Gas supply device and method for producing a gas supply device

Abstract

The invention relates to a gas supply device (1) having an electric motor drive (7) which comprises a stator (8) having high-voltage interfaces (11-13) which are used, in a housing (2) of the gas supply device (1), to provide an electrical connection (10) between the stator (8) and high-voltage electronics (9). In order to simplify production of the gas supply device (1), the high-voltage interfaces (11-13) in the housing (2) of the gas supply device (1) are embedded in a potting compound (15) such that high-voltage connections (31-33) between the stator (8) and the high-voltage electronics (9) are sealed in a fluid-tight, in particular air-tight, manner by the potting compound (15).

Description

[0001] Description

[0002] title

[0003] Gas supply device and method for producing a gas supply device

[0004] The invention relates to a gas supply device with an electric motor drive comprising a stator with high-voltage interfaces that serve to establish an electrical connection between the stator and high-voltage electronics in a housing of the gas supply device. The invention further relates to a method for manufacturing such a gas supply device.

[0005] State of the art

[0006] From the German patent application DE 10 2016 225 342 A1, a stator arrangement of an electrical machine is known with a housing and with a stator which has a stator base body and at least one winding head, wherein the stator base body and the winding head are cast in a heat-conducting epoxy resin.

[0007] Disclosure of the invention

[0008] The object of the invention is to simplify the manufacture of a gas supply device with an electric motor drive comprising a stator with high-voltage interfaces which serve in a housing of the gas supply device to provide an electrical connection between the stator and high-voltage electronics.

[0009] The object is achieved in a gas supply device with an electric motor drive, which comprises a stator with high-voltage interfaces which serve in a housing of the gas supply device to form an electrical connection between the stator and high-voltage electronics, in that the high-voltage interfaces in the housing of the gas supply device are embedded in a potting compound such that high-voltage connections between the stator and the high-voltage electronics are sealed fluid-tight, in particular airtight, by the potting compound. The stator comprises, for example, a stator base body with stator windings, stator iron and winding heads. During potting, impregnation and / or overmolding, the stator is penetrated and surrounded by a casting resin, impregnating resin and / or plastic material. For the sake of simplicity, the material surrounding the stator windings, stator iron and winding heads is referred to here as the potting compound.The high-voltage electronics comprise, for example, an inverter. The inverter can be arranged separately from the stator arrangement. However, the inverter can also be integrated into a housing of the gas supply device. The stator arrangement, together with a rotor, advantageously serves to represent an electric motor drive for the gas supply device, in particular for an air compressor. The high-voltage interfaces serve to represent electrical connections between the high-voltage electronics and the electric motor drive, in particular the stator. The claimed potting compound is an additional potting compound. This additional potting compound can be designed in the same way as or similar to the potting compound with which the stator windings, stator iron, and winding overhangs of the stator are potted. However, the additional potting compound can also be made of a different material than the stator potting compound.The additional potting compound can also include a suitable gel. While the stressed embedding of the high-voltage interfaces in the additional potting compound may require an additional primary molding process, this has the advantage of eliminating the need for sealing elements that would otherwise be required.

[0010] A preferred embodiment of the gas supply device is characterized in that, in addition to preferably three high-voltage interfaces, at least one sensor interface is embedded in the potting compound in such a way that a sensor connection is sealed fluid-tight, in particular airtight, by the potting compound. The sensor interface can also be referred to as a low-voltage interface. The sensor interface serves to connect a sensor integrated into the stator, which is designed, for example, as a temperature sensor. Via the sensor interface, the sensor in the stator can be connected to an external power supply and an external control system for power supply and control purposes. By combining the three high-voltage interfaces with the sensor interface in the potting compound, the manufacturing effort can be further reduced.

[0011] A further preferred embodiment of the gas supply device is characterized in that the electrical connection between the stator and the high-voltage electronics comprises stator-side high-voltage cables and inverter-side high-voltage cables, the mutually facing ends of which are stably and electrically connected to each other in the potting compound. The stable and electrical connection between the stator-side and inverter-side high-voltage cables can be established using plug-in connectors. The plug-in connectors are easy to install.

[0012] A further preferred embodiment of the gas supply device is characterized in that the stator-side high-voltage lines and the inverter-side high-voltage lines are securely and electrically connected to one another at their mutually facing ends in the potting compound by means of screw connections. The screw connections ensure good electrical conduction between the stator-side and inverter-side high-voltage lines. Furthermore, the screw connections prevent unwanted loosening of the connections between the stator-side high-voltage lines and the inverter-side high-voltage lines during potting or overmolding with the additional potting compound.

[0013] A further preferred embodiment of the gas supply device is characterized in that the stator-side high-voltage lines and the inverter-side high-voltage lines are designed as busbars. The busbars are simple in design and can be manufactured cost-effectively.

[0014] A further preferred embodiment of the gas supply device is characterized in that the inverter-side high-voltage cables are deliberately bent and arranged in an S-shape or zigzag pattern to allow tolerance compensation in opposite mounting directions. This further simplifies assembly. The S-shape or zigzag shape of the inverter-side high-voltage cables, in particular the inverter busbars, advantageously allows them to be pressed together during assembly and / or pulled toward the stator-side high-voltage cables when tightening the screw connections.

[0015] A further preferred embodiment of the gas supply device is characterized in that the stator-side high-voltage lines are enclosed in an electrical contact unit, which is attached to a temperature control sleeve surrounding the stator. The electrical contact unit is formed, for example, from a plastic material into which the stator-side high-voltage lines, in particular the ends of the stator-side high-voltage lines protruding from the stator, are embedded. The electrical contact unit significantly simplifies the connection of the inverter-side high-voltage lines to the stator-side high-voltage lines. Furthermore, the assembly of the previously described screw connections during assembly is significantly simplified.

[0016] A further preferred embodiment of the gas supply device is characterized in that the potting compound is designed and arranged such that, in addition to its sealing function, the potting compound also performs a cooling function on the high-voltage connections between the stator and the high-voltage electronics. This particularly advantageously prevents undesired heating in the area of ​​the high-voltage connections between the stator and the high-voltage electronics.

[0017] In a method for producing a gas supply device described above, the above-mentioned object is achieved alternatively or additionally by stably and electrically connecting the stator-side high-voltage lines and the inverter-side high-voltage lines at their mutually facing ends in the housing of the gas supply device before the high-voltage interfaces in the housing of the gas supply device are surrounded by the potting compound. After connecting the stator-side high-voltage lines to the inverter-side high-voltage lines, they can be potted and / or overmolded with a suitable potting material in the area of ​​the high-voltage interface. Of course, a suitable gel can also be used here.

[0018] A preferred embodiment of the method is characterized in that the stator is first cast, impregnated, and / or overmolded with a casting resin, impregnating resin, and / or plastic material. The high-voltage interfaces are then cast in an additional process step. The high-voltage interfaces are advantageously cast without the need for additional tools. The high-voltage interfaces produced using the screw connections can, for example, be cast, impregnated, and / or overmolded in a simple manner by pouring a suitable casting compound into a recess with the high-voltage interfaces. Particularly advantageously, the gas supply device is simply placed on a floor surface while the casting compound is being poured. Gravity can then be utilized when pouring the casting compound.

[0019] The invention further relates to a housing for a gas supply device as described above. The housing, with the high-voltage cables securely and electrically connected to one another, can be sold separately. Potting or overmolding with the potting compound can be performed, for example, in a second production facility at a different location.

[0020] The gas conveying device is in particular an air compressor for providing compressed air in a fuel cell system.

[0021] Further advantages, features and details of the invention will become apparent from the following description, in which various embodiments are described in detail with reference to the drawing.

[0022] Short description of the drawing

[0023] Figure 1 shows a perspective and partially sectioned view of three high-voltage interfaces in a housing of a gas supply device;

[0024] Figure 2 shows a similar but uncut representation of the high-voltage interfaces from a different perspective;

[0025] Figure 3 shows a longitudinal section through one of the high-voltage interfaces; and

[0026] Figure 4 is a perspective view of a gas supply device or gas conveying device designed as an air compressor with an electric motor drive.

[0027] Description of the embodiments

[0028] Figure 4 shows a perspective view of a gas conveying device or gas supply device 1. The gas supply device 1 is designed as an air supply device, in particular as an air compressor.

[0029] The air compressor 1 serves to provide compressed air in a mobile fuel cell system. The mobile fuel cell system, in turn, serves to provide electrical energy in a motor vehicle equipped with the fuel cell system, which is converted, for example, via an electric motor into propulsion energy for the motor vehicle.

[0030] The air supply device 1 comprises a multi-part housing 2 with an air connection 3 through which air is supplied, and with an air connection 4 through which compressed air is discharged. For compressing the air, the air supply device 1 comprises, for example, a compressor wheel that is rotatable within a compressor volute.

[0031] The compressor wheel is driven by an electric motor located in the housing 2. The electric motor drive comprises, for example, an electric motor with a rotor that rotates within a stator. The stator of the electric motor, in turn, comprises a power connection 5, via which three-phase alternating current is supplied to the stator.

[0032] Figures 1 to 3 show three high-voltage connections 31, 32, 33 between a stator 5 and high-voltage electronics 9 in various perspective and partially sectioned views. The stator 8, indicated only by a reference symbol, is arranged in a stator receiving space of a tempering sleeve 6. The tempering sleeve 6 serves primarily to cool the stator 8 during operation. Therefore, the tempering sleeve 6 is also referred to as a cooling sleeve.

[0033] The stator 8 comprises a stator base body with stator iron, stator windings, and winding heads, the structure and function of which are known. Arranged within the stator 8 is a rotor (not shown), which serves to represent an electric motor drive 7 of the gas conveying device 1 shown in Figure 4 and preferably designed as an air compressor.

[0034] The temperature control sleeve 6 is arranged with the high-voltage interfaces 11 to 13 within the housing 2 of the gas supply device 1. Outside the housing 2 of the gas supply device 1, a high-voltage electronics unit 9 is indicated only by a rectangle. The high-voltage electronics unit 9 preferably comprises an inverter.

[0035] The inverter can be implemented as an external component. Depending on the design of the gas supply device 1, the inverter 9 can also be integrated into the housing 2 of the gas supply device 1.

[0036] The high-voltage electronics 9 with the inverter is connected to the stator 8 in the temperature control sleeve 6 via an inverter connection device 20 via a total of three high-voltage interfaces 11, 12, 13 with high-voltage connections 31, 32, 33. The high-voltage interfaces 11, 12, 13 with the high-voltage connections 31, 32, 33 serve to represent a stable and secure electrical connection 10 between the stator 8 and the inverter 9, which represents the high-voltage electronics. According to an essential aspect of the invention, the three high-voltage interfaces 11 to 13 are embedded in a potting compound 15. The potting compound 15 can be the same potting compound with which the stator 8 is potted. However, the potting compound 15 can also be a different potting compound. The potting compound 15 advantageously serves to hermetically seal the high-voltage connections 31 to 33 between the stator 8 and the high-voltage electronics 9.

[0037] Three stator-side high-voltage lines 17, 18, and 19, which originate from the stator 8, and three inverter-side high-voltage lines 21, 22, 23, which originate from the inverter connection device 20, serve to represent the high-voltage connections 31 to 33. The free ends of the stator-side high-voltage lines 17 to 19 are enclosed in an electrical contact unit 24.

[0038] The electrical contact unit 24 is made, for example, of a suitable plastic material. The stator-side high-voltage lines 17, 18, 19 are designed as busbars.

[0039] At their free ends protruding from the electrical contact unit 24, the stator-side high-voltage cables 17, 18, 19 are each equipped with a fastening eyelet. By means of screw connections 25, 26, 27, these fastening eyes of the stator-side high-voltage cables 17, 18, 19 are securely and electrically connected to the inverter-side high-voltage cables 21, 22, 23, which are designed as busbars.

[0040] Figure 3 shows that the inverter-side high-voltage cables 21, 22, and 23, which are designed as busbars, each have an S-shape. This S-shape enables deformation of the inverter-side high-voltage cables 21 to 23 in opposite assembly directions 29 during assembly. This enables tolerance compensation when the electrical connections 31 to 33 are made using the screw connections 25, 26, and 27. Due to their S-shape, the inverter-side high-voltage cables 21 to 23, which are designed as busbars, can be pressed together during assembly. Furthermore, the S-shaped inverter-side high-voltage cables 21 to 23 can be pulled towards the stator-side high-voltage cables 17, 18, and 19 when tightening the screw connections 25 to 27.

[0041] Figure 3 shows how the high-voltage connections 31 to 33 are completely embedded in the potting compound 15. A cavity for receiving the potting compound 15 is defined on the left side of Figure 3 by the electrical contact unit 24.

[0042] In Figure 3, below and above, the receiving space for the potting compound 15 is delimited by the housing 2 of the gas supply device. In Figure 3, on the right, the receiving space for the potting compound 15 is delimited by the inverter connection device 20.

[0043] The inverter connection device 20 comprises additional protective sleeves 35, 36, 37 for the inverter-side high-voltage lines 21 to 23 at their exit from the inverter connection device 20.

Claims

Claims 1. Gas supply device (1) with an electric motor drive (7) which comprises a stator (8) with high-voltage interfaces (11-13) which serve in a housing (2) of the gas supply device (1) to form an electrical connection (10) between the stator (8) and high-voltage electronics (9), characterized in that the high-voltage interfaces (11-13) are embedded in a potting compound (15) in the housing (2) of the gas supply device (1) such that high-voltage connections (31-33) between the stator (8) and the high-voltage electronics (9) are sealed in a fluid-tight, in particular air-tight, manner by the potting compound (15).

2. Gas supply device according to claim 1, characterized in that in the potting compound (15), in addition to preferably three high-voltage interfaces (11-13), at least one sensor interface is embedded in the potting compound in such a way that a sensor connection is sealed fluid-tight, in particular airtight, by the potting compound.

3. Gas supply device according to one of the preceding claims, characterized in that the electrical connection (10) between the stator (8) and the high-voltage electronics (9) comprises stator-side high-voltage lines (17-19) and inverter-side high-voltage lines (21-23), the mutually facing ends of which are stably and electrically conductively connected to one another in the potting compound (15).

4. Gas supply device according to claim 3, characterized in that the stator-side high-voltage lines (17-19) and the inverter-side high-voltage lines (21-23) are stably and electrically conductively connected to one another at their mutually facing ends in the casting compound (15) by means of screw connections (25-27).

5. Gas supply device according to claim 3 or 3, characterized in that the stator-side high-voltage lines (17-19) and the inverter-side high-voltage lines (21-23) are designed as busbars.

6. Gas supply device according to one of claims 2 to 5, characterized in that the inverter-side high-voltage lines (21-23) are deliberately bent and arranged in an S-shape or zigzag shape so that they enable tolerance compensation in opposite assembly directions (29).

7. Gas supply device according to one of the preceding claims, characterized in that the stator-side high-voltage lines (17-19) are enclosed in an electrical contacting unit (24) which is attached to a tempering sleeve (6) surrounding the stator (8).

8. Gas supply device according to one of the preceding claims, characterized in that the potting compound (15) is designed and arranged such that the potting compound (15) in addition to its sealing function exerts a cooling function on the high-voltage connections (31 - 33) between the stator (8) and the high-voltage electronics (9).

9. Method for producing a gas supply device (1) according to one of claims 3 to 6, characterized in that the stator-side high-voltage lines (17-19) and the inverter-side high-voltage lines (21-23) are stably and electrically conductively connected to one another at their mutually facing ends in the housing (2) of the gas supply device (1) before the high-voltage interfaces (11-13) in the housing (2) of the gas supply device (1) are surrounded by the potting compound (15).

10. Housing (2) for a gas supply device (1) according to one of claims 1 to 8.

Images