DE102023200735A1 - Circuit arrangement, electrical machine, method for producing a circuit arrangement and vehicle - Google Patents

Abstract

A wiring arrangement (700) for electrically connecting an electrical machine comprises a first switching ring (100) with a first connection element (110) for applying an electrical voltage and at least one first contact element (115a) for electrically contacting first inputs of a plurality of windings of a first coil of the electrical machine. The first switching ring (100) has an electrically insulating first covering layer (105). In addition, the wiring arrangement (700) comprises a second switching ring (200) with a second connection element (210) and at least one second contact element (215a). The second switching ring (200) has an electrically insulating second covering layer (205). In addition, the wiring arrangement (700) comprises a third switching ring (300) arranged between the first switching ring (100) and the second switching ring (200) with a third connection element (310) and at least one third contact element (315a). The third switching ring (300) has no covering layer. Furthermore, the interconnection arrangement (700) comprises at least one star point element (600) for contacting outputs of the windings of the coils.

Description

The present invention relates to a circuit arrangement, an electrical machine, a method for producing a circuit arrangement and a vehicle.

Electric machines for driving vehicles can have a circuit with disks or rings in a sandwich design, as well as a power connection as a separate component. Insulating disks can be inserted between individual switching rings and the package can be overmolded. The power connection can be designed as a separate component that connects the circuit with the connection point of the phases of the electric machine.

Against this background, the present invention provides an improved circuit arrangement, an improved electrical machine, an improved method for producing a circuit arrangement and an improved vehicle according to the main claims. Advantageous embodiments emerge from the subclaims and the following description.

With the interconnection arrangement presented here, components and thus both installation space and costs can be advantageously reduced.

A wiring arrangement for electrically connecting an electrical machine comprises a first switching ring with a first connection element for applying an electrical voltage and at least one first contact element for electrically contacting first inputs of a plurality of windings of a first coil of the electrical machine. The first switching ring has an electrically insulating first covering layer. In addition, the wiring arrangement comprises a second switching ring with a second connection element for applying an electrical voltage and at least one second contact element for electrically contacting second inputs of a plurality of windings of a second coil of the electrical machine. The second switching ring has an electrically insulating second covering layer. In addition, the wiring arrangement comprises a third switching ring arranged between the first switching ring and the second switching ring with a third connection element for applying an electrical voltage and at least one third contact element for electrically contacting third inputs of a plurality of windings of a third coil of the electrical machine. The third switching ring does not have a covering layer. Furthermore, the wiring arrangement comprises at least one star point element for contacting outputs of the windings of the coils.

The electrical machine can be, for example, an electric drive or another electrical machine, for example for a vehicle. The electrical machine can comprise various components, such as a rotor and a stator. For example, a ring-shaped stator can be designed to accommodate several coils with windings for conducting electrical current. The windings can be, for example, flat wire windings with several partial strands that are alternately connected to one another. For example, the electrical machine can comprise a total of three coils. To apply a desired voltage to the respective windings, one coil can be contacted using a switching ring of the wiring arrangement presented here. A desired voltage can thus be applied to the respective connection element and transmitted to the corresponding coil via the switching ring via the at least one contact element. The individual switching rings can, for example, be shaped as flat rings and stacked on top of one another like a sandwich. If the rings are arranged slightly offset from one another along a circular shape, both the connection elements and the contact elements can be arranged next to one another along a circumference of the wiring arrangement. This means that the coils can advantageously be wound parallel to one another in order to enable the electrical machine to operate as evenly as possible. All outputs of the windings of all coils can also be contacted via the star point element or via a star point. In order to isolate the individual switching rings, or the switching rings and the star point element, from one another, the first switching ring and the second switching ring each advantageously have a covering layer.

These enveloping layers can be formed, for example, from an electrically insulating plastic and can be injected around the first and second switching rings, for example, using an injection mold during the manufacture of the circuit arrangement. In contrast, the third switching ring, which is arranged between the first and second switching rings, and the star point element do not have such an enveloping layer. The alternating arrangement of one enveloping switching ring and one non-enveloping switching ring or element in the circuit arrangement presented here provides insulation between the individual elements in a particularly compact and cost-effective manner. In this case, the The use of insulating disks between the individual switching rings can be dispensed with.

According to one embodiment, the contact elements can be designed to contact three parallel windings of a coil. For example, each coil of the electrical machine can comprise three windings, which can each be assigned to a phase, for example. The contact elements can advantageously be used to generate a current flow in the three parallel windings that is required for optimal operation of the electrical machine.

According to a further embodiment, the star point element can be formed with a finger-like geometry for contacting individual partial strands of the windings. For example, the star point element can be designed to contact partial strands of, for example, three parallel windings of a coil. For example, each so-called finger of the star point element can be assigned a winding. A star point element with such a geometry can advantageously be manufactured in a cost-effective manner and at the same time enable optimal contacting of parallel windings.

According to a further embodiment, the first switching ring can have a further first contact element for electrically contacting a further plurality of windings of the first coil of the electrical machine. The first contact element and the further first contact element can be arranged along a circumference of the first switching ring on different sides of the first connection element. Likewise, the second switching ring can have a further second contact element for electrically contacting a further plurality of windings of the second coil of the electrical machine. The second contact element and the further second contact element can be arranged along a circumference of the second switching ring on different sides of the second connection element. In addition, the third switching ring can have a further third contact element for electrically contacting a further plurality of windings of the third coil of the electrical machine. The third contact element and the further third contact element can be arranged along a circumference of the third switching ring on different sides of the third connection element. For example, each of the three switching rings can have a connection element and two contact elements radially opposite one another. The contact elements can each have the same shape, for example a finger-like geometry for contacting three parallel windings of a coil. The design of the switching rings with two contact elements each offers the advantage that the electrical machine can be designed with twice the number of coils, which can increase the overall performance of the machine.

According to a further embodiment, the interconnection arrangement can have a further star point element for contacting further outputs of the windings of the coils. The star point element and the further star point element can be arranged radially opposite one another. Both star point elements can be similarly shaped and designed in order to contact outputs of windings of different coils. This embodiment of the interconnection arrangement with a total of two star point elements is particularly advantageous if the switching rings are also designed with two contact elements each. In such a case, a star point element can be arranged in the area of a group of contact elements and the further star point element can be arranged in another area of further contact elements radially opposite the contact elements.

In addition, an electrical machine is presented. The electrical machine comprises a variant of the previously presented circuit arrangement and with at least three coils, each of which has a plurality of windings. The electrical machine can be designed, for example, to drive a vehicle and can comprise, for example, a component that can be designed either as a stator or as a rotor. For example, the component can comprise at least three coils, which can be electrically connected particularly advantageously using the previously presented circuit arrangement.

According to one embodiment, the windings can be designed using partial strands with a hairpin-like geometry. The windings can be, for example, flat wire windings, the individual partial strands of which can be designed as so-called hairpins or hairpin wires, i.e. as electrically conductive wires with a hairpin-like geometry. The individual partial strands of a winding can, for example, be connected to one another in alternating fashion. The design of a winding with hairpins offers the advantage that a particularly simple and cost-effective production of the winding is possible.

The electric machine is suitable, for example, for an electric axle drive. Such an electric axle drive for a vehicle comprises at least one electric Machine, a transmission device and a power converter. The power converter can be designed as an inverter, for example. Using the power converter, an electrical current required to operate the electrical machine can be provided. Using the transmission device, a torque provided by the electrical machine can be converted into a drive torque for driving at least one wheel of the motor vehicle. The transmission device can have a gearbox for reducing the speed of the electrical machine and optionally a differential.

Accordingly, a motor vehicle may comprise a said electric machine and additionally or alternatively a said electric axle drive.

In addition, a method for producing a variant of the previously presented interconnection arrangement is presented. The method comprises a step of providing the first switching ring, the second switching ring, the third switching ring and at least one star point element and a step of enveloping the first switching ring with the first enveloping layer and the second switching ring with the second enveloping layer. The method further comprises a step of stacking the switching rings and the star point elements, wherein the third switching ring is arranged between the first switching ring and the second switching ring and wherein the star point element is arranged adjacent to the second switching ring.

According to one embodiment, the enveloping step can be carried out using an injection molding tool. For example, the first and second switching rings can be separately molded with the insulating enveloping layer. Advantageously, using an injection molding tool is a simple, known and cost-effective variant of producing an enveloping layer.

• 1a eine schräge Draufsichtsdarstellung eines ersten Schaltrings ohne Hüllschicht gemäß einem Ausführungsbeispiel;
• 1b eine schräge Draufsichtsdarstellung eines ersten Schaltrings mit einer ersten Hüllschicht gemäß einem Ausführungsbeispiel;
• 1c eine Draufsichtsdarstellung eines ersten Schaltrings gemäß einem Ausführungsbeispiel;
• 1d eine Untenansicht eines ersten Schaltrings gemäß einem Ausführungsbeispiel;
• 2a eine schräge Draufsichtsdarstellung eines zweiten Schaltrings ohne Hüllschicht gemäß einem Ausführungsbeispiel;
• 2b eine schräge Draufsichtsdarstellung eines zweiten Schaltrings mit einer zweiten Hüllschicht gemäß einem Ausführungsbeispiel;
• 2c eine Draufsichtsdarstellung eines zweiten Schaltrings gemäß einem Ausführungsbeispiel;
• 2d eine Untenansicht eines zweiten Schaltrings gemäß einem Ausführungsbeispiel;
• 3 eine schräge Draufsichtsdarstellung eines dritten Schaltrings gemäß einem Ausführungsbeispiel;
• 4 eine schräge Draufsichtsdarstellung eines ersten Schaltrings mit einem dritten Schaltring gemäß einem Ausführungsbeispiel;
• 5 eine schräge Draufsichtsdarstellung eines ersten Schaltrings mit einem zweiten Schaltring und einem dritten Schaltring gemäß einem Ausführungsbeispiel;
• 6 eine schräge Draufsichtsdarstellung eines Sternpunktelements gemäß einem Ausführungsbeispiel;
• 7a eine schräge Draufsichtsdarstellung einer Verschaltungsanordnung gemäß einem Ausführungsbeispiel;
• 7b eine Querschnittsdarstellung einer Verschaltungsanordnung gemäß einem Ausführungsbeispiel;
• 8 eine schematische Darstellung eines Fahrzeugs gemäß einem Ausführungsbeispiel;
• 9 ein Ablaufdiagramm eines Verfahrens zum Herstellen einer Verschaltungsanordnung gemäß einem Ausführungsbeispiel; und
• 10 eine schematische Darstellung einer elektrischen Maschine mit einer Verschaltungsanordnung gemäß einem Ausführungsbeispiel.

The invention is explained in more detail by way of example with reference to the accompanying drawings. They show:

• 1a an oblique plan view of a first switching ring without a covering layer according to an embodiment;
• 1b an oblique plan view of a first switching ring with a first covering layer according to an embodiment;
• 1c a plan view of a first switching ring according to an embodiment;
• 1d a bottom view of a first switching ring according to an embodiment;
• 2a an oblique top view of a second switching ring without a covering layer according to an embodiment;
• 2 B an oblique plan view of a second switching ring with a second covering layer according to an embodiment;
• 2c a plan view of a second switching ring according to an embodiment;
• 2d a bottom view of a second switching ring according to an embodiment;
• 3 an oblique plan view of a third switching ring according to an embodiment;
• 4 an oblique plan view of a first switching ring with a third switching ring according to an embodiment;
• 5 an oblique plan view of a first switching ring with a second switching ring and a third switching ring according to an embodiment;
• 6 an oblique top view of a star point element according to an embodiment;
• 7a an oblique plan view of a circuit arrangement according to an embodiment;
• 7b a cross-sectional view of a circuit arrangement according to an embodiment;
• 8th a schematic representation of a vehicle according to an embodiment;
• 9 a flow chart of a method for producing a circuit arrangement according to an embodiment; and
• 10 a schematic representation of an electrical machine with a wiring arrangement according to an embodiment.

In the following description of preferred embodiments of the present invention, the same or similar reference numerals are used for the elements shown in the various figures and having a similar effect, whereby a repeated description of these elements is omitted.

The 1a , 1b , 1c and 1d each show a schematic representation of a first switching ring 100. The first switching ring 100 is in the 1a without a shell layer, in which 1b with a first cladding layer 105, in which 1c in a top view and in the 1d in a view from below.

The first switching ring 100 comprises a first connection element 110 for applying an electrical voltage. Such a voltage can be transmitted along the first switching ring 100 to a first contact element 115a and, in one embodiment, to a further first contact element 115b. The contact elements 115a, 115b are designed to electrically contact first inputs of a plurality of windings of a first coil of an electrical machine.

In the embodiment shown here, the contact elements 115a, 115b are each formed, for example, with a finger-like geometry for contacting individual partial strands of the windings. For example, each of the contact elements 115a, 115b has three fingers in order to contact, for example, three different phases of one winding each. In one embodiment, the first contact element 115a and the further first contact element 115b are arranged along a circumference of the first switching ring 100 on different sides of the first connection element 110 and, for example, radially opposite one another.

In contrast to the 1a The first switching ring 100 shown in the 1b , 1c and 1d The first switching ring 100 shown has a first covering layer 105. The first covering layer 105 is made of an electrically insulating material and, in one embodiment, is injected around the first switching ring 100 using an injection molding process. The first connection element 110 and the first contact elements 115a, 115b are arranged outside the covering layer 105, i.e. they are exposed in order to enable electrical contact in these areas.

The 2a , 2 B , 2c and 2d each show a schematic representation of a second switching ring 200. The second switching ring 200 is in the 2a without a shell layer, in which 2 B with a second cladding layer 205, in which 2c in a top view and in the 2d in a view from below.

The second switching ring 200 shown here is similar to the first switching ring described in the previous figure, with the difference that a second connection element 210 of the second switching ring 200 is arranged offset compared to the first connection element of the first switching ring, so that both switching rings can be placed on top of each other.

The second connection element 210 is designed to apply an electrical voltage. This can be transmitted along the second switching ring 200 to a second contact element 215a and, in one embodiment, to a further second contact element 215b. The contact elements 215a, 215b are designed to electrically contact second inputs of a plurality of windings of a second coil of an electrical machine.

In the embodiment shown here, the contact elements 215a, 215b are each formed, for example, with a finger-like geometry for contacting individual partial strands of the windings. For example, each of the contact elements 215a, 215b has three fingers in order to contact, for example, three different phases of one winding each. In one embodiment, the second contact element 215a and the further second contact element 215b are arranged along a circumference of the second switching ring 200 on different sides of the second connection element 210 and, for example, radially opposite one another.

In contrast to the 2a The second switching ring 200 shown in the 2 B , 2c and 2d The second switching ring 200 shown has a second covering layer 205. The covering layer 205 is made of an electrically insulating material and, in one embodiment, is injected around the second switching ring 200 using an injection molding process. The second connection element 210 and the second contact elements 215a, 215b are arranged outside the second covering layer 205, i.e. they are exposed in order to enable electrical contact in these areas.

3 shows an oblique top view of a third switching ring 300 according to an embodiment. The third switching ring 300 shown here is similar to the first and second switching rings described in the previous figures and comprises a third connection element 310 for applying an electrical voltage.

This can be transmitted along the third switching ring 300 to a third contact element 315a and, in one embodiment, to a further third contact element 315b. The third contact elements 315a, 315b are designed to electrically contact third inputs of a plurality of windings of a third coil of an electrical machine.

In the embodiment shown here, the third contact elements 315a, 315b are each formed with a finger-like geometry for contacting individual partial strands of the windings. For example, each of the contact elements 315a, 315b has three fingers in order to contact three different phases of one winding each. In one Embodiment, the third contact element 315a and the further third contact element 315b are arranged along a circumference of the third switching ring 300 on different sides of the third connection element 310 and, for example, radially opposite one another.

In contrast to the switching rings described in the previous figures, the third switching ring 300 shown here does not have a covering layer.

4 shows an oblique top view of a first switching ring 100 with a third switching ring 300 according to an embodiment. The first switching ring 100 shown here corresponds to or is similar to the one shown in the previous 1 described first switching ring and the third switching ring 300 shown here corresponds or is similar to the one shown in the previous 3 described third switching ring.

In the illustration shown here, the first switching ring 100 is arranged on the third switching ring 300, or the switching rings 100, 300 are stacked on top of one another, with the first switching ring 100 being arranged along a common circumference of the switching rings 100, 300 slightly offset from the third switching ring 300. Accordingly, in the embodiment shown here, the first connection element 110 and the third connection element 310 are arranged next to one another along the circumference. Likewise, the first contact element 115a is arranged along the circumference next to the third contact element 315a and the further first contact element 115b is arranged along the circumference next to the further third contact element 315b merely as an example.

Since the first switching ring 100 is largely enveloped by the electrically insulating first cladding layer 105 and the connection elements 110, 310 and the contact elements 115a, 315a, 115b, 315b are arranged at a distance from one another, the first switching ring 110 and the third switching ring 310 are electrically insulated from one another.

5 shows an oblique top view of a first switching ring 100 with a second switching ring 200 and a third switching ring 300 according to an embodiment.

The first switching ring 100 shown here corresponds or is similar to that shown in the previous 1 and 4 described first switching ring, the second switching ring 200 shown here corresponds or is similar to the one shown in the previous 2 described second switching ring and the third switching ring 300 shown here corresponds or is similar to the one shown in the previous 3 and described third switching ring.

In the illustration shown here, the first switching ring 100 is arranged on the third switching ring 300 and the third switching ring 300 is in turn arranged on the second switching ring 200. This means that the switching rings 100, 200, 300 are stacked on top of each other, with the third switching ring 300 being arranged between the first switching ring 100 and the second switching ring 200.

The switching rings 100, 200, 300 are arranged slightly offset from one another along a common circumference. Accordingly, in the embodiment shown here, the first connection element 110, the second connection element 210 and the third connection element 310 are arranged next to one another along the circumference. Likewise, the first contact element 115a is arranged along the circumference next to the second contact element 215a and this next to the third contact element 315a and the further first contact element 115b is arranged purely by way of example along the circumference next to the further second contact element 215b and this next to the further third contact element 315b.

Since the first switching ring 100 is largely enclosed by the electrically insulating first cladding layer 105 and the second switching ring 200 is largely enclosed by the electrically insulating second cladding layer 205 and the connection elements 110, 210, 310 and the contact elements 115a, 215a, 315a, 115b, 215b, 315b are arranged at a distance from one another, the first switching ring 110 and the third switching ring 310 are electrically insulated from one another, just as the third switching ring 300 is electrically insulated from the second switching ring 200.

6 shows an oblique top view of a star point element 600 according to an embodiment. The star point element 600 is designed to contact outputs of windings of coils of an electrical machine.

In one embodiment, the star point element 600 is formed with a finger-like geometry for contacting individual partial strands of the windings. In the embodiment shown here, the star point element 600 comprises only three star point contact elements 605a, 605b, 605c, which are designed similarly to the contact elements of the switching rings described in the previous figures, in order to electrically contact inputs of a plurality of windings of several coils of an electrical machine. In this case, each star point contact element 605a, 605b, 605c is designed only as an example. to contact three parallel windings of a coil.

In the figure shown here, a further star point element 610 is shown in addition to the star point element 601 as an example only. The further star point element 610 is similar in shape and function to the described star point element 600.

The 7a and 7b each show a schematic representation of a circuit arrangement 700 according to an embodiment. The circuit arrangement 700 is shown in the 7a shown in an oblique top view and in the 7b as a cross section. The interconnection arrangement 700 shown here is designed for electrically interconnecting an electrical machine and for this purpose comprises a first switching ring 100, a second switching ring 200, a third switching ring 300 and a star point element 600.

The first switching ring 100 corresponds or is similar to that in the previous 1 , 4 and 5 described first switching ring and has the first connection element 110 for applying an electrical voltage. In addition, the first switching ring 100 comprises the first contact element 115a for electrically contacting first inputs of a plurality of windings of a first coil of the electrical machine. The first switching ring 100 has the electrically insulating first covering layer 105.

The second switching ring 200 corresponds or is similar to that in the previous 2 and 5 described second switching ring and has the second connection element 210 for applying an electrical voltage. In addition, the second switching ring 200 comprises the second contact element 215a for electrically contacting second inputs of a plurality of windings of a second coil of the electrical machine. The second switching ring 200 has the electrically insulating second covering layer 205.

The third switching ring 300 is arranged between the first switching ring 100 and the second switching ring 200. This corresponds to or is similar to the one shown in the previous 3 , 4 and 5 described third switching ring and comprises the third connection element 310 for applying an electrical voltage. In addition, the third switching ring 300 comprises the third contact element 315a for electrically contacting third inputs of a plurality of windings of a third coil of the electrical machine. The third switching ring 300 has no covering layer, but is electrically insulated from them by means of the first covering layer 105 of the first switching ring 100 and the second covering layer 205 of the second switching ring 200.

The second cladding layer 205 also forms an insulating layer between the second switching ring 200 and the star point element 600, which is arranged, for example, on a side of the second switching ring 200 opposite the third switching ring 300. The star point element 600 is designed to contact outputs of the windings of the coils.

In this exemplary embodiment, the first switching ring 100 of the interconnection arrangement 700 comprises, merely by way of example, the further first contact element 115b for electrically contacting a further plurality of windings of the first coil of the electrical machine. The first contact element 115a and the further first contact element 115b are arranged along a circumference of the first switching ring 100 on different sides of the first connection element 110 and, merely by way of example, radially opposite one another.

In addition, in one embodiment, the second switching ring has the further second contact element 215b for electrically contacting a further plurality of windings of the second coil of the electrical machine. The second contact element 215a and the further second contact element 215b are arranged along a circumference of the second switching ring 200 on different sides of the second connection element 210 and, purely by way of example, radially opposite one another.

Likewise, in one embodiment, the third switching ring 300 comprises the further third contact element 315b for electrically contacting a further plurality of windings of the third coil of the electrical machine. The third contact element 315a and the further third contact element 315b are arranged along a circumference of the third switching ring 300 on different sides of the third connection element 310 and are arranged radially opposite one another merely by way of example.

The contact elements 115a, 115b, 215a, 215b, 315a, 315b are designed purely as an example to contact three parallel windings of a coil. In other embodiments, the electrical machine can be wired up to vary depending on the number of fingers for contacting the hairpins of the windings.

In one embodiment, the interconnection arrangement also comprises, for example, a further star point element 610 for contacting further outputs of the windings of the coils. The star point element 600 and the further star point element are arranged radially opposite each other.

In this exemplary embodiment, both the contact elements 115a, 115b, 215a, 215b, 315a, 315b and the star point elements 600, 605 are formed with a finger-like geometry for contacting individual partial strands of the windings. In this way, for example, partial strands with a hairpin-like geometry, so-called hairpins, of a winding can be contacted.

In other words, in the cases described here 7a and 7b a circuit arrangement 700 in a sandwich design with partially individually overmolded switching rings 100, 200, 300 and an integrated power connection is shown. The circuit arrangement 700 is suitable for the connection of an electrical machine with hairpin winding, whereby the omission of insulation disks enables a reduction in the number of individual parts. The individual overmolding of the first and second switching rings 100, 200 ensures that the required geometry is maintained. In addition, the air and creepage distances required for the machine (very high due to the high voltage level) are also maintained. In the cost-effective design shown here, various functions (circuitry and power connection) are combined to reduce costs. A modular approach is possible, which means that the circuit can be used for machines of different power classes. The circuit arrangement 700 can be designed as a self-supporting, highly rigid circuit with only one holding point in the later stator carrier with integrated clamping geometry.

Due to the individual overmolding, there is advantageously no deformation of the switching rings. In one embodiment, busbars form the power connection directly, and a screw thread can also be integrated into the busbar. The clamping geometry can also be integrated into the overmolding.

Highly rigid wiring generates a space advantage (fewer holding points are required) and enables an overall reduction in voltage in the electrical machine. The highly rigid wiring also generates a cost advantage, as no injected metal bushings are required for screwing in the housing (reduction in parts). In one embodiment, only one holding point can be realized by integrating clamping geometry in the overmolding, as well as an exemplary support of a screw-in torque with LAS connection using flattened busbars.

8th shows a schematic representation of a vehicle 800 according to an embodiment. The vehicle 800 has an electric axle drive with an electric machine 801, which comprises a circuit arrangement 700, as described with reference to the previous figures. Electrical energy for operating the electric machine 801 is provided by an energy supply device 802, for example a battery. For example, the energy supply device 802 provides a direct current, which is converted into an alternating current, for example a three-phase alternating current, using a power converter 804 of the transmission device and is provided to the electric machine 801. A shaft driven by the electric machine 801 is coupled directly or using a transmission device 806 to at least one wheel 808 of the vehicle 800. The vehicle 800 can thus be moved using the electric machine 801. According to one embodiment, the electric axle drive comprises a housing in which the power converter 804, the electric machine 801 and the transmission device 806 are arranged in an integrated manner.

9 shows a flow chart of a method 900 for producing a circuit arrangement according to an embodiment. The method 900 shown here is an example for producing a circuit arrangement as described in the previous 7 described above.

The method 900 comprises a step 905 of providing the first switching ring, the second switching ring, the third switching ring and at least one star point element and a step 910 of enveloping the first switching ring with the first enveloping layer and the second switching ring with the second enveloping layer. The method 900 further comprises a step 915 of stacking the switching rings and the star point elements, wherein the third switching ring is arranged between the first switching ring and the second switching ring and wherein the star point element is arranged adjacent to the second switching ring.

In one embodiment, the step 910 of enveloping is carried out using an injection molding tool. For example, the first and second switching rings are separately molded with the insulating enveloping layer.

In one embodiment, the individual overmoldings are formed with pins onto which the non-overmolded switching rings are plugged. This enables a sandwich design and largely eliminates handling effort. The individual overmoldings enable the positional accuracy to be ensured, for example. In addition, the positional accuracy of the individual overmoldings reduces the number of holding points in the injection molding tools, which enables a stable manufacturing process. In one embodiment, holding points can also be obsolete due to the individual overmoldings. Overall, this results in a reduction in the complexity of the injection molding tool (fewer holding points).

10 shows a schematic representation of an electrical machine 801 with, for example, three coils 1000, which are contacted using a wiring arrangement 700, as described with reference to the previous figures.

Reference symbols

100

first switching ring

105

first shell layer

110

first connection element

115a

first contact element

115b

further first contact element

200

second switching ring

205

second shell layer

210

second connection element

215a

second contact element

215b

additional second contact element

300

third switching ring

310

third connection element

315a

third contact element

315b

additional third contact element

600

Star point element

605a

first star point contact element

605b

second star point contact element

605c

third star point contact element

610

additional star point element

800

vehicle

801

electric machine

802

Energy supply facility

804

Power converter

806

Gearbox device

808

wheel

900

Method for producing an interconnection arrangement

905

Deployment step

910

Wrapping step

915

Step of stacking

1000

Wash

Claims (11)

Wiring arrangement (700) for electrically connecting an electrical machine (801), wherein the wiring arrangement (700) has the following features: a first switching ring (100) with a first connection element (110) for applying an electrical voltage and at least one first contact element (115a) for electrically contacting first inputs of a plurality of windings of a first coil of the electrical machine (801), wherein the first switching ring (100) has an electrically insulating first covering layer (105); a second switching ring (200) with a second connection element (210) for applying an electrical voltage and at least one second contact element (215a) for electrically contacting second inputs of a plurality of windings of a second coil of the electrical machine (801), wherein the second switching ring (200) has an electrically insulating second covering layer (205); a third switching ring (300) arranged between the first switching ring (100) and the second switching ring (200) with a third connection element (310) for applying an electrical voltage and at least one third contact element (315a) for electrically contacting third inputs of a plurality of windings of a third coil of the electrical machine (801), wherein the third switching ring (300) has no covering layer; and at least one star point element (600) for contacting outputs of the windings of the coils (1000). Circuit arrangement (700) according to Claim 1 , wherein the contact elements (115a, 215a, 315a) are designed to contact three parallel windings of a coil. Wiring arrangement (700) according to one of the preceding claims, wherein the star point element (600) is formed with a finger-like geometry for contacting individual partial strands of the windings. Wiring arrangement (700) according to one of the preceding claims, wherein the first switching ring (100) has a further first contact element (115b) for electrically contacting a further plurality of windings of the first coil of the electrical machine (801), wherein the first contact element (115a) and the further first Contact element (115b) are arranged along a circumference of the first switching ring (100) on different sides of the first connection element (110), and wherein the second switching ring (200) has a further second contact element (215b) for electrically contacting a further plurality of windings of the second coil of the electrical machine (801), wherein the second contact element (215a) and the further second contact element (215b) are arranged along a circumference of the second switching ring (200) on different sides of the second connection element (210), and wherein the third switching ring (300) has a further third contact element (315b) for electrically contacting a further plurality of windings of the third coil of the electrical machine (801), wherein the third contact element (315a) and the further third contact element (315b) are arranged along a circumference of the third switching ring (300) on different sides of the third connection element (310). Wiring arrangement (700) according to one of the preceding claims, with a further star point element (610) for contacting further outputs of the windings of the coils (1000), wherein the star point element (600) and the further star point element (610) are arranged radially opposite one another. Electrical machine (801) with a circuit arrangement (700) according to one of the preceding claims and with at least three coils (1000), each having a plurality of windings. Electrical machine (801) according to Claim 6 , wherein the windings are formed using partial strands with a hairpin-like geometry. Electric axle drive for a motor vehicle with at least one electric machine (801), a transmission device (806) and a power converter (804), characterized in that the electric machine (801) according to Claim 6 is trained. Vehicle (800) comprising an electric machine (801) according to Claim 6 and/or an electric axle drive according to Claim 8 . Method (900) for producing a circuit arrangement (700) according to one of the preceding Claims 1 until 5 , wherein the method (900) comprises the following steps (905, 910, 915): providing (905) the first switching ring (100), the second switching ring (200), the third switching ring (300) and at least one star point element (600); enveloping (910) the first switching ring (100) with the first enveloping layer (105) and the second switching ring (200) with the second enveloping layer (205); and stacking (915) the switching rings (100, 200, 300) and the star point element (600), wherein the third switching ring (300) is arranged between the first switching ring (100) and the second switching ring (200) and wherein the star point element (600) is arranged adjacent to the second switching ring (200). Procedure (900) according to Claim 10 , wherein the step (910) of enveloping is carried out using an injection molding tool.

Images