DRIVE DEVICE WITH A BRUSHLESS ELECTRIC MOTOR

Description

[0001] The invention relates to a drive device, in particular an electromechanical adjustment drive, preferably a (cable) window lift, of a motor vehicle.

[0002] A drive device, such as an electric motor actuator for a motor vehicle, which drives an actuating element, in particular a window pane of a vehicle side door, between two end positions along an adjustment path, typically comprises an electric motor and a gearbox coupled to it, which is arranged in a gearbox housing. The gearbox housing is connected to a motor housing, which accommodates the stator and rotor of the electric motor, for example via a flange-like connection, whereby the electric motor can typically be a brushed (internal rotor) commutator motor or a brushless external rotor motor. Such drive devices, especially window regulator drives, may be exposed to extreme humidity and high temperature fluctuations at their intended installation location.

[0003] From US patent 2017 / 0366070 A1, a drive device is known with a brushless electric motor comprising a rotor with a rotor shaft and a stator with a stator winding and a number of phase connection wires. A gearbox housing has an electronics compartment with a printed circuit board (PCB) that can be inserted or is already mounted therein, with connection points for the phase connection wires, and a housing shaft coaxial with the axis of rotation of the rotor shaft, into which the stator and the rotor with the rotor shaft are mounted. The phase connection wires, which are mounted in a connection adapter, are matched to the connection points of the PCB by their connection grid.

[0004] If a brushless, electronically commutated electric motor is used for such a drive device, and its stator has a multi-phase, usually three-phase, stator or three-phase winding, the phase terminals must be connected to motor electronics that supply current to the three-phase winding. The electrical connection of the phase terminals to the motor electronics can be made within the drive device to a circuit board on which the electrical and / or electronic components of the motor electronics are mounted and interconnected. Alternatively, the electrical connection of the phase terminals can also be made via a plug connector (plug-in connection) to motor electronics located outside the drive device.

[0005] A drive device known from DE 10 2011 121 716 B3 for adjusting a cover element of a vehicle, in particular for a window regulator, comprises an output element for adjusting the vehicle part and a brushless, electronically commutated electric motor with a stator, a rotor, and a drive shaft (motor or rotor shaft) connected thereto for driving the output element. The rotor is designed as an external rotor rotating radially outside the stator relative to the shaft axis. The stator base body, which accommodates the stator winding and is designed, for example, as a laminated core, can be mounted on a bushing- or tube-like, hollow cylindrical stator carrier through which the drive shaft carrying the rotor is or is guided into the gearbox housing.

[0006] The phase or winding wires of the stator winding (rotating field winding) can be bundled manually and fixed in a desired position using additional aids, such as adhesive tape or cable ties. However, an automated process for bundling and fixing, or pre-fixing, the phase connections or wires of the stator winding is desirable.

[0007] In a drive device known from DE 10 2019 203 525 A1, slots are provided on the circuit board of the motor or control electronics to allow the phase wires to be threaded onto or into the circuit board with precise positioning. However, such a process typically requires two axes or planes of movement during circuit board or assembly assembly: inserting the circuit board into a designated electronics compartment of the gearbox housing and subsequently threading the phase connection wires into the circuit board slots.

[0008] In an automated process, it is necessary that the stator, including its stator winding, or the assembly consisting of the stator and rotor, including the motor or rotor shaft (stator-rotor assembly), is aligned as precisely as possible before being inserted into the gearbox housing, so that the phase or winding wires (phase start and phase end wires) and the stator carrier (the stator bushing) can be reliably and reliably mounted to the gearbox housing.

[0009] The invention is based on the objective of providing a drive device with an improved concept for the phase connections of a brushless electric motor.

[0010] This problem is solved according to the invention by the features of claim 1. Advantageous further developments and embodiments are the subject of the dependent claims.

[0011] The drive device, in particular an electric motor-driven adjustment drive of a motor vehicle, comprises a brushless electric motor with a rotor, a rotor shaft coupled to it, and a stator. The stator includes a stator body mounted on a tubular or cylindrical stator carrier (stator bushing) and has a number of star-shaped stator teeth. The stator, or a stator body mounted (pressed onto) the stator carrier (positively and / or force-fit), is provided with a stator winding (rotating field winding) having a number of phase connection wires. These wires can run axially and / or circumferentially (azimuthally) in sections relative to the shaft or axis of rotation of the rotor shaft.The stator winding can be formed from a number of single, double or multiple coils, the ends of which are connected to each other, for example in a star or delta connection, and which form the phase connections as connecting wires, via which the (phase-off or phase-accurate) current is supplied to the stator winding.

[0012] The drive device comprises a gearbox housing with an electronics compartment and a housing shaft coaxial with the axis of rotation (shaft axis) of the rotor shaft. A printed circuit board with connection points for the phase connection wires is either installed or can be inserted into the electronics compartment. The electric motor or the stator-rotor assembly, including the rotor shaft and stator carrier, is installed or can be inserted into the housing shaft, which is preferably hollow cylindrical. For this purpose, the gearbox housing has an opening that opens into the housing shaft, through which the assembly consisting of the rotor and rotor shaft, as well as the stator with stator carrier and stator or rotating field winding, is inserted into the gearbox housing. Advantageously, the rotor or motor shaft already carries a worm gear, which, in the assembled state, meshes with a worm wheel of a 90° reversing gear (worm gear) rotatably mounted in the gearbox housing.

[0013] The drive device further comprises a connection adapter in which the phase connection wires are radially oriented. Within the connection adapter, the phase connection wires are also accommodated in a connection grid adapted to the connection points of the printed circuit board. It is particularly advantageous that the phase connection wires are radially oriented by means of the connection adapter and aligned in a line tangential to the rotor shaft. In other words, the connection adapter has a number of wire openings arranged in a connection grid tangentially oriented and radially spaced from the stator support. This grid corresponds to the line or plane of the associated connection points on the printed circuit board.The connection adapter can also have a number of slot-like wire openings, in particular a number corresponding to the number of phase connection wires, arranged along a circular arc with a central angle between 100° and 180°, preferably with a central angle of (130 ± 15°). These are suitably designed as axial grooves. The connection adapter is preferably a plastic part.

[0014] The connection adapter enables the printed circuit board (PCB) to be inserted into the electronics compartment perpendicular (radially) to the rotor shaft in a single plane or axis during an automated process. The phase connection wires automatically slide or thread into the PCB's connection points. The PCB connection points can therefore be advantageously designed as easily manufactured holes, which can also be tinned. The connection adapter has a number of circumferentially closed wire openings, i.e., holes, corresponding to the number of phase connection wires. Alternatively, slots can be provided, which are suitablely open wire openings facing the stator carrier.

[0015] In an advantageous embodiment, the connection adapter has at least one joining element, hereinafter also referred to simply as a mounting dowel, which corresponds to a joining opening in the gearbox housing, preferably in the area of ​​a transition between the electronics compartment or its shelf and the housing shaft. By means of the joining element, the connection adapter is fixed in the gearbox housing during assembly by means of a positive and / or force-fit connection, in particular precisely in a desired position. In one embodiment, the connection adapter has two axially oriented joining elements or pins.

[0016] In one variant, a single mounting dowel is integrally formed on the edge of an adapter opening, acting as a joining element, via at least one predetermined breaking point in the form of separable or breakable webs or ribs. When the connection adapter is installed in the gearbox housing, in the area of ​​a transition between the electronics compartment or its base and the housing shaft, the mounting dowel corresponds to a joining opening that leads into the gearbox housing shaft. By pressing the adapter-side mounting dowel into the housing-side joining opening, the dowel breaks off at the predetermined breaking points, creating a joining connection between the connection adapter and the gearbox housing. The mounting dowel suitably has a number of radial ribs or tabs, so that pressing the dowel into the housing-side joining opening creates a positive-locking and force-fit connection similar to an interference fit.

[0017] A suitable further development provides that the connection adapter has radially oriented crimping lugs for fixing the circuit board, and / or that at least one crimping lug for fixing the circuit board is provided in the electronics compartment of the gearbox housing. The crimping lugs are suitably deformable (cold or hot).

[0018] The stator, or its base body, preferably designed as a (stamped) laminated core, advantageously features an electrically insulating coil or winding body for the stator winding, which is formed in particular from single, double, or multiple coils. This winding body for the coils of the stator winding is suitably formed from two semi-shell-shaped slotted box insulations, which at least partially or section by way of the star-shaped stator teeth of the base body. At least one of the slotted box insulations mounted on the base body has a cuff-like cap section that surrounds the stator support. This cap section preferably has radially oriented contours forming radial grooves extending axially or at an acute angle to the axial direction, in which the individual phase connection wires are inserted section by section.

[0019] The connection adapter has a ring section that partially or completely surrounds the stator carrier. This ring section is formed on the connection adapter, which is preferably made of plastic, such that the adapter body, which has the wire openings for the phase connection wires, is attached tangentially to the ring section. Particularly preferably, the connection adapter has a ring section that partially or completely surrounds the cuff-like cap section of the slot box insulation. The ring section or ring of the connection adapter advantageously serves to align the (radial) height of the phase connection wires, which are expediently clamped in the connection adapter, with the center axis of the stator carrier (the stator bushing) or with the axis of rotation of the motor or rotor shaft.

[0020] In particular, in the variant of the connection adapter with a closed ring section, this section has a joining contour that corresponds to a joining groove of the cap section of the groove box insulation, creating a positive fit. Alternatively, preferably in a variant of the connection adapter with a partially closed ring section, this section has two arc-shaped or approximately quarter-circle-shaped locking arms with locking elements at their ends, which, in the assembled state, engage corresponding locking contours on the cap section of the groove box insulation, in particular in a positive-locking manner.

[0021] In the following, a "positive locking" or "positive locking connection" between at least two interconnected parts is understood to mean, in particular, that the cohesion of the interconnected parts in at least one direction is achieved either through a direct interlocking of the contours of the parts themselves or through an indirect interlocking via an additional connecting element. The "blocking" of mutual movement in this direction is thus due to the form.

[0022] A terminal adapter in the form of a clamping ring, which can be placed on or fitted onto the stator carrier, has a suitable number of recesses corresponding to the number of phase connection wires, through which the phase connection wires are guided. The clamping ring can be slid axially onto the stator carrier, with the phase connection wires being guided precisely into position via the recesses of the clamping ring. The clamping ring holds and / or fixes the phase connection wires in the desired, predetermined, or intended position. The position of the phase connection wires in the recesses of the clamping ring can be practically arbitrary.

[0023] In a suitable embodiment, the recesses of the clamping ring are designed as radial grooves open towards the stator support. The clamping ring appropriately comprises a radial ring section and an axial ring section. The axial ring section, which is directed towards the stator, is formed radially on the outside of the radial ring section. The radial ring section has an annular opening for the stator support and recesses for the phase connection wires.

[0024] The clamping ring advantageously features two interlocking or joined half-rings. Conveniently, only one of the two half-rings has the recesses for the phase connection wires. This allows for easy radial placement of the clamping ring onto the stator carrier or radial mounting of the clamping ring on both sides of the stator or stator carrier. The half-ring with the recesses is placed over the phase connection wires, which are arranged in an approximately semicircular pattern around the circumference of the stator carrier or are positioned axially.

[0025] According to a suitable embodiment of the clamping ring, it is designed as a circular arc with a central angle greater than 180° and less than or equal to 225°, preferably less than 220°, and in particular 216°. In this embodiment, the clamping ring, which extends over more than 180°, preferably over 3 / 5, of the circumference of the stator support, enables a secure snap-on engagement with the stator support or a sufficient snap-in function for a secure hold on the stator support.

[0026] The phase connection wires are suitably guided into a radially oriented joining and / or contacting position on the side of the clamping ring facing away from the stator, or can be bent into this position. Due to the secure positioning of the phase connection wires by means of the clamping ring, the phase connection wires can be easily and advantageously automatically or fully automatically brought into the desired position and orientation and preferably fixed there.

[0027] Advantageously, six phase connection wires or three phase connection pairs are provided. The phase connection wires are radially oriented by means of the connection adapter and aligned in the provided grid, preferably equidistant from each other. Due to the opening grid of the wire openings of the connection adapter, which preferably runs tangentially to the stator carrier and the rotor shaft (axis of rotation), the phase connection wires, radially oriented by means of this adapter, are aligned side by side and spaced apart from each other in a line parallel to the plane of the printed circuit board and perpendicular to the axis of rotation.

[0028] The advantages achieved with the invention consist in particular of the fact that, by means of the wire or connection adapter hereinafter referred to as the adapter, the phase connections as start and end wires of the stator or rotary winding, or of the coils forming them, are aligned as precisely as possible in a line with each other at the shortest possible distance to the printed circuit board via a defined detent dimension. This, in turn, allows (perforated) holes for the phase connection wires to be provided in the printed circuit board, in particular instead of slots. Furthermore, the printed circuit board can be mounted in only one orientation (plane) instead of two.

[0029] The adapter, preferably made of plastic, provides particularly reliable protection against unwanted bending of the (phase connection) wires relative to each other, especially during transport. Furthermore, it reduces the effort required for component handling, transport packaging, and, if necessary, communication processes prior to installation in the drive or gearbox housing. A tongue-and-groove or plug-in design of the adapter to the drive or gearbox housing ensures optimal alignment of the (phase connection) wires relative to the circuit board height, resulting in a particularly short tolerance chain. A lateral insertion ramp, advantageously provided on the adapter, allows the stator-rotor assembly to be radially aligned during insertion into the drive or gearbox housing, significantly improving the assembly process in terms of alignment effort and robustness.

[0030] Following the insertion of the stator-rotor assembly into the drive / gearbox housing, the stator carrier, designed as a stator bushing, can be radially and axially secured by pressing in the integrated, dowel-like joining element of the adapter through a designated bore or joining opening in the gearbox housing—specifically in the electronics compartment—and a bore or joining opening in the hollow cylindrical stator carrier (stator bushing). This results in a positive fit. This reduces the pressing forces required to insert the stator carrier into the drive / gearbox housing and increases the permissible component tolerances in the press fit between the stator carrier and the gearbox housing. This, in turn, improves the robustness of the drive unit's design.

[0031] Exemplary embodiments of the invention are explained below with reference to a drawing. The drawing shows: Fig. 1 in perspective view of a drive device with a drive or gearbox housing and an electric motor housed therein for driving a cable drum as the output element of an adjustment device, in particular a window regulator, of a motor vehicle; Fig. 2 in an exploded view of the drive device according to Fig. 1 with integrated motor electronics and with the electric motor with phase connection wires (phase terminals) of a stator winding in a pre-assembly position before the stator-rotor assembly of the electric motor is inserted into the drive or gearbox housing, Fig. 3 shows a partial perspective view of the drive or gearbox housing looking into an electronics compartment and at a connection adapter with radially oriented and aligned phase connection wires contained therein, as well as a mounting dowel as a joining element in a starting position, Fig. 4 shows a representation according to Fig. 3 The installation position of the connection adapter with pressed-in mounting dowel, viewed through a circuit board inserted into the electronics compartment and shown transparently by means of the dashed outer contours, Fig. 5; partial perspective view of the drive or gearbox housing, viewed into a housing shaft for the stator-rotor assembly with a housing-side connection adapter with pressed-in mounting dowel, Fig. 6; perspective view of the connection adapter with slotted wire or clamping openings for the phase connection wires of the stator winding, Fig. 7. Fig. 6 the connection adapter with perforated wire openings for the phase connection wires of the stator winding, Fig. 8 the connection adapter according to Fig. 6 or 7with an insertion ramp and with a wing tab as a rear or bottom grip in the gearbox housing, Fig. 9 shows a partial perspective view of the connection adapter with a view to a number of radial struts as a predetermined breaking point of the mounting dowel, Fig. 10 shows a perspective view of the connection adapter with a ring element and a semi-shell-shaped slot box insulation with a cuff-like cap section for the stator winding (rotating field winding) for a hollow cylindrical stator carrier (stator bushing), Fig. 11 shows a side view of the stator winding formed from coils and the slot box insulation with an integrally formed cap section and a connection adapter mounted on it in a version with mortising studs and with a fixing ring or ring section encompassing the cap section, Fig.Fig. 12 in a perspective view the stator winding formed from coils and the slot box insulation with molded cap section and connection adapter mounted thereon in an alternative design with slotted wire or clamping openings for the phase connection wires of the stator winding in a fixing ring (ring section) encompassing the cap section of the slot box insulation, Fig. 12 in a perspective view the connection adapter according to . Fig. 12a in a rear view with a joining contour (for pre-positioning) and a locking element, Fig. 12c the groove box insulation according to Fig. 12a with a locking groove and a locking contour in the cap section of the slot box insulation, Fig. 13 in a perspective exploded view, the drive or gearbox housing with joining or plug-in openings at a transition between a gearbox shaft for the stator-rotor assembly and the electronics compartment (bottom), as well as with the connection / adapter in a version with axial joining elements (connecting pins) corresponding to the joining or plug-in openings, Fig. 14 in a perspective view, the version according to Fig. 13 with the stator-rotor assembly inserted into the housing shaft and the connection adapter fixed in position by means of the inserted connecting pins, Fig. 15 in a representation according to Fig. 10 The semi-shell-shaped groove box insulation with cuff-like cap section and the connection adapter in a design with slotted wire openings and an approximately semi-circular ring element with locking elements in a pre-assembled position on the cap section of the groove box insulation, Fig. 16 in a perspective view, the design of the connection adapter according to Fig. 15 in a mounting position locked onto the cap section of the slot box insulation, Fig. 17 in a perspective view a clamping ring as a connection adapter for positioning and / or fixing the phase connection wires on or to the stator carrier, and Fig. 18 in a perspective view the stator with the stator carrier with the clamping ring mounted on it as a connection adapter according to Fig.1 and radially oriented phase connection wires.

[0032] Corresponding parts are marked with the same reference symbols in all figures.

[0033] The Figuren 1 and 2 show an electromechanical drive device 1 with a drive housing formed from a gearbox housing 2 and a motor housing 3, into which an electric motor 4 ( Fig. 2 ) is at least partially used. The gearbox housing 2 and the motor housing 3 are detachably connected to each other by means of a flange connection 5, preferably bolted with flange screws 6. In the exemplary embodiment, the electric motor 4 drives a cable drum 7 as the output element via a gearbox.

[0034] The gearbox of the drive device 1 is a 90° reversing gearbox, in particular a worm or spur gearbox (helical screw gearbox). Its (not visible) worm wheel, arranged in the gearbox housing 2 and coupled to the cable drum 7 for a pull cable, in particular for a window regulator of a motor vehicle, meshes with a worm 8 driven by the electric motor 4 ( Fig. 2 ). A connector 9 with connecting leads 10 for supplying power and voltage to the drive device 1, which serves as an adjustment drive for the motor vehicle, and for supplying and / or outputting control and / or sensor signals, is inserted into a housing-side connection receptacle 11.

[0035] In the Figuren 1 and 2 The axial direction A and the radial direction R are indicated by arrows. Furthermore, the [missing information] is shown in the Figuren 1 and 2 The axis of rotation or shaft of the rotor shaft 11 is illustrated by a dash and labelled D.

[0036] As from Fig. 2 As can be seen when the motor housing 3 is removed, the electric motor 4 has a stator 12 (not shown in detail) and a rotor 13 formed from permanent magnets. The stator 12 carries a stator or rotating field winding 14 ( Fig. 3 ), which is formed from coils (single and / or double coil) 15 ( Fig. 11, 12a and 16These are wound or mounted in a manner not shown in detail on radially outwardly directed stator teeth of a stator base body 12, which is designed in particular as a laminated core and is not shown in detail. A motor shaft (rotor shaft) 16 is supported or seated in the motor housing 3, which is designed as a housing cover, at a bearing point 17, preferably designed as an axial bearing. The permanent magnets of the rotor 13 are arranged on the inner wall of a cup-shaped housing (rotor housing) 18, the rotor housing 18 with the permanent magnets surrounding (enclosing) the stator 12 or its stator base body, which carries the rotating field winding 14, forming an air gap. The housing 18 is connected to the rotor shaft via a shaft journal.Motor shaft 16 is non-rotatably connected and thus rotates within the motor housing or housing cover 3 around the stator 12 of the brushless electric motor 4, which is thus designed as an external rotor motor, which is fixed in the gearbox housing 2.

[0037] On the rotor shaft 16, which carries the worm 8 meshing with the (not visible) worm wheel of the gearbox in the assembly state, a magnetic signal transmitter (pole wheel) 19 is also fixedly mounted on the shaft, which interacts without contact with a (not visible) magnetic sensor, for example a Hall sensor, to determine the speed and direction of rotation of the rotor shaft 16 of the rotor 13.

[0038] Inside the gearbox housing 2 is a printed circuit board 21 of a motor electronics unit 22, equipped with electronic and / or electrical components 20. The printed circuit board 21 is arranged in an electronics compartment 23 of the gearbox housing 2, which can be closed with a cover (not shown), or can be inserted into the electronics compartment 23, which is accessible via a compartment or housing opening. This compartment is closed by means of the housing cover (not shown) after the printed circuit board 21 of the motor electronics unit 22 has been installed.

[0039] Advantageously, before mounting the circuit board 21, the electric motor 4, which here and in the following means the stator-rotor assembly formed from the stator 12 with the rotating field winding 14 and the rotor 13 including the rotor shaft 16, is inserted, inserted, or plugged into an approximately hollow cylindrical housing shaft 25 of the gearbox housing 2 via an unspecified housing opening. The circuit board 21 is mounted radially spaced from the rotor shaft (motor shaft) 16 in the electronics compartment 23 of the gearbox housing 2, relative to the axial direction A and radial direction R shown. In this position, the pole wheel 19 is positioned accordingly for the magnetic sensor, one of the components 20 for the non-contact speed and direction detection of the rotor shaft (motor shaft) 16 of the electric motor 4.

[0040] In the exemplary embodiment, the rotating field winding 14 with its coils 15 has six phase connection wires 26, which are electrically contacted, in particular soldered, with connection points 27 of the printed circuit board 21 in the form of perforated terminals or bores. Here, the phase connection wires 26 are radially oriented and aligned in a line in three phase connection pairs, symbolically enclosed by the dashed circle 28. The phase connection wires 26 are arranged parallel to each other at their end sections, which are intended for joining or contacting the printed circuit board 21, and are bent radially upwards into the intended joining position for this purpose.

[0041] The stator base body, preferably designed as a stack of stamped sheet metal, is firmly mounted on a hollow cylindrical stator support 29, hereinafter also referred to as the stator bushing, over or through which the rotor shaft 16 is guided. A radial bearing for the rotor shaft 16 is expediently located within the stator bushing 29, though not shown in detail.

[0042] Fig. 3 Figure 1 shows a section of the drive or gearbox housing, hereinafter referred to simply as gearbox housing 2, with a view into the electronics compartment 23 and specifically to a transition or housing interface between the electronics compartment 23 and the housing shaft 25 with the stator-rotor assembly of the electric motor 4 inserted therein. A connection adapter 30, hereinafter also referred to simply as adapter, is visible at this interface and is preferably positively fitted into a housing contour. The phase connection wires 26 are received in the adapter 30. This means that, by means of the adapter 30, the phase connection wires 26 of the stator or rotating field winding 14 are oriented radially (in radial direction R) with respect to the axis of rotation D or axial direction A. Furthermore, the phase connection wires 26 are connected by means of the adapter 30.whose wire ends are aligned in a tangential line (plane) in a predetermined grid, relative to the somewhat circular cross-section of the housing shaft 25.

[0043] The adapter 30 has a joining element 31, hereinafter referred to as a mounting dowel. In the exemplary embodiment, this element is located on or in a cantilever 32 of the adapter 30. The mounting dowel 31 is held in a pre-assembled position on the adapter 30 or on or in the cantilever 32 by means of a predetermined breaking point 33.

[0044] Fig. 4 shows in one of the Figur 3 In a similar illustration, the gearbox housing 2 is shown in section, with a view into the electronics compartment 23 containing the printed circuit board 21. The circuit board is shown transparently and illustrated with dashed lines. The adapter 30 is visible, which in this embodiment has two radial crimping lugs 34. An additional crimping lug 34', which is integrally formed on the bottom side of the electronics compartment 23, serves, in addition to the crimping lugs 34 on the adapter side, to position and / or fix the printed circuit board 21 in the gearbox housing 2 by deforming or crimping the crimping lugs 34, 34' (cold or hot).

[0045] The adapter 30, shown here without the phase connection wires 26, is fixed in the illustrated mounting position in the gearbox housing 2 and there in the electronics compartment 23. For this purpose, the mounting dowel 31 is pressed radially R into a corresponding, non-visible opening in the bottom of the housing compartment 23.

[0046] This joining or fixing state of the adapter 30 in the gearbox housing 2 is in Fig. 5 The pressed-in mounting dowel 31 can be seen protruding into the housing shaft 25 and, in doing so, also penetrating a corresponding opening or bore in the stator carrier (stator bushing) 29 in a manner not shown in detail.

[0047] The Fig. 6 bis 8 shown are embodiments of the connection adapter 30. The connection adapter 30 according to Fig. 6 The adapter 30 has a number of slotted wire openings 35 corresponding to the number of phase connection wires 26. Using this adapter 30, the phase connection wires 26 can be threaded axially into the wire openings 35 and preferably clamped in place. For this purpose, clamping lugs or clamping ribs 36 are formed on one or both sides of the wire openings 35.

[0048] A circular opening 37 is clearly visible here, in which the mounting dowel 31 is inserted via four radial webs in the exemplary embodiment ( Fig. 9 ) is held in the pre-assembly position. These radial webs 38 form the predetermined breaking point 33 and are dimensioned with regard to their strength such that they break off and the mounting dowel 31 can be inserted radially R into the corresponding openings of the adapter 30 or its extension 32 and those in the electronics compartment 23 as well as those in the stator carrier 29 during the pressing process. In In the mounting position, the mounting dowel 31 is securely held in the adapter-side opening 37, preferably by means of an interference fit. For this purpose, the mounting dowel 31 has a number of radial ribs 39, four in the exemplary embodiment. These preferably have chamfers 40.

[0049] Fig. 7 Figure 1 shows an embodiment of the connection adapter 30 with wire openings 35 designed as bores. These are located in groove- or trough-like channels 41. These preferably serve to improve the solder flow or to improve the space available for the solder when soldering the phase connection wires 26 to the corresponding connection points 27 of the printed circuit board 21.

[0050] The in Fig. 8 The connection adapter 30 shown in this embodiment has, in particular on at least one narrow side, a molded tab or tongue 42. In the assembled state, this engages a corresponding contour in the gearbox housing 2. This reliably prevents the connection adapter 30, which serves as a wire holder, from detaching or rising, especially when the mounting dowel 31 is inserted or pressed in. Furthermore, the connection adapter 30 also has, in particular on at least one narrow side, an insertion chamfer 43 for radially aligning the stator-rotor assembly or the electric motor 4 with the gearbox housing 2.

[0051] Fig. 10 shows the connection adapter 30, which according to the invention is provided with a ring body or ring section, preferably molded on.

[0052] With this ring section 44, the adapter 30 can, for example, be placed directly onto the cylindrical stator carrier (stator bushing 29). In the exemplary embodiment, the adapter 30 is placed, by means of the circumferentially closed ring section 44, onto a slot box or slot cap insulation 45 and there onto an integrally formed, cuff-like (hollow cylindrical) cap section 46. In the assembled state, this cap section is penetrated by the stator carrier or the stator bushing 29.

[0053] As from Fig. 11 As is relatively clearly visible, the cap section 46 of the slot box insulation 45 has radially oriented contours 47 forming radial grooves 48. One of the phase connection wires 26 is initially axially oriented in each of these grooves. The ring section 44 of the adapter 30 of this embodiment has an internal joining contour 49, preferably diametrically opposite the wire openings 35 of the adapter 30. In the plug-in state, this fits into a corresponding joining groove 50 of the cap section 46 on the slot box side. In this way, the adapter 30 is held in this desired or intended position with tangential alignment on the stator-rotor assembly or on the electric motor 4.

[0054] Fig. 11 The dashed line 51 further illustrates the parallelism of the circuit board 21 with respect to an inclined position of the stator 12 - here illustrated by the single slot cap insulation 45 and the coils 15 of the rotating field winding 14 arranged on it - symbolized by the line 52.

[0055] Fig. 12a Figure 1 shows the stator 12, illustrated only by the slot box insulation 45 and the coils 15 of the rotating field winding 14 arranged on it, with an adapter 30 of a further embodiment placed on the cap section 46 of the slot box insulation 45.

[0056] As in connection with Fig. 12b As is relatively clearly recognizable, the adapter 30 in this embodiment is a ring body approximately L-shaped in cross-section with slotted wire openings 35. These are designed as axial slots relative to the axis of rotation D, the cap section 46 on the slotted side, or the stator carrier 29, which penetrate or extend through the ring body in the radial direction R. This allows the adapter 30 of this embodiment to be slid onto the cap section 46, whereby the initially axially extending phase connection wires 26 are subsequently bent radially outwards ( Fig. 12a ).

[0057] In In this embodiment, the adapter 30 has slotted wire openings (axial grooves) 35 arranged and configured along a circular arc with a central angle α of (130 ± 5)° such that the phase connection wires 26 are equidistant from each other in their radial orientation. In this embodiment of the adapter 30 as well, the phase connection wires 26 are bent into the desired radial orientation in or by means of the adapter 30 and aligned at their wire ends in the desired connection grid in a tangential line.

[0058] Fig. 12b shows the connection adapter 30 in a rear view with a joining contour 49 for (pre-)positioning and with a locking element 49a. Fig. 12c The groove box insulation 45 shows according to Fig. 12a with a locking or joining groove 50 provided in the cap section 46, corresponding to the joining contour 49 of the adapter 30. The locking element 49a on the adapter side corresponds to a locking contour 50a of the groove box insulation 45 in the area of ​​the cap section 46. When the adapter 30 is placed on the cap section 46, it locks into the groove box insulation 45 by the adapter-side locking element 49a engaging (positively interlocking) the groove box-side locking contour 50a in the intended position of the adapter 30.

[0059] Fig. 13 Figure 1 shows an embodiment of the connection adapter 30 with wire openings 35 arranged tangentially next to each other and preferably equidistantly spaced, with phase connection wires 26 already inserted and radially bent into them. In this embodiment, the adapter 30 has two axially oriented joining elements or axial pins 53. These correspond – as indicated by the dashed arrows – to plug-in openings 54 in the gearbox housing and there at the transition of the (hollow cylindrical) housing shaft 25 to the electronics compartment 23 in the area of ​​its base.

[0060] Based on the representation according to Fig. 13 The stator-rotor assembly of the electric motor 4, including the rotating field winding 14 and connection adapter 30, is prepared for insertion into the gearbox housing 2 and into the housing shaft 25. The phase connection wires 26 are already threaded into the adapter, radially oriented, and aligned in the desired grid pattern. The pre-assembly position of the stator-rotor assembly to be inserted into the gearbox housing 2 is also illustrated, including the joining elements 52, 53 for fixing the connection adapter 30. The phase connection wires 26 are threaded into the adapter, radially oriented, and aligned in the desired grid pattern adapted to the circuit board connection points 27.

[0061] In the Fig. 14 In the assembly state shown, with precisely aligned phase connection wires 26, the circuit board 21 can now be inserted into the electronics compartment 23 with or in only a single mounting axis (plane) – here along the radial direction R. The aligned, radially oriented phase connection wires 26 then thread themselves almost automatically into the corresponding connection points 27 of the circuit board 21.

[0062] The Fig. 15 and 16 show a further embodiment of the connection adapter 30 in a pre-assembly position for the groove box insulation 45 ( Fig. 15 ) or in the final assembly position with phase connection wires 26 radially and tangentially aligned in the desired grid in the wire openings 35 of the adapter 30. For illustration, the phase connection wires 26 are shown in their initial axial orientation and after radial bending in the desired radial and tangential orientation in the provided grid.

[0063] In this embodiment, the adapter 30 again has a ring section 44 according to the invention. However, this section is not closed on its circumference. Rather, the ring section 44 is formed from two quarter-circle locking arms 55 with locking hooks 56 at their ends. By means of these locking hooks 56, the adapter 30 is locked onto the cap section 46 of the groove box insulation 45. For this purpose, corresponding locking contours 57 are formed on the cap section 46.

[0064] Fig. 17 shows a clamping ring as a connection adapter 30 for the phase connection wires 26, and Fig. 18 Figure 1 shows the stator 12 with the clamping ring 30 as a connection adapter. The stator 12 has a stator base body 58 mounted on the tubular or cylindrical (hollow cylindrical) stator carrier 29, with a number of star-shaped stator teeth 59. The motor or rotor shaft 16 is guided over the hollow cylindrical stator carrier 29; that is, the stator carrier 29 has a central shaft passage for the rotor shaft 16.

[0065] The stator winding 14 is recognizable as being formed from the single or double coils 15 arranged on the stator teeth 60 of the stator 12 or its stator base 58. The coil ends, as phase connection wires 26, form the phase connections for the phase-correct current supply to the stator winding 14 and are connected in or with the motor electronics 22, for example in a star or delta connection.

[0066] In In an initial state, the phase connection wires 26 run - with reference to the shaft axis of the rotor shaft 16 - preferably at least partially axially, i.e. in the axial direction A. In In this initial state, the phase connection wires 26 lie semicircularly or in a circular arc along the circumference of the stator support 29, preferably directly against it, and are pre-positioned in this position and orientation. The phase connection wires 26 can also be spaced, particularly only slightly, away from the stator support 29 (radially). Subsequently, the clamping ring 30 is pushed onto the stator support 29, for example, in the axial direction A.

[0067] The clamping ring or adapter 30 has a number of recesses 61 corresponding to the number of phase connection wires 26. The phase connection wires 26 are guided through these recesses 61 when the clamping ring 30 is placed onto the stator carrier 29, with the phase connection wires 26 being guided precisely into position over the recesses 61 of the clamping ring 30. The clamping ring 30 holds and preferably also fixes the phase connection wires 26 in the desired, predetermined, or intended position.

[0068] The recesses 61 of the clamping ring or adapter 30 are designed as radial grooves open towards the stator carrier 29. The clamping ring 30 has two semi-rings 30a and 30b connected to each other, in particular interlocked, at radially opposite joints 62. Only one of the two semi-rings, here the upper semi-ring 30a, has the recesses 61 for the phase connection wires 26. This makes it possible to place the clamping ring 30 radially R onto the stator carrier 29 or to mount it radially on both sides. The semi-ring 30a with the recesses 61 is placed over the phase connection wires 26, which are arranged semicircularly or axially in the circumferential direction of the stator carrier 29.

[0069] The clamping ring as a connection adapter 30 has a radial ring section 63 and an axial ring section 64, which is integrally formed with the radial ring section 63 and points towards the stator 12. The radial ring section 63 has a central ring opening 65, the inner diameter or clear width of which corresponds to the outer diameter of the stator support 29, so that the clamping ring 30 can be easily and reliably placed on the stator support 29 and held thereon, preferably without play.

[0070] The phase connection wires 26 are guided into a radially oriented joining and / or contacting position on the side of the clamping ring 30 facing away from the stator 12 or its stator body 58, and are bent radially for this purpose. Due to the secure positioning of the phase connection wires 26 by means of the clamping ring or connection adapter 30, the phase connection wires 26 can be brought into the position and orientation shown automatically or fully automatically.

[0071] In the exemplary embodiment, six phase connection wires 26 or three phase connection pairs are provided. The phase connection wires 26 are arranged equidistant from each other around the circumference of the stator carrier 29 in the circular sector of approximately 135° formed by the clamping ring 30 and in the circumferential direction of the stator carrier 29. In this, preferably radial, orientation, the phase connections 26 can be reliably routed to the printed circuit board 21 of the motor electronics 22 for electrical contact and made there.

[0072] In summary, the invention relates to a drive device 1 with a brushless electric motor 4, comprising a rotor 13 and a stator 12, comprising a stator support 29 and a stator winding 14 with a number of phase connection wires 26. The drive device 1 has a gearbox housing 2 with an electronics compartment 23 containing a printed circuit board 21 with connection points 27 for the phase connection wires 26, which can be inserted or received therein, and a housing shaft 25 coaxial with the axis of rotation D or the rotor shaft 16, into which the electric motor 4 or the stator 12 with the stator support 29 and the rotor 13 with the rotor shaft 16, in particular as a stator-rotor assembly, can be received or inserted.

[0073] A connection adapter 30, in which the phase connection wires 26 are received, inserted, or threaded, serves to bend and / or orient the phase connection wires 26 in the radial direction R and to align the phase connection wires 26 in a connection grid adapted to the connection points 27 of the printed circuit board 21, in particular a tangential grid. The connection adapter 30 can also serve as transport protection or transport securing, in particular for the beginning (winding start) of the stator winding 14 and / or for the coil ends of the coils 15 (end wires).

[0074] The invention also relates to a drive device 1, comprising a brushless electric motor 4 with a rotor 13 and with a stator 12, which has a stator base body 58 mounted on a tubular or cylindrical stator carrier 29 with a number of stator teeth 59 and a stator winding 14 arranged thereon with a number of phase connection wires 26 extending at least partially axially, and a clamping ring 30 mounted on the stator carrier 29, preferably composed of half rings 30a, 30b, with a number of recesses 61 through which the phase connection wires 26 are guided.

[0075] The claimed invention is not limited to the embodiment described above. Rather, other variants of the invention can also be derived by a 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 embodiments can also be combined in other ways within the scope of the disclosed claims without departing from the subject matter of the claimed invention.

[0076] Furthermore, the described solution can be used not only in the specifically illustrated application case, but also in a similar form in other motor vehicle applications, such as door and tailgate systems, vehicle locks, adjustable seat and interior systems, and other electric drives.

Claims

1. Drive apparatus (1), in particular an electromotive adjusting drive of a motor vehicle, comprising - a brushless electric motor (4) having a rotor (13) with a rotor shaft (16) coupled to it and having a stator (12) which comprises a socket-like or hollow-cylindrical stator support (29) and a stator main body which is mounted on the stator support (29) and has a rotary field winding or stator winding (14) having a number of phase connection wires (26), - a gear mechanism housing (2) having an electronics compartment (23) with a printed circuit board (21) which can be inserted or is received in it and has connection points (27) for the phase connection wires (26) and having a housing shaft (25) which is coaxial with respect to the rotation axis (D) of the rotor shaft (16) and in which the stator (12) is received or can be inserted by way of the stator support (29) and the rotor (13) is received or can be inserted by way of the rotor shaft (16), and - a connection adapter (30) in which the phase connection wires (26) are radially oriented and are received in a connection grid which is adapted to the connection points (27) of the printed circuit board (21), - wherein the connection adapter (30) has an annular portion (44, 55, 63, 64) which engages partially or completely around the stator support (29).

2. Drive apparatus (1) according to Claim 1, characterized - in that the connection adapter (30) has a number, in particular a number corresponding to the number of phase connection wires (26), of hole- or slot-like wire openings (35), and / or - in that the connection adapter (30) has a number, in particular a number corresponding to the number of phase connection wires (26), of wire openings (35) which are arranged in a connection grid which is tangentially oriented and radially spaced-apart from the stator support (29), and / or - in that the connection adapter (30) has a number, in particular a number corresponding to the number of phase connection wires (26), of slot-like wire openings (35), which are arranged along an arc of a circle with a centre point angle (α) of between 100° and 180°, preferably with a centre point angle (α) of (130 ± 15)°, in particular as or in the form of axial grooves, or recesses (61), in particular as or in the form of radial grooves.

3. Drive apparatus (1) according to Claim 1 or 2, characterized in that the connection adapter (30) has at least one joining element (31, 53) which corresponds to a joining opening in the gear mechanism housing (2), preferably in the region of a transition between the electronics compartment (23) and the housing shaft (25).

4. Drive apparatus (1) according to any of Claims 1 to 3, characterized - in that the connection adapter (30) has a number of, preferably two, axially oriented, in particular pin-like or dowel-like, joining elements (53), or - in that the connection adapter (30) has an, in particular pin-like or dowel-like, preferably radially orientated, joining element (31) which is integrally formed via at least one predetermined breaking point (33), wherein a joining connection becomes or is established by pressing the joining element (31) on the adapter into the joining opening in the housing.

5. Drive apparatus (1) according to any of Claims 1 to 4, characterized - in that the connection adapter (30) has radially oriented caulking studs (34) for fixing the printed circuit board (21), and / or - in that at least one caulking stud (34') for fixing the printed circuit board (21) is provided in the electronics compartment (23) of the gear mechanism housing (2).

6. Drive apparatus (1) according to any of Claims 1 to 5, characterized by at least one, in particular half-shell-shaped, slot cell insulation (45) which is associated with the stator (12), is provided as a coil or winding former for the stator winding (14), which is formed in particular from individual, double or multiple coils, and has a collar-like cap portion (46) which engages around the stator support (29).

7. Drive apparatus (1) according to Claim 6, characterized in that the annular portion (44, 55) of the connection adapter (30) partially or completely engages around the sleeve-like cap portion (46) of the slot cell insulation (45).

8. Drive apparatus (1) according to Claim 7, characterized - in that the closed annular portion (44) of the connection adapter (30) has a joining contour (49) which corresponds to a joining groove (50) of the cap portion (46) of the slot cell insulation (45) so as to establish a positive-locking connection, or - in that the partially closed annular portion (44) of the connection adapter (30) has arc-shaped latching arms (55) with latching elements (56) at the end, the latching elements latching on corresponding latching contours (57) on the cap portion (46) of the slot cell insulation (45) in the assembled state.

9. Drive apparatus (1) according to Claim 2, characterized - in that the connection adapter, as a clamping ring (30), has a radial annular portion (63) with a ring opening (65) for the stator support (29) and with the recesses (61) for the phase connection wires (26) and has an axial annular portion (64) integrally formed on the radial annular portion (63), in particular directed towards the stator (12), and / or - in that the clamping ring, as the connection adapter (30), has two half-rings (30a, 30b) which can be or are joined to each other.

10. Drive apparatus (1) according to any of Claims 1 to 9, characterized in that six phase connection wires (26) or three phase connection pairs are provided.

11. Drive apparatus (1) according to any of Claims 1 to 10 for use in a window regulator, in particular in a cable window regulator.