Plug connection for an electric motor of a motor vehicle

Abstract

The invention relates to a plug connection (14) for an electric motor (12) of a motor vehicle (2), comprising a first plug (44) and a second plug (34). The first plug (44) has a first housing (48) having a cup-shaped opening (56) within which a male contact (50) is held. The male contact (50) is plugged into a female contact (66) of a second plug (34), which is circumferentially surrounded by a hollow cylindrical section (62) of a second housing (36) of the second plug (36), which section lies in the cup-shaped opening (56). The invention further relates to an electric motor (12).

Description

[0001] The invention relates to a plug connection for an electric motor of a motor vehicle and to an electric motor for a motor vehicle, comprising a plug connection. The plug connection comprises a first and a second plug.

[0002] Motor vehicles typically have a main drive for propulsion. This includes, for example, an internal combustion engine. If the motor vehicle is a scooter, the internal combustion engine is usually small and designed as a single-cylinder, especially since the power requirement is usually less than 10 kW. To increase efficiency, it is possible to electrify the main drive and thus use an electric motor. An electric motor also reduces noise, especially since the main drive on a scooter usually has comparatively poor sound insulation.

[0003] A brushed commutator motor, for example, is used as an electric motor. However, due to its design, there is direct mechanical contact between the rotor and stator, which creates friction and thus increases heat generation. Wear is also increased. As an alternative, a brushless electric motor can be used. This has a stator arranged in a usually hollow-cylindrical motor housing with several electrical coils that are interconnected to form electrical phases.

[0004] The power generated by the electric motor is determined by the electrical current it carries. Therefore, it is necessary to control or regulate the supplied electrical current, for which purpose a control unit is used. This unit adjusts the speed and / or the power generated by the electric motor accordingly, usually depending on an operation by the vehicle user, such as turning the throttle, for which the electrical current is regulated. To achieve a compact design and a comparatively high level of sealing, the control unit is usually housed in the same housing as the other components of the electric motor, so that they are available as a single module.

[0005] As a result, however, it is necessary to provide different modules of this type for different scooters, each with different power levels, for example, whereby only the electric motor or only the control unit is modified, while the other component remains unchanged. This requires manufacturers and workshops to maintain a relatively large inventory of the various modules. It is also necessary to adapt the housing to the different combinations, preventing the use of identical parts, which increases manufacturing costs.

[0006] The invention is based on the object of specifying a particularly suitable plug connection for an electric motor of a motor vehicle and a particularly suitable electric motor for a motor vehicle, wherein modularity / adaptability is advantageously increased and wherein manufacturing costs are expediently reduced.

[0007] With regard to the plug connection, this object is achieved according to the invention by the features of claim 1 and with regard to the electric motor by the features of claim 10. Advantageous further developments and refinements are the subject of the dependent claims.

[0008] The plug connection is suitable for an electric motor and is particularly intended and configured for this purpose. In other words, the plug connection is thus a component of the electric motor in the assembled state. The electric motor, in turn, is a component of a motor vehicle, preferably a land-based vehicle, in the assembled state. The electric motor is suitable, particularly intended, and configured for this purpose. The electric motor is expediently suitable, provided, and configured to be powered by an on-board electrical system of the motor vehicle, which carries, for example, a direct voltage of 12 V, 24 V, or 48 V.

[0009] The motor vehicle is, for example, a passenger car, a truck, or a bus. For example, the electric motor is a component of an auxiliary unit, such as an electric motor-driven adjustment drive or an electric motor-driven pump. However, the electric motor is particularly preferably a component of a main drive of the motor vehicle. In this case, a speed of travel of the motor vehicle is set, in particular, depending on the current supplied to the electric motor. In this case, the motor vehicle is expediently a two-wheeled motor vehicle, for example a bicycle or, particularly preferably, a motor scooter and thus a so-called e-scooter. Alternatively, in the two-wheeled motor vehicle, the electric motor is used in an adjustment drive or other auxiliary unit.

[0010] The electric motor is, for example, a brushed commutator motor. However, the electric motor is particularly preferably designed to be brushless. The electric motor is preferably a brushless direct current (BLDC) motor and expediently a synchronous motor. The electric motor has a motor housing, within which a stator is preferably arranged. The motor housing is, for example, at least partially hollow-cylindrical or has at least one hollow-cylindrical section, and the stator is preferably also hollow-cylindrical and arranged concentrically with the motor housing. The motor housing is expediently made of a metal, such as aluminum, i.e., pure aluminum or an aluminum alloy.

[0011] The electric motor expediently has a rotor, which is also arranged in the motor housing. The rotor itself is preferably connected to a shaft, which is in particular rotatably mounted. Suitably, the rotor is arranged concentrically to the shaft, which is in particular concentrically arranged to the motor housing and / or the stator. For example, the shaft is rotatably mounted about its axis, which corresponds in particular to a rotor axis, and by means of which an axial direction of the electric motor is defined. In this case, the motor axis is the same as the axis of rotation of the shaft and / or the rotor axis. Preferably, the rotor is circumferentially surrounded by the stator, i.e. in the radial direction of the electric motor.

[0012] The plug connection is used to make electrical contact between two components and is suitable, in particular provided and configured, for this purpose. For this purpose, the plug connection has a first plug and a second plug. These are preferably initially separate, and the electrical connection is in particular not established, i.e. separated, when the two plugs are spaced apart from one another. In contrast, when the two plugs are plugged into one another, the electrical connection is present and expediently the plug connection is created. Preferably, it is possible to fasten the two plugs to one another mechanically, preferably detachably. The electrical connection is thus stabilized, namely when the two plugs are fastened to one another. If the fastening is released, for example, the electrical connection is interrupted, and the plug connection is in particular in a released state.

[0013] The first connector has a first housing. This housing is, for example, constructed in multiple pieces or preferably in one piece, which increases robustness. In particular, the first housing is made of a plastic, for example, by injection molding, which reduces manufacturing costs. Furthermore, the first housing provides electrical insulation, preventing unwanted electrical connections.

[0014] In addition, the first plug has a male contact. This is made of an electrically conductive material, preferably a metal. In particular, the male contact is made of copper, aluminum, an alloy, or, for example, copper-coated aluminum or aluminum-coated copper. This increases electrical conductivity. In particular, the male contact has an effective cross-sectional area, on the basis of which a current-carrying capacity is determined, of between 16 mm2 and 35 mm2, so that a maximum electrical current of, for example, more than 100 A, 150 A, or 200 A can be carried by means of the male contact. Advantageously, a maximum current-carrying capacity is less than 500 A, 400 A, or 300 A. This means that weight and size are not excessively increased.In particular, if the connector is electrically conductive, the electrical current is conducted via the first plug. The current-carrying capacity of the connector is conveniently determined by the male contact.

[0015] The male contact is held in a cup-shaped opening of the first housing, at least in section. In other words, the first housing has the cup-shaped opening within which the male contact is arranged, wherein the male contact is fastened to the first housing such that its position is particularly predetermined. The male contact is suitably located in the center of the cup-shaped opening, which for example has a round cross-section. In this case, the male contact is arranged in particular at the center point of the cross-section. Preferably, the cup-shaped opening and the male contact run concentrically to one another, and the male contact is circumferentially enclosed by a wall of the cup-shaped opening. However, the male contact is always spaced from the wall. The male contact is thus protected by the first housing.

[0016] For example, the male contact protrudes beyond the cup-shaped opening. However, the male contact is particularly preferably at most flush with the end of the cup-shaped opening, in particular the first housing, or is recessed into the cup-shaped opening with respect to the end of the opening. Thus, the male contact is protected, and even if the first connector is handled improperly, it will not be damaged.

[0017] The male contact has in particular a substantially cylindrical shape and is, for example, rounded or touched at the end, in particular at the end opposite the bottom of the cup-shaped opening.

[0018] The second plug has a female contact into which the male contact is plugged, at least when the plug connection is realized or is in a connected state, i.e. when the first and second plugs are electrically contacted with one another. The female contact is preferably made of an electrically conductive material, preferably a metal, in particular the same material as the male contact, so that contact corrosion is avoided. The second plug is suitably designed, at least in sections, as a substantially hollow cylinder, so that the male contact is surrounded by it. The inner diameter of the female contact there is, for example, the same as or slightly smaller than the outer diameter of the male contact, so that a loose fit or an interference fit is realized between the two contacts.In this way, electrical contact is improved and unwanted detachment is avoided.

[0019] Preferably, the female contact is formed by several leaf-spring-like tongues arranged around the axis of the female contact and inclined at least slightly inwardly relative to the axis, at least when the male contact is not mounted. Preferably, the female contact has between two and five such tongues. Due to the inwardly bent free ends of the tongues, they are bent outward upon insertion of the male contact, thus creating a frictional connection. As a result, electrical contact is improved.

[0020] The female contact is surrounded, at least in part, by a hollow cylindrical section of a second housing. The second housing is expediently made of plastic, which electrically insulates the female contact. This prevents unwanted short circuits. For example, the second housing is a plastic injection-molded part, thus reducing manufacturing costs. Alternatively, or in combination, the second housing is made of the same material as the first housing.

[0021] For example, the female contact rests against the inside of the hollow cylindrical section, at least when the male contact is inserted into the female contact. This prevents movement of the female contact and thus also of the male contact and / or deformation, which could otherwise, for example, lead to a disruption of the electrical connection between the contacts. In particular, a clearance fit is realized between the hollow cylindrical section and the female contact, at least in sections and / or temporarily, which facilitates the insertion of the male contact and / or the mounting of the female contact on the second housing.

[0022] For example, if the tongues are present and the male contact is not inserted into the female contact, the free ends of the tongues are spaced from the hollow cylindrical section. However, when the male contact is inserted, the free ends rest against the hollow cylindrical section. Thus, the hollow cylindrical section prevents excessive outward deformation, so that even if the male contact is inserted improperly, none of the contacts are damaged.

[0023] The hollow cylindrical section lies in the cup-shaped opening, at least when the first plug is plugged into the second plug, i.e. when the male contact is plugged into the female contact. Thus, the hollow cylindrical section is also protected by the cup-shaped opening, which increases robustness. In particular, a clearance fit or a press fit is realized between the cup-shaped opening and the hollow cylindrical section, so that any relative movement between them, at least perpendicular to their course, is avoided. Consequently, any relative movement between the two contacts is also avoided, which further increases robustness. In addition, the electrical connection between the two contacts is improved.This also makes it easier to insert the male contact into the female contact because the two housings are guided together, thus preventing misalignment of the male contact with respect to the female contact. In particular, when creating the plug-in connection, i.e. more expediently when plugging the two plugs into each other, mechanical contact is first made between the hollow cylindrical section and the cup-shaped opening, so that the male contact and the female contact are aligned with each other. To establish / release the plug-in connection, the two plugs are preferably moved relative to each other parallel to the path of the male / female contact, so that... Suitably, due to the structural design of the two housings, any other movement is not possible and is, for example, inhibited.

[0024] Such a plug-in connection makes it possible to arrange the control unit separately from the electric motor, and these are electrically connected to one another via the plug-in connection using one or more cables. One of the cables is assigned to one of the plug-in connectors, and the other connector is assigned directly to the control unit, another cable, or preferably directly to the motor housing of the electric motor, and is preferably mechanically attached there. Consequently, it is possible to adapt the control unit and the electric motor separately to the respective motor vehicle, whereby, for example, the electric motor and / or the control unit can each be used for several different motor vehicles. This increases modularity and adaptability. Identical parts can therefore also be used, thus reducing manufacturing costs.Due to the design of the two connectors used to create the plug-in connection, it is mechanically comparatively robust. Furthermore, there is a comparatively large creepage distance between the cup-shaped opening and the hollow cylindrical section, making the ingress of foreign particles and / or liquids relatively unlikely and thus preventable. The plug-in connection preferably meets a specific protection classification, preferably IP 68.

[0025] For example, the first and second housings are simply plugged into one another. This prevents the two plugs from becoming detached from one another, in particular due to friction between the two plugs, preferably between the two housings. However, it is particularly preferred that the first and second housings are fastened to one another, for example by means of a fastening means. This increases robustness. For example, the two housings are screwed together, which increases robustness. Alternatively, they are glued or welded together, for example. This facilitates production and prevents the penetration of foreign particles. However, it is particularly preferred that the first and second plugs are locked together. For this purpose, the first and second housings are preferably locked together.This allows the mechanical connection between the two housings to be established without the need for any additional components or tools, while still ensuring a relatively secure connection between the two housings. This also allows the two housings to be separated from each other, allowing the plug-in connection to be removed.

[0026] For example, one of the housings has a locking tongue and / or snap hook and the other a corresponding undercut. However, it is particularly preferred that a pin running perpendicular to the male contact, and thus also to the female contact, is connected to the outside of the hollow cylindrical section. In particular, the pin is formed onto the hollow cylindrical section and is preferably integral with it. In particular, the second housing is integral and has the pin. The pin lies in a receptacle in the cup-shaped opening. A slot in the cup-shaped opening, running parallel to the male contact, opens into this slot. In particular, the slot runs away from the bottom of the cup-shaped receptacle.

[0027] Thus, when the two plugs are plugged together, the pin is moved through the slot into the receptacle. Preferably, the receptacle has a larger diameter than the thickness of the slot, so that when the pin is in the receptacle, a comparatively large amount of force is required to move it back into the slot and therefore also to detach the two housings from each other. Such a design increases the robustness of both housings, and breakage of the components required to create the snap-in connection is avoided. In particular, this way no lateral overhang is formed, thus preventing the accumulation of foreign particles and / or breakage of these components. Advantageously, several such pins and corresponding receptacles / slots are provided, which increases stability.Ideally, there are exactly two pins / receptacles / slots, which are arranged on opposite sides of the male / female contact. This reduces the space requirement.

[0028] For example, the hollow cylindrical section lies directly against the bottom of the cup-shaped opening, and / or no other components are arranged between them. This allows for comparatively high manufacturing tolerances. However, it is particularly preferred for the hollow cylindrical section to lie against the bottom of the cup-shaped opening at its end via a flat seal. This prevents foreign particles that enter between the edge of the cup-shaped opening and the hollow cylindrical section from penetrating the male / female contact. This further increases tightness and, suitably, achieves a protection classification according to IP 68. Preferably, a locking mechanism is provided, whereby the flat seal is at least partially compressed due to the locking mechanism. This means that it then rests force-fittingly against the bottom and the end faces of the hollow cylindrical section, which improves tightness.In this way, comparatively large manufacturing tolerances are also compensated.

[0029] For example, the first housing is molded onto the male contact, thus creating a direct, integral connection between them. However, the first housing particularly preferably comprises a first retaining opening, which is particularly cylindrical in shape. The first retaining opening opens into the cup-shaped opening, and these are particularly arranged concentrically to one another, but offset from one another along their extension direction / axes.

[0030] For example, the first holding opening is also limited at the end by means of the base of the cup-shaped opening. The male contact also lies in the first holding opening so that it extends through the first holding opening into the cup-shaped opening. For example, a clearance fit and / or a press fit is realized between the first holding opening and the male contact. Preferably, however, a gap is formed between the first holding opening and the male contact so that they do not lie directly against one another there. This gap is filled with a first potting compound. The first potting compound thus creates a material-to-material connection between the first housing and the male contact. This further increases tightness and compensates for manufacturing tolerances. The male contact is expediently attached to the housing by means of the first potting compound.This allows for separate manufacturing of the first housing and the male contact. This also allows for a slight deflection of the male contact relative to the first housing, for which the first encapsulation is elastically deformed. This facilitates insertion into the female contact, for example, if the two are not arranged completely parallel to each other.

[0031] For example, the male contact is rigidly connected to a stamped grid or other connection. However, the male contact is particularly preferably attached to a cable, preferably by crimping. Thus, the cable and the male contact are suitably electrically contacted with one another. In particular, the male contact is formed by means of a stamped and bent part or the like. The cable is preferably inserted into the male contact at the end and pressed there, for example. Thus, the end of the cable is surrounded by the male contact. Preferably, a viewing opening is provided in the male contact, through which it can be checked whether the cable is correctly positioned within the male contact.

[0032] For example, the cable is spaced apart from the first encapsulation. However, it is particularly preferred that the cable end be embedded in the first encapsulation, i.e., the part of the end not embedded in the male contact. Thus, the cable is stabilized to the first housing by means of the first encapsulation, which increases robustness. However, the attachment of the male contact to the cable or to other components, such as the busbar, is also independent of the presence of the first encapsulation and / or the first retaining opening.

[0033] For example, the second housing is molded onto the female contact, thereby creating a direct, integral connection between them. Particularly preferably, however, the second housing has a second retaining opening that opens into the hollow-cylindrical portion. For example, the hollow-cylindrical portion is defined by a base of the second retaining opening. The female contact is suitably located in the second retaining opening. For example, a clearance fit or interference fit is achieved there. Preferably, however, an intermediate space is formed between the edge of the second retaining opening and the female contact, which is filled with a second encapsulation. This also improves sealing. Furthermore, this allows slight movement of the female contact relative to the second housing, for which purpose the second encapsulation is elastically deformed.

[0034] For example, the end of the female contact is placed onto a cable which is at least partially arranged in the second holding opening. However, it is particularly preferred that a press fit be introduced into the female contact on the side opposite the male contact. The female contact is thus electrically contacted by the press fit, which is expediently arranged parallel to the female contact. A press fit is created between the press fit and the female contact, and the press fit is surrounded, in particular in a force-locking manner, by the female contact on the side opposite the male contact. For this purpose, the female contact is suitably designed as a hollow cylinder at that point. In particular, the female contact has a viewing opening there by means of which the correct positioning of the press fit can be checked.On the side opposite the female contact, the press fit has a screw opening, which is particularly parallel to the female contact. This makes it possible to screw a lead frame or the like onto the screw opening and thus electrically connect it to the female contact via the press fit. The press fit thus enables, in particular, a rigid connection to other components of the electric motor.

[0035] For example, the press fit is spaced apart from the second encapsulation. However, it is particularly preferred that it be embedded in the second encapsulation, at least in part. In this way, the press fit is stabilized by the second encapsulation.

[0036] In an alternative embodiment, the presence of the press fit is independent of the presence of the second encapsulation and / or the second retaining opening. In another alternative embodiment, for example, the female contact is directly electrically contacted with a cable or a lead frame, and the second retaining opening and / or the second encapsulation are not present.

[0037] The second housing preferably has a holding section which projects perpendicular to the path of the female contact beyond the hollow cylindrical section and / or the second holding opening, if present. Suitably, the holding section has one or more screw holes and / or a seal is arranged there. This enables a fluid-tight attachment to a motor housing of the electric motor. Preferably, the second housing is attached to the motor housing of the electric motor in the assembled state, and the second housing is suitable, in particular provided and configured, for this purpose. By means of any press fit, electrical contact is made between the female contact and components arranged inside the motor housing. The first plug is preferably arranged outside the motor housing.

[0038] For example, the first plug and the second plug each comprise only a single male / female contact. Preferably, however, they each comprise several such contacts, the number being suitably the same. All contacts are expediently arranged parallel to one another. This thus enables, in particular, the transmission of different electrical potentials / currents between those of the two plugs. Suitably, the first plug has exactly three male contacts and the second plug exactly three female contacts, which, when assembled, lie one inside the other in pairs. Due to the three male / female plugs, it is thus possible to transmit three different phase currents and, in particular, it is possible to supply current to a delta connection of the electric motor by means of such a plug connection if the motor is of brushless design.

[0039] For example, the male / female contacts can be positioned arbitrarily. Preferably, however, a straight line perpendicular to the contacts runs through all male and / or female contacts. Thus, the two connectors are designed like a flattened connector, which facilitates assembly. For example, the cup-shaped openings are spaced apart from each other, which increases sealing. Alternatively, the inner cup-shaped opening(s) merge at least partially into the adjacent cup-shaped openings, thus reducing space requirements.

[0040] When assembled, the electric motor is a component of a motor vehicle and is suitable, in particular intended, and configured for this purpose. The motor vehicle is, for example, a commercial vehicle, such as a truck or bus. Alternatively, the motor vehicle is a passenger car. However, the motor vehicle is particularly preferably a motor scooter, motorcycle, or pedelec / e-bike. For example, the electric motor is a component of an auxiliary unit or, preferably, a component of a main drive.

[0041] The electric motor has a motor housing, which is suitably made of aluminum. In particular, the electric motor comprises a rotor and a stator, which are arranged in the motor housing. Suitably, the stator has a plurality of electromagnets connected to form a plurality of phases, preferably three phases. Furthermore, the electric motor comprises a plug connection with a first plug and a second plug. The first plug has a first housing, which has a cup-shaped opening, within which a male contact is held, which is plugged into a female contact of the second plug. The female contact is surrounded on the circumference by a hollow cylindrical section of a second housing of the second plug, which lies in the cup-shaped opening.

[0042] The second housing is inserted into a mounting opening in the motor housing and fastened thereto, preferably screwed. In other words, the motor housing has the mounting opening through which the second housing extends. If the holding section is present, it expediently rests on the outside of the motor housing. In particular, a seal is arranged between the second housing, in particular the holding section, and the motor housing to prevent the ingress of foreign particles. The female contact is in electrical contact with a conductor arranged in the motor housing. For example, the conductor is a component of a printed circuit board, such as a conductor track, or preferably a lead frame.

[0043] The first connector is arranged outside the motor housing. In particular, the first connector is arranged at the end of a line which comprises a cable. Expediently, the line is connected to a control unit in the assembled state. The control unit is, for example, a component of the electric motor, but is arranged outside the motor housing and expediently spaced therefrom. The control unit is at least one component of an assembly comprising the control unit and the electric motor, which are connected to one another by means of the corresponding line. In particular, the invention also relates to such an assembly. Furthermore, the invention relates only to the first connector of the plug connection and only to the second connector of the plug connection.

[0044] The invention also relates to a motor scooter. The motor scooter has two wheels that, in its intended state, rest on a road. At least one of the wheels is driven by a main drive of the motor scooter. The main drive comprises an electric motor as described above. The electric motor is electrically connected to a control unit of the motor scooter via a cable and the plug connection, and the plug connection expediently supplies current to the stator arranged in the motor housing. Thus, the motor scooter also has the corresponding connection.

[0045] The further developments and advantages explained in connection with the plug connection are also to be transferred analogously to the electric motor / the assembly / each of the plugs / the scooter as well as to each other and vice versa.

[0046] An embodiment of the invention is explained in more detail below with reference to a drawing. In the drawings: Fig. 1 schematically shows a motor vehicle in the form of a scooter, with a main drive comprising an electric motor, Fig. 2 shows in perspective the electric motor, which has a plug connection with a first plug and a second plug, Fig. 3 perspective view of the two plugs in a transparent representation in a released state of the plug connection, Fig. 4 in a side view a male contact of the first connector, Fig. 5 perspective view of a female contact of the second connector, Fig. 6 perspective view of the second connector in a rear view, Fig. 7 perspective view of a mounting opening of a second plug inserted into the motor housing, Fig. 8 perspective view of the plug connection in the released state, and Fig. 9 according to Fig. 8 the plug connection in connected state.

[0047] Corresponding parts are provided with the same reference numerals in all figures.

[0048] In Fig. 1 shows a simplified schematic representation of a motor vehicle 2, namely an electric vehicle, in the form of a motor scooter 4. The motor scooter 4 has two wheels 6, one of which is driven by a main drive 8. The main drive 8 has a system 10 with an electric motor 12, which is a brushless direct current motor (BLDC), and by means of which a transmission (not shown in detail) is driven, which is operatively connected to one of the wheels 6. The electric motor 12 comprises a plug connection 14. A line 16 is connected to the plug connection 14 and extends to a control unit 18 of the system 10. The control unit 18 is thus connected, namely electrically, to the electric motor 12 by means of the line 16 and the plug connection 14.

[0049] The control unit 18 supplies current to the electric motor 12, namely via line 16. For this purpose, the control unit 18 comprises a converter (not shown in detail), and the current is supplied depending on the setting of a throttle grip (not shown in detail) by a user of the motor vehicle 2, to which the control unit 18 is signal-connected. Thus, the electric motor 12 realizes a speed and / or torque corresponding to the setting.

[0050] In Fig. 2 shows a perspective view of the electric motor 12. The electric motor 12 has a motor housing 22 with a substantially pot-shaped housing body 24 made of aluminum. The housing body 24 is closed by means of a substantially flat cover 26. For this purpose, the cover 26 is fastened to the housing body 24 by means of a plurality of mounting screws 28. For this purpose, the mounting screws 28 are guided from the outside of the motor housing 22 through corresponding recesses in outward-facing tabs of the cover 26 and are inserted at the ends into corresponding recesses in the housing body 24 and screwed there. In order to prevent the penetration of foreign particles and moisture between the cover 26 and the housing body 24, a circumferential seal (not shown in detail) is arranged there.

[0051] The housing body 24 has a signal connector 30, to which a signal line (not shown in detail) is connected in the assembled state. Signals detected within the motor housing 22 are routed out of the motor housing 22 via the signal connector 30. The signal connector 30 is integral with the other components of the housing body 24.

[0052] The housing body 24 further comprises a mounting opening 32 into which a second plug 34 of the plug connection 14 is inserted. The second plug 34 is fastened to the housing body 24 and thus to the housing 22. For this purpose, a second housing 36 of the second plug 34, which is manufactured by means of plastic injection molding, has a substantially rectangular / cuboid-shaped holding section 38 that lies flat against an associated outer surface of the housing body 24. The holding section 38 protrudes beyond the mounting opening 32 at the edge, and the holding section 38 has a total of four fastening openings 40 that are associated with the corners of the rectangular / cuboid-shaped holding section 38. A fastening screw 42 is inserted into each of the fastening openings 40 from the side facing away from the housing body 24 and screwed into the housing body 24. The second plug 34 is thus fastened to the motor housing 22.

[0053] The connector 14 further comprises a first plug 44 which can be plugged into the second plug 34 so that the connector 14 has a connected state. Fig. In Figure 2, however, the plug connection 16 is shown in the released state, in which the first plug 44 is spaced apart from the second plug 34. Thus, no electrical contact is established. The first plug 44 is attached to the end of the cable 16, which has three cables 46. Each of the cables 46 is assigned to one of the phases of the electric motor 12, so that a phase current is carried by the plug connection 14 in the assembled state and during operation. The plug connection 14 thus serves as a 3-phase connection for the motor current of the electric motor 12.

[0054] In Fig. Figure 3 shows a transparent illustration of the plug connection 14 in the released state. The first plug 44 has a first housing 48, which is made of the same plastic as the second housing 36, also by injection molding. Each of the cables 46 is assigned a male contact 50 of the first plug 44. Thus, the first plug 44 has a total of three male contacts 50, which are structurally identical to one another.

[0055] As in Fig. 4 in a side view of one of the male contacts 50, each male contact 50 is placed on the end of the respective associated cable 46, which is stripped in the area of direct mechanical contact with the respective male contact 50 so that they are electrically contacted with one another. The male contact 50 is a stamped and bent part and has, at the end opposite the cable 46, a substantial cylindrical section whose end face opposite the cable 46 is chamfered. This section merges into a hollow cylindrical part by means of which the cable 46 is surrounded at the end. A viewing opening 52 is provided in this section, through which the correct seating of the cable 46 can be checked. If this is the case, the cable 46 is pressed there, whereby the cable 46 is attached to the male contact 50 by crimping.

[0056] The hollow cylindrical part and the cylinder are concentric to each other, but offset from each other parallel to their extension. The cylinder has a smaller diameter than the hollow cylindrical part. A circumferential groove 54 is formed in the male contact 50 between the cylinder and the hollow cylindrical part, which engages a groove (not shown in detail) in the first housing 48.

[0057] The first housing 48 has three cup-shaped openings 56, into each of which a cylindrical first holding opening 58 opens. The cup-shaped opening 56 and the first holding openings 58 each have a round cross-section and are arranged concentrically, i.e. parallel, to one another. One of the male contacts 50 is inserted into each first holding opening 58 and the associated cup-shaped opening 56. The cylinder is located in the cup-shaped opening 56, whereas the hollow cylindrical part of the respective male contact 50 is arranged within the associated first holding opening 58. The length of the cylinder of the male contact 50 is the depth of the cup-shaped openings 56. The groove engaging in the first groove 54 is formed by means of a base of the cup-shaped opening 56.

[0058] The three male contacts 50 and thus also the cup-shaped openings 56 are arranged parallel to one another, but offset from one another in the same direction. The middle cup-shaped opening 56 is open at the edge toward the adjacent cup-shaped openings 56, so that all three cup-shaped openings 56 merge into one another. The three first holding openings 58, however, are separated from one another. Between the respective hollow cylindrical parts of each male contact 50 and the wall of the associated first holding opening 58, an intermediate space is formed, which is filled with a first encapsulation 60. The first encapsulation 60 is, for example, an elastomer.

[0059] Thus, each male contact 50 is attached to one of the cables 46, which rests at its end in the respective first potting compound 60. The first housing has the first retaining openings 58, which open into the respective pot-shaped opening 56 and in which the respective male contact 50 rests. The space between each first retaining opening 58 and the respective male contact 50 is filled with the first potting compound 60.

[0060] The length of the hollow cylindrical portion of the male contacts 50 is less than the depth of the first retaining opening 58, so that a portion of the cable 46 also rests at its end in the first encapsulation 60. Due to the first encapsulation 60, the space between the cable 46 and the first housing 48 is sealed, preventing foreign particles and / or liquids from penetrating the cup-shaped opening 56.

[0061] The second housing 36 of the second plug 34 has a region with three hollow cylindrical sections 62 that are arranged parallel but laterally offset from one another and are integrally formed. These sections are arranged on a common side of the cuboid-shaped holding section 38 and perpendicular to it. On the opposite side of the holding section 38, the second housing 36 has three second holding openings 64 that run perpendicular to the holding section 38. One of the second holding openings 64 opens through the holding section 38 into one of the hollow cylindrical sections 62. The pairs formed in this way are concentric to one another, i.e., parallel but offset from one another.

[0062] Each of these pairs is assigned a female contact 66, which are identical to each other, and one of which is Fig. 5 is shown in perspective. The female contact 66 is the stamped and bent part made of the same material as the male contacts 50. The female contact 66 has a first hollow cylindrical tab 68, which is formed by several essentially parallel, resilient tongues that are bent slightly inward at the free end. In the assembled state, the first hollow cylindrical part 68 lies in the associated hollow cylindrical section 62 of the second housing 36, wherein the length of the first hollow cylindrical part 68 is less than the length of the hollow cylindrical section 62. The female contact 50, with the exception of the free end of the tongues, rests against the inner wall of the hollow cylindrical section 62. The inner diameter of the first hollow cylindrical part 68 is, at the free end, less than the outer diameter of the cylinder of the male contacts 50.In the connected state of the plug connection 14 of the cylinder, one of the male contacts 50 is located in the first hollow cylindrical part 68, wherein the insertion is facilitated due to the chamfer. The tongues are bent outwards on the free end so that they rest force-fittingly on the male contact 50.

[0063] The first hollow cylindrical part 68 merges into a second hollow cylindrical part 70, with a circumferential second groove 72 being present between them. A groove (not shown in detail) of the second housing 36 engages into the second groove 72, and the second hollow cylindrical part 70 lies completely within the associated second holding opening 64, wherein the length of the second hollow cylindrical part 70 is less than the depth of the second holding opening 64. The second hollow cylindrical part 70 is spaced from the wall of the respectively associated second holding opening 64, thus forming an intermediate space.

[0064] A press fit 74 is pressed into the second hollow cylindrical part 70. In other words, the associated press fit 74 is inserted into the female contact 66 on the side opposite the male contact 50. This protrudes from the second housing 36 and thus from the associated second holding opening 64, as Fig. 6 in a perspective rear view of the second connector 30.

[0065] The space between each second retaining opening 64 and the respective female contact 66 is filled with a second encapsulation 76, which consists of the same material as the first encapsulation 60. Due to the reduced length of the second hollow cylindrical part 70, the respective press fit 74 also lies in the associated second encapsulation 76. The middle of the three second retaining openings 64 is connected to the two adjacent second retaining openings 64 by a respective gap 77, so that the second encapsulations 76 are molded onto one another.

[0066] In summary, the second housing 36 thus has the second retaining openings 64, into each of which one of the hollow cylindrical sections 62 opens, and in which the respective associated female contact 66 is located. The space between the respective second retaining opening 64 and the associated female contact 66 is filled with the respective second encapsulation 76.

[0067] By means of each press fit 74, an end-open screw opening 78 is formed on the side opposite the respective female contact 66, which is parallel to the course of the press fit 74 and the female contact 66.

[0068] The three second holding openings 64 are surrounded by a seal 80 which is attached to the holder section 38 and which, in the assembled state, rests against the housing body 24, as shown in Fig. 7. The electric motor 12 is shown there, but the cover 26 is not shown. The seal 80 is pressed against the housing body 24 by means of the fastening screws 42, thus preventing the penetration of foreign particles and / or moisture.

[0069] A flat seal 82 made of rubber is arranged on the end faces of the hollow cylindrical sections 62 opposite the holding section 38. The flat seal 82 is located outside the motor housing 22, whereas the pressfits 74 are arranged, at least at their ends, inside the motor housing 22. A conductor 84 in the form of a busbar is screwed to each pressfit 74, thus establishing electrical contact. A screw is screwed into the corresponding screw opening 78.

[0070] The conductors 80 are electrically contacted with electromagnets 86, connected to the three phases, of a hollow-cylindrical stator 88, which is circumferentially surrounded by the pot-shaped housing body 24 and fastened thereto. A cylindrical rotor 90 is circumferentially surrounded by the stator 88 and fastened to a shaft 90, which is rotatably mounted by means of bearings (not shown in detail) and arranged perpendicular to the cover 26. Several permanent magnets are assigned to the rotor 90 and interact with a magnetic field provided by the electromagnets 86 when they are energized via the respective conductors 84 and thus via the second plug 34.

[0071] To bring the plug connection 14 into the connected state, the second plug 34 is inserted into the first plug 44, which is located outside the motor housing 20. In summary, the second housing 36 is inserted into the mounting opening 38 of the motor housing 22 and fastened thereto, wherein the female contacts 66 are electrically contacted with the conductors 84 arranged in the motor housing 22, and wherein the first plug 44 is arranged outside the motor housing 22.

[0072] In Fig. 8 is a perspective view of the plug connection 14 in the released and in Fig. 9 in the connected state. In the released state, the two plugs 34, 44 are spaced apart from one another so that the male contact 50 and the female contacts 66 do not rest against one another and are therefore not electrically contacted. To bring them into the connected state, the hollow cylindrical section 62 is each inserted into one of the cup-shaped openings 56, whereby the two housings 36, 48 are aligned with one another. In this case, the flat seal 82 also dips into the cup-shaped openings 56. Following this, only a movement of the two plugs 34, 44 in a direction parallel to the male contact 50 and female contacts 66 is possible.

[0073] Upon further movement in this direction, the male contacts 50 each engage one of the female contacts 66 and spread the free ends of the tongues of the first hollow cylindrical part 68. Excessive bending, for example if the two housings 36, 48 become jammed, is prevented by the subsequent mechanical engagement of the respective tongue with the associated hollow cylindrical section 62 of the second housing 36. In summary, to transfer the male contacts into the connected state, they are inserted into one of the female contacts 66, namely the respective first hollow cylindrical part 68, which are each circumferentially surrounded by the associated hollow cylindrical section 62 of the second housing 36.

[0074] The insertion is completed when the flat seal 82 rests against the bottoms of the cup-shaped openings 56. The hollow cylindrical sections 62 of the second housing 36 then lie in the cup-shaped opening 56 of the first housing 48, within which the respective male contact 50 is held, as shown in Fig. 9. Consequently, each cable 46 is electrically connected to one of the press fits 74 via the associated male contact 50, which is plugged into the associated female contact 66 and electrically connected thereto.

[0075] To prevent accidental detachment of the two plugs 34, 44, a pin 94 extending perpendicular to the male and female contacts 50, 66 is attached to the outside of each of the two outer hollow-cylindrical sections 62. The two pins 94 lie on a common straight line but point away from each other.

[0076] The first housing 48, namely the two outer cup-shaped openings 56, each have a slot 96 running parallel to the male contacts 50, which opens into a receptacle 98. The receptacle 98 is provided by a round hole whose diameter essentially corresponds to the diameter of the pin 94, but is larger than the thickness of the slot 96.

[0077] When the two plugs 34, 44 are plugged into one another, i.e., when the plug connection 14 is transferred into the connected state, each pin 94 is inserted into one of the slots 96, which is consequently elastically widened. The length of the slots 96 is dimensioned such that the respective pin 94 lies in the receptacle 98 when the flat seal 82 is in force-fitting contact with the bottom of the cup-shaped openings 56, i.e., when the connected state exists. Due to the elastic design, the slots 96 then return to their original thickness. In summary, the pin 94, which runs perpendicular to the male contact 50, is connected to the outside of the two outer hollow-cylindrical sections 62 and lies in one of the receptacles 98 of the respectively associated cup-shaped opening 56, into which the associated slot 96 of the same cup-shaped opening 56, which runs parallel to the male contacts 50, opens.

[0078] Removing the pin 94 from the respective receptacle 98 requires a further elastic deformation of the slots 96, which requires a comparatively large amount of force. Thus, the first and second housings 36, 48 are locked together when the plug connection 14 is in the connected state.

[0079] In such a plug connection 14, the penetration of foreign particles and liquids between the cables 46 via the first retaining openings 58 is prevented by the first encapsulation 60. The penetration of foreign particles or liquids between the two housings 36, 48, namely along the inner wall of the cup-shaped opening 56, is made more difficult by the comparatively tight fit of the hollow cylindrical sections 62, since a type of labyrinth seal is formed here. Penetration to the male and female contacts 50, 66 is then prevented by the flat seal 82. The penetration of liquid into the motor housing 22 between the second housing 36 and the housing body 24 is prevented by the seal 80. Thus, the plug connection 14 meets an IP 68 classification.

[0080] The invention is not limited to the exemplary embodiment described above. Rather, other variants of the invention can also be derived therefrom by those skilled in the art without departing from the scope of the invention. In particular, all individual features described in connection with the exemplary embodiment can also be combined with one another in other ways without departing from the scope of the invention. List of reference symbols 2 motor vehicles 4 scooters 6 wheel 8 Main drive 10 Association 12 electric motor 14 Plug connection 16 Line 18 Control unit 20 Battery 22 Engine housing 24 housing bodies 26 lids 28 Mounting screw 30 Signal connection 32 mounting opening 34 second plug 36 second housing 38 stopping section 40 mounting hole 42 fixing screw 44 first plug 46 cables 48 first housing 50 male contact 52 viewing opening 54 first groove 56 pot-shaped opening 58 first holding opening 60 first casting 62 hollow cylindrical section 64 second holding opening 66 female contacts 68 first hollow cylindrical part 70 second hollow cylindrical part 72 second groove 74 Pressfit 76 second casting 77 gap 78 screw opening 80 Seal 82 Flat gasket 84 ladders 86 Electromagnet 88 Stator 90 rotor 92 Wave 94 cones 96 slot 98 recording

Claims

[1] Plug connection (14) for an electric motor (12) of a motor vehicle (2), with a first plug (44) and a second plug (34), wherein the first plug (44) has a first housing (48) which has a cup-shaped opening (56) within which a male contact (50) is held, which is plugged into a female contact (66) of a second plug (34), which is surrounded on the circumference by means of a hollow cylindrical section (62) of a second housing (36) of the second plug (36) which lies in the cup-shaped opening (56). [2] Plug connection (14) according to claim 1, characterized by that the first and second housings (36, 48) are locked together. [3] Plug connection (14) according to claim 2, characterized bythat on the outside of the hollow cylindrical section (62) a pin (94) running perpendicular to the male contact (50) is connected, which pin lies in a receptacle (98) of the cup-shaped opening (56), into which a slot (96) of the cup-shaped opening (56) running parallel to the male contact (50) opens. [4] Plug connection (14) according to one of claims 1 to 3, characterized by that the hollow cylindrical section (62) rests on the end face against the bottom of the cup-shaped opening (56) via a flat seal (82). [5] Plug connection (14) according to one of claims 1 to 4, characterized by in that the first housing (48) has a first holding opening (58) which opens into the cup-shaped opening (56) and in which the male contact (50) lies, wherein an intermediate space between the first holding opening (58) and the male contact (50) is filled with a first potting compound (60). [6] Plug connection (14) according to claim 5, characterized bythat the male contact (50) is attached to a cable (46) which lies at its end in the first potting (60). [7] Plug connection (14) according to one of claims 1 to 6, characterized by in that the second housing (36) has a second holding opening (64) which opens into the hollow cylindrical section (62) and in which the female contact (66) lies, wherein an intermediate space between the second holding opening (64) and the female contact (66) is filled with a second potting compound (76). [8] Plug connection (14) according to claim 7, characterized by that on the side opposite the male contact (50) a press fit (74) is introduced into the female contact (66), which press fit is partially embedded in the second casting (76). [9] Plug connection (14) according to one of claims 1 to 8, characterized by that the first plug (44) has a plurality of male contacts (50) and the second plug (34) has a plurality of female contacts (66). [10] Electric motor (12) for a motor vehicle (2), with a plug connection (14) according to one of claims 1 to 9, wherein the second housing (36) is inserted into a mounting opening (32) of a motor housing (22) and fastened thereto, wherein the female contact (66) is electrically contacted with a conductor (84) arranged in the motor housing (22), and wherein the first plug (44) is arranged outside the motor housing (22).

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