Stator for an electric motor

Abstract

The invention relates to a stator (1) for an electric motor, said stator comprising: a stator main body (2) which has radially inwardly directed stator teeth (7) and on which a multiphase stator winding (9) is mounted; an insulating ring (4) mounted on an end face (3) of the stator main body (2); and a connection adapter (5) which can be placed or is placed on the insulating ring (4) and which has a connection housing (15) and phase connection contacts (11) as well as contact elements (10) for connectedly contacting winding portions (12) of the stator winding (9), wherein the connection adapter (5) has, and wherein the insulating ring (4) has, on its periphery, a number of locking pins (16), and the connection adapter (5) has corresponding through-openings (17) through which the locking pins (16) pass in order to be subsequently deformed.

Description

[0001] Description

[0002] Stator for an electric motor

[0003] The invention relates to a stator for an electric motor, comprising a stator base body with a stator winding and an insulating ring arranged on the end face of the stator base body, as well as a connection adapter for connecting winding sections of the stator winding. It further relates to an electric motor with such a stator.

[0004] A brushless electric motor, in particular a three-phase electric machine, comprises a stator with a stator base body, e.g., designed as a stator core, with a number of stator teeth arranged, for example, in a star shape. The stator teeth, e.g., directed radially inward, carry an electrical rotating field or stator winding in the form of individual stator coils, which in turn are wound from an insulated wire and assigned to individual strands or phases of the rotating field or stator winding.

[0005] In a brushless electric motor as a three-phase AC machine, the stator has three phases and thus at least three phase conductors or phase windings. These are each supplied with electric current in a phase-shifted manner to generate a rotating magnetic field. In this rotating magnetic field, a rotor, usually equipped with permanent magnets, rotates around an axis of rotation, which also represents the central (stator) axis. The phase ends of the phase windings are connected to the motor electronics to control the electric motor. The coils of the stator winding are interconnected in a specific way, either with or via the phase ends. The type of interconnection is determined by the winding pattern of the stator or rotating field winding, with a star connection or a delta connection of the phase windings being the usual winding pattern.

[0006] An insulating ring can be placed on the end face of the stator base body. An insulating ring can also be arranged on the axially opposite end face of the stator base body. The wire or phase ends can be contacted during the wiring of the rotating field winding using insulation displacement contacts as contact elements. These can be accommodated in the slots of a ring-shaped contact adapter with simultaneous insulation displacement contact. The contact adapter can be placed on the insulating ring guiding the winding or coil wires and secured to it. The insulation displacement contacts can be used to contact, for example, busbar-like connecting contacts as phase connections and to create an electrically conductive connection to the motor electronics.

[0007] Often, this is problematic due to insufficient centering or alignment of the contact adapter and an undesirably large space requirement. Tolerances of the individual components and an air gap between the insulating ring and the contact adapter can lead to undesirable play of the contact adapter at the (mechanical) interface with the insulating ring, thus increasing the positional tolerance of the connecting contacts. Furthermore, a locking or snap-in connection between the contact adapter and the insulating ring can result in undesirably high tightening and removal forces.

[0008] The invention is based on the object of specifying a particularly suitable stator for an electric motor. In particular, a reliable mechanical connection between the contact adapter and the insulating ring should be provided. The highest possible pull-in and pull-out forces should be absorbed while requiring as little space as possible, in particular while avoiding an undesirable air gap. The electrical connections of the contact elements to the associated winding sections of the stator winding should be designed to be as flexible as possible. Furthermore, an electric motor with such a stator is to be specified. With regard to the stator, the stated object is achieved according to the invention with the features of claim 1 and with regard to the electric motor with the features of claim 10. Advantageous embodiments and further developments are the subject of the dependent claims.

[0009] The stator intended for an electric motor, in particular as an electric drive for an assembly or an adjusting element of a motor vehicle, comprises a stator base body and an insulating ring, as well as a contact or connection adapter connected to the insulating ring or attachable to it. The stator base body has radially inwardly directed stator teeth with a multi-phase stator winding arranged thereon. The connection adapter, also referred to below as the connection unit, has a disc- or ring-shaped connection housing and serves for connecting winding sections or ends (coil ends) of the stator winding, in particular for contacting, preferably axially oriented, phase connection contacts.

[0010] The insulating ring has a number of preferably deformable, caulking pins (caulking studs) on its circumference. The connection adapter has through-openings corresponding to the caulking pins, through which the preferably axially oriented caulking pins penetrate for the purpose of subsequent shaping or deformation. The respective through-opening is expediently surrounded by an annular support contour.

[0011] In an advantageous embodiment, the connection adapter or its (insulating) housing has radially oriented joining lugs with through-openings (caulking openings) which correspond to the caulking pins of the insulating ring. To hold the connection adapter on or at the insulating ring, the caulking pins pass through the through-openings and are then formed, in particular by hot forming. This enables simple, reliable and, in particular, space-saving assembly of the connection adapter in conjunction with the insulating ring on the stator. According to an expedient embodiment, the insulation has axial lugs arranged at a distance from one another. The caulking pins are formed onto the axial lugs provided as intended. The axial lugs are also used, in particular, for guiding and / or laying the winding sections or individual winding sections of the stator winding. Along these axial lugs, between which free spaces orIf axial grooves are formed, the winding sections or coil ends of the stator winding can be guided or laid on the circumference of the insulating ring.

[0012] Particularly advantageous is that the connection adapter or its connection housing rests only with the radially oriented joining tabs on the axial tabs of the insulating ring, which have the caulking pins. This enables a secure and error-free attachment between the connection adapter and the insulating ring during the (hot) caulking of the caulking pins, as well as a space-saving and, above all, gap-free connection of the connection adapter to the insulating ring.

[0013] The connection adapter has a number of contact elements and phase connection contacts. The phase connection contacts are preferably axially oriented and protrude from the connection housing in sections. The contact elements are preferably radially oriented and also protrude from the connection housing in sections. The phase connection contacts and the contact elements assigned to them are suitably designed in the manner of busbars, for example, as a stamped grid. The connection housing is suitably designed as a plastic overmold that partially encloses the contacts.

[0014] The insulating ring, preferably made of a plastic material, is placed on one end face of the stator base body. An insulating ring made of a plastic material can also be arranged on the axially opposite end face of the stator base body. The insulating rings have, for example, cap-like, insulating coil or winding bodies corresponding to the number of stator teeth, which can also be referred to as slot box insulation. The coil or winding bodies encompass the respective stator tooth, in particular leaving the tooth surface on the pole shoe side free. For example, only a certain axial section of the respective winding body can be molded onto the respective insulating ring. This section complements the corresponding section of the other insulating ring to form the winding body or slot box insulation.

[0015] According to a suitable development, the insulating ring has a holding structure assigned to the respective winding section of the stator winding. The winding section is arranged on or in this structure in the manner of a wire connection bridge and can be connected to the associated contact element of the connection adapter by establishing a welded or weld-clamping contact. In an advantageous embodiment, the holding structure assigned to the respective winding section of the stator winding has radially and / or tangentially or azimuthally oriented receiving contours as insertion grooves for the respective winding section.

[0016] The respective contact element of the connection adapter expediently projects radially toward the associated support structure. At the position of the support structure, the contact element engages over the winding section of the stator winding, which is held in the support structure as a wire or connection bridge, in the manner of a clamp or terminal. The contact element partially encompasses the winding section so that the contact element can be reliably and mechanically contacted with the wire bridge-like winding section in a simple manner, for example, by means of a welding die or the like. For this purpose, the respective contact element of the connection adapter is advantageously designed as a welding hook or a welding-clamping hook.

[0017] According to a practical development, the respective contact element of the connection adapter has a connecting leg accommodated in the connection adapter or its connection housing, and a clamping leg bent in a U- or V-shape relative to the connecting leg. To enable a welding or welding clamping tool or its welding die to be applied particularly reliably to the contact elements encompassing the associated winding section, the connecting leg of the hook-shaped contact element is bent or offset several times, forming a bead or recess. This enables reliable handling of the tool, as it can be brought into contact with both leg sections of the clamping leg.

[0018] The electric motor suitably comprises such a stator and a rotor surrounded by the stator and provided with permanent magnets, in particular with a rotor or shaft.

[0019] In the following, exemplary embodiments of the invention are explained in more detail with reference to a drawing. In the drawings:

[0020] Fig. 1 shows a perspective view of a stator with a wound stator base body and with an insulating ring as well as with a connection adapter with hook-shaped contact elements on wire or connection bridges distributed around the circumference,

[0021] Fig. 2 shows a partial perspective view of the connection adapter in the area of ​​a through-hole for a caulking connection with the insulating ring,

[0022] Fig. 3 shows a partial perspective view of the insulating ring arranged on the front side of the stator base body with an axially projecting caulking pin (caulking pin) for the caulking connection with the connection adapter,

[0023] Fig. 4 shows a detail of Fig. 1 on a larger scale with a view of the through-hole penetrated by the caulking pin in a joining lug of the connection adapter as well as with a view of a connection bridge with a contact element of the connection adapter in a mounting position on a winding section of a stator winding, and

[0024] Fig. 5a to 5c show a schematic side view of the joining situation of the connection adapter with the caulking pin of the insulating ring before, during, and after the caulking connection. Corresponding parts and sizes are provided with the same reference numerals in all figures.

[0025] Fig. 1 shows a stator 1, also referred to below as a stator assembly, which is intended for an electric motor, in particular as an electric drive for an assembly or an adjusting element of a motor vehicle. The stator or stator assembly 1 comprises a stator base body 2 and an (upper) insulating ring 4 arranged on or mounted on one end face 3 of the stator base body 2, as well as a connection adapter 5 fastened to the insulating ring 4. A further (lower) insulating ring 6 is arranged on the opposite end face of the stator base body 2.

[0026] The indicated central axis D of the stator 1 is also the axis of rotation of a rotor (not shown), which is designed, for example, as a rotor core with permanent magnets housed therein. In the internal rotor electric motor, the rotor is housed in a gap-like manner in the cylindrical space surrounded by the stator base body 2 and the insulating ring 4.

[0027] The stator base body 2 is formed, for example, as a laminated core of stacked stator laminations. The stator base body 2 has a number of stator teeth 7 directed inward in the radial direction R toward the central axis D. Coils 8 of a stator or rotating field winding 9 are arranged on the stator teeth 7. Insulating caps can be molded onto the upper insulating ring 4 (shown in Fig. 1) and also onto the lower insulating ring 6, which partially cover the stator teeth 7 in the manner of, or by forming, a slot box insulation for the coils 8 of the stator or rotating field winding 9.

[0028] In the exemplary embodiment, the stator 1 or its stator base body 2 has eighteen stator teeth 7 with a corresponding number of coils 8 or coil pairs. The coils 8 on three adjacent stator teeth 7 and an equal number of coils 8 on three opposite adjacent stator teeth 7 form, for example, a coil strand of the same phases of the stator winding 9. This forms three (current) phases (u, v, w), each with six coil strands or with two sets of three redundant coil strands.

[0029] The connection adapter 5 has a number of contact elements 10, oriented radially in the radial direction R (in the exemplary embodiment), and three phase connection contacts 11, oriented axially in the axial direction A (in the exemplary embodiment). The preferably hook-shaped contact elements 10 are provided and configured for connecting winding sections or coil ends 12 of the stator winding 9.

[0030] Individual winding sections or coil ends 12 of the stator winding 11 are visible, guided along the outer circumference of the insulating ring 4 in the circumferential direction U of the stator base body 2 and guided at corresponding points through axial grooves 13 of the insulating ring 4. These are formed between axial tabs 14 of the insulating ring 4, adjacent in the circumferential direction U, along which corresponding winding sections or coil ends 12 are guided.

[0031] The contact elements 10 and the phase connection contacts 11 are accommodated partially or in sections in a (connection) housing 15 of the connection adapter 5. The connection or insulating housing 15 of the connection adapter 5 is preferably designed as a plastic sheath with which corresponding sections of the contacts 10, 11 are overmolded.

[0032] The insulating ring 4 has a number of caulking pins or studs 16, distributed circumferentially in the exemplary embodiment, which correspond to caulking or through-openings 17 of the connection adapter 5. For this purpose, the housing 15 of the connection adapter 5 has radially oriented joining tabs 18 with the through-openings 17 as caulking openings. To hold the connection adapter 5 on or to the insulating ring 4, the caulking pins 16 penetrate the through-openings 17 of the joining tabs 18 of the connection adapter 5. The caulking pins 16 of the insulating ring 4 can then be formed, in particular by hot forming. This enables simple, secure, and space-saving assembly and mounting of the connection adapter 5 on the insulating ring 4 of the stator 1. Some winding sections or coil ends 12 of the stator winding 11 are guided in holding structures 19 of the insulating ring 4.The associated winding sections or coil ends 12 are arranged in the support structures 19 in the form of connecting or wire bridges 20 extending in the circumferential direction U or tangentially. The hook-shaped contact elements 10 are guided to these connecting or wire bridges 20 arranged in the support structures 19 or to the corresponding winding sections or coil ends 12 of the stator winding 11, where they are electrically contacted by means of a welding and clamping technique and mechanically connected to the winding section 12 or to the wire bridge (connecting bridge) 20.

[0033] The six retaining structures 19 of the insulating ring 4 in the exemplary embodiment and the hook-shaped contact elements 10 of the connection adapter 5 associated with them are each guided to a transition area between two coil strands. The retaining structures 19 and the associated contact elements 10 are thus located in the area between two stator teeth 7 adjacent in the circumferential direction U, with the coils 8 of the stator winding 9 arranged thereon. The contact elements 10 are electrically connected to the phase connection contacts 11, creating, for example, a delta connection. For this purpose, the contact elements 10 and the phase connection contacts 11 can be designed as busbars or as stamped grids.

[0034] The respective contact element 10 of the connection adapter 5 projects in the radial direction R to the associated holding structure 19 of the insulating ring 4. At the position of the holding structure 19 provided as a connection bridge, the contact element 10 engages over the winding section 12 of the stator winding 9, held as a wire bridge 20, in the manner of a clamp. The hook-shaped contact element 10 engages over the winding section 12, so that the contact element 10 can be easily and reliably contacted with the wire bridge-like winding section 12. The respective contact element 10 of the connection adapter 5 is designed as a welding hook or as a welding-clamping hook. Fig. 2 shows the area of ​​one of the joining tabs 18 of the connection adapter 5 or its housing 15 with the through-opening 17 for the corresponding caulking pin 16 of the insulating ring 4.As can be seen, the respective passage opening 17 is surrounded by an axially raised, annular support contour 21. This forms, in particular, a defined annular surface 22 for the attachment of a mortising or forming tool (Figs. 5a to 5c).

[0035] Fig. 3 shows the area of ​​one of the axial tabs 14 of the insulating ring 4. The respective caulking pin 16 is formed onto such an axial tab 14 and extends in the axial direction A. Adjacent to the caulking pin 16, the corresponding axial tab 14 forms a support surface 23 for the connection adapter 5. The connection adapter 5 rests against this support surface 23 with the radially oriented joining tab 18, as can be seen comparatively clearly in Fig. 4. This already achieves a secure and error-free joining connection of the connection adapter 5 with the insulating ring 4.

[0036] Fig. 4 shows the joint connection between the connection adapter 5 or its housing 15 and the insulating ring 4 in the area of ​​the joining pocket 18 with the through-opening 17 and the corresponding caulking pin 16 axially penetrating this or being received therein and protruding in sections. In addition, one of the holding structures 19 of the insulating ring 4 and one of the hook-shaped contact elements 10 of the connection adapter 5 can be seen, with the winding section 12 of the stator winding 9 of the stator 1 embedded in the holding structure 19. The associated contact element 10 is guided to this holding structure 19 as a contact hook of the connection adapter 5.

[0037] The holding structure 19 has two axial struts 24, spaced apart from one another in the circumferential direction U of the insulating ring 4, for the winding section 12 and for the wire bridge 16, respectively. The holding structure 19 has a radially oriented receiving contour 25 and a receiving contour 26 oriented in the circumferential direction U (azimuthally) or tangentially. The receiving contours 25, 26 are provided at the ends of the axial struts 24 between two pin-like contours and serve as insertion grooves of the holding structure 19 for the connecting bridge.

[0038] The respective contact element 10 of the connection adapter 5 has a connecting leg 10a that is partially received in the connection adapter 5 or its connection housing 15 and partially protrudes radially therefrom, as well as a clamping leg 10b that is bent in a U- or V-shape relative to the connecting leg. The connecting leg 10a of the hook-shaped contact element 10 is bent or offset to form a bead or recess. This enables reliable handling of a tool if it can be brought into contact with both leg sections of the clamping leg 10b.

[0039] Figures 5a to 5c illustrate work steps during the deformation or hot-staking of the mortising studs 16 using a mortising or forming tool 27. Fig. 5a shows the joint between the connection adapter 5 or its housing 15 and the insulating ring 4 in the area of ​​the joining pocket 18 with the through-opening 17 and the mortising pin 16 axially penetrating it. Fig. 5b shows the deformation or forming process in which the mortising pin 16 is hot-stacked or formed using the tool 27. Fig. 5c shows the mortising pin 16', which has been deformed into a mushroom head shape during the forming process with the tool 27 lifted.

[0040] In summary, the invention relates to a stator 1 with a stator base body 2 with a multi-phase stator winding 9 and an insulating ring 4 arranged on the end face, as well as with a connection adapter 5 for connecting winding sections 12 of the stator winding 9, wherein the connection adapter 5 is provided with a connection housing 15 and with, preferably axially oriented, phase connection contacts 11 and with, preferably radially oriented, contact elements 10 for connecting winding sections 12 of the stator winding 9, wherein the insulating ring 4 has a number of caulking pins 16 on its circumference, and the connection adapter 5 has corresponding through-openings 17 through which the caulking pins 16 pass for the purpose of their subsequent deformation.

[0041] By using different routing or connection paths within the connection adapter 5, both a delta connection and a star connection of the stator winding 9 can be realized. The connection concept, with the contact elements 10 arranged in a star configuration, for example, can be the same. The positions of the phase connection contacts 11 can be adapted to different requirements or circumstances. For this purpose, the connection adapter 5 and / or the insulating ring 4 may only need to be adapted to the respective installation situation or provided as a corresponding component.

[0042] The invention is not limited to the exemplary embodiment described above. Rather, other variants of the invention can also be derived therefrom by those skilled in the art without departing from the scope of the invention. In particular, all individual features described in connection with the exemplary embodiment can also be combined with one another in other ways without departing from the scope of the invention.

[0043] List of reference symbols

[0044] 1 StatorZ assembly

[0045] 2 stator base bodies

[0046] 3 Front side

[0047] 4 (upper) insulating ring

[0048] 5 connection adapters

[0049] 6 (lower) insulating ring

[0050] 7 stator tooth

[0051] 8 coil

[0052] 9 Stator Z rotating field winding

[0053] 10 Contact element

[0054] 10a Connecting leg

[0055] 10b clamping leg

[0056] 10c SickeZMulde

[0057] 11 Phase connection contact

[0058] 12 Winding sectionZCoil end

[0059] 13 Axial groove

[0060] 14 Axial lug

[0061] 15 connection housings

[0062] 16 star mzapfenZ-noppe

[0063] 16' deformed mortise tenon

[0064] 17 Passage Z-caulking opening

[0065] 18 joining tab

[0066] 19 Support structure

[0067] 20 wire Z connection bridge

[0068] 21 Support contour

[0069] 22 ring area

[0070] 23 Support surface

[0071] 24 Axial strut

[0072] 25 radial mounting contour Z insertion groove

[0073] 26 azimuthal mounting contour Z insertion groove

[0074] 27 Caulking-ZForming tool A Axial direction

[0075] D (rotational) axis

[0076] R radial direction U circumferential direction

Claims

Claims 1. Stator (1 ) for an electric motor, comprising - a stator base body (2) with stator teeth (7) directed radially inwards towards a central axis (D) with a multi-phase stator winding (9) arranged thereon, - an insulating ring (4) arranged on an end face (3) of the stator base body (2), and - a connection adapter (5) which can be placed or is placed on the insulating ring (4) and has a connection housing (15), in particular a disc-shaped or ring-shaped one, and with phase connection contacts (11) as well as with contact elements (10) for connecting winding sections (12) of the stator winding (9), - wherein the insulation (4) has a number of, preferably axially oriented, caulking pins (16) on the circumference and the connection adapter (5) has corresponding through-openings (17) through which the caulking pins (16) pass for the purpose of their subsequent deformation, in particular hot forming.

2. Stator (1) according to claim 1, characterized in that the insulating ring (4) has axial tabs (14) arranged at a distance from one another, of which the caulking pins (16) are formed onto a number of the axial tabs (14).

3. Stator (1) according to claim 1 or 2, characterized in that the respective passage opening (17) is surrounded by an annular support contour (21).

4. Stator (1) according to one of claims 1 to 3, characterized in that the connection adapter (5) or its connection housing (15) has radially oriented joining tabs (18) in which the passage openings (17) are provided.

5. Stator (1) according to one of the preceding claims, characterized in that the connection adapter (5) or its connection housing (15), in particular exclusively, rests with the radially oriented joining tabs (18) on the axial tabs (14) of the insulating ring (4) having the caulking pins (16).

6. Stator (1) according to one of claims 1 to 5, characterized in that the phase connection contacts (11) are axially oriented and the contact elements (10) are radially oriented and protrude in sections from the connection housing (15) of the connection adapter (5).

7. Stator (1) according to one of claims 1 to 6, characterized in that - that the contact elements (10) of the connection adapter (5) have a connecting leg (10a) and a clamping leg (10b) bent in a U- or V-shape relative to this, and / or - the respective contact element (10) of the connection adapter (5) is designed as a welding hook or as a welding clamp hook.

8. Stator (1) according to one of claims 1 to 7, characterized in that the contact element (10) engages over or partially around the respectively assigned winding section (12) of the stator winding (9) in the radial direction (R).

9. Stator (1) according to one of claims 1 to 8, characterized in that the insulating ring (4) has a holding structure (19) assigned to the respective winding section (12) of the stator winding (9), on which holding structure the winding section (12) is arranged as a wire or connection bridge (20) and is connected to the assigned contact element (10) of the connection adapter (5) by producing a welding and / or clamping contact.

10. Electric motor with a stator (1) according to one of claims 1 to 9.

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