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 6 and a method for assembling the contact bridge arrangement according to claim 7.

[0002] An electric machine for driving a vehicle is supplied with electrical current generated by a pulse-controlled inverter. The electrical current is introduced into a brush module of the electric machine via a conductor rail arrangement of a generic electrical contact bridge and from there passed on to the rotor windings of the electric machine. The conductor rail arrangement has two copper conductor rails that are connected to one another via a connecting element of the contact bridge. The conductor rails are connected to one another via the connecting element in such a way that the conductor rails are spaced apart from one another and encapsulated in the plastic material of the connecting element. For the mechanical and electrical function of the arrangement consisting of the electric machine and the pulse-controlled inverter, only a predefined distance between the conductor rails is required to ensure sufficient electrical insulation between the two conductor rails.

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

[0004] An integrated device for detecting high currents is known from CN 215184615 U. CN 215496991 U discloses a rubber-coated battery copper rail. DE 10 2017 126 010 B4 discloses a plurality of motor drive units connected to one another by detachable connecting elements. The subsequently published DE 10 2022 213 329 A1 describes a busbar device for contacting a first contact and a second contact arranged fixedly with respect to the first contact.

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

[0006] This object is achieved by the features of the independent claims. Preferred developments of the invention are disclosed in the subclaims.

[0007] According to the invention, a contact bridge is proposed with a conductor rail arrangement which has at least two or more conductor rails, preferably a first conductor rail and a second conductor rail, and with 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 installed. Since the connecting element does not remain connected to the conductor rail arrangement when installed, it is sufficient if the connecting element is made of material that reliably holds the conductor rails in position for a short time.On the other hand, a more cost-effective material can 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 can be reused multiple times.

[0008] According to the invention, it is provided that the connecting element is detachably connected to the first conductor rail and also to the second conductor rail, and that the connecting element is designed and / or suitable and / or connected to the first conductor rail and to the second conductor rail in such a way that the connecting element can be detachable from the first conductor rail and also from the second conductor rail without causing damage. In this way, the connecting element is particularly robust and can be produced cost-effectively. According to the invention, it is proposed that the connecting element connects the first conductor rail to the second conductor rail in such a way that the first conductor rail is spaced from the second conductor rail by a predefined distance. In this way, sufficient electrical insulation between the two conductor rails is always guaranteed.

[0009] In an exemplary embodiment, it can be provided that the connecting element is clipped, latched, clamped, and / or bonded to the conductor rail arrangement, preferably by means of a double-sided adhesive tape or by means of an adhesive or adhesive trace, and / or that the connecting element is clipped, latched, clamped, and / or bonded to the or all conductor rails, preferably both to the first conductor rail and to the second conductor rail, preferably by means of a double-sided adhesive tape or by means of an adhesive or adhesive trace. These connection types represent connection types that can be produced particularly cost-effectively and released with little effort.

[0010] Preferably, it can be provided that the connecting element has a grip tab by means of which the connecting element can be detached, preferably manually, from the conductor rail arrangement, preferably from the conductor rails.

[0011] For example, the connecting element can connect the first conductor rail to the second conductor rail in such a way that the first conductor rail is spaced apart from the second conductor rail by a predefined distance. This ensures sufficient electrical insulation between the two conductor rails at all times.

[0012] For example, the connecting element can connect the or all 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. Thus, an inadvertent short circuit cannot occur during installation of the contact bridge due to a sufficiently dimensioned air gap between the conductor rails.

[0013] 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 conductor rail and the second conductor rail 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 from occurring during installation of the contact bridge.

[0014] In an exemplary embodiment, it can be provided that the conductor rails, preferably the first conductor rail and / or the second conductor rail, are formed from a metal sheet, preferably a copper sheet. In this way, the conductor rails have a particularly low electrical resistance.

[0015] In an exemplary embodiment, the material of the connecting element can be made, preferably entirely, of plastic or, preferably partially, of plastic. This allows the connecting element to be manufactured particularly robustly and cost-effectively.

[0016] For example, the plastic may be polyethylene. The advantage of polyethylene is that it is a particularly cost-effective plastic.

[0017] According to the invention, a contact bridge arrangement is further proposed 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.

[0018] For example, it can be provided that in the contact bridge arrangement the contact bridge is free of the connecting element.

[0019] According to the invention, a method for assembling a contact bridge arrangement as described above is further proposed, comprising a provision step in which an inverter, an electric machine, 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 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 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 when installed, it is sufficient if the connecting element is made of material that reliably holds the conductor rails in position for a short time.On the other hand, a more cost-effective material can 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 can be reused multiple times.

[0020] In an exemplary embodiment of the method, it can be provided that in the final assembly step the connecting element is detached from both the first conductor rail and the second conductor rail, preferably in a non-destructive manner.

[0021] In an exemplary embodiment of the method, it can be provided that the assembly method comprises 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, specifically to form the contact bridge.

[0022] For example, it can be provided 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.

[0023] Embodiments of the invention are explained in more detail below with reference to the attached schematic drawing.

[0024] They show: Fig. 1 in a perspective view a contact bridge, Fig. 2 shows a perspective view of 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.

[0025] In the Fig. 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 formed here merely by way of example by two conductor rails, namely a first conductor rail 7 and a second conductor rail 9. Of course, the conductor rail arrangement 3 can also have three or more conductor rails in this or another embodiment of the contact bridge 1.

[0026] The first conductor rail 7 and the second conductor rail 9 are each formed, for example, from a copper sheet and each have an L-shape, also for example only. The connecting element 5 is made of plastic material, for example only.

[0027] The first conductor rail 7 is connected to the second conductor rail 9 via the connecting element 5. For example 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 removed non-destructively from both the first conductor rail 7 and the second conductor rail 9. The first conductor rail 7 and the second conductor rail 9 extend essentially in a common plane and are spaced apart from each other by a predefined distance in the common plane.

[0028] The first conductor rail 7 has an electric machine-side end and an inverter-side end. The electric machine-side end radially outwardly delimits a fastening bore 11 on the electric machine side assigned to the first conductor rail 7. The inverter-side end radially outwardly delimits a fastening bore 13 on the inverter side assigned to the first conductor rail 7.

[0029] The second conductor rail 9 has an electric machine-side end and an inverter-side end. The electric machine-side end radially outwardly delimits an electric machine-side mounting hole 15 associated with the second conductor rail 9. The inverter-side end radially outwardly delimits an inverter-side mounting hole 17 of the second conductor rail 9.

[0030] Based on the Fig. 2 and Fig. 3, a method for assembling a contact bridge assembly 19 is described below. The method comprises a contact bridge assembly step, a preparation step, a pre-assembly step, and a final assembly step. The final assembly step will be performed only after the pre-assembly step has been completed.

[0031] During the contact bridge assembly step, as shown in Fig. 2, the contact bridge 1 is first mounted. In this case, the first conductor rail 7 and the second conductor rail 9 are each detachably and non-destructively connected to the connecting element 5, here merely by way of example by means of a clip connection, and specifically to form the contact bridge 1, as shown, for example, in Fig. 1 is shown.

[0032] During the provision step, the contact bridge 1, an inverter formed by a pulse-controlled inverter, and an electric machine formed by a separately excited synchronous machine are provided. Subsequently, during the pre-assembly step, the conductor rail arrangement 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 electric machine-side fastening hole 11 and through the inverter-side fastening hole 13, and the electric machine-side end of the first conductor rail 7 is screwed to a first connection 21 of the electric machine using one of the screws, and the inverter-side end of the first conductor rail 7 is screwed to a first inverter connection 23 of the inverter using another of the screws.

[0033] In addition, a screw is passed through the electric machine-side fastening hole 15 and through the inverter-side fastening hole 17, and the electric machine-side end of the second conductor rail 9 is screwed to a second connection 25 of the electric machine using one of the screws, and the inverter-side end of the second conductor rail 9 is screwed to a second inverter connection 27 of the inverter using another of the screws.

[0034] During the final assembly step, the connecting element 5 is subsequently detached from the conductor rail arrangement 3, i.e., from both the first conductor rail 7 and the second conductor rail 9, manually and non-destructively. For this purpose, the connecting element 5 has a grip 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, forms part of the contact bridge 1. The connecting element 5, however, is removed during the final assembly step and can be reused for the assembly of additional 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 Electric machine side mounting hole 13 Inverter-side mounting hole 15 electrical machine side mounting hole 17 Inverter-side mounting hole 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 Grip tab

Claims

[1] Contact bridge with: 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), wherein the connecting element (5) is detachably connected to the conductor rail arrangement (3), and wherein the connecting element (5) 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 detached from both the first conductor rail (7) and the second conductor rail (9) without causing any damage, characterized by , that the connecting element (5) connects the first conductor rail (7) to the second conductor rail (9) in such a way that the first conductor rail (7) is spaced from the second conductor rail (9) by a predefined distance. [2] Contact bridge according to claim 1, 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. [3] Contact bridge according to one of the preceding claims, characterized by that 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). [4] Contact bridge according to one of the preceding claims, characterized bythat 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. [5] 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. [6] 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. [7] Method for assembling a contact bridge arrangement according to claim 6, comprising: a provision step in which an inverter, an electric machine and a contact bridge (1) according to one of claims 1 to 5 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. [8] Method according to claim 7, characterized by that 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. [9] Method according to claim 7 or 8, characterized bythat 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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