Housing cover unit for an electric drive device and electric drive device for an electric vehicle

Abstract

The invention relates to a housing cover unit (1) for an electric drive device and to an electric drive device with such a housing cover unit. The housing cover unit (1) comprises a cover body (2); an electronic rotor position sensor device (3) for detecting a rotor position, wherein the rotor position sensor device (3) is integrated into the cover body (2); and an interface (4) for electronic connection with an electronic system of the electric drive device, wherein the interface (4) is electronically connected to the rotor position sensor device (3) and is arranged on an inner surface of the cover body (2).

Description

[0001] The present invention relates to a housing cover unit for an electric drive device. Furthermore, the present invention relates to an electric drive device for an electric vehicle. State of the art

[0002] Rotary electric drives are frequently designed as internal rotor machines. The stator of an internal rotor machine has inwardly facing stator teeth whose ends surround an interior space. In an electronically commutated machine, a rotor equipped with permanent magnets is rotatably mounted within this interior space. The stator teeth are appropriately fitted with stator coils and are alternately energized according to electronic commutation to generate a traveling magnetic field within the interior of the electric machine. This field induces a torque in the rotor, causing it to rotate.

[0003] The stator is typically housed in a cylindrical casing that is appropriately sealed at both ends. At least at one end of the cylindrical casing, a housing cover is provided, which is fitted during the assembly of the electrical drive device. This cover supports a rotor shaft and, in particular, provides an electrical connection for the stator coil to supply electrical power.

[0004] Housing covers for electric drive devices or electric motors are generally integrated as a sub-housing within a larger assembly or used as a die-cast cover component to close the drive unit. The B-bearing side (rotor shaft bearing) is integrated as an additional geometric element, and the rotor position detection system as a separate assembly.

[0005] For example, DE 10 2011 080 038 A1 describes a drive unit for an electric vehicle, comprising an electric machine, in particular an electric motor, which can be arranged in a region of an end face of a vehicle axle of the electric vehicle, and a transmission unit which cooperates with the electric machine to drive a respective wheel of the electric vehicle, wherein the electric machine and the transmission unit can be arranged close to the wheel and that the electric machine is designed such that the electric machine can be arranged close to the wheel in the drive unit on any of the two end faces of the vehicle axle to drive the respective wheel.DE 10 2020 210 083 A1 describes an electronic arrangement comprising a base housing with an open side, at least one electronic component, and a liquid cooler which is configured to form a cover of the base housing in order to close the open side of the base housing, wherein the liquid cooler is a deep-drawn component, wherein the liquid cooler has a sheet metal base plate, an additional sheet, a cooling channel and a heat sink, wherein the cooling channel is formed between the sheet metal base plate and the additional sheet and the heat sink is arranged in the cooling channel, wherein the sheet metal base plate of the liquid cooler completely closes the open side of the base housing, and wherein the electronic component is fixed to an inner side of the sheet metal base plate facing the interior of the electronic arrangement. Disclosure of the invention

[0006] The invention provides a housing cover unit for an electric drive device with the features of claim 1 and / or an electric drive device for an electric vehicle with the features of claim 10.

[0007] According to a first aspect of the invention, a housing cover unit for an electric drive device is provided. The housing cover unit comprises a cover body and an electronic rotor position sensor device for detecting the rotor position. The rotor position sensor device is integrated into the cover body. Furthermore, the housing cover unit comprises an interface for electronic connection to an electronic system of the electric drive device. The interface is electronically connected to the rotor position sensor device and is located on an inner surface of the cover body.

[0008] According to a second aspect of the invention, an electric drive device for an electric vehicle is provided. The electric drive device comprises a housing cover unit according to the first aspect of the invention and a rotor with a rotor shaft. One end of the rotor shaft is mounted in the area of ​​the rotor position sensor device, so that the rotor position sensor device can detect the rotor position of the rotor shaft.

[0009] One of the underlying ideas of the present invention is that individual functions are integrated into separate components of the electric drive device. For example, the housing cover unit can be designed to provide system tightness and adhesive bonding, rotor position detection, EMC shielding, and component stiffness. In the electric drive device according to the invention, the housing cover unit does not function as a rotor shaft bearing, as is common in known housing covers for electric drives. This allows the requirements for the cover component or housing cover unit to be reduced in favor of simplified assembly and disassembly, combined with a reduction in material costs despite the multiple parts.In particular, the present invention allows for more cost-effective EMC protection than with conventional aluminum die casting by dividing the functions of the cover component into individual components. Ease of handling and / or serviceability is significantly improved by the interchangeability of individual assemblies of the electrical drive device.

[0010] For example, the housing cover assembly can consist of the cover body, the rotor position sensor assembly, the interface, and a mechanical connection for mounting it to a housing. In particular, the housing cover assembly may not include a bearing for a rotor shaft. This means that the housing cover assembly, or the cover body, lacks a bearing point or support for the rotor shaft, specifically one end of the rotor shaft. The advantage of using an internal rotor position assembly is retained; that is, no external wiring harnesses are required on the electrical drive device.

[0011] Advantageous designs and further developments result from the further sub-claims as well as from the description with reference to the figures in the drawing.

[0012] According to a further development of the invention, the lid body is made of a plastic. This allows the lid body to be manufactured very cost-effectively and quickly. Furthermore, the plastic lid body can be produced using various manufacturing processes, for example, injection molding, thermoforming, or similar methods. The plastic can be, for example, polyamide (PA), polyphenylene ether (PPE), or the like.

[0013] According to a further embodiment of the invention, the rotor position sensor assembly is enclosed by the cover body, and the interface is an integral part of the cover body. This allows the rotor position sensor assembly to be protected from oil, dirt, and other substances, particularly without the need for additional sealing. In other words, the housing cover unit can form a plastic cover with an integrated rotor position assembly or rotor position sensor assembly. For example, the rotor position sensor assembly can be coupled to the interface by means of an electrical conductor. The electrical conductor can be embedded in the cover body, i.e., extend inside the cover body, and be hot-stamped. The electrical conductor can have an insulating sheath. The rotor position sensor assembly can, for example, be designed as a circuit board.

[0014] According to a further embodiment of the invention, the lid body is made of aluminum. This allows for higher component stiffness, particularly compared to a plastic lid, with a similar material weight. Furthermore, this approach enables the use of additional bonding techniques and the standardization of adhesives with other housing seals.

[0015] Furthermore, the aluminum advantageously provides EMC shielding. EMC shielding refers to methods used to protect sensitive signals from external electromagnetic signals or to prevent stronger signals from escaping and interfering with surrounding electronic systems. For the purposes of this application, aluminum also includes aluminum alloys. The aluminum thus provides the EMC shield automatically.

[0016] According to a further embodiment of the invention, the housing cover unit also comprises a retaining element that supports the rotor position sensor device and the interface, wherein the retaining element is attached to the cover body. The retaining element can preferably be electrically insulating or made of an electrically insulating material. Furthermore, the retaining element can be attached to the cover body, for example, by means of a screw connection. The retaining element can also be designed to be sealing or have a seal against oil and dirt in order to protect the rotor position sensor device.

[0017] For example, the retaining element can be arranged in a recess in the lid body. In other words, the retaining element can be referred to as an insert.

[0018] According to a further embodiment of the invention, the lid body is manufactured using a deep-drawing process. This allows the lid body to be produced more cost-effectively and / or faster, particularly in high-volume production. For example, the lid body can be designed as a deep-drawn aluminum sheet metal part. The deep-drawn aluminum sheet metal part offers better resistance to stone chips and mechanical impacts.

[0019] According to a further embodiment of the invention, the interface is designed as a cutting and clamping connection. The interface can project from the lid body. In particular, the interface can project from the lid body at approximately a right angle.

[0020] According to a further embodiment of the invention, the interface has six or more, for example eight, connection elements. In this way, the rotor position sensor device and other electronic functions can be implemented.

[0021] According to a further embodiment of the invention, at least one of the six or more connection elements can be connected to an interlock safety system. This increases operational safety, as the electrical drive device is de-energized when the housing cover is missing, i.e., when the electrical drive device or its housing is open. The interlock safety system thus provides a protective device for detecting loose or missing connections in an electrical circuit. For example, two of the six or eight connection elements can be connected to an interlock safety system. Brief description of the drawings

[0022] The invention will now be explained with reference to the figures in the drawings. The figures show: Fig. 1 a schematic perspective view of a housing cover unit for an electric drive device according to an embodiment of the invention; Fig. 2 a schematic perspective view of a housing cover unit for an electric drive device according to a further embodiment of the invention; and Fig. 3 a schematic perspective view of a retaining part of the housing cover unit Fig. 2.

[0023] In the figures, the same reference symbols denote identical or functionally equivalent components, unless otherwise stated. The numbering of process steps is for clarity and generally does not imply a specific chronological order. In particular, several process steps can be performed simultaneously. Description of the exemplary implementations

[0024] Further advantages, features and details of the invention will become apparent from the following description, in which various embodiments are described in detail with reference to the drawing.

[0025] Fig. Figure 1 shows a schematic perspective view of a housing cover unit 1 for an electric drive device according to an embodiment of the invention.

[0026] The housing cover unit 1 includes, for example, a cover body 2, an electronic rotor position sensor device 3 for detecting a rotor position, an interface 4 for electronic connection with an electronic system of the electrical drive device and an electrical conductor 5.

[0027] The lid body 2 is shown here as an example made of a plastic. This plastic lid body 2 can be manufactured using various processes, such as injection molding, thermoforming, or similar methods. The plastic could be, for example, polyamide (PA), polyphenylene ether (PPE), or the like. For instance, the plastic lid body 2 can be manufactured using a thermoforming process. This method allows for more cost-effective and / or faster production of the lid body 2, especially for high-volume manufacturing.

[0028] The rotor position sensor device 3 is integrated into the cover body 2. As shown in the enlarged section in Fig. As shown in Figure 1, the rotor position sensor device 3 can be enclosed by the cover body 2. Furthermore, the interface 4 can be an integral part of the cover body 2. Thus, the rotor position sensor device 3 can be protected from oil, dirt, and other substances, particularly without the need for additional sealing. Specifically, the cutout shows the interior of the cover body 2. The rotor position sensor device 3 and the electrical conductor 5 can be arranged inside the cover body 2.

[0029] Furthermore, the interface 4 is electronically connected to the rotor position sensor device 3, for example by means of the electrical conductor 5, and is located on an inside of the cover body 2.

[0030] Optionally, interface 4 can be designed as an insulation displacement connection, as used in Fig. Figure 1 illustrates this by way of example. The interface 4 can protrude from the lid body 2. In particular, the interface 4 can protrude from the lid body 2 at approximately a right angle.

[0031] Furthermore, interface 4 can have six or more, for example eight, connection elements. At least one of the six or more connection elements can be connected to an interlock safety system. This increases operational safety, as the electric drive device is de-energized when the housing cover unit 1 is missing, i.e., when the electric drive device or its housing is open.

[0032] For example, the rotor position sensor device 3 can be coupled to the interface 4 by means of the electrical conductor 5. The electrical conductor 5 can be inserted into the cover body 2, i.e., extend inside the cover body 2, and hot-stamped. The electrical conductor 5 can optionally include an insulating sheath.

[0033] In a specific embodiment, the housing cover unit 1 can consist of the cover body 2, the rotor position sensor device 3, the interface 4, the electrical conductor 5, and a mechanical connection device for mounting it to a housing. All components of the housing cover unit 1 can have some or all of the features described above. However, the housing cover unit 1 may, in particular, not include a bearing for a rotor shaft. This means that the housing cover unit 1, or the cover body 2, lacks a bearing point for the rotor shaft.

[0034] Fig. Figure 2 shows a schematic perspective view of a housing cover unit 1 for an electric drive device according to a further embodiment of the invention. Fig. Figure 3 shows a schematic perspective view of a retaining part 6 of the housing cover unit 1. Fig. 2.

[0035] The housing cover unit 1 comprises, for example, a cover body 2, an electronic rotor position sensor device 3 for detecting a rotor position, an interface 4 for electronic connection with an electronic system of the electrical drive device, an electrical conductor 5 and a retaining part 6.

[0036] The cover body 2 is shown here as an example made of aluminum. This allows for greater component rigidity, especially compared to a plastic cover, with a similar material weight. Furthermore, this method enables the use of other bonding techniques and the standardization of adhesives with other housing seals.

[0037] The aluminum also advantageously provides EMC shielding. EMC shielding refers to methods used to protect sensitive signals from external electromagnetic signals or to prevent stronger signals from leaking out and interfering with surrounding electronic systems.

[0038] For example, the lid body 2 can be manufactured from aluminum using a deep-drawing process. This allows the lid body 2 to be produced more cost-effectively and / or faster, especially for high production volumes. For instance, the lid body 2 can be designed as a deep-drawn aluminum sheet metal part. The deep-drawn aluminum sheet metal part offers better resistance to stone chips and mechanical impacts.

[0039] The rotor position sensor device 3 is integrated into the cover body 2.

[0040] Furthermore, the interface 4 is electronically connected to the rotor position sensor device 3, for example by means of the electrical conductor 5, and is located on an inside of the cover body 2.

[0041] The retaining element 6 can support the rotor position sensor 3 and the interface 4, and is attached to the cover body 2. The retaining element 6 is preferably electrically insulating or made of an electrically insulating material. Furthermore, the retaining element 6 can be attached to the cover body 2, for example, by means of a screw connection. The retaining element 6 can also be sealed or have a seal against oil and dirt to protect the rotor position sensor 3. For example, the retaining element 6 can be arranged in a recess in the cover body 2. In other words, the retaining element 6 can be referred to as an insert.

[0042] Optionally, interface 4 can be designed as an insulation displacement connection, as used in Fig. 2 and Fig.Figure 3 illustrates this by way of example. The interface 4 can protrude from the cover body 2 or the retaining part 6. In particular, the interface 4 can protrude from the retaining part 6 at approximately a right angle.

[0043] Furthermore, interface 4 can have six or more, for example eight, connection elements. At least one of the six or more connection elements can be connected to an interlock safety system. This increases operational safety, as the electric drive device is de-energized when the housing cover unit 1 is missing, i.e., when the electric drive device or its housing is open.

[0044] For example, the rotor position sensor device 3 can be coupled to the interface 4 by means of the electrical conductor 5. The electrical conductor 5 can be inserted into the cover body 2, i.e., extend inside the cover body 2, and hot-stamped. The electrical conductor 5 can optionally include an insulating sheath.

[0045] In a specific embodiment, the housing cover unit 1 can consist of the cover body 2, the rotor position sensor device 3, the interface 4, the electrical conductor 5, the retaining part 6, and a mechanical connection device for mounting it to a housing. All components of the housing cover unit 1 can have some or all of the features described above. However, the housing cover unit 1 may, in particular, not include a bearing for a rotor shaft. This means that the housing cover unit 1, or the cover body 2, lacks a bearing point for the rotor shaft.

[0046] Although the present invention has been explained above by way of example embodiments, it is not limited to these, but can be modified in many ways. In particular, combinations of the preceding embodiments are also conceivable. QUOTES INCLUDED IN THE DESCRIPTION

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

[0000] DE 10 2011 080 038 A1

[0005] DE 10 2020 210 083 A1

[0005]

Claims

[1] Housing cover unit (1) for an electric drive device, comprising: a lid body (2); an electronic rotor position sensor device (3) for detecting a rotor position, wherein the rotor position sensor device (3) is integrated into the cover body (2); and an interface (4) for electronic connection with an electronic system of the electric drive device, wherein the interface (4) is electronically connected to the rotor position sensor device (3) and is arranged on an inside of the cover body (2). [2] Housing cover unit (1) according to claim 1, wherein the cover body (2) is made of a plastic. [3] Housing cover unit (1) according to claim 2, wherein the rotor position sensor device (3) is enclosed by the cover body (2) and the interface (4) is an integral part of the cover body (2). [4] Housing cover unit (1) according to claim 1, wherein the cover body (2) is made of aluminium. [5] Housing cover unit (1) according to claim 4, further comprising a retaining part (6) which carries the rotor position sensor device (3) and the interface (4), wherein the retaining part (6) is attached to the cover body (2). [6] Housing cover unit (1) according to one of the preceding claims, wherein the cover body (2) was produced by a deep drawing process. [7] Housing cover unit (1) according to one of the preceding claims, wherein the interface (4) is designed as an insulation clamp connection. [8] Housing cover unit (1) according to one of the preceding claims, wherein the interface (4) has six or more connection elements. [9] Housing cover unit (1) according to claim 8, wherein at least one of the six or more connection elements is connectable to an interlock safety system. [10] Electric drive device for an electric vehicle, comprising: a housing cover unit (1) according to one of the preceding claims; a rotor with a rotor shaft, wherein one end of the rotor shaft is mounted in the area of ​​the rotor position sensor device (3), so that the rotor position sensor device (3) can detect a rotor position of the rotor shaft.

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