Connecting structure for an electric motor and electric motor
The connecting structure for electric motors, utilizing leadframes integrated within a housing body, addresses the issues of size, complexity, and safety in existing motors, achieving a compact, cost-effective, and fail-safe design for Brake-By-Wire systems.
Patent Information
- Application Number
- PCT/IB2024/059628
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2023-10-03
- Filing Date
- 2024-10-02
- Publication Date
- 2025-04-10
AI Technical Summary
Existing electric motors for Brake-By-Wire systems have drawbacks such as increased size, complexity, and costs due to the use of busbars, and they lack safety features to ensure braking action in failure situations.
A connecting structure for electric motors that eliminates the need for busbars by using leadframes to transmit power to the stator windings, integrated within a housing body, which reduces size, complexity, and costs while enhancing safety through redundancy.
The solution results in an electric motor with reduced size, lower operational and maintenance costs, and improved safety, ensuring braking functionality even in failure scenarios due to redundant electrical connections.
Smart Images

Figure IB2024059628_10042025_PF_FP_ABST
Abstract
Description
"Connecting structure for an electric motor and electric motor"
[0001] Field of the invention
[0002] The present invention relates to a connecting structure for an electric motor, in particular an electro-mechanical connecting structure, and an electric motor which comprises the connecting structure, in particular an electric motor for actuating a braking system of the Brake-By-Wire ("BBW") type for vehicles with two or more wheels.
[0003] Background art
[0004] The braking systems of the BBW type comprise an electric motor associated with an actuator by means of a transmission system, in which the actuator converts the torque generated by the electric motor into a braking force directed against the disc brake pads.
[0005] The electric motors of the prior art comprise a housing structure, or flange, in which a rotor and a stator are housed.
[0006] The stator generally comprises either a single or a double three-phase winding to generate a rotating magnetic field.
[0007] Moreover, such known electric motors comprise a component, referred to as a "busbar," interposed between the housing structure of the electric motor and the stator, configured to make the electrical and mechanical connection of the stator with the housing structure, and in particular to make an interconnection between the stator and a power interface of the electric motor.
[0008] Specifically, the busbar is a circular component which electrically connects the various stator windings. The busbar has three inputs to be supplied with three-phase or six-phase power, which it transmits to the windings. Moreover, the busbar acts as a mechanical junction between the stator windings and the housing structure of the electric motor. Embodiments in which the busbar is co-molded inside the flange or in which the busbar is positioned separate from the flange are known.
[0009] However, the known electric motors have several drawbacks. Indeed, the busbar is a component which increases the overall size, the operation complexity, and the manufacturing and maintenance costs of the electric motor.
[0010] Moreover, the known electric motors do not have a high degree of safety because they do not ensure the braking action in the case of failure, and in particular in the case of busbar malfunction.
[0011] Therefore, the need is felt to have an electric motor with smaller overall size, lower operation complexity, and lower manufacturing and maintenance costs.
[0012] Moreover, the need is felt to have an electric motor having a higher degree of safety and such as to ensure the braking action in failure situations.
[0013] Solution
[0014] It is the object of the present invention to provide a connecting structure for an electric motor and an electric motor comprising such a connecting structure, having features such as to obviate at least some of the drawbacks of the prior art.
[0015] It is a particular object of the present invention to provide a connecting structure for an electric motor and an electric motor comprising such a connecting structure, which have smaller overall size, lower operation complexity, and lower manufacturing and maintenance costs.
[0016] It is a further particular object of the present invention to provide a connecting structure for an electric motor, and an electric motor comprising such a connecting structure, having a higher degree of safety and such as to ensure the braking action in failure situations.
[0017] These and other objects are achieved by a connecting structure for an electric motor, and an electric motor comprising such a connecting structure, according to the independent claims.
[0018] The dependent claims relate to preferred and advantageous embodiments of the present invention.
[0019] Figures
[0020] In order to better understand the invention and appreciate the advantages thereof, some non-limiting exemplary embodiments thereof will be described below with reference to the accompanying drawings, in which:
[0021] - figure 1 is a front perspective view of a connecting structure for an electric motor, according to an embodiment of the invention;
[0022] - figure 2 is a further front perspective view of the connecting structure depicted in figure 1 , showing visible and non-visible details of the connecting structure;
[0023] - figure 3 is a rear perspective view of the connecting structure depicted in figure 1 ;
[0024] - figure 4 is a further rear perspective view of the connecting structure depicted in figure 4, showing visible and non-visible details of the connecting structure;
[0025] - figure 5 is a frontal front view of the connecting structure depicted in figure 1 , showing visible and non-visible details of the connecting structure;
[0026] - figure 6 is a rear front view of the connecting structure depicted in figure 1 ,showing visible and non-visible details of the connecting structure;
[0027] - figure 7 is a front view of a plurality of components of a connecting structure for an electric motor, according to an embodiment of the invention;
[0028] - figure 8 is a front perspective view of a plurality of components of a connecting structure for an electric motor, according to an embodiment of the invention;
[0029] - figure 9 is a front perspective view of a partially disassembled stator of an electric motor, according to an embodiment of the invention;
[0030] - figure 10 is a front view of a stator of an electric motor, according to an embodiment of the invention;
[0031] - figure 11 is an exploded front perspective view of an electric motor, according to an embodiment of the invention;
[0032] - figure 12 is an exploded rear perspective view of the electric motor depicted in figure 11 .
[0033] Description of some preferred embodiments
[0034] Connecting structure 1
[0035] With reference to the figures, a connecting structure is generally indicated by reference numeral 1 .
[0036] The connecting structure 1 is adapted to be comprised in an electric motor 2. In particular, an electric motor 2 of the type comprising a stator 3 and a rotor 6.
[0037] In such an electric motor 2, the stator 3 extends about a motor axis 15, preferably it is coaxial to the motor axis 15. Moreover, the stator 3 comprises at least one three-phase winding 4, 5. Each winding of the at least one three-phase winding 4, 5 extends between two opposite winding terminals 29.
[0038] Moreover, the rotor 6 is substantially coaxial to the motor axis 15.
[0039] The connecting structure 1 defines the motor axis 15.
[0040] According to an aspect of the invention, the connecting structure 1 comprises a plurality of leadframes 7.
[0041] The leadframes 7 are configured to transmit electric power to the at least one three-phase winding 4, 5 of the stator 3. Preferably, the leadframes 7 are configured to transmit electric power from an electric power source 9 to the at least one three-phase winding 4, 5. Preferably, the electric power source 9 is outside the electric motor 2.
[0042] Moreover, the connecting structure 1 comprises a housing body 8.
[0043] The housing body 8 is configured to house at least one of the rotor 6 and the stator 3. Preferably, the housing body 8 is configured to accommodate both the rotor 6and the stator 3.
[0044] The housing body 8 is preferably substantially coaxial to the motor axis 15.
[0045] Moreover, the plurality of leadframes 7 is connected to the housing body 8.
[0046] "Leadframe" means an electrical connection or electrical interface, also referred to as a “lead frame”, in particular a metal structure, generally made of copper or aluminum or another metal, cut and bent, and configured to transmit electric power.
[0047] "Three-phase winding" means an assembly of three windings configured to transmit a three-phase electric power.
[0048] Advantageously, a connecting structure 1 thus configured allows the transmission of electric power to a stator 3 without using a busbar, and thus allows manufacturing an electric motor 2 having small overall size, low operation complexity, and low manufacturing and maintenance costs.
[0049] According to an embodiment, the housing body 8 is over-molded onto the plurality of leadframes 7.
[0050] According to an embodiment, the housing body 8 is co-molded onto the plurality of leadframes 7.
[0051] According to an embodiment, the housing body 8 is made of a polymer material.
[0052] Advantageously, the plurality of leadframes 7 allows transmitting electric power to the stator 3 without further bulky, complex, and expensive added components, such as a busbar, for example.
[0053] With further advantage, the over-molding of the housing body 8 onto the leadframes 7 and the consequent at least partial (in the case of over-molding) or substantially total (in the case of co-molding) integration of the leadframes 7 inside the housing body 8 allow reducing the overall size and complexities of the electric motor 2 comprising the connecting structure 1. Moreover, a connecting structure 1 thus configured allows making an effective electrical connection with the stator 3 of the electric motor 2 as well as a firm and simplified mechanical connection with the stator 3.
[0054] Leadframes 7
[0055] According to an embodiment, the plurality of leadframes 7 is configured to make a star-shaped or triangular connection between the electric power source 9 and the at least one three-phase winding 4, 5.
[0056] According to an embodiment, the plurality of leadframes 7 comprises a plurality of active leadframes 12.
[0057] Each active leadframe 12 is configured to transmit electric power to at least one winding of the at least one three-phase winding 4, 5 of the stator 3. Preferably, each leadframe 12 is configured to transmit electric power to a single respective winding of the at least one three-phase winding 4, 5.
[0058] According to an embodiment, the active leadframes 12 extend substantially coplanar on a plane transverse to the motor axis 15.
[0059] Advantageously, such a configuration reduces the axial overall size of the connecting structure 1 and thus of the electric motor 2.
[0060] According to an embodiment, each active leadframe 12 extends between a source terminal 13 and an opposite stator terminal 14.
[0061] The source terminal 13 is configured to be connectable to the electric power source 9.
[0062] The stator terminal 14 is configured to be connectable to at least one winding of the at least one three-phase winding 4, 5.
[0063] According to an embodiment, the stator terminals 14 of the active leadframes 12 extend in a direction parallel to the motor axis 15.
[0064] According to an embodiment, the stator terminals 14 are bent in a direction transverse to the plane on which the active leadframes 12 extend, so as to extend in the direction parallel to the motor axis 15.
[0065] According to an embodiment, the plurality of leadframes 7 further comprises at least one passive leadframe 16.
[0066] The passive leadframe 16 is configured to be electrically connectable to at least two windings of the at least one three-phase winding 4, 5.
[0067] Therefore, the at least one passive leadframe 16, unlike the active leadframes 12, is not directly connectable to the electric power source 9.
[0068] Advantageously, by means of the at least one passive leadframe 16, it is possible to connect the at least one three-phase winding 4, 5 through a respective starshaped connection.
[0069] According to an embodiment, at least one passive leadframe 16 substantially extends on a plane parallel to but not coincident with the plane on which the active leadframes 12 extend.
[0070] According to an embodiment, the at least one passive leadframe 16 comprises at least two passive terminals 17.
[0071] According to an embodiment, the passive terminals 17 of the at least onepassive leadframe 16 extend in the direction parallel to the motor axis 15.
[0072] According to an embodiment, the passive terminals 17 are bent in a direction transverse to the plane on which the at least one passive leadframe 16 extends, so as to extend in the direction parallel to the motor axis 15.
[0073] According to an embodiment, the passive terminals 17 extend along the same direction and wat as the stator terminals 14.
[0074] Redundant configuration
[0075] According to an embodiment, the connecting structure 1 is adapted to be comprised in an electric motor 2 of the type comprising a stator 3, which comprises a first three-phase winding 4 and a second three-phase winding 5. The first three-phase winding 4 is distinct from the second three-phase winding 5. Each winding of the first three-phase winding 4 and the second three-phase winding 5 extends between two opposite winding terminals 29.
[0076] According to this embodiment, the leadframes 7 are configured to transmit electric power to the first three-phase winding 4 and the second three-phase winding 5 of the stator 3. Preferably, the leadframes 7 are configured to transmit electric power from an electric power source 9 to the first three-phase winding 4 and the second three- phase winding 5 of the stator 3.
[0077] According to an embodiment, the plurality of leadframes 7 comprises a first group of leadframes 10 a second group of leadframes 11 .
[0078] The first group of leadframes 10 is configured to transmit electric power to the first three-phase winding 4.
[0079] The second group of leadframes 1 1 is configured to transmit electric power to the second three-phase winding 5.
[0080] According to an embodiment, the first group of leadframes 10 is distinct from the second group of leadframes 1 1 .
[0081] Advantageously, the separation between the first group of leadframes 10 connectable to the first three-phase winding 4 and the second group of leadframes 1 1 connectable to the second three-phase winding 5 gives redundancy to the connecting structure 1 , and thus to the electric motor 2, and in particular to the electrical connection between the power source 9 and the stator 3, and thus allows actuating the electric motor 2 and ensuring a braking action, even in the case of failure of one of the first or second three-phase winding 4, 5, since the other of the first or second three-phase winding 4, 5 is however powerable by the respective first or second group of leadframes 10, 11 to actuate the electric motor 2.
[0082] With added advantage, such a configuration allows achieving a redundancy of the electrical connection with a small axial overall size.
[0083] According to an embodiment, the first group of leadframes 10 is configured to make a star-shaped or triangular connection between the electric power source 9 and the first three-phase winding 4. Moreover, the second group of leadframes 1 1 is configured to make a star-shaped or triangular connection between the electric power source 9 and the second three-phase winding 5.
[0084] Each passive leadframe 12 is configured to transmit electric power to a respective winding of the first three-phase winding 4 or the second three-phase winding 5.
[0085] Specifically, each active leadframe 12 is configured to transmit electric power from an electric power source 9 to a single winding of the first three-phase winding 4 or the second three-phase winding 5, respectively.
[0086] Advantageously, the first and second groups of leadframes 10, 1 1 transmit a respective three-phase electric power to the stator 3 by means of the respective three active leadframes 12.
[0087] According to an embodiment, the active leadframes 12 of the first group of leadframes 10 extend substantially coplanar on a plane transverse to the motor axis 15.
[0088] According to an embodiment, the active leadframes 12 of the second group of leadframes 1 1 extend substantially coplanar on a plane transverse to the motor axis 15.
[0089] According to a preferred embodiment, the active leadframes 12 of the first group of leadframes 10 and of the second group of leadframes 1 1 extend substantially coplanar on the same plane transverse to the motor axis 15.
[0090] Advantageously, such a configuration reduces the axial overall size of the connecting structure 1 and thus of the electric motor 2.
[0091] According to an embodiment, the first group of leadframes 10 and the second group of leadframes 1 1 each comprise a passive leadframe 16, respectively.
[0092] Each passive leadframe 16 is configured to be electrically connectable to at least one of the three windings of the first three-phase winding 4 or the second three- phase winding 5. According to an embodiment, each passive leadframe 16 is configured to be electrically connectable to the three windings of either the first three-phase winding 4 or the second three-phase winding 5.
[0093] According to this embodiment, each passive leadframe 16 comprises at least three, preferably three, passive terminals 17.
[0094] Advantageously, such a configuration allows connecting the first three-phase winding 4 and the second three-phase winding 5 by means of a respective triangular connection. Specifically, in such a configuration, the neutral point, or common point, of the first three-phase winding 4 or the second three-phase winding 5 is made by the respective passive leadframe 16 connectable to all windings of the first or second three- phase winding 4, 5, respectively.
[0095] Specifically, each winding of the first or second three-phase winding 4, 5 is connectable to one of the three active leadframes 12 and to the passive leadframe 16 of the first or second group of leadframes 10, 1 1.
[0096] Advantageously, such a configuration reduces the axial overall size of the connecting structure 1 and thus of the electric motor 2, making a small-size, double starshaped connection.
[0097] According to an embodiment, the passive leadframe 16 of the first group of leadframes 10 substantially extends on a plane parallel to but not coincident with the plane on which the active leadframes 12 of the first group of leadframes 10 extend.
[0098] According to an embodiment, the passive leadframe 16 of the second group of leadframes 11 substantially extends on a plane parallel to but not coincident with the plane on which the active leadframes 12 of the second group of leadframes 11 extend.
[0099] According to a preferred embodiment, the passive leadframes 16 of the first and second groups of leadframes 10, 1 1 extend substantially coplanar on the same plane parallel to but not coincident with the plane on which the active leadframes 12 of the first and second groups of leadframes 10, 11 extend.
[0100] According to an embodiment, the source terminals 13 of the first group of leadframes 10 are connectable to a first electric power source, while the source terminals 13 of the second group of leadframes 1 1 are connectable to a second electric power source distinct from the first electric power source.
[0101] According to an embodiment, the stator terminals 14 of the first group of leadframes 10 are positioned, with respect to the motor axis 15, along an angular extension of less than 180°.
[0102] Specifically, the active leadframes 12 of the first group of leadframes 10 extend substantially along an arc of circumference transverse to the motor axis 15. The maximum extension of the arc of circumference is delimited by the stator terminals 14 of the first group of leadframes 10. Such an arc of circumference delimited by the stator terminals 14 of the first group of the leadframes 10 has an angular extension of less than 180°. As a result, the angular distance with respect to the motor axis 15 between themutually most distant stator terminals 14 of the first group of leadframes 10 is less than 180°.
[0103] Preferably, the stator terminals 14 of the first group of leadframes 10 are positioned, with respect to the motor axis 15, along an angular extension of less than 150°.
[0104] Advantageously, such a configuration reduces the overall size of the connecting structure 1 and the electric motor 2, because the stator terminals 14 of the first group of leadframes 10 are confined in a first half of the housing body 8.
[0105] According to a first embodiment, the stator terminals 14 of the first group of leadframes 10 are positioned substantially along the same arc of circumference, preferably coaxial to the motor axis 15.
[0106] Advantageously, such a configuration reduces the overall size of the connecting structure 1 and the electric motor 2, and simplifies the configuration thereof.
[0107] According to an embodiment, the stator terminals 14 of the second group of leadframes 1 1 are positioned, with respect to the motor axis 15, on an angular extension of less than 180°.
[0108] Specifically, the active leadframes 12 of the second group of leadframes 11 substantially extend along an arc of circumference about the motor axis 15. The maximum extension of the arc of circumference is delimited by the stator terminals 14 of the second group of leadframes 11 . Such an arc of circumference delimited by the stator terminals 14 of the second group of the leadframes 11 has an angular extension of less than 180°. As a result, the angular distance with respect to the motor axis 15 between the mutually most distant stator terminals 14 of the second group of leadframes 11 is less than 180°.
[0109] Preferably, the stator terminals 14 of the second group of leadframes 11 are positioned, with respect to the motor axis 15, on an angular extension of less than 150°.
[0110] Advantageously, such a configuration reduces the overall size of the connecting structure 1 and the electric motor 2, because the stator terminals 14 of the second group of leadframes 11 are confined in a second half of the housing body 8.
[0111] With added advantage, the stator terminals 14 of the first group of leadframes 10 are confined in a first half of the housing body 8, not superimposed on the second half of the housing body 8 in which the stator terminals 14 of the second group of leadframes 1 1 are confined. “First half and second half" mean a first and a second half of a section of the housing body 8 transverse to the motor axis 15.
[0112] According to an embodiment, the stator terminals 14 of the second group ofleadframes 11 are positioned along the same arc of circumference, preferably coaxial to the motor axis 15.
[0113] Advantageously, such a configuration reduces the overall size of the connecting structure 1 and the electric motor 2, and simplifies the configuration thereof.
[0114] According to a preferred embodiment, the stator terminals 14 of the first and second groups of leadframes 10, 11 are positioned along the same circumference, preferably coaxial to the motor axis 15.
[0115] According to an embodiment, the active leadframes 12 of the first group of leadframes 10 are not superimposed on the active leadframes 12 of the second group of leadframes 11 .
[0116] Therefore, the arc of circumference along which the active leadframes 12 of the first group of leadframes 10 substantially extend is not superimposed on the arc of circumference along which the active leadframes 12 of the second group of leadframes 11 substantially extend.
[0117] According to an embodiment, the passive leadframe 16 of the first and second groups of leadframes 10, 11 comprises three passive terminals 17.
[0118] Each of the three passive terminals 17 is configured to be connectable to a respective winding of the first three-phase winding 4 or the second three-phase winding 5.
[0119] Specifically, the three passive terminals 17 of the passive leadframe 16 of the first group of leadframes 10 are configured to be connectable to the first three-phase winding 4.
[0120] Moreover, the three passive terminals 17 of the passive leadframe 16 of the second group of leadframes 11 are configured to be connectable to the second three- phase winding 5.
[0121] According to an embodiment, the passive terminals 17 of each passive leadframe 16 are positioned, with respect to the motor axis 15, along an angular extension of less than 180°.
[0122] Specifically, each passive leadframe 16 substantially extends along an arc of circumference about the motor axis 15. The maximum extension of the arc of circumference is delimited by the passive terminals 17 of the respective passive leadframe 16. Such an arc of circumference delimited by the passive terminals 17 has an angular extension of less than 180°. As a result, the angular distance with respect to the motor axis 15 between the mutually most distant passive terminals 17 of the passive leadframes 16 is less than 180°.
[0123] Preferably, the passive terminals 17 of each passive leadframe 16 are positioned, with respect to the motor axis 15, along an angular extension of less than 150°.
[0124] Advantageously, such a configuration reduces the overall size of the connecting structure 1 and the electric motor 2, because the passive terminals 17 of the first group of leadframes 10 are confined in a first half of the housing body 8.
[0125] According to an embodiment, the passive terminals 17 of the first group of leadframes 10 are positioned along the same arc of circumference, preferably coaxial to the motor axis 15.
[0126] According to an embodiment, the passive terminals 17 of the second group of leadframes 11 are positioned along the same arc of circumference, preferably coaxial to the motor axis 15.
[0127] According to a preferred embodiment, the passive terminals 17 of the first and second groups of leadframes 10, 11 are positioned along the same circumference, preferably coaxial to the motor axis 15.
[0128] According to a preferred embodiment, the passive terminals 17 of the first and second groups of leadframes 10, 11 are positioned along the same circumference on which the stator terminals 14 of the first and second groups of leadframes 10, 11 are positioned.
[0129] According to an embodiment, the passive leadframe 16 of the first group of leadframes 10 is not superimposed on the active leadframe 16 of the second group of leadframes 11 .
[0130] According to an embodiment, each passive leadframe 16 is at least partially superimposed, in the direction parallel to the motor axis 15, on at least one active leadframe 12.
[0131] According to an embodiment, each passive leadframe 16 is at least partially superimposed, in the direction parallel to the motor axis 15, on a single active leadframe 12.
[0132] Advantageously, such a configuration reduces the overall size of the connecting structure 1 and the electric motor 2.
[0133] Housing body 8
[0134] According to an embodiment, the housing body 8 comprises a plurality of outlet holes 18.
[0135] The outlet holes 18 are positioned at the stator terminals 14 of the leadframes7.
[0136] Moreover, the connecting structure 1 is configured so that the stator terminals 14 of the leadframes 7 extend into the outlet holes 18 and lead outside the housing body8.
[0137] Specifically, each stator terminal 14 of the leadframes 7 extends into a single respective outlet hole 18.
[0138] According to an embodiment, the outlet holes 18 are positioned at the stator terminals 14 and, when provided, at the passive terminals 17 of the leadframes 7.
[0139] Moreover, the connecting structure 1 is configured so that the stator terminals 14 and the passive terminals 17 of the leadframes 7 extend into the outlet holes 18 and lead outside the housing body 8.
[0140] Specifically, each stator terminal 14 or passive terminal 17 of the leadframes7 extends to be inserted into a single respective outlet hole 18.
[0141] According to an embodiment, the outlet holes 18 extend in the direction parallel to the motor axis 15.
[0142] According to an embodiment, the leadframes 7 are at least partially embedded in the housing body 8 over-molded onto the leadframes 7, and the stator terminals 14 and the passive terminals 17 lead outside the housing body 8.
[0143] According to a preferred embodiment, a portion of the leadframes 7 substantially extending on a plane transverse to the motor axis 15 is embedded in the housing body 8, preferably over-molded or co-molded onto the leadframes 7, whereas the stator terminals 14 and the passive terminals 17, bent and extending in directions substantially parallel to the motor axis 15, lead outside the housing body 8.
[0144] According to an embodiment, the outlet holes 18 result from the over-molding or co-molding of the housing body 8 onto the plurality of leadframes 7. The housing body8 co-molded to the plurality of leadframes 7 incorporates a portion of the leadframes 7 substantially extending in a plane transverse to the motor axis 15, but does not incorporate the stator terminals 14 and, when provided, the passive terminals 17, so as to define respective outlet holes 18 through which the stator terminals 14 and the passive terminals 17 extend leading from the housing body 8.
[0145] According to an embodiment, the housing body 8 comprises a connecting wall 19. The connecting wall 19 is preferably planar.
[0146] The planar connecting wall 19 extends along a plane transverse to the motor 15.
[0147] Moreover, the housing body 8 comprises a perimetral wall 20.
[0148] The perimetral wall 20 extends externally around the connecting wall 19. According to an embodiment, the perimetral wall 20 extends from the planar connecting wall 19 in the direction parallel to the motor axis 15.
[0149] The connecting wall 19 forms a first surface 38 and an opposite second surface 39.
[0150] The first surface 38 is adapted to face the stator 3.
[0151] The second surface 39 is adapted to face an interface towards a braking actuator, in particular of the BBW type.
[0152] Preferably, the first and second surfaces 38, 39 are transverse to the motor axis 15.
[0153] According to an embodiment, the planar connecting wall 19 defines a shaft seat 22.
[0154] The shaft seat 22 extends passing through the planar connecting wall 19 in the direction coaxial to the motor axis 15. Specifically, the shaft seat 22 extends between the first surface 38 and the opposite second surface 39 of the connecting wall 19.
[0155] The shaft seat 22 is adapted to rotatably accommodate a rotor shaft 37 of a rotor 6 of an electric motor 2.
[0156] According to an embodiment, the planar connecting wall 19 is substantially circular in shape and the perimetral wall 20 is substantially cylindrical in shape.
[0157] According to an embodiment, the outlet holes 18 extend through the planar connecting wall 19, in the direction parallel to the motor axis 15.
[0158] Moreover, the outlet holes 18 lead onto the second surface 39 of the connecting wall 19.
[0159] Specifically, the stator terminals 14 and, when provided, the passive terminals 17 extend through the connecting wall 19, and lead from the second surface 39 and the connecting wall 19.
[0160] According to an embodiment, the leadframes 7 are at least partially embedded in the planar connecting wall 19, and the stator terminals 14 and, when provided, the passive terminals 17 lead outside the planar connecting wall 19. The planar connecting wall 19 is over-molded or co-molded onto the leadframes 7.
[0161] According to a preferred embodiment, a portion of the leadframes 7 substantially extending on a plane transverse to the motor axis 15 is embedded in the planar connecting wall 19, whereas the stator terminals 14, and when provided, thepassive terminals 17, bent and extending in directions substantially parallel to the motor axis 15, lead outside the connecting wall 19.
[0162] According to an embodiment, the outlet holes 18 are positioned along the same circumference coaxial to the motor axis 15.
[0163] Advantageously, such a configuration of the connecting structure 1 is more compact and allows easy electrical connection between the leadframes 7 and the windings of a stator 3.
[0164] According to an embodiment, the housing body 8 comprises a plurality of interface holes 23.
[0165] The interface holes 23 are positioned at the outlet holes 18.
[0166] Each interface hole 23 is configured to allow a single winding terminal 29 of the at least one three-phase winding 4, 5 to be inserted through the interface hole 23.
[0167] According to an embodiment, the interface holes 23 are configured so that the winding terminals 29 of the at least one three-phase winding 4, 5 inserted into the interface holes 23 lead outside the housing body 8.
[0168] Preferably, the interface holes 23 are configured so that the winding terminals 29 of the at least one three-phase winding 4, 5 inserted into the interface holes 23 lead outside the housing body 8, adjacent to the stator terminals 14 and, when provided, to the passive terminals 17.
[0169] According to an embodiment, the interface holes 23 are configured so that the winding terminals of the at least one three-phase winding 4, 5 inserted into the interface holes 23 lead from the second surface 39 of the connecting wall 19.
[0170] Advantageously, by means of the interface holes 23, a less cumbersome and less complex electrical and mechanical connection can be made between the stator 3 and the connecting structure 1 , and in particular between the stator 3 and the leadframes 7.
[0171] According to an embodiment, the interface holes 23 extend in the direction parallel to the motor axis 15.
[0172] According to an embodiment, the interface holes 23 extend through the planar connecting wall 19, in the direction parallel to the motor axis 15.
[0173] Moreover, the outlet holes 23 lead onto the second surface 39 of the connecting wall 19.
[0174] According to a preferred embodiment, the interface holes 23 extend passing through the planar connecting wall 19, in the direction parallel to the motor axis 15.Specifically, the interface holes 23 extend passing through between the first surface 38 and the second surface 39 of the connecting wall 19.
[0175] According to an embodiment, the interface holes 23 are positioned along the same arc of circumference coaxial to the motor axis 15.
[0176] According to an embodiment, the interface holes 23 are positioned along the same circumference coaxial to the motor axis 15 having a smaller diameter than the diameter of the circumference along which the outlet holes 18 are positioned.
[0177] According to an embodiment, the interface holes 23 are positioned along the same direction radially to the motor axis 15 as the respective outlet holes 18.
[0178] Advantageously, such a configuration simplifies and reduces the overall size of an electrical and mechanical connection between the stator terminals 14 and, when provided, the passive terminals 17 with the winding terminals of the stator 3.
[0179] According to an embodiment, the housing body 8 is made so that the planar connecting wall 19 is over-molded or co-molded onto the leadframes 7.
[0180] According to an embodiment, the leadframes 7 are positioned at the perimetral wall 20. Specifically, the leadframes 7 substantially extend along an arc of circumference coaxial to the motor axis 15 and coaxial and adjacent to the perimetral wall 20.
[0181] According to an embodiment, the housing body 8 comprises at least one power interface conduit 24 configured to interface or connect the connecting structure 1 with / to a power source 9.
[0182] According to an embodiment, the source terminals 13 of the leadframes 7 extend into the at least one power interface conduit 24.
[0183] According to an embodiment, the housing body 8 comprises two power interface conduits 24.
[0184] According to this embodiment, the source terminals 13 of the first group of leadframes 10 extend into one of the two power interface conduits 24, and the source terminals 13 of a second group of leadframes 11 extend into the other of the two power interface conduits 24.
[0185] Advantageously, such a configuration simplifies the connecting structure 1 and the electric motor 2.
[0186] According to an embodiment, the power interface conduits 24 extend from the perimetral wall 20 in the opposite direction to the planar connecting wall 19.
[0187] According to an embodiment, the power interface conduits 24 extend from the perimetral wall 20 in the direction traverse to the motor axis 15.
[0188] According to an embodiment, the power interface conduits 24 are substantially mutually parallel.
[0189] According to this embodiment, the source terminals 13 inserted into the power interface conduits 24 lead outside the perimetral wall 20, in the direction transverse to the motor axis 15.
[0190] According to an embodiment, the source terminals 13 of the first and second groups of leadframes 10, 11 extend along mutually parallel directions, oppositely to the planar connecting wall 19.
[0191] According to an embodiment, the connecting structure 1 comprises a first position sensor 26.
[0192] The first position sensor 26 is configured to detect the position of a rotor 6 connectable to the housing body 8.
[0193] According to an embodiment, the connecting structure 1 comprises a second position sensor 27.
[0194] The second position sensor 27 is configured to detect the position of a rotor 6 connectable to the housing body 8.
[0195] Moreover, the first position sensor 26 is independent of the second position sensor 27.
[0196] Therefore, both the first position sensor 26 and the second position sensor 27 are configured to detect the position of the rotor 6 independently from each other.
[0197] Advantageously, by means of such a redundant configuration, the correct detection of the rotor 6 is ensured even under conditions of malfunction of one of the two position sensors 26, 27.
[0198] According to an embodiment, the first and second position sensors 26, 27 are comprised within a single housing so as to form a redundant sensor.
[0199] According to an alternative embodiment, the first and second position sensors 26, in addition to being independent from each other, are also physically distinct from each other.
[0200] According to an embodiment, the first and second position sensors 26, 27 are, by way of example, optical readout sensors, or magnetic sensors, or Hall effect sensors.
[0201] According to an embodiment, the first and second position sensors 26, 27 are positioned at the planar connecting wall 19. Preferably, the first and second position sensors 26, 27 are placed at the second surface 39 of the connecting wall 19.
[0202] According to an embodiment, the first and second position sensors 26, 27 bothcomprise a respective sensor leadframe 28.
[0203] The sensor leadframe 28 is configured to connect the respective first or second position sensor 26, 27 to a power source 9.
[0204] The sensor leadframe 28 of the first position sensor 26 is distinct and independent of the sensor leadframe 28 of the second position sensor 27.
[0205] According to an embodiment, the sensor leadframes 28 substantially extend on a plane transverse to the motor axis 15. Preferably, the sensor leadframes 28 of both the first and second position sensors 26, 27 substantially extend on the same plane transverse to the motor axis 15.
[0206] According to an embodiment, the housing body 8 is made to be over-molded or co-molded onto the sensor leadframes 28. Therefore, the sensor leadframes 28 are embedded in the housing body 8.
[0207] According to an embodiment, the sensor leadframes 28 extend at least partially into a respective power interface conduit 24.
[0208] Preferably, the at least one sensor leadframe 28 of the first position sensor 26 extends into the power interface conduit 24 in which the source terminals 13 of the first group of leadframes 10 extend, while the at least one sensor leadframe 28 of the second position sensor 27 extends into the power interface conduit 24 in which the source terminals 13 of the second group of leadframes 11 extend.
[0209] Advantageously, such a configuration increases the compactness of the connecting structure 1 and electric motor 2.
[0210] According to this embodiment, the sensor leadframes 28 lead outside the perimetral wall 20, in the direction transverse to the motor axis 15.
[0211] According to an embodiment, the sensor leadframes 28 lead along mutually parallel directions, oppositely to the planar connecting wall 19.
[0212] Electric motor 2
[0213] According to a further aspect of the invention, an electric motor, in particular for a braking system of the BBW type, is generally indicated by reference numeral 2.
[0214] The electric motor 2 comprises a stator 3. The stator 3 extends about a motor axis 15. The stator 3 comprises at least one three-phase winding 4, 5. Each winding of the at least one three-phase winding 4, 5 extends between two opposite winding terminals 29.
[0215] The electric motor 2 further comprises a rotor 6. The rotor 6 is substantially coaxial to the motor axis 15.
[0216] Moreover, the electric motor 2 comprises a connecting structure 1 as previously described, the description of which is not repeated here to avoid redundancies. In particular, the connecting structure 1 comprises a housing body 8 and a plurality of leadframes 7 configured to transmit electric power to the at least one three- phase winding 4, 5, and where the plurality of leadframes 7 is connected to the housing body 8.
[0217] According to an aspect of the invention, the plurality of leadframes 7 is connected to the stator 3 so as to transmit electric power to the at least one three-phase winding 4, 5.
[0218] Advantageously, an electric motor 2 thus configured does not need a busbar or other further components for receiving electric power from a power source 9 and thus has small overall size, low operation complexity, and low manufacturing and maintenance costs.
[0219] According to an embodiment, the stator 3 comprises a first three-phase winding 4 and a second three-phase winding 5. Each winding of the first three-phase winding 4 and the second three-phase winding 5 extends between two opposite winding terminals 29. The first three-phase winding 4 is distinct from the second three-phase winding 5.
[0220] Moreover, the electric motor 2 comprises a connecting structure 1 as previously described, the description of which is not repeated here to avoid redundancies. In particular, the connecting structure 1 comprises a housing body 8 and a plurality of leadframes 7, preferably a first and a second group of leadframes 10, 1 1 as previously described, configured to transmit electric power to the first three-phase winding 4 and the second three-phase winding 5, and where the plurality of leadframes 7 is connected to the housing body 8.
[0221] According to an embodiment, the plurality of leadframes 7 is connected to the stator 3 so as to transmit electric power to the first three-phase winding 4 and the second three-phase winding 5.
[0222] Moreover, the electrical connection between the first three-phase winding 4 and the first group of leadframes 10 is independent of the electrical connection between the second three-phase winding 5 and the second group of leadframes 11 .
[0223] Advantageously, such a configuration gives redundancy to the electric motor2, and in particular to the electrical connection between the power source 9 and the stator3, and thus allows actuating the electric motor 2 and ensuring a braking action, even in the case of failure of one of the first or second three-phase winding 4, 5, since the otherof the first or second three-phase winding 4, 5 is however powerable by the respective first or second group of leadframes 10, 1 1 to actuate the electric motor 2.
[0224] With added advantage, such a configuration allows achieving a redundancy of the electrical connection with a small axial overall size.
[0225] According to an embodiment, one of the two winding terminals 29 of each winding of the first three-phase winding 4 is connected to a respective active leadframe 12 of the first group of leadframes 10. The other of the two winding terminals 29 of each winding of the first three-phase winding 4 is connected to the passive leadframe 16 of the first leadframe group 10 (in the case of a star-shaped connection) or to an additional active leadframe 12 of the first leadframe group 10 (in the case of a triangular connection).
[0226] Moreover, one of the two winding terminals 29 of each winding of the second three-phase winding 5 is connected to a respective active leadframe 12 of the second group of leadframes 1 1 . The other of the two winding terminals 29 of each winding of the second three-phase winding 5 is connected to the passive leadframe 16 of the second group of leadframes 1 1 (in the case of a star-shaped connection) or to an additional active leadframe 12 of the second group of leadframes 11 (in the case of a triangular connection).
[0227] Specifically, one of the two winding terminals 29 of each winding of the first or second three-phase winding 4, 5 is connected to a stator terminal 14 of the first or second group of leadframes 10, 1 1 , respectively. The other of the two winding terminals 29 of each winding of the first or second three-phase winding 4, 5 is connected to a passive terminal 17 or to an additional respective stator terminal 14 of the first or second group of leadframes 10, 11 , respectively.
[0228] Advantageously, the first three-phase winding 4 in a star-shaped or triangular connection is independent of the second three-phase winding 5 in a star-shaped or triangular connection. However, the first three-phase winding 4 and the second three- phase winding 5 have the same connection type, i.e., both are in a star-shaped connection or both are in a triangular connection.
[0229] According to an embodiment, the winding terminals 29 are welded to the stator terminals 14, and when provided, to the passive terminals 17 of the plurality of leadframes 7, respectively.
[0230] According to an embodiment, each winding terminal 29 is inserted into a respective interface hole 23 of the housing body 8, so as to connect to a respective stator terminal 14 or passive terminal 17.
[0231] According to an embodiment, the winding terminals 29 of the stator 3 extend in the direction parallel to the motor axis 15.
[0232] According to an embodiment, the first winding 4 and the second winding 5 of the stator 3 each define six magnetic poles 30.
[0233] Therefore, the stator 3, in the operating configuration, comprises twelve magnetic poles 30.
[0234] According to an embodiment, the stator 3 comprises a stator pack 31 .
[0235] The stator pack 31 extends substantially coaxially to the motor axis 15.
[0236] The first and second three-phase windings 4, 5 are wound on the stator pack 31.
[0237] According to an embodiment, the stator pack 31 comprises a plurality of stator teeth 32 mutually assembled so as to form the stator pack 31 .
[0238] Specifically, the stator teeth 32 are connected together in the circumferential direction with respect to the motor axis 15.
[0239] According to an embodiment, the stator pack 31 consists of twelve mutually assembled stator teeth 32.
[0240] According to an embodiment, each stator tooth 32 substantially extends on a plane parallel to the motor axis 15.
[0241] The first and second three-phase windings 4, 5 are wound on the stator teeth 32 of the stator pack 31 .
[0242] According to an embodiment, the first three-phase winding 4 is wound on six stator teeth 32 directly placed side-by-side and connected to one another, and the second three-phase winding 5 is wound on the remaining six stator teeth 32 directly placed side-by-side and connected to one another.
[0243] Naturally, the winding layout of the turns of the first and second three-phase windings 4, 5 on the stator pack 31 can differ depending on the particular constructional needs.
[0244] According to an embodiment, the electric motor 2 comprises a housing container 40.
[0245] The housing rod 40 is connectable to the connecting structure 1 .
[0246] According to an embodiment, the housing container 40 is connectable to the connecting structure 1 so as to face the first surface 38 of the connecting wall 19. Preferably, the housing rod 40 is connectable to the perimetral wall 20 of the connecting structure 1 .
[0247] The connecting structure 1 and the housing container 40, being connected and facing each other, thus form a stator seat 25. Specifically, the stator seat 25 is formed between connecting wall 19 and the housing container 40.
[0248] The stator 3 is housed inside the stator seat 25.
[0249] According to an embodiment, the stator 3 is substantially annular in shape and forms a rotor seat 21 therein.
[0250] The rotor 6 can be housed inside the rotor seat 21 formed by the stator 3.
[0251] According to this preferred embodiment, the rotor 6 is positioned coaxially to the stator 3.
[0252] The stator 3 and the rotor 6 are thus both housed in the space formed by the connecting structure 1 and the housing container 40, in particular by the connecting wall 19 and the housing container 40, preferably at the first surface 38 of the connecting wall 19.
[0253] According to an embodiment, the rotor 6 comprises a rotor shaft 37 extending coaxially to the motor axis 15.
[0254] The rotor shaft 37 is inserted through the shaft seat 22 of the housing body 8.
[0255] According to an embodiment, the motor 2 comprises a bearing 35.
[0256] The bearing 35 is housed inside the shaft seat 22, coaxial to the motor shaft 15. The bearing 35 is rotatably connected to the rotor shaft 37 of the rotor 6.
[0257] According to a further aspect of the invention, a braking system, in particular a braking system of the BBW type, comprises a connecting structure 1 as previously described.
[0258] According to an embodiment, the braking system comprises an electric motor 2 as previously described.
[0259] According to an embodiment, the braking system comprises an electric power source 9 and a printed circuit board 36, where the printed circuit board 36 is electrically connected at least to the electric power source 9 and the electric motor 2. Preferably, the printed circuit board 36 electrically connects the first and second position sensors 26, 27 to the electric power source 9.
[0260] According to an embodiment, the printed circuit board 36 is connected to the housing body 8, preferably is connected to the planar connecting wall 19.
[0261] According to an embodiment, the printed circuit board 36 houses the first and second position sensors 26, 27. Preferably, the printed circuit board 36 houses the first and second position sensors 26, 27 in the embodiment in which they are comprisedwithin a single housing, forming a redundant sensor.
[0262] Obviously, those skilled in the art will be able to make changes or adaptations to the present invention, without however departing from the scope of the following claims.List of reference numerals1. Connecting structure2. Electric motor3. Stator4. First three-phase winding5. Second three-phase winding6. Rotor7. Leadframes8. Housing body9. Electric power source10. First group of leadframes11 . Second group of leadframes12. Active leadframe13. Source terminal14. Stator terminal15. Motor axis16. Passive leadframe17. Passive terminal18. Outlet holes19. Planar connecting wall20. Perimetral wall21 . Rotor seat22. Shaft seat23. Interface hole24. Power interface conduit25. Stator seat26. First position sensor27. Second position sensor28. Sensor leadframes29. Winding terminal30. Magnetic pole31 . Stator pack32. Stator tooth35. Bearing36. Printed circuit board
Claims
Claims1. A connecting structure (1) for an electric motor (2) of the type comprising at least:- one stator (3), extending about a motor axis (15) and comprising at least one three- phase winding (4, 5);- one rotor (6), substantially coaxial to the motor axis (15), wherein the connecting structure (1) comprises:- a plurality of leadframes (7), configured to transmit electric power to the at least one three-phase winding (4, 5);- a housing body (8), configured to house at least one of the rotor (6) and the stator (3), and wherein the plurality of leadframes (7) is connected to the housing body (8).
2. A connecting structure (1) according to claim 1 , wherein the housing body (8) is overmolded or co-molded onto the plurality of leadframes (7), and preferably the housing body (8) is made of polymer material.
3. A connecting structure (1 ) according to claim 1 or 2, wherein the plurality of leadframes (7) comprises a plurality of active leadframes (12), wherein each active leadframe (12) is configured to transmit electric power to at least one winding of the at least one three- phase winding (4, 5) of the stator (3), and wherein the active leadframes (12) extend substantially coplanar on a plane transverse to the motor axis (15).
4. A connecting structure (1) according to any one of the preceding claims, wherein the plurality of leadframes (7) comprises a plurality of active leadframes (12), wherein each active leadframe (12) is configured to transmit electric power to at least one winding of the at least one three-phase winding (4, 5) of the stator (3), wherein each active leadframe (12) extends between a source terminal (13) and an opposite stator terminal (14), wherein the source terminal (13) is configured to be connectable to the electric power source (9), and the stator terminal (14) is configured to be connectable to at least one winding of the at least one three-phase winding (4, 5), and wherein the stator terminals (14) are bent in a direction transverse to the plane on which the active leadframes (12) extend so that the stator terminals (14) extend in a direction parallel to the motor axis (15).
5. A connecting structure (1 ) according to claim 3, wherein the plurality of leadframes (7) comprises at least one passive leadframe (16) configured to be electrically connectable to at least two windings of the at least one three-phase winding (4, 5), wherein the at least one passive leadframe (16) extends substantially on a plane parallel to but not coincident with the plane on which the active leadframes (12) extend, and wherein the at least one passive leadframe (16) comprises at least two passive terminals (17) bent in a transverse direction with respect to the plane on which the at least one passive leadframe (16) extends, so that the passive terminals (17) extend in a direction parallel to the motor axis (15), preferably along the same direction and way as the stator terminals (14).
6. A connecting structure (1 ) according to any one of the preceding claims, wherein the plurality of leadframes (7) comprises a first group of leadframes (10) and a second group of leadframes (1 1 ), wherein the first group of leadframes (10) is configured to transmit electric power to a first three-phase winding (4), and the second group of leadframes (11 ) is configured to transmit electric power to a second three-phase winding (5), and wherein the first group of leadframes (10) is distinct from the second group of leadframes (11 ).
7. A connecting structure (1 ) according to claim 6, wherein the active leadframes (12) of the first group of leadframes (10) extend substantially coplanar on a plane transverse to the motor axis (15), or wherein the active leadframes (12) of the second group of leadframes (11 ) extend substantially coplanar on a plane transverse to the motor axis (15), or wherein the active leadframes (12) of the first group of leadframes (10) and of the second group of leadframes (1 1 ) extend substantially coplanar on the same plane transverse to the motor axis (15).
8. A connecting structure (1 ) according to claim 6 or 7, wherein the first group of leadframes (10) and the second group of leadframes (1 1 ) each comprise a passive leadframe (16), respectively, wherein each passive leadframe (16) is configured to be electrically connectable to at least one of the three windings of either the first three-phase winding (4) or the second three-phase winding (5),and wherein the passive leadframe (16) of the first group of leadframes (10) extends substantially on a plane parallel to but not coincident with the plane on which the active leadframes (12) of the first group of leadframes (10) extend, or wherein the passive leadframe (16) of the second group of leadframes (11 ) extends substantially on a plane parallel to but not coincident with the plane on which the active leadframes (12) of the second group of leadframes (11 ) extend, or wherein the passive leadframes (16) of the first and second groups of leadframes (10, 11 ) extend substantially coplanar on the same plane parallel to but not coincident with the plane on which the active leadframes (12) of the first and second groups of leadframes (10, 1 1 ) extend.
9. A connecting structure (1 ) according to any one of the preceding claims, wherein the plurality of leadframes (7) comprises a first group of leadframes (10) and a second group of leadframes (1 1 ), wherein the first group of leadframes (10) is configured to transmit electric power to a first three-phase winding (4), and the second group of leadframes (1 1 ) is configured to transmit electric power to a second three-phase winding (5), wherein each active leadframe (12) extends between a source terminal (13) and an opposite stator terminal (14), wherein the source terminal (13) is configured to be connectable to the electric power source (9), and the stator terminal (14) is configured to be connectable to at least one winding of the at least one three-phase winding (4, 5), and wherein the stator terminals (14) of the first group of leadframes (10) are positioned, with respect to the motor axis (15), along an angular extension of less than 180°, preferably less than 150°, and / or wherein the stator terminals (14) of the first group of leadframes (10) are positioned substantially along the same arc of circumference, preferably coaxial to the motor axis (15), and / or wherein the stator terminals (14) of the second group of leadframes (11 ) are positioned, with respect to the motor axis (15), on an angular extension of less than 180°, preferably less than 150°, and / or wherein the stator terminals (14) of the second group of leadframes (11 ) are positioned along the same arc of circumference, preferably coaxial to the motor axis (15), and / or wherein the stator terminals (14) of the first and second groups of leadframes (10, 11 ) are positioned along the same circumference, preferably coaxial to the motor axis (15), and / or wherein the active leadframes (12) of the first group of leadframes (10) are notsuperimposed on the active leadframes (12) of the second group of leadframes (1 1 ).
10. A connecting structure (1 ) according to claim 6, wherein the first group of leadframes (10) and the second group of leadframes (1 1 ) each comprise, respectively, a passive leadframe (16) configured to be electrically connectable to at least one of the three windings of the first three-phase winding (4) or the second three-phase winding (5), wherein the passive leadframe (16) of the first and second groups of leadframes (10, 1 1 ) comprises three passive terminals (17), wherein each of the three passive terminals (17) is configured to be connectable to a respective winding of either the first three-phase winding (4) or the second three-phase winding (5), wherein the passive terminals (17) of each passive leadframe (16) are positioned, with respect to the motor axis (15), along an angular extension of less than 180°, preferably less than 150°, and / or wherein the passive terminals (17) of the first group of leadframes (10) are positioned along the same arc of circumference, preferably coaxial to the motor axis (15), and / or wherein the passive terminals (17) of the second group of leadframes (1 1 ) are positioned along the same arc of circumference, preferably coaxial to the motor axis (15), and / or wherein the passive terminals (17) of the first and second groups of leadframes (10, 11 ) are positioned along the same circumference, preferably coaxial to the motor axis (15), and / or wherein the passive terminals (17) of the first and second groups of leadframes (10, 11 ) are positioned along the same circumference on which the stator terminals (14) of the first and second groups of leadframes (10, 11 ) are positioned, and / or wherein the passive leadframe (16) of the first group of leadframes (10) is not superimposed on the passive leadframe (16) of the second group of leadframes (1 1 ), and / or wherein each passive leadframe (16) is at least partially superimposed, in the direction parallel to the motor axis (15), on at least one active leadframe (12), and / or wherein each passive leadframe (16) is at least partially superimposed, in the direction parallel to the motor axis (15), on a single active leadframe (12).
11. A connecting structure (1 ) according to any one of the preceding claims, wherein the housing body (8) comprises a plurality of outlet holes (18) positioned at stator terminals (14), and optionally at passive terminals (17), of the leadframes (7), and wherein the stator terminals (14), and optionally the passive terminals (17), of the leadframes (7) extend into the outlet holes (18) and lead outside the housing body (8),and the outlet holes (18) preferably extend in the direction parallel to the motor axis (15).
12. A connecting structure (1 ) according to claim 11 , wherein a portion of the leadframes (7) extending substantially on a plane transverse to the motor axis (15) is embedded within the housing body (8), whereas the stator terminals (14), and optionally the passive terminals (17), bent and extending in directions substantially parallel to the motor axis (15), lead outside the housing body (8).
13. A connecting structure (1 ) according to claim 11 or 12, wherein the housing body (8) comprises a connecting wall (19) extending along a plane transverse to the motor axis (15), and a perimetral wall (20) extending externally around the planar connecting wall (19), wherein the connecting wall (19) forms a first surface (38) and an opposite second surface (39), wherein the planar connecting wall (19) defines a shaft seat (22) extending and passing through the planar connecting wall (19), in the direction coaxial to the motor axis (15), between the first surface (38) and the opposite second surface (39), wherein the shaft seat (22) is adapted to rotatably accommodate a rotor shaft (37) of a rotor (6) of an electric motor (2), and wherein the outlet holes (18) extend through the planar connecting wall (19) in a direction parallel to the motor axis (15), and preferably, wherein the outlet holes (18) lead onto the second surface (39) of the connecting wall (19), and preferably, the outlet holes (18) are positioned along the same circumference coaxial to the motor axis (15).
14. A connecting structure (1 ) according to claim 13, wherein the stator terminals (14), and optionally the passive terminals (17), extend through the connecting wall (19), and lead from the second surface (39) of the connecting wall (19), and / or wherein a portion of the leadframes (7) extending substantially on a plane transverse to the motor axis (15) is embedded within the planar connecting wall (19), whereas the stator terminals (14), and optionally the passive terminals (17), bent and extending in directions substantially parallel to the motor axis (15), lead outside the connecting wall (19).
15. A connecting structure (1 ) according to claim 1 1 , wherein the housing body (8) comprises a plurality of interface holes (23) positioned at the outlet holes (18), wherein each interface hole (23) is configured to allow a single winding terminal (29) of the at least one three-phase winding (4, 5) to be inserted through the interface hole (23), and wherein the interface holes (23) are configured so that the winding terminals (29) of the at least one three-phase winding (4, 5) inserted into the interface holes (23) lead outside the housing body (8), adjacent to the stator terminals (14) and optionally to the passive terminals (17), wherein, preferably, the interface holes (23) extend in the direction parallel to the motor axis (15), and preferably, the interface holes (23) are positioned along the same circumference coaxial to the motor axis (15) having a smaller diameter than the diameter of the circumference along which the outlet holes (18) are positioned.
16. A connecting structure (1 ) according to claim 13, wherein the leadframes (7) are positioned at the perimetral wall (20), extending substantially along an arc of circumference coaxial to the motor axis (15) and coaxial and adjacent to the perimetral wall (20).
17. A connecting structure (1 ) according to any one of the preceding claims, wherein the housing body (8) comprises at least one power interface conduit (24) configured to connect the connecting structure (1 ) to a power source (9), wherein source terminals (13) of the leadframes (7) extend into the at least one power interface conduit (24), and / or wherein the housing body (8) comprises two power interface conduits (24), and wherein the source terminals (13) of a first group of leadframes (10) extend into one of the two power interface conduits (24), and the source terminals (13) of a second group of leadframes (1 1 ) extend into the other of the two power interface conduits (24), and / or wherein the power interface conduits (24) extend from a perimetral wall (20) of the housing body (8) in the opposite direction to a planar connecting wall (19) of the housing body (8), and / or wherein the power interface conduits (24) extend from a perimetral wall (20) of the housing body (8) in a transverse direction to the motor axis (15), and / or wherein the power interface conduits (24) are parallel to each other.
18. A connecting structure (1 ) according to any one of the preceding claims, comprising:- a first position sensor (26) configured to detect the position of a rotor (6) connectable to the housing body (8),- a second position sensor (27) configured to detect the position of a rotor (6) connectable to the housing body (8), wherein the first position sensor (26) is independent of the second position sensor (27) so that both the first position sensor (26) and the second position sensor (27) are configured to detect the position of the rotor (6) independently of each other.
19. A connecting structure (1 ) according to any one of the preceding claims, comprising:- a first position sensor (26) configured to detect the position of a rotor (6) connectable to the housing body (8), and- a second position sensor (27) configured to detect the position of a rotor (6) connectable to the housing body (8), wherein the first and second sensors (26, 27) both comprise a respective sensor leadframe (28) configured to connect the respective first or second sensor (26, 27) to a power source (9), wherein the housing body (8) is made to be over-molded or co-molded onto the sensor leadframes (28), and wherein the first and second sensors (26, 27) are comprised within a single housing so as to form a redundant sensor, or wherein the first and second sensors (26, 27) are physically distinct from each other.
20. An electric motor (2) comprising:- one stator (3), extending about a motor axis (15) and comprising at least one three- phase winding (4, 5);- a rotor (6), substantially coaxial to the motor axis (15);- a connecting structure (1 ) according to one of the preceding claims, wherein the plurality of leadframes (7) is connected to the stator (3) so as to transmit electric power to the at least one three-phase winding (4, 5), and wherein, preferably, winding terminals (29) are welded to the stator terminals (14), and optionally to the passive terminals (17), of the plurality of leadframes (7), respectively.
21. An electric motor (2) according to claim 20, wherein the stator (3) comprises a first three-phase winding (4) and a second three-phase winding (5), wherein the first three- phase winding (4) is distinct from the second three-phase winding (5), wherein the electric motor (2) comprises a connecting structure (1 ) according to claim 6, and wherein the electrical connection between the first three-phase winding (4) and the first group of leadframes (10) is independent of the electrical connection between the second three-phase winding (5) and the second group of leadframes (11 ).
22. An electric motor (2) according to one of claims 20 to 21 , wherein the stator (3) comprises a stator pack (31 ) extending substantially coaxial to the motor axis (15), wherein the first and second three-phase windings (4, 5) are wound on the stator pack (31 ), wherein the stator pack (31 ) comprises a plurality of stator teeth (32) mutually connected in a circumferential direction with respect to the motor axis (15) so as to form the stator pack (31 ), wherein, optionally, the stator pack (31 ) consists of twelve stator teeth (32) assembled together, and the first three-phase winding (4) is wound on six stator teeth (32) directly placed side-by-side and connected to one another, and the second three-phase winding (5) is wound on the remaining six stator teeth (32) directly placed side-by-side and connected to one other.
23. An electric motor (2) according to one of claims 20 to 22, wherein a connecting wall (19) of the connecting structure (1 ) defines a shaft seat (22) extending passing through the connecting wall (19) in a direction coaxial to the motor axis (15), wherein the rotor (6) comprises a rotor shaft (37) extending coaxial to the motor shaft (15) and inserted through the shaft seat (22) of the housing body (8), wherein the electric motor (2) comprises a housing container (40) connected to and facing the connecting structure (1 ) so as to form a stator seat (25), wherein the stator (3) is housed inside the stator seat (25), wherein the stator (3) is substantially annular in shape and forms a rotor seat (21 ) therein, and wherein the rotor (6) is housed inside the rotor seat (21 ), coaxial to the stator (3).
24. A braking system of the Brake-By-Wire type comprises a connecting structure (1 ) according to one of claims 1 to 19, and an electric motor (2) according to one of claims 20 to 23,wherein the braking system comprises an electric power source (9) and a printed circuit board (36), wherein the printed circuit board (36) is electrically connected at least to the electric power source (9) and the electric motor (2), and optionally, the printed circuit board (36) is connected to the housing body (8), and preferably, the printed circuit board (36) electrically connects a first and a second position sensor (26, 27) to the electric power source (9).
Citation Information
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