Electric machine, in particular for a motor vehicle, method for manufacturing such an electric machine and method for operating such an electric machine

Abstract

The invention relates to an electric machine, having at least one winding (12) that is able to be used to generate a magnetic field, and having a sensor device (22) that is able to be used to detect the magnetic field, wherein the sensor device (22) has: At least one circuit board (24) that has a plurality of circuit board regions (26) which are spaced at least partially from one another in the circumferential direction (36) of the electric machine and between which respective length regions (L) of the winding (12) are arranged; and magnetic field sensors (28) that are held on the circuit board (24) and that are able to be used to detect the magnetic field.

Description

[0001] Electrical machine, in particular for a motor vehicle, method for producing such an electrical machine and method for operating such an electrical machine

[0002] The invention relates to an electrical machine, in particular for a motor vehicle, according to the preamble of patent claim 1. Furthermore, the invention relates to a method for manufacturing such an electrical machine. The invention also relates to a method for operating such an electrical machine.

[0003] DE 102016 005232 A1 discloses a rotor position sensor for an electrical machine, comprising a capacitive sensor in which a first capacitor element is arranged on a rotating element and a second capacitor element and a third capacitor element are arranged on a static element of the electrical machine. Furthermore, DE 10 2013 020 985 A1 discloses an electrical machine, in particular for a motor vehicle, comprising a housing, a rotor shaft arranged at least partially in the housing and rotatable about an axis of rotation relative to the housing, and a sensor device comprising at least one rotor part connected in a rotationally fixed manner to the rotor shaft and at least one corresponding stator part fixed at least indirectly to the housing, for detecting at least one measured variable characterizing a rotation of the rotor shaft relative to the housing.DE 102013225141 A1 discloses a position sensor device for detecting the angular position of the rotor of an electrical machine. DE 102008042912 A1 discloses a sensor device for detecting the rotational position of a rotating component. DE 102007060241 A1 discloses an electrical machine with a stator and a rotor and a sensor device for detecting the relative position between the stator and rotor. DE 102012009906 A1 discloses an electrical machine with a stator, a rotor movable relative to the stator, and at least one sensor device. Furthermore, DE 102005004322 A1 discloses an electrical machine. DE 10331505 A1 discloses a sensor arrangement with an angle sensor for determining the position angle of a permanently excited synchronous machine.Furthermore, from DE 102007 028 482 A1 a sensor arrangement is known, comprising at least one sensor element which is arranged on at least one printed circuit board.

[0004] EP 2 214 296 A1 discloses an electronically commutating motor assembly with a motor housing opening into which a sensor housing with at least one Hall-effect sensor is engaged. The Hall-effect sensor is mounted on extensions of a circuit board that protrude from openings in the sensor housing and are positioned axially in slots between the teeth of the motor's stator laminations.

[0005] DE 102021 201 605 A1 relates to a rotor for an electric machine, wherein the rotor has at least one sensor element for detecting a state variable of the rotor. A signal processing unit generates measurement data from the detected state variable of the rotor, which is transmitted to a control device. An induction coil arranged on the front side of the rotor generates electrical energy during operation of the electric machine from a frontal stray field of the stator and makes it available to the sensor element and the signal processing unit.

[0006] The object of the present invention is to provide an electrical machine, in particular for a motor vehicle, a method for producing such an electrical machine and a method for operating such an electrical machine, so that a magnetic field of the electrical machine can be detected in a particularly advantageous manner.

[0007] This object is achieved by an electrical machine having the features of patent claim 1, by a method having the features of patent claim 11, and by a method having the features of patent claim 12. Advantageous embodiments with expedient further developments of the invention are specified in the remaining claims.

[0008] A first aspect of the invention relates to an electric machine, in particular for a motor vehicle. This means, for example, that the motor vehicle, also referred to as a vehicle and designed, for example, as a motor vehicle, in particular as a passenger car, has the electric machine in its fully manufactured state and can be driven, in particular purely electrically, by means of the electric machine. The electric machine has at least one winding by means of which a magnetic field can be generated, in particular for driving a rotor of the electric machine. This means, for example, that the electric machine, in its fully manufactured state, has the aforementioned rotor, which can be driven by means of the magnetic field.For example, in its fully manufactured state, the electric machine also has a stator, wherein the rotor can be rotated about a machine axis of rotation of the electric machine relative to the stator. In particular, the rotor can be driven by means of the stator and thus rotated about the machine axis of rotation relative to the stator. In particular, it is conceivable that the aforementioned winding is a winding of the stator and is therefore also referred to as a stator winding. For example, the electric machine can provide drive torques for driving the motor vehicle via its rotor. The electric machine also has a sensor device by means of which the magnetic field can be detected. In particular, a measured variable that characterizes the magnetic field, i.e. describes or indicates it, such as a magnetic flux of the magnetic field, can be detected by means of the sensor device.In other words, the sensor device can, for example, detect a magnetic flux of the magnetic field and thus the magnetic field itself, whereby the magnetic flux is also referred to as magnetic flux. Since the magnetic field can be used, for example, to drive the rotor, the magnetic field is also referred to as the rotor magnetic field. In particular, the magnetic field can be measured using the sensor device, so that the detection or measurement of the magnetic field is also referred to as magnetic field measurement or rotor magnetic field measurement.

[0009] In order to be able to detect the magnetic field particularly advantageously, the invention provides that the sensor device has a circuit board, also referred to as a printed circuit board or printed circuit card, which is also referred to as a printed circuit board and has a plurality of circuit board regions that are at least partially, in particular completely, spaced apart from one another in the circumferential direction of the electrical machine, between which respective longitudinal regions of the winding are arranged. The circumferential direction of the electrical machine runs around the machine axis of rotation. Since the circuit board regions are at least partially spaced apart from one another, respective through openings are arranged in the circumferential direction of the electrical machine between the circuit board regions, which through openings are continuous, in particular in the axial direction of the electrical machine, and coincide in the axial direction with the machine axis of rotation.The through-openings are penetrated by the longitudinal regions of the winding, in particular in the axial direction of the electrical machine. In particular, the circuit board regions are arranged between the longitudinal regions of the winding in the circumferential direction of the electrical machine in such a way that, viewed in the circumferential direction of the electrical machine, the longitudinal regions and the circuit board regions are arranged alternately one after the other. Furthermore, the invention provides that the sensor device has magnetic field sensors held on the circuit board, by means of which the magnetic field or the measured variable can be detected. In particular, the number of magnetic field sensors is at least 10. Preferably, the number of magnetic field sensors is greater than 10, in particular greater than or equal to 100. The invention enables a particularly cost-effective construction of the electrical machine, since the machine can be manufactured with only low material costs.Furthermore, cost-effective assembly is required, as no dedicated rotating part is required for detecting or measuring the magnetic field. Furthermore, a particularly space- and weight-efficient design of the electric machine is possible, as the magnetic field can be detected using only a small number of parts.

[0010] In particular, it is conceivable for the sensor device to have a plurality of circuit boards, namely the aforementioned circuit board and at least one or more further circuit boards, wherein the previous and following explanations regarding the first circuit board can easily be applied to the respective further circuit boards and vice versa. This makes it possible, for example, to detect the magnetic field simply and redundantly by means of the circuit boards and the respective magnetic field sensors held thereon. By detecting or measuring the magnetic field sensor or the magnetic flux, a failure of a current sensor can be detected at an early stage, for example. As a result, emergency operation of the electrical machine can be implemented, which can, for example, be operated, in particular controlled or regulated, in emergency operation depending on the detected magnetic field.

[0011] In order to realize a particularly weight-, space- and cost-effective design of the electrical machine and thus to be able to detect the magnetic field in a weight-, cost- and space-efficient manner, the invention provides that the circuit board regions are designed as teeth, which are also referred to as tabs or prongs. The teeth protrude in the radial direction of the electrical machine, the radial direction of which runs perpendicular to the axial direction of the electrical machine, and inwards from a base region of the circuit board that is common to the teeth. The teeth are held on the base region and held to one another via the base region, in particular in such a way that the teeth and the base region are designed as one piece with one another, i.e. are formed from a single piece.This means in particular that the teeth and the base region are not composed of parts that are formed separately from one another and connected to one another, but rather the teeth and the base region are preferably formed from a single piece, thus designed as a monoblock or formed by a monoblock. In other words, it is preferably provided that the teeth and the base region are formed from an integral body that is manufactured in one piece, thus formed from a single piece and thus manufactured integrally. Each tooth ends inwards in the radial direction of the electrical machine in a free end of the respective tooth that is opposite the annular region. The circuit board is therefore comb-shaped, thus in the form of a comb, the teeth of which are the prongs.This allows for a cost-effective, space-saving and weight-efficient design of the circuit board and thus of the sensor device as a whole, while also enabling time-saving and cost-effective assembly of the circuit board.

[0012] According to the invention, the circuit board is characterized in that the base region is circular or circular-segment-shaped on its side facing away from the teeth, which faces outward in the radial direction of the electric machine. This allows for a particularly space-saving design of the circuit board and thus of the sensor device as a whole on the outer circumference, so that the circuit board and thus the sensor device can be installed particularly advantageously. This allows for particularly good detection of the magnetic field.

[0013] According to the invention, the circuit board is inserted between the longitudinal sections in the radial direction of the electric machine, from the outside to the inside. This allows the circuit board and thus the sensor device to be assembled particularly quickly and cost-effectively, thereby enabling the electric machine to be manufactured particularly quickly and cost-effectively. Thus, the magnetic field can be detected, i.e., measured, in a particularly cost-effective manner.

[0014] In order to be able to detect the magnetic field particularly precisely and thus advantageously, one embodiment of the invention provides that a respective one of the magnetic field sensors is held, in particular precisely, on the respective circuit board area.

[0015] In a further embodiment of the invention, the magnetic field sensors are each at least partially embedded in the circuit board. This allows for a particularly space-efficient design of the sensor device, allowing the magnetic field to be detected particularly effectively.

[0016] In a further embodiment of the invention, the circuit board is manufactured by an injection molding process. In other words, the circuit board is preferably manufactured by injection molding. This allows a possibly complex circuit board geometry to be manufactured as needed in a particularly cost-effective manner, so that the circuit board can be advantageously positioned, particularly with respect to the winding. This allows the magnetic field to be detected particularly advantageously.

[0017] In order to be able to produce the circuit board particularly cost-effectively, a further embodiment of the invention provides that the circuit board is produced by laser direct structuring (LDS).

[0018] In a further, particularly advantageous embodiment of the invention, it is provided that the electrical machine has a laminated core carrying the winding, which is in particular formed separately from the winding.

[0019] It has proven particularly advantageous if a respective lamination segment of the laminated core is connected to the circuit board on both sides in the circumferential direction of the electric machine. This allows the circuit board to be integrated into the laminated core in a particularly space-efficient manner, particularly in the axial direction of the electric machine, thus enabling a particularly space-efficient design, especially in the axial direction of the electric machine.

[0020] For example, the circuit board is designed to fit a yoke (also referred to as a stator yoke) of the stator and / or an electrical pole of the electrical machine, allowing for a particularly advantageous integration of the circuit board and thus the sensor device into the electrical machine. For example, the circuit board is arranged directly between the stator yoke and a winding head of the winding, particularly in the axial direction of the electrical machine, allowing for a particularly advantageous arrangement of the circuit board and thus the sensor device. This allows for particularly effective detection, i.e., measurement, of the magnetic field.

[0021] For example, the stator yoke is the laminated core. The winding overhang is formed, for example, by the aforementioned longitudinal sections of the winding, such that the longitudinal sections and thus the winding overhang protrude from the stator or the laminated core in the axial direction of the electrical machine. In particular, it is provided that the longitudinal sections of the winding and thus the winding overhang protrude from an axial end face of the stator yoke or the laminated core in the axial direction of the electrical machine.

[0022] A further embodiment is characterized in that the respective sheet metal segment and the printed circuit board are arranged at least partially at the same height, viewed in the axial direction of the electrical machine. This allows for a particularly space-efficient design, particularly viewed in the axial direction of the electrical machine, and the printed circuit board and thus the sensor device can be integrated particularly advantageously into the electrical machine, allowing the magnetic field to be detected particularly effectively.

[0023] Furthermore, it is provided that the respective sheet metal segment and the circuit board are arranged flush with each other, particularly on a respective axial end face, which, for example, faces the winding head, thereby achieving a particularly space-efficient design. This allows the magnetic field to be detected particularly advantageously.

[0024] For example, the circuit board is at least partially, in particular at least predominantly and thus at least more than half or completely, overlapped by the laminated core in a first direction running parallel to the axial direction of the electrical machine or coinciding with the axial direction of the electrical machine. In this case, it is provided, for example, that the circuit board is arranged completely non-overlapping with the laminated core in a second direction running parallel to the axial direction of the electrical machine or coinciding with the axial direction of the electrical machine and opposite the first direction, and is therefore not overlapped by the laminated core. As a result, the magnetic field can be detected particularly advantageously by means of the sensor device, and the sensor device can be installed particularly easily and thus quickly and cost-effectively.

[0025] In a further embodiment of the invention, the respective magnetic field sensor is designed as a Hall sensor, whereby the magnetic field can be detected cost-effectively.

[0026] In order to be able to detect the magnetic field particularly precisely and thus particularly advantageously, it is provided in a further embodiment of the invention that the respective magnetic sensor is designed as an anisotropic magneto-resistive sensor, thus an AMR sensor.

[0027] Finally, it has proven particularly advantageous if the sensor device is designed to determine, i.e. to ascertain, at least one rotational position, also referred to as angular position or angular attitude, of the rotor of the electrical machine and / or an amplitude of the magnetic field and / or a temperature of the electrical machine as a function of the detected magnetic field or as a function of the detected measured variable. Since the rotor is rotatable about the machine axis of rotation relative to the stator, the rotor can be rotated into a plurality of mutually different rotational positions or angular attitudes relative to the stator. In this case, at least or exactly one of the rotational positions or a plurality of the rotational positions or angular attitudes can be detected by means of the sensor device as a function of the magnetic field.In particular, it is provided, for example, that the higher the number of magnetic field sensors, the higher the accuracy, also referred to as angular accuracy, with which the at least one rotational position or positions can be determined. The background of the invention is, in particular, that the electrical machine, preferably designed as a rotating field machine, can be operated, in particular controlled, particularly advantageously as a function of the rotational position, also referred to as the rotor position. Typically, determining the rotor position with the aid of magnetic field sensors is very inaccurate or a particularly large number of sensors is required, which must be individually mounted with precise positions, which leads to a very cost-intensive manufacturing process.The invention now makes it possible to assemble the circuit board and thus the sensor device in a time-efficient, cost-effective and particularly precise manner, so that the magnetic field and, for example, subsequently at least one rotational position can be detected precisely and cost-effectively. The amplitude, also referred to as flux amplitude or rotor flux amplitude, can be used as very advantageous additional information, for example to determine, in particular ascertain, and very particularly calculate the temperature as a function of the amplitude, in particular from the amplitude, where the temperature is, for example, a temperature of the rotor, also referred to as the rotor temperature. Furthermore, particularly advantageous condition monitoring of the electrical machine can be implemented, for example as a function of the amplitude.The invention also makes it possible to detect demagnetization or partial demagnetization of the rotor, as well as bearing damage and other damage, at an early stage, thus enabling particularly advantageous operation of the electrical machine. A second aspect of the invention relates to a method for producing an electrical machine, in particular according to the first aspect of the invention. In the method according to the second aspect of the invention, the electrical machine is equipped with at least one winding, by means of which a magnetic field can be generated, and with at least one sensor device, by means of which the magnetic field can be detected.

[0028] In order to detect the magnetic field in a particularly advantageous manner, the second aspect of the invention provides that the sensor device is made from a circuit board having a plurality of circuit board regions that are at least partially, in particular completely, spaced apart from one another in the circumferential direction of the electrical machine, between which respective length regions of the winding are arranged. Furthermore, the sensor device is made from magnetic field sensors mounted on the circuit board, by means of which the magnetic field can be detected. Advantages and advantageous embodiments of the first aspect of the invention are to be regarded as advantages and advantageous embodiments of the second aspect of the invention, and vice versa.

[0029] A third aspect of the invention relates to a method for operating an electrical machine according to the first aspect of the invention. Advantages and advantageous embodiments of the first aspect and the second aspect of the invention are to be regarded as advantages and advantageous embodiments of the third aspect of the invention, and vice versa.

[0030] Further advantages, features, and details of the invention will become apparent from the following description of a preferred embodiment and from the drawings. The features and combinations of features mentioned above in the description, as well as the features and combinations of features mentioned below in the description of the figures and / or shown alone in the figures, can be used not only in the respective specified combinations, but also in other combinations or on their own, without departing from the scope of the invention.

[0031] The drawing shows:

[0032] Fig. 1 is a schematic perspective view of a stator of an electrical machine, in particular for a motor vehicle; and Fig. 2 is a partial schematic perspective view of a circuit board of a sensor device of the electrical machine.

[0033] In the figures, identical or functionally identical elements are provided with the same reference symbols.

[0034] Fig. 1 shows a schematic perspective view of a stator 10 of an electrical machine, in particular of a motor vehicle. This means that the motor vehicle, also simply referred to as a vehicle and designed, for example, as a motor vehicle, in particular as a passenger car, has the electrical machine and can be driven, in particular purely electrically, by means of the electrical machine. Preferably, the electrical machine is a high-voltage component whose electrical voltage, in particular electrical operating or nominal voltage, is preferably greater than 50 volts, in particular greater than 60 volts, and very preferably amounts to several hundred volts. In its fully manufactured state, the electrical machine has the stator 10 and a rotor (not shown in the figures), which is rotatable relative to the stator 10 about a machine axis of rotation of the electrical machine, the axial direction of which coincides with the machine axis of rotation.In particular, the electric machine can provide drive torques to drive the motor vehicle via its rotor.

[0035] The electrical machine, in particular the stator 10, has at least one winding 12, by means of which a magnetic field, in particular with a magnetic flux also simply referred to as flux or magnetic flux, can be generated. The winding 12 is very preferably designed according to hairpin technology, also referred to as hairpin technology, and is therefore also referred to as a hairpin winding. Since the winding 12 is a winding of the stator 10, the winding 12 is also referred to as a stator winding. The stator 10 and thus the electrical machine have a laminated core 14, to which the winding 12 is held. Thus, the winding 12 is supported by the laminated core 14. The axial direction of the electrical machine and thus of the stator 10 is illustrated in Fig. 1 by a double arrow 16. For example, the laminated core 14 is formed, in particular assembled, from a plurality of laminated core segments that are formed separately from one another and connected to one another.From Fig. 1 it can be seen that respective length regions L of the winding 12 on a first axial end face AS1 of the laminated core 14 protrude in the axial direction of the laminated core 14 from the laminated core 14, in particular from the axial end face AS1, whereby the length regions L form at least one winding overhang 18 of the winding 12 arranged on the axial end face AS1. The laminated core 14 also has, for example, a second axial end face AS2 facing away from the axial end face AS1 in the axial direction of the electrical machine. In this case, it is conceivable, for example, that on the axial end face AS2 second length regions L2 of the winding 12 protrude in the axial direction of the electrical machine and thus of the stator 10 from the laminated core 14, in particular from the axial end face AS2, whereby, for example, the length regions L2 on the second axial end face AS2 form a second winding overhang 20 of the winding 12.

[0036] The electric machine also has a sensor device 22 by means of which the magnetic field, in particular the magnetic flux, can be detected.

[0037] In order to be able to detect, i.e. measure, the magnetic field particularly advantageously, the sensor device 22 has at least one circuit board 24, which is preferably formed separately from the laminated core 14 and is connected, for example, at least indirectly, in particular directly, to the laminated core 14.

[0038] Fig. 2 shows a section of the sensor device 22 in a schematic perspective view. Particularly clearly visible in Fig. 2 is the circuit board 24, which has, at least partially, in this case completely, spaced-apart circuit board regions 26 in the circumferential direction of the electrical machine extending around the machine's rotational axis, between which the longitudinal regions L are arranged. Conversely, the circuit board regions 26 are arranged between the longitudinal regions L in the circumferential direction of the electrical machine.

[0039] The sensor device 22 also has magnetic field sensors 28, which are held on the circuit board 24 and thus supported by the circuit board 24, in particular such that the magnetic field sensors 28 are each at least partially embedded in the circuit boards 24. Thus, the circuit board 24 is equipped with the magnetic field sensors 28. The magnetic field can be detected by means of the magnetic field sensors 28. Thus, for example, in the method for operating the electrical machine, it is provided that the magnetic field is detected by means of the magnetic field sensors 28. For example, the magnetic field sensors 28 and thus the sensor device 22 provide at least one, in particular electrical, signal that characterizes the magnetic field detected, i.e., measured, by the magnetic field sensors 28. From Fig. 2, it can be seen that a respective one of the magnetic field sensors 28 is held, in particular precisely, on the respective circuit board region 26.Thus, for example, the magnetic field sensors 28 are arranged between the length ranges L.

[0040] In the exemplary embodiment shown in the figures, the circuit board regions 26 are designed as teeth or prongs which protrude inwards in the radial direction of the electrical machine and thus of the stator 10 from a base region 30 of the circuit board 24 that is common to the teeth and which end inwards in the radial direction of the electrical machine and thus of the stator 10 at a respective free end E of the respective tooth that is opposite the base region 30. The circuit board 24 is thus comb-shaped, in the present case such that the circuit board 24 is designed in the form of a comb bent around the machine's axis of rotation. This makes it possible to assemble the circuit board 24 in a particularly time- and cost-effective manner such that, in a method for manufacturing the electrical machine, the circuit board 24 is inserted from the outside inwards between longitudinal regions L in the radial direction of the electrical machine and thus of the stator 10.The radial direction of the electric machine and thus of the stator runs perpendicular to the axial direction of the electric machine and thus of the stator and is illustrated in Figs. 1 and 2 by a double arrow 32. The axial direction of the electric machine and thus of the stator 10 is illustrated in Fig. 1 by a dash-dotted line 34, wherein the circumferential direction of the electric machine and thus of the stator 10 runs around the axial direction and is illustrated by a double arrow 36.

[0041] From Fig. 2 it can be seen that the base region 30 is designed in the shape of a circular segment on its side 35 facing away from the teeth (circuit board regions 26) and pointing outwards in the radial direction of the electrical machine. From Fig. 1 it can be seen that in the circumferential direction of the electrical machine and thus of the stator 10, a respective one of the lamination segments from which the laminated core 14 is formed adjoins the circuit board 24 on both sides, wherein a first of the lamination segments adjoining the circuit board 24 in the circumferential direction is designated by 38 and a second of the lamination segments adjoining the circuit board 24, in particular directly, in the circumferential direction is designated by 40.The respective lamination segment 38, 40 and the printed circuit board 24 are arranged at least partially, in particular completely, at the same height when viewed in the axial direction of the electrical machine, in this case such that the respective lamination segment 38, 40 and the printed circuit board 24 are arranged flush with one another on the axial end face AS1. In this case, the printed circuit board 24 is at least partially, in particular at least predominantly or completely, covered by the laminated core 14 in a first direction illustrated by an arrow 42, wherein the first direction illustrated by the arrow 42 runs parallel to the axial direction or coincides with the axial direction.In a second direction, indicated by an arrow 44 and opposite to the first direction, the printed circuit board 24 is arranged completely without overlap with the laminated core 14 and is therefore not overlapped by the laminated core 14, wherein the second direction runs parallel to the axial direction or coincides with the axial direction and is opposite to the first direction. Thus, the printed circuit board 24 is arranged in the axial direction of the electrical machine between the winding head 18 and at least a longitudinal region of the laminated core 14, whereby the magnetic field can be detected particularly advantageously. In particular, the magnetic field sensors 28 are arranged in the axial direction between the winding head 18 and at least the longitudinal region of the laminated core 14.

[0042] In order to be able to detect the magnetic field particularly precisely, it is preferably provided that the respective magnetic field sensor is designed as an AMR sensor, thus as an anisotropic magneto-resistive sensor.

[0043] It has proven particularly advantageous if the sensor device 22 is designed to determine, i.e., ascertain, at least one rotational position, in particular a plurality of rotational positions, of the rotor, in particular with respect to the stator 10 and / or an amplitude of the magnetic field and / or a temperature of the electrical machine, as a function of the detected magnetic field. The respective rotational position is also referred to as the rotor position and can be used, for example, to operate, in particular to control, the electrical machine as a function of the ascertained rotational position. The higher the number of magnetic field sensors 28, the higher the accuracy with which the rotational position of the rotor can be ascertained. This ensures particularly precise control of the electrical machine.

[0044] Preferably, at least one of the lamination segments of the laminated core 14 and the circuit board 24 itself, i.e., considered individually, are structurally identical, i.e., identically formed, in particular at least with regard to their respective outer contours, i.e., outer peripheral shapes. Preferably, the number of magnetic field sensors 28 is in a range from 10 to 100 inclusive. Very preferably, the circuit board 24 is manufactured by an injection molding process and by a laser direct structuring process, i.e., by laser direct structuring (LDS).Because the circuit board 24 is preferably designed in the form of a sheet metal segment of the laminated core 14, the circuit board 24 can be introduced into the manufactured winding 12, which is designed, for example, as a hairpin winding, in a time- and cost-effective manner, in particular in such a way that the comb-shaped circuit board 24 in the present case is inserted in the radial direction from the outside to the inside between the length regions L of the winding 12.

[0045] The temperature, for example, represented as the rotor temperature, can be calculated as a function of the amplitude, in particular from the amplitude, for example, because the amplitude changes proportionally with the temperature. By detecting the magnetic field or the magnetic flux, bearing damage can be detected, and a position signal can be detected redundantly, for example. Furthermore, changes in the electrical machine due to aging, temperature, or other damage can be compensated for. Compared to conventional solutions, moving parts or couplings are no longer required and can thus be avoided, allowing for particularly high levels of robustness.

[0046] List of reference symbols

[0047] 10 Stator 12 Winding

[0048] 14 sheet package

[0049] 16 Double arrow

[0050] 18 winding heads

[0051] 20 winding heads

[0052] 22 Sensor device

[0053] 24 boards

[0054] 26 board areas

[0055] 28 Magnetic field sensor 30 Base range

[0056] 32 double arrow

[0057] 34 dotted line

[0058] 35 page

[0059] 36 Double arrow

[0060] 38 sheet segment

[0061] 40 Sheet segment 42 Arrow

[0062] 44 Arrow

[0063] AS1 axial end face

[0064] AS2 axial end face L length ranges L2 length ranges E free end

Claims

Patent claims 1. An electrical machine having at least one winding (12) by means of which a magnetic field can be generated, and having a sensor device (22) by means of which the magnetic field can be detected, the sensor device (22) comprising: - at least one circuit board (24) which has a plurality of circuit board regions (26) which are at least partially spaced apart from one another in the circumferential direction (36) of the electrical machine and between which respective length regions (L) of the winding (12) are arranged; and - magnetic field sensors (28) held on the circuit board (24), by means of which the magnetic field can be detected, characterized in that the circuit board regions (26) are designed as teeth which are arranged in the radial direction (32) of the electrical machine protrude inwards from a base region (30) of the plate (24) common to the teeth and are fastened inwards in the radial direction (32) of the electrical machine to a respective Base region (30) opposite, free end (E) of the respective tooth and the base region (30) is circular or circular segment-shaped on its side (35) facing away from the teeth and pointing outwards in the radial direction (32) of the electrical machine and the circuit board (24) is inserted from the outside to the inside between the length regions (L) in the radial direction (32) of the electrical machine.

2. Electrical machine according to claim 1, characterized in that a respective one of the magnetic field sensors (28) is held on the respective circuit board area (26).

3. Electrical machine according to claim 1 or 2, characterized in that the magnetic field sensors (28) are each at least partially embedded in the circuit board (24).

4. Electrical machine according to one of the preceding claims, characterized in that the circuit board (24) is produced by an injection molding process.

5. Electrical machine according to one of the preceding claims, characterized in that the circuit board (24) is produced by direct laser structuring.

6. Electrical machine according to one of the preceding claims, characterized in that the electrical machine has a laminated core (14) carrying the winding (12).

7. Electrical machine according to claim 6, characterized in that in the circumferential direction (36) of the electrical machine on both sides of the circuit board (24) a respective sheet segment (38, 40) of the sheet stack (14) connects.

8. Electrical machine according to claim 7, characterized in that the respective sheet metal segment (38, 40) and the circuit board (24) are arranged at least partially at the same height when viewed in the axial direction (34) of the electrical machine.

9. Electrical machine according to one of the preceding claims, characterized in that the respective magnetic field sensor (28) is designed as a Hall sensor or as an anisotropic magneto-resistive sensor.

10. Electrical machine according to one of the preceding claims, characterized in that the sensor device (22) is designed to determine at least one rotational position of a rotor of the electrical machine and / or an amplitude of the magnetic field and / or a temperature of the electrical machine as a function of the detected magnetic field.

11. A method for producing an electrical machine, in which the electrical machine is equipped with at least one winding (12) by means of which a magnetic field can be generated, and with at least one sensor device (22) by means of which the magnetic field can be detected, wherein the sensor device (22) is produced from: - a circuit board (24) which has a plurality of circuit board regions (26) which are at least partially spaced apart from one another in the circumferential direction (36) of the electrical machine and between which respective length regions (L) of the winding (12) are arranged; and - magnetic field sensors (28) held on the circuit board (24), by means of which the magnetic field can be detected, characterized in that the circuit board regions (26) are designed as teeth which project inwards in the radial direction (32) of the electrical machine from a base region (30) of the circuit board (24) common to the teeth and end inwards in the radial direction (32) of the electrical machine at a respective free end (E) of the respective tooth opposite the base region (30), and the base region (30) is circular or circular segment-shaped on its side (35) facing away from the teeth and pointing outwards in the radial direction (32) of the electrical machine, the circuit board (24) being inserted between the longitudinal regions (L) from the outside to the inside in the radial direction (32) of the electrical machine.

12. A method for operating an electrical machine according to one of claims 1 to 10.

Images