Electronically commutated motor and modular assembly having said electronically commutated motor

Abstract

The invention relates to an electronically commutated motor comprising a permanent magnet rotor, which is mounted on a motor shaft, a stator laminated core, at least one insulating cap, which is arranged on an axial end face of the stator laminated core, a winding which runs over all the coils of the stator laminated core and is contacted by means of insulation displacement contacts, wherein the stator laminated core, the at least one insulating cap and the winding form the stator and surround the permanent magnet rotor; the stator is completely surrounded on its outer area and at least partially on its inner area by an overmoulding made of non-magnetic material and the overmoulding forms a motor housing; at least one groove running parallel to the axis is formed in the inner region of the overmoulding, at least two notches are formed on an axial end face of the overmoulding, which are connected to one another via a radially peripheral channel, and a receiving space is formed in the motor housing, in which an electronics system and a thermal plate are received. The invention further relates to a modular assembly for forming different and differently powerful fluid pumps, and different and differently powerful electric drives comprising the electronically commutated motor.

Description

[0001] Title: Electronically commutated motor and modular assembly comprising this electronically commutated motor

[0002] DESCRIPTION

[0003] The invention relates to an electronically commutated motor according to claim 1 and a modular assembly for forming different fluid pumps of different power according to claims 4 and 8, as well as a modular assembly for forming different electric drives of different power according to claim 12.

[0004] In conventional electronically commutated motors with integrated control electronics, heat is dissipated from the stator and electronic components on the circuit board through the motor housing to the ambient air. If the motor is used in a fluid pump, heat is additionally dissipated through a containment shell located between the rotor and stator. The disadvantage of this in fluid pumps is that the containment shell, as an additional component, results in additional material costs. The main disadvantage of these conventional motors is the poor heat dissipation through the housing to the ambient air.

[0005] The object of the invention is to propose an electronically commutated motor and a modular assembly for forming different fluid pumps of varying power, as well as electric drives of varying power with this electronically commutated motor. This assembly ensures efficient heat dissipation from the electronic components and the stator, good lubrication and actuation, enables easy scaling of the motor for different power classes, ensures a compact and robust motor design, reduces the number of components and thus saves costs through the use of common parts, and enables flexible design of the mechanical, hydraulic, and electrical application interfaces using common parts. A further object is to ensure reliable media separation in the fluid pumps without dynamic seals during long operating times.

[0006] This object is achieved by the electronically commutated motor according to claim 1 and by the modular assembly according to claims 4, 8 and 12.

[0007] The invention is based on the idea of ​​specifying an electronically commutated motor, comprising a permanent magnet rotor mounted on a motor shaft, a stator core, at least one insulating cap arranged on an axial end face of the stator core, a winding running over all coils of the stator core and contacted by means of insulation displacement contacts, wherein the stator core, the at least one insulating cap and the winding form the stator and surround the permanent magnet rotor; the stator is completely surrounded on its outer region and at least partially on its inner region with an overmolding made of non-magnetic material, and the overmolding forms a motor housing;at least one groove running parallel to the axis is formed in the inner region of the overmolding, at least two notches are formed on an axial end face of the overmolding, which are connected to one another via a radially circumferential channel, and a receiving space is formed in the motor housing, in which an electronics system and a thermal plate are accommodated;

[0008] The at least one insulating cap, preferably two insulating caps, can be plugged or mounted onto the axial end faces of the stator core as prefabricated parts. Alternatively, the at least one insulating cap can be molded onto the stator core using an injection molding process before the wound stator core is overmolded with non-magnetic material.

[0009] The overmolding is made of a non-magnetic material, i.e. a plastic material.

[0010] The winding, which runs over all coils of the stator core, can be formed by a continuous winding or by multiple winding wires and is contacted by means of insulation displacement contacts. The insulation displacement contacts are only partially encased by the overmolding and extend from the overmolding to a circuit board, where they are contacted. The insulation displacement contacts can be designed as single contacts or multiple contacts, such as a double bifilar contact. The advantage of using at least one double bifilar contact is that four wires are contacted simultaneously, which enables complex winding connections (e.g., delta semi-parallel) and enables higher current transmission because the current flow is divided across four paths. Alternatively, the winding can also be contacted by means of contact sheets or other contacting means known to those skilled in the art.

[0011] The connection can be realized by a star-parallel winding, star-series winding, delta-series winding, delta-parallel winding, delta-semi-parallel winding, delta-series connection, delta-double-parallel connection or a delta-quadruple-parallel connection.

[0012] At least one groove is formed in the interior of the overmolding, running parallel to the axis. This groove serves to optimize the circulation and fluid transport to dissipate heat from the stator into the fluid when using the electronically commutated motor in fluid pumps.

[0013] At least two notches are formed on an axial end face of the overmolding, which are connected to each other via a radially circumferential channel. These notches are located axially above the wound coils of the stator core in the overmolding and correspond to at least one axially parallel groove in the interior of the overmolding.

[0014] The motor housing contains a receiving space in which electronics and a thermal plate are housed. The electronics comprise a printed circuit board (PCB) responsible for motor control. It is advantageous if the PCB is equipped with electronics on both sides. Alternatively, the PCB can also be equipped with electronics on only one side. Pins for attaching the thermal plate to the motor housing, as well as pins for attaching the printed circuit board to the motor housing, are provided in the receiving space of the motor housing.

[0015] In a further development, the overmolding has at least one radial groove on the outer region for receiving a sealing element and / or a receiving contour for a plug. A plug housing is attached to the receiving contour. The plug housing can be fastened to the receiving contour in a material-locking and form-fitting manner using ultrasonic welding or laser welding. The receiving contour has, on its inner circumference, a spectacle-shaped receptacle for different plug housings through which these can be passed, and on its outer circumference at least one energy director or a circumferential elevation which, during ultrasonic welding or laser welding, is materially bonded to the plug housing and is thus welded tightly all around to the overmolding. In addition, the receiving contour comprises at least one guide, preferably two, into which the plug housing can be mounted.The advantage of the at least one guide is that the connector housing can also absorb forces in the at least one guide when assembled. The receiving contour on the overmolding ensures reduced complexity and improved manufacturability of the connector housing attachment to the overmolding. Furthermore, this enables greater variability for different applications without having to adapt or modify the tool during the injection molding process to produce the overmolding. Advantageously, the connector housing comprises at least one connector tab that contacts the printed circuit board.

[0016] Alternatively, the connector housing can be plugged onto the receiving contour. In another alternative, the connector housing can be molded directly onto the overmold without a receiving contour, or it can be formed or attached to an electronics cover that closes the receiving space of the motor housing.

[0017] The overmolding can advantageously have cutouts in the inner region, preferably between the axially parallel grooves, such that the stator laminations of the stator laminated core exposed within the cutouts are surrounded by a fluid or air in the motor interior. The cutouts in the overmolding expose the stator laminated core in this region. This advantageously promotes heat dissipation from the stator. Alternatively, the overmolding can only have grooves in its inner region. This is desirable for applications in which the stator laminated core should not be exposed. In an alternative embodiment, the overmolding can be designed as a can or have a base region on an axial end face; i.e. the overmolding can be designed as a can.

[0018] According to a further development, the thermal plate provides a bearing receptacle on one side and has a plurality of recesses for large electronic components arranged on a circuit board on the other side. The thermal plate is provided between the overmolding and the electronics, whereby the thermal plate can comprise a bearing receptacle for a bearing. A sensor magnet can be attached to the motor shaft towards the thermal plate. When using a monobearing, no bearing is required in the thermal plate. Large electronic components such as electrolytic capacitors can be accommodated in the recesses of the thermal plate in a space-saving manner. This is advantageous in that the circuit board can be equipped with electronic components on both sides, whereby the smaller electronic components can be accommodated in a space-saving manner on the underside of the circuit board.In addition, the thermal plate has several screw eyes to which the circuit board is attached. This allows some of the heat generated by the electronic components to be dissipated to the thermal plate. The additional use of thermally conductive materials such as thermal paste directly beneath the electronic components that generate heat is advantageous, so that the heat is transferred to the thermal plate over a large area. It is conceivable to coat individual contacts or contact points on the circuit board or the entire circuit board with potting material, but also to coat just a single side of the circuit board with potting material. The potting material can also be used to seal the connector tabs in the connector. Another advantage of this is that not only the connector tabs in the connector are sealed by the potting material, but also the contact points of the connector at the receiving contour of the overmolding.The potting material can also be used to attach large electronic components to the thermal plate, effectively "gluing" them in place and dampening potential vibrations. It is also conceivable to use the thermal paste, which is dispensed between the thermal plate and the circuit board, to fix the large electronic components to the thermal plate. Alternatively, the populated circuit board can also be encapsulated with potting material. When encapsulating the circuit board with potting material, the advantage of overmolding is that less potting material is required. This leads to cost and material savings.

[0019] The printed circuit board is advantageously dimensioned to match the size of the electronics cover and is attached to the overmold or fixed in the overmold receiving space. The electronics cover is flat and can feature a pressure compensation element and a honeycomb structure that supports additional heat dissipation from the electronic components on the circuit board. When mounting the electronics cover on the overmold, it is attached to the overmold using laser welding, ultrasonic welding, or hot gas welding. Alternatively, the electronics cover can also be screwed or glued to the overmold. The electronics cover can also be designed with a one-piece or multi-piece connector, which is then attached to the overmold.

[0020] The circuit board and the multiple recesses of the thermal plate can be filled with potting material. The circuit board and the thermal plate are encased in potting material. The encasement advantageously serves as an additional electronics cover. A separate electronics cover is no longer required in this case, which in turn avoids additional components and additional costs.

[0021] The thermal plate is accommodated in at least one receiving contour on the inner region of the overmolding and seals the overmolding axially on one side. The thermal plate can serve as a separating element between a wet chamber and a dry chamber in fluid pumps and additionally as a heat dissipation element in fluid pumps or electric drives. Thanks to the at least one receiving contour on the inner region of the overmolding, the thermal plate can be precisely inserted into the overmolding and fastened to the overmolding by laser welding. Alternatively, the thermal plate can be ultrasonically embossed with the overmolding using at least one pin, preferably three or four pins. In this case, at least one pin penetrates the thermal plate and is ultrasonically embossed with it. It is also conceivable for the thermal plate to be hot-stitched to it using at least one pin.However, other fastening methods for the thermal plate to the overmolding known to those skilled in the art, such as screwing, are also conceivable. The fastening method for the thermal plate to the overmolding can involve a material-to-material connection. A force-fitting fastening of the thermal plate to the overmolding could be achieved, for example, by pressing in. Alternatively, the thermal plate can be attached to the overmolding by means of direct thermal joining if the thermal plate is made of metallic material. The thermal plate can be made of a non-magnetic material, such as plastic or metallic material. The choice of material for the thermal plate depends on the performance class of the electronically commutated motor.In a further alternative, the thermal plate can be overmolded with non-magnetic material in a single process step together with the stator, forming the base or containment shell base of the overmold. This would eliminate the need for an additional fastening process for the thermal plate to the overmold.

[0022] Furthermore, the invention is based on the idea of ​​providing a modular assembly for forming different fluid pumps with different power outputs as well as different electric drives with different power outputs using the electronically commutated motor, comprising a permanent magnet rotor mounted on a motor shaft, a stator core; at least one insulating cap arranged on an axial end face of the stator core; a winding running over all coils of the stator core and contacted by means of insulation displacement contacts, wherein the stator core, the at least one insulating cap and the winding form the stator and surround the permanent magnet rotor; the stator is completely surrounded on its outer region and at least partially on its inner region by an overmolding made of non-magnetic material, and the overmolding forms a motor housing;at least one groove running parallel to the axis is formed in the inner region of the overmolding, at least two notches are formed on an axial end face of the overmolding, which are connected to one another via a radially circumferential channel, and a receiving space is formed in the motor housing, in which an electronics unit and a thermal plate are accommodated, wherein, to form a centrifugal pump, the motor housing is closed on an axial end face by an intermediate plate and wherein an impeller is pressed onto the motor shaft;

[0023] The intermediate plate can be connected to the engine housing by a material bond, for example, using laser welding. Alternatively, the intermediate plate can be connected to the engine housing by a force-fit connection, for example, using screws. It is also conceivable for the intermediate plate to be manufactured together with the overmolding in a single process step. Several fluid openings are formed in the intermediate plate through which the fluid enters the engine interior.

[0024] In a preferred embodiment, a pump head with a suction inlet and a pressure outlet is attached to the intermediate plate. The pump head can be connected to the intermediate plate by a material fit, for example, by laser welding. Alternatively, the pump head can be connected to the intermediate plate by a force fit, for example, by means of screws.

[0025] In a further development, the motor shaft is supported by two bearings, and a thrust washer can be arranged between the intermediate plate and the permanent magnet rotor. One bearing can be located below the impeller, and the other can be formed in the intermediate plate. Support contours for a thrust washer can be formed circumferentially in the intermediate plate at the bearing point. These support contours enable the motor shaft to start the rotor smoothly, with the support of the thrust washer.

[0026] According to a preferred embodiment, a bearing is accommodated in the intermediate plate and the intermediate plate is sealed from the pump head and the overmolding. The bearing can be inserted in the bearing holder or injected during the production of the intermediate plate by injection molding. The intermediate plate has a radially larger diameter than the overmolding and is precisely connected to the overmolding using a suitable process, such as laser welding. This creates a material-to-material connection between the motor housing and the intermediate plate on an axial end face. Alternatively, a force- or form-fitting connection can be provided. The advantage of this is that no additional seals are required. Alternatively, the intermediate plate can be manufactured simultaneously with the overmolding in a single injection molding step, thus eliminating the need for additional connection of the overmolding to the intermediate plate.In a further embodiment, the intermediate plate can have an extended edge that encompasses the overmolding. The radial diameter of the intermediate plate is adapted to the overmolding. The area between the extended edge of the intermediate plate and the overmolding is sealed with a gasket.

[0027] Furthermore, the invention is based on the idea of ​​providing a modular assembly for forming different fluid pumps with different power outputs as well as different electric drives with different power outputs using the electronically commutated motor, comprising a permanent magnet rotor mounted on a motor shaft, a stator core; at least one insulating cap arranged on an axial end face of the stator core; a winding running over all coils of the stator core and contacted by means of insulation displacement contacts, wherein the stator core, the at least one insulating cap and the winding form the stator and surround the permanent magnet rotor; the stator is completely surrounded on its outer region and at least partially on its inner region by an overmolding made of non-magnetic material, and the overmolding forms a motor housing;at least one groove running parallel to the axis is formed in the inner region of the overmolding, at least two notches are formed on an axial end face of the overmolding, which are connected to one another via a radially circumferential channel, and a receiving space is formed in the motor housing, in which electronics and a thermal plate are received, wherein, to form a fluid pump, in particular an oil pump, the motor housing is closed on an axial end face by a pump head with at least one hydraulic interface, and wherein a holder is arranged in the pump head, wherein the holder receives a pump rotor, which is formed from an inner rotor and an outer rotor, and is pressed onto the motor shaft and mounts the motor shaft in the holder.;

[0028] The holder can be inserted into the pump head and screwed into the interior of the pump head. It is also conceivable for the holder to be fastened in or on the pump head using other fastening means or methods known to those skilled in the art. The holder can be made of a metallic material or of a thermosetting plastic material. A design made of thermosetting plastic is advantageous in relation to the overall weight of the fluid pump in certain applications because it saves weight. Another advantage is that post-processing is usually not necessary. It is also advantageous if the pump head is made of a thermoplastic material. Alternatively, the pump head can also be made of a metallic material.

[0029] According to a further development, the bracket has a receptacle for the pump rotor and is designed as a fluid passage plate on one axial end face. The fluid passage plate has a receptacle for the motor shaft in the center. Furthermore, the fluid passage plate has several fluid openings and several screw eyes in the edge region. Alternatively, the bracket can also be designed in two parts; i.e., the fluid passage plate can be mounted on the bracket as a finished part. The bracket or the fluid passage plate can be made of a thermosetting plastic material and / or a metallic material.

[0030] In one embodiment, the holder in the fluid passage plate comprises or accommodates at least one bearing, preferably a plain bearing designed as a monobearing, and the at least one bearing has a pressure groove that can be designed as a hydrodynamic groove. Alternatively, a plain bearing bush can be injection-molded or mounted in the holder instead of the plain bearing. The monobearing forms an axially extended bearing receptacle in the holder, so that the monobearing extends into the inner rotor. An axial bearing can be formed by an inner rotor pressed onto the motor shaft. The motor shaft can also be guided in an inner diameter of the holder. The inner diameter of the holder is therefore designed and tolerated in such a way that a bearing can be represented or formed thereby. In addition, the inner diameter of the holder has a pressure groove, which can be designed as a hydrodynamic groove.The inner rotor is pressed onto the motor shaft for a rotationally fixed fit. The outer rotor is rotatably mounted in the bracket. The mono-bearing in the bracket is selected and constructed with an axial length that allows it to extend into the inner rotor, depending on the modular performance classes.

[0031] A further advantage is that the motor shaft is pressed into the inner rotor and supported by a bearing. This allows for the use of a simple, cost-effective motor shaft without additional shoulders. Another advantage is that the inner rotor is self-centering axially, eliminating the need for a bearing disk or other axial bearings.

[0032] In a further embodiment, a fluid bypass is formed in the pump head from the at least one hydraulic interface to the motor interior. The fluid flow leads through the fluid inlet via the fluid bypass to the motor interior, flushes a gap between the overmolding and the permanent magnet rotor, additionally leads through at least one fluid bore in the permanent magnet rotor, is pumped through the pump rotor, and exits through a fluid outlet. This causes the fluid to circulate through the fluid pump and more effectively dissipates the heat from the stator and the thermal plate, which cools the electronics, into the fluid. This achieves excellent cooling of the heat-generating electronic components. A further advantage of the fluid bypass is that the pump chamber can be filled from two sides, preventing cavitation at high fluid flow rates. Furthermore, no pressure builds up inside the motor due to leakage from the pump.

[0033] Furthermore, the invention is based on the idea of ​​specifying a modular assembly for forming different fluid pumps with different power outputs as well as different electric drives with different power outputs using the electronically commutated motor according to claims 1 to 4, comprising a permanent magnet rotor mounted on a motor shaft, a stator core; at least one insulating cap arranged on an axial end face of the stator core; a winding running over all coils of the stator core and contacted by means of insulation displacement contacts, wherein the stator core, the at least one insulating cap and the winding form the stator and surround the permanent magnet rotor; the stator is completely surrounded on its outer region and at least partially on its inner region by an overmolding made of non-magnetic material, and the overmolding forms a motor housing;at least one groove running parallel to the axis is formed in the inner region of the overmolding, at least two notches are formed on an axial end face of the overmolding, which are connected to one another via a radially circumferential channel, and a receiving space is formed in the motor housing, in which an electronics unit and a thermal plate are accommodated, wherein, to form an electric drive, the motor housing is closed on an axial end face by a bearing plate and wherein the motor shaft is mounted in the bearing plate;

[0034] In an advantageous embodiment, the bearing plate and / or the thermal plate accommodates or includes a bearing. The bearing in the bearing plate and / or the thermal plate is preferably designed as a ball bearing. Alternatively, a double bearing can also be accommodated or included only in the bearing plate.

[0035] In an alternative embodiment, the stator is partially overmolded on its outer region so that the stator laminated core is partially free of non-magnetic material. The advantage here is that the stator laminated core is not completely overmolded with non-magnetic material on its outer region, so that the heat from the stator is dissipated via the stator laminated core into the ambient air or a housing. Not completely overmolded means that the stator laminated core is partially free of non-magnetic material on its outer surface. The motor is cooled via the bearing shield to the outside into the ambient air and can also be provided via a metal ring that partially projects over the stator and can be formed as part of the bearing shield. The bearing shield can advantageously be made of metallic material, which supports heat dissipation from the stator to the ambient air or the housing.However, a bearing plate made of a plastic material is also conceivable. The thermal plate also dissipates heat from the electronic components to the ambient air, especially if the motor interior is flushed with air.

[0036] According to a further development, receiving contours are formed on the bearing shield, which serve for the connection of various applications, such as a gearbox or other applications known to the person skilled in the art.

[0037] List of reference symbols

[0038] 1 . Engine 32. Bearing

[0039] 2. Permanent magnet rotor 33. Oil pump

[0040] 3. Motor shaft 34. Pump head oil pump

[0041] 4. Stator core 35. Bracket

[0042] 5. Insulating cap 36. Pump rotor

[0043] 6. Winding 37. Inner rotor

[0044] 7. Stator 38. Outer rotor

[0045] 8. Outdoor area 39. Mounting bracket

[0046] 9. Interior 40. Fluid passage plate

[0047] 10. Overmolding 41. Bearing

[0048] 11 . Motor housing 42. Pressure groove

[0049] 12. Axis-parallel groove 43. Fluid bypass

[0050] 13. Notch 44. Drive

[0051] 14. Channel 45. Bearing shield

[0052] 15. Recording space 46. Connector flag

[0053] 16. Electronics 47. Electronics cover

[0054] 17. Thermoplate 48. Screw eyes

[0055] 18. Radial groove 49. Pin circuit board

[0056] 19. Mounting contour 50. Pin thermal plate

[0057] 20. Plug 51 . Ball bearing

[0058] 21. Recesses

[0059] 22. Stocktaking

[0060] 23. Recesses

[0061] 24. Electronic components

[0062] 25. Circuit board

[0063] 26. Centrifugal pump

[0064] 27. Pump head centrifugal pump

[0065] 28. Wheel

[0066] 29. Storage location

[0067] 30. Thrust washer

[0068] 31. Intermediate plate The invention is explained in more detail below using exemplary embodiments with reference to the accompanying drawings. They show:

[0069] Fig. 1 is a sectional view of the electronically commutated motor according to the invention according to a preferred embodiment;

[0070] Fig. 2 is a dimensional plan view of the overmolding according to Fig. 1;

[0071] Fig. 3 a dimensional view of the underside of the overmolding according to Fig. 2

[0072] Fig. 4 is a dimensional plan view of the thermal plate according to Fig. 1;

[0073] Fig. 5 is a dimensional view of the underside of the thermal plate according to Fig. 4 Fig. 6 is a sectional view of a modular assembly for forming a centrifugal pump according to Fig. 1

[0074] Fig. 7 is a sectional view of a modular assembly for forming an oil pump according to Fig. 1

[0075] Fig. 8 a dimensional view of the bracket according to Fig. 7

[0076] Fig. 9 shows a dimensional plan view of the bracket according to Fig. 8.

[0077] Fig. 10 is a sectional view of a modular assembly for forming a drive according to Fig. 1

[0078] Fig. 1 shows a sectional view of the electronically commutated motor (1) according to the invention, comprising a permanent magnet rotor (2) mounted on a motor shaft (3), a stator core (4), at least one insulating cap (5) arranged on an axial end face of the stator core (4), and a winding (6) running over all coils of the stator core (4) and contacted by means of insulation displacement contacts. The stator core (4), the at least one insulating cap (5), and the winding (6) form the stator (7) and surround the permanent magnet rotor (2). The stator (7) is completely surrounded on its outer region (8) (not shown here) and at least partially surrounded on its inner region (9) (not shown here) by an overmolding (10) made of non-magnetic material. The overmolding (10) forms a motor housing (11).In the inner region (9) (not shown here) of the overmolding (10), at least one axially parallel groove (12) (not shown here) is formed, and on an axial end face of the overmolding (10), at least two notches (13) are formed, which are connected to one another via a radially circumferential channel (14). A receiving space (15) is formed in the motor housing (11), in which electronics (16) and a thermal plate (17) are accommodated. The electronics (16) comprise a printed circuit board (25) responsible for controlling the motor. The printed circuit board (25) can be equipped with electronic components (24) on one or both sides. It is advantageous if the large electronic components (24) are arranged on the printed circuit board (25) in the direction of the thermal plate (17) and protrude into the recesses (23) (not shown here) in the thermal plate (17). A receiving contour (19) for a plug (20) is formed on the outer region of the overmolding (10).The connector (20) comprises at least one connector lug (46) that contacts the circuit board (25). The receiving space (15) of the motor housing (11) can be closed by an electronics cover (47).

[0079] Fig. 2 shows a dimensional plan view of the overmolding (10) according to Fig. 1. The stator (7) is completely surrounded on its outer region (8) and at least partially on its inner region (9) with an overmolding (10) made of non-magnetic material. The overmolding (10) forms a motor housing (11). In the inner region (9) of the overmolding (10) at least one axially parallel groove (12) is formed. On an axial end face of the overmolding (10) at least two notches (13) are formed, which are connected to one another via a radially circumferential channel (14). These notches (13) are located in the overmolding (10) in the axial direction above the wound coils of the stator laminated core (4) and correspond to the at least one axially parallel groove (12) in the inner region (9) of the overmolding (10).The overmolding (10) has at least one radial groove (18) on the outer region (8) for receiving a sealing element and / or a receiving contour (19) for a plug (20) (not shown here). In the inner region (9), the overmolding (10) has recesses (21), preferably between the axially parallel grooves (12), such that the stator laminations of the stator lamination stack (4) (not shown here) exposed within the recesses (21) are free of non-magnetic material. This allows the heat from the stator (7) to be dissipated directly into the liquid or the ambient air. At least one screw eye (48) is formed on the outer region (8) of the overmolding (10) so that the motor housing (11) can be attached to various applications. Fig. 3 shows a dimensional view of the underside of the overmolding (10) according to Fig. 2.A receiving space (15) is formed in the motor housing (11), in which electronics (16) (not shown here) and a thermal plate (17) (not shown here) are accommodated. At least one pin (49) is formed in the receiving space (15), on which the printed circuit board (25) (not shown here) is received. Furthermore, at least one pin (50) is formed, on which the thermal plate (17) is received.

[0080] Fig. 4 shows a dimensional plan view of the thermal plate (17) according to Fig. 1 . The thermal plate (17) has a bearing holder (22) on one side and several recesses (23) for large electronic components (24) (not shown here) on the other side, which are arranged on a circuit board (25) (not shown here). A bearing can be accommodated in the bearing holder (22), in which the motor shaft (3) (not shown here) is mounted. Alternatively, the motor shaft (3) can also be accommodated in the bearing holder (22) without a bearing. On the radial outer surface, the thermal plate (17) has at least one fastening hole, by means of which the thermal plate (17) is fastened to the overmolding (10) (not shown here) with the at least one pin (50) (not shown here), as well as a plurality of contours which are adapted to the receiving space (15) (not shown here) of the motor housing (11) (not shown here).

[0081] Fig. 5 shows a dimensional view of the underside of the thermal plate (17) according to Fig. 4. The thermal plate (17) has several recesses (23) on the side facing the electronics (16) (not shown here), in which large electronic components (24) (not shown here) are accommodated. Alternatively, the thermal plate (17) can also be designed as a flat plate without recesses (23). In this case, the large electronic components (23) on the circuit board (25) would point towards the electronics cover (47) (not shown here).

[0082] Fig. 6 shows a sectional view of a modular assembly for forming a centrifugal pump (26) according to Fig. 1. The modular assembly is designed to form different fluid pumps with different power outputs as well as different electric drives with different power outputs using the electronically commutated motor (1). The electronically commutated motor (1) comprises a permanent magnet rotor (2) mounted on a motor shaft (3), a stator core (4), at least one insulating cap (5) arranged on an axial end face of the stator core (4), and a winding (6) running over all coils of the stator core (4) and being contacted by means of insulation displacement contacts, the stator core (4), the at least one insulating cap (5) and the winding (6) forming the stator (7) and surrounding the permanent magnet rotor (2).The stator (7) is completely surrounded on its outer region (8) (not shown here) and at least partially surrounded on its inner region (9) (not shown here) by an overmolding (10) made of non-magnetic material. The overmolding (10) forms a motor housing (11). In the inner region (9) (not shown here) of the overmolding (10) at least one groove (12) (not shown here) running parallel to the axis is formed, and on an axial end face of the overmolding (10) at least two notches (13) (not shown here) are formed, which are connected to one another via a radially circumferential channel (14) (not shown here). A receiving space (15) is formed in the motor housing (11), in which an electronics unit (16) and a thermal plate (17) are accommodated. The electronics unit (16) comprises a populated printed circuit board (25) responsible for controlling the motor. The printed circuit board (25) can be equipped with electronic components (24) on one or both sides.It is advantageous if the large electronic components (24) are arranged towards the thermal plate (17) on the circuit board (25) and protrude into the recesses (23) (not shown here) of the thermal plate (17). A receiving contour (19) for a plug (20) is formed on the outer region of the overmolding (10). The plug (20) comprises at least one plug lug (46) that makes contact with the circuit board (25). The receiving space (15) of the motor housing (11) can be closed by an electronics cover (47).

[0083] To form a fluid pump, in particular a centrifugal pump (26), the motor housing (11) is closed on an axial end face by an intermediate plate (31), and an impeller (28) is pressed onto the motor shaft (3). A pump head (27) with a suction inlet and a pressure outlet is fastened to the intermediate plate (31). An impeller (28) is accommodated in the pump head (27) and is pressed onto the motor shaft (3). The motor shaft (3) is mounted in two bearing points (29). A thrust washer (30) is arranged between the intermediate plate (31) and the permanent magnet rotor (2). A bearing (32) is accommodated in the intermediate plate (31), and the intermediate plate (31) is sealed off from the pump head (27) and the overmolding (10).The electronically commutated motor (1) can thus be used without modification as the main component of the modular assembly by replacing components of the centrifugal pump (26) to construct different centrifugal pumps (26) with different power outputs. This makes it possible to adapt the centrifugal pump (26) to different applications without major design changes.

[0084] Fig. 7 shows a sectional view of a modular assembly for forming an oil pump (33) according to Fig. 1. The modular assembly is designed to form different fluid pumps with different power outputs as well as different electric drives with different power outputs using the electronically commutated motor (1). The electronically commutated motor (1) comprises a permanent magnet rotor (2) mounted on a motor shaft (3), a stator core (4), at least one insulating cap (5) arranged on an axial end face of the stator core (4), a winding (6) extending over all coils of the stator core (4) and contacted by means of insulation displacement contacts, wherein the stator core (4), the at least one insulating cap (5) and the winding

[0085] (6) form the stator (7) and surround the permanent magnet rotor (2). The stator

[0086] (7) is completely surrounded on its outer region (8) (not shown here) and at least partially on its inner region (9) (not shown here) with an overmolding (10) made of non-magnetic material. The overmolding (10) forms a motor housing (11). In the inner region (9) (not shown here) of the overmolding (10) at least one groove (12) running parallel to the axis is formed and on an axial end face of the overmolding (10) at least two notches (13) are formed, which are connected to one another via a radially circumferential channel (14) (not shown here). A receiving space (15) is formed in the motor housing (11), in which an electronics unit (16) and a thermal plate (17) are accommodated. The electronics unit (16) comprises a populated printed circuit board (25) responsible for controlling the motor. The printed circuit board (25) can be equipped with electronic components (24) on one or both sides.It is advantageous if the large electronic components (24) are arranged in the direction of the thermal plate (17) on the circuit board (25) and protrude into the recesses (23) (not shown here) of the thermal plate (17). A receiving contour (19) for a plug (20) is formed on the outer region of the overmolding (10). The plug (20) comprises at least one plug lug (46) which is contacted with the circuit board (25). The receiving space (15) of the motor housing (11) can be closed by an electronics cover (47). The thermal plate (17) can be formed as a separate component or can be injection-molded onto one side of the overmolding (10).

[0087] To form a fluid pump, in particular an oil pump (33), the motor housing (11) is closed on an axial end face by a pump head (34) having at least one hydraulic interface. A holder (35) is arranged in the pump head (34). The holder (35) accommodates a pump rotor (36), which is formed from an inner rotor (37) and an outer rotor (38). The pump rotor (36) is pressed onto the motor shaft (3) with its inner rotor (37). The motor shaft (3) is mounted in the holder (35). The holder (35) has a receptacle (39) (not shown here) for the pump rotor (36) and is designed as a fluid passage plate (40) on an axial end face. The holder (35) accommodates or includes at least one bearing (41) in the fluid passage plate (40), preferably a plain bearing designed as a monobearing.The at least one bearing (41) has a pressure groove (42) (not shown here) which is designed as a hydrodynamic groove. A fluid bypass (43) is formed in the pump head (34) from the at least one hydraulic interface to an interior motor chamber. This allows the fluid (oil) to be directed specifically into the interior motor chamber of the oil pump (33), advantageously preventing oil turbulence. The electronically commutated motor (1) can thus be used, without modifications, as the main component of the modular assembly by replacing components of the oil pump (33) to construct different oil pumps (33) with different power levels. This makes it possible to adapt the oil pump (33) to different applications without major design changes.

[0088] Fig. 8 shows a dimensional view of the holder (35) according to Fig. 7. The holder (35) has a receptacle (39) for the pump rotor (36) and is designed as a fluid passage plate (40) on one axial end face. In addition, the holder (35) forms or comprises at least one bearing (41) in the fluid passage plate (40), preferably a plain bearing designed as a monobearing. The at least one bearing (41) has a pressure groove (42), which can be designed as a hydrodynamic groove. On the radial outer circumference of the holder (35), at least one screw eye is formed, by means of which the holder (35) is screwed into the pump head (34) after being pressed into the pump head (34) (not shown here). A plurality of fluid recesses are formed in the fluid passage plate (40), which ensure targeted fluid circulation in and out of the motor interior.

[0089] Fig. 9 shows a dimensional plan view of the holder (35) according to Fig. 8. The holder (35) is designed on an axial end face as a fluid passage plate (40) which receives or forms at least one bearing (41). The bearing (41) here is preferably a plain bearing designed as a monobearing. As a result, the bearing (41) is designed to be long enough to extend into the inner rotor (37) of the pump rotor (36) (not shown here). A fluid bypass (43) in the pump head (34) is formed from the at least one hydraulic interface to a motor interior through a fluid opening in the fluid passage plate (40).

[0090] Fig. 10 shows a sectional view of a modular assembly for forming a drive according to Fig. 1. The modular assembly is designed to form different fluid pumps with different power outputs as well as different electric drives with different power outputs using the electronically commutated motor (1). The electronically commutated motor (1) comprises a permanent magnet rotor (2) mounted on a motor shaft (3), a stator core (4), at least one insulating cap (5) arranged on an axial end face of the stator core (4), a winding (6) running over all coils of the stator core (4) and contacted by means of insulation displacement contacts, wherein the stator core (4), the at least one insulating cap (5) and the winding (6) form the stator (7) and surround the permanent magnet rotor (2). A ball bearing (51) can be provided.The stator (7) is completely surrounded on its outer region (8) (not shown here) and at least partially on its inner region (9) (not shown here) with an overmolding (10) made of non-magnetic material. The overmolding (10) forms a motor housing (11). In the inner region (9) (not shown here) of the overmolding (10) at least one groove (12) running parallel to the axis is formed and on an axial end face of the overmolding (10) at least two notches (13) are formed, which are connected to one another via a radially circumferential channel (14). A receiving space (15) is formed in the motor housing (11), in which an electronics unit (16) and a thermal plate (17) are accommodated. The electronics unit (16) comprises a populated printed circuit board (25) responsible for controlling the motor. The printed circuit board (25) can be equipped with electronic components (24) on one or both sides.It is advantageous if the large electronic components (24) are arranged towards the thermal plate (17) on the circuit board (25) and protrude into the recesses (23) (not shown here) of the thermal plate (17). A receiving contour (19) for a plug (20) is formed on the outer region of the overmolding (10). The plug (20) comprises at least one plug lug (46) that makes contact with the circuit board (25). The receiving space (15) of the motor housing (11) can be closed by an electronics cover (47).

[0091] To form an electric drive (44), the motor housing (11) is closed on one axial end face by a bearing shield (45). The motor shaft (3) is mounted in the bearing shield (45). The bearing shield (45) and / or the thermal plate (17) accommodates or includes a bearing. The bearing in the bearing shield (44) and / or in the thermal plate (17) is preferably designed as a ball bearing (51). Alternatively, a double bearing can also be accommodated or included only in the bearing shield (44). In an alternative embodiment, the stator (7) can be partially overmolded on its outer region (8) (not shown here) so that the stator laminated core (4) is partially free of non-magnetic material. At least one receiving contour is formed on the bearing shield (45), which serves as a connection for various applications, such as a gearbox.The electronically commutated motor (1) can thus be used without modification as the main component of the modular assembly by using components of an electric drive (44) to construct different drives (44) with different power levels. This makes it possible to adapt the drives (44) to different applications without major design changes.

Claims

PATENT CLAIMS 1 . Electronically commutated motor (1 ) comprising - a permanent magnet rotor (2) mounted on a motor shaft (3), - a stator laminated core (4); - at least one insulating cap (5) arranged on an axial end face of the stator laminated core (4), - a winding (6) which runs over all coils of the stator core (4) and is contacted by means of insulation displacement contacts, whereby - the stator laminated core (4), the at least one insulating cap (5) and the winding (6) form the stator (7) and surround the permanent magnet rotor (2); - the stator (7) is completely surrounded on its outer region (8) and at least partially on its inner region (9) by an overmolding (10) made of non-magnetic material, and the overmolding (10) forms a motor housing (11); - at least one groove (12) running parallel to the axis is formed in the inner region (9) of the overmolding (10), - at least two notches (13) are formed on an axial end face of the overmolding (10), which are connected to one another via a radially circumferential channel (14), and - a receiving space (15) is formed in the motor housing (11), in which an electronics unit (16) and a thermal plate (17) are accommodated.

2. Electronically commutated motor according to claim 1, wherein the overmolding (10) has at least one radial groove (18) for receiving a sealing element and / or a receiving contour (19) for a plug (20) on the outer region (8).

3. Electronically commutated motor according to claim 1, wherein the thermal plate (17) provides a bearing receptacle (22) on one side and has a plurality of recesses (23) for large electronic components (24) arranged on a printed circuit board (25) on the other side.

4. Modular assembly for forming different fluid pumps of different power outputs as well as different electric drives of different power outputs with the electronically commutated motor (1) according to the preceding claims, comprising a permanent magnet rotor (2) mounted on a motor shaft (3), a stator core (4), at least one insulating cap (5) arranged on an axial end face of the stator core (4), a winding (6) running over all coils of the stator core (4) and contacted by means of insulation displacement contacts, wherein the stator core (4), the at least one insulating cap (5) and the winding (6) form the stator (7) and surround the permanent magnet rotor (2);the stator (7) is completely surrounded on its outer region (8) and at least partially on its inner region (9) by an overmolding (10) made of non-magnetic material, and the overmolding (10) forms a motor housing (11); in the inner region (9) of the overmolding (10), at least one groove (12) running parallel to the axis is formed, on an axial end face of the overmolding (10) at least two notches (13) are formed, which are connected to one another via a radially circumferential channel (14), and in the motor housing (11), a receiving space (15) is formed, in which an electronics unit (16) and a thermal plate (17) are accommodated, wherein, to form a fluid pump, in particular a centrifugal pump (26), the motor housing (11) is closed on an axial end face by an intermediate plate (31), and wherein an impeller (28) is pressed onto the motor shaft (3); 5. Modular assembly according to claim 4, wherein a pump head (27) having a suction inlet and a pressure outlet is attached to the intermediate plate.

6. Modular assembly according to claim 4, wherein the motor shaft (3) is mounted in two bearing points (29) and wherein a thrust washer (30) is arranged between the intermediate plate (31) and the permanent magnet rotor (2).

7. Modular assembly according to claim 4, wherein a bearing (32) is accommodated in the intermediate plate (31) and the intermediate plate (31) is sealed to the pump head (27) and the overmolding (10).

8. Modular assembly for forming different and differently powerful fluid pumps as well as different and differently powerful electric drives with the electronically commutated motor (1) according to the preceding claims, comprising a permanent magnet rotor (2) mounted on a motor shaft (3), a stator core (4); at least one insulating cap (5) mounted on an axial end face of the stator core (4) is arranged, a winding (6) which runs over all the coils of the stator laminated core (4) and is contacted by means of insulation displacement contacts, wherein the stator laminated core (4), the at least one insulating cap (5) and the winding (6) form the stator (7) and surround the permanent magnet rotor (2); the stator (7) is completely surrounded on its outer region (8) and at least partially on its inner region (9) with an overmolding (10) made of non-magnetic material and the overmolding (10) forms a motor housing (11);at least one axially parallel groove (12) is formed in the inner region (9) of the overmolding (10), at least two notches (13) are formed on an axial end face of the overmolding (10), which are connected to one another via a radially circumferential channel (14), and a receiving space (15) is formed in the motor housing (11), in which an electronics unit (16) and a thermal plate (17) are accommodated, wherein, to form a fluid pump, in particular an oil pump (33), the motor housing (11) is closed on an axial end face by a pump head (34) with at least one hydraulic interface, and wherein a holder (35) is arranged in the pump head (34), wherein the holder (35) receives a pump rotor (36), which is formed from an inner rotor (37) and an outer rotor (38), and is pressed onto the motor shaft (3), and the motor shaft (3) is mounted in the holder (35) stored.; 9. Modular assembly according to claim 8, wherein the holder (35) has a receptacle (39) for the pump rotor (36) and is designed as a fluid passage plate (40) on an axial end face.

10. Modular assembly according to claim 8 or 9, wherein the holder (35) in the fluid passage plate (40) accommodates or comprises at least one bearing (41), preferably a plain bearing, which is designed as a monobearing, and the at least one bearing has a pressure groove (42), which can be designed as a hydrodynamic groove.

11. Modular assembly according to one of the preceding claims, wherein a fluid bypass (43) is formed in the pump head (34) from the at least one hydraulic interface to an engine interior.

12. A modular assembly for forming different fluid pumps of different power levels, as well as different electric drives of different power levels, with the electronically commutated motor (1) according to the preceding claims, comprising a permanent magnet rotor (2) mounted on a motor shaft (3), a stator core (4), at least one insulating cap (5) arranged on an axial end face of the stator core (4), a winding (6) extending over all coils of the stator core (4) and contacted by means of insulation displacement contacts, wherein the stator core (4), the at least one insulating cap (5) and the winding (6) form the stator (7) and surround the permanent magnet rotor (2); the stator (7) is completely enclosed at its outer region (8) and at its inner region (9) is at least partially surrounded by an overmolding (10) made of non-magnetic material, and the overmolding (10) thereby forms a motor housing (11); at least one groove (12) running parallel to the axis is formed in the inner region (9) of the overmolding (10), at least two notches (13) are formed on an axial end face of the overmolding (10), which are connected to one another via a radially circumferential channel (14), and a receiving space (15) is formed in the motor housing (11), in which receiving space an electronics unit (16) and a thermal plate (17) are accommodated, wherein, in order to form an electric drive (44), the motor housing (11) is closed on an axial end face by a bearing plate (45), and wherein the motor shaft (3) is mounted in the bearing plate (45).

13. Modular assembly according to claim 12, wherein the bearing plate (45) and / or the thermal plate (17) accommodates or comprises a bearing.

14. Modular assembly according to claim 12, wherein the stator (7) is partially overmolded on its outer region (8) so that the stator laminated core (4) is partially free of non-magnetic material.

15. Modular assembly according to one of claims 12 to 14, wherein at least one receiving contour is formed on the bearing plate (45), which serves as a connection for various applications.

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