Method for producing a converter for a heat pump

Abstract

The invention relates to a method (62) for producing a converter (16) for a heat pump (2) on an installation aid (64), said converter having a heat sink (30), a housing (18) with an upper part (22) and a lower part (20), and electronics (46), wherein the heat sink (30), the housing (18), and the electronics (46) are each moved to the installation aid (64) one after the other in a common preferred direction (78) and are assembled and joined together in the preferred direction (78) on the installation aid. The invention additionally relates to a converter (16) for a heat pump (2).

Description

[0001] Description

[0002] Method for manufacturing a converter for a heat pump

[0003] The invention relates to a method for manufacturing a converter for a heat pump and to a converter for a heat pump. The converter comprises a heat sink, a housing, and electronics.

[0004] Heat pumps are increasingly being used to heat buildings. These have a refrigerant circuit with a compressor. The compressor, in turn, is driven by an electric motor. To reduce wear and tear and increase efficiency, the electric motor is usually brushless. Therefore, an inverter is required to operate the electric motor. This usually has electronics that provide the functionality of the inverter. The electronics usually comprise power electronics with a bridge circuit that is adapted to the number of phases of the electric motor. The electronics also usually have an intermediate circuit capacitance that includes one or more capacitors, such as electrolytic capacitors. To protect the electronics and to provide contact protection, the electronics are usually arranged in a housing.This also simplifies the installation of the converter on other components of the heat pump and simplifies storage.

[0005] When the converter is in operation, electrical losses occur primarily in the DC link capacitance and the power electronics, which cause them to heat up. To ensure that the converter can operate smoothly over a relatively long period of time and with reduced load, it must be cooled. For this purpose, the housing usually has several ventilation slots through which heated air can escape. Cooling is also usually provided, which can include a fan, for example. This draws (colder) ambient air into the interior of the housing, so that the electronics inside are exposed to an airflow. In the process, the electronics transfer heat to the airflow, which can escape from the housing through the slots.Alternatively, or in combination with this, a (further) fan is provided, by means of which heated air is sucked from the interior of the housing into the environment. The supply of cold air into the housing is achieved, for example, by means of the other fan or via any slots. To improve the cooling effect, a heat sink is usually provided, which is usually made of metal. The heat sink has a comparatively large surface area, which is provided, for example, by several cooling fins. In this case, the heat sink is arranged inside the housing and is in direct contact with the power electronics. Alternatively, the heat sink is attached to the outside of the housing, so that the housing itself is cooled over a large area. In other words, heat dissipation from the entire housing into the environment is improved.

[0006] For assembly, the individual components of the converter are usually brought to an assembly station and assembled there. The housing, for example, is constructed from individual sheet metal panels that are mounted, as if suspended, on a cuboid metal frame. First, the electronics are arranged within the cuboid frame and, for example, some of the sheet metal panels are mounted. The fan is then positioned appropriately, usually on a side panel, and the housing is then closed by assembling the remaining sheet metal panels. After closing, the heat sink is mounted, for example, on the underside of the housing.

[0007] This approach results in a comparatively compact and robust converter. However, assembly requires the frame to be pivoted several times to install the individual components. This is typically done manually, requiring a person to train the system. This increases both manufacturing costs and production time.

[0008] The invention is based on the object of specifying a particularly suitable method for producing a converter for a heat pump and a particularly suitable converter for a heat pump, wherein a production time and / or production costs are expediently reduced, and wherein an effort and / or complexity are suitably reduced.

[0009] With regard to the method, this object is achieved according to the invention by the features of claim 1 and with regard to the converter by the features of claim 10. Advantageous further developments and refinements are the subject of the respective subclaims.

[0010] The method serves to manufacture a converter for a heat pump. The heat pump is used in particular to heat a building, for example a single-family home, an apartment building or a factory building. In particular, the heat pump has a nominal heat output of between 2.6 kW and 15 kW or of up to 60 kW. The converter is suitable, provided and configured to operate an electric motor of the heat pump, i.e. in particular to supply it with current. In this case, for example, a speed and / or torque of the electric motor is specified and expediently regulated by means of the converter. In turn, a compressor is driven in particular by means of the electric motor. The compressor is suitably used to compress a refrigerant in a refrigerant circuit of the heat pump.Alternatively or in combination with this, a fan of the heat pump is driven by means of the, a further or second electric motor, by means of which fan, in particular, air is blown or sucked over cooling fins or through a cooling network of the heat pump. The cooling fins / cooling network is suitably a component of the refrigerant circuit or at least thermally contacted with a component of the refrigerant circuit. The converter has electronics. The electronics suitably comprise a bridge circuit, in particular a B6 circuit. Preferably, the converter comprises a number of bridge branches. If the converter is designed as a three-phase device, in particular three such bridge branches are present. Each of the bridge branches has, in particular, two semiconductor switches connected electrically in series, preferably field-effect transistors, for example MOSFETs, GTOs, or IGBTs.If the converter is single-phase, only one bridge branch or a single switch is present. For example, the bridge circuit is discretely constructed, or the converter preferably includes a power module that forms the bridge circuit. For example, the power module may also include additional components.

[0011] Suitably, the converter, expediently the electronics, has a connection unit for connecting the electric motor. The connection unit suitably has several individual connections, wherein the number of connections expediently corresponds to, and preferably corresponds to, the number of phases of the electric motor and / or the number of bridge branches.

[0012] In particular, the converter, for example the electronics, has a supply connection. During operation, a direct voltage is applied to the supply connection, for which the supply connection is designed accordingly. However, it is particularly preferred that an alternating voltage is applied there during operation, for example a single-phase alternating voltage or a three-phase alternating voltage. The alternating voltage has, for example, an amplitude of 230 V or 110 V and / or a frequency of 50 Hz or 60 Hz. The supply connection is suitable, in particular provided and configured, for this purpose. The converter, in particular the electronics, expediently comprises a rectifier, which is designed, for example, as a diode rectifier. This is suitably electrically connected to any bridge circuit via an intermediate circuit, so that the converter is designed in the manner of a power converter.The converter further comprises a housing, which serves in particular to protect the electronics. In the assembled state, the electronics are expediently arranged within the housing and preferably completely enclosed on the circumference by the housing. The housing is, for example, made entirely of a plastic, or at least individual components of the housing are made of the plastic. The housing has an upper part and a lower part. For example, the housing also comprises further components. However, it is particularly preferred that the housing be formed solely by the upper part and the lower part. The upper and lower parts are expediently made of a plastic and are preferably plastic injection-molded parts.

[0013] For example, the upper part or the lower part is designed to be substantially flat. However, the lower part is particularly preferably designed in the manner of a bowl, so that the lower part has a continuous rim and, suitably, a base. In other words, the lower part is designed to be substantially pot-shaped. This facilitates the arrangement of components therein. This also increases the mechanical integrity of the lower part. Alternatively, or particularly preferably in combination with this, the upper part is designed in the manner of a bowl. Thus, it also has an rim. The upper part thus expediently also has a base, which is, for example, flat or has one or more steps.

[0014] For example, the upper and lower parts are structurally identical or, if appropriate, different from each other. This makes it possible to adapt the upper and lower parts to the respective arrangement and / or the components they surround in the assembled state, thus reducing the required installation space. Suitably, the upper and lower parts are positioned adjacent to each other at their respective edges in the assembled state, so that the lower part is sealed by the upper part. This prevents the penetration of at least large foreign particles.

[0015] For example, the upper part and / or the lower part are designed to be essentially continuous. Alternatively, one or more openings / perforations are provided, allowing connection of the electronics located therein. Particularly preferably, the upper part and / or the lower part comprises a number of ventilation slots. This allows for air exchange and, consequently, the dissipation of lost heat and / or excess heat from the housing into the environment.

[0016] The converter also has a heat sink. The heat sink is suitably made of a metal, such as copper or, preferably, aluminum. This reduces manufacturing costs and weight. In particular, the heat sink has multiple cooling fins, thus increasing its surface area. The converter is suitably air-cooled, which simplifies design and manufacturing. Mounting the converter to other components of the heat pump is also simplified.

[0017] In the method, the converter is manufactured using an assembly aid. The assembly aid is a workpiece carrier that can suitably be used to manufacture multiple converters, in particular successively over time. In other words, the assembly aid is reusable. In particular, the assembly aid comprises a table or is formed by means of one. The table is expediently aligned essentially horizontally, which facilitates carrying out the method. The assembly aid is expediently static, which increases robustness and reduces manufacturing costs. Alternatively, it is possible, for example, to move the assembly aid and, in particular, to move it to different assembly or assembly positions. However, it is particularly preferred not to pivot the assembly aid.In other words, it is only possible to move the assembly aid transversely, which simplifies construction. The table has rollers, for example, or these are attached to the table. Alternatively, the table is suspended from an assembly line. Since the table cannot be pivoted, construction is simplified and manufacturing costs for the assembly aid are reduced. The requirements for the location where production takes place are also reduced, in particular for the assembly line. The method provides for the heat sink, the housing and the electronics to be moved one after the other in a common preferred direction towards the assembly aid. In other words, the converter comprises at least three components, namely the heat sink, the housing and the electronics. Expediently, the preferred direction is essentially vertical, expediently vertically downwards.Thus, the heat sink, the housing, and the electronics are each first positioned vertically above the mounting aid, or the mounting aid is placed vertically below the heat sink, the housing, and the electronics, one after the other, and then each of them is moved toward the mounting aid. These are appropriately placed on the mounting aid, for example, directly or indirectly over other parts / components.

[0018] For example, the upper and lower parts are moved together to the assembly aid. These are preferably moved there one after the other, for example, directly after each other, or another component, such as the electronics or the heat sink, is moved there in between.

[0019] The heat sink, the housing and the electronics are placed on top of one another on the assembly aid, expediently on the assembly aid. In this case, the first of the components to be moved to the assembly aid is in particular initially only placed on the assembly aid, and the next component, which is moved in the preferred direction to the assembly aid, is suitably placed on the component already located there. The component subsequently added in the preferred direction is expediently arranged on one of the components already located there. For example, the individual components are simply arranged on top of one another or at least partially inserted into one another. In particular, this results in the individual components being stacked on top of one another in the preferred direction.

[0020] Furthermore, the components are joined together on the assembly aid, in particular in the preferred direction. In other words, the joining, in particular fastening, takes place by applying a force in the preferred direction and / or by moving a corresponding fastening means in the preferred direction, for example, in each case solely, primarily, or at least also.

[0021] For example, the individual components are only joined together after all components have been moved to the assembly aid. However, it is particularly preferred that the component being moved to the assembly aid be joined to one of the components already located there before another component is moved to it. This stabilizes the component, which facilitates the joining of the subsequently added component.

[0022] Conveniently, the individual components are fastened to one another only in the preferred direction. At least, the corresponding fastening is established exclusively or predominantly in this way. Conveniently, the assembly aid is not rotated during the method, and / or the preferred direction is perpendicular to the assembly aid, in particular its extension. If the assembly aid has a table, the preferred direction is in particular perpendicular to the table, which is suitably arranged horizontally.

[0023] With this method, manufacturing the converter essentially only requires moving the individual components in the preferred direction. In other words, pivoting the partially assembled converter is not necessary, which means that the assembly aid does not have to be moved or pivoted. This reduces the complexity of the assembly aid and other devices used to manufacture the converter. This reduces manufacturing costs and the risk of errors. Manufacturing time is also reduced. In addition, the complexity of manufacturing the converter is reduced, which reduces errors. Consequently, scrap is reduced and reworking is essentially unnecessary. It is also possible to carry out the process at least partially or fully automatically, which further reduces manufacturing costs.For example, the housing is first moved to the assembly aid and then the heat sink is placed on top of it. However, it is particularly preferred that the heat sink is first inserted into a receptacle in the assembly aid. The receptacle expediently stabilizes and / or aligns the heat sink. The receptacle is in particular formed at least partially by a hole in any table of the assembly aid, which facilitates insertion. The complexity of the assembly aid is also reduced. In particular, after insertion, a positive fit is at least partially formed at the edge between the heat sink and the receptacle. Suitably, the assembly aid, for example the receptacle, and / or the heat sink comprises an anti-twist device so that the heat sink can only be inserted into the receptacle in one position. This further reduces scrap and eliminates the need for reworking the converter.In addition, the procedure can also be carried out by an unskilled person.

[0024] The lower part is then placed onto the heat sink and connected to it. The lower part is placed onto the heat sink in the preferred direction so that the lower part is located above the heat sink in the preferred direction. For example, there is no mechanical contact between the lower part and the mounting aid. In other words, the lower part and the mounting aid remain spaced apart from one another. Alternatively, the lower part rests on the mounting aid and is stabilized in this way. Suitably, the lower part has one or more projections that engage in corresponding openings in the mounting aid, in particular the table. This at least partially aligns the lower part. The projections are expediently shaped so that they can be used to mount the converter to other components of the heat pump after its manufacture.In particular, at least one of the projections is shaped like a snap or locking hook, although this is suitably not secured to the assembly aid. This makes it easier to remove the finished converter from the assembly aid, and the respective projection performs two different functions. In particular, the lower part is shaped like a shell, and the heat sink is located on the outside of the shell, preferably the base. For example, the base of the lower part is continuous, so that the heat sink remains outside the housing. Alternatively, the lower part has a further opening which is closed by the heat sink and / or into which the heat sink is at least partially inserted, so that part of the heat sink extends into the housing. At least the heat sink is guided through the lower part.Alternatively or in combination with this, the heat sink has, for example, one or more projections, such as domes, which run in particular in the preferred direction and which are immersed in corresponding receptacles of the lower part and thus partially protrude through the lower part or in particular into it.

[0025] The lower part is expediently attached to the heat sink, for example by screwing. Suitably, the screws are guided in the preferred direction towards the assembly aid and / or screwed in in the preferred direction so that they run in the preferred direction. For example, the lower part is rigidly attached to the heat sink so that any subsequent relative movement between the two is not possible. However, it is particularly preferred to allow at least slight movement of the heat sink with respect to the lower part even after attachment, while preventing detachment. This enables tolerance compensation in particular. Alternatively or in combination with this, vibrations of the heat sink are not transmitted to the lower part during operation, or are transmitted only to a lesser extent, and vice versa. In other words, the heat sink and the lower part are at least partially decoupled, which reduces operating noise.Alternatively, in a further step of the process, the fastening is changed, whereby the heat sink is rigidly attached to the lower part.

[0026] For example, immediately after inserting the heat sink into the holder, the lower part is placed onto it. However, it is particularly preferred to first insert a fan holder in the preferred direction into a second holder of the assembly aid before placing the lower part onto the heat sink. In other words, the fan holder is moved in the preferred direction and thus inserted into the second holder of the assembly aid. As a result, the heat sink and the fan holder are positioned next to each other perpendicular to the preferred direction. In other words, the two holders are arranged next to each other so that when the heat sink is inserted into the holder and the fan holder is inserted into the second holder, the fan holder and the heat sink are next to each other.

[0027] For example, the fan mount and the heat sink are inserted into their respective mounts simultaneously, or the fan mount is moved in front of the heat sink according to the mounting aid. Particularly preferred is the heat sink being inserted first, followed by the fan mount. The second mount is preferably provided with an anti-twist device, allowing the fan mount to be inserted into the second mount in only one position.

[0028] After the fan mount and heatsink have been positioned, the bottom part in particular is placed on the fan mount and heatsink.

[0029] For optimal robustness, the fan mount and heat sink are conveniently connected to the base. Alternatively, the fan mount can simply be attached to the heat sink.

[0030] The fan mount serves to hold a fan and is suitable, in particular provided and configured, for this purpose. During operation, it is possible to use the fan to generate an air flow along the heat sink, which air flow is suitably parallel to any cooling fins of the heat sink. For example, the fan draws air through the heat sink or, more preferably, blows it. In particular, the fan mount is designed in such a way that, for example, the fan mount merely forms a holder for the fan, which has a fan impeller driven by an electric motor. However, the fan mount particularly preferably also comprises a diffuser or the like, by means of which the air flow created by the fan is suitably guided, in particular towards or away from the heat sink.The diffuser is designed, for example, in the manner of a funnel and / or is expediently in direct mechanical contact with the heat sink, so that a comparatively efficient airflow can be generated through it. Preferably, the fan mount is a single piece and / or a plastic injection-molded part.

[0031] The fan mount expediently has an opening through which a fan can be inserted into the fan mount. For example, the opening is accessible from a side of the fan mount facing away from the lower part. Alternatively, the opening is oriented towards the lower part, i.e. expediently opposite to the preferred direction. When the lower part is placed on the fan mount, for example, the opening remains free. However, the opening is particularly preferably accessible from the lower part, so that the opening in the fan mount extends into the lower part. For this purpose, the lower part has a corresponding recess, which is in particular aligned with the opening. This also allows access to the fan from the lower part, at least after the lower part has been installed.Since the opening extends into the lower part, it is protected by the housing, which prevents damage to the fan located therein after the converter has been manufactured.

[0032] For example, the fan is already located in the fan mount when the fan mount is inserted into the second mount, i.e., before the base is installed. However, it is particularly preferred to insert the fan into the fan mount through the opening in the preferred direction only after the base has been positioned. This eliminates the need for pre-assembly of the unit consisting of the fan mount and the fan. This reduces the number of work steps required and / or the space required to manufacture the converter.

[0033] For example, the fan is simply inserted loosely into the fan mount. However, it is particularly preferred that the fan is secured there to prevent it from accidentally becoming detached from the fan mount. Relative movement between the fan mounts is also avoided, thus reducing noise during operation. The fan is preferably secured to the fan mount. For this purpose, the fan mount expediently has one or more locking elements, preferably locking tongues, which grip around the edges of the fan when installed. Due to this fastening, no additional tools and / or fastening devices are required to install the fan. Also, for installation, the fan is only moved in the preferred direction and a force is exerted on it in the preferred direction. This also enables automated production here.

[0034] A device is expediently provided to ensure that the fan is mounted in the correct position. For example, the device is a component of the mounting aid. Suitably, the device comprises a camera by means of which a visual inspection of the fan partially inserted into the fan mount is carried out. In particular, the fan has a visual marking, such as a sticker, by means of which a suction side or a blowing side is identified. Suitably, the device has an adjustable stop which is arranged in the fan mount when the fan is inserted into the fan mount. The stop limits insertion into the fan mount. For example, the stop is designed in the manner of a dome which projects through a corresponding auxiliary opening into the fan mount.After checking / confirming that the fan has been inserted into the fan mount in the correct orientation, the stop, in particular, is retracted, preferably out of the entire fan mount. This allows further insertion of the fan into the mount, and the fan can be secured in the mount, preferably by rusting.

[0035] The electronics system suitably comprises a first circuit board. A plurality of electrical and / or electronic components are expediently attached to the first circuit board. These components are preferably at least partially electrically contacted with one another by means of the first circuit board, preferably conductor tracks of the first circuit board, so that a circuit is formed. For example, the electronics system is formed solely by the first circuit board and the electrical / electronic components attached thereto. This reduces complexity and facilitates production. However, it is particularly preferred that the electronics system also comprise further components, thereby increasing functionality.

[0036] The first circuit board is inserted into the lower part. The first circuit board is moved at least in the preferred direction, so that the circuit board is inserted into the lower part, in particular, is immersed in it. After insertion, the first circuit board is expediently enclosed on its periphery by the shell-like lower part.

[0037] For example, the first circuit board is arranged parallel to the preferred direction or suitably perpendicular to the preferred direction, so that a comparatively flat converter is created. Preferably, before insertion, the first circuit board is at least partially inclined with respect to the preferred direction, and during insertion it is at least partially pivoted, expediently about an axis perpendicular to the preferred direction. The pivoting takes place in particular by means of a guide, by means of which the first circuit board is moved and / or aligned. In this way, high manufacturing tolerances can be selected when moving the first circuit board to the assembly aid, wherein a comparatively precise alignment of the first circuit board takes place so that it is located in a comparatively precisely defined position. Expediently, the lower part comprises the guide, so that the number of components required is reduced.

[0038] Any power module is expediently attached to the first circuit board. The first circuit board is suitably inserted into the lower part, which is expediently designed in a shell-like manner, in such a way that the power module rests against the heat sink. In this case, the power module is located in particular in front of the first circuit board in the preferred direction and thus on the side of the first circuit board facing the bottom of the lower part. In particular, the power module has a heat sink, for example a rudimentary one, which is suitably made of a metal. The heat sink preferably rests against the heat sink. For example, the power module rests against the heat sink directly or via a heat-conducting agent, such as a thermal paste or a thermal pad.Thus, during operation, excess heat and / or waste heat is dissipated from the power module to the heat sink, resulting in comparatively efficient cooling of the power module. The heat sink is located at least partially outside the lower part / housing, and the lower part expediently has a further opening or aperture through which thermal contact is made between the power module and the heat sink. Suitably, the heat sink lies at least partially in the further opening, or the further opening is closed by the heat sink. Since the power module rests against the heat sink by inserting the first circuit board, readjustment or additional work steps are not necessary, which further reduces manufacturing time and costs.In summary, the heat sink is preferably thermally connected to the power module, allowing heat to be dissipated, particularly by thermal conduction. Direct heat conduction is preferably implemented between the heat sink and the power module.

[0039] Particularly preferably, all electrical and / or electronic components of the first circuit board are arranged on a common side. In other words, the circuit board is populated only on one side, which reduces manufacturing costs. Alternatively, it is populated on both sides, allowing a comparatively compact design. Particularly preferably, all electrical / electronic components, with the exception of the power module, are arranged on one side. Thus, on the one hand, a circuit board populated essentially on one side can be used. On the other hand, the heat emitted by the power module does not affect the other electrical and / or electronic components.

[0040] Preferably, the fan receptacle is provided, and the fan is inserted into it before the first circuit board is inserted. For example, the fan is powered independently of the first circuit board. More preferably, however, it is powered via the first circuit board. This reduces the number of individual electronic components. For example, the fan is also electrically contacted to the first circuit board by inserting the first circuit board. For this purpose, the first circuit board expediently has a suitable contacting option on the side facing the fan. More preferably, however, after the fan has been inserted, a connecting cable for the fan is connected to the first circuit board. This reduces the demands on the fan, and, for example, an existing fan can be used.Due to the flexible design of the connecting cable, it is expediently contacted from the side of the first circuit board opposite the heat sink. This allows the use of a first circuit board that is essentially populated on one side. For example, the opening is not covered by the first circuit board, which facilitates the installation of the connecting cable. However, it is particularly preferred that the opening is covered by the first circuit board, allowing the first circuit board to have a comparatively large surface area. This also prevents foreign particles from penetrating the opening.

[0041] After inserting the fan, the connecting cable is expediently guided through the opening, and its end is laterally moved out of the base. This is preferably followed by the insertion of the first circuit board, and the end of the connecting cable is then contacted with the first circuit board, for which purpose, in particular, corresponding connectors are inserted into one another. Consequently, the connecting cable runs around one edge of the first circuit board.

[0042] Preferably, a capacitor, such as an electrolytic capacitor, is attached to the first circuit board and is associated with any intermediate circuit. Preferably, several such capacitors, preferably four electrolytic capacitors, are attached to the first circuit board. These are expediently located on the side of the first circuit board opposite the power module, so that the electronic components that generate a comparatively large amount of heat during operation of the converter, namely the power module and the capacitors, are separated from one another by the first circuit board. In particular, the capacitors are offset perpendicular to the preferred direction with respect to the power module. In this way, thermal interaction between them is reduced by means of the first circuit board.

[0043] For example, the first circuit board is simply loosely inserted into the lower part. However, the first circuit board is particularly preferably connected to the lower part. For example, the first circuit board is rigidly attached to the lower part or, particularly preferably, it is at least partially floating. In particular, the first circuit board is fastened to the lower part for connection. In particular, a force is exerted on the first circuit board in the preferred direction so that the corrosion is created. In particular, one or more locking hooks are formed on the lower part, or the lower part has at least corresponding locking hooks which, once connected, engage around the edge of the first circuit board.

[0044] Preferably, the guide is provided by means of which the first circuit board is at least partially pivoted. Suitably, when the first circuit board is inserted into the lower part, one edge of the first circuit board is moved along the guide, and the opposite edge of the first circuit board is locked to the lower part, whereby this expediently only takes place after the first circuit board has been completely pivoted. The guide in particular has one or more sliding ribs along which the edge is moved. In particular, the sliding rib runs, at least in sections, perpendicular to the preferred direction. When the first circuit board is inserted, the edge abuts the sliding ribs and is moved by means of these, in particular perpendicular to the preferred direction, so that the first circuit board is pivoted.Suitably, the sliding rib has an edge by means of which the edge is moved at least partially counter to the preferred direction, so that a comparatively rapid pivoting of the first circuit board takes place.

[0045] In particular, by means of the sliding rib, the edge is moved into an undercut in the lower part, which undercut is encompassed, for example, by the guide, before the pivoting of the first circuit board is completed. In other words, during insertion in the preferred direction of rotation, the first circuit board is inserted into the undercut of the guide due to the pivoting. The undercut is expediently substantially perpendicular to the preferred direction. Suitably, the edge of the first circuit board opposite the undercut is secured to the lower part, i.e. in particular is gripped by means of the locking hook, so that detachment of the first circuit board from the lower part is prevented. In this case, in particular, a floating bearing is provided at least partially, so that the first circuit board can be moved at least partially in its plane of extension.The guide expediently comprises one or more guide ribs that extend at least partially in the preferred direction. For example, these extend obliquely to the preferred direction or are rounded at the ends. The guide ribs guide the circuit board, particularly laterally, expediently toward the sliding rib. Suitably, the first circuit board slides along the guide ribs during insertion. This thus threads the first circuit board into the desired position. In summary, the guide ribs act like a funnel. This enables automated implementation of the method, allowing comparatively large manufacturing tolerances during insertion of the first circuit board.

[0046] The connection of the first circuit board to the lower part, in particular the guide, which expediently comprises the guide rib(s), which are suitably arranged in a funnel shape, and / or the sliding rib, by means of which pivoting of the first circuit board is caused, whereby one edge of the first circuit board is preferably moved into the undercut, and whereby the other edge is expediently rusted, is in particular independent of the method, in particular the assembly only in the preferred direction of rotation. This is also independent of the use in a converter and is rather considered an independent invention.

[0047] For example, the power module is connected to the heat sink simply by applying it or any thermal paste. However, the power module is particularly preferably screwed to the heat sink. Suitably, the first circuit board has a mounting opening through which a mounting screw is guided in the preferred direction and inserted into a screw receptacle of the power module. In particular, the heat sink, if present, has the screw receptacle. Suitably, after the mounting screw has been fastened, a head of the mounting screw rests mechanically directly on the power module. Suitably, the size of the mounting opening is larger than the head of the mounting screw, and in the assembled state, the mounting screw is suitably spaced from the mounting opening. In other words, the mounting opening serves merely to guide the mounting screw, so that the power module can be screwed to the heat sink by means of this.Due to the mounting opening, the necessary connecting elements, namely the mounting screw, can also be inserted here, so that assembly can also be carried out in the preferred direction, for example from above.

[0048] Suitably, the first circuit board comprises several such mounting openings, preferably two, and a mounting screw is passed through each of these openings, by means of which the power module is screwed to the heat sink. In particular, the power module has as many screw openings as there are mounting screws used, and each screw receptacle is expediently assigned one of the mounting screws. This increases robustness.

[0049] Due to such a configuration, the heat sink, in particular, is rigidly connected to the power module and thus to the first printed circuit board. The first printed circuit board is expediently mounted in a floating manner in the lower part, allowing slight movement of the first printed circuit board relative to the lower part. The heat sink is also expediently mounted only in a floating manner on the lower part. The finished converter thus suitably comprises the heat sink, which is arranged at least partially or preferably entirely outside the housing, and / or by means of which the housing is at least partially closed. The converter also comprises the first printed circuit board, which is arranged inside the housing and which is rigidly attached to the heat sink, namely by means of the power module.The first circuit board and the converter are at least slightly movable relative to the lower part, preferably the complete housing, namely expediently mounted in a floating manner. Consequently, vibrations are transmitted only to a minimal extent between the housing and the heat sink / first circuit board. If the heat sink vibrates during operation due to cooling, this is transmitted to the first circuit board. From there, the vibrations are not transmitted, or only to a minimal extent, to the housing, which, in the assembled state, is attached in particular to other components of the heat pump, for example, to a support. This reduces acoustic and mechanical stress.The floating mounting of the heat sink and / or the first circuit board, with the heat sink being rigidly attached to the first circuit board, is independent of the method, in particular the assembly of the individual components of the converter only in the preferred direction. Rather, this is considered an independent invention.

[0050] In summary, the first circuit board is preferably firmly screwed to the heat sink in the assembled state. On the other hand, the first circuit board is expediently secured to the lower part by means of clamp connections. Thus, there is no fixed connection between the housing and the first circuit board, which provides vibration isolation.

[0051] The heat sink preferably comprises one or more bolts which protrude through corresponding openings in the lower part, or these are at least fastened to the heat sink. In this case, a clearance fit is suitably formed between the bolts and the respective opening, such that at least slight movement is possible. In particular, the first circuit board rests against the bolts at its ends and is thus at least partially stabilized. Alternatively or in combination with this, the first circuit board is screwed to the bolts, which increases stability. Preferably, the first circuit board is electrically contacted with the bolts, preferably by means of the screws. In this case, the bolt or the screw rests in particular on a connection pad of the first circuit board, by means of which the heat sink is electrically connected to ground or another predetermined electrical potential.This increases safety or at least electromagnetic compatibility (EMC).

[0052] For example, the assembly aid has a groove or the like into which the lower part is inserted so that alignment occurs. However, the lower part particularly preferably has a first centering opening which is placed on a first centering element of the assembly aid. By means of this, the lower part is aligned with the assembly aid, so that subsequent assembly is facilitated. In this way, larger manufacturing tolerances can also be selected when feeding the lower part, i.e. when moving it in the preferred direction towards the assembly aid. If the first centering opening is placed on the first centering element, a clearance fit is created between them. This reduces the amount of force required to place the lower part on top and also to remove it subsequently, while still ensuring comparatively precise alignment of the lower part.

[0053] The first centering element is expediently designed to be substantially conical, in particular truncated cone-shaped. Due to the conical shape, the insertion of the first centering element into the first centering opening is possible even with comparatively large tolerances, wherein comparatively precise alignment is achieved by further positioning. For example, the first centering element is in one piece with other components of the assembly aid, in particular any table. However, it is particularly preferred that the first centering element is adjustable or at least adjustable compared to the other components of the assembly aid, such as the table. In this way, it is possible to adapt the assembly aid to different batches or embodiments of the lower part, so that a corresponding alignment is achieved in each case. Wear can also be compensated for in this way. The first centering element is expediently made of steel.This makes it possible to produce a comparatively large number of converters using the same mounting aid. Alternatively, or in a particularly preferred combination, the lower part has one or more projections that engage corresponding receptacles in the mounting aid when the lower part is moved toward the mounting aid. This simplifies alignment of the lower part. The projections are suitably used for fastening the converter to other components of the heat pump when mounting the converter.

[0054] The first circuit board preferably has a second centering opening, which is placed on a second centering element of the lower part. The second centering element is in particular fastened to other components of the lower part, in particular molded onto it, preferably to a possible base if the lower part is bowl-shaped. In particular, the second centering element points away from the assembly aid and / or is oriented counter to the preferred direction. A second centering opening of the first circuit board is placed on the second centering element. Expediently, the second centering opening is provided by a hole, in particular a round hole, and the second centering element is, for example, conical or has two triangular or trapezoidal plates oriented counter to the preferred direction, which are rotated by 90° relative to one another around an axis parallel to the preferred direction, thus creating a type of cone.In other words, the cross-section of the second centering element is at least partially cross-shaped perpendicular to the preferred direction. This also enables a comparatively precise alignment of the circuit board with respect to the lower part, while the design of the second centering element requires only a comparatively small amount of material. The lower part is expediently made in one piece from a plastic. This design of the second centering element facilitates demolding, and even upon cooling, no warping occurs. As a result, it is possible to manufacture the second centering element with comparatively tight manufacturing tolerances.

[0055] For example, the two centering elements can be positioned arbitrarily relative to one another. However, it is particularly preferred that the first centering element and the second centering element are arranged on a common straight line that is parallel to the preferred direction. For example, the two centering elements are congruent with one another or are arranged such that their projection on one another parallel to the preferred direction only partially overlap. Due to such an arrangement, the first circuit board is also aligned relatively precisely with respect to the assembly aid, so that in further work steps of the method, the position of the first circuit board is determined and known relatively precisely. This means, for example, that electrical contacting of individual areas of the first circuit board can be carried out reliably and automatically.It is possible to select comparatively large manufacturing tolerances for other components of the lower part, particularly with regard to the attachment of the first circuit board to the lower part, for example, any floating mounting. In summary, the first circuit board is aligned for assembly thanks to the two centering elements. In particular, this aspect, expediently in connection with the guidance and / or locking of the first circuit board to the lower part, is independent of other method steps and is considered an independent invention.

[0056] For example, the housing is created with the lower part and the upper part, or these are assembled together separately from the assembly aid. Thus, when the lower part is moved towards the assembly aid, the upper part is also moved towards the assembly aid. However, it is advisable to first arrange the lower part on the assembly aid and only subsequently arrange for the upper part to be moved towards the assembly aid in the preferred direction. Thus, pre-assembly is not necessary here either. For example, the upper part is placed directly onto the lower part, particularly after the first circuit board has been mounted. For example, the upper part is positioned directly on the lower part and, for example, fastened directly to it, so that the housing is in particular closed. However, it is particularly preferred that the upper part be positioned next to the lower part perpendicular to the preferred direction.This means that the housing remains open so that additional components can be mounted.

[0057] Particularly preferably, the upper part is connected to the lower part so that detachment of the upper part from the lower part is prevented. This facilitates subsequent steps of the method. Preferably, the upper part is bowl-shaped, and the lower part is expediently also bowl-shaped so that individual components of the converter, such as the first circuit board, can be arranged therein. For example, a hinge is used to connect the upper part to the lower part, which is, for example, additionally brought together. Particularly preferably, however, the lower part and the upper part each have an edge-side hinge part which are fastened to one another so that a hinge is formed. Expediently, the lower part and the upper part each comprise two such hinge parts, so that two hinges are formed. In this way, stability is increased.

[0058] To fasten the two hinge parts to one another, a mounting means such as a bolt is used, for example. However, one of the hinge parts is particularly preferably formed by means of a laterally open sleeve or the like, into which the other hinge part is inserted / hooked, which is expediently designed in the manner of a bolt. In summary, the two hinge parts are preferably hooked into one another. In particular, for fastening, the two hinge parts are pressed against one another in the preferred direction. Thus, to create the hinge, only the application of force in the preferred direction is required, which is why the requirements for the tools used for this purpose are reduced. This can also be done automatically. Suitably, the hinge parts are at least partially locked, so that in order to detach the two hinge parts from one another, at least partial deformation of the latter is necessary.This prevents unwanted detachment and therefore increases robustness.

[0059] To close the housing, the upper part is pivoted onto the lower part using the hinge so that they rest against each other at the edges, expediently all the way around. Suitably, the upper part is fastened to the lower part again so that it cannot pivot back. Snap hooks are expediently used for fastening, or the upper and lower parts are rust-bonded together. This also enables automated production here, and no additional tools are required. For example, the upper part is designed to be flat. However, it is particularly preferred to have one or more elevations / protrusions that are adapted in particular to the components of the converter arranged in the housing.Preferably, a pot- or box-shaped elevation / protrusion is provided, within which any capacitors associated with the intermediate circuit are arranged and which are attached, for example, to the first circuit board. Preferably, the upper part has several slots to allow air to pass through them, thus providing cooling.

[0060] For example, the upper part serves merely to close the housing. However, it is particularly preferred that a second circuit board is inserted into the upper part in the preferred direction and connected to it. The second circuit board is a component of the electronics. For example, the electronics are formed solely by the second circuit board. However, it is particularly preferred that the first circuit board is also present, and the electronics thus comprises the first and second circuit boards. These are moved parallel to one another, in particular offset in time, to the assembly aid and placed and joined onto the respective assigned component.

[0061] For example, the second circuit board is screwed to the upper part, for which screws are used in particular, which are screwed in in the preferred direction. However, the upper part particularly preferably has a guide, which is expediently designed according to the guide described above. By means of this guide, the second circuit board is bolted to the upper part, so that no additional fastening means are required. Expediently, the undercut is provided, into which an edge of the second circuit board is inserted. Preferably, one or more guide ribs and / or one or more sliding ribs are provided, by means of which the second circuit board is pivoted. Suitably, the second circuit board is only populated on one side, preferably on the side facing away from the assembly aid.Thus, after fastening, the electrical and / or electronic components fastened to the second circuit board are accessible, in particular plugs. Preferably, the first circuit board is present, and after the second circuit board has been connected to the upper part, the two are connected, preferably by means of a cable. A ribbon cable is used in particular for this purpose. Suitably, the ribbon cable is plugged into corresponding plugs that are fastened to the circuit boards. The plugs are offset in particular in the direction of the hinge, such that their distance from the hinge is less than half the length of the respective circuit board. Preferably, the ribbon cable is guided over the edge of the upper part and the lower part that has the hinge. In this way, the material required for the ribbon cable is reduced.On the other hand, this way, other components of the converter are not obstructed by the ribbon cable when the upper part is folded onto the lower part. Once the second circuit board has been connected and, preferably, electrically contacted with the first circuit board, the upper part is folded onto the lower part, thus closing the housing.

[0062] In particular, the upper part has an opening through which electrical contact can be made with one or more connection points of the electronics, expediently the first circuit boards. This allows electrical contact to be made with the electronics from outside the housing, in particular after assembly has been completed, so that a functional check can be carried out. The first circuit board is preferably aligned using the centering elements. This also enables automated testing. Preferably, several connections of the electronics are provided, such as the supply connection and / or the connection unit. Alternatively or in combination with this, further connections are provided, via which control can expediently be carried out. These are suitably arranged in corresponding openings in the housing and are expediently also electrically contacted during the functional check.

[0063] The converter is suitable, in particular intended and configured, for forming a component of a heat pump. In this case, the converter expediently serves to supply current to an electric motor, which in particular drives a compressor of a refrigerant circuit. The converter comprises a heat sink, a housing, and electronics. The electronics are expediently arranged within the housing so that they are protected by the housing.

[0064] The heat sink is preferably arranged at least partially on the outside of the housing and suitably dips into an opening in the housing. In particular, the electronics are in thermal contact with the heat sink, expediently directly, so that heat dissipation is improved. In particular, the housing has an upper part and a lower part which are joined to one another, but are expediently not integral with one another. The heat sink, the housing and the electronics, preferably all parts or components of the converter, are only fastened to one another in one preferred direction. In other words, they are only fastened to one another in one preferred direction. However, movement of the components perpendicular to the preferred direction is prevented / inhibited or at least limited due to other circumstances.This eliminates the need to tilt the partially assembled converter during production, and allows them to simply be stacked on top of each other in the preferred direction. This enables, or at least facilitates, automated production of the converter.

[0065] Alternatively, or in combination with fastening only in the preferred direction, the heat sink is, for example, rigidly fastened to the electronics, and this assembly is expediently mounted in a floating manner on the housing. The heat sink suitably protrudes from the housing and is thus arranged at least partially or completely outside the housing, whereas the electronics are located inside the housing, for example partially or preferably completely. Consequently, during operation, relatively large vibrations of the housing (for example due to a connection of the housing to a compressor, fan, etc. of the possible heat pump) are not transmitted to the heat sink and the electronics, or are only transmitted to a small extent. Consequently, vibration loads on the electronics are reduced. Also, vibrations of the heat sink, for example, are not transmitted to the housing, or are only transmitted to a small extent, and vice versa.As a result, noise pollution is reduced.

[0066] Alternatively or in combination with the mounting or fastening only in the preferred direction, the converter, preferably the housing, has a guide by means of which a printed circuit board of the electronics, preferably the possible first or the possible second printed circuit board, is guided during assembly so that it is located in a predetermined position. The guide in particular has an undercut, wherein a guide rib and / or a sliding rib are expediently arranged such that an edge of the printed circuit board is guided into the undercut when it is moved in the preferred direction. The sliding rib is in particular located below the respective printed circuit board in the preferred direction, and by means of this the edge of the printed circuit board is at least partially lifted, preferably counter to the preferred direction, and inserted into the undercut.However, the circuit board initially comes into contact with the guide rib, which is suitably arranged above the undercut in the preferred direction in particular, during assembly when it is moved in the preferred direction. This ensures that the (respective) circuit board is centered perpendicular to the preferred direction. The guide also suitably has a snap-in connection by means of which the edge of the circuit board opposite the undercut is secured. Therefore, no additional fastening means are required to attach the (respective) circuit board to the housing part, such as the lower part and / or the upper part, and the connection is achieved by moving the circuit board relative to the housing in the preferred direction, with the circuit board being pivoted appropriately. The guide expediently comprises a centering element by means of which the circuit board is also aligned. The circuit board has a centering opening for this purpose.Ideally, the centering element is assigned to the edge of the circuit board that will be rusted. This ensures that the rusting actually occurs, although increased tolerances can be selected as the circuit board is brought closer. If a component is referred to as the first, second, etc. component, this only refers to a specific component. In particular, this does not mean that a corresponding number of such components are present.

[0067] The invention further relates to a heat pump with such a converter.

[0068] The further developments and advantages explained in connection with the process can also be transferred analogously to the converter / the housing / the guide / the bearing / the heat pump as well as to each other and vice versa.

[0069] An embodiment of the invention is explained in more detail below with reference to a drawing. In the drawings:

[0070] Fig. 1 schematically shows a heat pump having an inverter,

[0071] Fig. 2, 3 perspective and sectional view of the converter, which has a housing with an upper part and a lower part

[0072] Fig. 4 shows a method for manufacturing the converter,

[0073] Fig. 5, 6 from different perspectives an assembly aid for the production of the converter,

[0074] Fig. 7, 8 from different perspectives the converter in a first manufacturing stage,

[0075] Fig. 9, 10 perspective section of a guide of the lower part,

[0076] Fig. 11 shows a plan view of the converter in a second manufacturing stage, with a first printed circuit board inserted into the lower part,

[0077] Fig. 12 shows in perspective the upper part into which a second circuit board is inserted,

[0078] Fig. 13, 14 perspective section of a guide of the upper part,

[0079] Fig. 15 shows in perspective the upper part and the lower part resting on the assembly aid, and

[0080] Fig. 16 shows a perspective view of the finished converter resting on the assembly aid.

[0081] Corresponding parts are provided with the same reference numerals in all figures. Figure 1 shows a simplified schematic of a heat pump 2 which is used to heat a building. The heat pump 2 has a refrigerant circuit 4 which includes a compressor 6. During operation, the compressor 6 compresses a gaseous refrigerant. As a result, the refrigerant is heated. This is led to a first heat exchanger 8 which, in the assembled state, is thermally coupled to other components of a heater. Thermal energy is extracted from the refrigerant circuit of the heat pump 2 via the first heat exchanger 8. As a result, the refrigerant cools down and changes to the liquid state. The refrigerant is then led to an expansion valve 10, which reduces the pressure and evaporates part of the liquid refrigerant.As a result, the cooled refrigerant also cools down comparatively significantly. The cooled refrigerant is fed to a second heat exchanger 12, which, depending on the design of the heat pump 2, is pressurized with ambient air or a liquid medium. There, energy is absorbed by the refrigerant, which leads to its evaporation, which is then fed back to the compressor 6, thus closing the refrigerant circuit 4.

[0082] The compressor ß is driven by an electric motor 14, which is designed as a brushless direct current (BLDC) motor. In a variant not shown in detail, the electric motor 14 is designed differently, for example, as a brushed commutator motor. A converter 16 is used to supply current to the electric motor 14. This converter is electrically connected to a supply network, by means of which, in particular, an alternating electrical current is conducted.

[0083] Figure 2 shows a perspective view of the converter 16, and Figure 3 shows a sectional view of the converter 16. The converter 16 has a housing 18 comprising a lower part 20 and an upper part 22, which are injection-molded from a plastic material. The lower part 20 and the upper part 22 are each bowl-shaped, with their openings facing toward one another and their edges abutting one another. The upper part 22 also has a box-shaped projection 24 directed away from the lower part 20, so that the base of the upper part 22, i.e., the wall facing away from the lower part 20, is not flat but stepped.

[0084] The upper part 22 is pivotally mounted on the lower part 20 by means of two hinges 26. Uncontrolled pivoting is prevented by means of two snap hooks 28, by means of which the upper part 22 and the lower part 20 are secured, and which are located in an area of ​​the housing 18 spaced apart from the hinges 26.

[0085] On the side facing away from the upper part 22, a heat sink 30 is attached to the lower part 20. The heat sink 30 is made of aluminum and has a plurality of cooling fins 32 arranged parallel to one another. The cooling fins 32 point away from the lower part 20 and are oriented perpendicular to it. Also attached to the lower part 20 is a fan holder 34, which has a diffuser 36 and a holder 38 and is made of plastic. The diffuser 36 fluidically connects the heat sink 30 and the holder 38. A fan 40 is held in the holder 38 and is arranged perpendicular to the cooling fins 32 and perpendicular to the bottom of the lower part 20. The holder 38 has an opening 42 that extends into the lower part 20 so that it is accessible from inside the housing 18.

[0086] A first circuit board 44 of an electronics unit 46 is arranged within the housing 18. The first circuit board 40 is arranged parallel to the bottom of the lower part 20, and a power module 48 is attached to the first circuit board on the side facing the bottom. The power module 48 comprises a plurality of power semiconductor switches (not shown in detail) by means of which a bridge circuit is formed. Furthermore, the power module 48 comprises a heat sink 50 made of aluminum, with the power semiconductor switches located between the heat sink 50 and the first circuit board 44.

[0087] In the area of ​​the power module 48, the lower part 20 has a further opening 52, which is completely covered and thus closed by the heat sink 30. The heat sink 50 is located in the further opening 52 and is mechanically in contact with the heat sink 30, either directly or via a thermally conductive paste (not shown in detail), so that they are thermally connected to one another.

[0088] On one side of the first circuit board 44, only the power module 48 is located, and otherwise, the first circuit board 44 is populated on the opposite side. There, four (electrical) capacitors 54 are also located on the first circuit board 44, which are not congruent with the power module 48, but are arranged laterally offset relative to it. The capacitors 54 are enclosed within the projection 24. A second circuit board 56 of the electronics 46 is connected to the inside of the projection 24, namely at its base, and is arranged parallel to the first circuit board 44.

[0089] The first circuit board 44 and the second circuit board 56 are connected for signaling and electrical purposes by means of a ribbon cable 58. The ribbon cable 58 is routed along the inner side of the upper part 22 facing the hinges 26. In addition, several slots 60 are provided in the upper part 22 through which air can enter and exit the housing 18.

[0090] When the converter 16 is operating, the electrical voltage required to operate the electric motor 14 is provided by the power module 48. As a result, the power semiconductor switches heat up, dissipating the waste heat to the heat sink 50. From there, the heat is transferred to the heat sink 30, heating it. When the fan 40 is operating, an airflow is created through the diffuser 36, which is directed along the cooling fins 32, dissipating the excess heat into the ambient air and cooling the heat sink 30.

[0091] The power module 48 is supplied by means of an intermediate circuit which has the capacitors 54. By means of these, the electrical voltage of the intermediate circuit is stabilized. The heat loss generated during this process and due to the other operation of the electronics 46 is dissipated to the environment via the slots 60. Figure 4 shows a method 62 for manufacturing the converter 16. The method 62 is carried out at least partially or completely automatically, for which purpose an assembly aid 64 is used, shown in a perspective top view in Figure 5 and in perspective from below in Figure 6. The assembly aid 64, which in particular forms a workpiece carrier, has a substantially flat table 66, into which a receptacle 68 is introduced, which merges into a second receptacle 70. Two first centering elements 72 are adjustably fastened on the upper side of the table 66.The first centering elements 72 are identical in construction and are provided by a truncated cone made of stainless steel. The two first centering elements 72 are assigned to opposite corners of the assembly consisting of the two mounts 68, 70, and the projection above the top of the table 66 can be adjusted by means of adjustment.

[0092] Four mounting rails 74 are attached to the underside of the table 66, with each receptacle 68, 70 being assigned one of the mounting rails 74 on opposite sides. The mounting rails 74, which are assigned to the same receptacle 68, 70, extend to different depths into the respective receptacle 68, 70.

[0093] In the method 62, in a first step 76, the heat sink 30 is inserted into the receptacle 68, and the fan receptacle 34 is inserted into the second receptacle 70. For insertion, the heat sink 30 and the fan receptacle are moved in a preferred direction 78 toward the assembly aid 64 and inserted into the corresponding receptacles 68, 70. The preferred direction 78 runs perpendicular to the extension of the table 66, and the first centering elements 72, namely the axis of the respective truncated cone, is parallel to the preferred direction 78.

[0094] The shape of the receptacle 68 is adapted to the heat sink 30, and the shape of the second receptacle 70 is adapted to the fan receptacle 34, in particular the diffuser 46. Due to the mounting rails 74 and their projection into the respective receptacles 68, 70, the insertion of the heat sink 30 and the fan receptacle 34 is only possible in a single orientation. As a result, the diffuser 36 subsequently rests against the edge of the heat sink 30. The fan receptacle is arranged perpendicular to the preferred direction 78 next to the heat sink 30. The receptacle 68 thus forms, in particular, a "heat sink receptacle," and the second receptacle 70 forms, in particular, a "diffuser receptacle."

[0095] The lower part 20 is then moved in the preferred direction 78 toward the assembly aid 64 and placed onto it at the edges. Due to the configuration of the receptacles 68, 70, the lower part 20 is also placed onto the heat sink 30 and the fan receptacle 34. The first centering elements 72 each engage a correspondingly shaped first centering opening 80 of the lower part 20, which are designed like blind holes, with the shape of the blind hole being frustoconical. This creates a clearance fit between the first centering elements 72 and the first centering openings 80, and consequently aligns the lower part 20. This ensures that the opening 42 of the fan receptacle 34 extends into the lower part 20, and that the further opening 52 of the lower part 20 is closed by the heat sink 30, as shown in perspective in Figure 7 from the side facing away from the table 66.The mounting rails 74 and the first centering elements 72 are preferably "Poka-Yoke" centering elements for the diffuser 46 and heat sink 30. These are used to suitably pre-align the diffuser 46 and heat sink 30 so that they can be successfully received in the lower part 20.

[0096] In addition, in the first work step 76, several screws 82 are moved in the preferred direction 78 into the lower part 20, by means of which the lower part 20 is screwed to the heat sink 30 and the fan mount 34. The holes in the lower part 20 through which the screws 20 are guided are comparatively large, so that a floating mounting of the heat sink 30 and the fan mount 34 on the lower part 20 is realized. Also, two bolts 84 of the heat sink 30 are guided in the preferred direction 78 through corresponding openings in the lower part 20 and screwed to the other components of the heat sink 30, so that the heat sink 30 protrudes into the lower part 20.As a result, the converter 16 shown in Figure 7 in a perspective top view and in Figure 8 in a perspective bottom view has a first manufacturing stage, whereby up to that point the individual components of the converter 16 have only been moved in the preferred direction 78 to the assembly aid 64 and there placed on top of one another and joined together in the preferred direction 78.

[0097] In a subsequent second work step 86, the fan 40 is inserted in the preferred direction 78 through the opening 42 into the fan receptacle 34, namely into the holder 38, up to an adjustable stop located in the holder 38. The adjustable stop is formed by a dome of the assembly aid 64 (not shown in detail), which is inserted through an auxiliary opening 88 of the holder 38 from the side facing away from the table 66 and is parallel to the preferred direction 78. Due to the dome, complete insertion of the fan 40 into the holder 38 is initially prevented. When the fan 40 rests against the adjustable stop, a visual check is carried out to determine whether the fan 40 is correctly oriented, namely whether its intake side is facing away from the heat sink 30.If this is the case, the dome is moved out of the auxiliary opening 80 in the preferred direction 78, and the fan 40 is inserted further into the holder 38 by applying force in the preferred direction 78 until the fan 40 locks with the fan receptacle 34. For this purpose, the holder 38 has locking elements (not shown in detail), by means of which the fan 40 is gripped on the side facing the opening 42. One end of a connection cable 90 (Figure 11) of the fan 30 is placed over the edge of the lower part 20 so that it is located outside the lower part 20. In summary, the opening 42 thus forms in particular an opening for the installation of the fan 40, i.e. a "fan opening." The auxiliary opening 88, on the other hand, forms in particular an "opening for fan query."

[0098] Subsequently, the first circuit board 44 is inserted into the lower part 20. The first circuit board 44 is already pre-assembled, so that the capacitors 54, the power module 48 and the other electrical and / or electronic components are attached to it. For assembly, the first circuit board 44 is moved in the preferred direction 78 towards the assembly aid 64, wherein the first circuit board 44 is inclined with respect to the table 66. As a result, an edge of the first circuit board 44 initially dips into the lower part 20. The two edges of the first circuit board 44 running perpendicular to this edge slide along several guide ribs 92 of a guide 94 of the lower part 20, some of which are shown in perspective in Figure 9.The guide ribs 92 are attached to the inside of the edge of the lower part 20 and are inclined with respect to the preferred direction 78, with the guide ribs 92 having a reduced extension and being rounded at the end facing away from the table 66. Thus, the guide ribs 92 act like a funnel for the first circuit board 44 at the edge, and this is aligned longitudinally within the lower part 20.

[0099] Therefore, upon further insertion of the first circuit board 44 in the preferred direction 78, the front edge of the first circuit board 44 is securely moved against two sliding ribs 96 of the guide 94, only one of which is shown in Figure 9. The sliding rib 96 is arranged parallel to the table 66 in the region of the first contact with the edge. If further force is now exerted on the first circuit board 44 in the preferred direction 78, the edge is moved perpendicular to the preferred direction 78 along the sliding rib 96, which leads to a pivoting of the first circuit board 44. In doing so, the edge is brought against a section of the sliding ribs 96 that is inclined counter to the preferred direction 78, which accelerates the pivoting. By means of the sliding ribs 96 and the guide ribs 92, the edge is then inserted into three adjacent undercuts 98, each of which has a slot arranged essentially parallel to the table.Thus, the edge of the first circuit board 44 is gripped by means of the undercuts 98, which is why further transverse displacement of the edge is prevented.

[0100] Upon further movement of the first circuit board 44 in the preferred direction 78, the edge of the first circuit board 44 opposite the undercuts 98 is moved along three locking hooks 100 in the preferred direction 78, one of which is shown in perspective in Figure 10. When the first circuit board 44 is aligned parallel to the table 66 due to the force acting in the preferred direction 78, the locking hooks 100 engage around the edge, so that detachment of the first circuit board 44 from the lower part 20 is no longer possible. In other words, the first circuit board 44 is connected to the lower part 20. The first circuit board 44 rests at its end against the bolts 84, so that further movement in the preferred direction 78 is not possible.

[0101] When inserting the first circuit board 44, a second centering opening 102 of the first circuit board 44, which is formed by a hole in the region of the edge encompassed by the locking hook 100, is placed onto a second centering element 104 having a cross-shaped cross-section. The second centering element 104 runs parallel to the preferred direction 78, and its free end is molded on, thus facilitating the insertion of the first circuit board 44. The second centering element 104 is arranged on the inside of one of the first centering openings 80, so that the first centering element 72 assigned to this first centering opening 80 and the second centering element 104 are arranged on a common straight line that is parallel to the preferred direction 78.As a result, a comparatively precise alignment of the first circuit board 44 with respect to the table 66 is achieved, although otherwise comparatively large manufacturing tolerances can be selected for the lower part 20. This ensures that the power module 48, namely the heat sink 50, comes into direct contact with the heat sink 30, so that they rest against one another. Thus, direct heat conduction between the power module 48 and the heat sink 30 is realized. After inserting the first circuit board 44, no subsequent checking or alignment is required, as this is achieved simply by inserting the first circuit board 44. The thermal contact between the power module 48 and the heat sink 30 is expediently achieved by means of or through the further opening 52, which thus forms an opening for contacting the power module 48 with the heat sink 30, i.e., a "semiconductor module / power module opening."

[0102] After inserting the first circuit board 44, mounting screws 108 are guided through two mounting openings 106 of the first circuit board 44 and inserted into a respective screw receptacle of the power module 48, namely the heat sink 50, where they are screwed to the heat sink 30. The diameter of the mounting screws 108 is smaller than the diameter of the mounting openings 106, so that the mounting screws 108 are located completely below the first circuit board 44 in the preferred direction 78 and are only in contact with the power module 48 and the heat sink 30.

[0103] Furthermore, the first circuit board 44 is screwed to the bolts 84 on which the first circuit board 44 rests by means of additional screws 110. The additional screws 110 are electrically contacted with conductor tracks (not shown in detail) of the first circuit board 44 and thus also with the heat sink 30. Subsequently, the end of the connecting cable 90 located outside the lower part 20 is plugged into a corresponding connector on the side of the first circuit board 44 facing away from the table 66 and thus electrically contacted with the first circuit board 44. The converter 16 thus has the second manufacturing stage shown in Figure 11.

[0104] In a subsequent third work step 112, the upper part 22, shown in perspective in Figure 12, is moved in the preferred direction 78 towards the assembly aid 64 and placed on the table 66. The upper part 22 is positioned perpendicular to the preferred direction 78 next to the lower part 20. The upper part 22 has two hinge parts 114 on the edge, which are designed like U-shaped tabs. These each engage in a corresponding hinge part 114 of the lower part 20, which are designed like an open sleeve or at least have snap hooks or locking hooks. As a result, the two hinges 26 are formed. In summary, the two edge-side hinge parts 114 of the upper part 22 are each fastened to one of the edge-side hinge parts 114 of the lower part 20, for which purpose they are reinforced, so that the two hinges 26 are formed.

[0105] The second circuit board 56 is then inserted into the upper part 22, namely into the projection 24, and connected to it. For this purpose, the upper part 22 also has a guide 94, which is designed to correspond to the guide 94 of the lower part 20. This guide 94 therefore also has the two sliding ribs 96, several guide ribs 92 and three undercuts 98, some of which are shown in perspective in Figure 13. In addition, the guide 94, as shown in Figure 14, also has corresponding locking hooks 100. The procedure and type of connection of the second circuit board 56 to the upper part 22 corresponds to the connection of the first circuit board 44 to the lower part 20. The only difference here is that the second centering opening 102 and the second centering element 104 are not present.

[0106] As a result, the converter 16 has the manufacturing stage shown in perspective in Figure 15, in which both the lower part 20 and the upper part 22 rest on the table 66, and wherein the first circuit board 44 is arranged within the lower part 20 and the second circuit board 56 is arranged within the upper part 22, and wherein the upper part 22 and the lower part 20 are fastened to one another by means of the hinges 26.

[0107] Subsequently, a fourth work step 114 is performed. In this step, the ribbon cable 58 is moved in the preferred direction 78 toward the assembly aid 64 and plugged in the preferred direction 78 into corresponding connector receptacles of the first circuit board 44 and the second circuit board 56. Following this, the upper part 22 is folded onto the lower part 20 by means of the hinges 26 and secured there by means of the snap hooks 28, as shown in Figure 16. Following this, the converter 16 is completed, and it is removed from the assembly aid 64, shown transparently in Figure 16.

[0108] In summary, to assemble the converter 16, all components, such as the heat sink 30, the individual components of the housing 18, and the electronics 46, which includes the two circuit boards 44, 46, are moved only in the preferred direction 78 toward the assembly aid 64, which is not moved or only moved transversely during the process 62. On the assembly aid 64, the components are placed one on top of the other in the preferred direction 78 and joined together. Thus, the individual components are attached to one another only in the preferred direction 78.

[0109] 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.

[0110] List of reference symbols

[0111] 2 heat pumps

[0112] 4 Refrigerant circuit

[0113] 6 Compressor

[0114] 8 first heat exchanger

[0115] 10 Expansion valve

[0116] 12 second heat exchanger

[0117] 14 Electric motor

[0118] 16 inverters

[0119] 18 housings

[0120] 20 lower part

[0121] 22 Top

[0122] 24 lead

[0123] 26 Hinge

[0124] 28 snap hooks

[0125] 30 heat sinks

[0126] 32 cooling fins

[0127] 34 Fan mount

[0128] 36 Diffuser

[0129] 38 bracket

[0130] 40 fans

[0131] 42 Opening

[0132] 44 first circuit board

[0133] 46 Electronics

[0134] 48 power module

[0135] 50 heat sinks

[0136] 52 further opening

[0137] 54 Capacitor

[0138] 56 second circuit board

[0139] 58 ribbon cables

[0140] 60 slot

[0141] 62 Procedure Assembly aid Table Holder Second holder First centering element Mounting rail First work step Preferred direction First centering opening Screw Bolt Second work step Auxiliary opening Connecting cable Guide rib Guide Sliding rib Undercut Snap hook Second centering opening Second centering element Mounting opening Mounting screw Further screw Third work step Fourth work step

Claims

Claims 1 . Method (62) for producing a converter (16) for a heat pump (2) on an assembly aid (64), which converter has a heat sink (30), a housing (18) with an upper part (22) and with a lower part (20) and an electronics (46), in which the heat sink (30), the housing (18) and the electronics (46) are each moved one after the other in a common preferred direction (78) to the assembly aid (62) and there are placed on top of one another and joined to one another in the preferred direction (78).

2. Method (62) according to claim 1, characterized in that first the heat sink (30) is inserted into a receptacle (68) of the assembly aid (64) and then the lower part (20) is placed on the heat sink (30) and connected to it.

3. Method (62) according to claim 2, characterized in that firstly a fan receptacle (34) is inserted in the preferred direction (78) into a second receptacle (70) of the assembly aid (64) and positioned perpendicular to the preferred direction (78) next to the heat sink (30), and that subsequently the lower part (20) is also placed on the fan receptacle (34) in such a way that an opening (42) of the fan receptacle (34) extends into the lower part (20).

4. Method (62) according to claim 3, characterized in that a fan (40) is inserted in the preferred direction (78) through the opening (42) into the fan receptacle (34).

5. Method (62) according to one of claims 2 to 4, characterized in that a first circuit board (44) of the electronics (46) is inserted into the lower part (20) in such a way that a power module (48) fastened to the first circuit board (44) rests against the heat sink (30).

6. Method (62) according to claim 5, characterized in that the first printed circuit board (44) is connected to the lower part (20), and in that a mounting screw (108) is inserted through a mounting opening (106) of the first printed circuit board (44) in the preferred direction (78) into a screw receptacle of the power module (48) and screwed to the heat sink (30).

7. Method (62) according to claim 5 or 6, characterized in that a first centering opening (80) of the lower part (20) is placed on a first centering element (72) of the assembly aid (64), and that a second centering opening (102) of the first circuit board (44) is placed on a second centering element (104) of the lower part (20), wherein the two centering elements (72, 104) are arranged on a common straight line which is parallel to the preferred direction (78).

8. Method (62) according to one of claims 1 to 7, characterized in that the upper part (22) is positioned perpendicular to the preferred direction (78) next to the lower part (20), wherein an edge-side hinge part (114) of the lower part (20) is fastened to an edge-side hinge part (114) of the upper part (22).

9. Method (62) according to claim 8, characterized in that a second printed circuit board (56) is inserted into the upper part (22) in the preferred direction (78) and connected to it.

10. Converter (16) for a heat pump (2), comprising a heat sink (30), a housing (18), and electronics (46) that are attached to one another only in a preferred direction (78).

11. Converter (16) according to claim 10, characterized in that the heat sink (30) is rigidly attached to the electronics (46), and that this assembly is mounted in a floating manner on the housing (18).

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