DE102021004542A1 - Electric motor with an interconnection unit and a stator and method for producing such an electric motor - Google Patents

Abstract

Electric motor with a stator and a connection unit and method for its production, wherein individual phases of a multi-phase electrical winding of the stator can be connected to one another, in particular in a star connection, and to phase connections for the power supply by means of the connection unit, the connection unit having a ring axis, in particular concentrically, surrounding carrier ring and a plurality of, in particular exactly four or at least four, spaced-apart metal conductor elements, which in particular are shaped essentially in the shape of a circular arc, the carrier ring at least partially enclosing the conductor elements, in particular at least partially enclosing the conductor element cross-section completely and in a materially bonded manner, with each conductor element at least has a contacting section for making electrical contact with a section of the electrical winding, each conductor element, esp especial relative to the ring axis, covers a circumferential angle area, with the circumferential angle area covered by each conductor element overlapping with at least one circumferential angle area covered by another conductor element, in particular with the covered circumferential angle areas of all other conductor elements, and with each conductor element in a direction parallel to the ring axis, i.e. in the axial direction , in particular in circumferential angle and/or radial sections, overlaps at most with one further conductor element.

Description

The invention relates to an interconnection unit for an electric motor, a stator of an electric motor, an electric motor with this interconnection unit and this stator, and a method for producing this electric motor.

• Aus der DE 10 2017 216 084 A1 ist ein Stator für eine elektrische Maschine, eine elektrische Maschine und ein Verfahren zum Herstellen eines solchen Stators bekannt.
• Aus der DE 10 2012 023 477 A1 ist ein Schaltelement für einen Elektromotor, Stator mit einem solchen Schaltelement und ein Elektromotor bekannt.
• Aus der US 2011 057 524 A1 ist eine elektrische Verbindungsvorrichtung für einen bürstenlosen Motor bekannt.
• Aus der DE 10 2018 215 787 A1 ist ein Stator für eine elektrische Maschine, eine elektrische Maschine und ein Verfahren einer elektrischen Maschine bekannt.
• Aus der DE 10 2017 223 519 B3 ist ein Stator eines dreiphasigen elektronisch kommutierten Gleichstrommotors bekannt.
• Aus der DE 10 2016 211 230 A1 ist eine Verschaltungsvorrichtung eines Stators, eine elektrische Maschine beinhaltend eine solche Verschaltungsvorrichtung und ein Verfahren zum Herstellen einer solchen bekannt.
• Aus der DE 10 2016 206 657 A1 ist ein Verschaltungsring und ein Verfahren zum Verschalten von Wicklungsdrähten eines Stators bekannt.
• Aus der DE 10 2015 200 093 A1 ist eine Verschaltungsplatte eines Stators einer elektrischen Maschine bekannt, wobei die Verschaltungsplatte Leiterelemente aufweist, welche mit der elektrischen Wicklung verbindbar sind.

It is generally known that an electric motor has a stator on which a multi-phase winding is arranged. The winding consists, for example, of the three phases U, V and W, it being possible for each phase to consist of a number of coils connected to one another. There are known parallel or serial star connection and delta connection. In the case of the parallel star connection, individual coils are connected in parallel per phase, whereas in the case of the serial star connection, the individual coils are connected in series for each phase. The coils usually consist of winding wires that have to be connected to one another. Various types of such interconnections using interconnection devices are known from the prior art:

• From the DE 10 2017 216 084 A1 a stator for an electrical machine, an electrical machine and a method for producing such a stator are known.
• From the DE 10 2012 023 477 A1 a switching element for an electric motor, a stator with such a switching element and an electric motor is known.
• From the U.S. 2011 057 524 A1 an electrical connection device for a brushless motor is known.
• From the DE 10 2018 215 787 A1 a stator for an electric machine, an electric machine and a method of an electric machine are known.
• From the DE 10 2017 223 519 B3 a stator of a three-phase electronically commutated DC motor is known.
• From the DE 10 2016 211 230 A1 a connection device of a stator, an electrical machine including such a connection device and a method for producing such is known.
• From the DE 10 2016 206 657 A1 discloses an interconnection ring and a method for interconnecting winding wires of a stator.
• From the DE 10 2015 200 093 A1 a wiring board for a stator of an electrical machine is known, the wiring board having conductor elements which can be connected to the electrical winding.

The invention is therefore based on the object of further developing an electric motor with an interconnection unit and a stator and a method for its production, with the production effort being reduced during production and the electric motor being simpler, more cost-effective and more stable to produce.

According to the invention, the object is achieved with the connection unit according to the features specified in claim 1, with the stator according to the features specified in claim 5, with the electric motor according to the features specified in claim 9 and with the method for producing the electric motor.

Important features of the connection unit for a stator of an electric motor, by means of which individual phases of a multi-phase electrical winding of the stator can be connected to one another, in particular in a star connection, and to phase connections for the power supply, are that the connection unit has a carrier ring surrounding a ring axis, in particular concentrically and has a plurality of, in particular exactly four or at least four, metallic conductor elements spaced apart from one another, which in particular are shaped essentially in the shape of a circular arc,
wherein the support ring at least partially encloses the conductor elements, in particular at least partially enclosing the conductor element cross-section completely and with a material bond, each conductor element having at least one contacting section for making electrical contact with a section of the electrical winding, each conductor element covering a circumferential angle area, in particular relative to the ring axis, with the circumferential angle area covered by each conductor element overlaps with at least one circumferential angle area covered by another conductor element, in particular with the covered circumferential angle areas of all other conductor elements, and that in the direction parallel to the ring axis, i.e. in the axial direction, each conductor element overlaps circumferential angle sections with at most one further conductor element.

The term “carrier ring” is to be understood in such a way that this part is essentially ring-shaped. This means that the carrier ring has approximately the shape of a ring with a central opening. A ring plane and a ring axis are defined by this ring, which is intended to be clarified by the expression “a ring axis, in particular concentrically, surrounding the carrier ring”. The carrier ring thus has a ring axis, by means of which specific directions in space can be defined. The ring cross-section of the carrier ring, ie a section perpendicular to the plane of the ring and through the ring axis, can be of any shape and also be designed to be variable in the circumferential direction. Likewise, the cross section of the carrier ring, ie a section parallel to the plane of the ring, can deviate from the perfect circular ring shape, for example due to introduced grooves, depressions, projections or the like.

A direction parallel to the ring axis is also referred to as the "axial direction". The directions “circumferential direction” and “radial direction” are to be understood correspondingly in relation to the ring axis. “Circumferential direction” is therefore to be understood as a direction parallel to the plane of the ring and concentrically around the ring axis, i.e. following the circumference of a circle around the ring axis. “Radial direction” is therefore to be understood as a direction parallel to the ring plane and perpendicular to the ring axis, i.e. following a radius of a circle, with the circle lying in the ring plane and having the intersection point between the ring axis and the ring plane as its center.

The carrier ring is preferably made of plastic in order to electrically insulate the spaced metallic conductor elements contained in it from one another. Alternatively, another electrically insulating material is also conceivable. The expression "at least partially enclose" is intended to express that the conductor elements are not completely surrounded by the material of the carrier ring, but that certain sections, in particular the contacting sections, protrude from the carrier ring. The carrier ring accommodates the conductor elements and thus ensures the spatial arrangement of the conductor elements in relation to one another. The conductor elements are therefore spaced apart from one another, ie they do not touch one another, ie are not in direct contact with one another.

The conductor elements are made of an electrically conductive material, preferably metal or metal sheet and in particular copper sheet. The conductor elements are preferably designed in one piece and/or preferably as stamped and bent parts. The production can advantageously be carried out by means of water jet cutting or laser cutting.

The wording “wherein each conductor element has at least one contacting section” is to be understood in such a way that the contacting section is part of the conductor element. The at least one contacting section is advantageously connected in one piece to the rest of the respective conductor element.

The wording "whereby the circumferential angular range covered by each conductor element overlaps with at least one circumferential angular range covered by another conductor element" is to be understood as follows: Each conductor element covers, in particular relative to the ring axis, a specific circumferential angular range, i.e. an angular range in the circumferential direction. If the circumferential angular range covered by a first conductor element overlaps with the circumferential angular range covered by a second conductor element, this means that for certain angular ranges the first conductor element is arranged in front of or behind the second conductor element in the radial direction from the ring axis, i.e. overlaps in this projection direction . However, the two conductor elements do not touch one another, since they are radially spaced apart from one another, particularly in this overlapping angular range.

The wording "in the direction parallel to the ring axis, i.e. in the axial direction, each conductor element overlaps at most with one further conductor element, in particular in circumferential angles and/or radial sections" is to be understood as follows: Seen in the axial direction, i.e. in the viewing direction parallel to the ring axis, there is Areas in which a conductor element is arranged in front of or behind another conductor element, i.e. they overlap in the axial direction. In other words, a projection of the conductor elements in the axial direction onto a plane perpendicular to the axis of the ring would result in overlapping areas which are covered by at most two conductor elements. It is therefore entirely possible for a conductor element to be overlapped by several other conductor elements in the axial direction, but the respective overlapping areas are then located at different positions in the circumferential direction and/or radial direction, which is illustrated by the term circumferential angle and/or radial section.

The advantage of the interconnection unit is that it can be easily prefabricated and simple interconnection, in particular in a star connection, is made possible.

In an advantageous embodiment, the carrier ring has exactly four conductor elements, in particular with the conductor elements each having a different shape.
The advantage here is that an interconnection in a star connection is made possible with as few parts as possible.

In an advantageous embodiment, the carrier ring encloses the conductor elements at least in sections in the cross section of the conductor element completely and in a material-to-material manner. This means that in the circumferential direction relative to the ring axis there are areas in which the cross section of the conductor elements is completely surrounded by the material of the carrier ring, for example plastic. The support ring is preferably produced by an injection molding process, with the conductor elements preferably partially overmoulded, i.e. enclosed, and thereby the materially bonded connection between the conductor element and the carrier ring is produced.
The advantage here is that a stable connection can be produced between the conductor element and the carrier ring.

In an advantageous embodiment, the at least one contacting section has an essentially U-shaped cross section in a plane parallel to the ring axis, i.e. in a tangential plane, and/or the at least one contacting section has a notch, which runs in the circumferential direction and in particular on the radial outwardly facing surface of the contacting section is introduced. Alternatively, the notch can also be made on the radially inward-pointing surface of the contacting section.
The advantage here is that simple contacting is possible with a winding wire, in particular one having a round cross section, and/or that reliable contacting is possible with a correspondingly shaped contacting element that will be explained in more detail later.

In an advantageous embodiment, three, in particular exactly three, of the multiple conductor elements each have exactly one connection section for electrical contacting with a phase connection, in particular with these three conductor elements each having a step-like offset section, in particular in a direction parallel to the ring plane, and/or two contacting sections each exhibit.
The advantage here is that simple contacting with the phase shorts of an AC network is made possible. A step-like offset section is to be understood as meaning a kink in the conductor elements, which are advantageously shaped in sections essentially in the shape of a circular arc. Advantageously, this kink runs in a direction parallel to the plane of the ring, so that, for example, a conductor element has two circular arc sections which differ in radius. The advantage here is that a more compact design can be achieved. The advantage of the two contacting sections is that a parallel star connection can thereby be realized in which, for example, each of the three phases has two parallel coils.

In an advantageous embodiment, one, in particular exactly one, of the plurality of conductor elements has three or six, in particular exactly three or exactly six, contacting sections and in particular a step-like offset section, in particular in a direction parallel to the plane of the ring.
The advantage here is that this enables a star connection. One conductor element can be described as a star point element, since it connects the coils of the multi-phase winding in a star point configuration. With a parallel star connection (two coils in parallel per phase), the star point element has six contacting sections, whereas with a serial star connection (two coils in series per phase) only three contacting sections are necessary.

In an advantageous embodiment, all of the contacting sections of the plurality of conductor elements protrude from the carrier ring in a direction parallel to the ring axis, that is to say in the axial direction.
The advantage here is that simple contacting of the winding sections with the conductor elements is possible.

In an advantageous embodiment, all contacting sections are arranged on the radially outer side of the respective conductor elements.
The advantage here is that a compact design of the interconnection unit is made possible in the direction parallel to the plane of the ring.

In an advantageous embodiment, all of the contacting sections and/or all of the conductor elements intersect at least one plane perpendicular to the axis of the ring.
The advantage here is that a compact design of the connection unit is made possible in the axial direction.

In an advantageous embodiment, all contacting sections are spaced essentially the same distance from the ring axis in the radial direction.
The advantage here is that a compact design of the interconnection unit is made possible in the direction parallel to the plane of the ring.

Important features of the stator for an electric motor are that the stator has a stator core surrounding a stator axis with a closed yoke ring and a plurality of stator teeth pointing radially inward from the yoke ring, in particular the stator core being designed as a laminated core, the stator furthermore having a substantially ring-shaped, has an insulating end disk, the end disk being attached to an axial end of the stator core in such a way that both the yoke ring and the stator teeth are covered by the end disk at least in the direction parallel to the stator axis, i.e. the axial direction, with the individual covered by the end disk Stator teeth each winding wire of a multi-phase electrical winding is wound, the end plate having several, in particular in the axial direction projecting, connection projections for receiving winding wire sections, wherein in each Connection projection, in particular in the axial direction, in each case a contacting element can be used in such a way that an electrical connection is established between the contacting element that can be used and a winding wire section accommodated in a respective connection projection.
The advantage here is that the contacting elements serve as connection points instead of the winding wire ends for later interconnections, and these connection points can therefore be shaped advantageously in order to enable simpler and more reliable interconnection.

The phrase "substantially annular, insulating end plate" is to be understood as follows: The end plate is a part which has a central opening and is closed around this opening. Therefore, it can be described as "substantially ring-shaped". In particular, the wording does not stipulate that the cross section of the end disk is a perfect circular ring. The cross section can deviate from this shape, for example due to the introduction of grooves, depressions, projections or the like, both on the radially inner and on the radially outer circumference. The wording "end plate" is only intended to imply that the expansion of the end plate in the axial direction is less than the expansion in a plane perpendicular to the stator axis, i.e. perpendicular to the axial direction.

In an advantageous embodiment, the contacting elements are designed as insulation displacement contacts, so that the electrical connection between the respective contacting elements and the respective winding wire sections is made by means of an insulation displacement connection
The advantage here is that a simple and secure connection to the winding wire is made possible.

In an advantageous embodiment, the contacting elements can each be inserted completely into the respective connection projection.
The advantage here is that a compact design of the stator can be achieved. The phrase "completely insertable" means that the entire contact element can be inserted into the connection projection and therefore does not protrude from the connection projection, particularly in the axial direction. This makes it clear that the contacting element is a separate part compared to the conductor element mentioned above. The contacting element is therefore in particular not part of the interconnection unit. The advantage of separate contacting elements that are part of the stator is that the stator can be prefabricated as a separate structural unit with contacted wires, in particular automatically, and the contacting elements then serve as connection points for the conductor elements of the interconnection unit. The interconnection unit can also be prefabricated as a separate structural unit. The coils are then interconnected later by the interconnection unit being applied to the stator, with electrical connections being produced between the contacting sections of the interconnection unit and the contacting elements of the stator.

In an advantageous embodiment, the connecting projections have shaft-like housing contours for, in particular complete, receiving a contacting element, with a slot-like depression being provided in the radially inner and radially outer shaft wall for receiving a winding wire section.
The advantage here is that precise positioning of the winding wire is made possible, which facilitates subsequent electrical contacting with the contacting elements.

In an advantageous embodiment, the end plate has groove-like depressions running in the circumferential direction on its radially outer circumferential region for guiding winding wire sections, in particular with the groove-like depressions running exclusively in planes, in particular at most three, perpendicular to the stator axis and/or in particular with the groove-like depressions running in the circumferential direction are partially interrupted.
The advantage here is that when several stator teeth are wound with the same winding wire (through winding), exact guidance and positioning of the winding wire is made possible, and this also prevents different winding wires from touching one another.

Important features of the electric motor, in particular a permanently excited synchronous motor, are that the electric motor has a rotor which is arranged such that it can rotate about an axis of rotation, a stator which concentrically surrounds the rotor and an interconnection unit,
wherein the stator has a stator core surrounding a stator axis with a closed yoke ring and a plurality of stator teeth pointing radially inwards from the yoke ring, in particular wherein the stator core is designed as a laminated core, wherein the stator also has a substantially ring-shaped, insulating end disk, the end disk being attached in such a way is attached to an axial end of the stator core, so that both the return ring and the stator teeth are covered by the end disk at least in the direction parallel to the stator axis, i.e. in the axial direction, with winding wire of a multi-phase electrical winding being wound around the individual stator teeth covered by the end disk , The end plate having a plurality of connection projections, in particular projecting in the axial direction, for receiving winding wire sections ten, wherein a contact element can be inserted into each connection projection, in particular in the axial direction, in such a way that an electrical connection is established, in particular by means of an insulation displacement connection, between the contact element that can be used and a winding wire section accommodated in a respective connection projection, the interconnection unit having a one ring axis, in particular concentrically, surrounding the carrier ring and a plurality of, in particular exactly four or at least four, spaced metallic conductor elements, which in particular are shaped essentially in the shape of a circular arc, the carrier ring at least partially enclosing the conductor elements, in particular at least partially enclosing the conductor element cross-section completely and in a materially bonded manner , Each conductor element having at least one contacting portion for electrical contact with a portion of the electr ical winding, wherein each conductor element, in particular relative to the ring axis, covers a circumferential angle range, wherein the circumferential angle range covered by each conductor element overlaps with at least one covered by another conductor element circumferential angle range and
that in the direction parallel to the ring axis, i.e. in the axial direction, each conductor element overlaps at most one further conductor element, in particular in circumferential angles and/or radial sections, in particular with the ring axis of the interconnection unit, the stator axis of the stator core and the axis of rotation of the rotor coinciding, with each contacting element, an electrical connection can be made between a winding wire section accommodated in a respective connection projection and a respective contacting section of a conductor element for interconnecting the winding wires to form a multi-phase winding, in particular with the interconnection unit for interconnection in the direction parallel to the axis of rotation, i.e. in the axial direction, being pluggable onto the end plate is.
The advantage here is that quick, simple and reliable electrical interconnection of the winding wires is made possible. Because the winding wires in the stator are already electrically connected to the contacting elements, the contacting elements now serve as connection points for the conductor elements accommodated in the interconnection unit. This enables a simple connection of the interconnection unit to the stator, for example plugging in or plugging in. In this way, the stator can be prefabricated and, in a final processing step, the interconnection can be carried out safely using simple means.

In an advantageous embodiment, each contacting section has a notch running in the circumferential direction, in particular with the notch being made on the surface of the respective contacting section pointing radially outwards or radially inwards, and with all contacting elements each having a spring section, with the respective spring section being such cooperates with the respective notch that a latching connection or clip connection can be produced between the respective contacting element and the respective contacting section.
The advantage here is that improved and stable contacting can be implemented, which prevents or at least reduces accidental separation of the two contacting partners caused by stress.

In an advantageous embodiment, the carrier ring has a circumferential collar section on its outer circumference, which can be slipped over the end plate in the axial direction, in particular the carrier ring and the end plate being releasably connectable to one another, in particular clip-connectable.
The advantage here is that the connection unit can be easily installed on the end plate of the stator. An advantageous, stable mechanical connection also results here, in particular in conjunction with the latching or clip connection between the contacting elements and contacting sections. If, for example, the motor is used in an environment in which high shaking vibrations can occur, the load on the mechanical connection between contacting elements and contacting sections is reduced by the collar section mechanically fixing the carrier ring. As a result, it is less common for a mechanical and thus electrical connection between contacting elements and contacting sections to break off or be interrupted. The advantage of the detachable connection compared to hot caulking, for example, is that the interconnection unit can be fitted in one work step. Additional work steps are not necessary.

In an advantageous embodiment, the end disk has one or more centering pins, which interact with corresponding centering pin receptacles in the support ring in such a way that the support ring can be plugged onto the end disk in a twist-proof manner.
The advantage here is that a fail-safe installation of the connection unit on the end plate of the stator is made possible. Advantageously, by hot caulking the centering mandrels with the respective centering mandrel receptacles, a safeguard against axial displacement, ie in particular a safeguard against loss, can also be implemented.

In an advantageous embodiment, the carrier ring has at least one recess in the axial direction for the passage of a temperature sensor, with which the temperature of the winding can be measured.
The advantage here is that safety is increased and wear on the winding wires can be detected at an early stage.

Important features of the method for producing an electric motor are that the method has the following steps: producing an interconnection unit as described above, producing a stator as described above, each contacting element being used to establish an electrical connection between a winding wire section accommodated in a respective connection projection and a respective contacting section a conductor element is produced for interconnecting the winding wires to form a multi-phase winding, in particular the interconnection unit being plugged onto the end plate for interconnection in the direction parallel to the axis of rotation, ie in the axial direction.
The advantage here is that quick, simple and reliable electrical interconnection of the winding wires is made possible.

Important features of the method for manufacturing an electric motor are that the method has the following steps: in a first step, manufacturing an interconnection unit according to one of claims 1 to 5, in a second step, manufacturing a stator according to one of claims 6 to 9, in a third step connecting the interconnection unit to the stator, wherein in the third step an electrical connection between a winding wire section accommodated in a respective connection projection and a respective contacting section of a conductor element is established by means of each contacting element for interconnecting the winding wires to form a multi-phase winding, in particular the interconnection unit for connection in the direction parallel to the axis of rotation, i.e. in the axial direction, is plugged onto the end plate.
The advantage here is that the connection unit can be easily installed on the end plate of the stator.

In an advantageous embodiment, the interconnection unit produced in the first step is produced by the following sub-steps: in a first sub-step, production of metallic conductor elements by means of a stamping and bending process, in a second sub-step, the conductor elements are placed in an injection mold, in a third sub-step, the conductor elements are overmolded with an insulating material, in particular plastic. The advantage here is that automated and reproducible production can be carried out.

In an advantageous embodiment, the interconnection unit produced in the first step is either a first interconnection unit or a second interconnection unit, the first and the second interconnection unit each being produced by a method with the sub-steps mentioned above, the first interconnection unit comprising first conductor elements, which are divided into a first injection mold are inserted and the second interconnection unit comprises second conductor elements, which are inserted into a second injection mold, the number and/or shape of the first conductor elements differing from the second conductor elements and the first and second injection molds are identical or the first and the second injection mold are identical.
The advantage here is that different interconnection topologies can be produced with a single injection mold. For example, a parallel and a serial star connection can be implemented without having to use a separate injection mold for each. The carrier ring made of plastic has the same shape in both cases, only the shape and/or number of the conductor elements embedded in the carrier ring differ depending on the interconnection topology.

In an advantageous embodiment, the stator produced in the second step is produced by the following sub-steps: in a first sub-step, production of a stator core by means of stamped stacking of laminations, in a second sub-step production of an end plate by means of an injection molding process, in a third sub-step, placing the end plate on one end side of the stator core, in a fourth sub-step winding the stator teeth of the stator core with winding wire, in particular by means of an automated needle winding process, in a fifth sub-step inserting winding wire ends into the shaft-like depressions of the connection projections of the end plate and in a sixth sub-step inserting contacting elements into the connection projections for electrical contacting the winding wires with the contacting elements.
The advantage here is that automated and reproducible production can be carried out.

Further advantages result from the dependent claims. The invention is not limited to the combination of features of the claims. For the person skilled in the art, there are further meaningful combinations of claims and/or individual claim features and/or features of the description and/or the figures, in particular special from the task and/or the task arising from comparison with the state of the art.

• In der 1 ist eine Anordnung von Leiterelementen einer ersten erfindungsgemäßen Verschaltungseinheit in Schrägansicht gezeigt, welche sich zu einer seriellen Sternschaltung eignet.
• In der 2 ist eine Anordnung von Leiterelementen einer zweiten erfindungsgemäßen Verschaltungseinheit in Schrägansicht gezeigt, welche sich zu einer parallelen Sternschaltung eignet.
• In der 3 ist die erste erfindungsgemäße Verschaltungseinheit in Draufsicht gezeigt, wobei diese die in 1 gezeigte Anordnung von Leiterelementen enthält.
• In der 4 ist die zweite erfindungsgemäße Verschaltungseinheit in Draufsicht gezeigt, wobei diese die in 2 gezeigte Anordnung von Leiterelementen enthält.
• In der 5 ist ein erfindungsgemäßer Stator für einen Elektromotor in perspektivischer Seitenansicht gezeigt.
• In der 6 ist ein erfindungsgemäßer Elektromotor mit montierter Verschaltungseinheit in Schrägansicht gezeigt.
• In der 7 ist ein Kontaktierungsabschnitt und ein dazugehöriges Kontaktierelement vor dem Aufstecken der Verschaltungseinheit in Schrägansicht gezeigt.
• In der 8 ist ein Kontaktierungsabschnitt und ein dazugehöriges Kontaktierelement nach dem Aufstecken der Verschaltungseinheit in Schrägansicht gezeigt.
• In der 9 ist ein Kontaktierelement in Detailansicht gezeigt.
• In der 10 ist ein Ausschnitt eines Querschnittes durch den Elektromotor vor dem Aufstecken der Verschaltungseinheit auf die Endscheibe gezeigt.
• In der 11 ist ein Ausschnitt eines Querschnittes durch den Elektromotor nach dem Aufstecken der Verschaltungseinheit auf die Endscheibe gezeigt. Der Querschnitt verläuft dabei durch eine andere Ebene als in 10.

The invention will now be explained in more detail with reference to figures:

• In the 1 an arrangement of conductor elements of a first interconnection unit according to the invention is shown in an oblique view, which is suitable for a serial star connection.
• In the 2 an arrangement of conductor elements of a second interconnection unit according to the invention is shown in an oblique view, which is suitable for a parallel star connection.
• In the 3 the first interconnection unit according to the invention is shown in plan view, this being the in 1 shown arrangement of conductor elements contains.
• In the 4 the second interconnection unit according to the invention is shown in plan view, this being the in 2 shown arrangement of conductor elements contains.
• In the 5 an inventive stator for an electric motor is shown in a perspective side view.
• In the 6 an electric motor according to the invention with a mounted connection unit is shown in an oblique view.
• In the 7 a contacting section and an associated contacting element are shown in an oblique view before the interconnection unit is plugged on.
• In the 8th a contacting section and an associated contacting element are shown in an oblique view after the interconnection unit has been plugged on.
• In the 9 a contacting element is shown in detail.
• In the 10 shows a section of a cross section through the electric motor before the interconnection unit is plugged onto the end plate.
• In the 11 shows a section of a cross section through the electric motor after the interconnection unit has been plugged onto the end plate. The cross-section runs through a different plane than in 10 .

1 shows an example of an arrangement of conductor elements (1, 2, 3, 4) for a first connection unit according to the invention, which is suitable for realizing a serial star connection. The figure shows the spatial arrangement of the conductor elements before they are overmoulded with a plastic, for example by means of an injection molding process, in order to form the carrier ring. The first embodiment has four conductor elements of the first type (1, 2, 3, 4), which are produced from flat metal strips by means of a stamping and bending process. The conductor elements of the first type (1, 2, 3, 4) are essentially arranged in a plane parallel to the ring plane of the carrier ring. In other words, there is at least one plane parallel to the plane of the ring, which intersects all the conductor elements of the first type (1, 2, 3, 4).
The conductor cross section of all conductor elements of the first type (1, 2, 3, 4) is essentially rectangular and the extension in the direction of the ring axis, ie in the axial direction, is greater than the extension in the radial direction. Alternatively, a round or polygonal cross section is also conceivable.

The first, second and third conductor elements of the first type (1, 2, 3), each referred to below as the first, second and third phase element of the first type, each have a contacting section 5 for making electrical contact with a section of the electrical winding of the electric motor. In addition, each phase element of the first type (1, 2, 3) has a connection section 6 for making electrical contact with a phase connection 7. In the case of a three-phase winding with the phases U, V and W, each phase element of the first type (1, 2, 3) each assigned to a phase. An electrical connection of the phases to coils of the winding is then established via the contacting sections 5 .

In the present exemplary embodiment, the stator has twelve stator teeth, with a coil being wound around each stator tooth using winding wire. Thus, each of the three phases has four coils, these four coils being connected in series and each being wound through by means of a winding wire. One end of each winding wire is connected, in particular indirectly, to a contact section 5 of a phase element of the first type (1, 2, 3). The respective other end of the winding wire is connected to one of the three contacting sections 5 of the fourth conductor element of the first type 4, hereinafter referred to as the star point element of the first type. This connection is also advantageously carried out indirectly with the aid of a contacting element, as will be described in more detail later. The star point element of the first type 4 ensures that the three phases are interconnected by means of a common star point, which is why it has three contact sections 5 .

All of the conductor elements of the first type (1, 2, 3) are essentially in the form of a circular arc in sections shaped. As can be seen from the figure, the contacting web 8 of the first phase element of the first type 1, which is bent in the radial direction, does not run completely parallel to the connection section 6 in the ring plane, so that this phase element 1 can also be described as being shaped essentially like a circular arc. The second and third phase elements of the first type (2, 3) each have a circular arc section and a straight section between the contacting web 8 and the connecting section 6. The star point element of the first type 4 in turn has three circular arc sections 9, with a step-like offset section 10 being formed between each two circular arc sections 9. As a result, two connected circular arc sections each have a different circle radius. In the figure, the offset section 10 runs in a direction which runs parallel to the plane of the ring. Alternatively, a course exactly in the radial direction is also conceivable.

Depending on the radius of the circular arc section 9, the respective contacting webs 8 differ in their length in the radial direction. This length is selected in each case in such a way that the contacting sections 5 are essentially equidistant from the ring axis in the radial direction. In addition, the contacting sections 5 have an essentially U-shaped cross section in a plane parallel to the axis of the ring, which can also be referred to as the tangential plane. They all protrude in the same direction, so that later only one side of the carrier ring is used for the interconnection. As can be seen from the figure, all the contacting sections are arranged on the radially outer side of the respective conductor elements.

As can be seen from the figure, each conductor element (1, 2, 3, 4) of the first type covers a circumferential angular range relative to the axis of the ring. The covered circumferential angular range of the second phase element of the first type 2 overlaps in one angular range with the covered circumferential angular range of the first phase element of the first type 1 and in another angular range with the covered circumferential angular range of the star point element of the first type 4. In other words, if you have a projection from the ring axis from outwards in the radial direction, then areas arise which are covered by two conductor elements of the first type and areas which are only covered by one conductor element of the first type. The former are referred to as overlap areas. It is essential to the invention that the circumferential angle area covered by each conductor element overlaps with at least one circumferential angle area covered by another conductor element. In the present first exemplary embodiment, the circumferential angle range of the first phase element of the first type 1 and of the third phase element of the first type 3 each overlaps with a further covered circumferential angle range of another conductor element of the first type, whereas the covered circumferential angle ranges of the second phase element of the first type 2 and the neutral point element 4 each have two overlap other covered circumferential angle areas of other conductor elements of the first type. The overlap takes place in each case in other angular ranges.

A further feature according to the invention is that in the direction parallel to the ring axis, ie in the axial direction, each conductor element overlaps at most one further conductor element, in particular in circumferential angle and/or radial sections. In other words, viewed in the axial direction, in all areas only at most one conductor element of the first type is always arranged above another conductor element of the first type. Or to put it another way, a projection in the axial direction onto a plane parallel to the plane of the ring creates areas that are covered by a maximum of two conductor elements, i.e. “axial overlapping areas”. In the present example, this axial overlap occurs only at two points, namely where the contacting webs 8 of the star point element of the first type 4 each run axially above the second and third phase element of the first type (2, 3). The conductor elements are therefore not stacked one on top of the other in the axial direction, but there are only isolated areas in which at most two conductor elements are arranged one above the other. This makes it possible to achieve a compact design in the axial direction.

2 shows an example of an arrangement of conductor elements (21, 22, 23, 24) for a second connection unit according to the invention, which is suitable for realizing a parallel star connection. This second connection unit is suitable for the same stator as the first connection unit, ie for a stator with twelve teeth, each of the three phases having four coils. In this case, however, two series-connected coils wound from a winding wire are connected to two other series-connected coils wound from a winding wire per phase. In order to implement this star connection, the three phase elements of the second type (21, 22, 23) have two contacting sections 5 in addition to their connection section 6. The star point element of the second type 24 correspondingly has six contact sections in order to implement the star connection. In contrast to the first exemplary embodiment, in the second exemplary embodiment all conductor elements of the second type have a step-like offset section 10 . Furthermore, obvious similarities with the first exemplary embodiment that can be seen in the figure are not described again separately.

In the second exemplary embodiment, too, it applies that in the direction parallel to the ring axis, ie in the axial direction, each conductor element overlaps at most one further conductor element, in particular in circumferential angle and/or radial sections. As described above for the first exemplary embodiment, a projection parallel to the ring axis, ie in the axial direction, onto a plane parallel to the ring plane only leads to areas that are covered by at most two conductor elements. Thus, the third phase element of the second type 23 is arranged with one contacting section 5 axially over the star point element of the second type 24 and with another contacting section 5 axially over both the first and the second phase element of the second type (21, 22), these axial overlapping areas are located however, at different positions, in particular in the circumferential and/or radial direction.

As for the first exemplary embodiment, it also applies to the second exemplary embodiment that the circumferential angle area covered by each conductor element overlaps with at least one circumferential angle area covered by another conductor element. In the present second exemplary embodiment, the covered circumferential angle range of the first phase element of the second type 21 even overlaps in a circumferential angle range with the covered circumferential angle ranges of all other conductor elements of the second type.

3 shows a top view of a first embodiment of an interconnection unit 30 according to the invention. This first interconnection unit 30 has a first support ring 31, which in this exemplary embodiment consists of plastic and was produced by means of an injection molding process. The conductor elements of the first type (1, 2, 3, 4) in the spatial arrangement according to FIG 1 arranged and thus at least partially cohesively enclosed.

In the center of the first carrier ring 31, the ring axis (RA) is indicated by a point, to which the first carrier ring 31 is arranged concentrically, ie it surrounds. The essentially ring-shaped shape of the first support ring can be clearly seen in the figure. The illustration is a plan view of that side of the first carrier ring 31 which will later be placed on an end side of the stator for connection. This means that in this view the contacting sections 5 protrude vertically upwards out of the plane of the paper, which is a plane parallel to the plane of the ring. This view also clearly shows that the contacting sections 5 are all essentially at the same distance from the ring axis (RA). The contact plug 32 contains the phase connections 7 (not visible) and can simply be plugged onto the first carrier ring 31 for easy contacting with the connection sections 6, which are not shown in this figure.

The first carrier ring 31 has two centering mandrel receptacles 33, which are used for the non-rotating assembly of the first carrier ring 31 on the end plate of the stator. This functionality will be in 10 described more clearly.

The first carrier ring has first, second and third bulges (34, 35, 36) in the radial direction. The second bulges 35 are shaped in such a way that a contacting section 5 can be accommodated and protrudes axially from the second bulge. The third bulges also accommodate a contacting section 5, but they extend further in the circumferential direction, so that the position of the contacting section 5 can be changed in the circumferential direction, ie the contacting section 5 can be positioned at different positions. The first bulges 34, on the other hand, do not accommodate any contacting sections 5 in the first exemplary embodiment; these are blind bulges 34, so to speak.

4 shows a top view of a second embodiment of an interconnection unit 40 according to the invention. This second interconnection unit 40 has a second carrier ring 41, which in this exemplary embodiment consists of plastic and was produced by means of an injection molding process. Inside the second support ring 41 are - not visible in this view - the conductor elements of the second type (21, 22, 23, 24) in the spatial arrangement according to 2 arranged and thus at least partially cohesively enclosed.

As can be seen, the outer geometric shape of the second carrier ring 41 is identical to the shape of the first carrier ring 31. This is due to the fact that both carrier rings (31, 41) were produced using the same, ie identical, injection mold. Alternatively, two identical injection molds can also be used. The only difference between the two support rings (31, 41) is that they each accommodate different conductor elements in order to implement the different interconnection topologies.

The outer shape of the carrier rings (31, 41) is therefore adapted in such a way that there are corresponding bulges in the carrier ring for both interconnection topologies. In the second exemplary embodiment, there are also first bulges 42 without contacting sections 5 and second bulges bulges 43 with contacting sections 5. The first bulges 42 of the second exemplary embodiment correspond to the second bulges 35 of the first exemplary embodiment. Consequently, the second bulges 43 of the second embodiment correspond to the first bulges 34 of the first embodiment. The assignment with contact sections 5 is just the opposite. The third bulges (36, 44) of both embodiments each have a contacting section 5, although their position in the circumferential direction differs from one another.

5 shows a stator 50 according to the invention for an electric motor in a perspective side view, consisting of a stator core 51 designed in particular as a laminated core and an end sheath 52 fastened to an axial end of the stator core 51. The end plate 52 is preferably made of plastic and advantageously produced by means of an injection molding process. For each of the two interconnection topologies, a separate end disk, ie one with a different shape, is used. However, the functions described below are the same.

The end disk 52 has a plurality of connection projections 53 distributed over its circumference, which protrude from the end disk 52 in the direction parallel to the stator axis SA, ie in the axial direction. These connection projections 52 advantageously have shaft-like housing contours, a slot-like depression 54 being provided in the radially inner and radially outer shaft wall for receiving a winding wire section 55 . The wire ends of the coils accommodated on the stator teeth are thus accommodated by the slit-like indentations and spatially fixed. A contacting element, which is advantageously designed as an insulation displacement contact 56, is then inserted into the connection projection in the axial direction, so that an insulation displacement connection is created between the insulation displacement contact 56 and the winding wire 55. The insulation displacement contact 56 thus later serves as a connection point for the interconnection unit (31, 41).

The end disk 52 has, on its radially outer peripheral region, groove-like indentations 57 running in the peripheral direction for guiding winding wire sections. Such guides are necessary when several coils connected in series, each coil being wound around a respective stator tooth, are wound through by means of a winding wire. Since the respective stator teeth are not necessarily exactly adjacent, the winding wire can be easily and reliably guided to a stator tooth which is arranged further away in the circumferential direction by means of the indentations 57 . This ensures that different winding wire sections do not touch. As shown, these indentations 57 advantageously run exclusively in planes perpendicular to the stator axis. In the circumferential direction, these indentations 57 are interrupted in sections by recesses in the end plate 52 in order to enable the wire to be guided into the interior of the stator, ie to the stator teeth. A centering mandrel 58 which protrudes axially from the end disk 52 can also be seen in this figure.

6 shows an electric motor 60 according to the invention with a mounted connection unit (30, 40) in an oblique view. Here you can see the radially inwardly projecting stator teeth 61, which are covered in the axial direction by inwardly pointing winding aids 62 of the end cap 52. The winding aids 62 ensure that the winding wire (not shown) wound around the stator teeth is electrically insulated from the face of the corresponding stator tooth. Insulating paper is advantageously used for insulation in the stator slots.

7 shows an example of a section of a conductor element, for example the star point element 4 of the first type, before it is connected to the contacting element 56. As already described, the contacting element 56 was connected to the winding wire in a previous production step. 8th then shows the conductor element 4 that has already been attached in the axial direction 7 . It is advantageously plugged on in such a way that a notch 70 made in the radially outward-facing surface of the contacting section 5 in the circumferential direction, in particular parallel to the plane of the ring, interacts with a spring section 71 of the contacting element 56 in such a way that it engages. Correspondingly, the notch can also be applied to the radially inward-pointing surface if the spring section 71 of the contacting element 56 is shaped accordingly. Thus, overall, simple and reliable contacting of the conductor elements with the winding wire 55 can be implemented. In 7 For example, the notch 70 is introduced on both legs of the U-shaped contacting section 5 . However, the shape of the contacting sections 5 can also be shaped differently, that is, the notch 70 is not only advantageous in connection with the U-shaped cross section. The only advantage of the U-shaped cross section is that it can be adapted to the geometry of the wire, for example in that the radius of the U is slightly larger than the radius of the winding wire. As in 7 shown, the insulation displacement connection is made by means of the two connecting brackets (72, 73).

9 shows a detailed view of a contacting element 56 according to the invention with its two connecting brackets (72, 73) for receiving the winding wire. The spring section 71 can also be seen. By attaching the contacting section 5, the spring section 71 is pressed in the direction of that side of the contacting element 56 to which it is attached. As soon as the tip of the spring section 71 reaches the notch 70 when plugging in, the elastic spring force causes the spring section 71 to clip into the notch 70. This produces a stable mechanical and correspondingly stable electrical connection.

In the 10 shows a section of a cross section along a radial direction through the electric motor before the interconnection unit (30, 40) is plugged onto the end plate 52. The section runs through the center of a centering mandrel 58 or a centering mandrel receptacle 33. This illustration shows how the winding wire 55 is guided in the groove-like depressions on the outside of the end plate 52 and how it is guided inside the stator 51 the stator teeth 61 and the winding aids 62 to form coils 100 . The winding wire 55 is advantageously guided through notches 104 in the end plate 52 from the inside to the outside or vice versa. Wire 55 is not shown in notch 104 in the present illustration. As already described, the wire ends are fixed in the slit-like depressions 54 of the connection projections 53 before (not shown) a contacting element is introduced into a connection projection 53 in the axial direction. The coils are then connected by the connection unit (30, 40) being pushed onto the end plate 52 in the axial direction, as indicated by the arrow. One or more centering pins 58 of the end disk 52, which interact with corresponding centering pin receptacles 33 of the interconnection unit, are used for centering and fail-safe assembly.

For improved guidance during attachment and in addition to protecting the winding wires 55 accommodated in the groove-like depressions 57 of the end plate 52, the support ring (31, 41) has a collar section 101 running around its outer circumference, which can be slipped over the end plate 52 in the axial direction. Advantageously, there is a clip connection or latching connection, for example by a latching lug 102 located on the collar section 101, which interacts with a latching lug receptacle 103 of the end plate and thereby causes latching. A detachable connection is thus created in a simple manner, which contributes to the mechanical stability.

In the 11 shows a section of a cross section along the radial direction through the electric motor before the connection unit (30, 40) is plugged onto the end plate 52. The section runs through the center of a connecting projection 53 in which a contacting element 56 is accommodated. The winding wire, which is advantageously connected to the contacting element 56 by means of an insulation displacement connection, is hidden in this illustration. It can be seen how a contacting section 5 engages in the contacting element 56 in order to produce an electrical connection between the conductor element 24 and the contacting element 56 and thus with the winding wire 55 (not shown). The contacting element advantageously has a spring section 71, the tip of which can be accommodated in a notch in the contacting section 5 in order to achieve a stable connection. The notch is in the 11 not visible because the section of the figure runs through the middle of the contacting section 5 (compared to this, see the detailed view of 7 ). The contacting section 5 extends on its sides to about the bottom of the connecting projection 53. In this floor itself are as in 11 recesses are again shown, which receive the contacting element 55 . The winding wire is laterally surrounded by the advantageous U-shaped cross section of the contacting section 5 .

11 shows the connection principle for the second embodiment of the connection unit 40. This principle also applies correspondingly to the first connection unit 30.

Reference List

1

First phase element of the first kind

2

Second phase element of the first kind

3

Third phase element of the first kind

4

Star point element of the first kind

5

contacting section

6

connector section

7

phase connection

8th

contact bridge

9

circular arc section

10

Stepped offset section

21

First phase element of the second kind

22

Second phase element of the second kind

23

Third phase element of the second kind

24

Star point element of the second kind

30

First switching unit

31

First carrier ring

32

contact plug

33

centering mandrel mount

34

First bulge of the first embodiment

35

Second bulge of the first embodiment

36

Third bulge of the first embodiment

40

Second switching unit

41

Second carrier ring

42

First bulge of the first embodiment

43

Second bulge of the first embodiment

44

Third bulge of the first embodiment

50

stator

51

stator core

52

end plate

53

connection boss

54

Slit-like indentation

55

winding wire

56

contacting element

57

Groove-like indentation

58

centering mandrel

60

electric motor

61

stator tooth

62

winding aid

70

score

71

spring section

72

First connection bracket

73

Second connection bracket

100

winding

101

collar section

102

detent

103

detent mount

RA

ring axis

SA

stator axis

QUOTES INCLUDED IN DESCRIPTION

This list of documents cited by the applicant was 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.

Patent Literature Cited

• DE 102017216084 A1 [0002]
• DE 102012023477 A1 [0002]
• US2011057524A1 [0002]
• DE 102018215787 A1 [0002]
• DE 102017223519 B3 [0002]
• DE 102016211230 A1 [0002]
• DE 102016206657 A1 [0002]
• DE 102015200093 A1 [0002]

Claims (15)

Interconnection unit for a stator of an electric motor, by means of which individual phases of a multi-phase electrical winding of the stator can be connected to one another, in particular in a star connection, and to phase terminals for the power supply, the interconnection unit having a carrier ring surrounding a ring axis, in particular concentrically, and a plurality of, in particular exactly four or has at least four metallic conductor elements spaced apart from one another, which, in particular in sections, are shaped essentially in the shape of a circular arc, the carrier ring at least partially enclosing the conductor elements, in particular completely and materially in the cross section of the conductor element at least in sections, with each conductor element having at least one contacting section for electrical contacting with a section of the electrical winding, each conductor element, in particular relative to the ring axis, over a circumferential angle range covered, characterized in that the circumferential angle area covered by each conductor element overlaps with at least one circumferential angle area covered by another conductor element, in particular with the covered circumferential angle areas of all other conductor elements, and that in the direction parallel to the ring axis, i.e. in the axial direction, each conductor element, in particular circumferential angle and/or radially in sections, overlapped at most with a further conductor element. Interconnection unit according to one of the preceding claims, characterized in that three, in particular exactly three, of the plurality of conductor elements each have exactly one connection section for electrical contacting with a phase connection, in particular these three conductor elements each having a step-like offset section, in particular in a direction parallel to the ring plane, and/or each have two contacting sections. Interconnection unit according to one of the preceding claims, characterized in that one, in particular exactly one, of the plurality of conductor elements has three or six, in particular exactly three or exactly six, contacting sections and in particular a step-like offset section, in particular in a direction parallel to the plane of the ring. Interconnection unit according to one of the preceding claims, characterized in that all contacting sections are arranged on the radially outer side of the respective conductor elements and/or that all contacting sections and/or all conductor elements intersect at least one plane perpendicular to the ring axis and/or that all contacting sections in the radial direction in Are substantially equidistant from the ring axis. Stator for an electric motor, having a stator core surrounding a stator axis with a closed yoke ring and a plurality of stator teeth pointing radially inwards from the yoke ring, in particular wherein the stator core is designed as a laminated core, and a substantially annular, insulating end plate, the end plate being attached to an axial end of the stator core is fixed such that both the yoke ring and the stator teeth are covered by the end disk at least in the direction parallel to the stator axis, i.e. in the axial direction, with winding wire of a multi-phase electrical winding being wound around each of the individual stator teeth covered by the end disk, with the end plate has a plurality of connection projections, in particular projecting in the axial direction, for receiving winding wire sections, characterized in that in each connection projection, in particular in the axial direction, a contacting element such as e can be used that in each case an electrical connection is established between the contact element that can be used and a winding wire section accommodated in a respective connection projection. stator after claim 5 , characterized in that the contacting elements are designed as insulation displacement contacts, so that the electrical connection between the respective contacting elements and the respective winding wire sections is made by means of an insulation displacement connection and/or that the contacting elements can each be inserted completely into the respective connection projection. Stator after one of Claims 5 until 6 , characterized in that the connection projections for, in particular complete, accommodation of a contacting element have shaft-like housing contours, a slot-like recess being provided in the radially inner and the radially outer shaft wall for receiving a winding wire section. Stator after one of Claims 5 until 7 , characterized in that the end plate has groove-like depressions running in the circumferential direction on its radially outer circumferential region for guiding winding wire sections, in particular with the groove-like depressions running exclusively in planes, in particular at most three, perpendicular to the stator axis and/or in particular with the groove-like depressions being interrupted in sections in the circumferential direction. Electric motor, in particular permanent-magnet synchronous motor, with a rotor arranged to rotate about an axis of rotation, a stator concentrically surrounding the rotor according to one of Claims 6 until 9 , and a switching unit according to one of Claims 1 until 5 , in particular wherein the ring axis of the interconnection unit, the stator axis of the stator core and the axis of rotation of the rotor coincide, characterized in that by means of each contacting element of the stator, an electrical connection, in particular by means of an insulation displacement connection, is established between a winding wire section accommodated in a respective connection projection and a respective contacting section of a conductor element of the interconnection unit can be produced for interconnecting the winding wires to form a multiphase winding, in particular the interconnection unit being pluggable onto the end plate for interconnection in a direction parallel to the axis of rotation, ie in the axial direction. electric motor after claim 9 , characterized in that each contacting section has a notch running in the circumferential direction, in particular wherein the notch is made on the surface of the respective contacting section pointing radially outwards or radially inwards, and wherein all contacting elements each have a spring section, the respective spring section being such cooperates with the respective notch that a latching connection or clip connection can be produced between the respective contacting element and the respective contacting section. Electric motor according to one of claims 9 or 10 , characterized in that the carrier ring has a circumferential collar section on its outer circumference, which can be slipped over the end plate in the axial direction, in particular the carrier ring and the end plate can be releasably connected to one another, in particular clip-connected. Electric motor according to one of claims 9 until 11 , characterized in that the end plate has one or more centering pins, which interact with corresponding centering pin receptacles in the support ring in such a way that the support ring can be plugged onto the end plate in a twist-proof manner. Process for manufacturing an electric motor claim 9 with the following steps: (i) in a first step producing a circuit unit according to one of Claims 1 until 4 , (ii) in a second step producing a stator according to one of Claims 5 until 8th , (iii) in a third step, connecting the interconnection unit to the stator, characterized in that in the third step, each contacting element is used to produce an electrical connection between a winding wire section accommodated in a respective connection projection and a respective contacting section of a conductor element for interconnecting the winding wires to form a multi-phase winding, in particular the interconnection unit being plugged onto the end plate for interconnection in the direction parallel to the axis of rotation, ie in the axial direction. procedure after Claim 13 , wherein the interconnection unit produced in the first step is produced by the following sub-steps: (i) in a first sub-step producing metal conductor elements by means of a stamping and bending process, (ii) in a second sub-step placing the conductor elements in an injection mold, (iii) in a third sub-step encapsulation of the conductor elements with an insulating material, in particular plastic. procedure after Claim 13 , Wherein the interconnection unit produced in the first step optionally comprises a first interconnection unit according to one of Claims 1 until 4 or a second interconnection unit according to one of Claims 1 until 4 is, wherein the first and the second interconnection unit each by a method Claim 14 is manufactured, wherein the first interconnection unit comprises first conductor elements, which are inserted into a first injection mold and the second interconnection unit comprises second conductor elements, which are inserted into a second injection mold, characterized in that the number and/or shape of the first conductor elements differs from differ between the second conductor elements and that the first and the second injection mold are identical or the first and the second injection mold are of the same design.

Images