fig. 13, shows in Fig. 14 shows more clearly the details of the connecting means 5, with the receiving shaft 11, the wire holder 10, the stop means 24 and the counter contour 13.

[0043] Fig. 15 shows a front view of the insulating body 4 with the holding means 7, which is provided with an additional groove 27 for receiving the additional guide 26 (see Fig. 13). Also shown are the wire guide means 15, which are designed as axially projecting pins, as well as the wire passages 22 between a radially outer and a radially inner stator region. Deflection means 31 radially outside the return ring 2 serve to deflect a winding wire section for the two radially furthest apart wire receptacles 10. No additional deflection means 31 is required for the third wire receptacle 10.

[0044] Fig. 16 shows an enlarged section H from Fig. 15, with the insulating body 4, the holding means 7, the additional groove 27, the wire guide means 15, the deflection means 31, the wire passages 22, and the groove linings 23, which also insulate the end faces of the stator poles 3. To facilitate assembly of the connection means 5, chamfers 28 are provided on the holding means 7. A first depth stop 32 and a second depth stop 33 are provided on the holding means 7 radially outside the return ring 2, which limit the height of the winding wire 6 (in the axial direction). It should be noted that, as a rule, two winding wires 6 are placed one above the other and therefore occupy different height levels. Crossing points must also be guided with the help of the wire guide means 15 and the additional deflection means 31 in such a way that an undesirable height buildup is avoided.

[0045] Fig. Figure 17 shows an exploded view of individual parts of the electric motor, with the insulating body 4, the connecting means 5, the locking means 25, the insulation displacement contacts 9, and a housing cover 40, on the edge of which a locking tab 39 protrudes parallel to the axis. This locking tab 39 is adapted to the locking means 25 and, when installed, forms a positive connection with it. This prevents the connecting means 5, with its mating contour 13, from slipping radially out of the guide 12 of the insulating body 4. The housing cover 40 is cup-shaped and has snap-in means 41 on its cup edge, which can be locked with corresponding snap-in lugs 42 of the insulating body 4.

[0046] Fig.Figure 18 shows an assembly aid 34 with a stator receptacle 36 with a connection receiving area 37 and with stop points 35, which are designed here as stop pins. The assembly aid 34 is further provided with adjustment pins 38, which serve to align the stator in the winding device and in a workpiece carrier. List of reference symbols 1 stator 2 Return ring 3 Stator pole 4 insulating body 5 Connection devices 6 winding wire 7 Holding devices 8 wire guide groove 9 insulation displacement contact 10 wire recordings 11 Receiving slot 12 Guide 13 Counter contour 14 Motor axle 15 wire guides 16 Mounting eye 17 Supporting equipment 18 guidance tools 19 Dashed line 20 insulating end disc 21 Stator coil 22 Wire passage 23 Groove lining 24 lifting gear 25 locking devices 26 Additional tour 27 Additional groove 33 Second depth stop 34 assembly aids 35 anchor point 36 Stator holder 37 Connection area 38 Adjusting pin 39 locking tabs 40 housing cover 41 snap-on devices 42 Snap Nose

Claims

[1] A method for producing a stator (1) of an electronically commutated DC motor with a multi-phase stator (1) and an inner rotor, wherein the stator (1) has a closed return ring (2) and a plurality of inwardly directed stator poles (3) integral therewith, and an insulating body (4) with a connection means (5) for a winding wire (6) extending radially over the stator outer diameter, comprising the following method steps: - providing an assembly aid (34) for attaching the winding wires (6), - providing an insulated stator (1), - inserting the insulated stator (1) into the assembly aid (34), - inserting this arrangement into a winding device, - attaching a winding wire (6) to a stop point (35) of the assembly aid (34) arranged radially outside the stator (1),- joining the wire of a first phase around a first to an n-th pole of the stator (1) in succession, - guiding the wire to a second stop point of the assembly aid (34) and attaching the wire to this second stop point, - joining the same wire as a second phase without interruption around a first to an n-th further pole of the stator (1) in succession, - guiding the wire to a third stop point of the assembly aid (34) and attaching the wire to this third stop point, - uninterrupted joining of the same wire as a third phase around successively a first to an nth further pole of the stator (1), - guiding the wire to the first stop point and stopping it thereon, - joining the wire receptacles (10) of the connecting means (5) in parallel arranged winding wire sections between the insulating material body (4) and the stop points (35) of the assembly aid (34) at right angles to the wire extension, - sliding the connecting means (5) onto the guide (12) of the holding means (7), - joining the insulation displacement contacts (9), welding or soldering contacts into the receiving shafts (11), - severing the wire sections radially outside the connecting means (5), e.g. using a blade. [2] Method for producing a stator (1) according to claim 1, characterized by the process step: mounting a locking tab (39) on the stator (1) and locking the connecting means (5) by positive locking. [3] Method for producing a stator (1) according to claim 1, characterized bythe method step: mounting a housing cover (40) with a locking tab (39) integral therewith on the stator (1) and locking the connecting means (5) by positive locking. [4] Method according to claim 1, characterized by that the connecting means (5) is not integral with the insulating material body (4), but is mounted on a holding means (7) which is integral with the insulating material body (4). [5] Method according to claim 1, characterized by that the connecting means (5) has slot-like wire receptacles (10) in which the winding wires (6) received therein cannot become jammed. [6] Method according to claim 5, characterized by that the connecting means (5) has receiving shafts (11) for insulation displacement contacts (9), welding or soldering contacts, which are aligned at right angles to the wire receptacles (10). [7] Method according to at least one of the preceding claims, characterized bythat the connection of the connecting means (5) to the holding means (7) is positively locked in a first direction. [8] Method according to claim 7, characterized by that the holding means (7) has a guide (12) which corresponds to a counter contour (13) on the connecting means (5). [9] Method according to claim 7 or 8, characterized by that the connection of the connecting means (5) to the holding means (7) is locked by a locking tab (39). [10] Method according to claim 9, characterized by that the locking tab (39) is integral with a housing part, e.g. a housing cover (40) of the DC motor. [11] Method according to at least one of the preceding claims, characterized byin that, for deflecting the winding wire (6), a plurality of wire guide means (15) are arranged in an annular region of the insulating material body (4), which represents an axial projection of the return ring (2) onto the insulating material body (4) and in a 90° angle sector (30), in which the connecting means (5) is completely contained, and are integral with the insulating material body (4). [12] Method according to claim 11, characterized by that further deflection means (31) are provided radially outside this ring area on the holding means (7) of the insulating body (4). [13] Method according to claim 11 or 12, characterized by that in the angular sector (30) the winding wire (6) is guided at least once inwards axially in front of an already wound stator pole (3) around a wire guide means (15). [14] Method according to claim 11, 12 or 13, characterized bythat in the angular sector (30) the winding wire (6) is guided at least twice inwards axially in front of an already wound stator pole (3) around a respective different wire guide means (15). [15] Method according to claim 11, 12, 13 or 14, characterized by that the winding wire (6) is laid in a zigzag manner around at least two wire guide means (15). [16] Method according to at least one of the preceding claims, characterized by that there is no wire guide means (15) which has retaining geometries acting in an axis-parallel direction.

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