DE102011081896A1 - Electromotor i.e. inner rotor-type permanent-excited electrical synchronous machine, for e.g. electrical vehicle, has terminal conductors airtightly connected with insulating body, and sealing element arranged between housing and body - Google Patents

Abstract

The electromotor (10) has a separate terminal housing (40) comprising insertion openings for inserting electrical power supply conductors and/or phase connection conductors (34). The power supply conductors are connected in an interconnecting space (40a) by a connection assembly connected with terminal conductors (30) of a circular stator (16). The terminal conductors are airtightly connected with an insulating body (42). A circulating sealing element e.g. lip seal, is arranged between the terminal housing and the insulating body. The insulating body is formed as a plastic injection molded part.

Description

The invention relates to an electric motor according to the preamble of patent claim 1, in particular an electric motor for a vehicle drive train of an electric or hybrid vehicle.

A generic electric motor is for example in the WO 03/021747 A1 described. In particular, there is disclosed a wiring structure for a hybrid vehicle engine in which the electrical connections of a stator winding system are connected to bus bars via a first connection terminal disposed within the motor housing and wherein the bus bars extend radially outward through a motor opening directly into an adjacent receiving space a connection housing extend and are connected there by means of a second connection terminal with power source cables or phase terminals.

In such an arrangement, there is the problem that under certain operating conditions and ambient conditions, the humidity in Verschaltungsraum can rise to an impermissible extent, which can form condensation, especially in the region of the connection arrangement of the terminal conductor and the phase terminals. As a result, due to the lying at different electrical potential elements to electrical flashovers and so to unwanted short circuits to failure of the electric machine.

The above problem is solved by an electric motor of the type mentioned, which additionally has the features specified in the characterizing part of claim 1.

Accordingly, an electric motor is proposed which comprises a ring-shaped stature having a stator winding, which has a plurality of connection conductors for connection to an electrical energy source, and wherein the connection conductors are surrounded by an insulating body at least over part of the extension. The electric motor further comprises a motor housing, which surrounds the stator radially on the outside and wherein the connection conductors of the stator winding extend through an opening of the motor housing to the outside. Furthermore, the electric motor has a connection device with a separate connection housing, which is fixed on the outside to the motor housing and has a bottom-side recess, through which the connection conductors can be introduced or inserted in a connection space formed there. The connection housing has insertion openings for the introduction of electrical energy source conductors or phase connection conductors, wherein the energy source conductors in the connection space are connected or connectable by means of a connection arrangement with the connecting conductors of the stator. According to the invention, the motor is characterized in that the connection conductors are connected substantially airtight with the insulating body and that between the connection housing and the insulating body, a circumferential sealing element is arranged.

The inventors have first recognized that between the engine compartment, d. H. the space enclosed by the motor housing and the space enclosed by the connection housing Verschaltungsraum significant temperature gradients may occur, which allow an air exchange within these interconnected spaces. It is preferably performed by the power loss of the electric motor heated air of the engine compartment with the elimination of water vapor and condensation in the usually cooler Verschaltungsraum. The invention is based on the idea to prevent air exchange between these two spaces, which is achieved by the combination of features specified in claim 1. In this way, the engine compartment and Verschaltungsraum are mutually hermetically separated and at the same time the bottom-side recess of the terminal housing is sealed to achieve a hermetically sealed Verschaltungsraumes by the sealing element. For this purpose, all other housing openings have sealing means for sealing the connection housing.

The sealing element can be arranged at the designated area at different positions. According to a first variant, the sealing element between a bottom-side and facing the motor housing, preferably laterally formed surface of the connection housing and one of these opposite and in particular parallel surface of the insulating body may be provided. According to a further arrangement variant, the sealing element can be arranged in the region of the bottom-side recess, in particular on an inner peripheral surface of the recess, where the sealing element can cooperate with an outer circumferential surface of the insulating body.

Further advantageous embodiment variants and further developments of the invention are specified in the dependent claims.

According to a preferred embodiment, it is proposed to form the insulating body as a plastic injection molded part, in which the connection conductors are embedded. As a result, a compact composite component is created, wherein the connection conductors are air-tight and liquid-tight in a plastic matrix preferably produced from a thermosetting or thermoplastic embedded.

The sealing element may be designed differently depending in particular on the above-mentioned specific positioning. For the first mentioned positioning there is particularly suitable an O-ring seal, while for the second-mentioned positioning the sealing element is preferably designed as a lip seal and wherein an elastic sealing lip is aligned with the insulating body and comes to rest on this.

For the arrangement of the sealing element on an inner peripheral surface of the bottom-side recess of the connection housing, the connection housing in this area particularly preferably has a wall region projecting from the housing bottom toward the opening of the motor housing. To protect the sealing element against excessive pressure on the one hand and to protect against a loss of sealing contact on the other hand, a limitation of a lateral Justage- or compensation area between the terminal conductor having and protruding from the engine compartment insulator and the connection housing is provided by means of a fixed stop. Such a limitation can be advantageously realized, in which the projecting wall portion is arranged offset by a defined amount from the edge of the recess, the latter acting as a fixed stop.

It can thus thus in the lateral plane between the electrical machine-side connection part, d. H. the insulating body with the connecting conductors and the terminal housing take place a certain compensating movement while maintaining the sealing contact.

According to an advantageous embodiment of the invention, the stator winding comprises a plurality of annular connection conductors fixed to the stator, to which the connecting conductors of the electric motor are connected in a materially and inseparably connected manner, for example by welding, soldering or a similar connection technique. Here is dispensed with an additional, detachable connection point. This means that between the preferably formed with individual coils stator winding and provided within the connection housing connection arrangement with the external phase terminals only cohesive and permanent connections of the current-carrying conductors are provided. Only the aforementioned connection arrangement is designed as a detachable connection, in particular as a screw connection.

With further advantage, the connecting conductors are guided radially from their junction with the annular connecting conductors on the shortest path to the outside in the terminal housing. The latter two features serve a total of low-impedance design of the electrical connections of the electric motor.

To secure the electromagnetic compatibility between the electric motor and provided in its environment electronic components such. As a control device of the electric motor or an internal combustion engine, an EMC sealant can be arranged between the terminal housing and the housing of the electric machine.

With particular advantage, the external phase connection conductors have a polarity reversal protection by means of mechanically coded connection connectors.

Access to Verschaltungsraum of the terminal housing via a removable housing cover, wherein between this and a housing base body connected to a power electronics or a control device of the electric machine or connectable electrical signal terminal is provided for detecting a lid opening state. In particular, the signal terminal is designed as a two-part connector, wherein a male part is fixed to the connector housing and wherein the other male part engages with connected connector in a recess of the housing cover and blocks the housing cover at least in an opening direction. In addition thereto, interlocking positive locking profiles can be provided between the housing cover and the housing and designed such that the mutual engagement of the positive locking profiles can only be canceled by releasing the opening direction blocked by the signal terminal.

To compensate for pressure differences between the Verschaltungsraum and the atmosphere, the terminal housing may advantageously have a pressure compensation element.

The invention will be explained by way of example with reference to the accompanying drawings. Show it:

1 a schematic representation of an electric motor with a connection device;

2 a sealed with a lid terminal housing of the connection device;

3 a lid of the connection housing according to 2 ;

4 a view into an open connection housing with phase conductor arranged therein;

5 a front view of the terminal housing with insertion openings for phase conductor;

6 a bottom-side view of the connection housing with a sealing element arranged there;

7 a sectional view of a connecting device with a connection housing after the 2 - 6 ,

1 shows first a schematic representation of an electric motor 10 with a connection device 12 ; which by means of 2 - 7 will be explained in detail. The electric motor 10 is present as a permanent magnet electric synchronous machine in internal rotor design with a rotatable about a Ratorwelle A rotor 14 and with a radially surrounding this outer ring-shaped circular stator 16 executed. The stator 16 is by means of a likewise annular stator carrier 18 in a motor housing 20 set, which is present here as a portion of a transmission case of a gear change transmission of a vehicle drive train.

The stator 16 is to form a polyphase winding 22 with single tooth coils 24 equipped, which are assigned to individual electrical strands. The coil ends of the single tooth coils 24 are by means of an in 1 only schematically indicated interconnecting device 26 in a predetermined manner with several, here three coaxial with the stator 16 arranged connecting conductors 28 interconnected and by means of separately from the connecting conductors 28 manufactured connecting conductors 30 and the connection device 12 via power electronics 32 with energy source conductors or external phase connection conductors 34 an electrical energy source 36 connected, so that the winding 22 the electric machine 10 according to specification of a control device 33 can be acted upon by a current of variable phase and amplitude.

The connection ladder 28 are designed as a strip conductor of a copper material and bent into an open ring, the ends in a peripheral region outside the connecting conductor 30 are arranged. That is, the connection ladder 28 are in the connection area of the connecting conductors 30 executed continuously. To arrange the connection conductor 30 at the stator 16 These are of a designed as a plastic annular support member 38 taken each other isolated from each other. The carrier element 38 relies on 1 axially to insulating or winding bodies of the coils 24 from and is also centered radially by the defined by these inner peripheral surface.

The connection conductors 30 are circumferentially spaced on the stator, but arranged there in a common radial plane. In 1 is therefore only a single connection conductor 30 shown. While in each case an end portion of the connecting conductor 30 on the cross-sectional area with the front sides of the stature 16 radially staggered connecting conductor 28 cohesively connected by soldering or welding, is the second end portion 28 the connection conductor in a separate connection housing 40 the connection device 12 for connection to the phase connections 34 the source of energy 36 intended.

The connection conductors 30 are mutually spaced apart on a part of their extension and completely in an insulating body formed of plastic, in particular as a plastic injection molded part 42 essentially embedded airtight. The to the connection with the phase connections 34 certain end sections of the connecting conductors 30 are with contact elements 30a executed, which are designed here as screw sleeves, as this in the German patent application 102011080250.9 is described and whose contents are fully incorporated by this reference in the disclosure of the present invention.

How special in 7 The connecting conductors of the stator winding extend recognizably 22 through an opening 44 of the motor housing 20 outward. Here are the connection conductors 30 from their junction with the annular connecting conductors 28 radially on the shortest way to the outside in a Verschaltungsraum 40a of the connection housing 40 introduced.

That with the 2 - 7 illustrated connection housing 40 is with a trough-shaped basic body 40b and a removable lid 40c executed and opposite the motor housing 20 made separately. The connection housing 40 is by means of several through holes 40d or eyelets and here not graphically illustrated bolts on the outside of the motor housing 20 set, wherein in the mounting plane, a lateral range of motion is provided by the correspondingly sized through holes. The lid 40c can by means of several Durchgriffsöffnungen 40e and here not shown bolts on tapped holes 40f of the basic body 40b be attached.

The connection housing 40 also has a bottom-side recess 40g which with the opening 44 of the motor housing 20 is brought into cover and through which the connecting conductors 30 in a trained there Verschaltungsraum 40a are introduced or imported. Further insertion openings 40i serve to introduce the electrical power source conductors 34 or phase connection conductor.

In the Verschaltungsraum are the power source conductors 34 using cable lugs and the, in the German patent application 102011080250.9 explained connection arrangement by means of bolts with the connecting conductors 30 of the stator 16 connected or connectable. For mutual hermetic separation of engine compartment 20 and wiring space 40a is between the connector housing 40 and that, with the connecting wires 30 connected insulating body 42 a circumferential sealing element 46 arranged. This is in the area of the recess 40g at the bottom of the housing a projecting wall area 40k trained, the opening 44 of the motor housing 20 indicates and intervenes in this. The wall area 40k carries in particular a patch on this and circumferential lip seal 46 with a substantially U-shaped cross section, the lip seal 46 includes two legs 46a , b, being a leg 46a at the recess 40g directed to the outside and wherein the other leg 46b points into the interior of the recess and with a trained there and projecting from this elastic sealing lip 46c at that, the connecting conductors 30 of the electric motor 10 carrying insulating body 42 comes to the plant.

To protect the sealing element 46 On the other hand, an excessive pressure on the one hand and to protect against a loss of sealing contact by means of a fixed stop 40l a boundary of a lateral adjustment area between the insulator 42 and the connection box 40 intended. This is how in 7 shown, the projecting wall area 46 by a defined amount from the edge of the recess 40g staggered.

The also sealed in the openings 40i introduced three external phase connection conductors 34 wear here as YAZAKI eyelets executed connection connector 34a , a housing feedthrough and cable lugs include. The YAZAKI eyelets are for displaying a reverse polarity protection 48a C mechanically coded differently by means of a known pin-hole arrangement, as this in 5 based on the corresponding thereto executed housing connections.

As already mentioned, this is within the wiring space 40a lying connection arrangement of the connection conductor 30 with the external phase connections 34 designed as a detachable connection, in particular as a screw connection. The associated bolts are in 7 not shown.

Between the connection housing 40 and the housing 20 the electric machine 12 is still an EMC sealant 50 arranged in the form of a wire mesh, which in a at the bottom of the connection housing 40 and is inserted in a groove formed offset and at least largely prevents the passage of electromagnetic radiation between the two parts.

Access to the wiring room 40a via the removable housing cover 40c , wherein between this and the housing base body 40b a sealing element 40m and further on with the driver 32 the electric machine 12 connected or connectable electrical signal terminal 52 is provided for detecting a lid opening state. In particular, the signal terminal 52 as a two-part electrical connector 52a , B executed, wherein a plug-in part 52a directly on a lateral extension of the connection housing 40 is fixed and wherein the other, here only schematically indicated plug-in part 52b in connected connector in a through a bracket 40o formed recess 54 of the housing cover 40c engages and the housing cover 40c blocked at least in an opening direction. The fasteners 52c for fixing the male part 52a are with the lid on 40c inaccessible. In the plug-in part 52a a shorting bridge is incorporated, with the plug connection closed one by means of the male part 52b connected signal circuit closes. That is, even if the screwing of the housing cover 40c solved is the lid 40c not from the housing body 40b be lifted off. This is only possible if the male part 52b from the male part 52a is deducted, while the power electronics 32 and / or the drive device 33 recognizes this condition and the phase connections 34 de-energized, leaving the wiring space 40a can be opened and is safely accessible. To pry the lid 40c despite the existing connector of the parts 52a , to prevent b, are complementary between the housing cover 40c and the housing body 40b interlocking positive locking profile 56a , b, which is embodied here as an eye engagement profile. The positive connection is designed such that the mutual engagement of the positive connection profiles 56a , b is exclusively cancelable by the signal connection 52 blocked opening direction is released. That is, only when unplugged plug-in part 52b can the lid 40c be raised to the connection of the positive locking profiles 56a to solve b. A lateral removal of the lid 40c from the housing body 40b is because of another, on the lid in the form of a housing to the body 40b projecting and in the wiring room 40a engaging wall area 40n not possible.

To compensate for pressure differences between the Verschaltungsraum 40a and the atmosphere is on the lid 40c of the connection housing 40 a pressure compensation element 58 used.

LIST OF REFERENCE NUMBERS

10

electric motor

12

connection device

14

rotor

16

stator

18

stator

20

motor housing

22

stator

24

Single-tooth coil

26

Connecting device

28

connecting conductors

30

connecting conductors

30a

contact element

32

power electronics

33

driving

34

Phase connection conductors

34a

Connector (YAZAKI eyelets)

36

energy

38

support element

40

connection housing

40a

Verschaltungsraum

40b

body

40c

cover

40d

Through opening

40e

Through opening

40f

threaded hole

40g

recess

40i

insertion

40k

wall area

40l

fixed stop

40m

sealing element

40n

wall area

40o

hanger

42

insulator

44

Opening of the motor housing

46

sealing element

46a,

b thighs

46c

sealing lip

48a-c

Reverse polarity protection

50

EMC sealant

52

signal connection

52a, b

Connectors

52c

fastener

54

recess

56a, b

Form-fit profile

58

Pressure compensation element

A

rotor shaft

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• WO 03/021747 A1 [0002]
• DE 102011080250 [0031, 0035]

Claims (12)

Electric motor ( 10 ), comprising - a ring-shaped stator ( 16 ) with a stator winding ( 22 ), which has several connection conductors ( 30 ) for connection to an electrical energy source ( 36 ), wherein the connecting conductors ( 30 ) at least to a part of the extension of an insulating body ( 42 ), - a motor housing ( 20 ), which the stator ( 16 ) radially outwardly surrounds and wherein the connecting conductors ( 30 ) of the stator winding ( 22 ) through an opening ( 44 ) of the motor housing ( 20 ) extend to the outside, further comprising - a connection device ( 12 ) with a separate connection housing ( 40 ), which on the outside of the motor housing ( 20 ) is fixed and a bottom-side recess ( 40g ), through which the connecting conductors ( 30 ) in a wiring space formed there ( 40a ) are inserted or inserted and wherein the connection housing ( 40 ) Insertion openings ( 40i ) for introducing electrical energy source conductors ( 34 ) and phase conductors and wherein the power source conductors ( 34 ) in the wiring space ( 40a ) by means of a connection arrangement with the connecting conductors ( 30 ) of the stator ( 16 ) are connected or connectable, characterized in that the connecting conductors ( 30 ) substantially airtight with the insulating body ( 42 ) and that between the connector housing ( 40 ) and the insulating body ( 42 ) a circumferential sealing element ( 46 ) is arranged. Electric motor ( 10 ) according to claim 1, characterized in that the insulating body ( 42 ) is formed as a plastic injection molded part, in which the connecting conductors ( 30 ) are embedded. Electric motor ( 10 ) according to claim 1 or 2, characterized in that the sealing element ( 46 ) as a lip seal with a to the insulating body ( 42 ) aligned and adjacent to this elastic sealing lip ( 46c ) is executed. Electric motor ( 10 ) according to one of claims 1 to 3, characterized in that the connection housing ( 40 ) in the region of the bottom-side recess ( 40g ) one from the housing bottom to the opening ( 44 ) of the motor housing ( 20 ) projecting wall area ( 40n ), on which the sealing element ( 46 ) is arranged. Electric motor ( 10 ) according to one of claims 1 to 4, characterized in that the projecting wall area ( 40n ) by a defined amount from the edge of the recess ( 40g ) is arranged offset. Electric motor ( 10 ) according to one of claims 1 to 5, characterized in that the stator winding ( 22 ) several, in stature ( 16 ) fixed annular connecting conductors ( 28 ), wherein the connecting conductors ( 30 ) cohesively with the connecting conductors ( 28 ) are connected. Electric motor ( 10 ) according to one of claims 1 to 6, characterized in that between the connection housing ( 40 ) and the motor housing ( 20 ) EMC sealant ( 50 ) are arranged. Electric motor ( 10 ) according to one of claims 1 to 7, characterized in that the phase connection conductors ( 34 ) a polarity reversal protection by means of mechanically coded connection connector ( 34a ) exhibit. Electric motor ( 10 ) according to one of claims 1 to 8, characterized in that the connection housing ( 40 ) a removable housing cover ( 40c ) and that between this and a housing base body ( 40b ) with a power electronics ( 32 ) or a drive device ( 33 ) of the electric machine ( 12 ) connected or connectable electrical signal terminal ( 52 ) is provided for detecting a lid opening condition. Electric motor ( 10 ) according to claim 9, characterized in that the signal terminal ( 52 ) as a two-part connector ( 52a , b), wherein a plug-in part ( 52a ) is fixed to the connection housing and wherein the other plug-in part ( 52b ) in connected connection in a recess ( 54 ) of the housing cover ( 40c ) engages and blocks it at least in an opening direction. Electric motor ( 10 ) according to claim 10, characterized in that between the housing cover ( 40c ) and the housing body ( 40b ) interlocking positive locking profiles ( 56a , b) are provided and designed such that the mutual engagement of the positive-locking profiles ( 56a , b) can only be canceled by releasing the opening direction blocked by the signal connection. Electric motor ( 10 ) according to any one of claims 1-11, characterized in that the connection housing ( 40 ) a pressure compensation element ( 58 ) having.

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