Interconnection apparatus for an electric machine for a vehicle, electric machine, vehicle, and method for producing an interconnection apparatus
Patent Information
- Application Number
- PCT/EP2026/056883
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2025-03-13
- Filing Date
- 2026-03-12
- Publication Date
- 2026-09-17
Smart Images
Figure EP2026056883_17092026_PF_FP_ABST
Abstract
Description
[0001] ZF Friedrichshafen AG File 212184 Friedrichshafen 2025-03-11
[0002] Circuit device for an electric machine for a vehicle, electric machine, vehicle and method for manufacturing a circuit device
[0003] The present invention relates to a wiring device for an electric machine with a plurality of coils for a vehicle, an electric machine for a vehicle, an electric axle drive for a vehicle, a vehicle and to a method for manufacturing a wiring device.
[0004] Electric motors for powering vehicles can have a sandwich-design connection system with contact rings for the coil windings, as well as a separate power connection. Insulating washers can be inserted between individual contact rings and / or the assembly can be overmolded. The power connection can be a separate component that connects the connection system to the phase terminals of the electric motor. The connection system and the neutral conductor are typically implemented as separate components, with the neutral conductor suspended beneath the connection system.
[0005] Against this background, the present invention provides an improved wiring device for an electric machine with a plurality of coils for a vehicle, an improved electric machine for a vehicle, an improved electric axle drive for a vehicle, an improved vehicle, and an improved method for manufacturing a wiring device according to the main claims. Advantageous embodiments are described in the dependent claims and the following description.
[0006] The approach presented here offers a simple and reliable way to stabilize a star conductor module within an electric machine with minimal effort. This approach advantageously allows the star conductor module to be held in a designated position, thus preventing it from being affected by external influences or vibrations. Generally, vibrations or stresses occurring at, for example, weld points can be dampened. ZF Friedrichshafen AG File 212184 Friedrichshafen 2025-03-11
[0007] so that the functionality of the corresponding component can be improved.
[0008] A connecting device for an electric machine with a plurality of coils for a vehicle, wherein the connecting device is a connecting assembly with a first connection element for applying an electrical voltage and a first contact element electrically connected to the first connection element for electrically contacting first terminals of a plurality of windings of a first coil of the electric machine, with a second connection element for applying an electrical voltage and a second contact element electrically connected to the second connection element for electrically contacting first terminals of a plurality of windings of a second coil of the electric machine,and comprises a third connection element for applying an electrical voltage and a third contact element electrically connected to the third connection element for electrically contacting the first terminals of a plurality of windings of a third coil of the electric machine. Furthermore, the connection device comprises a star conductor configured to electrically connect the second terminals of the plurality of windings of the coils to one another, the star conductor having a contact section, an electrically insulating stabilizing element at least partially surrounding the contact section, and an auxiliary rail arranged transversely to the star conductor. A first end of the auxiliary rail is embedded in the stabilizing element, and a second end of the auxiliary rail opposite the first end contacts the first contact element.to connect the star conductor to the switching device in a vibration-damping manner.
[0009] An electric machine can comprise various components, such as a rotor and a stator. For example, a ring-shaped stator can consist of a laminated core with several coils containing windings for conducting electric current. These windings can be, for instance, flat wire windings with multiple, alternately connected sections. For example, the electric machine can comprise a total of three coils. To apply a desired voltage, the windings of the coils can be... [ZF Friedrichshafen AG File 212184 Friedrichshafen 2025-03-11]
[0010] The connection arrangement presented here allows for contact. A desired voltage can be applied to the respective terminal element and transmitted to the corresponding coil via the contact elements of the connection arrangement. All winding outputs of all coils can also be contacted via the star conductor or a star point. The connection device can, for example, serve as an interface between the electric machine, such as an electric motor, and a vehicle's power converter, for example, as a three-phase connection. The vehicle can be a passenger car or a commercial vehicle. The power converter can be an inverter, designed to convert direct current (DC) to alternating current (AC) or vice versa.The connection device can have three terminal elements, each assigned to one of the three phases, as well as contact elements, which can be designed, for example, as contact points. The contact elements can be, for example, plate-like and thus flat and electrically conductive. The windings can each have first and second terminals, which can be electrically connected to the connection device and to the star conductor, respectively. The star conductor can advantageously be rail-shaped and function as the neutral point. It follows that the first terminals of the windings are electrically connected to the contact elements of the connection device, and the second terminals to the star conductor. The stabilizing element is arranged on or around the star conductor in such a way that the auxiliary rail can be at least partially integrated into it.This means that the stabilizing element can advantageously function simultaneously as a support element and an insulating element. This allows vibrations occurring during operation of the electric machine to be dampened, thus preventing the star conductor from slipping or shifting and keeping it in its intended position.
[0011] According to one embodiment, the auxiliary rail can be designed to allow electrical contact with the wiring unit. Advantageously, this allows, depending on the application and function of the electric machine, an electrical connection to be made. ZF Friedrichshafen AG File 212184 Friedrichshafen 2025-03-11
[0012] The connection is made using the auxiliary rails. Additionally or alternatively, the auxiliary rail can be designed as a support element, so that a mechanical connection between the star conductor and the contact element can be established.
[0013] Furthermore, the star conductor can have an additional contact section for arranging an electrically insulating additional stabilizing element of the interconnection device, wherein the additional stabilizing element can at least partially surround the additional contact section, and wherein an additional auxiliary rail is arranged transversely to the star conductor, wherein a first end of the additional auxiliary rail is embedded in the additional stabilizing element, and wherein a second end of the additional auxiliary rail opposite the first end contacts the second contact element in order to connect the star conductor to the interconnection device in a vibration-damping manner. The stabilizing element and the additional stabilizing element can advantageously be of the same shape, provided that the star conductor is of the same shape in the contact section and in the additional contact section.This means that the stabilizing element corresponds to, or at least resembles, a shape of the contact section, since it surrounds the star conductor in the contact section. Accordingly, the shape of the further stabilizing element can be adapted to a shape of the further contact section.
[0014] The interconnection device can have a second auxiliary rail, which can be arranged transversely to the star conductor. A first end of the second auxiliary rail can be embedded in the stabilizing element, and a second end of the second auxiliary rail, opposite the first end, can contact the first contact element to connect the star conductor to the interconnection device in a vibration-damping manner. The second auxiliary rail can advantageously be designed like the first auxiliary rail, differing only in its position. This means that the second auxiliary rail can advantageously be arranged parallel to the first auxiliary rail in the contact section. Furthermore, the first terminals of the windings of the first coil can be arranged between the first auxiliary rail and the second auxiliary rail, thus further improving the stability of the interconnection device.Furthermore, the interconnection device may have a second auxiliary rail, ZF Friedrichshafen AG File 212184 Friedrichshafen 2025-03-11.
[0015] which can be arranged perpendicular to the star conductor. A first end of the second auxiliary rail can also be embedded in the stabilizing element. A second end of the second auxiliary rail, opposite the first end, can further contact the second contact element to connect the star conductor to the wiring device in a vibration-damping manner. Advantageously, the second contact section can therefore have the same structure as the first contact section.
[0016] According to one embodiment, the star conductor can form a bulge to shape the contact section, and the shape of the stabilizing element can depend on the shape of this bulge. This means that the star conductor can, for example, have a bend in the contact section. Advantageously, the stabilizing element can be precisely adapted to this shape.
[0017] The bulge can have two opposing edge regions and a central region arranged between them, the central region being straight. Advantageously, at least one auxiliary rail can be arranged in the central region. The bulge can also be shaped to create a gap to, for example, partial windings, thereby preventing short circuits. The electrically insulating stabilizing element can advantageously be arranged on the bulge and surround the star conductor, thus preventing such short circuits. Additionally, the stabilizing element can be wider in a section located in the central region than in adjacent regions to advantageously accommodate the auxiliary rail.The adjacent areas can still be arranged at the edges of the bulge and adapted to its shape.
[0018] According to one embodiment, the stabilizing element can be made of plastic. Advantageously, the stabilizing element can therefore be molded from a curable plastic so that it can form-fittingly surround the star conductor in the contact section. ZF Friedrichshafen AG File 212184 Friedrichshafen 2025-03-11
[0019] The star conductor and the connection device can still be arranged parallel to each other. Advantageously, the arrangement of the connection device and the star conductor allows for the efficient use of available installation space, for example, above a laminated core of the electric machine.
[0020] According to one embodiment, the star conductor can be configured as a busbar. To improve electrical conductivity, the star conductor can advantageously be made of copper or be constructed from copper.
[0021] Furthermore, an electric machine for a vehicle is presented, wherein the electric machine comprises a plurality of coils, each coil having a winding, as well as a connection device in a previously mentioned variant for electrically contacting the windings. The electric machine can advantageously be designed as an electric motor that can be used in a vehicle. Alternatively, the electric machine can also be used for other applications. Advantageously, the connection device can be configured as an interface to a power converter of the vehicle.
[0022] According to one embodiment, the windings can be formed using partial strands with a hairpin-like geometry. These partial strands can also be referred to as hairpins.
[0023] Furthermore, an electric axle drive for a vehicle with at least one electric machine in a previously mentioned variant, a transmission device and a power converter is presented.
[0024] The axle drive can be designed, for example, as part of a passenger car or as part of a commercial vehicle.
[0025] A vehicle also features an electric motor and an electric axle drive in the aforementioned variants. ZF Friedrichshafen AG File 212184 Friedrichshafen 2025-03-11
[0026] The vehicle can advantageously be designed as a passenger car, for example an electric vehicle. Alternatively, the vehicle can also be designed as a commercial vehicle.
[0027] Furthermore, a method for manufacturing a connection device in a previously mentioned variant is presented, wherein the method comprises a provisioning step in which a connection device is provided which has a first connection element for applying an electrical voltage and a first contact element electrically connected to the first connection element for electrically contacting first terminals of a plurality of windings of a first coil of the electrical machine, a second connection element for applying an electrical voltage and a second contact element electrically connected to the second connection element for electrically contacting first terminals of a plurality of windings of a second coil of the electrical machine.and a third connection element for applying an electrical voltage and a third contact element electrically connected to the third connection element for electrically contacting the first terminals of a plurality of windings of a third coil of the electrical machine. Furthermore, in the provisioning step, a star conductor is provided, configured to electrically connect the second terminals of the plurality of windings of the coils to one another, the star conductor having a contact section, as well as a stabilizing element, and an auxiliary rail with a first end and a second end opposite the first end. The method further comprises a step of arranging and connecting the star conductor to the second terminals of the plurality of windings.as well as a subsequent step of arranging and connecting the interconnection device to the first terminals of the majority of windings, while simultaneously arranging and connecting the second end of the auxiliary rail to the contact element of the interconnection device to contact the contact element in order to connect the star conductor to the interconnection device in a vibration-damping manner and thus to produce the interconnection device. ZF Friedrichshafen AG File 212184 Friedrichshafen 2025-03-11
[0028] The process can advantageously be carried out or controlled using a manufacturing tool to produce the interconnection device. Advantageously, the interconnection device can be implemented as a single component comprising the interconnection mechanism, the current conductor, the stabilizing element, and the auxiliary rail. The interconnection device can advantageously be used as an interface and thus as a three-phase connection between the coils of an electric machine and a power converter. Furthermore, the method presented here simplifies the production of the interconnection device, as fewer process steps are required.
[0029] The invention is explained in more detail with reference to the accompanying drawings. These show:
[0030] Fig. 1 shows a schematic representation of a vehicle according to an exemplary embodiment;
[0031] Fig. 2 shows a schematic representation of an embodiment of an electric machine for a vehicle;
[0032] Fig. 3 shows a schematic representation of an embodiment of a circuit device for an electrical machine;
[0033] Fig. 4 shows a schematic side view of an embodiment of a circuit device for an electrical machine;
[0034] Fig. 5 shows a schematic side view of an embodiment of an electric machine for a vehicle;
[0035] Fig. 6 shows a schematic representation of an embodiment of an electric machine for a vehicle;
[0036] Fig. 7 shows a schematic side view of an embodiment of an electric machine for a vehicle;
[0037] Fig. 8 shows a schematic top view of an embodiment of an electric machine for a vehicle;
[0038] Fig. 9 shows a schematic side view of an embodiment of an electric machine for a vehicle; ZF Friedrichshafen AG File 212184 Friedrichshafen 2025-03-11
[0039] Figs. 10 to 13 show a schematic representation of an embodiment of a star conductor with stabilizing elements;
[0040] Figures 14 to 17 show a schematic representation of an embodiment of a star conductor without stabilizing elements; and
[0041] Fig. 18 shows a flowchart of an exemplary embodiment of a method for manufacturing a circuit device.
[0042] In the following description of preferred embodiments of the present invention, the same or similar reference numerals are used for the elements shown in the various figures and having a similar effect, without repeating these elements.
[0043] Fig. 1 shows a schematic representation of a motor vehicle 100 according to an exemplary embodiment. The motor vehicle 100 is further referred to as vehicle 100 and has an electric axle drive 102, which in turn comprises at least one electric machine 104, a transmission unit 106, and a power converter 108. The electric machine 104 is also referred to, for example, as a drive unit or an electric motor and is coupled, for example, to the transmission unit 106. The vehicle 100 further comprises a power supply unit 110, which is referred to, for example, as a battery. According to this exemplary embodiment, the power converter 108 is connected between the power supply unit 110 and the electric machine 104. The power converter 108 comprises a capacitor 112 and a plurality of switches 114, for example, six in number.Furthermore, according to this embodiment, the power converter 108 has electrical lines 116 which are connected to a connection device 118 of the electric machine 104. The connection device 118 is, for example, implemented as a three-phase connection and provides an electrical connection between the lines 116 and, according to one embodiment, three coils 120, 122, 124 of the electric machine 104.
[0044] Exemplary embodiments of the interconnection device 118 are described in more detail with reference to the following figures. ZF Friedrichshafen AG File 212184 Friedrichshafen 2025-03-11
[0045] Fig. 2 shows a schematic representation of an embodiment of a component of an electric machine 104 for a vehicle, as described, for example, in Fig. 1. The electric machine 104 comprises the component shown, which has an annular laminated core 200 with a plurality of coils. By way of example, the component is configured as the stator of the electric machine 104, and a rotor is rotatably arranged within the laminated core 200. Each of the coils in turn has a plurality of windings 202, 204, 206, which, according to one embodiment, are formed using partial strands 208 with a hairpin-like geometry. These partial strands 208 are also referred to, for example, as hairpins and, when joined together, form the windings 202, 204, 206. For this purpose, legs of the partial strands 208 are guided through grooves in the laminated core 200 and are mounted on the surface shown in Fig.The two circuits shown on the circuit side of the electrical machine 104 are electrically connected to each other in order to form the windings 202, 204, 206 by means of a suitable series connection.
[0046] The electric machine 104 further comprises the connection device 118, which is designed to electrically contact the windings 202, 204, 206. According to this embodiment, the connection device 118 is arranged on the connection side of the electric machine 104, via which the electric machine 104 is connected to, for example, a power converter of the vehicle using the connection device 118. For this purpose, the connection device 118 has a connection assembly 210, which has at least one, and in particular three, connection elements 212, 214, 216 for applying an electrical voltage. The first connection element 212 is electrically conductively connected to a first contact element 218 for electrically contacting the first terminals of a plurality of windings 202 of a first coil of the electric machine 104.Similarly, the second terminal element 214 for applying an electrical voltage is electrically connected to a second contact element 220 for electrically contacting the first terminals of a plurality of windings 204 of the second coil of the electric machine 104, and the third terminal element 216 for applying an electrical voltage is electrically connected to a third contact element 222 for electrically contacting the first terminals of a plurality of windings 206 of the third coil of the electric machine 104. ZF Friedrichshafen AG File 212184 Friedrichshafen 2025-03-11.
[0047] This means that the interconnection device 210 is designed, for example, to apply the electrical voltage to the contact elements 218, 220, 222. The connection elements 212, 214, 216 represent, for example, the three phases of a three-phase connection, as are often used in conjunction with power converters for vehicles. The contact elements 218, 220, 222 are optionally implemented as rail-like parts of the interconnection device 210.
[0048] Furthermore, the connection device 118 has a star conductor 224, which, as the star point, connects the coils of the electric machine 104, more precisely the coil terminals of the windings 202, 204, and 206. The star conductor 224 is, for example, configured as a busbar, such as a copper busbar, which is arranged parallel to and offset from the connection device 210. The star conductor 224, in turn, has at least one contact section 226, on which a stabilizing element 228 is arranged, at least partially surrounding the contact section 226. The stabilizing element 228 is, for example, made of plastic or is formed from plastic and surrounds the star conductor 224 in the contact section 226, so that the star conductor 224 is, for example, electrically insulated.Also in the area of contact section 226, the interconnection device 118 has an auxiliary rail 230, which is arranged transversely to the star conductor 224 and is at least partially embedded in the stabilizing element 228. More precisely, a first end of the auxiliary rail 230 is embedded in the stabilizing element 228. A second end of the auxiliary rail 230, opposite the first end, contacts the first contact element 218 to connect the star conductor 224 to the interconnection device 210 in a vibration-damping manner. The auxiliary rail 230 is described in more detail in at least one of the following figures. The auxiliary rail 230 thus establishes a vibration-damping connection between the stabilizing element 228 and the first contact element 218. Similarly, the interconnection device 118 optionally has a second auxiliary rail 232, which is arranged parallel to the auxiliary rail 230 and also contacts the first contact element 218.Optionally, the auxiliary rails 230 and 232 are designed to electrically contact the switching device 210. ZF Friedrichshafen AG File 212184 Friedrichshafen 2025-03-11.
[0049] Likewise, the star conductor 224 additionally has a further contact section 234, which is shaped like the contact section 226. In the further contact section 234, the connecting device 118 has a further stabilizing element 236 as well as further auxiliary rails 238, 240, which are at least partially embedded in the further stabilizing element 236.
[0050] Thus, the star conductor 224 is not implemented as a separate, exposed component. Integrating the star conductor 224 prevents vibration and stress problems caused by natural modes in the low-frequency range, and consequently, avoids potential displacement of the star conductor 224. The interconnection device 118 described here advantageously reduces high mechanical stresses, for example, at a weld point between the ends of the windings 202, 204, 206 forming the partial strands 208 and the star conductor 224, and also stabilizes the star conductor 224 itself.
[0051] The interconnection device 118 thus provides a contact connection between the star conductor 224 and the interconnection device 210 of the interconnection device 118 for vibration damping using auxiliary rails 230, 232, 238, 240.
[0052] Fig. 3 shows a schematic representation of an embodiment of a switching device 118 for an electric machine. The switching device 118 described here corresponds to the switching device described in Fig. 2 and can therefore also be used for a vehicle, as described, for example, in Fig. 1.
[0053] As in Fig. 2, two identically implemented stabilizing elements 228, 236 are arranged on the star conductor 224, each of which incorporates two auxiliary rails 230, 232, 238, 240. Connections for the windings 202 of the first coil are arranged between the auxiliary rails 230, 232, and connections for the windings 204 of the second coil are arranged between the other auxiliary rails 238, 240. ZF Friedrichshafen AG File 212184 Friedrichshafen 2025-03-11
[0054] Fig. 4 shows a schematic side view of an embodiment of a connection device 118 for an electric machine. This is also a connection device 118 as described, for example, in one of Figures 1 to 3. According to this embodiment, only the first terminals 400, 402, 404 of the plurality of windings 202, 204, 206 and the second terminals 406, 408, 410 of the plurality of windings 202, 204, 206 are visible due to the perspective of the drawing. The first terminals 400, 402, 404 of the majority of windings 202, 204, 206 are connected to the contact elements 218, 220, 222, and the second terminals 400, 402, 404 of the majority of windings 202, 204, 206 are connected to the star conductor 224. The corresponding auxiliary rails 230, 232 are also connected to the first contact element 218, and the auxiliary rails 238, 240 to the second contact element 220.The stabilizing element 228 is arranged between the second terminals 406, 408 of the windings 202, 204 and the further stabilizing element 236 is arranged between the second terminals 408, 410 of the windings 204, 206.
[0055] Fig. 5 shows a schematic side view of an embodiment of an electric machine 104 for a vehicle. The electric machine 104 has a connection device 118, as described, for example, in at least one of Figures 1 to 4. As in Figures 2 to 4, the partial strands 208 of the windings 202, 204, 206, the ends of which form the windings 202, 204, 206, are connected to the star conductor 224 and to the connection device 210. Here, too, the electric machine 104 has the connection device 118 as described in at least one of Figures 1 to 4.
[0056] The connecting device 118 is arranged on a connecting side 500 of the electric machine 104, where the free ends of the partial strands 208 are electrically connected to each other and to the connecting device 118. Legs of the partial strands 208 are guided through grooves in the lamination stack 200 in a plurality of winding layers. On a connecting side 504 of the electric machine 104, connecting sections of the partial strands 208 are guided. ZF Friedrichshafen AG File 212184 Friedrichshafen 2025-03-11
[0057] Fig. 6 shows a schematic representation of an embodiment of an electric machine 104 for a vehicle. The electric machine 104 corresponds in its construction and function to the electric machine described in Fig. 5 and, according to this embodiment, is shown rotated about a longitudinal axis 600. The laminated core 200 of the electric machine 104 carries the coils. Here, too, the electric machine 104 has the connection device 118 as described in at least one of Figures 1 to 5. A rotor of the electric machine 104 is not shown in Fig. 6.
[0058] Fig. 7 shows a schematic side view of an embodiment of an electric machine 104 for a vehicle. The electric machine 104 corresponds in its construction and function to the electric machine described in Fig. 6 and is also shown rotated about its longitudinal axis 600, as in this embodiment. Here too, the electric machine 104 has the connection device 118 as described in at least one of Figures 1 to 6.
[0059] Fig. 8 shows a schematic top view of an embodiment of an electric machine 104 for a vehicle. The electric machine 104 corresponds in its construction and function to the electric machine described in Fig. 7 and is shown from above in this embodiment. Here too, the electric machine 104 has the connection device 118 as described in at least one of Figures 1 to 7.
[0060] In this embodiment, it becomes clear that the shape of the interconnection device 118 is adapted to the circumference of the electric machine 104. The laminated core 200 of the electric machine 104, which supports the coils, represents the thickest point, i.e., the point with the largest outer diameter of the electric machine 104. The interconnection device 118 is arranged on the interconnection side 500 of the electric machine 104 and is adapted to a diameter of the windings. ZF Friedrichshafen AG File 212184 Friedrichshafen 2025-03-11
[0061] adapted, which have a smaller outer diameter than the sheet metal package 200.
[0062] Fig. 9 shows a schematic side view of an embodiment of an electric machine 104 for a vehicle. The electric machine 104 corresponds in its construction and function to the electric machine described in Fig. 6 and, according to this embodiment, is shown from the side, more precisely in a rear view. Here too, the electric machine 104 has the connection device 118 as described in at least one of Figures 1 to 8. Accordingly, the star conductor is arranged on a side of the electric machine 104 facing away from the viewer and is therefore not visible in Fig. 9.
[0063] Figures 10 to 13 each show a schematic representation of an embodiment of a star conductor 224 with stabilizing elements 228, 236, each figure rotated by 90° relative to the previous one. This is a star conductor 224 as described, for example, in at least one of Figures 2 to 8. Furthermore, the star conductor 224 can be used in conjunction with a switching device as described in at least one of Figures 1 to 9.
[0064] Fig. 10 shows a bottom view of the star conductor 224, which has a plurality of straight sections 1000, 1002, 1004. The contact sections 226, 234, in each of which a stabilizing element 228, 236 is arranged, are raised above the adjacent sections 1000, 1002, 1004. These sections 1000, 1002, 1004 also serve, for example, as connection points where the second terminals of the windings contact the star conductor 224.
[0065] As already mentioned, the stabilizing elements 228, 236 surround the contact sections 226, 234 and are adapted to the shape of the star conductor 224. More precisely, according to this embodiment, the star conductor 224 has one protrusion 1006, 1007, and according to this embodiment, two protrusions 1006, 1007, which each ZF Friedrichshafen AG File 212184 Friedrichshafen 2025-03-11
[0066] Form one of the contact sections 226, 234. The shape of the stabilizing elements 228, 236 depends on the shape of the protrusions 1006, 1007. This means that the protrusions 1006, 1007 each have two opposing edge regions 1010, 1012 and a straight central region 1008 arranged between the edge regions 1010, 1012. Similarly, the stabilizing elements 228, 236 are wider in a central region than at their edges, so that the auxiliary rails 230, 232, 238, 240 are at least partially embedded in the stabilizing elements 228, 236, as further illustrated in Fig. 11. The auxiliary rails 230, 232, 238, 240 are distinguished as first auxiliary rail 230, second auxiliary rail 232, further first auxiliary rail 238 and further second auxiliary rail 240, which, however, are implemented in the same way according to this embodiment.
[0067] More precisely, a first end 1100 of the auxiliary rail 228 and a first end 1102 of the second auxiliary rail 232 are embedded in the stabilizing element 228. The corresponding second ends 1104, 1106 are designed to provide vibration-damping contact to the first contact element of the interconnection device. Since the further auxiliary rails 238, 240 are shaped identically to the auxiliary rails 230, 232, this means that their first ends 1108, 1110 are embedded in the further stabilizing element 236. Likewise, their second ends 1112, 1114, opposite the first ends 1108, 1110, are designed to provide vibration-damping contact to the second contact element of the interconnection device. According to this embodiment, all auxiliary rails 230, 232, 238, 240 are slightly S-shaped, meaning bent twice in opposite directions. This allows, for example, contact with the wiring device to be achieved by means of pressure.According to this embodiment, all auxiliary rails 230, 232, 238, 240 are arranged transversely to the star conductor 224, so that its position can be stabilized in the assembled state of the interconnection device.
[0068] Figures 11 and 13 further illustrate that sections 1000, 1002, and 1004 each have at least one through-opening 1116, which can, for example, be implemented as a fastening opening. Furthermore, ZF Friedrichshafen AG file 212184, Friedrichshafen, March 11, 2025.
[0069] Sections 1000, 1002, and 1004 each have angular recesses 1118, which, according to this embodiment, are implemented in a stepped manner. In other words, this means that, according to this embodiment, the star conductor 224 is consistently wider in the contact sections 226 and 234 than in sections 1000, 1002, and 1004.
[0070] Figures 14 to 17 each show a schematic representation of an embodiment of a star conductor 224 without the previously described stabilizing elements. The star conductor 224 is shown rotated by 90° relative to the previous star conductor 224. This is a star conductor 224 as described, for example, in at least one of Figures 2 to 13. Furthermore, the star conductor 224 can be used in conjunction with a switching device as described in at least one of Figures 1 to 9.
[0071] According to this embodiment, the star conductor 224 is designed as a one-piece busbar having two protrusions 1006, 1007 which form the contact sections 226, 234. As in Figures 11 and 13, the star conductor 224 also has the stepped recesses 1118 and the through-openings 1116 in Figures 15 and 17.
[0072] Fig. 18 shows a flowchart of an embodiment of a method 1800 for manufacturing a switching device, as described, for example, in at least one of Figures 1 to 9. The method 1800 comprises a step 1802 of providing, a step 1804 of arranging and connecting the star conductor, and a step 1806 of arranging and connecting the switching device.In step 1802 of the provisioning, a switching device is provided with a first connection element, i.e., for example, with a phase connection, for applying an electrical voltage and a first contact element electrically connected to the first connection element for electrically contacting the first terminals of a plurality of windings of a first coil of the electrical machine, with a second connection element for applying an electrical voltage and a second contact element electrically connected to the second connection element for electrical contacting. ZF Friedrichshafen AG File 212184 Friedrichshafen 2025-03-11.
[0073] The first terminals of a plurality of windings of a second coil of the electric machine are connected, and a third terminal element is provided for applying an electrical voltage. A third contact element, electrically connected to the third terminal element, is also provided for electrically connecting the first terminals of a plurality of windings of a third coil of the electric machine. Furthermore, a star conductor is provided, configured to electrically connect the second terminals of the plurality of windings of the coils to one another. The star conductor has a contact section, and it also includes a stabilizing element and an auxiliary rail with a first end and a second end opposite the first end. In step 1804 of arranging and connecting the star conductor, the star conductor is arranged and connected to the second terminals (406, 408, 410) of the plurality of windings (202, 204, 206).In step 1806 of arranging and connecting the interconnection device, the interconnection device is arranged and connected to the first terminals of the majority of windings, and the second end of the auxiliary rail is arranged and connected to the contact element of the interconnection device in order to connect the star conductor to the interconnection device in a vibration-damping manner and to produce the interconnection device.
[0074] For example, the process is controlled and / or carried out by an automated manufacturing tool or by a control unit of such a manufacturing tool.
[0075] The attachment of the star conductor, also referred to as a star conductor switching element, is achieved without an additional process step during the manufacturing of the switching device, thus simplifying production. In step 1806 of the overmolding process, the star conductor is encapsulated in a plastic material, so that the auxiliary copper rails are embedded in the plastic, i.e., in the stabilizing element. Stabilization of the star conductor is achieved through a material-bonded connection and / or contacting of the switching device with several "blind" copper rails. The contacting process of the switching device with the auxiliary rails is described, for example, in ZF Friedrichshafen AG File 212184, Friedrichshafen, March 11, 2025.
[0076] parallel to the contacting of the circuit with the winding. This eliminates an additional process step. The geometry of the auxiliary rails corresponds to that of a hairpin. The stabilization of the star conductor is achieved by the plastic overmolding itself. ZF Friedrichshafen AG File 212184
[0077] Friedrichshafen 2025-03-11
[0078] BezuQzeichen
[0079] 100 vehicles
[0080] 102 electric axle drive
[0081] 104 electric machine
[0082] 106 Gearbox unit
[0083] 108 power converters
[0084] 110 Power supply unit 112 Capacitor
[0085] 114 Plural of switches
[0086] 116 electrical lines
[0087] 118 Interconnection device
[0088] 120 first coil
[0089] 122 second coil
[0090] 124 third coil
[0091] 200 sheet metal packages
[0092] 202 windings
[0093] 204 windings
[0094] 206 windings
[0095] 208 sub-strands
[0096] 209 Interior
[0097] 210 Interconnection device
[0098] 212 first connection element
[0099] 214 second connection element
[0100] 216 third connection element
[0101] 218 first contact element
[0102] 220 second contact element
[0103] 222 third contact element
[0104] 224 Star conductor
[0105] 226 Contact section
[0106] 228 Stabilizing element
[0107] 230 Auxiliary rail ZF Friedrichshafen AG File 212184
[0108] Friedrichshafen 2025-03-11
[0109] 232 second auxiliary rail
[0110] 234 further contact section
[0111] 236 additional stabilizing element
[0112] 238 additional auxiliary rails
[0113] 240 additional second auxiliary rails
[0114] 400 first connections
[0115] 402 first connections
[0116] 404 first connections
[0117] 406 second connections
[0118] 408 second connections
[0119] 410 second connections
[0120] 500 wiring page
[0121] 504 Connection page
[0122] 600 Longitudinal axis
[0123] Section 1000
[0124] Section 1002
[0125] Section 1004
[0126] 1006 Bulge
[0127] 1007 Bulge
[0128] 1008 Center area
[0129] 1010 Edge area
[0130] 1012 Edge area
[0131] 1100 first end of the auxiliary rail
[0132] 1102 first end of the second auxiliary rail
[0133] 1104 second end of the auxiliary rail
[0134] 1106 second end of the second auxiliary rail
[0135] 1108 first end of the further auxiliary rail
[0136] 1110 first end of the further second auxiliary rail ZF Friedrichshafen AG File 212184 Friedrichshafen 2025-03-11
[0137] 1112 second end of the further auxiliary rail
[0138] 1114 second end of the further second auxiliary rail
[0139] 1116 Passage opening
[0140] 1118 Exclusion
[0141] 1800 Method for manufacturing a wiring device
[0142] 1802 Step of providing
[0143] 1804 Step of arranging and connecting the star conductor
[0144] 1806 Step of arranging and connecting the wiring device
Claims
ZF Friedrichshafen AG File 212184 Friedrichshafen 2025-03-11 Patent claims 1. Interconnection device (118) for an electric machine (104) with a plurality of coils (120, 122, 124) for a vehicle (100), wherein the interconnection device (118) has the following features: a connection device (210) with a first terminal element (212) for applying an electrical voltage and a first contact element (218) electrically connected to the first terminal element (212) for electrically contacting first terminals (400) of a plurality of windings (202) of a first coil (120) of the electric machine (104), with a second terminal element (214) for applying an electrical voltage and a second contact element (220) electrically connected to the second terminal element (214) for electrically contacting first terminals (402) of a plurality of windings (204) of a second coil (122) of the electric machine (104),and with a third terminal element (216) for applying an electrical voltage and a third contact element (222) electrically connected to the third terminal element (216) for electrically contacting first terminals (404) of a plurality of windings (206) of a third coil (124) of the electric machine (104); a star conductor (224) configured to electrically connect second terminals (406, 408, 410) of the plurality of windings (202, 204, 206) of the coils (120, 122, 124) to each other, wherein the star conductor (224) has a contact section (226); an electrically insulating stabilizing element (228) that at least partially surrounds the contact section (226); and an auxiliary rail (230) arranged transversely to the star conductor (224), wherein a first end (1100) of the auxiliary rail (230) is embedded in the stabilizing element (228), and wherein a second end (1104) of the auxiliary rail (230) opposite the first end (1100) contacts the first contact element (218) to to connect the star conductor (224) to the interconnection device (210) in a vibration-damping manner.
2. Interconnection device (118) according to claim 1, wherein the auxiliary rail (230) is designed to electrically contact the interconnection device (210).
3. Interconnection device (118) according to one of the preceding claims, wherein the star conductor (224) has a further contact section (234) for arranging an electrically insulating further stabilizing element (236) of the interconnection device (118), wherein the further stabilizing element (236) at least partially surrounds the further contact section (234), and wherein a further auxiliary rail (238) is arranged transversely to the star conductor (224), wherein a first end (1108) of the further auxiliary rail (238) is embedded in the further stabilizing element (236), and wherein a second end (1112) of the further auxiliary rail (238) opposite the first end (1108) contacts the second contact element (220) in order to connect the star conductor (224) to the interconnection device (210) in a vibration-damping manner.
4. Interconnection device (118) according to one of the preceding claims, with a second auxiliary rail (232) arranged transversely to the star conductor (224), wherein a first end (1102) of the second auxiliary rail (232) is embedded in the stabilizing element (228), and wherein a second end (1106) of the second auxiliary rail (232) opposite the first end (1102) contacts the first contact element (218) to connect the star conductor (224) to the interconnection device (118) in a vibration-damping manner.
5. Interconnection device (118) according to one of the preceding claims, wherein the star conductor (224) forms a protrusion (1006) for forming the contact section (226), wherein a shape of the stabilizing element (228) depends on a shape of the protrusion (1006).
6. Interconnection device (118) according to claim 5, wherein the protrusion (1006) has two opposing edge regions (1010, 1012) and an intermediate ZF Friedrichshafen AG File 212184 Friedrichshafen 2025-03-11 has a central area (1008) arranged between the outer areas (1010, 1012), wherein the central area (1008) is shaped in a straight line.
7. Interconnection device (118) according to one of the preceding claims, wherein the stabilizing element (228) comprises a plastic.
8. Interconnection device (118) according to one of the preceding claims, wherein the star conductor (224) and the interconnection device (210) are arranged parallel to each other.
9. Interconnection device (118) according to one of the preceding claims, wherein the star conductor (224) is configured as a busbar.
10. Electric machine (104) for a vehicle (100), wherein the electric machine (104) has the following features: a plurality of coils (120, 122, 124), each of the coils (120, 122, 124) having a winding (202, 204, 206); and a connecting device (118) according to one of the preceding claims for electrically contacting the windings (202, 204, 206).
11. Electric machine (104) according to claim 10, wherein the windings (202, 204, 206) are formed using partial strands (208) with a hairpin-like geometry.
12. Electric axle drive (102) for a vehicle (100) comprising at least one electric machine (104) according to one of claims 10 to 11, a transmission device (106) and a power converter (108).
13. Vehicle (100) comprising an electric machine (104) according to any one of claims 10 to 11 and an electric axle drive (102) according to claim 12. ZF Friedrichshafen AG File 212184 Friedrichshafen 2025-03-11 14. Method (1800) for manufacturing a circuit device (118) according to any one of claims 1 to 9, wherein the method (1800) comprises the following steps: Providing (1802) a connection device (118) with a first terminal element (212) for applying an electrical voltage and a first contact element (218) electrically connected to the first terminal element (212) for electrically contacting first terminals (400) of a plurality of windings (202) of a first coil (120) of the electric machine (104), with a second terminal element (214) for applying an electrical voltage and a second contact element (220) electrically connected to the second terminal element (214) for electrically contacting first terminals (402) of a plurality of windings (204) of a second coil (122) of the electric machine (104),and with a third terminal element (216) for applying an electrical voltage and a third contact element (222) electrically connected to the third terminal element (216) for electrically contacting first terminals (404) of a plurality of windings (206) of a third, coil (124) of the electric machine (104), providing (1802) a star conductor (224) configured to electrically connect second terminals (406, 408, 410) of the plurality of windings (202, 204, 206) of the coils (120, 122, 124) to each other, wherein the star conductor (224) has a contact section (226), providing (1802) a stabilizing element (228), and providing (1802) an auxiliary rail (230) with a first end (1100) and a second end (1104) opposite the first end (1100); Arranging and connecting (1804) the star conductor (224) to the second terminals (406, 408, 410) of the plurality of windings (202, 204, 206); and Arranging and connecting (1806) the switching device (210) to the first terminals (400, 402, 404) of the plurality of windings (202, 204, 206) and arranging and connecting (1806) the second end (1104) of the auxiliary rail (230) to the contact element (218) for contacting the contact element (218) to the ZF Friedrichshafen AG File 212184 Friedrichshafen 2025-03-11 to connect the star conductor (224) to the interconnection device (210) in a vibration-damping manner and to manufacture the interconnection device (118).