Drive assembly for a vehicle, comprising a separate connection assembly, and method for installing said drive assembly

Abstract

The invention relates to a drive assembly (1) for a vehicle with an electric machine (2) which has a stator (3) and an internal rotor (4). The stator (3) comprises a multiphase stator winding (6) with a wiring assembly (26), said wiring assembly (26) having a respective stator contact (31) per phase. The drive assembly additionally comprises power electronics (12) which have a connection contact (34) per phase and a reduction gear (9) for transmitting a force to a vehicle wheel or the like. A housing (16) comprises, in the axial direction, a motor compartment (17) for receiving the electric machine (2), a gear compartment (18) for receiving the reduction gear (9), and a connection compartment (19) for electrically connecting the power electronics (12). Additionally, a connection assembly (35) is provided in the gear compartment (18) between the power electronics (12) and the wiring assembly (26), said connection assembly having a busbar (36) per phase and being used to electrically contact the connection contacts (34) to the stator contacts (31) in phases.

Description

[0001] DRIVE ARRANGEMENT FOR A VEHICLE WITH A SEPARATE CONNECTION ASSEMBLY AND METHOD FOR ASSEMBLING THIS DRIVE ARRANGEMENT

[0002] The invention relates to a drive arrangement for a vehicle having the features of the preamble of claim 1. Furthermore, the invention relates to a method for assembling the drive arrangement.

[0003] Electrical machines are known in which a stator winding of a stator is contacted by means of a wiring arrangement with a high-voltage connection of power electronics in order to apply a voltage to the individual phases of the stator winding. To prevent electrical hazards caused by unintentional, improper, or otherwise caused disconnection between the high-voltage connection and the wiring arrangement, covers with so-called interlock systems, also known as high-voltage interlocks (HVIL), are known. These interrupt an electrical circuit when the cover is removed. In the so-called T-shaped axis arrangement, the electrical contact between the power electronics and the stator winding is made axially in the axial direction of the rotor.

[0004] US 2015 083 505 A1 discloses an integrated drive system arrangement for an electric vehicle, comprising a transmission arranged on a centerline of the vehicle, an inverter mounted on the transmission and arranged on one side of the centerline; and an electric motor mounted on the transmission on another side of the centerline and electrically connected to the inverter, with a rotor shaft of the electric motor extending into the transmission. The transmission, the electric motor, and the inverter are assembled into a single unit with a multi-part housing.

[0005] The invention is based on the object of creating a drive arrangement of the type mentioned at the outset, which is characterized by a simple and cost-effective connection of power electronics. This object is achieved by a drive arrangement having the features of claim 1 and a method having the features of claim 15. Further embodiments and advantages according to the invention will become apparent from the corresponding subclaims as well as the following description and attached figures.

[0006] The subject matter of the invention is a drive arrangement designed and / or suitable for a vehicle. The drive arrangement can be a purely electric or a hybrid drive train.

[0007] The drive arrangement comprises an electric machine that is designed and / or suitable for generating a drive torque, in particular a traction torque. The electric machine is preferably designed as a so-called traction machine.

[0008] The electric machine has a stator with a multi-phase stator winding. In particular, the stator winding has exactly three phase windings. The stator preferably has a stator body on which the stator winding is arranged. For example, the stator body is designed as an annular laminated core. The stator winding is preferably designed as a hairpin winding or a wave winding.

[0009] In addition, the electric machine has a rotor arranged radially within the stator. In other words, the electric machine is designed as an internal rotor. In particular, the rotor essentially comprises a rotor shaft and a rotor body connected in a rotationally fixed manner to the rotor shaft. The rotor is rotatably mounted relative to the stator via the rotor shaft, wherein the rotor body is arranged radially within the stator, in particular the stator body. The rotor, with its axis of rotation, preferably defines an axis of rotation of the electric machine.

[0010] The drive assembly includes a transmission designed and / or suitable for transmitting the drive torque of the electric motor to at least or precisely one wheel of the vehicle. In particular, the transmission is designed as a reduction gear with a gear ratio of i > 1. In other words, the transmission serves to reduce the speed. The transmission can be designed, for example, as a single- or multi-stage spur gear.

[0011] The drive arrangement has a wiring assembly designed and / or suitable for wiring the stator winding, wherein the wiring assembly has a stator contact for each phase. In particular, the wiring assembly has a winding connection bar for each phase, which is designed and / or suitable for electrically contacting the stator winding. Preferably, the stator winding, in particular the phase windings, each has at least one winding end per phase, wherein each winding connection bar is contacted with one of the winding ends on the one hand and forms the stator contact with a free end on the other. The phase windings can be wired to form a star connection via the wiring assembly.

[0012] Optionally, the interconnection assembly can include a positioning device designed and / or suitable for correctly positioning the winding ends on the respective associated winding connection rail. The positioning device serves to capture the individual winding ends during assembly of the interconnection assembly and subsequently align them with the respective winding connection rail.

[0013] The drive train has power electronics which are designed and / or suitable for controlling the electrical machine, wherein the power electronics has a connection contact for each phase. In particular, the power electronics essentially serves to convert a direct current provided by an energy storage device into an alternating current in drive mode or an alternating current provided by the electrical machine into a direct current in generator mode. For this purpose, the power electronics has a printed circuit board and electronic components electrically connected thereto, which are designed to control or regulate the current. For example, the power electronics can essentially have a direct current connection, an alternating current connection and an inverter. The power electronics can be designed in a modular manner so that it can be assembled as a complete unit.

[0014] The drive arrangement has a housing, wherein the housing is divided in the axial direction with respect to the axis of rotation into a motor compartment for accommodating the electric machine, a gear compartment for accommodating the gear, and a connection compartment for the electrical connection of the power electronics. The gear compartment is particularly preferably arranged axially between the connection compartment and the motor compartment. In principle, the motor compartment and the gear compartment and / or the connection compartment and the gear compartment can be spatially separated from one another. For example, the connection compartment and / or motor compartment can be designed as a dry compartment and the gear compartment as a wet compartment. Alternatively, however, at least the motor compartment and the gear compartment can be spatially connected to one another. For example, the motor compartment and the gear compartment together can form a wet compartment. In particular, the drive arrangement is T-shaped, with the gear compartment orThe transmission compartment extends along a central axis of the T-shape, and the electric machine or motor compartment and the power electronics or connection compartment extend from the transmission or transmission compartment in opposite directions along a transverse axis of the T-shape. Preferably, the electric machine, the transmission, and the power electronics are arranged as a common structural unit in the housing.

[0015] Within the scope of the invention, it is proposed that the drive arrangement have a connection module arranged between the power electronics and the wiring module. In particular, the connection module serves to electrically connect the power electronics to the stator winding. For this purpose, the connection module has a busbar for each phase, via which the connection contacts of the power electronics are electrically contacted with the stator contacts in phases via the gear chamber. In particular, the connection module is arranged in the gear chamber in the axial direction with respect to the axis of rotation between the power electronics and the wiring module. In principle, the connection module can be arranged entirely within the gear chamber. Alternatively, however, the connection module can also be arranged in sections in the connection chamber and / or largely in the gear chamber.The busbars can be electrically connected to the connection contacts on a side facing the power electronics and to the stator contacts on a side facing the stator. The stator contacts and / or the connection contacts for this purpose preferably extend substantially in the axial direction and / or in the same direction as the rotation axis. In addition to the electrical connection, the connection assembly can also perform other functions, such as tolerance compensation and / or a sealing function.

[0016] The invention is based on the finding that, depending on the installation space, the electrical connection between the power electronics and the electric machine must be axial relative to the rotor's rotational axis, particularly in a T-shaped drive arrangement. This typically requires a housing cover with an interlock to screw the connection contacts to the stator contacts, thus electrically protecting the connection point during assembly and disassembly. However, this entails increased assembly effort and additional costs.

[0017] The advantage of the invention is that by arranging a connection module between the power electronics and the electrical machine, an additional connection interface is created between the connection contacts of the power electronics and the stator contacts of the stator winding. This additional connection interface remains permanently in place after final assembly and no longer needs to be secured by an additional interlock. By arranging the connection module in the gear compartment, the connection between the busbars and stator contacts can remain, whereby the connection between the busbars and connection contacts can be released in the already secured connection compartment. Furthermore, the connection module can be used to compensate for tolerances between the connection contacts and the stator contacts, ensuring a reliable connection.In a specific embodiment, it is provided that the busbars are aligned in the axial direction with respect to the axis of rotation, so that the connection contacts and the stator contacts are connected to the busbar in the axial direction. In particular, the busbars serve to bridge an axial distance and / or a radial and / or tangential offset between the respective connection contact and the respective stator contact. Preferably, the busbars are aligned in the same direction at least in the axial direction and / or parallel to the axis of rotation. Particularly preferably, the busbars are produced by forming, in particular by bulk forming. The busbars thus make it easy to create an axial connection between the connection contacts and the stator contacts via the gear chamber. This facilitates assembly and the electrical connection of the drive arrangement.

[0018] In a specific implementation, it is provided that the busbars are arranged in the connection assembly so as to be movable, at least in the axial direction with respect to the axis of rotation, in order to compensate for axial tolerances. In particular, the busbars are arranged in the connection assembly so as to be displaceable in the axial direction relative to one another and / or relative to the connection contacts or stator contacts. The busbars are preferably guided straight, separate from one another, in the connection assembly. This means that the busbars can be aligned precisely to the respective stator contact when electrically connecting the electrical machine or precisely to the respective connection contact when electrically connecting the power electronics, thereby further improving the assembly process.

[0019] In a further specific implementation, it is provided that the busbars are arranged in a fluid-tight manner in the connection assembly to seal the connection compartment from the gear compartment. In particular, the busbars are supported in a fluid-tight manner in the connection assembly via at least one or exactly one sealing means. The busbars are preferably mounted in a floating manner in the connection assembly via the sealing means. This not only compensates for axial tolerances but also ensures a fluid-tight seal between the connection compartment and the gear compartment. This prevents any liquid in the gear compartment, such as oil, from penetrating from the gear compartment into the connection compartment.

[0020] In one specific embodiment, the connection module is designed as an AC filter. In particular, the AC filter serves to filter and / or dampen unwanted interference, preferably so-called common-mode voltages. The AC filter is preferably designed to dampen the harmonics of the supply voltage. For this purpose, the AC filter can have an annular filter core surrounding the busbars, through which the busbars are guided in sections in the axial direction. For example, the filter core can be made of a wound strip material or a nanocrystalline material. By designing the connection module as an AC filter, the AC filter, which is required anyway, can be used to bridge the electrical connection between the connection contacts and the stator contacts, without the drive arrangement having to be equipped with an additional connection module.This allows both the costs and the weight of the drive arrangement to be reduced.

[0021] In a further development, it is provided that the connection assembly is detachably mounted in the gear compartment in the axial direction with respect to the axis of rotation on a housing section of the housing. In particular, the housing section serves to spatially separate the connection compartment and the gear compartment. For this purpose, the housing section preferably extends substantially in a radial plane of the axis of rotation. The connection assembly can be detachably fastened to the housing section via at least one or exactly one screw connection. In particular, the screw connection for this purpose is accessible from the connection compartment. For example, the connection assembly has at least one screw receptacle and the housing section has at least one screw leadthrough, wherein a screw means for forming the screw connection is mounted from the connection compartment via the screw leadthrough into the screw receptacle.Specifically, the housing section can be designed as a gear cover or bell housing. In the event of dismantling, the connection assembly can be easily removed from the housing section without having to disconnect the connection between the busbars and stator contacts. This ensures access to the gearbox during repair or service without having to disconnect the connection between the stator contact and the busbar.

[0022] In one specific embodiment, the housing section forms a bearing plate that axially delimits the gear chamber and on which a shaft, preferably the rotor shaft or a gear shaft, is rotatably mounted. The shaft is preferably guided sectionally into the gear chamber and supported at one axial end on the bearing plate via at least one bearing device. Optionally, the bearing plate serves to fasten the power electronics by fastening a base support for the power electronics to the housing section on the side facing away from the gear chamber or in the connection chamber. A particularly compact design of the drive arrangement is thus proposed, wherein the bearing plate can be used to fasten several components, such as the connection module and power electronics.

[0023] In a further embodiment, the connection assembly comprises an insulating housing. In particular, the insulating housing serves for the electrically insulating passage of the busbars through the housing. For this purpose, the insulating housing has a guide section for each busbar, in which the busbars are accommodated in sections in an electrically insulating manner with respect to the housing. In particular, the busbars are arranged in the guide sections in such a way that at least the areas that make electrical contact with the connection contacts and the stator contacts are exposed and the areas guided through the housing section are electrically insulated. Particularly preferably, the connection assembly is fixed or supported to the housing, in particular the housing section, via the insulating housing. The insulating housing can be made from any electrically insulating material, for example from plastic or ceramic.The insulating housing thus prevents mechanical contact between the busbars and the housing. Furthermore, the busbars can be pre-positioned in the correct and / or fixed positions using the guide sections, further simplifying the assembly process for electrically connecting the electrical machine.

[0024] In one specific embodiment, it is provided that the busbars are positively received in the respective guide section in the radial and / or tangential direction with respect to the axis of rotation. Alternatively or optionally in addition, the busbars are received or mounted in the respective guide section in a floating manner in the axial direction. In particular, each of the busbars is inserted and / or straight-guided and / or positively guided in the axial direction with respect to the axis of rotation through the respective guide section. Preferably, the busbars are guided from the receiving space via the respective guide section into the gear chamber. Due to the positive reception, the busbars can be easily fixed with regard to their radial and / or tangential end position by the insulation housing, wherein at the same time, the floating mounting enables axial tolerance compensation.This means that process reliability during electrical connection can be significantly increased.

[0025] In a further specific embodiment, the connection chamber and the gear chamber are connected to one another via a connection opening. The insulation housing has a connection section via which the insulation housing is received in the connection opening in a precise and / or fluid-tight manner. In particular, the connection opening serves to lead the busbars from the connection chamber into the gear chamber. For this purpose, the connection opening can be designed as an opening axially introduced into the housing section, in particular the bearing plate. The connection section preferably has a similar geometric contour to the connection opening. The connection section is preferably arranged in the connection opening in a form-fitting and / or force-fitting manner in the tangential and radial directions.Optionally, the connection assembly has at least one further sealing means, via which the connection section rests in a circumferentially sealing manner in the connection opening. In particular, the further sealing means is arranged or fixed on an outer circumference of the connection section. The further sealing means is designed, for example, as a lip seal, sealing ring or the like. In particular, the insulation housing is inserted into the connection opening in the axial direction, in particular from the gear compartment or on a side facing away from the connection compartment, via the connection section. Due to the precise fit of the insulation housing in the connection opening, the insulation housing can be fastened to the housing section in exactly one specified orientation, which further improves assembly reliability. In addition, the gear compartment and the connection compartment can be reliably sealed against one another in a fluid-tight manner via the connection section.

[0026] In a further embodiment, it is provided that the busbars each have a first connection interface for electrically contacting the associated connection contact and a second connection interface for electrically contacting the associated stator contact, wherein the first connection interfaces are arranged within the connection space and the second connection interfaces are arranged within the gear space. Preferably, the connection contacts protrude substantially radially and / or axially and / or in the same direction as the first connection interfaces into the connection space. Preferably, the stator contacts protrude axially and / or in the same direction as the first connection interfaces into the gear space. In particular, the first connection interfaces each form an axial contact surface for axially contacting the connection contacts with respect to the axis of rotation.Alternatively, or optionally in addition, the second connection interfaces each form a radial contact surface with respect to the rotational axis for radial contacting of the stator contacts. In other words, the connection contacts are contacted in the axial direction with the respective first connection interface and / or the stator contacts are contacted in the radial direction with the respective second connection interface. Thus, a connection assembly is proposed in which at least the first connection interface is accessible via the connection compartment, in order to enable the power electronics to be easily removed during dismantling.

[0027] In a specific development, it is provided that the first connection interfaces are each formed by a bolt section, wherein the guide sections of the insulation housing each have a bolt receiving area which is designed and / or suitable for receiving the bolt sections. The bolt sections are each supported in the bolt receiving area via the at least one sealing means for floating support and / or fluid-tight sealing. In particular, the bolt sections each have at least one circumferential annular groove on their outer circumference, in which a sealing means designed as a sealing ring is received. The bolt sections are preferably supported in a circumferentially sealing manner in the respective guide section via the associated sealing means. Particularly preferably, the busbars are each supported on the insulation housing exclusively via the sealing means.The sealing rings enable both a floating mounting and a fluid-tight seal for the busbars in the insulation housing. The elastic support of the busbars on the insulation housing also allows for acoustic decoupling from the housing.

[0028] In a further specific implementation, it is provided that at least the second connection interfaces each have a screw receptacle and the stator contacts each have a screw feedthrough, wherein a screw means is mounted in the screw receptacle via the screw feedthrough to form a screw connection in the radial direction. Alternatively, however, it can also be provided that the second connection interfaces each have the screw feedthrough and the stator contacts each have the screw receptacle. The screw feedthrough is each formed by an elongated hole extending in the axial direction with respect to the axis of rotation to compensate for axial tolerances. In particular, the busbars are displaceable to a limited extent in the axial direction over the axial extent of the elongated hole.A connection assembly is thus proposed which enables tolerance compensation in the axial direction in a simple manner, whereby the busbars can be fixed in their end position by subsequently tightening the screws.

[0029] In a further implementation, it is provided that the housing has at least or exactly one radial connection opening, wherein the second connection interfaces are accessible from the outside via the at least one connection opening. In a final assembly state, the at least one connection opening is closed by a non-detachable connection cover to provide contact-proof coverage. The connection cover has the particular function of permanently covering the second connection interfaces after final assembly, so that the high-voltage connection is covered against contact from the outside or is inaccessible. Particularly preferably, the connection cover is mounted in the connection opening in a non-detachable and / or non-destructive manner after final assembly. For example, the connection cover can be designed as a plastic cover which is mounted in the connection opening via a snap connection that is inaccessible from the outside.Specifically, the housing has a separate connection opening for each second connection interface or each stator contact, wherein the second connection interface and the respectively associated connection opening are arranged congruently and / or aligned and / or overlapping with one another in the end position in the radial direction with respect to the axis of rotation. Preferably, the individual connection openings are each covered by a separate connection cover. Optionally, the connection openings can each be additionally covered by a further connection cover, preferably a screw plug. Thus, a drive arrangement is proposed which is characterized by particularly simple assembly, wherein, moreover, the inaccessible protection of the connection opening makes additional interlock protection unnecessary.

[0030] A further object of the invention relates to a method for assembling the drive arrangement as already described above, in which:

[0031] - the interconnection assembly is electrically connected to the stator winding;

[0032] - the connection assembly is mounted in the gearbox compartment;

[0033] - the power electronics are mounted in the connection compartment;

[0034] - the connection contacts of the power electronics are electrically contacted in phases with the stator contacts of the interconnection module via the busbars of the connection module.

[0035] In particular, the connection module is pre-positioned in a correct end position on the housing via the connection section and / or the screw connection. Alternatively, or optionally additionally, the interconnection module is pre-positioned in a correct end position at the winding ends via the positioning device. The busbars can then be aligned in the axial direction with respect to the stator contacts and / or the connection contacts and connected. For this purpose, the second connection interfaces, in particular the screw means, are accessible from the outside via the at least one connection opening during assembly in order to tighten or loosen the screw means. During assembly, the screw means is guided over the screw means feedthrough and screwed into the screw means receptacle.The busbars can then be aligned axially relative to each other in their final position and secured in the final position by tightening the screw. The terminal cover is then inserted into the terminal opening during final assembly, preferably in a radial direction relative to the rotation axis. During disassembly, the connection between the busbar and the stator contact remains intact, with only the connection between the busbar and the terminal contact being removed. The terminal assembly can then be removed from the housing section during disassembly of the housing section to allow access to the gear compartment.

[0036] The present invention is further explained below with reference to the drawings. They show:

[0037] Fig. 1 shows a drive arrangement in a sectional view along a rotation axis as an embodiment of the invention;

[0038] Fig. 2 is a perspective view of a connection assembly of the drive arrangement from Fig. 1.

[0039] Figure 1 shows an electric drive assembly 1 that is designed and / or suitable for driving a vehicle. For example, the vehicle can be designed as a hybrid or electric vehicle.

[0040] The drive arrangement 1 has an electric machine 2, which serves to generate an electric drive torque, in particular a traction torque. The electric machine 2 is designed as an internal rotor and for this purpose has a stator 3 and a rotor 4 arranged radially inside the stator 3. The stator 3 is essentially formed from a stator body 5 and a multi-phase stator winding 6, wherein the stator body 5 carries the stator winding 6. The rotor 4 is essentially formed from a rotor body 7 and a rotor shaft 8, wherein the rotor body 7 is connected to the rotor shaft 8 in a rotationally fixed manner.

[0041] The drive assembly 1 has a transmission 9, which serves to transmit the electric drive torque to at least one vehicle wheel (not shown). The transmission 9 is designed as a reduction gear, which reduces the drive speed of the electric machine. The transmission 9 can be designed, for example, as a two-stage spur gear. For this purpose, the transmission 9 has a transmission shaft 10 that is rotationally fixedly coupled to the rotor shaft 8, wherein the transmission shaft 10 has at least one transmission wheel section 11 for forming a first transmission stage.

[0042] The drive assembly 1 has power electronics 12, shown only schematically, which, in drive mode, serves to supply the electric machine 1 with electrical energy from an energy storage device (not shown), and, in generator mode, to feed electrical energy back into the energy storage device. The power electronics 12 essentially has a DC connection 13 for connecting the energy storage device, an inverter 14, and an AC connection 15 for connecting the electric machine 1.

[0043] Furthermore, the drive assembly 1 has a housing 16, which is divided in the axial direction with respect to a rotational axis 22 of the electric machine 1 into a motor compartment 17 for accommodating the electric machine 2, a gear compartment 18 for accommodating the gear 9, and a connection compartment 19 for accommodating the power electronics 12. The gear compartment 18 is arranged axially between the motor compartment 17 and the connection compartment 19 and is spatially separated from the connection compartment 19 and the motor compartment 17 by a respective housing section 20, 21. For example, the connection compartment 19 can be designed as a dry compartment and the gear compartment 18 and / or the motor compartment 17 as a wet compartment. The housing sections 20, 21 are each designed as a bearing plate 23, which provides a bearing location for a respective bearing device 24, 25, e.g.a rolling bearing, wherein the rotor shaft 8 and the gear shaft 10 are rotatably supported on the respective housing section 20, 21 via the bearing devices 24, 25.

[0044] The drive arrangement 1 has a wiring assembly 26, which serves to connect the stator winding 6. The stator winding 6 is formed by a plurality of plug-in coils, for example in the form of hairpins or I-pins, which are interconnected via the wiring assembly 26 in a specific pattern to form three phase windings. The phase windings each have at least one winding end 27, which extend in the axial direction with respect to a rotational axis 22, parallel and / or aligned with one another, on an inner diameter of the stator winding 6.

[0045] The interconnection assembly 26 essentially comprises three winding connection rails 28 and a positioning device 29, wherein the winding connection rails 28 are arranged in the positioning device 29 in an electrically insulated manner from one another or are embedded in sections. For this purpose, the positioning device 29 is made of an electrically insulating material, for example, plastic.

[0046] The winding connection bars 28 each have a winding connection lug 30 at one end and a stator contact 31 at the other end. The winding ends 27 are each electrically connected to one of the winding connection lugs 30, which extend in the axial direction with respect to the rotational axis 22 or in the same direction as the respective winding end 27. In other words, the winding ends 27 of a phase winding are each electrically connected to a winding connection bar 24. For example, the winding ends 27 can be permanently connected to the respective winding connection lug 30 in a materially bonded manner, preferably by means of a welded connection. The stator contacts 31 serve for the electrical connection to the power electronics 12, wherein the stator contacts 31 extend in the axial direction with respect to the rotational axis 22 and / or in the same direction from one another into the gear chamber 18.The stator contacts 31 are each designed as an external connection lug, which extends in the axial direction with respect to the rotation axis 22 or in the same direction as the winding connection lugs 30.

[0047] The positioning device 29 serves for the correct positioning of the interconnection assembly 26 or the winding ends 27 on the respectively associated winding connection rail 28, wherein the positioning device 29 is arranged for this purpose in the axial direction with respect to the rotation axis 22 on an inner side of the gear chamber 18 on the motor-side housing section 21 and is releasably fastened via at least one fastening means 32.

[0048] The AC connection 15 essentially comprises three supply connection rails 33, which extend essentially in the axial direction with respect to the rotation axis 22 and / or in the same direction to one another in the connection space 19 and each have a connection contact 34 at one end. The connection contacts 34 serve for the electrical connection of the electrical machine 2, wherein at least the connection contacts 34 extend in the radial direction with respect to the rotation axis 22 and / or in the same direction to one another in the connection space 19.

[0049] The drive arrangement 1 also has a connection assembly 35, via which the connection contacts 34 are electrically connected to the stator contacts 31 in phases. The connection assembly 35 serves to bridge an axial distance between the power electronics 12 and the electric machine 2 caused by the gear chamber 18. For this purpose, the connection assembly 35 has a busbar 36 for each phase, which are accommodated in sections in an insulation housing 37. The insulation housing 37 serves to electrically insulate the busbar 36 from the electronics-side housing section 20 and from one another, wherein the insulation housing 37 is made of an electrically insulating material, for example plastic, for this purpose.

[0050] The busbars 36 extend in the same direction and / or in the axial direction with respect to the axis of rotation 22, with a first connection interface 38 for electrically connecting the connection contacts 34 being arranged at one axial end and a second connection interface 39 for electrically connecting the stator contacts 31 being arranged at the other axial end. The first connection interface 38 is arranged in the connection space 19 and the second connection interface 39 is arranged in the gear space 18. The first connection interface 38 provides an axial contact surface 40 for axially contacting the respectively associated connection contact 34 and the second connection interface 41 provides a radial contact surface 41 for radially contacting the respectively associated stator contact 31.

[0051] In the exemplary embodiment shown, the connection contacts 34 are connected to the respective first connection interface 38 via a first screw connection 42, and the stator contacts 31 are connected to the respective second connection interface 39 via a second screw connection 43. The first and second connection interfaces 38, 39 each have a screw receptacle 44, and the stator contacts 31 and the connection contacts 34 each have a screw feedthrough 45, wherein a screw 46 is screwed into the respective screw receptacle 44 via the respective screw feedthrough 45 to form the screw connection 42, 43.

[0052] To compensate for axial tolerances between the connection contacts 34 and the stator contacts 31, the busbars 36 are arranged in the insulation housing 37 so as to be movable in the axial direction relative to the rotation axis 22. Furthermore, at least the screw bushings 45 of the stator contacts 31 can be designed as elongated holes extending in the axial direction relative to the rotation axis 22, so that the busbars 36 are movable relative to the stator contacts 31 or the connection contacts 34 within an axial play defined by the elongated holes.

[0053] For this purpose, the insulation housing 37 has a guide section 47 for each busbar 36, through which the respective busbar 36 is inserted or guided in a straight line in the axial direction with respect to the rotation axis 22. The busbars 36 are positively received in the respective guide section 47 in the radial and tangential directions with respect to the rotation axis 22 and are mounted in the respective guide section 47 in a floating and fluid-tight manner in the axial direction.

[0054] For this purpose, the first connection interfaces 38 are each formed by a bolt section 48, wherein the guide sections 47 of the insulation housing 37 each have a bolt receiving area 49 in which the bolt sections 48 are supported by two sealing means 50, e.g. two O-rings. The bolt receiving areas 49 are each designed as cylindrical openings and the bolt sections 48 as cylindrical bolts, wherein the bolt sections 48 are supported in a circumferentially sealing manner in the respectively associated bolt receiving area 49 exclusively by the sealing means 50. By means of the sealing means 50, the busbars 36 are, on the one hand, supported in a fluid-tight manner in the bolt receiving area 49 and, at the same time, are mounted floatingly in the axial direction. For example, the sealing means 50 can each be received in an annular groove arranged on the bolt section 48.

[0055] The electronics-side housing section 20 has a connection opening 51 through which the busbars 36, in particular the bolt sections 48, are guided from the connection chamber 19 into the gear chamber 20. The insulation housing 37 has a connection section 52 complementary to the connection opening 51, via which the insulation housing 37 is received in the connection opening 41 in a precise and fluid-tight manner.

[0056] The insulation housing 37 is additionally detachably fastened to the housing section 20 on a side facing away from the power electronics 12 via a further screw connection 53, wherein the further screw connection 53 is accessible from the connection space 19 and can thus be released in the event of dismantling in order to enable access to the gear compartment 18 by releasing the electronics-side housing section 20.

[0057] In the exemplary embodiment shown, the connection assembly 35 is designed as an AC filter, wherein the connection assembly 35 has a filter core 54 surrounding the busbars 36 and arranged within the insulation housing 37. The filter core 54 is designed to attenuate and / or filter unwanted interference and / or signals. The filter core 54 is accommodated in a receiving section 55 of the insulation housing 37, wherein the receiving section 55 is open on one side in the axial direction and closed by a closure cap 56. The filter core 54 can be made, for example, from a wound strip material.

[0058] The housing 16 has at least one radial connection opening 57, through which the gear chamber 18 is accessible from the outside to form the second screw connections 43. During assembly, the screw means 46 can be fitted with the aid of a tool via the respective screw leadthrough 45 of the stator contacts 31 into the respectively associated screw receptacle 44 of the second connection interfaces 39. In a final assembly state, the connection opening 57 is closed by a non-detachable or non-destructive connection cover 58, so that the screw connections 43 are permanently protected against contact from the outside. For this purpose, the connection cover 58 can be inserted into the connection opening 57 in the radial direction with respect to the axis of rotation 22, wherein the connection cover 58 is secured against loosening, for example, by a snap connection formed in the gear chamber 18.Since the first screw connection 42 is accessible via the connection compartment 19 and the connection module 35 can be removed from the housing 16 during dismantling, the connection opening 57 does not need to be additionally secured by an interlock.

[0059] As shown in Figure 2, the connection section 52 is formed circumferentially to the bolt receiving areas 49, wherein the connection assembly 35 has a further sealing means 59 arranged on the outer circumference of the connection section 52, via which the connection section 52 rests in a circumferentially sealing manner in the connection opening 51, as shown in Figure 1. Thus, the sealing means 50 ensures a seal between the individual busbars 36, in particular the bolt sections 48, and the insulation housing 37, and the further sealing means 59 ensures a seal between the insulation housing 37 and the housing 16, in particular the housing section 20.The insulation housing 37 has a plurality of screw tabs 60, which serve to mount the insulation housing 37 to the housing section 20. To form the further screw connection 53, a further screw means 61 can be mounted from the connection chamber 19 into the respective associated screw tab 60. For example, the screw tabs 60 each have an overmolded threaded bushing.

[0060] As can be seen from Figure 2, the second connection interfaces 39 are designed as connection lugs, which are formed, for example, by solid forming. The screw receptacles 44 are each formed by a press-in nut arranged in the second connection interfaces 39.

[0061] Reference symbol

[0062] 1 drive arrangement

[0063] 2 electric machine

[0064] 3 Stator

[0065] 4 Rotor

[0066] 5 Stator body

[0067] 6 Stator winding

[0068] 7 Rotor body

[0069] 8 Rotor shaft

[0070] 9 gearboxes

[0071] 10 Gear shaft

[0072] 11 Gear section

[0073] 12 Power electronics

[0074] 13 DC connection

[0075] 14 inverters

[0076] 15 AC connection

[0077] 16 housings

[0078] 17 Engine compartment

[0079] 18 Gearbox compartment

[0080] 19 Connection compartment

[0081] 20 electronics-side housing section

[0082] 21 Motor-side housing section

[0083] 22 axis of rotation

[0084] 23 Bearing shield

[0085] 24 electronics-side storage facility

[0086] 25 engine-side bearing device

[0087] 26 interconnection module

[0088] 27 winding ends

[0089] 28 Winding connection bar

[0090] 29 Positioning device

[0091] 30 Winding terminal lug

[0092] 31 Stator contacts 32 Fasteners

[0093] 33 supply connection rails

[0094] 34 connection contacts

[0095] 35 Connection module

[0096] 36 Busbar

[0097] 37 Insulation housing

[0098] 38 first connection interface

[0099] 39 second connection interface

[0100] 40 axial contact surface

[0101] 41 radial contact surface

[0102] 42 first screw connection

[0103] 43 second screw connection

[0104] 44 Screw holder

[0105] 45 Screw feedthrough

[0106] 46 screw tools

[0107] 47 Guide Section

[0108] 48 bolt section

[0109] 49 Bolt receiving area

[0110] 50 sealants

[0111] 51 Connection opening

[0112] 52 connecting section

[0113] 53 additional screw connections

[0114] 54 filter core

[0115] 55 Recording section

[0116] 56 cap

[0117] 57 Connection opening

[0118] 58 Connection cover

[0119] 59 additional sealant

[0120] 60 screw-on tab

[0121] 61 additional screwing tools

Claims

Patent claims 1. Drive arrangement (1 ) for a vehicle, - with an electric machine (2) for generating a drive torque, which has a stator (3) and a rotor (4) arranged radially inside the stator (3), wherein the stator (3) has a multi-phase stator winding (6); - with a wiring assembly (26) for wiring the stator winding (6), wherein the wiring assembly (26) has one stator contact (31) for each phase, - with power electronics (12) for controlling the electrical machine (2), wherein the power electronics (12) has a connection contact (34) for each phase, - with a transmission (9) for translating a drive torque of the electric machine (2) to at least one vehicle wheel, - with a housing (16), wherein the housing (16) is divided in the axial direction with respect to the axis of rotation (22) into a motor compartment (17) for accommodating the electrical machine (2), a gear compartment (18) for accommodating the gear (9) and a connection compartment (19) for electrically connecting the power electronics (12), characterized by a connection module (35) arranged between the power electronics (12) and the interconnection module (26), wherein the connection module (35) has a busbar (36) for each phase, via which the connection contacts (34) are electrically contacted in phases with the stator contacts (31) via the gear compartment (18).

2. Drive arrangement (1) according to claim 1, characterized in that the busbars (36) are aligned in the axial direction with respect to the axis of rotation (22), so that the connection contacts (34) and the stator contacts (31) are connected in the axial direction to the busbar (36).

3. Drive arrangement (1) according to claim 1 or 2, characterized in that the busbars (36) are arranged in the connection assembly (35) so as to be movable at least in the axial direction with respect to the axis of rotation (22) in order to compensate for axial tolerances.

4. Drive arrangement (1) according to one of the preceding claims, characterized in that the busbars (36) are arranged in a fluid-tight manner in the connection assembly (35) for sealing the connection space (19) from the gear space (18).

5. Drive arrangement (1) according to one of the preceding claims, characterized in that the connection module (35) is designed as an AC filter.

6. Drive arrangement (1) according to one of the preceding claims, characterized in that the connection assembly (35) is detachably mounted in the gear chamber (18) on a housing section (20) of the housing (16) in the axial direction with respect to the axis of rotation (22).

7. Drive arrangement (1) according to claim 6, characterized in that the housing section (20) forms a bearing plate (23) which axially delimits the gear chamber (18) and on which a shaft (8, 10) of the drive arrangement (1) is rotatably mounted.

8. Drive arrangement (1) according to one of the preceding claims, characterized in that the connection assembly (35) has an insulating housing (37), wherein the insulating housing (37) has a guide section (47) for each busbar (36), in which the busbars (36) are accommodated in sections in an electrically insulating manner with respect to the housing (16).

9. Drive arrangement (1) according to claim 8, characterized in that the busbars (36) are received in the respective guide section (47) in a form-fitting manner in the radial and / or tangential direction with respect to the axis of rotation (22) and / or in a floating manner in the axial direction.

10. Drive arrangement (1) according to claim 8 or 9, characterized in that the connection space (19) and the gear space (18) are connected via a connection opening (51 ) are connected to each other, wherein the insulation housing (37) has a connection section (52) via which the insulation housing (37) is received in the connection opening (51) in a precisely fitting and / or fluid-tight manner 11. Drive arrangement (1) according to one of the preceding claims, characterized in that the busbars (36) each have a first connection interface (38) for electrically contacting the associated connection contact (34) and each have a second connection interface (39) for electrically contacting the associated stator contact (31), wherein the first connection interfaces (38) are arranged within the connection space (19) and the second connection interfaces (39) are arranged within the gear space (18).

12. Drive arrangement (1) according to claim 8 and 11, characterized in that the first connection interfaces (38) are each formed by a bolt section (48), wherein the guide sections (47) of the insulation housing (52) each have a bolt receiving area (49) for receiving the bolt sections (48), wherein the bolt sections (48) are each supported by at least one sealing means (50) in the bolt receiving area (49) for floating mounting and / or fluid-tight sealing.

13. Drive arrangement (1) according to claim 11 or 12, characterized in that the second connection interfaces (39) each have a screw means receptacle (44) and the stator contacts (31) each have a screw means feedthrough (45), wherein in each case a screw means (46) for forming a screw connection (43) is mounted in the screw means receptacle (44) in the radial direction via the screw means feedthrough (45), wherein the screw means feedthroughs (45) are each formed by an elongated hole extending in the axial direction with respect to the axis of rotation (22) for compensating axial tolerances.

14. Drive arrangement (1) according to one of claims 10 to 13, characterized in that the housing (16) has at least one radial connection opening (57), wherein at least the second connection interfaces (39) are accessible from the outside via the at least one connection opening (57), wherein the connection opening (57) in a final assembly state is closed by a non-detachable connection cover (58) to provide a touch-proof cover.

15. Method for assembling the drive arrangement (1) according to one of the preceding claims, in which: - the interconnection assembly (26) is electrically connected to the stator winding (6); - the connection assembly (35) is mounted in the gear chamber (18); - the power electronics (12) is mounted in the connection compartment (19); - the connection contacts (34) of the power electronics (12) are electrically contacted in phases with the stator contacts (31) via the busbars (36) of the connection module (35).

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