Electric drive device for a vehicle, housing assembly for an electric drive device, and method for installing a housing assembly

Abstract

The invention relates to a housing assembly for an electric drive device for a vehicle, comprising a housing, which defines an interior and which has an opening that extends between an outer surface of the housing and the interior; a receiving area, which is arranged in the interior in the region of the opening; an electric cable, which is connected to the receiving area and which extends through the opening; and a cable holding device with a cover, which has a first recess filled with a sealant on a contact surface facing the outer surface of the housing, and with a counter bearing, which is provided on the outer surface of the housing and which has a second recess laterally adjoining the opening of the housing, said second recess being filled with sealant at least in some regions. The cover covers the opening of the housing, and the first recess and the second recess are arranged one over the other. The cable runs between the counter piece and the cover through the first and second recess and is enclosed by the sealant in the recesses.

Description

[0001] Description

[0002] title

[0003] Electric drive device for a vehicle and housing assembly for an electric drive device and method for assembling a housing assembly

[0004] Technical area

[0005] The present invention relates to an electric drive device for a vehicle, a housing assembly for an electric drive device and a method for assembling a housing assembly.

[0006] State of the art

[0007] Electric drive systems for vehicles feature an electric motor to generate torque at the vehicle's wheels. The electric motor is typically housed in a housing. Sensors are typically located inside the housing to monitor the operation of the electric motor. The data collected by the sensors is transmitted via electrical conductors in the form of cables. The cable is routed to the outside through an opening in the housing. To prevent water, dirt, and the like from penetrating the interior of the housing, the opening is sealed with the cable.

[0008] DE 199 21 564 A1 describes a cable feedthrough from a gearbox housing, wherein the opening through which the cable extends is filled with a casting compound. Disclosure of the invention

[0009] Against this background, the present invention provides a housing assembly having the features of claim 1, a method for assembling a housing assembly having the features of claim 9, and an electric drive device having the features of claim 10. Advantageous embodiments and further developments emerge from the further subclaims and from the description with reference to the figures of the drawing.

[0010] According to a first aspect of the invention, a housing assembly for an electric drive device for a vehicle comprises a housing defining an interior space and having an opening extending between an outer surface of the housing and the interior space, a receptacle arranged in the region of the opening in the interior space, an electrical cable connected to the receptacle and extending through the opening, and a cable holder having a cover having a first recess filled with a sealing compound on a contact surface facing the outer surface of the housing, and having a counterbearing provided on the outer surface of the housing, which counterbearing has a second recess laterally adjacent to the opening of the housing and at least partially filled with sealing compound. The cover covers the opening of the housing, and the first recess and the second recess are arranged one above the other.The cable runs between the counterpart and the cover through the first and second recesses and is enclosed by the sealing compound in the recesses.

[0011] According to a second aspect of the invention, a method for assembling a housing assembly according to the first aspect of the invention is provided. The method comprises passing the cable through the opening of the housing, connecting the cable to the receptacle, positioning the cable in the second recess of the counterpart, which is at least partially filled with sealant, and positioning the cover such that it covers the opening of the housing and the first recess filled with sealant and the first and second recesses lie one above the other to enclose the cable with sealant.

[0012] According to a third aspect, an electric drive device for a vehicle comprises a housing assembly according to the first aspect of the invention and an electric machine accommodated in the interior of the housing.

[0013] One idea underlying the invention is to guide a cable outwards through an opening in the housing such that it runs between a cover, which covers the opening, and a counter-bearing or counterpart, wherein a recess filled with moldable sealing compound is formed in the cover and the counterpart, through which recess the cable extends. The sealing compound in the recesses, which are arranged one above the other or, in other words, facing or opposite one another, encloses the cable and thus ensures a reliable seal. Between the cover and the counterpart, the cable thus runs in a direction transverse to a central axis of the opening, e.g. along a radial direction.

[0014] One advantage of routing the cable between the cover and the counterpart through the sealant-filled recesses in the cover and counterpart is its quick and easy installation. In particular, the cable can be freely connected to the receptacle through the opening and positioned in the recess of the counterpart. This is advantageous given the tolerance-dependent positioning of the receptacle relative to the opening. The opening is then closed by the cover, whereby a very good seal is achieved due to the cable being enclosed in the moldable sealant in the recesses of the cover and counterpart.

[0015] The sealant can be present in the recesses as a gel or viscoelastic fluid. For example, the sealant can be a two-component silicone gel.

[0016] According to some embodiments, it may be provided that the

[0017] The counterpart is implemented as a separate component from the housing and is attached to the housing. For example, the counterpart can have a frame connected to the housing, e.g., screwed to it, which surrounds the opening. The second recess can be formed in the frame, e.g., in the form of a groove extending transversely to the center axis of the opening. One advantage of providing the counterpart as a separate component is that it can be manufactured as a simple and cost-effective component, e.g., from a plastic material.

[0018] According to some embodiments, the counterpart may have a circumferential groove enclosing the opening, which groove is connected to the second recess and filled with sealing compound. The cover may have a web protruding from its contact surface, which is interrupted in the region of the first recess, and the web protrudes into the groove of the counterpart. Thus, the web of the cover is immersed in the sealing compound located in the groove, further improving the sealing effect of the cable holder.

[0019] According to some embodiments, it can be provided that the second recess is divided by a first separating web into a first region filled with sealing compound and a second region free of sealing compound, wherein the first separating web has a first interruption through which the cable is guided from the first into the second region. The first region can in particular be a region which is located inside or adjacent to the opening with respect to a radial direction, wherein the radial direction extends transversely to the central axis of the opening. The first separating web prevents the sealing compound from being removed or from escaping from the second opening, e.g. when the housing is subjected to high-pressure water from the outside during cleaning.

[0020] According to some embodiments, it can be provided that the second region is additionally delimited by a second separating web which has a second interruption through which the cable is led out of the second region. The second region thus extends between the first and the second separating web and forms a type of sealant-free barrier against external influences. In particular, the first and the second separating web create a type of encapsulation which even more effectively prevents the penetration of moisture, e.g. water, when the housing assembly is cleaned with a high-pressure cleaner. The second interruption can, for example, be dimensioned such that the cable is clamped in the second interruption. The cable itself therefore further improves the seal, for example against pressure loading when cleaning with a high-pressure cleaner.

[0021] According to some embodiments, it can be provided that at least two projections are formed in the second region, which are wrapped around the cable in such a way that the cable runs in a meandering manner between the projections. The projections can be designed as pins, for example. The cable only partially wraps around the projections. This creates frictional contact between the projections and the cable in order to form strain relief for the connection of the cable to the receptacle. The meandering course of the cable at least locally narrows a gap between the cable and the side walls of the second opening. Thus, the cable's meandering installation forms an additional barrier against the penetration of dirt and moisture.

[0022] According to some embodiments, the receptacle may be designed as a plug socket with a retaining opening into which a functional component electrically connected to the cable is inserted. The functional component may be, for example, a sensor.

[0023] According to some embodiments, a temperature sensor can be accommodated in the receptacle, which is electrically connected to the cable. For example, the temperature sensor can be designed as a cylindrical body that is inserted into the retaining opening.

[0024] According to some embodiments, the retaining opening can optionally have a funnel-shaped cross-section. This facilitates the insertion of the functional component into the retaining opening. The invention is explained below with reference to the figures of the drawings. The figures show:

[0025] Fig. 1 is a schematic sectional view of an electric drive device according to an embodiment of the invention;

[0026] Fig. 2 is a schematic sectional view of a housing assembly according to an embodiment of the invention in a partially exploded view;

[0027] Fig. 3 is a plan view of the housing assembly shown in Fig. 2;

[0028] Fig. 4 is a plan view of a contact surface of a cover of a cable holder of the housing assembly;

[0029] Fig. 5 is a sectional view of the housing assembly shown in Fig. 2 in the assembled state; and

[0030] Fig. 6 shows the sequence of a method for assembling a housing assembly according to an embodiment of the invention;

[0031] In the figures, the same reference symbols denote identical or functionally identical components, unless otherwise stated.

[0032] Fig. 1 schematically shows an electric drive device 200 for a vehicle, in particular for a motor vehicle such as a car. As schematically shown in Fig. 1, the drive device 200 comprises a housing assembly 100 and an electric machine 210.

[0033] The electric machine 210 is shown only schematically in Fig. 1 and can, for example, be a three-phase machine. As shown in Fig. 1, the electric machine 210 has a stator 211 and a rotor 212 rotatable relative to the stator 211, having a rotor shaft 213 which can be kinematically coupled to a wheel (not shown) of the vehicle. The housing assembly 100 comprises a housing 1, a receptacle 2, a cable 3, and a cable holder 4, as shown schematically in Fig. 1. Figs. 2, 3, and 5 show schematic detailed views of the housing assembly 1 in the region of the cable holder 4.

[0034] As shown in Fig. 1 purely by way of example, the housing 1 can, for example, be a cylindrical housing 1 with opposite, substantially flat end faces 1 C, 1 D. In general, the housing 1 has an outer surface 1 a and an inner surface 1 b oriented opposite thereto, which defines an interior space 10.

[0035] As shown in Fig. 1, the electric machine 210 is accommodated in the interior 10 of the housing 1. The rotor shaft 213 can protrude through a shaft opening 12 in the end face 1C.

[0036] As further shown in Fig. 1, the housing 1 has an opening 11 for the passage of the cable 3. The opening 11 extends generally between the outer surface 1a and the inner surface 1b of the housing 1. The opening 11 can, for example, have a circular circumference. Alternatively, other circumferential shapes can also be provided, e.g. oval, rectangular, polygonal or the like. The opening 11 defines a central axis A11. A radial direction R1 extends perpendicular to the central axis A11. The opening 11 can, for example, be positioned on one of the end faces 1C, 1D, as is shown purely by way of example in Fig. 1.

[0037] The housing 1 can, in particular, be made of a metal material, e.g., an aluminum alloy, a steel, or the like. For example, the housing 1 can be manufactured using a casting process.

[0038] The receptacle 2 is shown only schematically in Fig. 1 and in detail in Figs. 2 and 5, the receptacle 2 can be designed, for example, as a plug socket with a holding opening 20. As shown in Fig. 2 purely as an example, the holding opening 20 can have a funnel-shaped cross-section at least in one end region. The receptacle 2 serves to hold or fix a functional component 6, such as a temperature sensor. The receptacle 2 is firmly connected to the housing 1 and arranged in the interior 10 of the housing 1 in the region of the opening 11, such that it is accessible from the outside through the opening 11. In particular, the receptacle 2 can be positioned within the circumference of the opening 11 with respect to the radial direction R1.

[0039] The cable 3 is an electrical cable with at least one electrical conductor (not shown) and an electrically insulating sheath 30. The cable 3 can be designed or provided, for example, for supplying energy and / or for transmitting signals, such as measurement signals. As shown by way of example in Fig. 2, a functional component 6, e.g. in the form of a temperature sensor 60, can be electrically conductively connected to the cable 3. As shown in Fig. 5, the cable 3 extends through the opening 11 of the housing 1 and is connected to the receptacle 2, e.g. by the functional component 6 being inserted into the receptacle opening 20.

[0040] The cable holder 4 is shown only schematically in Fig. 1 and in more detail in Figs. 2, 3, and 5. As shown schematically in Fig. 2, the cable holder 4 has a cover 40 and a counterpart or counter-bearing 44.

[0041] The cover 40 has a contact surface 40a, which can be designed, for example, as a substantially flat surface. As shown by way of example in Fig. 4, the cover 40 can, for example, have a circumference with a circular section 40C and a linear cut 40D. Other circumferential shapes are of course also conceivable. In general, the cover 40 is designed as a flat component. As shown schematically in Figs. 2 and 4, the cover 40 has a first recess 41 which is formed in the contact surface 40. The recess 41 can, for example, have a rectangular circumference, as shown purely by way of example in Fig. 4, or a different circumference. Optionally, the cover 40 also has a web 42 protruding from its contact surface 40a. As shown by way of example in Fig. 4, the web 42 can, for example, extend in the shape of a ring segment. In general, the web 42 can define a frame which is interrupted in the region of the first recess 41.

[0042] As schematically shown in Figs. 2 and 4, the first recess 41 of the lid 40 is filled with a sealing compound 5. The sealing compound 5 is formed from a moldable, e.g., gel-like or viscous material. For example, the sealing compound can be a two-component silicone gel.

[0043] As shown by way of example in Figs. 2, 3 and 5, the counterpart or counter bearing 44 can be realized as a component separate from the housing 1, which is arranged on the outer surface 1 a of the housing 1 and fastened to the housing 1. As shown by way of example in Fig. 2, the counter bearing 44 can be fixed to the housing 1, for example, by means of screws S.

[0044] As can be seen in particular in Fig. 3, the counter bearing 44 is implemented as a flat, for example plate-shaped component. The counter bearing 44 can have a first surface 44a and a second surface 44b oriented opposite thereto. As shown in Figs. 2, 3 and 5, the counter bearing 44 can have a collar 43A protruding from the second surface 44b. A through opening 43 extends between the first and second surfaces 44a, 44b and optionally through the collar 43A. As shown in Figs. 3 and 5, the counter bearing 44, if implemented as a separate component, can be positioned on the housing 1 in such a way that the second surface 44b faces the outer surface 1a of the housing 1 and optionally rests against it, and in such a way that the through opening 43 is located coaxially to the opening 11 of the housing 1. The collar 43, if provided, projects into the opening 11 of the housing 1.Optionally, a sealing ring 7 can be positioned between the collar 43 and the inner circumference of the opening 11, as shown by way of example in Fig. 2.

[0045] As can be seen in particular in Figs. 2 and 3, the counter bearing 44, regardless of whether it is implemented as a separate component from the housing 1 or not, has a second recess 45 which is also filled with sealing compound 5, at least in some regions. As shown in Figs. 2 and 3, the second recess 45 is arranged laterally adjacent to the opening 11 with respect to the radial direction R1 and, if appropriate, laterally adjacent to the opening 43. As shown schematically and merely by way of example in Fig. 3, the recess 45 can extend along the radial direction R1. For example, the recess 45 can be designed as an elongated or channel-shaped groove. As further shown in Fig. 3, the second recess 45 can be divided by a first separating web 47A into a first region which is filled with sealing compound 5 and a second region which is free of sealing compound 5. The first separating web 47A has, as shown in Fig.3, a first interruption or a first opening 48A for the passage of the cable 3. Optionally, the second region can also be additionally delimited by a second separating web 47B, which is arranged on a side of the first separating web 47A facing away from the opening 11 with respect to the radial direction R1. The second separating web 47B has a second interruption or a second opening 48B for the passage of the cable 3. Optionally, at least two projections 49 can be formed in the second region, which projections are spaced from one another in the radial direction R1 and optionally additionally in a direction parallel to the first surface 44a of the counter-bearing 44 or parallel to the outer surface 1a of the housing 1.

[0046] Furthermore, the counterpart 44 can have a circumferential groove 46 surrounding the opening 11 or the opening 43, if provided. The groove

[0047] 46 is formed in the first surface 44a of the counterpart 44, as shown schematically in Figs. 2 and 3. As further shown by way of example in Fig. 3, the groove 46 can, for example, extend in a ring shape around the opening 11 or 43. Alternatively, the groove 46 can also have a different course which defines a frame enclosing the opening 11 or 43. As shown in Figs. 2 and 3, the groove 46 is filled with sealing compound 5 and with the second recess 45, so that the groove 46 and the second recess 45 form a continuous depression in the first surface 44a of the counterpart 44. As further shown by way of example in Fig. 3, an optional third web 47C can be provided at the transition between the groove 46 and the second recess 45.In general, the first region of the second recess 45 can additionally be delimited by the third separating web 47C, which is arranged on a side of the first separating web 47A facing the opening 11 with respect to the radial direction R1. The third separating web 47C has a third interruption or a third opening 48C for the cable 3 to pass through. Fig. 5 shows the housing assembly 100 in the assembled state. As shown in Fig. 5, the cable 3 extends through the opening 11 of the housing 1 and is connected to the receptacle 2, e.g. by the functional component 6 being inserted into the receptacle opening 20. As shown in Figs. 3 and 5, the cable 3 also extends in the second recess 45 of the counter bearing 44 and through the second recess 45. The cable 3 is guided through the bridge 48A-C of the separating webs 47A-C. As shown in Fig.3, the cable 3 wraps around the optional projections 49 in such a way that it meanders between the projections 49. As a result of the wrapping, a frictional contact is created between the projections 49 and the cable 3, which counteracts the transmission of a tensile force applied to the cable 3 to the receptacle 2.

[0048] As further shown in Fig. 5, the cover 40 is positioned relative to the opening 11 such that it covers the opening 11. The contact surface 40a is oriented towards the first surface 44a of the counter-bearing 44 or the outer surface 1a of the housing 1 and can, for example, rest against the first surface 44a of the counter-bearing 44, as shown by way of example in Fig. 5. Furthermore, the cover 40 is positioned such that the first recess 41 of the cover 40 and the second recess 45 of the counter-bearing 44 are arranged one above the other or overlap one another. The cable 3 thus runs between the counter-bearing 44 and the cover 40 through the first and second recesses 41, 45. As a result, the cable 3 is completely enclosed by the sealing compound 5 located in the recesses 41, 45.Due to its malleable properties, the sealing compound 5 wraps around the cable 3, thus ensuring a reliable seal that prevents moisture from penetrating the interior 10 of the housing 1 from the outside. As further shown in Fig. 5, the web 42 of the cover 40 protrudes into the groove 46 of the counter-bearing 44 and thus dips into the sealing compound 5 located in the groove 46. This further improves the seal. The cover 40 and the counter-bearing 44 can be connected or fastened to one another, e.g., screwed, glued, welded, or in a similar manner.

[0049] Fig. 6 shows schematically the sequence of a method M for assembling the

[0050] Housing assembly 100. In a first step M1, the cable 3 is passed through the opening 11 of the housing 1. The cable 3 is introduced from the side of the outer surface 1a of the housing 1 into the interior 10 of the housing 1

[0051] In step M2, the cable 3 is connected to the receptacle 2. This may, for example, involve inserting the functional component 6 connected to the end of the cable 3 into the holding opening 20.

[0052] In step M3, the cable 3 is positioned in the second recess 45 of the counterpart 44, which is at least partially filled with sealing compound 5. In this step, the cable 3 is inserted into the second recess 45 and, if necessary, guided through the openings 48A-C of the separating webs 47A-C and laid around the projections 49.

[0053] In step M4, the cover 40 is positioned such that it covers the opening 11 of the housing 1 and the first recess 41 filled with sealing compound 5 and the first and second recesses 45 lie on top of each other to enclose the cable 3 with sealing compound 5, as shown in Fig. 5.

[0054] Although the present invention has been explained above using exemplary embodiments, it is not limited thereto, but can be modified in a variety of ways. For example, it is not absolutely necessary for the counterbearing 44 to be formed by a component separate from the housing 1. The counterbearing 44 can also be formed by the housing 1 itself. For example, the second recess 45 and the groove 46 can also be formed in the outer surface 1a of the housing 1. Combinations of the above exemplary embodiments are also conceivable.

Claims

Claims 1 . Housing assembly (100) for an electric drive device (200) for a vehicle, comprising: a housing (1) defining an interior space (10) and having an opening (11) extending between an outer surface (1a) of the housing (1) and the interior space (10); a receptacle (2) arranged in the region of the opening (11) in the interior space (10); an electrical cable (3) connected to the receptacle (2) and extending through the opening (11); and a cable holder (4) with a cover (40) which has a first recess (41) filled with a sealing compound (5) on a contact surface (40a) facing the outer surface (1a) of the housing (1), and with a counter bearing (44) provided on the outer surface (1a) of the housing (1), which counter bearing has a second recess (45) laterally adjacent to the opening (11) of the housing (1) and at least partially filled with sealing compound (5);wherein the cover (40) covers the opening (11) of the housing (1) and the first recess (41) and the second recess (45) are arranged one above the other, and wherein the cable (3) runs between the counter-bearing (44) and the cover (40) through the first and the second recess (41, 45) and is enclosed by the sealing compound (5) in the recesses (41, 45); 2. Housing assembly (100) according to claim 1, wherein the counter bearing (44) is realized as a component separate from the housing (1) which is fastened to the housing (1).

3. Housing assembly (100) according to claim 1 or 2, wherein the counter bearing (44) has a circumferential groove (46) surrounding the opening (11), which is connected to the second recess (45) and is filled with sealing compound (5), and wherein the cover (40) has a web (42) projecting from its contact surface (40a), which is interrupted in the region of the first recess (41), and wherein the web (42) projects into the groove (46) of the counter-bearing (44).

4. Housing assembly (100) according to one of the preceding claims, wherein the second recess (45) is divided by a first separating web (47A) into a first region filled with sealing compound (5) and a second region free of sealing compound (5), wherein the first separating web (47A) has a first interruption (48A) through which the cable (3) is guided from the first into the second region.

5. Housing assembly (100) according to claim 4, wherein the second region is additionally delimited by a second separating web (47B) which has a second interruption (48B) through which the cable (3) is led out of the second region.

6. Housing assembly (100) according to claim 4 or 5, wherein at least two projections (49) are formed in the second region, which are wrapped around by the cable (3) in such a way that the cable (3) runs meanderingly between the projections (49).

7. Housing assembly (100) according to one of the preceding claims, wherein the receptacle (2) is designed as a plug socket with a holding opening (20) into which a functional component (6) electrically connected to the cable (3) is inserted, wherein the holding opening (20) optionally has a funnel-shaped cross-section.

8. Housing assembly (100) according to one of the preceding claims, additionally comprising: a temperature sensor (60) accommodated in the receptacle (2), which is electrically conductively connected to the cable (3).

9. Method (M) for assembling a housing assembly (100) according to one of the preceding claims, comprising: Passing (M1) the cable (3) through the opening (11) of the housing; connecting (M2) the cable (3) to the receptacle (2); Positioning (M3) the cable (3) in the second recess (45) of the counterpart (44), which is at least partially filled with sealing compound (5); and Positioning (M4) the cover (40) such that it covers the opening (11) of the housing (1) and the first recess (41) filled with sealing compound (5) and the first and second recesses (45) lie one above the other in order to enclose the cable (3) with sealing compound (5).

10. An electric drive device (200) for a vehicle, comprising: a housing assembly (100) according to any one of claims 1 to 8; and an electric machine (210) accommodated in the interior (10) of the housing (1).

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