WO2024256547A1 - Dispositif de mise en contact pour un stator de moteur électrique - Google Patents

Dispositif de mise en contact pour un stator de moteur électrique Download PDF

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Publication number
WO2024256547A1
WO2024256547A1 PCT/EP2024/066379 EP2024066379W WO2024256547A1 WO 2024256547 A1 WO2024256547 A1 WO 2024256547A1 EP 2024066379 W EP2024066379 W EP 2024066379W WO 2024256547 A1 WO2024256547 A1 WO 2024256547A1
Authority
WO
WIPO (PCT)
Prior art keywords
stator
contact
crimp
coil end
coil
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/EP2024/066379
Other languages
German (de)
English (en)
Inventor
Kartik Sawarkar
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Brose Fahrzeugteile SE and Co KG
Original Assignee
Brose Fahrzeugteile SE and Co KG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Brose Fahrzeugteile SE and Co KG filed Critical Brose Fahrzeugteile SE and Co KG
Publication of WO2024256547A1 publication Critical patent/WO2024256547A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/46—Fastening of windings on the stator or rotor structure
    • H02K3/52—Fastening salient pole windings or connections thereto
    • H02K3/521—Fastening salient pole windings or connections thereto applicable to stators only
    • H02K3/522—Fastening salient pole windings or connections thereto applicable to stators only for generally annular cores with salient poles
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
    • H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
    • H01R4/183—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping for cylindrical elongated bodies, e.g. cables having circular cross-section
    • H01R4/184—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping for cylindrical elongated bodies, e.g. cables having circular cross-section comprising a U-shaped wire-receiving portion
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/04—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for forming connections by deformation, e.g. crimping tool
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/30—Manufacture of winding connections
    • H02K15/33—Connecting winding sections; Forming leads; Connecting leads to terminals
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K2203/00—Specific aspects not provided for in the other groups of this subclass relating to the windings
    • H02K2203/09—Machines characterised by wiring elements other than wires, e.g. bus rings, for connecting the winding terminations

Definitions

  • the invention relates to a contact device for a stator of an electric motor, having a connection ring that is placed or can be placed on the front of a stator package, and a number of busbars for connecting coil ends of a stator winding to a number of phase connections, wherein at least one busbar has an axially directed contact lug.
  • the invention further relates to a stator, a method for producing a stator, and an electric motor.
  • a brushless electric motor in particular as an electric three-phase machine usually has a stator with a number of stator teeth, for example arranged in a star shape, which carry an electric rotating field or stator winding in the form of individual coils, which in turn are wound from an insulating wire.
  • the coils are assigned to individual strands or phases with their coil ends (winding wire ends) and are connected to one another in a predetermined manner and led to phase connections for energizing the rotating field winding.
  • phase winding The phases of a three-phase current feeding the rotating field winding and the associated rotating field are referred to as (motor) phases.
  • this also includes the stator coils (phase winding) assigned to each such phase with the associated connecting cables (phase end).
  • the stator has three phases and thus at least three phase conductors or phase windings, each of which is supplied with electrical current in a phase-shifted manner in order to generate a magnetic rotating field in which a rotor or runner, usually provided with permanent magnets, rotates.
  • the phase ends of the phase windings are led to motor electronics to control the electric motor.
  • the coils of the rotating field winding are connected in a star connection or in a delta connection and electrically contacted with the three phase connections.
  • contact devices in the form of interconnection systems or switching units are common, which are placed on the front of the stator or a stator package. Such contact devices are used in particular to electrically connect the coil ends of the winding wire sections forming the coil windings, so that individual coil ends are electrically short-circuited with one another, and thus the coil or phase windings can be supplied with current in series.
  • Such contact devices often have a number of integrated or molded conductor tracks or busbars as connecting conductors for connecting or contacting the coil ends.
  • the coil ends When assembling the electric motor or stator, the coil ends are contacted with the busbars, so that coil windings assigned to a common phase are short-circuited with one another via the contact device.
  • the contacting of the coil ends with the busbars is usually carried out by means of a material connection, for example by means of soldering or welding.
  • Page 3 A "material bond” or a “material bond” between at least two interconnected parts is understood here and below in particular to mean that the interconnected parts are held together at their contact surfaces by material union or cross-linking (for example due to atomic or molecular bonding forces), possibly with the effect of an additive.
  • brazing is conventionally used, which is relatively insensitive to positional tolerances or wire misalignment of the coil ends, since an electrode presses a coil end to be soldered against a contact or welding lug of the busbar, thereby creating a brazed connection.
  • additional soldering materials such as Silfos
  • Silfos are cost-intensive and require an additional process in the manufacture of the stator.
  • Other joining techniques such as laser welding, are comparatively sensitive to positional and positioning tolerances.
  • Such connection methods therefore require a relatively high degree of positioning accuracy when positioning the coil end on the busbar.
  • a direct (point) contact of the insulated coil end on the busbar is necessary.
  • the invention is based on the object of specifying a particularly suitable contact device for a stator. In particular, simple and reliable contacting of the coil ends is to be achieved. The invention is also based on the object of specifying a particularly suitable stator and a particularly suitable method as well as a particularly suitable electric motor. Page 4
  • the contact device according to the invention is intended for a stator of an electric motor and is suitable and designed for this purpose.
  • the contact device has a connection ring that is placed or can be placed on the front of a stator package, by means of which the coil or winding ends of a wound stator package are connected to form a multi-phase stator winding.
  • the connection ring has a number of busbars for connecting coil ends of the stator winding to a number of phase connections.
  • the phase connections form the interface to a motor electronics or a motor control unit, via which a three-phase current is fed in during motor operation.
  • the busbars which are designed in particular as stamped and bent parts, are embedded or integrated in the connection ring, for example.
  • the busbars are preferably molded as an insert with the connection ring designed as an injection-molded part, with the busbars being exposed at least in sections in the contact area with the coil ends.
  • the contact areas of the busbars with the coil ends are each designed as an axially directed contact lug, according to the invention each having a crimp contour for non-adhesive electrical (crimp) contact with the respective associated coil end.
  • the coil ends are therefore not welded or soldered to the contact lugs in a material-locking manner, but are crimped in a form-fitting and/or force-fitting manner without a material-locking connection. This creates a particularly suitable contact device.
  • axial or an “axial direction” is understood here and in the following to mean a direction parallel (coaxial) to the axis of rotation of the electric motor, i.e. perpendicular to the front sides of the stator. Accordingly, here and in the Page 5
  • radial or a “radial direction” is understood to mean in particular a direction oriented perpendicular (transversely) to the axis of rotation of the electric motor along a radius of the stator or the electric motor.
  • Tangential or a “tangential direction” is understood here and in the following to mean in particular a direction along the circumference of the stator or the electric motor (circumferential direction, azimuthal direction), i.e. a direction perpendicular to the axial direction and the radial direction.
  • the conjunction “and/or” is to be understood here and in the following in such a way that the features linked by means of this conjunction can be designed both together and as alternatives to one another.
  • a “positive connection” or a “positive connection” between at least two interconnected parts is understood here and in the following in particular to mean that the interconnected parts are held together at least in one direction by a direct interlocking of contours of the parts themselves or by an indirect interlocking via an additional connecting part.
  • a “force connection” or a “force-locking connection” between at least two interconnected parts is understood here and below in particular to mean that the interconnected parts are prevented from sliding off one another due to a frictional force acting between them. If there is no “connecting force” causing this frictional force (this means the force that presses the parts against one another, for example a screw force or the weight itself), the force-locking connection cannot be maintained and can therefore be released.
  • the contact lug has an axial crimp slot, which divides the contact lug into two crimp legs in sections.
  • the crimp slot serves as a contact or clamping slot for the coil end to be contacted, which is used for the crimp contact with the Page 6 Crimp leg is crimped. This allows for a structurally simple crimp contact using the contact lug.
  • the crimp slot opens into a wire holder, which has a wider diameter than the crimp slot.
  • the wire holder is adapted to the outer circumference of the coil end to be contacted. With a coil end designed as a round wire, the wire holder is designed as a circular through-opening of the contact lug.
  • the stator according to the invention is intended for an electric motor and is suitable and designed for this purpose.
  • the stator has a stator package, designed for example as a punched laminated core, with a number of radial stator teeth, each of which is wound or equipped with a coil.
  • the coils each have two axially oriented coil ends.
  • a contact device described above for contacting and connecting the coils or coil ends to a multi-phase rotating field or stator winding is placed axially on the front side of the stator package.
  • the contact device or its connection ring has a number of axial through-openings corresponding to the number of coil ends, through which the coil ends to be connected are guided to a respective contact lug.
  • the coil ends are crimped or crimp-contacted using the crimp contours of the contact lugs. This creates a particularly suitable stator which can be manufactured particularly cost-effectively.
  • the or each coil end to be contacted is bent radially for the crimp contact.
  • the Page 7 The coil end is pivoted during bending in such a way that the coil end is pressed into the wire receptacle through the axial crimp slot.
  • the coil end is suitably inserted axially in the wire receptacle of the contact lug with a positive fit.
  • two crimp legs of the contact lug are pressed radially and/or tangentially onto the coil end for the crimp contact.
  • the information radial and/or tangential refers in particular to a longitudinal direction of the approximately cylindrical coil end.
  • the crimp legs are pressed from the outside onto the outer circumference of the coil end. This ensures reliable and operationally safe contacting of the coil end.
  • the method according to the invention is intended for producing a stator as described above and is suitable and designed for this purpose.
  • a stator package, a number of coils or coil wires and a contact device as described above are provided here.
  • a number of radial stator teeth of the stator package are fitted or wound with coils, the coil ends of the coils being aligned in an axially oriented manner.
  • the contact device is then placed on the front of the stator package in such a way that at least one coil end is guided through a through-opening of the connection ring to a contact lug, and the coil end is crimp-contacted to the contact lug. This creates a particularly suitable method for producing a stator.
  • the coil ends of the stator to be contacted are axially oriented, the connection ring having axial through-openings for the coil ends, which are arranged adjacent to the contact lugs. When placed on, the coil ends are thus oriented essentially parallel to the contact lugs.
  • the coil ends are preferably bent approximately radially and pressed axially in a form-fitting manner into a wire holder through a crimping slot in the contact lug, two crimping legs of the contact lug being crimped from the outside to the Page 8 the respective coil end is pressed (on). This enables reliable and structurally simple contacting of the coil ends.
  • the electric motor according to the invention is intended for a motor vehicle and is suitable and designed for this purpose.
  • Fig. 1 shows a schematic and simplified representation of an electric motor of a motor vehicle
  • Fig. 2 shows a contact device of a stator in perspective
  • Fig. 3 shows the stator and the contact device in perspective exploded view
  • Fig. 4 shows a contact lug of the contact device in perspective
  • Fig. 5 shows the contact lug with a contacted coil end in perspective
  • Fig. 6 shows a crimp contact of the coil end in perspective.
  • Parts and sizes that correspond to one another are always provided with the same reference numerals in all figures.
  • Fig. 1 shows a schematic and highly simplified representation of an electric motor 2 of a motor vehicle.
  • the electric motor 2 has a stator 4 with a multi-phase rotating field or stator winding 6, which is connected to a motor electronics 12 for energization by means of phase connections (phase contacts) 8 of a contact device 10 (Fig. 2, Fig. 3).
  • the rotating field winding 6 When energized, the rotating field winding 6 generates a magnetic rotating field, which drives a rotor of the electric motor 2 (not shown in detail).
  • the stator winding 6 is designed in particular as three-phase with three (motor) phases U, V, W.
  • Each phase U, V, W is Page 9 is formed from a phase winding which is essentially formed by connecting at least one coil of the stator winding.
  • phases U, V and W are connected to one another in a delta connection.
  • Fig. 2 shows a perspective view of the contact device (switching unit) 10 for the stator 4.
  • Fig. 3 shows the stator 4 and the contact device 10 in a partially disassembled state.
  • the contact device 10 is placed on the front side of the stator 4 or on a stator package 14 in the assembled state.
  • the stator package 14 of the stator 4 comprises, for example, twelve inwardly directed stator teeth onto which the stator or rotating field winding 6 of the electric motor 2 is applied.
  • the coil windings are wound in particular as (individual) coils 16, for example on insulating winding supports or coil supports 18, and are placed with these on the stator teeth of the stator package.
  • Each of the frame-like winding supports carries a coil 16 as part of the stator winding 6.
  • the coils 16 each have two approximately axially directed coil ends 20.
  • the coils 16, coil supports 18, and coil ends 20 are provided with reference numerals in the figures merely as examples.
  • the coil ends 20 of the (individual) coils 16 are connected to the stator winding 6, which is 3-phase in this embodiment, by means of the contact device 10 placed on the front of the stator 4.
  • the contact device 10 In electromotive operation, the energized windings of the stator winding 6 generate a stator-side magnetic field, which interacts with permanent magnets of a rotor of the brushless electric motor 2 rotating around the central stator or motor axis.
  • the contact device 10 has a circular ring-shaped connection ring 22.
  • the coil ends 20 of the coils 16 are guided through axial through-openings 24 and are provided on the top of the connection ring 22 with contact lugs 26.
  • the through-openings 24 and contact lugs 26 are provided with reference numerals in the figures merely as examples.
  • the contact device 10 has a number of busbars or conductor tracks 28 as connecting conductors for interconnecting the coil ends 20 or the contact lugs 26 with the phase connections 8.
  • the approximately axially directed contact lugs 26 are integrally formed on the busbars 28 as contact points for contacting or electrically conductive connection with the respectively assigned coil end 20, i.e. in one piece or monolithically.
  • the contact lugs 26 are designed as angled rail ends of the busbars 28.
  • the busbars 28 are preferably embedded in the interconnection ring 22 or overmolded with it, with essentially only the contact lugs 26 protruding.
  • the contact lugs 26 are designed in particular as crimp lugs for a material-free crimp connection with the stripped coil ends 20.
  • the busbars 28 and contact lugs 26 are designed, for example, as common stamped and bent parts made of a copper material.
  • Figures 4 to 6 show sections of a contact lug 26 and a through-opening 24. As can be seen in Figure 4, for example, the contact lug 26 has a crimp contour 29 with an axial crimp slot 30, which divides the contact lug 26 into two crimp legs 32 in a fork-like manner.
  • the crimp slot 30 is widened towards the free ends of the crimp legs 32, so that an insertion bevel 34 is formed to facilitate the insertion of the coil end 20.
  • a circular through-opening is made in the contact lug 26 as a wire receptacle 36.
  • the wire receptacle 36 has a wider diameter than the crimp slot 32.
  • the diameter of the wire receptacle 36 preferably corresponds to the diameter of the (stripped) coil end 20.
  • Page 11 As shown in Figures 5 and 6, for example, the axial coil end 20 is bent approximately radially and pressed axially through the crimp slot 32 into the wire receptacle 36 via the insertion bevel 34.
  • the coil end 20 is then seated axially in the wire receptacle 36 in a form-fitting manner (Fig. 5).
  • the crimp legs 32 are then pressed from the outside against the outer circumference of the coil end 20 seated in the wire receptacle 36 using a pressing tool 38 and are thus crimped or crimp-contacted using the crimp contour 29.
  • the claimed invention is not limited to the embodiments described above. Rather, other variants of the invention can also be derived from this by the person skilled in the art within the scope of the disclosed claims without departing from the subject matter of the claimed invention. In particular, all individual features described in connection with the various embodiments can also be combined in other ways within the scope of the disclosed claims without departing from the subject matter of the claimed invention.
  • Page 12 List of reference symbols 2 Electric motor 4 Stator 6 Stator/rotating field winding 8 Phase connection 10 Contact device 12 Motor electronics 14 Stator package 16 Coil 18 Coil carrier 20 Coil end 22 Connection ring 24 Through opening 26 Contact lug 28 Busbar 29 Crimp contour 30 Crimp slot 32 Crimp leg 34 Lead-in chamfer 36 Through opening 38 Press tool

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Power Engineering (AREA)
  • Windings For Motors And Generators (AREA)

Abstract

L'invention concerne un dispositif de mise en contact (10) pour un stator (4) de moteur électrique (2), ledit dispositif présentant une bague de connexion (22) montée ou pouvant être montée côté frontal sur un noyau de stator (14), et un certain nombre de barres omnibus (28) pour assurer le raccordement d'extrémités de bobine (20) d'un enroulement de stator (6) avec un certain nombre de connexions de phase (8), au moins une barre omnibus (28) présentant une patte de contact (26) orientée axialement, et la patte de contact (26) présentant un contour de sertissage (29) pour assurer la mise en contact avec une extrémité de bobine (20) respectivement associée.
PCT/EP2024/066379 2023-06-13 2024-06-13 Dispositif de mise en contact pour un stator de moteur électrique Ceased WO2024256547A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102023205469.8 2023-06-13
DE102023205469.8A DE102023205469A1 (de) 2023-06-13 2023-06-13 Kontaktvorrichtung für einen Stator eines Elektromotors

Publications (1)

Publication Number Publication Date
WO2024256547A1 true WO2024256547A1 (fr) 2024-12-19

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Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/EP2024/066379 Ceased WO2024256547A1 (fr) 2023-06-13 2024-06-13 Dispositif de mise en contact pour un stator de moteur électrique

Country Status (2)

Country Link
DE (1) DE102023205469A1 (fr)
WO (1) WO2024256547A1 (fr)

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102008054529A1 (de) * 2008-12-11 2010-06-17 Robert Bosch Gmbh Elektromotor, insbesondere Stell- oder Antriebsmotor in Kraftfahrzeugen
DE102016206657A1 (de) * 2016-04-20 2017-10-26 Robert Bosch Gmbh Verschaltungsring und Verfahren zum Verschalten von Wicklungsdrähten eines Stators
US20170331342A1 (en) * 2015-02-03 2017-11-16 Brose Fahrzeugteile Gmbh & Co. Kommanditgesellschaft, Wuerzburg Electric motor and switching unit therefor
DE102020212198A1 (de) * 2020-09-28 2022-03-31 Brose Fahrzeugteile SE & Co. Kommanditgesellschaft, Würzburg Kontaktvorrichtung eines Stators

Family Cites Families (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE3172692D1 (en) * 1981-05-06 1985-11-28 Amp Inc Electric motor stator and a method of manufacturing the stator
US5065503A (en) * 1990-08-01 1991-11-19 Axis, U.S.A., Inc. Apparatus for connecting stator coil leads
JPH0759288A (ja) * 1993-08-18 1995-03-03 Sankyo Seiki Mfg Co Ltd ブラシレスモータのステータ
JP2623438B2 (ja) * 1993-10-12 1997-06-25 株式会社ミツバ コイル線材とリード線の接続構造
JP6444930B2 (ja) * 2016-04-15 2018-12-26 ファナック株式会社 巻線を圧着結線して構成される配線基板を備える電動機
JP6674847B2 (ja) * 2016-06-02 2020-04-01 タイコエレクトロニクスジャパン合同会社 モータのステータ組立方法およびモータのステータ構造

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102008054529A1 (de) * 2008-12-11 2010-06-17 Robert Bosch Gmbh Elektromotor, insbesondere Stell- oder Antriebsmotor in Kraftfahrzeugen
US20170331342A1 (en) * 2015-02-03 2017-11-16 Brose Fahrzeugteile Gmbh & Co. Kommanditgesellschaft, Wuerzburg Electric motor and switching unit therefor
DE102016206657A1 (de) * 2016-04-20 2017-10-26 Robert Bosch Gmbh Verschaltungsring und Verfahren zum Verschalten von Wicklungsdrähten eines Stators
DE102020212198A1 (de) * 2020-09-28 2022-03-31 Brose Fahrzeugteile SE & Co. Kommanditgesellschaft, Würzburg Kontaktvorrichtung eines Stators

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Publication number Publication date
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