DE102016205633A1 - Contact device for a stator of an electrical machine - Google Patents

Abstract

The present invention relates to a contactor for a stator, in particular a segmented stator, an electric machine, with an electrically insulating contact carrier, which concentrically extends about an axis, with first electrical conductors for interconnecting coil winding ends according to a winding scheme, second electrical conductors for connection the coil windings to an electrical voltage source, and electrical connection means for electrically connecting the coil winding ends with the first and / or second electrical conductors, wherein the first electrical conductors are arranged on a lower side of the contact carrier and the second electrical conductors on an upper side of the contact carrier. The present invention further relates to a stator for an electric machine, in particular a segmented stator, with such a contact device, an electric machine, in particular an electric motor, with such a stator and a method for producing such a stator.

Description

State of the art

The present invention relates to a contactor for a stator of an electric machine, comprising an electrically insulating contact carrier concentrically extending about an axis, having first electrical conductors for interconnecting coil winding ends according to a winding scheme, second electrical conductors for connecting the coil windings to an electrical voltage source , and electrical connection means for electrically connecting the coil winding ends to the first and / or second electrical conductors. The present invention further relates to a stator with the contact device and a method for producing the stator.

From the publication DE 10 2010 039 335 A1 a contact device in a stator of an electrical machine is known. For contacting coil windings of the stator, which are arranged distributed in the circumferential direction around the stator, the contact device has a plurality of electrically conductive pathways. The conductor paths are punched out of a metal sheet as a stamped bending component and received in different planes which lie parallel to the contact carrier plane.

Disclosure of the invention

Object of the present invention is to provide an alternative contact device, which is very fast and easy to install and allows a good overview of the electrical connections to the coil windings.

The object is achieved with a contact device for a stator of an electrical machine, preferably for a segmented stator. The contact device has an electrically insulating contact carrier which extends concentrically around an axis. In a preferred embodiment, the contact carrier is annular, so that it has a central recess for the passage of a rotor and / or a shaft. It is particularly preferred as an injection molded part made of an electrically insulating material, in particular plastic such as polyethylene.

The contact device has first electrical conductors for interconnecting coil winding ends of the stator, in particular according to a winding scheme. Furthermore, it has second electrical conductors for connecting the coil windings to an electrical voltage source. For electrically connecting the coil winding ends with the first and / or second electrical conductors, it also has electrical connection means.

It is characterized in that the first electrical conductors are arranged on an underside of the contact carrier, and the second electrical conductors are arranged on an upper side of the contact carrier.

Due to this functional separation, the wiring of the coil windings for the installer is very manageable. The assembly of the second electrical conductor can be carried out independently of the assembly of the first electrical conductor, in particular in the context of a pre-assembly of the contact carrier. And the assembly of the first electrical conductors can be carried out according to various winding schemes, in particular with conventional conductor wire. Overall, the assembly is very fast, inexpensive and error-prone possible. The manufacture of the contact carrier made of an electrically insulating material ensures electrical insulation between the first and the second electrical conductors.

The first electrical conductors are preferably formed of wire conductors, in particular of round conductors or of flat conductors. The use of flat conductors for the first electrical conductors and / or the stator ends to be connected to them has the advantage that they abut each other well, without rolling away from each other, and the electrical contact is therefore very good. In this case, full-wire conductors are preferred. Particularly preferably, the first electrical conductors are latched in latching and / or snap elements of the contact carrier. They are very particularly preferably electrically isolated, preferably lacquered. But is also preferred the use of plastic or other materials insulated electrical conductors.

For performing the first electrical conductor from the bottom to the top, first through-holes are preferably provided in the contact carrier. The first electrical conductors are furthermore preferably guided through the first through-holes onto the upper side of the contact carrier. Escaping to the first through-holes, the connecting means are preferably arranged. The first electrical conductors can therefore be fed through the first through-holes to the connecting means, in particular into the connecting means insertable.

It is particularly preferred to use cut to length and pre-bent wire conductors. In this embodiment, the prefabricated wire conductors can be mounted in the first through-holes by insertion in a mounting direction.

Particularly preferably, the connecting means are formed sleeve-shaped. Further preferred they are designed as Crimpers or as welding sleeves. The use of welding sleeves is very particularly preferred. By welding, even with insulated, especially lacquered, wire conductors, a stripping can be omitted.

Preferably, the connecting means in receptacles of the contact carrier, in particular tool-free, can be inserted and / or anchored. For anchoring in the recordings, they may, for example, have force and / or positive locking means, such as hook-shaped projections. Furthermore, it is preferred that they are designed to accommodate at least two electrical conductors, in particular a first electrical conductor and a coil winding end.

It is also preferred that the first through-holes are arranged radially on the outside of the contact carrier. As a result, axially outside coil winding ends can be inserted directly into the connecting means. In the case of radially outwardly emerging coil winding ends, these can be introduced into the connecting means after bending. The first through holes are preferably funnel-shaped, so that they taper in the mounting direction. As a result, the first electrical conductors and / or coil winding ends introduced into the first through-hole in the mounting direction are guided into the center of the first through-hole.

The positioning radially outside also has the advantage that they are easily accessible connecting means and therefore are easily crimped, soldered and / or welded.

For latching the contact device on the stator snap means are preferably provided on the underside of the contact carrier. The snap means are preferably arranged transversely to a plane which spans the contact carrier. As a result, the contact device can be pushed onto the stator and latched.

The object is also achieved with a stator for an electrical machine, in particular a segmented stator, with such a contact device. The coil windings of the stator are due to the use of the contact device easily, in particular according to the winding scheme, quickly and clearly mounted.

The object is further achieved with an electric machine, in particular with an electric motor, with such a stator. The electric machine is preferably used for an adjustment or a hand tool.

• – Ablängen und Biegen der ersten elektrischen Leiter; und
• – Durchführen der ersten elektrischen Leiter in eine Montagerichtung durch die ersten Durchgangsbohrungen in die Verbindungsmittel, sowie Verrasten der ersten elektrischen Leiter in den Rast- und/oder Schnappelementen an der Unterseite des Kontaktträgers.

The object is further achieved with a method for producing a stator with such a contact device. The method preferably comprises the steps:

• - cutting and bending the first electrical conductor; and
• - Performing the first electrical conductor in a mounting direction through the first through-holes in the connecting means, as well as latching of the first electrical conductor in the locking and / or snap elements on the underside of the contact carrier.

As electrical conductors for conventional wire conductors are used. The wire conductors preferably have an electrically insulating sheathing, in particular an insulating lacquer. The assembly of the first electrical conductor is thereby very cost and with conventional methods, in particular according to different winding schemes, possible.

• – Einführen der Spulenwicklungsenden in Montagerichtung in die Verbindungsmittel; und
• – Verkrimpen, Verlöten und/oder Verschweißen der ersten Verbindungsmittel mit den ersten elektrischen Leitern und den Spulenwicklungsenden.

The method preferably comprises the further steps:

• - Inserting the coil winding ends in the mounting direction in the connecting means; and
• Crimping, soldering and / or welding the first connection means to the first electrical conductors and the coil winding ends.

A prefabricated contact carrier with already mounted second electrical conductors is then pushed against the mounting direction on a main body of the stator and latched.

In the following the invention will be described with reference to figures. The figures are merely exemplary and do not limit the general idea of the invention.

1 shows in (a) and (b) respectively a lower side of an embodiment of a contact device, and in (c) and (d) each have a top side of an embodiment of the contact device;

2 shows in (a) and (b) a connecting means in various perspective views;

3 shows in (a) - (c) respectively a section of an embodiment of a contact device;

4 shows in (a) and (b) detailed representations of a contact carrier; and

5 shows in (a) - (d) respectively a section of the upper side of various embodiments of the contact device in a perspective view.

1 shows in (a) and (b) each an embodiment of a contact device 1 from the bottom 22 , The contact device 1 is for electrically connecting coil windings (not shown) of a stator (not shown), in particular a segmented stator, an electric machine (not shown) with each other, in particular according to a winding scheme, and for electrically connecting the coil windings with an electrical voltage source (not shown) intended.

For this, the contact device 1 an electrically insulating contact carrier 2 on. The contact carrier 2 is annular and concentrically extends about an axis 11 , He has the bottom 22 as well as a top 21 on. Both the bottom 22 as well as the top 21 are essentially just trained. The contact carrier 2 is therefore essentially plate-shaped. A central opening 12 of the contact carrier 2 is in the assembled state of the stator optionally penetrated by a rotor shaft (not shown).

At its bottom 22 are first electrical conductors 3 arranged for electrically connecting the coil winding ends 8th (S. 3 (c) ) of the coil windings are provided. Second electrical conductor 5 . 50 for connecting the coil windings to the electric voltage source are at the top 21 of the contact carrier 2 arranged (s. 1 (c) and (d)).

Due to the separation of the first and second electrical conductors 3 . 5 . 50 to different sides 21 . 22 of the contact carrier 2 is the interconnection of the coil windings for a mechanic immediately manageable. In addition, conventional wire conductors can be used for the interconnection. In the illustrated embodiments of the 1 (a) and (b) round conductors are provided for this purpose. But there are also flat conductor usable. The contact carrier 2 isolates the first electrical conductors 3 also from the second electrical conductors 5 . 50 ,

The first electrical conductors 3 are by means of locking and / or snap means 231 . 232 . 233 on the contact carrier 2 attached. The catch and / or snap 231 . 232 . 233 are integral with the contact carrier 2 educated. They have different heights h. This allows the first electrical conductors 3 on different levels (not shown) parallel to the contact carrier 2 to be ordered. The first electrical conductors 3 are also straight through the bottom 22 mountable.

Furthermore, the first electrical conductors 3 through first electrical through-holes 201 of the contact carrier 2 from its bottom 22 in the mounting direction 10 on top 21 guided. For this are opposite ends of the line 31 the first electrical conductor 3 respectively, in particular about a right angle, in the mounting direction 10 bent. The first electrical conductors 3 are thereby in mounting direction 10 in the through holes 201 insertable.

The contact device 1 also has electrical connection means 4 for electrically connecting the coil winding ends 8th with the first electrical conductors 3 on. The connecting means 4 are aligned with the first through holes 201 arranged. When passing the first electrical conductor 3 in the through holes 201 These are therefore in the lanyard 4 introduced.

To easily insert the first electrical conductor 3 in the first through holes 201 to allow tapering the first through holes 201 in mounting direction 10 , This funnel shape becomes the first electrical conductor 3 in the center (not marked) of the through holes 201 directed.

For connecting the second electrical conductor 5 . 50 to the coil winding ends 8th are second through holes 202 intended. These are aligned with the first electrical connection means 51 arranged.

1 shows in (c) and (d) each an embodiment of a contact device 1 from the top 21 , Visible are the crimpable, solderable and / or weldable connection means 4 , These are radially on the outside of the contact carrier 2 intended. This makes them easily accessible during installation. The first electrical conductors 3 are through the first through holes 201 in the connecting means 4 introduced.

At the top 21 are also the second electrical conductors 5 arranged. In the present embodiments, these are manufactured as stamped and bent parts. The first electrical connection means 51 to the coil winding ends 8th can be connected, are here in one piece with the second electrical conductors 5 produced. They are each at a first end (not labeled) of the second electrical conductor 5 educated.

The second electrical conductor 5 lie flat at the top 21 of the contact carrier 2 at. They are pre-assembled and here by pins 7 on the contact carrier 2 attached. To connect the voltage source are at a second, the first end opposite end (not labeled) each plug contacts 6 provided, which are transverse to the contact carrier 2 extend and for attaching a connector socket (not shown) are provided. These are preferably form-fitting to the second electrical conductors 5 attached. But you can also be attached to this riveted or otherwise electrically contacting.

The assembled contact device 1 is on a coil body supporting the coil body of the stator against the mounting direction 10 pushed. For that are at the bottom 22 of the contact carrier 2 snap means 24 for locking the contact device 2 arranged on the base body. These extend transversely to the contact carrier 2 and against the mounting direction 10 , Furthermore, there are guide bars 25 provided that facilitate the postponement.

When sliding the contact device 1 become the coil winding ends 8th through the first through holes 201 in the connecting means 4 introduced. These then only have to be crimped, soldered and / or welded.

The insertion of the first electrical conductor 3 and the coil winding ends 8th in the connecting means 4 is tool-free possible Also the mounting of the connecting means 8th on the contact carrier 2 is preferably possible tool-free. For that show the 2 (a) and (b) the connecting means 4 , The connecting means 4 has a sleeve 41 with a gap 43 on. The sleeve 41 is therefore circumferentially open. The sleeve 41 limits a recording room 42 ,

On the sleeve 41 is a push-in bar 44 provided for insertion into a receptacle of the contact carrier 2 is provided. At the insertion point 44 are broadening 441 intended. These are for example for locking on the top 21 of the contact carrier 2 provided, or for squeezing in the recording. This will be the connecting means 4 during a fusion of the in the sleeve 41 inserted electrical conductor 3 . 5 . 50 on the contact carrier 2 held.

The sleeve 41 has a diameter d that is suitable for arranging at least two electrical conductors 3 . 50 is provided.

2 (a) shows an embodiment of the connecting means 8th in which the sleeve 41 at one of the insertion ridge 44 facing side a rejuvenation 411 having. This will be electrical conductors 3 . 5 . 50 in the mounting direction 10 in the sleeve 41 be pushed into the recording room 42 guided.

The pods 41 the connecting means 4 of the 2 (a) and (b) also differ in their ratio of their width B to their depth T. The sleeve 41 of the bonding agent 4 of the 2 (a) has a greater width B than depth T. It is therefore suitable for an aligned in the tangential direction mounting, wherein the width B of the sleeve 41 extends in tangential direction. The in the sleeve 41 inserted electrical conductor 3 . 8th are then arranged side by side in a tangential direction.

The sleeve 41 of the bonding agent 4 of the 2 B) has a greater depth T than width B. It is therefore suitable for an aligned in the radial direction mounting, in which the depth T of the sleeve 41 extends in the radial direction. The in the sleeve 41 inserted electrical conductor 3 . 8th are then arranged side by side in the radial direction.

By choosing the appropriate sleeve 41 , in particular their orientation, can be a twisting of the electrical conductors 3 . 8th be avoided.

The use of such fasteners 4 has the advantage that a current used for welding when welding both in the sleeve 41 inserted electrical conductor 3 . 8th can flow through. This achieves a very good welding quality.

The connecting means 4 are also preferably tinned inside to improve the quality of contact.

3 (c) shows the on the contact carrier 2 fixed connection sleeve 4 with inserted first electrical conductor 3 as well as inserted coil winding end B. The first electrical conductor 3 and the coil winding end 8th are approximately in the middle of the recording room 42 the connection sleeve 41 placed. In this arrangement, the first electrical conductor 3 and the coil winding end 8th Easily accessible and weldable from above.

3 (a) shows ladder guide means 26 . 27 on the bottom 22 of the contact carrier 2 for receiving the first electrical conductor 3 are provided. Here are the first conductor guide means 27 in the contact carrier 2 sunk. As a result, first electrical conductors 3 in the sunk first conductor guide means 27 pressed. Above the first conductor guide means 27 are second conductor guiding means 26 provided in the further first electrical conductor 3 can be inserted. The first electrical conductors 3 are thereby crossable, without the height h, especially against the mounting direction 10 to enlarge.

As a result, in the region of the crossovers a distance, preferably of about 0.1-0.4 mm, between the first electrical conductors 3 be ensured. A fixing of the first electrical conductor 3 at their ends 30 is for example by means of snap hooks 231 possible.

3 (b) shows a section A from 3 (a) in another perspective view.

4 shows in (a) another conductor guidance means 29 which at the bottom 22 of the contact carrier 2 is provided and a crossing of the first electrical conductor 3 allows to increase considerably without the height h. 4 (b) shows a section through the contact carrier 2 in the area of the further conductor guiding means 29 , wherein at the contact carrier 2 first electrical conductor 3 are arranged. Visible are at least partially in the contact carrier 2 sunken first electrical conductor 3 ,

The ladder guiding means 26 . 27 . 29 of the 3 and 4 are integral with the contact carrier 2 educated.

In the 5 (a) - (d) are each sections of a contact carrier 2 shown. Shown is the top 21 of the contact carrier 2 ,

In the 5 (a) are the second electrical conductors 5 made of flat conductors, and analogous to the 1 (c) and (d) as a stamped and bent part from a sheet metal. The first connection means 51 is integral with the second electrical conductor 5 produced. Each at the second end of the second electrical conductor 5 arranged plug contacts 6 are preferably form-fitting to the second electrical conductors 5 attached.

Both 5 (b) - (d) conventional wire conductors designed as round conductors are second electrical conductors 50 intended. The first connection means 51 are manufactured as stamped and bent parts and here each have a sleeve-like end 521 for insertion and crimping, soldering and / or welding of the wire conductors.

For attaching the plug contacts 6 are in the embodiment of the 5 (b) second connection means 52 provided, which also has a sleeve-like end 521 for securing the wire conductors. at 5 (c) are the plug contacts 6 in recordings 621 of the contact carrier 2 introduced and the wire conductor by means of third connection means 71 , which are here designed as brackets, next to the plug contacts 6 can be arranged and crimped with these, soldered or welded. In the embodiment of the 5 (d) Finally, the stripped wire conductors as plug contacts 32 used. The wire conductors are for this purpose by means of brackets 72 on sockets 622 attached to the contact carrier 2 are molded on, clipped on.

The connecting means 4 as well as the connection means 51 . 52 . 73 allow reliable and permanent crimping, soldering and / or welding of the coil winding ends 8th with the electrical conductors 3 . 5 . 50 , Incidentally, the assembly is essentially possible tool-free. It is fast, cost-effective and clearly arranged.

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

• DE 102010039335 A1 [0002]

Claims (14)

Contact device ( 1 ) for a stator, in particular a segmented stator, an electric machine, with an electrically insulating contact carrier ( 2 ) concentric about an axis ( 11 ), with first electrical conductors ( 3 ) for interconnecting coil winding ends ( 8th ) - in particular according to a winding scheme - second electrical conductors ( 5 . 50 ) for connecting the coil windings ( 8th ) to an electrical voltage source, and electrical connection means ( 4 ) for electrically connecting the coil winding ends ( 8th ) with the first electrical conductors ( 3 ), characterized in that the first electrical conductors ( 3 ) on a lower side ( 22 ) of the contact carrier ( 2 ) and the second electrical conductors ( 5 . 50 ) on a top side ( 21 ) of the contact carrier ( 2 ) are arranged. Contact device ( 1 ) according to claim 1, characterized in that the first electrical conductors ( 3 ) formed of wire conductors and in latching and / or snap elements ( 231 . 232 . 233 ) of the contact carrier ( 2 ) are locked. Contact device ( 1 ) according to one of the preceding claims, characterized in that the contact carrier ( 2 ) first through holes ( 201 ), wherein the first electrical conductors ( 3 ) through the first through holes ( 201 ) on the top ( 21 ) of the contact carrier ( 2 ), in particular the through-holes ( 201 ) on the bottom ( 22 ) Introduction phases ( 203 ) for the first electrical conductors ( 3 ) exhibit. Contact device ( 1 ) according to one of the preceding claims, characterized in that the first through-holes ( 201 ) radially outward on the contact carrier ( 2 ) are arranged. Contact device ( 1 ) according to one of the preceding claims, characterized in that the connecting means ( 4 ) in alignment with the first through-holes ( 201 ) are arranged. Contact device ( 1 ) according to one of the preceding claims, characterized in that the first through-holes ( 201 ) and the connecting means ( 4 ) for receiving the first electrical conductor ( 3 ) and the coil winding ends ( 8th ) are provided - and preferably two wire conductors electrically interconnect. Contact device ( 1 ) according to one of the preceding claims, characterized in that the connecting means ( 4 ) are formed as welding sleeves, in particular by means of a locking toothing ( 441 ) in the contact carrier ( 2 ) are attached. Contact device ( 1 ) according to one of the preceding claims, characterized in that on the underside ( 22 ) of the contact carrier ( 2 ) Snap-action ( 24 ) for latching the contact device ( 1 ) are provided on a main body of the stator, whereby the contact device ( 1 ) is pushed onto the stator. Contact device ( 1 ) according to one of the preceding claims, characterized in that the second electrical conductors ( 5 . 50 ) at each end two receiving sleeves ( 51 ) for two seprate wire conductors and at the opposite end plug contacts ( 6 ) for the electrical power source. Contact device ( 1 ) according to one of the preceding claims, characterized in that the connecting means ( 4 ) in pictures of the contact carrier ( 2 ), in particular tool-free, can be inserted and / or latched. Stator for an electric machine, in particular segmented stator, with a contact device ( 1 ) according to one of the preceding claims. Electric machine, in particular electric motor, with a stator according to claim 11. Method for producing a stator with a contact device ( 1 ) according to any one of claims 1-10, comprising the steps of: cutting to length and bending of the first electrical conductors ( 3 ); - passing the first electrical conductors ( 3 ) in a mounting direction ( 10 ) through the first through holes ( 201 ) in the connecting means ( 4 ), as well as latching of the first electrical conductors ( 3 ) in the latching and / or snap elements ( 231 . 232 . 233 ) on the bottom ( 22 ) of the contact carrier ( 2 ). Method according to claim 13, characterized by the further steps: - inserting the coil winding ends ( 8th ) in mounting direction ( 10 ) through the first through holes ( 201 ); and - crimping, soldering and / or welding the first connecting means ( 4 ) with the first electrical conductors ( 3 ) and the coil winding ends ( 8th ).

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