Stator for an electric motor of a motor vehicle

Abstract

The invention relates to a stator (36) for an electric motor (32) of a motor vehicle (2), which has a plurality of electrical coils (42) that are arranged to form a hollow cylindrical structure (46) about an axis (40), and which has a receptacle (54) within which a circuit board (60) is arranged. The invention further relates to an electric motor (32) and to an auxiliary unit (16) for a motor vehicle (2).

Description

[0001] Page 1

[0002] 2024543 WO

[0003] Description

[0004] Stator for an electric motor of a motor vehicle

[0005] The invention relates to a stator for an electric motor of a motor vehicle. The stator comprises several electrical coils arranged around an axis to form a hollow cylindrical structure. The invention further relates to an electric motor and an auxiliary unit for a motor vehicle.

[0006] Motor vehicles, such as passenger cars, have a variety of auxiliary components that do not directly contribute to the vehicle's propulsion. These auxiliary components are necessary, for example, for the operation of the main engine or serve to provide or enhance comfort for the vehicle's occupant. An example of an auxiliary component is an electric actuator, such as an electric window regulator. Alternatively, an auxiliary component could be an electric refrigerant compressor, which is a component of the vehicle's refrigerant circuit.

[0007] In another alternative, the electric motor is a component of the vehicle's braking system. Here, the electric motor is, for example, part of an anti-lock braking system (ABS), traction control (TCS), or an electrically actuated brake force distribution system. It is also possible to use the electric motor in a brake booster. In this case, the electric motor amplifies the applied pedal force. For example, the brake booster is at least partially hydraulic, and the electric motor is used to operate a hydraulic pump and / or actuate any valves.

[0008] Alternatively, the brake booster can be electromechanical. The electromechanical brake booster usually includes an input rod,

[0009] 2024543 WO Page 2, which is moved longitudinally by means of a foot pedal to actuate the brake. The input rod acts on a working piston, which increases the pressure in a brake fluid system. The electric motor acts on the input rod, thus assisting the actuation of the foot pedal. This reduces the force required by the user to actuate the brake. Furthermore, due to the electric motor, the brake booster is independent of actual pedal actuation, and the input rod can be moved independently of the foot pedal, particularly by means of the electric motor, depending on certain driving situations, resulting in deceleration of the vehicle.

[0010] To minimize wear, the electric motor is usually designed as a brushless direct current (BLDC) motor. This type of motor has a rotor containing several permanent magnets, which is fixed to a rotor shaft. The rotor shaft is mounted to rotate around a rotor axis by means of one or more bearings, each bearing being attached to its own end shield. The stator contains several electrical coils, which are connected to form three phases by means of a stator ring mounted on the stator.

[0011] To ensure that the behavior of the electric motor, and consequently its auxiliary components, corresponds to a desired target value, it is necessary to regulate the motor's speed to a specific value. This is typically achieved using a speed sensor, which comprises a component that rotates with the rotor and a stationary component, usually a Hall effect sensor. For simplified assembly, and to pre-process the data provided by the Hall effect sensor and enable its operation, the sensor is usually mounted on a circuit board. This circuit board is typically placed on the mounting ring after the stator has been installed and secured there. This allows the circuit board and stator to be manufactured independently. However, this method increases the overall size of the electric motor.

[0012] 2024543 WO Page 3 The invention is based on the objective of providing a particularly suitable stator for an electric motor of a motor vehicle as well as a particularly suitable electric motor for a motor vehicle as well as a particularly suitable auxiliary unit for a motor vehicle, wherein advantageously a construction space is reduced and / or a manufacturing process is simplified, and wherein robustness is expediently increased.

[0013] With regard to the stator, this problem is solved according to the invention by the features of claim 1, with regard to the electric motor by the features of claim 9, and with regard to the auxiliary unit by the features of claim 10. Advantageous further developments and embodiments are the subject of the respective dependent claims.

[0014] The stator is for an electric motor. Consequently, the stator is particularly suitable, and expediently designed and configured, to form an integral part of the electric motor in its assembled state. The electric motor, in turn, is expediently a component of an auxiliary unit. The electric motor is suitable, and in particular designed and configured, for this purpose. The auxiliary unit is a component of a motor vehicle. In other words, in its intended state, the auxiliary unit is mounted to other components of the motor vehicle. The auxiliary unit is suitable, and in particular designed and configured, for this purpose. The motor vehicle is primarily intended for land use and preferably has multiple tracks. It is expediently possible to position the motor vehicle essentially freely, for example, on a suitable roadway. The motor vehicle is expediently equipped with appropriate wheels for this purpose.In summary, it is preferably possible to position the motor vehicle on land essentially independently of other conditions. In other words, the motor vehicle is preferably not rail-guided. Preferably, the motor vehicle is a passenger car or a commercial vehicle, such as a truck or bus.

[0015] The auxiliary unit, when used as intended, does not directly propel the vehicle and therefore does not constitute a primary drive system.

[0016] Page 4 of 2024543 represents the auxiliary unit of a motor vehicle. For example, the auxiliary unit serves to operate the main drive or to provide functions necessary for the operation of the motor vehicle that do not directly contribute to its propulsion. Alternatively, the auxiliary unit may enhance comfort or provide comfort functions. In another alternative, the electric motor may be a component of the main drive. For example, the main drive of the motor vehicle may be powered by the electric motor.

[0017] The auxiliary unit has, for example, a nominal or maximum power output between 100 W and 1000 W, preferably between 300 W and 700 W, and for example between 400 W and 500 W. The auxiliary unit is, for example, an electric actuator, such as an electric window regulator. Alternatively, the auxiliary unit is, for example, an electric refrigerant compressor, which is particularly a component of a vehicle's refrigerant circuit. Another alternative is an electric pump, such as a water pump. Suitablely, the electric pump is a lubricant pump, such as an engine oil pump or a transmission oil pump. In each case, the electric motor drives a pump impeller that is adapted to the fluid being pumped.In another alternative, the electric motor is a component of a fan, such as a radiator fan or a blower, which thus constitutes the respective auxiliary unit. Alternatively, the auxiliary unit is a power steering system, and the electric motor is used, in particular, to drive a steering rod or at least to adjust or assist the steering angle of steerable wheels of the vehicle.

[0018] In a preferred alternative, the auxiliary unit is a braking system or part of the braking system of the motor vehicle. Here, the electric motor is, for example, a component of an anti-lock braking system, an anti-slip control system, or an electrically actuated brake force distribution system. Particularly preferred is the auxiliary unit a brake booster, wherein, when operated by means of the electric motor, the pedal force applied to a brake pedal by a user, also referred to as a driver, is amplified.

[0019] 2024543 WO page 5 For example, the brake booster is at least partially hydraulically designed, and the electric motor is used in particular to operate a hydraulic pump and / or actuate any valves.

[0020] For example, the brake booster is at least partially hydraulically designed, and the electric motor is used to operate a hydraulic pump and / or actuate any valves. However, it is particularly preferred that the brake booster is electromechanically designed, and the auxiliary unit is thus an electromechanical brake booster. As a result, the design of the auxiliary unit is simplified.

[0021] The electromechanical brake booster advantageously comprises an input rod that is moved longitudinally by means of a foot pedal to actuate the brake. For example, the foot pedal is directly connected to the input rod or via a linkage. At a minimum, however, the foot pedal is operatively connected to the input rod. The input rod acts on a working piston. For example, the working piston is directly attached to the input rod, particularly by integral part. Alternatively, further mechanics are arranged between them. The working piston is particularly located in a pump chamber, which contains brake fluid during operation. When the working piston moves linearly within the pump chamber, the brake fluid is either forced out of or drawn into the pump chamber, depending on the direction of movement.Preferably, any brake pistons of brakes of a motor vehicle braking system are hydraulically connected to the pump chamber, so that when brake fluid is forced out of the pump chamber, the brakes are actuated.

[0022] The input rod is advantageously provided with a circumferential thread onto which an internally toothed drive gear is mounted. The input rod and the drive gear together form a type of spindle. The drive gear is advantageously driven by the electric motor, for example directly or preferably via a gearbox. When the...

[0023] 2024543 WO page 6 The electric motor thus introduces force into the input rod via the drive gear and consequently also onto the working piston.

[0024] Preferably, the electromechanical brake booster includes a sensor that detects when the foot pedal, acting as the brake pedal, is actuated during operation. The electric motor is then energized accordingly. Adequately, the electromechanical brake booster includes a control unit that reads the sensor and adjusts the current flow to the electric motor. In a further development, the control unit energizes the electric motor independently of actual pedal actuation, preferably based on a signal transmitted, in particular via a bus system. This signal is generated, for example, by a vehicle assistance system or an on-board computer. Specifically, the signal is generated based on certain driving situations, such as those of an emergency brake assist system.Alternatively or in combination with this, the vehicle is designed to be partially or fully autonomous, so that movement occurs independently of user control. The command is generated in particular by a so-called autopilot.

[0025] The electric motor comprises a stator with several electrical coils, preferably made of enamelled wire, for example, aluminum or copper enamelled wire. Preferably, two of the electrical coils are formed by means of a common wire and thus connected by a wire segment, so that the respective two electrical coils are electrically connected in series. In particular, the stator has between six and twenty such electrical coils, and suitably twelve electrical coils.

[0026] The electrical coils are arranged around an axis, forming a hollow cylindrical structure. In particular, the electrical coils are equidistant from the axis, and expediently, they are arranged rotationally symmetrically with respect to the axis. The axis is

[0027] 2024543 WO Page 7 preferably the same as the axis of rotation of the electric motor, around which a rotor of the electric motor is rotated, particularly during operation. The coil axes are oriented with respect to the axis, particularly in a radial direction, and expediently intersect at a common point on the axis.

[0028] Advantageously, each of the electrical coils, also simply referred to as a coil, is wound on a corresponding stator tooth. The stator teeth are preferably formed by means of a common laminated core. Each electrical coil forms an electromagnet, or the respective electromagnet also includes at least the corresponding stator tooth.

[0029] The electrical coils are advantageously connected in multiple phases, with each phase being assigned the same number of coils. When one phase is energized during operation, all coils in that phase are energized. In particular, the coils of the same phase are connected in parallel or in series. For example, the stator comprises two such phases, making the electric motor two-phase, or preferably three such phases, making the electric motor three-phase. The phases themselves are connected to each other, for example, in a delta or star configuration. In particular, the electric motor is thus designed as a brushless direct current (BLDC) motor.

[0030] The stator further comprises a printed circuit board (PCB). The PCB expediently has a body, preferably formed by a glass-fiber-reinforced epoxy resin, to which, for example, several conductor tracks are attached and / or in which several such conductor tracks are embedded. The conductor tracks are expediently made of copper. The PCB also expediently comprises several electrical and / or electronic components, such as resistors, capacitors, or integrated circuits. Preferably, one of these components is a Hall sensor. The components are mounted, for example, by surface mounting and / or through-hole mounting on the PCB body.

[0031] 2024543 WO page 8 printed circuit board attached. In particular, an electrical circuit is thus provided by means of the printed circuit board. Advantageously, the printed circuit board is a component of a speed sensor and / or position sensor of the electric motor. In particular, it is possible to determine, and especially to measure, the rotational position of the rotor of the electric motor relative to the stator by means of the printed circuit board.

[0032] The stator further comprises a receptacle within which the printed circuit board (PCB) is arranged. In other words, the PCB is held by the receptacle, so that the PCB is at least partially embedded within it. Specifically, the PCB is fastened to the receptacle, for example, by screws or adhesive. Preferably, the PCB is hot-stitched to the receptacle. This provides a relatively robust fastening that can be achieved within a comparatively short time. Advantageously, the PCB has several openings through which appropriate fastening elements are inserted, such as screws and / or a rivet created during the hot-stitching process.

[0033] The mounting fixture provides a defined position for the printed circuit board (PCB), simplifying assembly. Since the PCB is at least partially supported by the fixture, the required installation space is reduced, particularly the length parallel to the axis. In summary, the fixture partially defines the connection of the PCB to the other stator components, simplifying manufacturing and improving quality. Furthermore, the PCB is at least partially protected during operation, enhancing its robustness. Due to its position within the fixture, the surface area exposed to forces is smaller, thus preventing damage or detachment of the PCB in the event of incorrect assembly.

[0034] For example, the printed circuit board is arranged parallel to the axis or, preferably, tilted to it. Particularly preferably, the printed circuit board is arranged perpendicular to the axis. This makes it possible to arrange the printed circuit board comparatively

[0035] 2024543 WO page 9 to be designed with a large surface area, whereby the installation space in the radial direction is not increased, provided the hollow cylinder structure has a sufficiently large diameter. Furthermore, this improves the functionality of any Hall sensor on the circuit board and simplifies the measurement of the rotor's speed / position using the circuit board.

[0036] The receptacle is particularly preferably ring-shaped, with the receptacle being guided around the axis. For example, the printed circuit board (PCB) is also ring-shaped. At the very least, the PCB suitably extends around the axis. Due to the ring shape of the receptacle and the PCB, the advantages of the hollow cylinder structure are not negated, and in particular, it is possible to arrange further components of the electric motor along the axis, especially the rotor, for example, a rotor shaft. These are not obstructed by the receptacle and the PCB, and, for example, no extensive modification of an existing design is required. The receptacle particularly preferably includes an outwardly projecting recess, which thus extends radially. A corresponding projection of the PCB suitably lies within the recess.This means, for example, that it is essentially Q-shaped. Due to the projection and the deflection, the circuit board can only be positioned in a single location within the holder. This prevents rotation and simplifies assembly.

[0037] For example, the mounting is closed at the end. This prevents the printed circuit board from unintentionally detaching during stator manufacturing and operation. However, it is particularly preferred that the mounting is open at the end. Suitablely, the printed circuit board thus forms at least part of the stator's end face, i.e., its end parallel to the axis. This allows the printed circuit board to be subsequently mounted to the other stator components, for example, after the stator has already been positioned in a housing of the electric motor. It is also possible in this way to prefabricate the stator, with the exception of the printed circuit board, and then attach the printed circuit board to complete the stator. This makes it possible to...

[0038] 2024543 WOPage 10 different work steps and / or from different manufacturers, which facilitates production.

[0039] Advantageously, the mounting is pot-shaped and has a base. The printed circuit board (PCB) is mounted on the base. Specifically, the base and the PCB are arranged parallel to each other. For example, the PCB rests fully against the base, which increases stability. Alternatively, the PCB is supported on the base by spacers, such as domes. This allows air circulation around the PCB, improving heat dissipation. Advantageously, the base is perpendicular to the axis, and preferably, the PCB is also perpendicular to the axis. This simplifies PCB mounting and enables comparatively efficient use of the available installation space.

[0040] For example, the mounting is only partially enclosed on its circumference. However, it is particularly preferred that the printed circuit board (PCB) is completely surrounded on its radial outer edge, specifically by the mounting and consequently by the stator component that provides the mounting. The radial outer edge is, in particular, the edge of the PCB that is furthest from the axis. This mounting design provides comparatively strong stabilization of the PCB, thus increasing its robustness. Furthermore, this design offsets the PCB from one end of the stator parallel to the axis, thereby protecting it. In addition, this design does not increase, or only slightly increases, the overall length of the stator parallel to the axis.

[0041] A laminated core is particularly preferred, which is assigned to the electrical coils. Here, the laminated core is, for example, formed as a single continuous piece, and each electrical coil is specifically assigned a layer of the laminated core. Thus, the individual electrical coils are stabilized by means of the laminated core, which facilitates the formation of the hollow cylinder structure. Alternatively, each electrical coil is assigned a portion of the laminated core, and the stator is provided by means of individual tooth windings.

[0042] 2024543 WO page 11 The sheet metal package is then expediently created by joining the individual teeth together.

[0043] For example, the mounting is provided by means of the laminated core. However, the stator preferably includes a cover that covers the end face of the laminated core. Preferably, the cover is annular and, in particular, arranged concentrically to the axis. Advantageously, the cover is at least partially made of plastic. In particular, the laminated core is thus concealed at one end parallel to the axis by means of the cover. The cover protects the laminated core from damage and thus increases its robustness. The mounting is particularly preferably integrated into the cover. This eliminates the need to modify an existing laminated core, and / or the tools already used to manufacture the laminated core can be reused.This method also makes it possible to design the mounting for different circuit boards, requiring only the appropriate adjustment of the cover.

[0044] For example, the cover serves only to increase mechanical robustness and provide a mounting surface. More preferably, however, the cover forms a wiring unit, in particular a wiring ring, which is expediently arranged perpendicular to and around the axis. The wiring unit connects the electrical coils to each other. Preferably, the wiring unit connects the electrical coils to the respective phases and / or the phases to the delta or star connection.

[0045] The wiring unit expediently comprises several conductors, which are stabilized and / or electrically insulated from each other, particularly by means of a plastic cover. The conductors are, for example, overmolded with the plastic cover or held in place by appropriate retaining structures. The conductors are provided, for example, by means of stamped and bent parts and / or wires. In particular, the conductors run at least partially in an arc around the axis.

[0046] 2024543 WO page 12

[0047] In summary, the cover performs two functions: firstly, it facilitates the interconnection of the electrical coils, and secondly, it holds the circuit board and defines its mounting position. This effectively repurposes an existing component to provide the mounting space, thus reducing the number of required parts. Furthermore, this approach allows for the efficient utilization of previously unused space, ensuring that the overall size remains unchanged.

[0048] The wiring unit, for example, has a number of sockets, each containing a contact element. This element serves to electrically connect at least some of the conductors and an electronic circuit that energizes the electrical coils during operation.

[0049] The electric motor is suitable, expediently designed, and configured for use in a motor vehicle. The motor vehicle is, in particular, a passenger car. The electric motor comprises a stator with several electrical coils arranged around an axis in a hollow cylindrical structure. The stator also has a housing within which a circuit board is mounted. The electric motor further comprises a rotor rotatably mounted parallel to the axis within the hollow cylindrical structure. Specifically, the rotor is arranged along the axis and concentrically to it. Expediently, the rotor is circumferentially surrounded by the stator, and the electric motor is designed as an internal rotor motor.

[0050] Preferably, the rotor is rotatably arranged about the axis, and the axis corresponds in particular to a rotational axis of the electric motor. For example, the rotor comprises a laminated core in which permanent magnets are embedded or to which they are attached. The rotor is suitably rotatably mounted by means of one or more bearings, wherein at least one of the bearings is expediently connected to a bearing shield of the electric motor. If the other bearing is present, it is preferably associated with another bearing shield.

[0051] 2024543 WO page 13, for example, is formed by means of a (motor) housing of the electric motor. For example, the electric motor is a component of a main drive of the motor vehicle, which is thus designed as an electric vehicle or hybrid vehicle. Particularly preferably, however, the electric motor is a component of an auxiliary unit of the motor vehicle.

[0052] The auxiliary unit is suitable for, and in particular designed and equipped for, a motor vehicle. In its installed state, the auxiliary unit is thus expediently a component of the motor vehicle, which is, for example, a commercial vehicle such as a bus or a truck. Particularly preferably, the auxiliary unit in its installed state is a component of a passenger car. The auxiliary unit does not directly propel the motor vehicle, but rather, for example, operates a main drive system, provides comfort functions, and / or adjusts the direction of travel of the motor vehicle. Particularly preferably, the auxiliary unit is a brake booster, which is particularly preferably electromechanically designed. In this case, when the electric motor is operated, the brake booster increases the pressure in a brake fluid system.The brake fluid system comprises, in particular, a pump chamber of the electromechanical brake booster, suitably a compensation chamber, and preferably several brake pistons, wherein, in particular, at least one brake piston is assigned to each wheel of the motor vehicle. Suitably, several brake pistons are assigned to each wheel, which are, in particular, arranged on a brake caliper or a brake caliper.

[0053] The auxiliary unit at least includes an electric motor with a stator and a rotor. The stator comprises several electrical coils arranged around an axis in a hollow cylindrical structure. The stator also has a housing within which a circuit board is located. The electric motor further includes a rotor that is rotatably mounted parallel to the axis within the hollow cylindrical structure.

[0054] 2024543 WO Page 14 Furthermore, the invention relates to a motor vehicle with such an auxiliary unit.

[0055] The further developments and advantages explained in connection with the stator can also be applied analogously to the electric motor / the auxiliary unit / the motor vehicle and to each other and vice versa.

[0056] An embodiment of the invention is explained in more detail below with reference to a drawing. The drawing shows:

[0057] Fig. 1 schematically shows a motor vehicle with an auxiliary unit designed as an electromechanical brake booster,

[0058] Fig. 2 schematically shows in a sectional view the auxiliary unit, which has an electric motor with a stator, and

[0059] Fig. 3 shows the stator in perspective.

[0060] Corresponding parts are marked with the same reference symbols in all figures.

[0061] Figure 1 shows a simplified schematic representation of a motor vehicle 2 in the form of a passenger car. The motor vehicle 2 has several wheels 4, which make contact with a road surface (not shown). Some of the wheels 4 are driven by a main drive (not shown). For braking, the motor vehicle 2 has several brakes 6, of which only one is shown. Each brake 6 comprises a brake disc 8, which is non-rotatably connected to the respective wheel 4. A brake caliper 10 of the brake 6, which has several brake pistons (not shown), is fixed to the vehicle body.

[0062] The brake pistons are a component of a brake fluid system 12, which includes a reservoir 14 that is fluidly coupled to the brake pistons. Furthermore, an auxiliary unit 16 in the form of an electromechanical brake booster is coupled to the reservoir 14. This is connected by means of

[0063] Page 15 of 2024543 WO is actuated by a foot pedal 18, namely a brake pedal. The brake fluid system 12 is filled with brake fluid, and when the foot pedal 18 is actuated, the pressure in the brake fluid system 12 is increased by means of the electrical auxiliary unit 16, i.e., the electromechanical brake booster, so that the brake pistons are actuated via the reservoir 14. As a result, brake pads attached to the brake caliper 10 are pressed against the associated brake disc 8, so that the motor vehicle 2 is braked.

[0064] Figure 2 shows a sectional view along a longitudinal axis 19 of the auxiliary unit 16, i.e., the electromechanical brake booster. This unit has a pump chamber 20, within which a working piston 22 is arranged and guided along the longitudinal axis 19 by the side wall of the pump chamber 20. The working piston 22 extends to the inner walls of the pump chamber 20, thus dividing it into two parts. One of the parts is fluidically connected to the reservoir 14 via an outlet (not shown) and is completely filled with brake fluid. Moving the working piston 22 within the pump chamber 20 therefore changes the amount of brake fluid contained therein.

[0065] The working piston 22 is attached via a connecting rod 24, which is arranged parallel to the longitudinal axis 19, to an input rod 26, which also extends along the longitudinal axis 19 and is slidably mounted along the longitudinal axis 19 by means of a bearing (not shown). The input rod 26 is mounted in a rotationally fixed manner, thus preventing rotation of the input rod 26. At the end opposite the connecting rod 24, the input rod 26 is supported on the foot pedal 18 by means of a mechanism.

[0066] When the foot pedal 18 is actuated, the input rod 26 and consequently also the connecting rod 24 are moved along the longitudinal axis 19, so that the working piston 22 is also moved. As a result, the brake fluid is forced out of the pump chamber 20. Furthermore, the auxiliary unit 16 has a non-

[0067] 2024543 WOPage 16 shows a spring which acts on the input rod 26 and therefore also on the connecting rod 24 and consequently also on the working piston 22. Due to the spring force, when the foot pedal 18 is not actuated, the working piston 22 is moved as far as possible out of the pump chamber 20, so that the volume of brake fluid taken up by the pump chamber 20 is maximized.

[0068] The input rod 26 has external teeth, and a drive gear 28, which in turn has internal teeth, is mounted on it. The input rod 26 and the drive gear 28 are thus designed in the manner of a spindle. Additionally, the drive gear 28 has external teeth and engages with a gearbox 30. The gearbox 30 is driven by an electric motor 32, which comprises a motor housing 34 containing a hollow cylindrical stator 36. A hollow cylindrical rotor 38 is arranged concentrically to an axis 40 within the stator 36. The rotor 38 is rotatably mounted about the axis 40 by means of bearings (not shown) attached to the motor housing 34.

[0069] The rotor 38 comprises a laminated core (not shown) to which permanent magnets (also not shown) are attached. These magnets interact with electromagnets of the stator 36 during operation, causing the rotor 38 to rotate about the rotor axis 40. Consequently, the electric motor 32 is designed as a brushless direct current (BLDC) motor. A gear 48 is fixed to the end of the rotor 38 and engages with the gearbox 30. This transmits power from the electric motor 32 to the gearbox 30. Thus, the gearbox 30, or at least the working piston 22 driven by it, forms an actuator driven by the electric motor 32.

[0070] The electromagnets of the stator 36, shown in perspective in Figure 3, are provided by several electrical coils 42 wound on a common laminated core 44. The laminated core 44 has several teeth extending radially with respect to the axis 40, and one of the electrical coils 42 is wound on each of these teeth. Thus, the electrical coils 42 are provided with the

[0071] 2024543 WO page 17 lamination stack 44 assigned. Due to the radially extending teeth, the electrical coils 42 are arranged around the axis 40 to form a hollow cylinder structure 46, with the lamination stack 44 also being assigned to the hollow cylinder structure 46.

[0072] On one of the end faces of the hollow cylindrical structure 46, the sheet metal stack 44 is covered by a cover 48. On the opposite side, there is another cover, made entirely of plastic, which is not shown in detail. The cover 48 has a plastic body 50 in which several electrical conductors 52 are embedded. By means of the conductors 52, the electrical coils 42 are connected to each other to form several electrical phases, namely 3 electrical phases. The electrical phases, in turn, are electrically connected to each other in a delta or star connection. Thus, the cover 48 forms a connection unit, namely a connection ring, by means of which the electrical coils 42 are electrically connected to each other.The conductors 52, each assigned to a different electrical phase, are led to a socket 53 located on the side of the cover 48 opposite the sheet metal assembly 44. In the assembled state, electronics (not shown) are connected there, which supply current to the electrical coils 42.

[0073] On the side facing away from the sheet metal package 44, the cover 48, namely the plastic body 50, has an essentially ring-shaped receptacle 54.

[0074] This runs along the radial inner side of the connecting ring and thus extends to the radial inner end of the cover 48. However, with respect to the pure ring shape, a notch 56 is provided for a circular arc. Thus, the receptacle 54 is ring-shaped with the radially outwardly projecting notch 56.

[0075] The receptacle 54 is essentially cup-shaped and thus has a circumferential rim at its radially outer end, running parallel to the axis 40 and terminating at its end in a base 58 arranged perpendicular to the axis 40. The conductors 52 are arranged radially with respect to the receptacle 54.

[0076] 2024543 WOPage 18 offset on the outside, however, these overlap at least partially parallel to axis 40.

[0077] Within the recess 54, a printed circuit board 60 is arranged, positioned perpendicular to the axis 40 on the base 58, with an air gap formed between the printed circuit board 60 and the base 58. The printed circuit board 60 is essentially ring-shaped and extends around the axis 40. It has a central, round opening through which the axis 40 passes. The printed circuit board 60 also has a projection 62 that fits into the recess 56 and extends radially outwards. Due to the plastic body 50, damage to the conductors 52 or the electrical coils 42 is prevented.

[0078] The thickness of the printed circuit board 60 is less than the length of the edge of the mounting 54 in the axial direction, which is parallel to the axis 40. The thickness of the air gap formed between the base 58 and the printed circuit board 60 is also comparatively small, so that the printed circuit board 60 is completely surrounded on its radial outer surface by the plastic body 50. Since the conductors 52 are located essentially at the same height in the axial direction, which is parallel to the axis 40, the overall length of the stator 36 in the axial direction is not increased despite the presence of the printed circuit board 60, and a previously unused installation space is used for positioning the printed circuit board 60.

[0079] The receptacle 54 is open on the side opposite the lamination stack 44. In other words, the receptacle 54 is open at its end face, i.e., on the side opposite the base 58. Consequently, the circuit board 56 can be installed in the receptacle 54 after the cover 48 has been attached to the lamination stack 44 and the coils 42 have been electrically connected. It is also possible to install the circuit board 60 only after the other components of the stator 36 have already been installed in the motor housing 54.

[0080] 2024543 WO Page 19 In the illustrated example, a position sensor or speed sensor is provided by means of the circuit board 60, by means of which the current position of the rotor 38, in particular its rotational or angular position, about the axis 40 with respect to the stator 34 can be measured. This data is then transmitted to the electronics. Depending on this, the phases formed by the electrical coils 42 are selected and energized so that the rotor 38 rotates at a desired speed and / or torque.

[0081] The invention is not limited to the embodiment described above. Rather, other variants of the invention can also be derived by a person skilled in the art without departing from the subject matter of the invention. In particular, all individual features described in connection with the embodiment can also be combined with one another in other ways without departing from the subject matter of the invention.

[0082] 2024543 WO page 20

[0083] Reference symbol list

[0084] 2 motor vehicles

[0085] 4-wheeler

[0086] 6 Brake

[0087] 8 brake disc

[0088] 10 brake calipers

[0089] 12 Brake fluid system 14 Expansion tank

[0090] 16 Auxiliary unit

[0091] 18 Foot pedal

[0092] 19 Longitudinal axis

[0093] 20 Pump room

[0094] 22 working pistons

[0095] 24 Connecting rod 26 Entrance rod

[0096] 28 Drive gear

[0097] 30 gearboxes

[0098] 32 Electric motor

[0099] 34 Engine housing

[0100] 36 Stator

[0101] 38 Rotor

[0102] 40 axle

[0103] 42 electrical coil

[0104] 44 sheet metal package

[0105] 46 Hollow cylinder structure 48 Cover

[0106] 50 plastic bodies

[0107] 52 ladders

[0108] 53 slip pockets

[0109] 54th entry

[0110] 56 Disconnection

[0111] 58 Floor

[0112] 2024543 WO page 21

[0113] 60 Circuit board 62 Protrusion

[0114] 2024543 WO

Claims

Page 22 Claims 1. Stator (36) for an electric motor (32) of a motor vehicle (2), which has several electrical coils (42) arranged around an axis (40) to form a hollow cylindrical structure (46), and which has a receptacle (54) within which a circuit board (60) is arranged.

2. Stator (36) according to claim 1 , characterized by that the circuit board (60) is arranged perpendicular to the axis (40).

3. Stator (36) according to claim 2, characterized by that the receptacle (54) is ring-shaped with a radially outwardly projecting notch (56), wherein the circuit board (60) runs around the axis (40) and has a projection (62) located in the notch (56).

4. Stator (36) according to one of claims 1 to 3, characterized by that the opening (54) is open at one end.

5. Stator (36) according to one of claims 1 to 4, characterized by that the receptacle (54) is pot-shaped with a bottom (58) that is perpendicular to the axis (40) and on which the circuit board (60) is arranged.

6. Stator (36) according to any one of claims 1 to 5, characterized by that the circuit board (60) is circumferentially surrounded on a radial outer side. 2024543 WO page 23 7. Stator (36) according to one of claims 1 to 6, characterized by that the electrical coils (42) are associated with a laminated core (44) which is covered at the end face by a cover (48) into which the receptacle (54) is inserted.

8. Stator (36) according to claim 7, characterized by that the cover (48) forms a circuit unit by means of which the electrical coils (42) are electrically contacted with each other.

9. Electric motor (32) for a motor vehicle (2), comprising a stator (36) according to one of claims 1 to 8, and a rotor (38) rotatably mounted parallel to the axis (40) within the hollow cylinder structure (46).

10. Auxiliary unit (16) for a motor vehicle (2), comprising an actuator driven by an electric motor (32) according to claim 9. 2024543 WO

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