Electric motor for a motor vehicle

Abstract

The invention relates to an electric motor (2) for a motor vehicle, comprising a motor housing (4), an electronic unit (8) arranged at the end face of the motor housing (4), wherein a number of phase connections (42, 70, 121) are led from the motor housing (4) into the electronic unit (8), a printed circuit board assembly (34) of the electronic unit (8) as a control unit for the electric motor (2), and a cable harness connection (12) of the electronic unit (8) for a cable harness (10), wherein the cable harness connection (12) is designed for plug-in contact with the cable harness (10).

Description

The invention relates to an electric motor for a motor vehicle. The invention relates in particular to an improved concept for maintenance, service or repair work on an electronic motor system and / or a cable harness connected to the electric motor.In a modern motor vehicle, electric machines are used in a variety of ways as (adjusting) drives for different actuating elements. Electric machines are used, for example, as window lifter, sliding roof or seat adjustment drives, as steering drives (EPS, Electrical Power Steering), as brake drives, as pump drives, as radiator fan drives or as gear actuators. Furthermore, electric machines are used, for example, as (traction) drives in electrically driven or drivable vehicles, having two, three, or four wheels.An in particular brushless electric motor as an electric (three-phase) machine usually has a stator provided with a field or stator winding, which is arranged coaxially with respect to a rotor having one or more permanent magnets. Both the rotor and the stator are constructed, for example, as laminated cores, wherein stator teeth carry the coils of the stator winding in intermediate stator slots.In a brushless electric motor, the alternating current provided for feeding the stator winding is usually generated by a converter (inverter). This converter, together with associated control electronics, is frequently arranged on a printed circuit board and accommodated in an electronics compartment which is integrated into the motor housing.The electronics compartment has, for example, a housing connection region in the form of an electrical interface for electrically contacting the electronics. The interface is provided and configured to contact the electronics to a vehicle electrical system or to a (vehicle) electrical system. The interface, also referred to below as cable harness connection, has current contacts for supplying the electric motor or the electronics with a current and signal contacts for connecting the electronics to a signal or communication line, in particular a bus line, for example a CAN bus line.The integration design for electric motors, in which the circuit board is integrated into the electronics compartment of the motor housing, complicates maintenance, repair, and service operations on the internal circuit board due to assembly limitations.For example, the printed circuit board is regularly fixed firmly in the electronics compartment at various points by screw connections. In particular, the printed circuit board is frequently also contacted with the phase contacts of the stator winding by means of phase contact screws. Furthermore, the connections to the cable harness are generally mounted from the interior of the engine. The signal connection (CAN connection) provided in the cable harness is also directly connected to plug connectors (for example. Ern) of the printed circuit board. Therefore, in order to remove the circuit board or the wire harness, it is often necessary to completely disassemble both components. Maintenance or replacement of the cable harness and / or of the printed circuit board assembly is therefore not possible in the installed state.Any damage to the circuit board during transport or during operation thus renders the complete motor unit unusable. In such cases, the circuit board used as a motor control unit needs to be removed and replaced / remachined. Further, replacement of the wire harness with respect to different cable specifications is not possible in consideration of design and mounting constraints.The object of the invention is therefore to specify a particularly suitable electric motor for a motor vehicle, which is improved in particular with regard to maintenance, repair or service work. In particular, a concept is to be specified of how the printed circuit board assembly can be removed from the electric motor without interrupting the internal connections.The object is achieved according to the invention with the features of claim 1. Advantageous embodiments and developments are the subject matter of the dependent claims (dependent claims).The electric motor according to the invention is provided for a motor vehicle and is suitable and configured for this purpose. The electric motor is preferably a drive or traction motor, wherein the motor vehicle is in particular an electrically driven or drivable motor vehicle, for example an electric or hybrid vehicle, having two, three or four wheels.The brushless electric motor, in particular, has a stator and a rotor. The stator is equipped with a polyphase stator winding or rotating field winding which has a number of phase contacts corresponding to the number of phases. The rotating field winding is, for example, of three or six-phase design. The stator and the rotor are arranged in a motor housing.An electronics unit is arranged on the end face of the motor housing, wherein the phase contacts of the stator winding are guided from the motor housing into the electronics unit.The electronics unit here has a printed circuit board assembly which is contacted by the phase contacts as a control unit or (motor) control unit (MCU; Electronic Control Unit, ECU). The printed circuit board assembly has a printed circuit board or printed circuit board as a circuit carrier, which is equipped with a converter circuit or inverter circuit and with a controller. In order to energize the stator winding, the intermediate circuit of the inverter circuit can be connected to a direct current circuit of an on-board power supply system by means of a cable harness. For this purpose, the electronic unit has a cable harness connection for a corresponding cable harness. The cable harness has in particular two power lines (HV+, HV-) for a power supply and at least one signal line for connection to a signal bus or vehicle bus, in particular a CAN bus (CAN: controller area network).According to the invention, the cable harness connection is at least partially designed for plug-in contact with the cable harness or a cable harness plug. Here, "designed at least partially for plug-in contact" is to be understood in particular as meaning that at least one connection of the cable harness plug, i.e. the power connection for the power lines and / or the signal connection for the signal / bus line, is designed for plug-in contact. This realizes a particularly suitable electric motor.The conjunction "and / or" is to be understood here and below in such a way that the features linked by means of this conjunction can be formed both jointly and as alternatives to one another.The electric motor concept according to the invention enables a service concept for electric motors which have an integrated printed circuit board assembly and are connected to a cable harness for the power supply and CAN communication. Service, maintenance and repair work on the electric motor electronics is simplified by the plug connection of the contact beam connection. The proposed concept can be realized with a combination of different types of plug connectors as well as wire connections within the printed circuit board for each type of electric motor, in this case especially for a traction motor.According to the invention, the printed circuit board assembly and the cable harness connection for the power supply and the CAN communication signal are connected to the motor assembly in such a way that the respective assembly process is completely independent of other assembly processes and also independent of one another. The aforementioned concept of the assembly process converts the entire assembly of circuit board and cable harness into a functional unit.The utility capability of the present invention is a combination of removal and replacement / reassembly of the circuit board assembly and the motor assembly wiring harness. Preferably, a completely independent assembly process is implemented which optimizes design to facilitate access for maintenance. In order to remove the printed circuit board assembly from the electric motor or phase contacts, it is not necessary to remove all other mounted components that are not directly connected to the printed circuit board. The inventive concept thus eliminates dependencies on other components that are not directly connected to the circuit board or cable harness mounting.The plug connections improve the assembly process and the accessibility to the circuit board assembly and to the cable harness at any point in operation. The mentioned serviceability can also be used in vehicle-mounted motors without removing the motor or the motor housing from the mounting location.The electric motor concept according to the invention includes in particular an assembly process of the electronic unit as a slide-fit or sandwich-press-fit assembly, so that no further additional processes are required for connection to the respective interface.The electric motor concept according to the invention further enables a modular configuration such that both the circuit board assembly module and the cable harness can be packaged separately and independently, and can be sold independently to complete the electric motor when viewed as a component to be maintained. Thus, the same electric motor can meet different power specifications simply by changing the cable specifications for the power terminals.In a first embodiment of the invention, the electronics unit is designed for plug-in mounting. The electronics unit has an insertion compartment formed integrally on the motor housing, i.e. in one piece or monolithically. The insertion compartment has an end-face or lateral insertion opening for an insertion carrier in which the printed circuit board assembly is arranged. The cable harness connection is here integrated into the plug-in carrier. In the assembled state, the insert carrier is inserted into the insert compartment along an insertion direction. This allows simple assembly and disassembly of the electronic unit.In a suitable development, the insert carrier has a flange plate on the end face for screw fastening to the insert compartment, wherein the cable harness connection is integrated into the flange plate. In the assembled state, the insertion opening of the insertion compartment is closed by the flange plate. The flange plate is thus designed as a cover plate.In a preferred embodiment, the phase contacts projecting into the electronics compartment are designed as vertically projecting contact lugs. The phase contacts of the stator winding are guided through a motor-side base of the plug-in compartment. The phase contacts are distributed and staggered in this case, so that when the insert carrier is inserted along the insertion direction, each phase contact can be plug-contacted without collision with an associated phase connection of the insert carrier or the printed circuit board.Here and in the following, the printed circuit board-side (phase) mating contacts for the stator-side phase contacts are referred to in particular as phase connections. The phase contacts are connected to the stator windings, wherein the phase connections are contacted to the printed circuit board assembly.The phase contacts are arranged distributed along the insertion direction and are each arranged offset with respect to one another in an offset direction oriented transversely to the insertion direction. The plug-in carrier or the printed circuit board assembly has a number of plug-in socket-like phase connections which are matched to the distribution or offset dimension of the phase contacts and are in contact with the printed circuit board assembly.The phase terminals are here, for example, substantially U- or C-shaped and are open in the insertion direction, so that the contact lugs of the phase contacts slide during insertion into the receptacles of the phase terminals, and thus implement plug-in contact with the printed circuit board assembly. This realizes a particularly simple and cost-reduced contacting of the stator phases, in which only the insert carrier is inserted into the insert compartment. The contacting can be easily removed by pulling out the insert carrier for maintenance, service and repair work.In a second embodiment, the electronics unit is designed for sandwich press-fit mounting. For this purpose, the electronics unit has an electronics compartment with a compartment base formed integrally onto the motor housing and a cooling cover joined thereto, wherein the printed circuit board assembly is arranged in the mounting space formed between the compartment base and the cooling cover. On a circuit board top side of the circuit board assembly facing the cooling cover, an upstanding connection assembly with the cable harness connection is arranged.The cooling cover has a window-like recess which, in the assembled state, is at least partially penetrated by the connection assembly, in particular the cable harness connection. The cable harness connection is thus arranged on an upper side of the cooling cover and is therefore particularly easily accessible.In a suitable development, the connection assembly protrudes beyond an edge of the printed circuit board assembly. The connection assembly thus stands up from the edge of the printed circuit board assembly. The connection assembly has phase connections for contacting the phase contacts on an underside of the protruding region facing the compartment base. The connection assembly thus has both the cable harness connection and the contact points for the phase contacts.The phase contacts are in this case in particular designed in the form of sockets of a phase contact adapter, and are arranged in axial alignment below the phase connections. In an expedient embodiment, the phase connections have upstanding contact pins or contact bolts which are inserted or pressed into the plug-in or contact sockets of the phase contact adapter.In a preferred embodiment, the connection assembly is held in a sandwich-like manner between the cooling cover and the contact bushes of the phase contact adapter. In particular, the sandwich-like mounting ensures reliable and reliable contacting of the phase contacts and phase connections.In a third embodiment, the electronics unit has a base (base plate) arranged in the motor housing and a heat sink module covering the latter. The heat sink module has a plate-like mounting carrier with a (mounting) carrier lower side facing the base and a (mounting) carrier upper side facing away from the base. The printed circuit board assembly is arranged on the carrier top side and connected to phase connections on the carrier bottom side by means of busbars integrated into the mounting carrier.The phase contacts are arranged in particular on the base in alignment with the phase connections. The phase terminals and phase 0-series contacts are, for example, screw-contacted to one another from the carrier top side by phase contact screws. The screw contacting of the phase connections is thus accessible from the outside.In one conceivable configuration, the cable harness connection has a communication connection integrated into the mounting carrier on the end face and an integrated power connection which is contacted with the cable harness by means of phase contact screws.Exemplary embodiments of the invention are explained in more detail below with reference to a drawing. Shown therein are: FIG. 1 shows a perspective illustration of an electric motor in a first embodiment, FIG. 2 shows a perspective illustration of an insert carrier of the electric motor, FIG. 3 shows a perspective exploded illustration of the plug-in carrier with a printed circuit board assembly FIG. 4 shows a perspective illustration of the plug-in carrier with the printed circuit board assembly, FIG. 5 shows a perspective illustration of an insertion compartment of the electric motor, FIG. 6 shows a perspective illustration of an assembly of the electric motor, FIG. 7 shows a perspective illustration of the electric motor in a second embodiment, FIG. 8 shows a perspective illustration of a connection assembly of the electric motor, FIG. 9 shows a perspective illustration of the connection assembly with a view of a bottom side, FIG. 10 shows an exploded perspective view of an electronic unit of the electric motor, FIG. 11 shows a perspective illustration of an assembly of the electric motor, FIG. 12 shows a perspective illustration of a detail of the connection assembly in the assembled state FIG. 13 shows a perspective illustration of the electric motor in a third embodiment, FIG. 14 shows a perspective illustration of a mounting carrier of a cooling body module of the electric motor, FIG. 15 shows a perspective illustration of the mounting carrier with a view to a bottom side FIG. 16 shows a perspective exploded illustration of the heat sink module, FIG. 17 shows a perspective illustration of an assembly of the electric motor, and FIG. 18 is a perspective view of a phase contact screw.Parts and sizes corresponding to one another are always provided with the same reference numerals in all figures.FIG. 1 shows a detail of an electric motor 2 as a traction drive for an electrically driven or drivable motor vehicle. The electric motor 2 described in more detail below with reference to FIGS. 1 to 6 has a motor housing 4, in which a stator and rotor, not shown in more detail, are arranged. The rotor is joined to a motor shaft 6 (FIG. 5 ) in a shaft-fixed manner. An electronics unit 8 for operating the electric motor 2 is arranged on the end face of the motor housing 4.The electronics unit 8 has a (first) electrical interface for energizing the motor phases or stator winding of the brushless electric motor 2, and a further (second) electrical interface for connection to a cable harness 10 of a vehicle electrical system.The cable harness-side interface is designed as a cable harness connection 12. The cable harness 10 has two connection contacts 14 with a vehicle battery (KL 30, KL 31) and a connection contact 16 with a bus line (COM), which are connected to corresponding mating contacts 18, 20 of the cable harness connection 12. The cable harness 10 and the cable harness connection 12 are designed here for a plug connection or plug connection. The mating contacts 18, 20 are designed in this embodiment as plug sockets for the connecting contacts 14 designed as plug contacts. The cable harness connection 12 is thus designed as a hybrid connection for the power supply and the signal connection of the electric motor 2.The electronics unit 8 has an insertion compartment 22 formed integrally, i.e. in one piece or monolithically, onto the motor housing 4. The insertion compartment 22 is opened to one side with an insertion opening 24. The plug-in compartment 22 has a compartment base 26, through which axially oriented phase contacts 28 of the motor or stator winding are guided (FIG. 5 ).The electronics unit 8 has, on the housing side facing away from the compartment base 26, a number of upstanding cooling ribs 30, which are provided with reference numerals in the figures merely by way of example.The electronics unit 8 furthermore has an insertion carrier (printed circuit board mounting slide) 32 for a printed circuit board assembly 34 of the electronics unit 8, which can be pushed into the insertion opening 24.The printed circuit board assembly 34 has a printed circuit board 36 as a circuit carrier, which is equipped with a number of electronic components and components. In particular, an inverter circuit for generating a polyphase alternating current for energizing the stator winding, and a controller as a control device, are arranged on the printed circuit board 36. The power switches (power semiconductor switches) of the inverter circuit are arranged on a circuit board top side 38 facing the cooling ribs 30, wherein six phase connections 42 for the phase contacts 28 are provided on a circuit board bottom side 40 facing the compartment base 26.The insert carrier 32 has an approximately rectangular holding frame 44 for the printed circuit board assembly 34 and a flange plate 46 on the end face, which is oriented perpendicularly to the frame plane. The insert carrier 32 is in particular designed as an injection-molded part.The cable harness connection 12 or the counter contacts 18, 20 is integrated into the flange plate 46. The contacts 18, 20 are designed as stamped screens around which the plastic is applied. The contacts 18, 20 are designed here on the circuit board side as bent-up contact lugs 48.During assembly, the printed circuit board assembly 34 is inserted into the holding frame 44 and is screw-fixed to the latter, for example, by means of six fastening screws 50. In this case, the upwardly directed contact lugs 48 engage from below in corresponding openings of the printed circuit board 36 and are contacted on the printed circuit board top side 38, in particular by means of soldering, with the conductor tracks of the printed circuit board 36.The flange plate 46 serves as a cover or closure for the insertion opening 24. the flange plate 46 has for this purpose a circumferential flange collar which abuts the edge of the insertion opening 24 and is joined to the latter by means of six fastening screws 52. The fastening screws 52 are provided with reference numerals in the figures merely by way of example.On the rear side of the flange collar, i.e. on the side of the flange plate 46 facing the interior of the insertion compartment 22, a circumferential sealing element 54 is arranged, which securely and reliably seals the insertion opening 24 in the assembled state.As can be seen, for example, in FIG. 5, the motor shaft 6 engages at least in sections into the insertion compartment 22 through a passage opening of the compartment base 26. On the shaft end side, a transmitter cap 55 with a transmitter magnet is arranged on the motor shaft 6, wherein the printed circuit board assembly 34 has a corresponding magnetic field sensor, in particular a Hall sensor, in order to detect and monitor a position or position of the motor shaft 6 or of the rotor during motor operation.As shown in FIG. 5, in this exemplary embodiment, six phase contacts 28 designed as contact lugs are guided perpendicularly by means of vias 56 through the compartment base 26 into the electronics unit 8.The phase contacts 28 are grouped as two groups of three, wherein the groups are arranged on the opposite long sides of the approximately cuboidal compartment interior. The phase contacts 28 of each group are arranged distributed along an insertion direction E oriented perpendicularly to the flange plate 46 or insertion opening 24 and along a transverse direction (offset direction) oriented perpendicularly thereto. The phase connections 28 arranged further to the rear in the insertion direction E are positioned offset in particular toward a center line of the insertion compartment 22. Viewed from the insertion opening 24, the phase contacts 28 are thus not aligned, but are arranged offset or without overlap with respect to one another.The phase terminals 42 of the printed circuit board assembly 34 are arranged in a complementary manner to the phase contacts 28. For stabilizing the phase connections 42, these are inserted into holding receptacles 58 of the holding frame 44, which are integrally formed on the holding frame 44.The mounting of the electronic unit 8 is shown in FIG. 6. In this case, the insertion carrier 32 equipped with the printed circuit board assembly 34 is inserted into the insertion opening 24 of the insertion compartment 22 along the insertion direction E, and the flange collar 46 is fixed to the insertion compartment 22. In this case, the phase contacts 28 as male plug connectors are plug-connected to the phase terminals 42 acting as female plug connectors. Finally, the cable harness 10 is plug-connected to the cable harness connection 12.The phase terminals 42 are here, for example, substantially U- or C-shaped and are open in the insertion direction E, so that the contact lugs of the phase contacts 28 slide when the insertion compartment 22 is inserted into the receptacles of the phase terminals 42 and thus implement plug-in contact with the printed circuit board assembly 34.The exemplary embodiment of FIGS. 1 to 6 thus implements a push-on printed circuit board assembly 34 using the insert carrier 32 with hybrid cable harness connection 12 for current and signal.A second exemplary embodiment of the electric motor 2 is explained in more detail below with reference to FIGS. 7 to 12.In this embodiment, the electronic unit 8 is designed for sandwich press-fit mounting. For this purpose, the electronics unit 8 has an electronics compartment with a compartment base 60 integrally formed on the motor housing and a cooling cover 62 joined to the latter, wherein the printed circuit board assembly 34 is arranged in the mounting space formed between the compartment base 60 and the cooling cover 62.On the circuit board top side 38 of the circuit board assembly 34 facing the cooling cover 62, a connection assembly 64 with the cable harness connection 12 is arranged, which is shown individually in FIGS. 8 and 9.The connection assembly 64 designed as an injection-molded part has a joining plate 66. The cable harness connection 12 is integrally formed on the upper side of the joining plate, wherein the mating contacts 18, 20 are guided as stamped screens around them onto an underside of the joining plate 66 and said mating contacts project approximately vertically as soldering lugs 67.The cable harness connection 12 is enclosed by an annular sealing element 68, which is arranged on the upper side of the joining plate 66.On the lower side of the rectangular joining plate 66, six phase terminals 70 are arranged in a row distributed along one of the long sides. The phase connections 70 are provided with reference symbols in the figures merely by way of example. The phase connections 70 each have an elongate contact surface from which a, for example, conical contact pin 72 extends. The contact pins 72 are arranged here on the edge of the joining plate 66. Opposite the contact pins 72, the phase connections 70 have contact legs 74 bent up perpendicularly on the contact surface.The connection assembly 64 is arranged on the circuit board top side 38 of the circuit board assembly 34 in the assembled state. The joining plate 66 is inserted in the region of the soldering lugs 67 and contact legs 74 into corresponding receptacles of the printed circuit board 36, wherein in particular the soldering lugs 67 are soldered contacted to the printed circuit board 36. The half of the joining plate 66 having the contact pins 72 projects beyond the edge of the printed circuit board 36.The mating contacts 18, 20 of the cable harness connection 12 are thus placed in a protruding manner on the circuit board top side 38.As can be seen in FIG. 10, for example, the cooling cover 62 has a window-like cutout or passage opening 76 for the cable harness connection 12 and a number of cooling ribs 30. For mounting the electronic unit 8, the connection assembly 64 is first arranged and fixed on the printed circuit board assembly 34. The cooling cover 62 is then placed on the assemblies 34, 64. In this case, the cable harness connection 12 is guided through the cutout 76, wherein the sealing element 68 seals the cutout 76 in a circumferential manner. The assemblies 34, 64, in particular the printed circuit board 36, are screwed to the cooling cover 62 by means of six fastening screws 78 from the printed circuit board bottom side 40.The cooling cover 62 equipped with the assemblies 34, 64 is then placed on the compartment base 60. The six phase contacts 28 are guided by means of a phase contact adapter 80 as a through-connection through the compartment base 60 to six sockets arranged in a row. The sockets or phase contacts 28 are arranged here axially flush with the row of contact pins 72 of the section of the connection assembly 64 protruding from the printed circuit board 36.Between the cooling cover 62 and the compartment base 60 a sealing element 82 is arranged which encloses the assemblies 34, 64 on the outer circumference.For joining the cooling cover 62 to the compartment base 60, six screw tabs 84 protruding at the edge are integrally formed on the cooling cover edge. The screw lugs 84-and thus the fitted cooling cover 62-are screw-fastened to the compartment base 60 or motor housing 4 by means of fastening screws 86. The screw lugs 84 and fastening screws 86 are provided with reference numerals merely by way of example in the figures.When the cooling cover 62 is screw-fastened, the contact pins 72 are inserted or pressed into the sockets of the phase contacts 28. As shown in FIG. 12, the terminal assembly 64 is sandwiched between the cooling cover 62 and the female terminals of the phase contact adapter 80.The electric motor concept shown in FIGS. 7 to 12 thus has a connection assembly 64 with a hybrid connection (power and signal) and sandwich phase contacts 28, 70 for press-fitting.FIGS. 13 to 18 show a third embodiment of the electric motor 2, which is explained in more detail below.In this embodiment, the electronics unit 8 has a base plate 88 inserted into the motor housing 4 and a heat sink module 90 covering the latter. The bottom 88 is surrounded by a circumferential annular wall which has a window-like recess or passage opening 92 on one side.In this embodiment, the harness terminal 12 is configured as a signal terminal 12 aand a power terminal 12 b. The connecting contacts 14 of the cable harness 10 are here integrated into a carrier structure 94 and guided through the passage opening 92, wherein the carrier structure 94 is fastened, in particular screw-fixed, to the annular wall or the motor housing 4.The heat sink module 90 has a plate-like mounting carrier 96, which is shown in more detail in FIGS. 14 and 15.The mounting support 96 has a trough-shaped receptacle 98 with a central recess 100 for the passage of the transmitter cap 55 of the motor shaft 6. The approximately rectangular receptacle 98 is surrounded on three sides by a support surface 102 for the printed circuit board assembly 34. The receptacle 98 and the bearing surface 102 are surrounded on a mounting carrier top side 104 shown in FIG. 14 by a circumferential sealing element 106. Formed radially outside the sealing element 106 are eight upstanding screw domes 108 for receiving phase contact screws 110. The screw domes 108 and phase contact screws 110 are provided with reference numerals in the figures merely by way of example.Embedded or integrated in the mounting carrier 96 is an injection-molded stamped grid 112, which is connected and contacted to the printed circuit board assembly 34 by means of protruding contact sections in the region of the contact surface 102.The stamped grid 112 has, on a mounting carrier underside 114 shown in more detail in FIG. 15, eight exposed contact surfaces 116, which are arranged axially flush with the screw domes 108. The contact surfaces 116 each have a passage opening for a shank 118 of the phase contact screws 110. The contact surfaces 116 are surrounded by a circumferential sealing element 120, which is arranged on the mounting carrier lower side 114.The signal connection 12 ais integrally formed on one side of the mounting carrier top side 104, wherein the mating contact 20 is designed as part of the stamped grid 112. The signal terminal 12 ais flanked by two phase domes 108 as the current terminal 12 b, wherein the contact surfaces 116 arranged underneath form the mating contacts 18. The remaining six contact surfaces 116 form the phase terminals 121FIG. 16 shows a (pre)mounting of the heat sink module 90; in this case, the sealing element 106 is placed on the mounting carrier top side 104. The printed circuit board assembly 34 is then placed on the support surface 102 and connected to the contact sections of the stamped grid 112. Thereafter, a plate-shaped heat sink 122 with cooling ribs 30 as a cover is placed on the printed circuit board assembly 34. From the mounting carrier lower side 114, the mounting carrier 96 is joined to the printed circuit board assembly 34 and the cooling body 122 by means of six fastening screws 124 arranged in a distributed manner. The fastening screws 124 are provided with reference numerals in the figures merely by way of example.The sealing element 106 seals the edge of the cooling cover 122 with respect to the mounting carrier top side 104. The fastening points for the fastening screws 124 are arranged here radially inside the sealing elements 106, 120.FIG. 17 shows an assembly of the electronics unit 8, for which purpose the (pre-assembled) cooling body module 90 is placed with the annular sealing element 120 interposed on the base plate 88 or in the receptacle formed by the encircling annular wall. Six phase contacts 28 are guided through the base plate 88 as screw lugs, wherein the mounting carrier 95 of the heat sink module 90 is placed on the base 88 in such a way that the contact surfaces 116 rest on the screw lugs of the phase contacts 28.The heat sink module 90 is then fastened on the end face of the motor housing 4 from the mounting carrier top side 104 by means of eight fastening screws 126 arranged distributed on the circumference. The fastening screws 126 are provided with reference numerals in the figures merely by way of example.Subsequently, the connecting contacts 14 are inserted through the passage opening 92, so that they are arranged below the contact surfaces 116 or counter contacts 18. The connecting contacts 14 have a threaded bore, not designated in more detail, for the phase contact screws 110. The support structure 94 is fastened by screws to the motor housing 4.Next, the phase contact screws 110 are inserted into the screw domes 108. The phase contact screws 110 shown in more detail in FIG. 18 have the shank 118 with a screw head 128. A disk-like clamping head 130 is arranged around the screw head 128, which clamping head surrounds the screw head 128, which is provided with tool engagement 132, in a radially protruding manner. On the underside of the clamping head 130, a sealing ring 134 is arranged.The phase contact screws 110 are screwed into respectively corresponding threaded bores of the connecting contacts 14 and phase contacts 28, so that a more secure contact contact between the contact surfaces 116 or mating contacts 18 and phase connections 121 is ensured. Finally, cover caps 136 are placed on the end face of the screw domes 108. The covering caps 136 are provided with a reference sign in the figures merely by way of example.The third exemplary embodiment of the electric motor 2 thus has a hybrid heat sink module 90 with a heat sink 122 and with an integrated mounting housing for busbars 112 and CAN connections 12 a.Each of the three embodiments described above improves the maintainability of the circuit board assembly 34 and the wire harness 10 at any point of operation or life.The claimed invention is not limited to the above-described embodiments. Rather, other variants of the invention can also be derived herefrom by the person skilled in the art within the scope of the disclosed claims without departing from the subject matter of the claimed invention. In particular, all individual features described in connection with the various exemplary embodiments can also be combined in another manner within the scope of the disclosed claims without departing from the subject matter of the claimed invention.List of reference characters2 Electric motor 4 Motor housing 6 Motor shaft 8 Electronics unit 10 Cable harness 12 Cable harness connection 12 aSignal connection 12 bCurrent connection 14, 16 Connecting contact 18, 20 mating contact 22 plug-in compartment 24 plug-in opening 26 compartment base 28 phase contact 30 cooling ribs 32 plug-in carrier 34 circuit board assembly 36 circuit board 38 circuit board top side 40 circuit board bottom side 42 phase connection 44 holding frame 46 flange plate 48 contact lug 50 fastening screw 52 fastening screw 54 sealing element 55 transmitter cap 56 through-connection 58 holding receptacle 60 compartment base 62 cooling cover 64 connection assembly 66 joining plate 67 soldering lug 68 sealing element 70 phase connection 72 contact pin 74 contact leg 76 recess 78 fastening screw 80 phase contact adapter 82 sealing element 84 screw tab 86 fastening screw 88 base plate 90 heat sink module 92 passage opening 94 carrier structure 96 mounting carrier 98 receptacle 100 recess 102 contact surface 104 mounting carrier top side 106 sealing element 108 screw dome 110 phase contact screw 112 stamped grid 114 mounting carrier bottom side 116 contact surface 118 shank 120 sealing element 121 phase connection 122 cooling body 124 fastening screw 126 fastening screw 128 screw head 130 clamping head 132 tool holder 134 sealing ring 136 covering cap E insertion direction

Claims

Electric motor (2) for a motor vehicle, having - a motor housing (4), - an electronics unit (8) arranged on the end face of the motor housing (4), wherein a number of phase connections (42, 70, 121) are guided from the motor housing (4) into the electronics unit (8), - a printed circuit board assembly (34) of the electronics unit (8) as a control unit for the electric motor (2), and - a cable harness connection (12) of the electronics unit (8) for a cable harness (10), - wherein the cable harness connection (12) is at least partially designed for plug-contacting with the cable harness (10).Electric motor (2) according to Claim 1, characterized - in that the electronics unit (8) has an insertion compartment (22) which is integrally formed on the motor housing (4), - in that the printed circuit board assembly (34) is arranged in an insertion carrier (32), - in that the cable harness connection (12) is integrated into the insertion carrier (32), and - in that the insertion carrier (32) is inserted into the insertion compartment (22) along an insertion direction (E).Electric motor (2) according to Claim 2, characterized - in that the insert carrier (32) has a flange plate (46) on the end face for screw fastening to the insert compartment (22), and - in that the cable harness connection (12) is integrated into the flange plate (46).Electric motor (2) according to Claim 2 or 3, characterized - in that the phase contacts (28) are guided as vertically upstanding contact lugs through a base (26) of the plug-in compartment (22), - in that the phase contacts (28) are arranged distributed in the plug-in direction (E), - in that the phase contacts (28) are arranged offset with respect to one another in an offset direction oriented transversely with respect to the plug-in direction (E), and - in that the plug-in carrier (32) has a number of phase connections (42) which are contacted with the printed circuit board assembly (34) and which are arranged on the plug-in carrier (32) in such a way that, when being inserted along the plug-in direction (E), each phase connection (42) is plug-contacted with an associated phase contact (28).Electric motor (2) according to Claim 1, characterized - in that the electronics unit (8) has an electronics compartment with a compartment base (60) which is integrally formed on the motor housing (4) and a cooling cover (62) which is joined to the latter, - in that an upstanding connection assembly (64) with the cable harness connection (12) is arranged on a printed circuit board upper side (38) of the printed circuit board assembly (34) which faces the cooling cover (62), and - in that the connection assembly (64) passes through a window-like cutout (76) of the cooling cover (62) at least in sections.Electric motor (2) according to Claim 5, characterized in that the connection assembly (64) projects beyond an edge of the printed circuit board assembly (34), wherein the connection assembly (64) has phase connections (70) for contacting the phase contacts (28) on an underside of the projecting region facing the compartment base (60).Electric motor (2) according to Claim 6, characterized in that the phase connections (70) have upstanding contact pins (72) which are pressed into corresponding contact sockets of a phase contact adapter (80) connected to the phase contacts (28).Electric motor (2) according to Claim 7, characterized in that the connection assembly (64) is held in a sandwich-like manner between the cooling cover (62) and the contact bushes of the phase contact adapter (80).Electric motor (2) according to Claim 1, characterized - in that the electronics unit (8) has a base (88) arranged in the motor housing (4) and a heat sink module (90) covering the latter, - in that the heat sink module (90) has a plate-like mounting carrier (96) having a mounting carrier underside (114) facing the base (88) and a mounting carrier upper side (104) facing away from the base (88), and - in that the printed circuit board assembly (44) is arranged on the mounting carrier upper side (104) and is connected to phase connections (121) on the mounting carrier underside (114) by means of busbars (112) integrated into the mounting carrier (96).Electric motor (2) according to Claim 9, characterized in that the cable harness connection (12) has a signal connection (12a) integrated into the mounting carrier (96) on the end side and an integrated power connection (12b), which is in contact with the cable harness (10) by means of phase contact screws (110).

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