Stator

Abstract

Brushless motor with a permanent magnet rotor and a wound stator (1'), comprising a stator yoke (2') with a plurality of stator poles (3'), an end-face insulating element (4'), a stator winding (6') comprising a plurality of coils (5'), wherein each stator pole (3') is wound with a coil (5'), a connection arrangement (7') for connecting the coils (5') to each other and to electrical terminals (22), wherein a single winding wire without interruption forms all coils (5') of the stator winding (6') and connecting sections (8') between the coils (5'),Each connecting section (8') of the winding wire between two coils (5') runs only between spatially adjacent coils (5') and forms an electrical connection between these coils (5'), and the connecting sections (8') between two spatially adjacent coils (5') are laid exclusively radially outside the coils (5') in recesses (9') and / or around projections (10') of the insulating element (4'), characterized in that the insulating element (4') has receptacles (12') for contact elements (11') radially outside the coils (5') or a circumcircle (23) bounded by the coils (5'), and in that, in a plurality of connecting sections (8') between two spatially adjacent coils (5'), the winding wire runs from a coil longitudinal side (25') of the first coil to one of the contact elements (11') and from there to a coil longitudinal side (25') of the second coil (5'), and the two Coil longitudinal sides (25') are those,those that are furthest apart.

Description

[0001] The invention relates to a brushless motor with a permanent magnet rotor and a wound stator, consisting of a stator yoke with a plurality of stator poles, an insulating element arranged at the end face, a stator winding comprising a plurality of coils, wherein each stator pole is wound with a coil, and a connection arrangement for connecting the coils to each other and to electrical connections.

[0002] BLDC motors for driving oil pumps are currently designed as internal rotors due to the required high acceleration. To achieve a sufficiently compact size, rare-earth magnets, which are expensive, are typically used. Since these motors are often installed directly in an oil bath, there is no need for a steel housing for corrosion protection. The stators are therefore constructed as laminated, self-supporting units.

[0003] The corresponding stator windings are applied using a needle winding machine. For this, a space must be left free in the winding area between the stator poles, into which the winding needle can dip. The width of this empty space is typically at least three times the nominal wire diameter and cannot be used for accommodating winding wires.

[0004] This means that the usable winding space depends heavily on the wire diameter. The smaller the wire diameter, the larger the usable winding space.

[0005] BLDC motors typically have a 3-phase drive system. The number of individual coils is therefore always a multiple of 3. 6-, 9-, or 12-pole stators are common; however, the number of stator poles can be significantly higher. These are then referred to as torque motors.

[0006] Modern motors typically use coils connected in series. This means that only a relatively small number of turns are required, often in the single digits. However, this also means that the winding wire diameters are relatively large compared to the available winding space. Consequently, the winding space cannot be efficiently filled with the wire, resulting in poor utilization of the copper wire.

[0007] In series circuits, the connections are made by skipping the next two adjacent coils after winding one coil and then continuing to wind the third coil until the required number of poles per phase is wound ( Fig. 1) However, this has the disadvantage that relatively long distances must be bridged to connect the individual coils of a phase. The length of the winding wire required for the coil connection is often on the order of one turn. This connecting wire does not contribute to torque generation, but increases both the required copper weight and the winding resistance, thereby generating additional ohmic losses.

[0008] To connect the individual coils, the connecting wires must be arranged axially one above the other. Spacers must also be used to prevent contact. Up to four wires must be run in parallel. Fig. 2).

[0009] Because of the thick winding wire, a lot of space is needed in the axial and radial direction for the coil connection, which is also lost for the active torque generation of the motor.

[0010] Despite the aforementioned disadvantages, series connection is widely used because the wiring technique is well-known and because comparatively fewer contact points are required for electronic control. In a series connection of a stator with delta winding, only 3 to 6 contacts are needed, depending on the winding method; in a star connection, at least 6 contact points are required. In contrast, a parallel winding of a stator requires at least as many contacts as coils; thus, 6 contacts for a 6-pole stator and 9 contacts for a 9-pole stator.

[0011] From DE 102010 025 261 A1 an electric motor is known with a stator having a plurality of excitation windings which are wound at least partially from a winding wire, with a contact grid for contacting the excitation windings which has a plurality of conductor tracks insulated from each other, wherein the conductor tracks have contacts on which the winding wire is fixed.

[0012] DE 20 2005 011 721 U1 discloses a stator of an electric motor with a single- or multi-strand stator winding formed from a number of stator coils and a connection arrangement attached to an end face of the stator with winding contact elements connected via conductor bridges, each assigned to a winding strand, which serve as winding support points between the stator coils

[0013] WO 2010 / 102 753 A1 describes a stator with a stator body that has arms projecting radially from a ring, each surrounded by a winding. The stator also has insulation provided with openings for a winding wire. The openings are open towards the ring and the arms. A first opening is provided on a radially inner ring of the insulation. This first opening is associated with a second opening that intersects or connects to a receptacle for an insulation displacement contact. The stator can thus be wound with the winding wire in one continuous operation. The wire is fed radially outwards from the interior of the stator body through one of these openings and then wound around at least one arm. The winding wire is then fed radially inwards through the next opening, to the following opening, and again radially outwards through it to perform the next winding operation.

[0014] DE 20 2007 014 169 U1 discloses an electric motor with a rotor rotatable about an axis of rotation and an associated stator with prominent poles, each carrying a winding. The windings form a winding arrangement, with electrical connecting lines provided between some of the windings. The stator includes connecting elements on at least one insulating support, equipped with contact and fastening elements that are electrically and mechanically connected to the connecting lines. The motor comprises at least one connection arrangement with conductors and receiving openings associated with the contact parts of at least two connecting elements to establish an electrical connection from the respective connecting line via fastening, connecting, and spring-loaded contact elements.

[0015] DE 10 2004 049 072 A1 describes a permanent magnet motor comprising a stator and a rotor, wherein the stator has a stator lamination stack with a plurality of pole teeth formed by slots and a plurality of windings arranged in the slots, and the rotor has a rotor lamination stack with a plurality of pole teeth formed by centrally symmetrically arranged cutouts and a plurality of permanent magnets arranged in the cutouts. The cutouts are arranged such that the pole teeth are connected to each other along the circumference of the rotor by webs, so that the cutouts form channels for receiving permanent magnets and the surface of the rotor lamination stack facing the stator is completely closed.

[0016] US 2005 / 0088049A1 concerns a stator for an electric motor. The stator comprises an annular stator core with several stator teeth. On the end face of the core is an annular connecting unit with deflecting elements. This unit includes a support component with a recess and slots. Several electrically insulated terminal rings are arranged in the recess, with their contact elements extending outwards through the slots.

[0017] JP 2010 – 6 088 A discloses a device for an electric power steering system. The device mechanically and electrically connects a mounting section, a relay component, and the power board by means of a screw. The ground of the power board is contacted with the mounting section of the electric motor housing via the relay component.

[0018] The object of the invention is to improve a BLDC motor based on the internal rotor principle in such a way that it can be manufactured in a significantly more compact, lighter, and more cost-effective manner while maintaining the same motor torque and motor output power, or that a substantial increase in performance can be achieved while maintaining the same overall size. This object is achieved according to the invention by the features of claim 1. To minimize ohmic losses, it is provided that a single winding wire forms all coils of the stator winding and connecting sections between the coils without interruption, that each connecting section of the winding wire between two coils runs only between spatially adjacent coils and forms an electrical connection between these coils, and that the connecting sections between two spatially adjacent coils are routed exclusively radially outside the coils in recesses and / or around projections of the insulating element.This eliminates the need to route connecting wires across multiple poles, thus minimizing wire sections that do not contribute to torque. Because the insulating element has receptacles for contact elements radially outside the coils and within a circle defined by the coils, the path to the contact elements is short, further avoiding unnecessary wire lengths. In most connection sections between two spatially adjacent coils, the winding wire runs from a longitudinal side of the first coil to one of the contact elements and from there to a longitudinal side of the second coil, with the two coil longitudinal sides being the ones furthest apart. In this configuration, the wire lengths are slightly longer, but the bending radii are wider, making this stator design easier to wind.

[0019] Further developments of the invention are described in the dependent claims.

[0020] According to a prior art embodiment of the invention, in a plurality of connection sections between two spatially adjacent coils, the winding wire runs from a longitudinal side of the first coil to one of the contact elements and from there to a longitudinal side of the second coil, with the two longitudinal sides of the coils being directly opposite each other. This allows for the shortest possible wire lengths between adjacent coils; however, relatively tight bending radii for the winding wire are necessary.

[0021] It is advantageous to avoid points of contact between two wires. Since, in the embodiment according to the invention, the two connecting sections of a coil intersect with their respective spatially adjacent coils, the routing geometries are selected such that the intersecting wires do not touch at the point of intersection.

[0022] It is advantageous that the contact elements are insulation displacement contacts, which have a distal contact section and a proximal contact section, with each connecting section being directly contacted by the proximal contact section of the contact element. In particular, it is provided that the receptacles of the insulating element are equipped with openings for wire reception and / or wire guidance, and that the contact elements can be fixed in the receptacles by a plug-in assembly process, with the distal contact sections being aligned in an optimal position for assembly, preferably axially. In this way, the winding wires can be laid with high accuracy and process reliability.

[0023] According to a further development of the invention, the contact elements can also be designed as welded contacts.

[0024] In a particularly advantageous embodiment of the invention, the stator is wound and connected with a three-phase parallel winding. The stator can also be wound and connected with a five-phase parallel winding or a bipolar single-phase winding. A parallel winding allows for a significantly smaller wire diameter. This results, firstly, in the winding filling the winding space more precisely and completely, and secondly, in the winding needle having a smaller width. A thinner winding needle allows for narrower gaps between two pole shoes and a larger cross-sectional area for winding. This allows for a smaller stator and motor design. Rotor dynamics can also be improved due to a shorter rotor and thus a lower moment of inertia. Furthermore, a higher torque can be achieved with the same overall size.

[0025] From an assembly perspective, it makes sense for the distal contact sections of the contact elements to be pressed into a printed circuit board.

[0026] In many applications, brushless motors are exposed to high environmental and vibration stresses. For such cases, the wound stator and contact elements are overmolded with plastic material. This prevents the contacts from loosening, thus increasing the service life.

[0027] For the sake of simplicity, the stator of a previously described brushless motor can be designed so that the winding start and end are arranged one above the other or side by side in the same receptacle and connected to the same contact. This eliminates the need for an additional receptacle and contact for the winding start and end, respectively. Alternatively, the winding start and end can, of course, be arranged in two separate receptacles. This can ensure greater contact reliability.

[0028] For interference suppression reasons, it can be advantageous to provide an additional ground contact to connect the control electronics to a ground, e.g., a vehicle ground. This additional ground contact can, for example, be connected to the end face of a stator lamination by at least one spring.

[0029] One variant proposes that the stator core be overmolded with insulating material. This allows the slots to be provided with a thinner insulating layer, thereby increasing the cross-sectional area of ​​the slots that can be wound.

[0030] A useful further development of the invention is achieved by contacting and connecting the three phases of the stator winding via overmolded conductive plates. These conductive plates can be easily manufactured by stamping. Typically, individual conductor tracks are connected to each other by webs. In this state, the conductive plate is overmolded, and the layering is fixed by an insulating material. After overmolding, the webs can be cut or stamped out, thereby providing galvanic isolation of the conductor tracks.

[0031] A reduced number of assembly steps can be achieved if the guide vanes of a stator in a previously described brushless motor are integrally formed with insulation displacement contact sections. Such guide vanes can be manufactured simply and with sufficient accuracy using a stamping and bending process.

[0032] To increase contact reliability, one variant provides that at least one, preferably each, connection section is / are connected with two insulation displacement contact sections.

[0033] As an alternative to guide vanes, the three phases of the stator winding of a previously described brushless motor can also be interconnected via a printed circuit board (PCB). PCBs are reliable to manufacture and can be assembled with high precision. Press-fit contacts are preferably used, forming a contact section of the contact elements and being pressed into the PCB.

[0034] As part of a process for manufacturing a previously described stator of a previously described brushless motor, another way to avoid vibration-related failures is to fill the pockets with a tough, elastic, oil-resistant material before inserting the contacts. This oil resistance allows its use as an oil pump motor.

[0035] Alternatively or additionally, the recordings can be filled with gel after contacting as part of a process for manufacturing a previously described stator of a previously described brushless motor.

[0036] The invention is explained in more detail below using exemplary embodiments. The figures show: Fig. 1 Winding diagram of a series circuit according to the state of the art, Fig. 2 a view of a known three-phase stator, Fig. 3 a parallel winding according to the state of the art, Fig. 4 an equivalent series winding according to the state of the art, Fig. 5a a winding diagram of a parallel circuit according to the state of the art, Fig. 5b a wired winding scheme according to Fig. 5a, Fig. 6 a known embodiment of a stator of the brushless motor, Fig. 7 a further representation of the known embodiment, Fig. 8 an enlarged representation of the known design, Fig. 9 a representation of the known embodiment supplemented by a circuit arrangement in the form of a printed circuit board, Fig. 10 the embodiment of the stator according to the invention with contact elements, Fig. 11 a further representation of the embodiment according to the invention, Fig. 12 a first variant of the embodiment according to the invention, Fig. 13 a first embodiment of a guide plate, Fig. 14 a bridge member with contact section Fig. 15 the first embodiment of the guide plate with plastic overmolding, Fig. 16 a second embodiment of a circuit arrangement with a second embodiment of a guide plate, Fig. 17 a representation of the contacting of the stator by guide plates and Fig. 18 an alternative embodiment of a contact element.

[0037] Note: Reference numerals with an apostrophe and corresponding reference numerals without an apostrophe denote identical details in the drawings and the drawing description. These refer to the use in a different embodiment, the prior art, and / or the detail being a variant. For the sake of simplicity, the claims, the introductory description, the list of reference numerals, and the summary contain only reference numerals without an apostrophe.

[0038] Fig. Figure 1 shows a winding diagram of a series circuit according to the state of the art, where the winding is continuously wound with a single winding wire. As can be clearly seen, in all phases A, B, C, the first pole is wound first, then two poles are left unwound, the next pole is wound, two poles are left unwound, and the last pole is wound. In the following phases B, C, only the starting position is shifted; otherwise, the winding is carried out analogously to phase A. Bridging wire sections 26 between the winding wires increase the ohmic losses and do not contribute to increasing the torque. Since the number of turns in series circuits is often in the single digits, the winding resistances increase by more than 10% in some cases. The motor's power output therefore decreases by the same factor. In parallel circuits, on the other hand, the winding resistance only increases by approximately...1-2%, because the number of turns is higher and the connecting sections are shorter. The large wire diameter in a series connection also has the disadvantage that the bridge wire sections 26 of the wire winding require more space outside the coil space in the yoke area of ​​the stator. Applications where the stator has to be pulled into a housing require additional space for an assembly tool. For this reason, it may be necessary to increase the stator diameter.

[0039] Fig. Figure 2 shows a second view of the known three-phase stator with up to four axially separated bridge wire sections 26. The additional bridge wire sections 26 increase the ohmic resistance and thus reduce the efficiency. The four bridge wire sections also result in a longer motor.

[0040] Fig. Figure 3 shows a known parallel winding and Fig. Figure 4 shows a known equivalent series winding, where the different wire diameters and number of turns are clearly visible. Due to the smaller wire diameter, the parallel winding can be fitted more precisely to the slot than the series winding. This results in a higher copper fill factor and thus higher efficiency. The wire diameter also influences the width of a winding needle, which corresponds to approximately three times the nominal wire diameter. The space required for the winding needle cannot be used as winding space. This is another advantage of the parallel winding. Furthermore, the distance between the poles or the opposing pole shoes can be smaller. The distance d of the parallel connection is significantly smaller than the distance D of the series connection. This also reduces pole sensitivity or cogging torque.The total amount of copper placed in the slots increases by approximately a factor of 1.6 in a parallel winding compared to a series winding. This allows the motors to deliver correspondingly higher torque or, with the same torque, to be built smaller. This reduces weight and increases efficiency. For example, it is possible to shorten the motor, which also reduces the rotor length and thus the moment of inertia. Another advantage of parallel windings is that the winding resistance of the individual coils is higher than in a series connection. This makes contact resistances at the junctions less critical relative to the winding resistance.

[0041] Fig. Figure 5a shows a winding diagram of a parallel circuit according to the state of the art, in which winding is carried out from coil to coil without interruption. The length of the connecting wire section can therefore be kept very short. Fig. 5b shows a wired winding scheme according to Fig. 5a.

[0042] Fig. Figure 6 shows a known embodiment of a stator 1 of the brushless motor, with nine stator poles 3, which extend inwards from a stator yoke 2. Each stator pole 3 is wound with a coil 5. All coils 5 together form a stator winding 6. In the circumferential direction, a free space 27 remains between each coil 5 for a winding needle. The stator 1 here consists of a stack of laminations. An insulating element 4 is located on both end faces of the stack of laminations. One of the insulating elements 4 has receptacles 12 for contact elements. An opening 13 in the receptacles 12 allows a connecting section 8 of a winding wire to pass between two coils 5.The connecting section 8 between two spatially adjacent coils 5 runs from a longitudinal side 25 of the first coil to one of the receptacles 12 and from there to a longitudinal side 25 of the second coil, with the two longitudinal sides 25 being directly opposite each other. On the insulating element 4, the connecting section 8 runs through a recess 9 and around a projection 10 and then through the receptacle 12. The receptacle 12 is arranged such that the winding wire cannot be laid in the free space 27.

[0043] Fig. Figure 7 shows a further representation of the known embodiment of the stator 1, the stator yoke 2, the stator poles 3, the coils 5 with their coil longitudinal sides 25, the connecting sections 8 of the winding wire, the receptacles 12, the recesses 9 and the projections 10 in the insulating element 4, and contact elements 11, which have a distal contact section 14 and proximal contact sections 15 (not visible here). The "distal contact section 14" is understood to be the part of the contact element 11 that is further away from the stator 1 than the "proximal contact section 15," which is located closer to the stator 1.

[0044] Fig. Figure 8 shows an enlarged representation of the known embodiment of the stator 1, with the stator yoke 2, the stator poles 3, the insulating element 4, the receptacles 12, the openings 13, the recesses 9, the projections 10, the contact elements 11 with the distal contact sections 14 and the connecting sections 8 of the winding wire.

[0045] Fig. Figure 9 shows a representation of the known embodiment of the stator 1, supplemented by a circuit arrangement in the form of a printed circuit board 20, with the stator yoke 2, the stator poles 3, the insulating element 4, the receptacles 12, the openings 13, the recesses 9, the projections 10, the contact elements 11 with the distal contact sections 14, the connecting sections 8 of the winding wire and a ground contact 21. Conductor traces are arranged on the printed circuit board 20 such that the desired circuit of the coils 5 is achieved.

[0046] Fig. Figure 10 shows the embodiment of the stator 1' according to the invention, the difference being that, in a plurality of connecting sections 8' between two spatially adjacent coils 5', the connection runs from a coil longitudinal side 25' of the first coil to one of the projections 10' and from there to a coil longitudinal side 25' of the second coil 5', and the two coil longitudinal sides 25' are those that are furthest apart. Figure 10 further shows that the connection sections 8' between two spatially adjacent coils 5' extend from a coil longitudinal side 25' of the first coil to one of the projections 10' and from there to a coil longitudinal side 25' of the second coil 5', and that the two coil longitudinal sides 25' are those that are furthest apart. Fig. 10 several screw eyes 24, which are part of a stator yoke 2' and recesses 9' for receiving the connecting sections 8', stator poles 3' and an insulating element 4'. The coils 5' are located radially within a circle 23 and the connecting sections 8' are located radially outside the circle 23.

[0047] Fig. Figure 11 shows a further illustration of the embodiment of the stator 1' according to the invention, comprising the stator yoke 2', the stator poles 3', the insulating element 4', the coils 5', the recesses 9', the projections 10', receptacles 12', and a contact element 11' which has two proximal contact sections 15'. The connecting sections 8' run diagonally but are close to each other. The distance is defined by the depth of the recesses 9' and the height of secondary projections 28' on the insulating element 4'. The position of the contact elements 11' is to be selected such that the wire can be easily routed and the contact elements 11' can be easily overmolded. Therefore, the contacts are preferably aligned parallel to the motor axis.

[0048] Fig. Figure 12 shows a first variant of the embodiment according to the invention, comprising a stator 1", a stator yoke 2", stator poles 3", an insulating element 4", coils 5", connecting sections 8" of the winding wire, recesses 9", projections 10", contact elements 11", receptacles 12", and openings 13". The contact elements 11" here have only a proximal contact section 15 in the form of an insulation displacement profile and are arranged obliquely to a radial. The projections 10" are arc-shaped. The recesses 9" have an increasing height corresponding to an inclined plane from the coil 5" to the receptacle 12", so that the winding wire runs over the connecting section 8" of the adjacent coil pair on the opposite side of the receptacle 12", with both sections crossing but not touching.

[0049] Fig. Figure 13 shows a first embodiment of a guide plate 16, which is an essential component of a wiring arrangement. The guide plate 16 comprises three terminals 22, each integrally formed with arc-shaped connecting conductors 29, 30, 31. Each connecting conductor 29, 30, 31 has three connection sections 32, which are bent relative to the connecting conductors 29, 30, 31. The connecting conductors 29, 30, 31 are connected to one another via webs 33, which serve to simplify handling during the manufacturing process. These webs 33 are cut or punched out after an overmolding process, so that the three connecting conductors 29, 30, 31 are galvanically isolated from one another. The connecting conductors 29, 30, 31 are arranged essentially concentrically with each other.

[0050] Fig. Figure 14 shows an enlarged view of a single contact element 11" with a bridge member 34 having a distal contact section 14''', which has an insulation displacement profile. Together, the bridge member 34 and the contact section 14''' form the contact element 11'''. The bridge member 34 serves to bridge a connecting conductor of the guide plate 16 ( Fig. 13), without touching it. The bridge member 34 can be welded to the connecting section 32 of the guide plate 16.

[0051] Fig. Figure 15 shows a first embodiment of a wiring arrangement 7 with the guide plate 16, the terminals 22 (concealed), the first connecting conductor 29, the second connecting conductor 30, the third connecting conductor 31, the webs 33 and the connection sections 32, a connector housing 35 and a carrier 36. The webs 33 are superfluous after overmolding and are cut off before assembly in the motor.

[0052] Fig. Figure 16 shows a second embodiment of a connecting arrangement 7' with a second embodiment of a guide plate 16', consisting of a first arcuate connecting conductor 29', a second arcuate connecting conductor 30', and a third arcuate connecting conductor 31', wherein the connecting conductors 29', 30', 31' each have several integral bridge members 34' extending radially outwards. Furthermore, the connecting conductors 29', 30', 31' are integrally formed with terminals 22', which are angled at right angles to the connecting conductors 29', 30', 31'. The guide plate 16' is embedded in a support 36'. The bridge members 34' cross adjacent connecting conductors at close intervals; for this purpose, the connecting conductors are arranged at different height levels.The connecting conductors 29', 30', 31' are each arranged in one plane with their one-piece bridge members 34' up to bending edges 19; the connections 22' are of correspondingly different lengths. Two proximal contact sections 15'' are connected to each bridge member 34', which are angled from the side edges of the bridge members 34' and have an insulation displacement contact contour.

[0053] Fig. Figure 17 shows the embodiment of a stator 1''' according to the invention, comprising a stator yoke 2''', stator poles 3''', coils 5''', connecting sections 8''' of the winding wire, an insulating element 4''' with projections 10''' and recesses 9''', the guide plate 16' with the bending edges 19 and the terminals 22'. A support is not shown for clarity. The guide plate 16' includes the connecting conductors 29', 30' and 31' with the bridge members 34' and the proximal contact sections 15''.

[0054] Fig.Figure 18 shows a further embodiment of a contact element 11'''' which is integrally formed with contact hooks as proximal contact sections 15''' and has a distal contact section 14''' which is designed as a press-fit contact. A projection 10''' and a connecting section 8''' are also visible. The contact hooks can be used for welding or clamping the connecting section 8'''. Reference symbol list 1 Stator 2 Stator yoke 3 Stator pole 4 insulating element 5 coil 6 Stator winding 7. Wiring arrangement 8 Connection section 9 Exclusion 10 lead 11 Contact element 12 recording 13 Opening 14 distal contact section 15 proximal contact section 16 guide plate 17 Insulation clamp contact section 18 Insulation clamp contact plates 19 Bending edge 20 circuit boards 21 Ground contact 22 connection 23 radius 24 screw-in mounting eyes 25 Coil length side 26 Bridge wire section 27 Free space 28 Secondary advantage 29 first connecting conductor 30 second connecting conductor 5 31 third connecting conductor 32 Connection section 33 Bridge 34 Bridge element 35 connector housings 36 carriers

Claims

[1] Brushless motor with a permanent magnet rotor and a wound stator (1'), comprising a stator yoke (2') with a plurality of stator poles (3'), an end-face insulating element (4'), a stator winding (6') comprising a plurality of coils (5'), wherein each stator pole (3') is wound with a coil (5'), a connection arrangement (7') for connecting the coils (5') to each other and to electrical terminals (22), wherein a single winding wire without interruption forms all coils (5') of the stator winding (6') and connecting sections (8') between the coils (5'),Each connecting section (8') of the winding wire between two coils (5') runs only between spatially adjacent coils (5') and forms an electrical connection between these coils (5'), and the connecting sections (8') between two spatially adjacent coils (5') are laid exclusively radially outside the coils (5') in recesses (9') and / or around projections (10') of the insulating element (4'). characterized by, that the insulating element (4') has receptacles (12') for contact elements (11') radially outside the coils (5') or a circumcircle (23) bounded by the coils (5') and that in a plurality of connection sections (8') between two spatially adjacent coils (5') the winding wire runs from a coil longitudinal side (25') of the first coil to one of the contact elements (11') and from there to a coil longitudinal side (25') of the second coil (5') and the two coil longitudinal sides (25') are those that are the greatest distance apart. [2] Brushless motor according to claim 1, characterized by , that the two connecting sections (8') of a coil (5') cross each other with their spatially adjacent coils (5') without touching at the crossing point. [3] Brushless motor according to claim 1 or 2, characterized by, that the contact elements (11') are insulation displacement contacts which have a distal contact section (14') and a proximal contact section (15'), wherein a connecting section (8') is directly contacted by the proximal contact section (15') of the contact element (11'). [4] Brushless motor according to claim 3, characterized by , that the receptacles (12') of the insulating element (4') are provided with openings (13') for wire reception and / or wire guidance and the contact elements (11') can be fixed in the receptacles (12') by a plug-in joining process, wherein the distal contact sections (14') are aligned in a position that is optimal for joining, preferably axially. [5] Brushless motor according to claim 1 or 2, characterized by , that the contact elements (11') are welding contacts. [6] Brushless motor according to at least one of the preceding claims, characterized by, that the stator (1') is wound and connected with a three-phase or a five-phase parallel winding or with a bipolar single-phase winding. [7] Brushless motor according to at least one of the preceding claims, characterized by , that the distal contact sections (14') of the contact elements (11') are pressed or soldered into a printed circuit board (20). [8] Brushless motor according to at least one of the preceding claims, characterized by , that the wound stator (1') and the contact elements (11') are overmolded. [9] Stator of a brushless motor according to at least one of claims 1 to 8, characterized by , that the beginning and end of the winding are arranged one above the other or next to each other in the same receptacle (12') and are connected to the same contact. [10] Stator of a brushless motor according to at least one of claims 1 to 8, characterized by, that the beginning and end of the winding are arranged in two different receptacles (12'). [11] Stator according to at least one of claims 9 or 10, characterized by , that an additional ground contact (21) is provided which connects a control electronics to a ground potential, e.g. of a vehicle. [12] Stator according to claim 11, characterized by , that the additional ground contact (21) is connected to the end face of a stator lamination by at least one spring. [13] Stator according to at least one of the preceding claims 9 to 12, characterized by that the stator core is overmolded with insulating material. [14] Stator of a brushless motor according to at least one of claims 1 to 8, characterized by , that the three phases of the stator winding (6') are contacted and interconnected by overmolded guide plates (16). [15] Stator according to claim 14, characterized by, that the guide plates (16) are integral with insulation clamp contact sections (17). [16] Stator according to claim 15, characterized by , that at least one, preferably each, connection section (8') is / are connected to two insulation displacement contact sections (17). [17] Stator of a brushless motor according to at least one of claims 1 to 8, characterized by , that the three phases of the stator winding (6') are interconnected by the circuit board (20). [18] Method for manufacturing a stator according to at least one of claims 9 to 17, characterized by , that the pockets are filled with a tough, elastic, oil-resistant material before the contacts are inserted. [19] Method for manufacturing a stator according to at least one of claims 9 to 17, characterized by , that the recordings (12) are poured with gel after contact.

Images