Contacting ring for contacting a converter unit integrated into a housing

Abstract

The invention proposes an electric machine, in particular a three-phase asynchronous machine or a three-phase synchronous machine, in a housing, comprising a converter unit (3) integrated into the housing, in particular into the bearing shield. The electric machine also contains a stator having a contacting ring (1). The line ends of the stator winding are provided with plug-in contacting units (12), which are secured to the contacting ring (1) at defined positions by means of first fixation geometries (11). The contacting ring (1) and the stator have second fixation geometries (14), by means of which the contacting ring (1) is connected to the stator. The method for producing such an electric machine has multiple installation steps. First, plug-in contacting units (12) are attached to the line ends of the winding lines of a stator; the plug-in contacting units (12) are then inserted into the first fixation geometries (11) of a contacting ring (1) and the contacting ring (1) is secured to the stator by means of the second fixation geometries (14); the stator unit is then inserted or pressed axially into the housing; and finally a converter unit (3) which is equipped with plug-in contacting counter-pieces (13) is pushed axially into the housing until the end position thereof is reached, in which the plug-in contacting units (12) and the plug-in contacting counter-pieces (13) are joined together in such a way that the stator and the converter unit (3) are contacted.

Description

[0001] 202415103

[0002] 1

[0003] Description

[0004] Contact ring for connecting a housing-integrated inverter unit

[0005] The present invention relates to an electric machine, in particular a three-phase asynchronous or a three-phase synchronous machine, and a method for assembling an electric machine.

[0006] State of the art

[0007] Currently, the stator winding of an electric machine, such as three-phase asynchronous and three-phase synchronous motors, is connected to connecting leads, typically with cable lugs at the ends, using various contact methods such as crimping, soldering, or welding. These connecting leads are then manually fed through an opening in the housing to a terminal block in the junction box for connection to the necessary power supply.

[0008] For variable-speed dynamoelectric machines, such as electric motors, especially synchronous, asynchronous, and reluctance motors, frequency converters are needed to adjust the desired speed.

[0009] In decentralized inverter designs, particularly those mounted on walls in control cabinets, the connection between the inverter and motor is made via a separate cable to the terminal block. In contrast, with so-called integrated inverter designs, the connecting cables are routed directly through the housing opening to the inverter. In these solutions, previously referred to as integrated inverters, the inverter units are mounted onto an opening in the housing of the electric machine. Alternatively, they are referred to as motor-mounted inverters. Here, too, the connecting cables are usually routed manually. This approach results in high installation costs, especially for smaller units, and compromises the compactness of the drive system.

[0010] Additional wires for thermal monitoring or other components are also manually routed through the housing opening, further increasing the manual effort. These methods require the use of ferrules and connections via terminal blocks or cage clamp contacts, which also increases complexity and cost. 202415103

[0011] 2

[0012] Up to now, as illustrated in Figure 2, the power supply, signal lines, and inverter connections have been made on a terminal block in the terminal box on the motor housing. This mounting method directly on the housing requires a lot of installation space and makes the drive comparatively large and heavy.

[0013] Furthermore, existing solutions limit the modularity and interchangeability of drive systems and lead to increased space requirements and manual effort when connecting components. Another disadvantage of existing methods is the need to connect each component individually, which is both time-consuming and prone to errors. Alternative materials or contact designs have so far been rarely used, as existing methods are based on industry standards and established practices.

[0014] Approaches where the motor and inverter are arranged axially one behind the other are known, for example, from EP 0 854 560 A1. However, current designs with inverters mounted directly on the motor require considerable installation space because the bearing is located between the motor and the inverter. This makes the drive comparatively large and heavy.

[0015] From DE 102004 031 399 A1, for example, a converter motor with a self-ventilated electric motor and a frequency converter is known, wherein components of the frequency converter are arranged at the bottom of the cup-shaped bearing shield.

[0016] This drive also requires a comparatively large amount of installation space.

[0017] Consequently, it is technically necessary to propose an improved solution that avoids the disadvantages known from the prior art. In particular, the proposed solution should enable increased compactness while simultaneously simplifying assembly.

[0018] The problems underlying the present invention are solved by an electric machine according to claim 1. The problem relating to assembly is solved by a manufacturing method according to claim 10. Advantages and embodiments of the invention, which can be used individually or in combination, are the subject of the dependent claims. 202415103

[0019] 3

[0020] Description of the invention

[0021] The electrical machine according to the invention, in particular a three-phase asynchronous or three-phase synchronous machine, comprises a housing-integrated converter unit, in particular a bearing shield-integrated converter unit, and a stator with a contact ring. The winding leads of the stator have conductor ends that have plug-in contact units which are attached to the contact ring at defined positions by means of first fixing geometries. Both the contact ring and the stator have second fixing geometries by means of which the contact ring is connected to the stator.

[0022] The stator and contact ring preferably form a single structural unit. Advantageously, the stator unit and converter unit are arranged in the housing such that the contact ring is located axially between the stator and the housing-integrated converter unit.

[0023] In the electrical machine according to the invention, plug connectors are preferably used instead of terminals. The use of the contact ring, which serves to fix the plug connectors to the stator, is particularly advantageous. The machine comprises an integrated inverter solution, which, together with the contact ring, ensures a high degree of compactness. Part of the proposed solution involves integrating the power electronics into the housing, in particular into the end shield. The limited installation space and the round design of the inverter solution present a particular challenge.

[0024] The advantages lie, firstly, in the structural flexibility. The use of plug-in connectors instead of terminals allows for very simple assembly of the stator and inverter within the housing. Secondly, there is the advantage of increased stability. The joining properties of both the stator and inverter units can be optimized. The contact ring is a mechanical attachment for securing the cable ends and providing plug-in connectors at predefined positions, corresponding to the positions of mating connectors on the inverter unit. The contact ring and stator are preferably mechanically and force-fittedly connected, meaning the contact ring is fixed to the stator. The contact ring enables a reduction to essentially two structural components within the housing. 202415103

[0025] 4

[0026] The terms plug-in unit and plug-in counterpart refer specifically to plugs and sockets, whereby plugs and sockets can also be reversed. Stator cable ends can terminate in plugs and the sockets can be integrated into the inverter unit, or vice versa.

[0027] A housing-integrated inverter unit means that the inverter or individual inverter components are located inside the housing. This ensures that the electrical connection is also made within the housing and does not extend beyond it. It could also be referred to as a (motor) interior-positioned inverter unit. To integrate an inverter unit into the housing, it can be attached, in particular, to the inner wall of the housing. A bearing shield-integrated inverter unit, as proposed, for example, in EP 24199792.3 or EP 24200040.4, is particularly advantageous. A combined solution, in which the inverter unit is partially integrated into the housing and partially into the bearing shield, is also conceivable. Such embodiments of a housing-integrated inverter unit can serve as a basis for the connection ring solution proposed here.

[0028] A housing is the enclosure of an electric machine, which provides, in particular, cooling elements, mounting elements, and the routing of power cables. Cooling elements are typically cooling fins.

[0029] A further advantage is the solution to the challenge of space utilization. Round inverter designs are particularly preferred. Preferred diameters depend on the stator diameter, which can be approximately 10 cm to 15 cm. The proposed solution may also be of interest for other power classes. In particular, the proposed solution is used in three-phase asynchronous or three-phase synchronous machines with power ratings of 1 kW to 15 kW and shaft heights of 80 mm to 160 mm. The solution can also be used in motors with power ratings up to 90 kW and shaft heights up to 280 mm.

[0030] An advantageous application of the invention is possible, for example, in a drive with at least one dynamoelectric rotary machine arranged in a housing, with a winding system arranged in a stator and a rotor separated from it by an air gap, which is rotatably mounted about an axis via at least one bearing of a cup-shaped end shield. The stator and rotor are located in 202415103

[0031] 5. a motor interior. This preferably includes an inverter comprising at least some of the following components, such as power semiconductors, inductors, capacitors, control and regulation units, and communication units, and located in an inverter housing that is radially surrounded, at least partially, by the bearing shield. Some components of the inverter are thermally connected to the bearing shield, in particular by arranging heat-intensive components of the inverter on an inner side wall of the cup-shaped bearing shield. Preferably, the inverter is arranged axially between the dynamo-electric rotary machine and the bearing of the cup-shaped bearing shield. The motor interior and the inverter housing are separated, in particular, by a shielding element.

[0032] In an advantageous embodiment of the electrical machine according to the invention, the housing-integrated converter unit has electrical connections which are designed as plug-in counterparts to the plug-in contact units.

[0033] For convenience, the plug-in contact units and their mating connectors are arranged to match each other; that is, the plug-in contact units, mating connectors, and initial fixing geometries are identical in position (and number), particularly in their position relative to the radial distance from the axis of rotation and in their concentric arrangement. Once the inverter has reached its final position in the housing, all sockets and plugs of the stator and inverter are connected. The stator is thus fully assembled with the inverter.

[0034] In a further advantageous embodiment of the electric machine according to the invention, the contact ring is mounted on the connection side of the stator winding head. This variant has the advantage of being even more compact. The contact ring is, in particular, fitted over the stator winding head.

[0035] The winding leads refer to the wires or conductors used in the windings of an electric machine. These windings are crucial for the machine's function, as they generate the magnetic field necessary for operation. Here, we primarily refer to stator windings. The winding leads are advantageously well insulated to prevent short circuits and maximize the machine's efficiency. The way the windings are arranged and constructed significantly influences the machine's performance and characteristics. 202415103

[0036] 6

[0037] Preferably, the stator is inserted or pressed into the housing. This has the advantage of creating a suitable fit of the stator within the housing, resulting in comparatively good heat transfer from the stator's laminated core to the housing and any optional housing fins.

[0038] In a further advantageous embodiment of the electric machine according to the invention, the second fixing geometries are designed as snap-in or plug-in elements. Fixing is preferably achieved via snap-in or plug-in elements in the contact ring, which engage in correspondingly provided geometries or recesses in the stator lamination.

[0039] Alternatively, the stator can be fixed using snap-in or plug-in elements, which lock into correspondingly provided geometries or recesses in the contact ring.

[0040] In a further advantageous embodiment of the electrical machine according to the invention, the contact ring is fixed to the winding head bandage on the connection side. In particular, the ring is additionally radially aligned with the stator core by a geometry.

[0041] In a further advantageous embodiment of the electrical machine according to the invention, further conductor ends have plug-in contact units, in particular conductor ends of thermocouples and / or attachment elements, which are attached to defined positions on the contact ring by means of further first fixing geometries and for which the housing-integrated converter unit has further electrical connections, which are designed as plug-in counterparts to the plug-in contact units.

[0042] The contact ring is specifically designed so that the connecting and signal lines, such as temperature sensors, or the insulated wire ends of the windings can be routed through the ring, or alternatively along the outside of the ring and secured there. The wire ends are connected to corresponding connection elements, referred to here as plug-in contact units, which are firmly fixed in defined positions on the contact ring. 202415103

[0043] 7

[0044] For example, the plug-in units have sockets, in particular plastic sockets, while the plug-in counterparts have pins, in particular copper pins. Alternatively, the plug-in units can have pins, in particular copper pins, and the plug-in counterparts can have sockets, in particular plastic sockets.

[0045] In a further advantageous embodiment of the electrical machine according to the invention, the first fixing geometries are designed as snap, press or plug-in elements.

[0046] In a further advantageous embodiment of the electrical machine according to the invention, the contact ring is made of an electrically non-conductive material, in particular plastic.

[0047] In a further advantageous embodiment of the electric machine according to the invention, the contact surfaces of the plug-in connectors are designed to compensate for potential relative movements of the stator and inverter unit. This can be achieved, in particular, by means of spring elements, providing an effective means of compensating for the relative movement. Alternatively, a simple plug connector, due to its contact surface or contact path, can also compensate for movements of several millimeters in the axial direction. The pin moves along the contact surface of the socket. Pins with integrated radial springs extending outwards, to ensure better contact even during axial movement, can also be used.

[0048] Sockets and plugs must be designed in such a way that possible relative movements of the stator and inverter can be compensated for, so that the contact does not break down.

[0049] The manufacturing method according to the invention comprises the assembly steps: attaching plug-in contact units to the conductor ends of the winding conductors of a stator, attaching the plug-in contact units to or in first fixing geometries of a contact ring, and attaching the contact ring to the stator by means of second fixing geometries, axially inserting or pressing the stator into a housing, and axially sliding a converter unit with plug-in contact counterparts into the housing up to 202415103

[0050] 8 to an end position of the converter unit, in which end position plug contact units and plug contact counterparts are joined together so that the stator and converter unit are contacted.

[0051] A particular advantage of this method is that the axial mounting of the inverter in the housing is simultaneously used for contacting.

[0052] Another advantage is that proven assembly methods such as press-fitting or insertion can be used. This preserves established processes. Furthermore, the number of components is reduced.

[0053] Press-fitting has the additional advantage of ensuring excellent thermal transfer to the housing. Furthermore, all proposed mounting and fixing mechanisms are mechanical in nature. Most of them are detachable connections, which are advantageous for repair and disassembly.

[0054] In an advantageous variant of the manufacturing process according to the invention, plug-in contact units are attached to the conductor ends of the winding conductors of a stator by means of crimping, plugging or cage clamping.

[0055] In a further advantageous variant of the manufacturing process according to the invention, the assembly step of attaching plug-in contact units to further conductor ends of the stator, in particular to conductor ends of thermosensors and / or attachment elements, is additionally carried out.

[0056] In a further advantageous variant of the manufacturing process according to the invention, the first and / or second fixing geometries are designed as plug-in, press-fit and / or snap-fit ​​elements.

[0057] In a further advantageous embodiment of the manufacturing process according to the invention, the fixing geometries for the plug-in contact units are designed as receptacles, in particular as recesses or protrusions in the contact ring, into which the plug-in contact units are inserted. Alternatively, the fixing geometries can also be designed as protrusions, in particular lugs, onto which the plug-in contact units are pushed or pressed. 202415103

[0058] 9

[0059] In a further advantageous variant of the manufacturing process according to the invention, at least one of the assembly steps is carried out semi-automatically or automatically.

[0060] A key feature of the proposed solution is the structural integration of the stator with a contact ring, creating a compact unit. The contact ring forms a single unit with the stator, and the connection ends are provided within this ring. This design offers several advantages: its compactness allows for easier and faster assembly, which can also be automated. This significantly improves the interchangeability of the drive systems.

[0061] Another significant advantage of the proposed solution is the integration of contacting and assembly into a single process step. Inserting the inverter into the housing simultaneously establishes the contact. The effort required to prepare the stator wire ends remains virtually unchanged. Due to the fixation on the contact ring, an automated solution is feasible.

[0062] Additionally, the need for separate connections of the stator leads and inverter terminals in the terminal block is eliminated. Routing the stator leads through the housing opening is also no longer required. This results in a significant reduction in the installation space required in the connection area, as the very large terminal block with its numerous connections is reduced to the three power supply connections and any interface connections. This eliminates the need for additional components such as an auxiliary terminal box and its installation.

[0063] The advantages of the proposed solution encompass several aspects. First, it enables automated contacting of the stator terminals. Second, contacting and assembly are combined into a single process step, making the entire process more efficient. Third, the solution leads to cost reductions because fewer process steps are required. Fourth, further cost savings can be achieved by eliminating the need for additional components, such as an auxiliary terminal block. Finally, manual handling of the wiring, such as routing cables and making connections in the terminal box, is significantly reduced.

[0064] The proposal therefore includes an electric machine, in particular a three-phase asynchronous or three-phase synchronous machine, in a housing comprising a housing-integrated converter unit, which is in particular integrated into the end shield. Furthermore, 202415103

[0065] Figure 10 includes a stator with a contact ring. The leads of the stator winding are fitted with plug-in contact units, which are attached to the contact ring at defined positions using primary fixing geometries. Both the contact ring and the stator have secondary fixing geometries, which connect the contact ring to the stator. The manufacturing process for such an electrical machine comprises several assembly steps. First, plug-in contact units are attached to the leads of the stator windings. Then, the plug-in contact units are inserted into the primary fixing geometries of a contact ring, and the contact ring is attached to the stator using the secondary fixing geometries. Finally, the stator unit is axially inserted or pressed into the housing.Finally, a converter unit equipped with plug-in counterparts is inserted axially into the housing until it reaches its final position, in which the plug-in units and the plug-in counterparts are joined together so that the stator and the converter unit are contacted.

[0066] Character description

[0067] Examples and embodiments of the present invention are further described by way of example with reference to Figures 1 to 6 of the attached drawing. In the exemplary embodiments and figures, identical or similarly functioning elements may be provided with the same reference numerals. The depicted elements and their relative sizes are generally not to be considered to scale; rather, individual elements may be shown proportionally larger for better clarity and / or understanding.

[0068] Although the invention is illustrated and described in detail by the preferred embodiment, it is not limited by the disclosed examples. Variations thereof can be derived by a person skilled in the art without departing from the scope of protection of the invention as defined by the claims.

[0069] The drawing shows schematically:

[0070] Figure 1 shows an electric machine 10,

[0071] Figure 2 shows a contact arrangement, according to the prior art, of a power line, signal and converter connections on a terminal block on a housing 5, 202415103

[0072] 11

[0073] Figure 3 shows a section through an electric machine 10 according to the invention, in which a housing-integrated converter unit 3 contacts the stator lines 22 by means of a contacting ring 1 and

[0074] Figure 4 shows a partial perspective view of the components stator 2, converter unit 3 and contact ring 1 along their mounting axis.

[0075] Figure 5 shows a first example of a contact ring design and

[0076] Figure 6 shows a second example of a contact ring design.

[0077] Figure 1 shows a perspective view of the exterior of an electric machine 10 in a housing 5, with a bearing receptacle at the base of the end shield 7. The shaft 6 protrudes from the housing 5. On the stator side (see Figure 3), the driven machine, such as a compressor or pump, is connected to the shaft 6. Modular attachments, such as a brake unit, external fan module, or encoder / rotary encoder, can be mounted on the end shield 7. Cooling fins 51 are shown on the outer wall of the housing. The terminal box 40 is shown smaller than required for conventional terminal boards (see Figure 2). The terminal box 40 can be further reduced in size by using the solution proposed according to the invention, to the point where it is no longer needed at all.

[0078] For the electrical connection of electrical machines 10, for example electric motors, connecting leads 22 are electrically contacted at the ends of the winding phases. The proposed solution is particularly interesting for three-phase asynchronous and three-phase synchronous motors. Contact is made using methods such as crimping, soldering, or welding. Cable lugs are typically located at the ends of the connecting leads 22. These leads are currently fed manually through a housing opening, usually to the terminal board in the junction box 40, to provide user-friendly access to the connections. In decentralized, so-called wall-mounted inverter designs, the connection between the inverter 3 and the stator 2 is made via a supply line to the terminal board. In integrated, so-called surface-mounted or...In motor-mounted inverter designs, such as those shown in Figure 2, the connecting cables 41 are currently routed directly to the inverter 3 through the housing opening. The connecting cables for the mains voltage 41 are typically 202415103.

[0079] 12 times with wire end ferrules, contact is made by means of terminal blocks or cage clamp contacts.

[0080] In addition to the voltage connection leads 41, there is the option of further leads 46, 47, for example for thermal motor monitoring 46 or other components, such as a standstill heater, which can also be manually routed through the housing opening into the terminal box 40 or directly into the motor-mounted inverter 3. Connections in the terminal box 40 are typically made via terminal blocks. Furthermore, Figure 2 shows connections for the motor 42, connections for digital inputs and outputs 43, connections for a 24V power supply 44 (switched / unswitched), connections for DIP switches 45 (dual in-line package switches), connections for a motor temperature sensor 46, connections for a braking resistance measurement 47, and connections for an electromagnetic brake, for example, 180V.The proposed solution advantageously avoids the previously considerable manual effort of routing the stator leads 21 and additional leads from the winding through the housing opening, and thus reduces the previously disproportionately high assembly costs, especially for smaller sizes.

[0081] Unlike previous so-called integrated converter designs, which are actually mounted or attached converter solutions (see Figure 2), the housing-integrated converter unit 3 proposed here is actually integrated into the housing 5 (see Figures 3 and 4). In particular, the housing-integrated converter unit 3 is arranged radially around the shaft 6 and can be connected directly to the stator lines 22.

[0082] It is shown that stator 2, winding head 21 and converter 3 are arranged axially one behind the other. In the embodiment shown in Figure 3, it is not necessary to connect or wire the stator leads 22 to a terminal block.

[0083] Figure 3 schematically shows a cross-section of a stator 2 with mounted plug-in contact units 12 in the housing 5, the contact ring 1, and the inverter 3 adjusted and connected to it. The plug-in contact counterparts 13 are joined to the plug-in contact units 12. The contact ring 1 and the stator 2 form a single structural unit. 202415103

[0084] 13

[0085] Figure 4 shows a sketch of the stator 2 with mounted plug-in contact units 12, here sockets 12, as well as the contact ring 1 and the converter unit 3 with plug-in contact counterparts 13, here pins 13, along their mounting axis. The axial mounting of the converter 13 in the housing 5 is thus used for contacting. First, the contact ring 1 is attached to the stator 2. It forms a structural unit with the stator 2. This allows the stator unit 2+1 to be inserted or pressed into the housing 5, preferably conventionally. In a prior assembly step, the ends of the stator leads 22 are not fitted with the usual contact materials such as cable lugs or ferrules, but are connected to plug-in contact units 12, in particular plastic sockets 12. Other cable ends, for example from temperature sensors or attachments, are also provided with these plastic sockets 12.The contacting in the socket 12 itself can be achieved using conventional technologies such as crimping, plugging, or cage clamping. The plug-in contact units 12 are then firmly attached to the contact ring 1, and the contact ring 1 is in turn attached to the stator 2. Depending on the attachment method, the contact ring 1 is first fixed to the stator 2, and then the plug-in contact units 12 are attached to the contact ring 1, or vice versa. To secure the plastic sockets 12 or plugs of the stator terminals to the contact ring 1, the ring 1 is equipped with fixing geometries 11, such as tabs for sliding or pressing on, or recesses for inserting the plug-in contact units 12. The mounting of the plug-in contact units 12 onto the fixing geometries 11 of the contact ring 1 is generally done manually, but can also be automated. The contact ring 1 is preferably made of plastic, in particular a non-electrically conductive material.

[0086] The proposed solution is therefore based on an inverter 3 integrated inside the motor. The inverter 3 is mounted axially behind the stator 2 with winding 21 in the housing 5 and / or in the bearing shield 7.

[0087] The core of the proposed solution is the direct contacting of stator 2 and the housing-integrated inverter 3 within the motor interior. For this purpose, a special contact ring 1 is provided, which is mounted on the winding head 21 of stator 2 (see Figures 3 to 6). The ring 1 is secured using snap-in or plug-in elements 14 that engage in correspondingly provided geometries 14 or recesses in the stator lamination. Alternatively, the ring 1 can be fixed to the end face of the winding head 21, which can be achieved with additional radial alignment by means of a geometry on the stator core. 202415103

[0088] 14

[0089] The contact ring 1 is designed to allow connecting and signal lines 22, such as temperature sensors or insulated wire ends from the windings, to pass through it. Alternatively, these lines 22 can also be routed along the outside of the ring 1 and secured there. The line ends are then connected to corresponding connection elements 12, such as sockets or plugs, which are fixed at defined positions on the contact ring 1. This securing can be achieved by push-fit, press-fit, or snap-fit ​​mechanisms 11 between the connection element 12 and the ring 1. All these manufacturing steps can be carried out manually or automatically before the stator 2 is inserted into the housing 5.

[0090] The contact ring 1 should be made of an electrically non-conductive material, preferably plastic. Possible design embodiments are shown in Figures 5 and 6. After the stator 2, equipped with and contacted by the contact ring 1, has been inserted into the housing 5, the inverter element 3 can be guided into the motor housing 5. The inverter element 3 has mating contacts 13 corresponding to the terminals 12 on the stator contact ring 1, positioned in identical, opposite positions. Once the inverter element 3 has reached its final position, the inverter 3 is also fully contacted with the stator 2. The contact surface between socket 12 and plug 13 is designed to compensate for any relative movements between the stator 2 and inverter 3 without interrupting the contact.

[0091] In a further step, the inverter 3 is mounted in the housing 5 by axially inserting it. The inverter 3 incorporates corresponding connector units 13, as shown in Figure 4. These connectors 13 are identical in position and number to the mounted sockets 12 of the stator 2. When the inverter 3 reaches its final position, all sockets 12 and connectors 13 of the stator 2 and inverter 3 are inserted into each other, thus fully assembling the stator 2 with the inverter 3. The contact surface of the socket 12 with the connector 13 is designed to compensate for relative movements between the stator 2 and inverter 3, for example, due to vibrations. This has the advantage of ensuring uninterrupted contact. The connectors 13 on the inverter 3 can be mounted on the end face of the inverter 3 or integrated into its design.It is also possible that plug 12 and socket 13 are reversed, so that the plug-in contact units 12 are designed as plugs and the plug-in contact counterparts 13 are integrated as sockets in the inverter 3. 202415103.

[0092] 15

[0093] The key advantage of the proposed solution lies in combining contacting and assembly into a single process step. Inserting the inverter 3 into the housing 5 automatically establishes the contact. The effort required to prepare the stator 2 conductor ends remains virtually unchanged. Furthermore, thanks to the fixation on the contact ring 1, automated implementation is feasible.

[0094] A further advantage is that separate contacting of the stator leads 22 and converter connections 13 in the terminal box 40 is no longer necessary. The routing of the stator leads 22 through the housing opening is also eliminated, resulting in a significant reduction of the installation space in the connection area. The previously required, very large terminal block with numerous connections is reduced to the three connections of the power supply line 41 and, if necessary, interface connections. This eliminates the need for additional components such as an auxiliary terminal box 40 and another terminal block, as well as their installation.

[0095] In summary, the following advantages result: The contacting of the stator terminals 12 can be automated, contacting and assembly are combined in a single process step, and costs are reduced due to fewer process steps and the elimination of additional components such as an auxiliary terminal block. Furthermore, the manual handling of the conductors 22, such as cable routing and connection work in the terminal box 40, is significantly reduced.

[0096] 202415103

[0097] 16

[0098] Reference symbol list

[0099] 1 contact ring

[0100] 2 Stator

[0101] 3 converter unit

[0102] 5 (engine housing)

[0103] 6 wave

[0104] 7 Storage sign

[0105] 10 electric machine

[0106] 11 Receptacle for plug-in contact unit

[0107] 12 Plug-in contact unit

[0108] 13 plug contacts (pins)

[0109] 14 fixing geometries

[0110] 21 Winding system, or stator winding head of the winding system

[0111] 22 stator leads

[0112] 40 terminal boxes

[0113] 41 connections mains voltage

[0114] 42 connections motor

[0115] 43 connections Digital inputs / outputs

[0116] 44 power supply connections

[0117] 45 DIP switches

[0118] 46 connections temperature sensor

[0119] 47 connections brake resistor

[0120] 48 connections EM brake

[0121] 51 cooling fins

Claims

202415103 17 Patent claims 1. Electrical machine (10), in particular a three-phase asynchronous or three-phase synchronous machine, in a housing (5) comprising a housing-integrated converter unit (3), in particular a bearing shield-integrated converter unit (3) and a stator (2) with a contact ring (1), comprising winding leads (22) whose leads have plug-in contact units (12) which are fixed at defined positions on the contact ring (1) by means of first fixing geometries (11) and wherein the contact ring (1) as well as the stator (2) have second fixing geometries (14) by means of which the contact ring (1) is connected to the stator (2).

2. Electric machine (10) according to claim 1, wherein the housing-integrated converter unit (3) has electrical connections which are designed as plug-in counterparts (13) to the plug-in units (12).

3. Electric machine (10) according to claim 1 or 2, wherein the contact ring (1) is applied to the stator winding head (21) on the connection side.

4. Electric machine (10) according to one of the preceding claims, wherein the second fixing geometries (14) are designed as snap-in or plug-in elements.

5. Electric machine (10) according to one of the preceding claims, wherein the contact ring (1) is fixed on the connection side of the winding head bandage.

6. Electric machine (10) according to one of the preceding claims, wherein further conductor ends have plug-in contact units (12), in particular conductor ends of thermosensors and / or attachment elements, which are attached to defined positions on the contact ring (1) by means of further first fixing geometries (11) and for which the housing-integrated converter unit (3) has further electrical connections, which are designed as plug-in counterparts (13) to the plug-in contact units (12). 202415103 18 7. Electric machine (10) according to one of the preceding claims, wherein the first fixing geometries (11) are designed as snap, press or plug elements.

8. Electric machine (10) according to one of the preceding claims, wherein the contact ring (1) is made of an electrically non-conductive material, in particular plastic.

9. Electric machine (10) according to one of the preceding claims, wherein the contact surfaces of the plug-in counterparts (13) to the plug-in units (12) are designed in such a way that possible relative movements of stator (2) and converter unit (3) can be compensated.

10. Manufacturing method for an electric machine (10) according to one of the preceding claims, comprising the assembly steps: Attaching plug-in contact units (12) to the conductor ends of the winding conductors (22) of a stator (2), Attaching the plug-in contact units (12) to or in first fixing geometries (11) of a contact ring (1), and attaching the contact ring (1) to the stator (2) by means of second fixing geometries (14), Axial insertion or pressing of the stator (2) into a housing (5), Axial insertion of an inverter unit (3) with plug-in contact counterparts (13) into the housing (5) to an end position of the inverter unit (3), in which end position plug-in contact units (12) and plug-in contact counterparts (13) are joined together such that the stator (2) and inverter unit (3) are contacted.

11. Manufacturing method according to claim 10, wherein the attachment of plug-in contact units (12) to the conductor ends of the winding conductors (22) of a stator (2) is carried out by crimping, plugging or cage clamping.

12. Manufacturing method according to claim 10 or 11, wherein the assembly step of attaching plug contact units (12) to further conductor ends of the stator (2) is additionally carried out, in particular to conductor ends of thermosensors and / or attachment elements. 202415103 19 13. Manufacturing method according to any one of claims 10 to 12, wherein the first and / or second fixing geometries (11, 14) are designed as plug-in, press-fit, and / or snap-fit ​​elements.

14. Manufacturing method according to any one of claims 10 to 13, wherein the fixing geometries (11) for the plug-in contact units (12) are designed as receptacles, in particular recesses or protrusions in the contact ring (1), and into which fixing geometries (11) the plug-in contact units (12) are inserted, or wherein the fixing geometries (11) for the plug-in contact units (12) are designed as protrusions, in particular lugs, onto which the plug-in contact units (12) are pushed or pressed.

15. Manufacturing method according to any one of claims 10 to 14, wherein at least one of the assembly steps is semi-automated or automated.

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