ELECTRIC MOTOR WITH STATOR WINDING, SENSOR AND INSULATION RING

Description

[0001] The invention relates to an electric motor with stator winding, sensor and insulating ring.

[0002] It is generally known that an electric motor has a stator winding contained in a stator lamination stack and a rotor rotatably mounted relative to the stator lamination stack.

[0003] An electrical machine is known from DE 10 2018 119 831 A1.

[0004] A stator of an electric motor is known from DE 10 2019 206 641 A1.

[0005] A stator for an electric machine is known from DE 10 2016 213 710 A1.

[0006] From DE 10 2013 003 024 A1 an electric motor of a vehicle component is known.

[0007] From the DE 10 2013 003 052 A1 The most recent state of the art is an electric motor with a stator winding.

[0008] From the DE 10 2020 107860 A1 A device for attaching a temperature sensor to an electric machine is known.

[0009] From the EP 1 727 261 A1 is a known stator for an electric motor.

[0010] From the EP 2 306 622 A1 A stator arrangement for an electric motor is known.

[0011] The invention is therefore based on the objective of further developing an electric motor, enabling simple and safe assembly and simple and safe operation. According to the invention, this objective is achieved in the electric motor according to the features specified in claim 1.

[0012] Important features of the invention in the electric motor are that the electric motor is designed with a stator winding, sensor and insulating ring, in particular wherein the sensor is a temperature sensor, in particular a Pt1000, wherein a lever area is formed on the insulating ring in which the sensor is received, wherein the sensor is elastically pressed against the stator winding by the lever area.

[0013] An advantage of this design is that actuating the lever mechanism allows the sensor to tilt in such a way that the insulating ring can be easily and safely slid into place before the potting compound is applied. After the insulating ring is slid into place, the lever mechanism can be released, allowing the sensor to be pressed against the stator winding with elastic preload. The potting compound can then be applied.

[0014] In an advantageous embodiment, the insulating ring is connected to a connecting ring, in particular by clips. The connecting ring comprises sheet metal parts that are mounted in a carrier, in particular a plastic carrier, of the connecting ring, the sheet metal parts being electrically connected to the ends of the winding wires of the stator winding. An advantage of this arrangement is that the insulating ring is held over the connecting ring, which in turn is held over the winding wire. This ensures that the insulating ring is securely held over the connecting ring. The insulating ring surrounds the connecting ring radially and thus contributes to increased insulation strength. This is because the insulating ring is arranged radially between the current-carrying sheet metal parts of the connecting ring and the metallic stator housing.

[0015] In an advantageous embodiment, the winding wires, particularly the stator winding, are held in place by the connecting ring, especially in that potting compound additionally surrounds the connecting ring and contacts both the insulating ring and the stator winding. It is advantageous that the connecting ring is axially spaced from the stator lamination stack that supports the stator winding. A particularly high level of reliability can be achieved by means of the potting compound.

[0016] In an advantageous embodiment, radially inwardly projecting connection areas are formed on the insulating ring, which are clipped to the connecting ring. The advantage here is that a simple, quick, and secure connection is enabled by allowing the insulating ring to be slipped onto the connecting ring and positively locked in place.

[0017] According to the inventionThe insulating ring has two radially inward-projecting protrusions that are spaced apart from each other in the circumferential direction. wherein the lever area is connected to a first of the two projections via a first rotational area, in particular wherein the lever area, on its side facing away from the first rotational area in the circumferential direction, is connected to the second of the two projections via a second rotational area, in particular wherein the two rotational areas are formed with a smaller material thickness than the lever area and the respective projection. It is advantageous that the rotational areas can be easily implemented as thinned material regions. The projections are integrally formed on the insulating ring, wherein the lever area is connected to the projections via the thinned material regions, i.e., rotational areas.

[0018] In an advantageous embodiment, the sensor is inserted into a tube, the first end of which is sealed by a material-bonded connection, in particular by compression welding, and the first end of the tube is inserted into a recess located on the lever area and extending through the lever area. An advantage of this design is that the sensor can be held securely and easily.

[0019] In an advantageous embodiment, an electrical connection cable is attached to the sensor, protruding from the other end of the hose. Two circumferentially spaced hook areas, projecting radially inwards, guide and / or hold the connection cable. It is advantageous that the hose surrounds the sensor and at least part of the connection cable. This provides a protective function and improves safety.

[0020] In an advantageous embodiment, a first, radially inwardly projecting hook area is formed on the insulating ring, which guides and / or holds the sensor's connecting cable. The advantage here is that the connecting cable is securely held in a simple manner.

[0021] In an advantageous embodiment, a second hook area projecting radially inwards is formed on the insulating ring, which guides and / or holds the sensor's connecting cable. wherein the first hook area is spaced apart from the second hook area in the circumferential direction, in particular wherein the first hook area has a smaller distance to the lever area than the second hook area, in particular wherein the first hook area has a nose area, in particular a nose area radially limiting the connecting lead, which is directed towards the stator winding, in particular wherein the second hook area has a nose area which is directed away from the stator winding. It is advantageous that the two oppositely configured hooks ensure a secure hold of the connecting leads and thus improve safety.

[0022] In an advantageous embodiment, the connection ring with its sheet metal components is designed such that the stator winding is connected in either a star or delta configuration. A key advantage is that the specific connection configuration is defined within the connection ring. This reduces wiring errors and thus increases safety.

[0023] In an advantageous embodiment, connections for electrical supply lines are arranged on the connecting ring, wherein the insulating ring has a double wall which covers an area circumferentially, containing the area covered circumferentially by the connections. It is advantageous that the connecting ring can be connected to the supply lines at its connections and is mechanically held by the winding wire ends connected to the sheet metal parts, thereby simultaneously achieving electrical contact for supplying the stator winding.

[0024] In an advantageous embodiment, the axial direction is aligned parallel to the direction of rotation of the electric motor's rotor, wherein the area covered in the axial direction by the sheet metal parts and / or the connections is encompassed by the area covered in the axial direction by the double wall. It is advantageous that the connection area is protected radially outwards with increased safety by the double wall made of electrically insulating material of the insulating ring.

[0025] In an advantageous embodiment, the lever area protrudes on the side of the insulating ring facing away from the stator winding. The advantage here is that the lever area can be easily actuated while the insulating ring is being placed onto the connecting ring, in order to keep the sensor away from the stator winding during this process, particularly as protection against damage to the sensor.

[0026] Additionally, the sensor is protected by the overlying hose, which itself is made of electrically insulating material.

[0027] In an advantageous embodiment, the stator winding is housed in a stator lamination stack. In particular, wherein the stator lamination stack is inserted into a stator housing of the electric motor, and especially wherein the insulating ring is radially spaced from the stator housing, or wherein the insulating ring is inserted into the stator housing with some play. It is advantageous that the insulating ring is attached to the stator lamination stack via the connecting ring and the winding wires or the stator winding, and that this stator lamination stack can be inserted into the stator housing, with the play preventing damage to the insulating ring. Finally, the connecting ring can be surrounded by potting compound, which at least touches the inside of the insulating ring.

[0028] In an advantageous embodiment, the rotor of the electric motor is rotatably mounted by means of at least one bearing, wherein the bearing is received in the stator housing or the bearing is received in a bearing shield or bearing flange connected to the stator housing. An advantage of this is that the electric motor is easy to manufacture.

[0029] Further advantages arise from the sub-claims.

[0030] The invention will now be explained in more detail with reference to schematic illustrations: In the Figure 1 The stator of an electric motor according to the invention is shown in an oblique view, wherein a connecting ring and an insulating ring are provided on a stator winding.

[0031] In the Figure 2 is in contrast to Figure 1 The circuit ring is hidden.

[0032] In the Figure 3A radially cut section is shown in which a sensor 5 with hose is provided.

[0033] In the Figure 4 A top view in the axial direction towards sensor 5 is shown.

[0034] As in the Figures 1 to 4 As shown, the stator has a stator lamination stack 3 in which a stator winding 2 with a winding head is accommodated. The winding head is the region of the stator winding 2 that projects axially from the stator lamination stack 3, in particular where the winding wires are deflected in the winding head.

[0035] The winding wire ends of the stator winding 2 protrude axially and are electrically connected to sheet metal parts 7, in particular copper sheets, of the interconnection ring. The interconnection ring is also held in place by the winding wire ends.

[0036] The sheet metal parts 7 are held in a plastic carrier 6, so that the interconnection ring can be slid onto the winding wire ends as a unit during assembly.

[0037] In the interconnection ring, the stator winding is connected as a star connection or as a delta connection.

[0038] An insulating ring 1, made of electrically insulating material, in particular plastic, is aligned coaxially with the connecting ring. The axis of rotation of the rotor of the electric motor (not shown in the figures) is therefore coaxial with the ring axis of the connecting ring or the insulating ring 1.

[0039] The insulating ring 1 is pushed onto the connecting ring in the axial direction during assembly and connected to the connecting ring by radially inward projecting connection areas 8 formed on the insulating ring 1, in particular by clipping it into the connecting ring. Preferably, a locking lug is formed on each connection area 8, which enables the insulating ring 1 to be locked onto the connecting ring.

[0040] The area covered in the axial direction by the sheet metal parts 7, in particular copper sheets, is encompassed by the area covered in the axial direction by the insulating ring 1. Thus, the insulating ring 1 insulates the current-carrying sheet metal parts 7 from the stator housing 30, which radially surrounds the insulating ring.

[0041] In particular, the insulating ring 1 surrounds the sheet metal parts 7 radially.

[0042] As in Figure 4As shown, radially inwardly directed projections 40 are formed on the insulating ring 1, which are spaced apart from each other in the circumferential direction. In the circumferential direction between the two projections 40, a lever section 4 of the insulating ring 1 is formed, which is connected to the projections 40 via two rotational sections 41, which act as pivot joints.

[0043] The rotation areas 41, the lever area 4 and the projections 40 are formed integrally, in particular in one piece, on the insulating ring 1. Thus, the insulating ring 1 is preferably designed as a plastic injection-molded part.

[0044] The lever area 4 projects from the rotation areas 41 both in the axial direction and in the opposite direction to the axial direction.

[0045] The torsion sections 41 are made with a much thinner material compared to the material thickness of the projections 40 and / or the lever section 4. Thus, when the lever section 4 pivots, each of the two torsion sections is elastically twisted and therefore acts as a pivot joint with a restoring force or as a torsional spring. During assembly, the portion of the lever section 4 that projects axially upwards in the figures is pressed radially inwards, thereby pushing the other end of the lever section 4 away from the stator winding 2, in particular from the winding head. After releasing the lever section 4, it pivots back into its original position.

[0046] The stator housing 30 accommodates the stator lamination stack 3 by inserting the latter into an internal cylindrical recess of the stator housing 30. The insulating ring 1 is also inserted into the recess, but there is a non-zero axial gap between the stator lamination stack 3 and the insulating ring 1.

[0047] A groove-like receptacle for the sensor 5, which is inserted into a hose, is formed on the lever area 4. The sensor cable 32, which serves as a connecting cable, protrudes through the hose to a first end of the hose 5 and is guided and held by two circumferentially spaced, radially inwardly projecting hook areas 21.

[0048] The second end of the hose is crimped and welded, specifically crimped and sealed by thermal heating. This second hose end is inserted through a through-hole, in particular a hole, the recess being located at the end of the lever section 4 facing the stator lamination stack. Specifically, the recess extends axially through the material of the lever section 4. In this way, the sensor 5 is positively locked in place.

[0049] The hook sections 21 are oriented in opposite directions. Thus, in particular, the first of the two hook sections 21, which is located closer to the sensor 5 than the second of the two hook sections 21, is oriented away from the stator lamination stack. The second hook section 21 is oriented towards the stator lamination stack.

[0050] In particular, the first hook section has a radially inwardly projecting arm section formed on the insulating ring 1, at the radially inward end of which a nose section projects axially away from the stator lamination stack 30. Similarly, the second hook section has a radially inwardly projecting second arm section formed on the insulating ring 1, at the radially inward end of which a nose section projects axially toward the stator lamination stack 30.

[0051] After releasing the lever area 4 during assembly, the sensor 5 is pressed radially inwards against the stator winding 2, in particular against the winding head protruding from the stator lamination stack 3, as shown in Figure 3 clearly visible.

[0052] Preferably, the interconnection ring, including the insulating ring, is encased in potting compound, wherein the insulating ring 1 is in contact with the potting compound not on its radially outer surface, but only on its radially inner surface. The plastic carrier 6 of the interconnection ring, together with the sheet metal parts 7, is encased in the potting compound.

[0053] The end region of the lever region 4, facing away from the stator lamination stack 3, protrudes from the remaining insulating ring in an axial direction.

[0054] A double wall 9 is formed on the insulating ring 1, which covers in the circumferential direction the area in which the connections of the wiring ring are arranged, in particular those that can be connected to supply lines for supplying the electric motor. The double wall 9 is preferably spaced at a constant distance in the radial direction from the radially outer edge of the insulating ring 1, in particular, it is designed with a constant distance from the radially outer edge of the insulating ring 1.

[0055] In further embodiments according to the invention, the plastic carrier 6 together with the insulating ring 1 is manufactured in one piece, i.e. as a single unit, in particular as a plastic injection molded part.

[0056] In further embodiments of the invention, the end region of the lever section 4 facing away from the stator lamination stack 3 is made shorter in the axial direction, so that the lever section 4 does not project axially beyond the remaining insulating ring 1. In particular, the lever section 4 can also be designed as a one-sided lever that projects axially only towards the stator lamination stack. During assembly, the sensor 5 is then pressed radially outwards and released after or during insertion, so that the sensor 5 then comes into contact with the stator winding 2, in particular the winding head of the stator winding. Reference symbol list

[0057] 1 Insulating ring 2 Stator winding, in particular winding head 3 Stator lamination stack 4 Lever area of ​​insulating ring 1 5 Sensor with hose 6 Plastic carrier 7 Sheet metal part, in particular copper sheet 8 Connection area 9 Double wall 20 Hook area 21 Hook area 30 Stator housing 31 End area of ​​the hose 32 Sensor cable 40 Projection, in particular radially inward 41 Rotation area, in particular acting as a swivel joint

Claims

1. Electric motor comprising a stator winding (2), a sensor (5) and an insulating ring (1), the insulating ring being made of highly electrically insulating material, in particular plastics material, the insulating ring insulating current-carrying sheet metal parts of the electric motor from the stator casing of the electric motor, which stator casing radially encloses the insulating ring, the sensor in particular being a temperature sensor, in particular a Pt1000, a lever region (4) in which the sensor is housed being formed on the insulating ring, the sensor being resiliently pressed onto the stator winding by the lever region, characterised in that two radially inwardly protruding projections (40) that are spaced apart from one another in the circumferential direction are formed on the insulating ring, the lever region being formed between the two projections in the circumferential direction and being connected to a first of the two projections by means of a first torsion region (41).

2. Electric motor according to claim 1, characterised in that the insulating ring is connected, in particular clip-connected, to an interconnection ring, the interconnection ring having sheet metal parts that are housed in a support, in particular a plastics support of the interconnection ring, the sheet metal parts being electrically connected to ends of the winding wires of the stator winding.

3. Electric motor according to claim 2, characterised in that the winding wires, in particular the stator winding, hold the interconnection ring, potting compound in particular additionally enclosing the interconnection ring and being in contact with both the insulating ring and the stator winding.

4. Electric motor according to claim 2 or claim 3, characterised in that the connection regions (8) are clip-connected to the interconnection ring.

5. Electric motor according to any of the preceding claims, characterised in that the lever region is connected, on its side facing away from the first torsion region in the circumferential direction, to the second of the two projections by means of a second torsion region, the two torsion regions in particular being formed having a lower material thickness than the lever region and the associated projection.

6. Electric motor according to any of the preceding claims, characterised in that the sensor is inserted into a tube, the first tube end of which is sealed in an integrally bonded manner, in particular is fused together in a compressed manner, the first tube end being inserted into a through-opening that is arranged on the lever region and passes through the lever region.

7. Electric motor according to any of the preceding claims, characterised in that an electrical connection line is connected to the sensor and projects out of the other tube end of the tube, the connection line being guided and / or held by two radially inwardly projecting hook regions that are spaced apart from one another in the circumferential direction.

8. Electric motor according to any of the preceding claims, characterised in that a first radially inwardly protruding hook region is formed on the insulating ring and guides and / or holds the connection line of the sensor.

9. Electric motor according to any of the preceding claims, characterised in that a second radially inwardly protruding hook region is formed on the insulating ring and guides and / or holds the connection line of the sensor, the first hook region and the second hook region being spaced apart from one another in the circumferential direction, the first hook region in particular being at less of a distance from the lever region than the second hook region, the first hook region in particular having a lug region pointing towards the stator winding, in particular a lug region that radially delimits the connection line, the second hook region in particular having a lug region pointing away from the stator winding.

10. Electric motor according to claim 2 and according to any of the other preceding claims, characterised in that the interconnection ring having the sheet metal parts is suitably configured such that the stator winding is wired in a Y configuration or a delta configuration.

11. Electric motor according to claim 2 and according to any of the other preceding claims, characterised in that terminals for electrical supply lines are arranged on the interconnection ring, the insulating ring having a double wall which, in the circumferential direction, covers a region that includes the region covered by the terminals in the circumferential direction.

12. Electric motor according to claim 11, characterised in that the axial direction is oriented in parallel with the direction of the axis of rotation of the rotor of the electric motor, the region covered by the sheet metal parts and / or the terminals in the axial direction being encompassed by the region covered by the double wall in the axial direction.

13. Electric motor according to any of the preceding claims, characterised in that the lever region protrudes on the side of the insulating ring facing axially away from the stator winding.

14. Electric motor according to any of the preceding claims, characterised in that the stator winding is housed in a stator laminated core, the stator laminated core in particular being pushed into a stator casing of the electric motor, the insulating ring in particular being radially spaced apart from the stator casing, or the insulating ring being inserted into the stator casing with play.

15. Electric motor according to any of the preceding claims, characterised in that a rotor of the electric motor is rotatably mounted by means of at least one bearing, the bearing being housed in the stator casing, or the bearing being housed in an end shield or bearing flange connected to the stator casing.