Electric motor, having a stator and a rotor shaft rotatably mounted relative to the stator, as well as a protective cover and angle sensor

Abstract

The invention relates to an electric motor, having a stator and a rotor shaft rotatably mounted relative to the stator, as well as a protective cover and an angle sensor for detecting the rotational position of the rotor shaft, wherein a support part is attached to the protective cover, to which a sensor plug housing of the angle sensor is connected in a rotationally fixed manner, wherein the support part has a yoke region, a first leg region, a second leg region and lug regions, wherein the lug regions are adjacent to the respective end regions of the first leg region, the second leg region and the yoke region, wherein a press-in nut is pressed into each of the lug regions.

Description

[0001] Electric motor, comprising a stator and a rotor shaft rotatably mounted relative to the stator and

[0002] Protective cover and angle sensor

[0003] Description:

[0004] The invention relates to an electric motor comprising a stator and a rotor shaft rotatably mounted relative to the stator, as well as a protective cover and angle sensor.

[0005] It is generally known that a stationary housing of an angle sensor, which is designed to detect the rotational position of a shaft, is connected to a stationary part via a torque arm. The measured values ​​recorded by the angle sensor are transmitted digitally or analogously via a sensor cable, i.e., an electrical cable.

[0006] From JP 2019 - 146 346 A, an electric motor is known as the closest state of the art.

[0007] From DE 102017 112 231 A1 a method for anchoring connecting elements in a permanently deformable flat material is known.

[0008] From DE 102004 042 478 A1 a method for the rotationally secure fastening of a functional element in a component is known.

[0009] A drive is known from DE 102015 012 796 A1.

[0010] A planar double-cardanic stator coupling is known from DE 102019 003 071 B3.

[0011] The attachment of an angle sensor to a motor is known from JP 2001 - 169 512 A.

[0012] The invention is therefore based on the object of connecting an electric motor with an angle sensor in a stable manner.

[0013] According to the invention, the object is achieved in the electric motor according to the features specified in claim 1 or 2. Important features of the invention in the electric motor according to claim 1 are that the electric motor has a stator and a rotor shaft rotatably mounted relative to the stator, as well as a protective cover and an angle sensor for detecting the rotational position of the rotor shaft, wherein a support part is fastened to the protective cover, to which support part a sensor plug housing of the angle sensor is connected in a rotationally fixed manner, wherein the support part has a yoke region, a first leg region, a second leg region and tab regions, wherein the tab regions adjoin the respective end regions of the first leg region, the second leg region and the yoke region, wherein a press-in nut is pressed into each of the tab regions.

[0014] The advantage here is that the support part can be designed flat, making it rigid in the circumferential direction relative to the rotational axis of the rotor shaft. This allows the angle sensor's connector housing to be connected in a torsionally rigid manner to the protective cover and thus to the motor housing, stator, and / or a housing section of the electric motor.

[0015] Likewise, the housing of the angle sensor can be connected to the fan cover of the electric motor by means of a torque support to dissipate torque.

[0016] The U-shaped design of the support part, with a yoke area connecting the two leg areas, makes it easier to thread the sensor cable through and allows axial tolerances to be compensated.

[0017] The tab areas are preferably of the same shape, i.e. they merge into one another through a mathematical rotation of 90°, 180° or 270°.

[0018] The vibration capability is particularly well suppressed when the press-in nuts arranged on the tab areas are located at the corners of a square that is rotated by an angular amount relative to a second square, which contains portions of the outer edges of the leg areas and the yoke area in its outer edge. The rotation axis is arranged and aligned coaxially with the rotation axis of the rotor shaft.

[0019] Important features of the electric motor according to claim 2 are that the electric motor has a stator and a rotor shaft rotatably mounted relative to the stator, as well as a protective cover and an angle sensor for detecting the rotational position of the rotor shaft, wherein a support part is attached to the protective cover, to which a sensor plug housing of the angle sensor is connected in a rotationally fixed manner, wherein the support part has a yoke region, a first leg region, a second leg region and tab regions, wherein the yoke region adjoins both the first and the second leg region, wherein a first tab region (24) is arranged at the end region of the first leg region facing away from the yoke region, wherein a second tab region (25) is arranged at the end region of the yoke region facing the first leg region, wherein a third tab region (24) is arranged at the end region of the yoke region facing the second leg region,wherein a fourth tab region (25) is arranged at the end region of the second leg region facing away from the yoke region, wherein a press-in nut is pressed into each of the tab regions.

[0020] The advantage here is that the support part can be designed flat, making it rigid in the circumferential direction relative to the rotational axis of the rotor shaft. This allows the angle sensor to be connected to the protective cover and thus to the motor housing, stator, and / or a housing section of the electric motor in a torsionally rigid manner. The U-shaped design of the support part, featuring a yoke section connecting the two leg sections, facilitates threading relative to the rotor shaft and also allows for compensation of axial tolerances.

[0021] The tab areas are preferably of the same shape, i.e. they merge into one another through a mathematical rotation of 90°, 180° or 270°.

[0022] The vibration capability is particularly well suppressed when the press-in nuts arranged on the tab areas are located at the corners of a square that is rotated by an angular amount relative to a second square, which contains portions of the outer edges of the leg areas and the yoke area in its outer edge. The rotation axis is arranged and aligned coaxially with the rotation axis of the rotor shaft.

[0023] In an advantageous embodiment, the support part is made from a stamped metal sheet. This allows for cost-effective production and the dissipation of high torque. Furthermore, despite being made from sheet metal, the support part can be made very rigid in the circumferential direction. In the axial direction, however, the support part is not rigid but rather elastic, allowing tolerances to be compensated and distortions to be avoided. Furthermore, vibrations in the axial direction can be efficiently dampened.

[0024] In an advantageous embodiment, the support part is U-shaped. This allows for simple manufacturing because the rotor shaft can be easily threaded into the opening of the U-shape.

[0025] In an advantageous embodiment, the support part, including its yoke area, the leg areas, and the tab areas, is formed in one piece, in particular as a single piece. This is advantageous in that the support part can be manufactured simply and cost-effectively, in particular by punching out a metal sheet.

[0026] In an advantageous embodiment, the support part is flat, in particular, it is quasi-two-dimensional, with the normal direction of the plane accommodating the support part oriented parallel to the rotational axis of the rotor shaft. This is advantageous in that, even with a thin wall thickness of the support part, it maintains high torsional rigidity, allowing transverse forces, which are transmitted, for example, via a cable to the sensor connector housing, to be dissipated.

[0027] In an advantageous embodiment, all edges of the first square connecting the centers of gravity of the press-in nuts each form a non-zero angle, in particular with an angle value between 10° and 30°, with all edges of the second square, whose edges contain at least partial regions of the outer edges, in particular with respect to the rotational axis of the rotor shaft, in particular the radially outer edges, of the yoke region and the two leg regions. This is advantageous in that the vibrational capacity of the support part is reduced.

[0028] In an advantageous embodiment, the tab areas and / or the press-in nuts are arranged radially outside the sensor connector housing, particularly with respect to the rotational axis of the rotor shaft. It is advantageous that the first square encompasses the second square, in particular that the first square contains the second square.

[0029] In an advantageous embodiment, each of the press-in nuts has an internal thread whose screw axis is aligned parallel to the axial direction and / or the direction of the rotational axis of the rotor shaft. Advantageously, the support part is arranged in a plane whose normal direction is aligned parallel to the direction of the rotational axis of the rotor shaft. This enables a torsionally rigid connection of the sensor connector housing to the protective cover.

[0030] In an advantageous embodiment, a first longitudinal slot is provided in the first leg region and a second longitudinal slot in the second leg region, in particular wherein the two longitudinal slots extend parallel to one another and / or are aligned. This advantageously allows the sensor connector housing to be positively connected to the support part without play, thus achieving a rigid connection.

[0031] In an advantageous embodiment, the longitudinal slots are each rectangular or cuboid-shaped, in particular with the respective edges of the two longitudinal slots aligned parallel or perpendicular to each other. This is advantageous in that a secure and positive connection can be achieved.

[0032] In an advantageous embodiment, pin areas formed on the sensor connector housing are inserted into the longitudinal slots and pressed into place with a positive fit without play. This provides the advantage of achieving a stable connection. The respective pin area can be formed in a correspondingly cuboid shape and thus can be pressed into the respective longitudinal slot by means of a press fit.

[0033] In an advantageous embodiment, the protective cover is attached to a bearing flange of the electric motor. The bearing flange accommodates a bearing that rotatably supports the rotor shaft, and the stator is connected to the bearing flange in a rotationally fixed manner. This allows for efficient utilization of the air flow driven by a fan impeller, and the angle sensor can be supported and / or attached to the protective cover.

[0034] In an advantageous embodiment, a fan wheel having fan blades and rotationally fixed to the rotor shaft is radially surrounded by the protective cover. This is advantageous in that the air flow is drawn in through the grille openings of the protective cover to the fan cover located inside the protective cover, past the angle sensor, and is conveyed by the fan cover along a bearing flange and / or stator on the side of the fan cover facing away from the angle sensor.

[0035] In an advantageous embodiment, the threaded area, in particular the external thread area, of a respective screw is screwed into the respective internal thread area of ​​a respective press-in nut, wherein the screw projects through an opening in the protective hood, in particular through a grille opening of a fan grille of the protective hood, wherein the screw head of the screw rests on the side of the protective hood facing away from the press-in nut. It is advantageous in this case that the support part is fastened to the protective hood by means of the screws. The sensor connector housing is connected to the support part by pressing the pin areas of the sensor connector housing into the longitudinal slots of the support part, without play and with a positive fit in the circumferential direction. The rotor shaft is connected in a rotationally fixed manner to a rotatably mounted part of the angle sensor, the housing of which is held in a rotationally fixed manner by a torque arm that is connected to the fan cover.

[0036] Further advantages emerge from the dependent claims. The invention is not limited to the combination of features in the claims. Further possible combinations of claims and / or individual claim features and / or features of the description and / or the figures will become apparent to those skilled in the art, particularly from the problem and / or the problem posed by comparison with the prior art.

[0037] The invention will now be explained in more detail using schematic illustrations:

[0038] In Figure 1, a B-side region of an electric motor having a support part 1 is shown exploded in an oblique view, wherein the stator and rotor of the electric motor are not shown.

[0039] Figure 2 shows the support part 1 in plan view.

[0040] In Figure 3, the electric motor together with its stator 30, its fan cover 35 and its protective cover 3 is shown exploded in an oblique view.

[0041] As shown in the figures, the electric motor has a protective cover 3 which is slipped onto the stator or onto a bearing flange connected to the stator and is fastened to the stator or bearing flange, in particular by means of screw parts.

[0042] An angle sensor comprises a sensor connector housing 2, with the sensor itself arranged axially spaced therefrom within the protective cover 3. The sensor itself comprises a sensor housing and a shaft portion rotatably mounted relative to the sensor housing. The shaft portion protrudes from the angle sensor toward the stator and is rotationally fixedly connected to the rotor shaft of the electric motor.

[0043] The angle sensor detects the rotational position of the rotor shaft. The angle sensor's sensor cable runs inside the protective cover 3 to the sensor connector housing 2, where it is attached to connection devices and connected to an external cable.

[0044] To dissipate transverse forces and corresponding torques, the sensor connector housing 2 is connected to the support part 1 in a rotationally fixed manner. For this purpose, the support part 1 has longitudinal slots 23 into which shaped pin areas on the sensor connector housing 2 protrude. The pin areas are pressed into the longitudinal slots 23 without play.

[0045] Each longitudinal slot 23 is arranged in a respective leg region (21, 22) of the support part 1. The first of the leg regions 21 is connected to the second of the leg regions 22 via a yoke region 20.

[0046] The support part 1 is manufactured as a stamped part from a sheet metal and is U-shaped, wherein the U-shape is formed from the yoke region 20 and the first leg region 21 as well as the second leg region 22.

[0047] At the end region of the yoke region 20 facing the first leg region 21, a tab region 25 is formed which projects in particular radially outward.

[0048] At the end region of the yoke region 20 facing the second leg region 22, a tab region 24 is formed which projects in particular radially outwards.

[0049] At the end region of the first leg region 21 facing away from the yoke region 20, a tab region 24 is formed, in particular projecting radially outwards.

[0050] At the end region of the second leg region 22 facing away from the yoke region 20, a tab region 25 is formed which projects in particular radially outwards.

[0051] In each of the tab areas (24, 25) a press-in nut is arranged in an axially continuous recess, which is connected in a rotationally fixed manner to the respective tab area (24, 25).

[0052] In particular, the centers or centers of gravity of the press-in nuts are arranged at the corners of a first imaginary, mathematical, first square, not shown in Figure 2. The center of this first square is located on the axis of rotation of the rotor shaft.

[0053] The support part 1, including the yoke region 20, the first leg region, the second leg region 22, and the four aforementioned tab regions (24, 25), is formed in one piece, in particular as a single part. The support part 1 is connected to the protective cover 3 by means of the screws 4, which are screwed into the press-in nuts 26. For this purpose, the protective cover 3 has through-openings, in particular grille openings of a fan grille, through which the screws 4 protrude.

[0054] The longitudinal slots 23 are rectangular. In particular, the yoke region 20, the first leg region 21, and the second leg region 22 are also rectangular.

[0055] The edges of the square whose corners coincide with the centers of gravity of the press-in nuts 23 are not parallel to the outer edges of the yoke region 20, the first leg region and the second leg region, but they have a non-zero angle thereto.

[0056] The outer edges, i.e., outer edges of the leg regions (21, 22) and the yoke region 20, are shown in plan view in Figure 2 and thus, as can be seen in Figure 2, are enclosed by a second, imaginary square, not fully shown in Figure 2. The center of this second square is located on the rotational axis of the rotor shaft.

[0057] The tab region 24 arranged at the end region of the first leg region 21 facing away from the yoke region 20 merges, by rotation of 90° counterclockwise, into the tab region 25 arranged at the end region of the yoke region 20 facing the first leg region 21. By further rotation of 90° counterclockwise, it merges into the tab region 24 arranged at the end region of the yoke region 20 facing the second leg region 22. By yet another rotation of 90°, it then merges into the end region of the second leg region 22 facing away from the yoke region 20.

[0058] The screws 4 protrude through the grid openings of the protective hood 3 and are screwed into the press-in nuts 26 so that the respective screw head of the respective screw 4 rests against the protective hood 3 and, on the side of the protective hood 3 facing away from the screw head, the support part 1 rests against the protective hood and, on the side of the support part 1 facing away from the screw head, the press-in nuts 23 protrude from the support part 1, into the internal thread of which the screws 4 are screwed with their threaded area. In particular, the outer edge of the sensor connector housing resting against the protective hood 3 has a circular contour, wherein the maximum diameter of the circular contour is arranged radially inside the press-in nuts 23 but radially outside the second square.

[0059] As can be seen in Figure 3, the bearing flange 36, to which the fan cover 35 and the protective cover 3 are attached, is connected to the stator 30. The rotatably mounted part of the angle sensor 31 is rotationally fixedly connected to the rotor shaft 37 by means of a coupling 32.

[0060] The housing of the angle sensor 31 is connected to the fan cover via the torque support 33 and is thus held in position with low vibration.

[0061] The sensor connector housing 2 of the angle sensor is designed in two parts, i.e. it is composed of a lower part and an upper part.

[0062] The fan wheel 38 with fan blades is connected in a rotationally fixed manner to the rotor shaft 37.

[0063] In further embodiments of the invention, the protective hood is not made of metal, but as a plastic injection-molded part.

[0064] List of reference symbols

[0065] 1 support part, in particular torque support

[0066] 2 Sensor connector housing of the angle sensor

[0067] 3 Protective cover

[0068] 4 screw

[0069] 20 yoke area

[0070] 21 first thigh area

[0071] 22 second thigh area

[0072] 23 Longitudinal slot

[0073] 24 Tab area

[0074] 25 tab area

[0075] 26 Press-in nut

[0076] 30 Stator

[0077] 31 Angle sensor

[0078] 32 Clutch

[0079] 33 Torque support

[0080] 34 Sensor cable

[0081] 35 Fan cover

[0082] 36 bearing flange

[0083] 37 Rotor shaft

[0084] 38 Fan wheel with fan blades

Claims

Patent claims:

1. Electric motor, comprising a stator and a rotor shaft rotatably mounted relative to the stator, as well as a protective cover and an angle sensor for detecting the rotational position of the rotor shaft, wherein a support part is fastened to the protective cover, to which a sensor plug housing of the angle sensor is connected in a rotationally fixed manner, wherein the support part has a yoke region, a first leg region, a second leg region and tab regions, wherein the tab regions adjoin the respective end regions of the first leg region, the second leg region and the yoke region, wherein a press-in nut is pressed into each of the tab regions.

2. An electric motor comprising a stator and a rotor shaft rotatably mounted relative to the stator, as well as a protective cover and an angle sensor for detecting the rotational position of the rotor shaft, wherein a support part is attached to the protective cover, to which a sensor plug housing of the angle sensor is connected in a rotationally fixed manner, characterized in that the support part has a yoke region, a first leg region, a second leg region, and tab regions, wherein the yoke region adjoins both the first and the second leg region, wherein a first tab region (24) is arranged at the end region of the first leg region facing away from the yoke region, wherein a second tab region (25) is arranged at the end region of the yoke region facing the first leg region, wherein a third tab region (24) is arranged at the end region of the yoke region facing the second leg region,wherein a fourth tab region (25) is arranged at the end region of the second leg region facing away from the yoke region, wherein a press-in nut is pressed into each of the tab regions.

3. Electric motor according to claim 1 or 2, characterized in that the support part is made of a metal sheet as a stamped part.

4. Electric motor according to one of the preceding claims, characterized in that the support part is U-shaped.

5. Electric motor according to one of the preceding claims, characterized in that the support part together with its yoke region, the leg regions and the tab regions is formed in one piece, in particular in one part.

6. Electric motor according to one of the preceding claims, characterized in that the support part is flat, in particular quasi-two-dimensional, wherein the normal direction of the plane receiving the support part is aligned parallel to the axis of rotation of the rotor shaft.

7. Electric motor according to one of the preceding claims, characterized in that all edges of the first square connecting the centers of gravity of the press-in nuts each have a non-vanishing angle, in particular with an angle value between 10° and 30°, to all edges of the second square, the edges of which contain at least partial regions of the outer, in particular with respect to the axis of rotation of the rotor shaft, in particular radially outer, edges of the yoke region and the two leg regions.

8. Electric motor according to one of the preceding claims, characterized in that the tab areas and / or the press-in nuts are arranged radially outside the sensor connector housing, in particular with respect to the axis of rotation of the rotor shaft.

9. Electric motor according to one of the preceding claims, characterized in that each of the press-in nuts has an internal thread whose screw axis is aligned parallel to the axial direction and / or direction of the axis of rotation of the rotor shaft.

10. Electric motor according to one of the preceding claims, characterized in that a first longitudinal slot is introduced in the first leg region and a second longitudinal slot is introduced in the second leg region, in particular wherein the two longitudinal slots extend parallel to one another and / or are aligned.

11. Electric motor according to one of the preceding claims, characterized in that the longitudinal slots are each aligned rectangularly or cuboidally, in particular wherein the respective edges of the two longitudinal slots are aligned parallel to one another or perpendicular to one another.

12. Electric motor according to one of the preceding claims, characterized in that pin areas formed on the sensor connector housing are inserted into the longitudinal slots and pressed in a form-fitting manner without play.

13. Electric motor according to one of the preceding claims, characterized in that the protective cover is fastened to a bearing flange of the electric motor, wherein the bearing flange accommodates a bearing which rotatably supports the rotor shaft, wherein the stator is rotationally connected to the bearing flange.

14. Electric motor according to one of the preceding claims, characterized in that a fan wheel having fan blades and being connected in rotation to the rotor shaft is radially surrounded by the protective cover, wherein a fan cover (35) is arranged within the protective cover, which Radially surrounds the fan wheel including the fan blade, wherein the angle sensor is supported on the fan cover (35) by means of a torque support.

15. Electric motor according to one of the preceding claims, characterized in that the threaded area, in particular the external threaded area, of a respective screw is screwed into the respective internal threaded area of ​​a respective press-in nut, wherein the screw projects through an opening in the protective hood, in particular through a grille opening of a fan grille of the protective hood, wherein the screw head of the screw rests on the side of the protective hood facing away from the press-in nut.

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