Contact bridge, contact bridge arrangement and method for assembling the contact bridge arrangement

Abstract

The invention relates to a contact bridge with a conductor rail arrangement (3) comprising a first conductor rail (7) and a second conductor rail (9), and with a connecting element (5), wherein the connecting element (5) mechanically connects the first conductor rail (7) to the second conductor rail (9). According to the invention, the connecting element (5) is detachably connected to the conductor rail arrangement (3).

Description

[0001] The invention relates to a contact bridge according to the preamble of claim 1, a contact bridge arrangement according to claim 7 and a method for assembling the contact bridge arrangement according to claim 8.

[0002] An electric motor for propelling a vehicle is powered by an electric current generated by a pulse inverter. The electric current is introduced into a brush module of the electric motor via a conductor rail assembly of a generic electrical contact bridge and from there into the rotor windings of the electric motor. The conductor rail assembly comprises two copper conductor rails connected by a connecting element of the contact bridge. The conductor rails are connected by the connecting element in such a way that they are spaced apart and encapsulated in the plastic material of the connecting element. For the mechanical and electrical function of the electric motor and pulse inverter assembly, only a predefined distance between the conductor rails is required to ensure sufficient electrical insulation between the two conductor rails.

[0003] The disadvantages of the contact bridge are therefore the higher price per unit and the increased weight due to the connecting element, which is not required for the mechanical and electrical function. Furthermore, there is a risk that a crack may develop in the plastic of the connecting element over time, which could create an undesirable creepage path for electrical current between the two conductor rails.

[0004] CN 215184615 U discloses an integrated device for detecting large currents. CN 215496991 U discloses a rubber-coated battery copper busbar.

[0005] The object of the invention is to provide a contact bridge that is cost-effective, weight-optimized and optimally designed with regard to the electrical insulation of the two conductor rails from each other.

[0006] The problem is solved by the features of the independent claims. Preferred embodiments of the invention are disclosed in the dependent claims.

[0007] The invention proposes a contact bridge with a conductor rail arrangement comprising at least two or more conductor rails, preferably a first conductor rail and a second conductor rail, and a connecting element, wherein the connecting element mechanically connects the conductor rails, preferably the first conductor rail to the second conductor rail. According to the invention, the connecting element is detachably connected to the conductor rail arrangement. The connecting element is thus easily removable after the contact bridge has been assembled. Since the connecting element does not remain connected to the conductor rail arrangement in the installed state, it is sufficient if the connecting element is made of a material that reliably holds the conductor rails in position for a short period.However, a less expensive material can generally be used, since the material of the connecting element – ​​unlike before – does not have to withstand the operational stresses of a vehicle. Furthermore, the connecting element is reusable.

[0008] In an exemplary embodiment, the connecting element can be detachably connected to the conductor rail(s), preferably to both the first and second conductor rail(s), and / or the connecting element can be designed and / or is suitable for and / or connected to the conductor rail(s), preferably to the first and second conductor rail(s), in such a way that the connecting element can be detached from the conductor rail(s), preferably from both the first and second conductor rail(s), without causing damage. In this way, the connecting element is particularly robust and can be manufactured cost-effectively.

[0009] In an exemplary embodiment, the connecting element can be clipped, latched, clamped, and / or, preferably by means of double-sided adhesive tape or an adhesive or adhesive bead, bonded to the conductor rail assembly, and / or the connecting element can be clipped, latched, clamped, and / or, preferably by means of double-sided adhesive tape or an adhesive or adhesive bead, bonded to the conductor rail(s) or all of them, preferably to both the first and second conductor rail. These connection types represent particularly cost-effective connection methods that can be detached with minimal effort.

[0010] Preferably, the connecting element may have a handle tab by means of which the connecting element can be detached from the conductor rail arrangement, preferably from the conductor rails, preferably manually.

[0011] For example, the connecting element can be designed to connect the conductor rails in such a way that the conductor rails are spaced apart from each other by a predefined distance. This ensures sufficient electrical insulation between the conductor rails at all times.

[0012] For example, the connecting element can be designed to connect the first conductor rail to the second conductor rail in such a way that the first conductor rail is spaced a predefined distance from the second conductor rail. This ensures sufficient electrical insulation between the two conductor rails at all times.

[0013] For example, the connecting element can be designed to connect one or all of the conductor rails in such a way that there is no direct connection between the, preferably adjacent, conductor rails and / or that the conductor rails are connected to each other exclusively via the connecting element. During assembly of the contact bridge, an unintentional short circuit cannot occur due to a sufficiently dimensioned air gap between the conductor rails.

[0014] In a preferred embodiment, the connecting element can connect the first conductor rail to the second conductor rail in such a way that there is no direct connection between the first and second conductor rails and / or that the first conductor rail is connected to the second conductor rail exclusively via the connecting element. This prevents an unintentional short circuit during assembly of the contact bridge.

[0015] In an exemplary embodiment, the conductor rails, preferably the first conductor rail and / or the second conductor rail, can be formed by a metal sheet, preferably a copper sheet. In this way, the conductor rails exhibit a particularly low electrical resistance.

[0016] In an exemplary embodiment, the material of the connecting element can be provided, preferably entirely, by plastic or, more preferably, partially comprised of plastic. In this way, the connecting element is particularly robust and can be manufactured cost-effectively.

[0017] For example, the plastic used could be polyethylene. The advantage of polyethylene is that it is a particularly cost-effective plastic.

[0018] The invention further proposes a contact bridge arrangement with an inverter, preferably of a motor vehicle, an electric machine, preferably of a motor vehicle, and a conductor rail arrangement as described above, wherein the conductor rail arrangement electrically connects the inverter to the electric machine.

[0019] For example, it can be provided that in the contact bridge arrangement the contact bridge is free from the connecting element.

[0020] The invention further proposes a method for assembling a contact bridge arrangement as described above, comprising a provisioning step in which an inverter, an electric motor, and a contact bridge as described above are provided, and a pre-assembly step in which the conductor rail arrangement of the contact bridge is electrically connected to the inverter and electrically to the electric motor. The assembly method includes a final assembly step in which the connecting element of the contact bridge is detached from the conductor rail arrangement, preferably non-destructively. The connecting element is thus easily removed after the contact bridge has been assembled. Since the connecting element does not remain connected to the conductor rail arrangement in the installed state, it is sufficient if the connecting element is made of a material that reliably holds the conductor rails in position for a short period.However, a less expensive material can generally be used, since the material of the connecting element – ​​unlike before – does not have to withstand the operational stresses of a vehicle. Furthermore, the connecting element is reusable.

[0021] In an exemplary embodiment of the method, it can be provided that during the final assembly step the connecting element is detached from both the first conductor rail and the second conductor rail, preferably without damage.

[0022] In an exemplary embodiment of the method, it can be provided that the assembly method includes a contact bridge assembly step in which the conductor rails, preferably the first conductor rail and the second conductor rail, are each detachably connected to the connecting element, forming the contact bridge.

[0023] For example, it may be stipulated that the contact bridge assembly step is carried out and / or completed before the provision step and / or before the assembly step and / or before the final assembly step.

[0024] Exemplary embodiments of the invention are explained in more detail below with reference to the attached schematic drawing.

[0025] They show: Fig. 1. A contact bridge in a perspective view, Fig. 2 in a perspective view the contact bridge, wherein a conductor rail arrangement of the contact bridge is connected to electrical terminals of an inverter and to electrical terminals of an electric machine, and Fig. 3 in a perspective view the conductor rail arrangement which is connected to the electrical terminals of the inverter and to the electrical terminals of the electric machine.

[0026] In the Fig. Figure 1 shows an electrical contact bridge 1. The contact bridge 1 has a conductor rail arrangement 3 and a connecting element 5. The conductor rail arrangement 3 is shown here only as an example, consisting of two conductor rails, namely a first conductor rail 7 and a second conductor rail 9. Of course, in this or another embodiment of the contact bridge 1, the conductor rail arrangement 3 can also have three or more conductor rails.

[0027] The first conductor rail 7 and the second conductor rail 9 are each represented here by a copper sheet and each have an L-shape, also for illustrative purposes only. The connecting element 5 is shown here as being made of plastic material for illustrative purposes only.

[0028] The first conductor rail 7 is connected to the second conductor rail 9 via the connecting element 5. For illustrative purposes only, the connecting element 5 is clipped onto both the first conductor rail 7 and the second conductor rail 9 in such a way that the connecting element 5 can be detached from both the first conductor rail 7 and the second conductor rail 9 without damage. The first conductor rail 7 and the second conductor rail 9 extend essentially in a common plane and are spaced apart from each other in this common plane by a predefined distance.

[0029] The first conductor rail 7 has an end on the electric motor side and an end on the inverter side. The end on the electric motor side defines the radial outward boundary of a mounting hole 11 associated with the first conductor rail 7. The end on the inverter side defines the radial outward boundary of a mounting hole 13 associated with the first conductor rail 7.

[0030] The second conductor rail 9 has an end on the electric motor side and an end on the inverter side. The end on the electric motor side defines the radial outward boundary of an electric motor-side mounting hole 15 associated with the second conductor rail 9. The end on the inverter side defines the radial outward boundary of an inverter-side mounting hole 17 of the second conductor rail 9.

[0031] Based on the Fig. 2 and Fig. Section 3 below describes a method for assembling a contact bridge arrangement 19. The method comprises a contact bridge assembly step, a provisioning step, a pre-assembly step, and a final assembly step. The final assembly step is performed only after the pre-assembly step has been completed.

[0032] During the contact bridge assembly step, as described in Fig. As shown in Figure 2, the contact bridge 1 is first mounted. The first conductor rail 7 and the second conductor rail 9 are each temporarily and / or provisionally connected to the connecting element 5 in a non-destructive manner, here only by means of an example using a clip connection, thus forming the contact bridge 1, as shown, for example, in Fig. 1 is shown.

[0033] In the provisioning step, the contact bridge 1, an inverter formed by a pulse inverter, and an electric machine formed by a separately excited synchronous machine are provided. Subsequently, in the pre-assembly step, the conductor rail assembly 3 of the contact bridge 1 is electrically connected to the inverter and the electric machine. For this purpose, a screw is passed through the mounting hole 11 on the electric machine side and through the mounting hole 13 on the inverter side. One of these screws connects the electric machine-side end of the first conductor rail 7 to a first terminal 21 of the electric machine, and another screw connects the inverter-side end of the first conductor rail 7 to a first inverter terminal 23 of the inverter.

[0034] In addition, a screw is passed through the mounting hole 15 on the electric motor side and through the mounting hole 17 on the inverter side, and the electric motor-side end of the second conductor rail 9 is screwed to a second terminal 25 of the electric motor via one of the screws, and the inverter-side end of the second conductor rail 9 is screwed to a second inverter terminal 27 of the inverter via another of the screws.

[0035] In the final assembly step, the connecting element 5 is then manually and non-destructively detached from the conductor rail assembly 3, that is, from both the first conductor rail 7 and the second conductor rail 9. For this purpose, the connecting element 5 has a gripping tab 29, via which a release force can be applied to detach the connecting element 5 from the conductor rails 7 and 9. As shown in the Fig. As shown in Figure 3, only the conductor rail assembly 3, which is electrically connected to both the electric motor and the inverter, is part of the contact bridge 1. The connecting element 5, on the other hand, is removed during the final assembly step and can be reused for the assembly of further conductor rail assemblies, if necessary. LIST OF REFERENCE SYMBOLS: 1 contact bridge 3 conductor rail arrangement 5 Connecting element 7 first conductor rail 9 second conductor rail 11 mounting holes on the side of the electrical machine 13 inverter-side mounting holes 15 mounting holes on the side of the electrical machine 17 inverter-side mounting holes 19 contact bridge arrangement 21 First connection of the electric machine 23 first inverter connection 25 second connection of the electric machine 27 second inverter connection 29 Handle tab QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] CN 215184615 U

[0004] CN 215496991 U

[0004]

Claims

[1] Contact bridge comprising: a conductor rail arrangement (3) comprising a first conductor rail (7) and a second conductor rail (9), and a connecting element (5), wherein the connecting element (5) mechanically connects the first conductor rail (7) to the second conductor rail (9), characterized by , that the connecting element (5) is detachably connected to the conductor rail arrangement (3). [2] Contact bridge according to claim 1, characterized by that the connecting element (5) is detachably connected to both the first conductor rail (7) and the second conductor rail (9), and / or that the connecting element (5) is designed and / or suitable for and / or is connected to the first conductor rail (7) and to the second conductor rail (9) in such a way that the connecting element (5) can be detachably removed from both the first conductor rail (7) and the second conductor rail (9) without causing any damage. [3] Contact bridge according to claim 1 or 2, characterized by that the connecting element (5) is clipped, latched, clamped and / or glued to the conductor rail arrangement (3), preferably by means of a double-sided adhesive tape or by means of an adhesive or adhesive trace, and / or that the connecting element (5) is clipped, latched, clamped and / or glued to both the first conductor rail (7) and the second conductor rail (9), preferably by means of a double-sided adhesive tape or by means of an adhesive or adhesive trace. [4] Contact bridge according to one of the preceding claims, characterized bythat the connecting element (5) connects the first conductor rail (7) to the second conductor rail (9) in such a way that there is no direct connection between the first conductor rail (7) and the second conductor rail (9) and / or that the first conductor rail (7) is connected to the second conductor rail (9) exclusively via the connecting element (5). [5] Contact bridge according to one of the preceding claims, characterized by that the first conductor rail (7) is formed by a metal sheet, preferably by a copper sheet, and / or that the second conductor rail (9) is formed by a metal sheet, preferably by a copper sheet. [6] Contact bridge according to one of the preceding claims, characterized by that the material of the connecting element (5) is preferably completely formed from plastic or, preferably partially, comprises plastic. [7] Contact bridge arrangement with: an inverter, an electric machine, and a conductor rail arrangement (3) according to one of the preceding claims, wherein the conductor rail arrangement (3) electrically connects the inverter to the electric machine. [8] A method for assembling a contact bridge arrangement according to claim 7, comprising: a provision step in which an inverter, an electric machine and a contact bridge (1) according to one of claims 1 to 6 are provided, and a pre-assembly step in which the conductor rail arrangement (3) of the contact bridge (1) is electrically conductively connected to the inverter and electrically conductively to the electric machine, wherein the assembly method comprises a final assembly step in which the connecting element (5) of the contact bridge (1) is detached from the conductor rail arrangement (3), preferably in a non-destructive manner. [9] Method according to claim 8, characterized bythat in the final assembly step the connecting element (5) is detached from both the first conductor rail (7) and the second conductor rail (9), preferably non-destructively. [10] Method according to claim 8 or 9, characterized by that the assembly method comprises a contact bridge assembly step in which the first conductor rail (7) and the second conductor rail (9) are each detachably connected to the connecting element (5), specifically to form the contact bridge (1).

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