DE102023201733A1 - Contacting component and method for contacting a stator for an electric motor with an energy transmission unit. - Google Patents

Abstract

The present invention relates to a contacting component (10) for contacting a stator (12) for an electric motor with an energy transmission unit for an electric drive of a motor vehicle, wherein the contacting component (10) has a plurality of first contacting elements (14) for contacting conductor ends (16) of electrical conductors (18) of the stator coil (12) and a plurality of second contacting elements (22) for contacting an energy supply device, wherein the contacting component (10) has a connecting body (24) for connecting the first contacting elements (14) and the second contacting elements (22), wherein the connecting body (24) has a switching structure (26) by means of which the first contacting elements (14) and the second contacting elements (22) are interconnected, wherein the first contacting elements (14) are positioned in an arcuate arrangement.

Description

The present invention relates to a contacting component for contacting a stator for an electric motor with an energy transmission unit for an electric drive of a motor vehicle. The present invention further relates to an arrangement comprising a stator for an electric motor and a contacting component as well as a method for contacting a stator for an electric motor with a contacting component.

In the automotive industry, electric machines are increasingly being installed in the production of motor vehicles. For example, car manufacturers operating in the market produce vehicles with hybrid drives, i.e. a combustion engine and an electric machine, or with fully electric drives.

The vehicles produced have electrical machines with different performance characteristics depending on the size and weight of the vehicle and the price segment. The corresponding manufacturing process for these electrical machines is such that coils are drawn into different stators in the same way and then contacted with one another in a defined circuit to create a winding pattern with the relevant performance characteristics. The coils are then contacted with energy transfer units to supply the electrical machine with electrical energy.

A certain remedy to simplify the production process and create variability in performance classes is described EN 10 2017 209 479 A1 This document shows a terminal box that is designed to electrically change the winding pattern of the coils while the vehicle is in operation, so that the corresponding electrical machine changes to a different efficiency map or a different power class. For production, this means that only one type of contact can be implemented in the terminal box, thus simplifying the process.

However, this terminal box is electrically complex and expensive. In addition, the variability of the winding schemes during driving is simply not necessary in many applications because vehicles of different classes and price segments can get by well with a fixed winding scheme.

State-of-the-art solutions in this regard can thus be further improved, particularly with regard to simple construction and reliable functionality.

It is the object of the present invention to at least partially overcome at least one disadvantage of the prior art. It is a particular object of the present invention to provide a solution with the aid of which contacting of a stator coil of an electric motor with a power supply unit can be improved, in particular with regard to a simple structure and reliable functionality.

The present object is achieved by a contacting component with the features of claim 1. The present object is further achieved according to the invention by an arrangement with the features of claim 5 and by a method with the features of claim 9. Preferred embodiments of the invention are described in the subclaims, in the description or in the figures, wherein further features described or shown in the subclaims or in the description or in the figures can represent an object of the invention individually or in any combination, unless the context clearly indicates the opposite.

A contacting component is described for contacting a stator for an electric motor with an energy transmission unit for an electric drive of a motor vehicle, wherein the contacting component has a plurality of first contacting elements for contacting conductor ends of electrical conductors of the stator coil and a plurality of second contacting elements for contacting an energy supply device, wherein the contacting component has a connecting body for connecting the first contacting elements and the second contacting elements, wherein the connecting body has a switching structure by means of which the first contacting elements and the second contacting elements are interconnected, and wherein the first contact elements are positioned in an arcuate arrangement.

Such a contacting component offers significant advantages over state-of-the-art solutions.

The contacting component described serves to contact a stator, in particular a stator coil, for an electric motor with an energy transmission unit for an electric drive of a motor vehicle. Accordingly, in the sense of the present invention, the contact ating a plurality of stator coils. An electrically powered vehicle can basically be understood as a purely electrically powered vehicle or a hybrid vehicle. The electric drive or the drive system has an electric motor, which can be designed in a manner known per se and comprises a stator with a stator coil and a rotor. With regard to the performance data or the performance characteristics, the electric motor can be adapted to the selected area of application, for example to the type of vehicle that is to be powered by the electric motor.

Such electric motors, which can also be referred to as electrical machines, can preferably work in motor and/or generator mode and can be used, for example, as a drive unit of the motor vehicle. The energy supply device preferably contains a high-voltage accumulator (for example 400 V or 800 V) and an inverter or converter that converts the direct current supplied by the accumulator into alternating current.

For appropriate contacting, the contacting component comprises a plurality of first contacting elements for contacting conductor ends of electrical conductors of the stator coil. The first contacting elements are thus provided and designed to come into contact with the conductor ends of the electrical conductors wound in the stator coil. Furthermore, a plurality of second contacting elements are included, which serve to contact the energy supply device. For this purpose, the energy supply device, such as the converter, can come into direct contact with the second contacting elements, or corresponding connecting conductors and/or adapters can be provided, which are arranged between the second contacting elements and the energy supply device.

The contacting elements are preferably made of metal and are preferably monolithic bent/punched parts that are bent into desired shapes such that they are exposed at the defined positions. In this regard, the contacting elements have, for example, bent tabs and/or bent sections.

The contacting component further comprises a connecting body for connecting the first contacting elements and the second contacting elements. Accordingly, the first contacting elements and the second contacting elements can be arranged on the connecting body and fixed detachably or preferably non-detachably.

The connecting body has a switching structure by means of which the first contacting elements and the second contacting elements are connected and wired together. For example, the connecting body consists of the switching structure. It can be designed as a single piece or in multiple parts with the first and/or the second contacting elements. If a plurality of components is provided, these can be connected to one another, for example, by joining methods known per se, such as soldering or welding. For example, a metallic component can thus be provided which is designed as a single piece and comprises the contacting elements and the connecting body consisting of the switching structure. Alternatively, multi-part interconnected components can also be provided in any number of components. Whether a single-piece or multi-part design is selected can be selected, for example, depending on the selected circuit.

In any case, the switching structure is arranged with respect to a current flow between the first contacting elements and the second contacting elements and connects the first contacting elements and the second contacting elements to form a defined switching structure. The invention also includes the fact that some of the first contacting elements are connected or interconnected with one another. Switching structures of the connecting body that form circuits are usually necessary or preferred in order to connect the electric motor or the electric machine with a certain performance characteristic to the energy supply device.

One or more insulating intermediate layers are preferably arranged between the different levels of the contacting elements. The connecting body is preferably designed such that the positions of the exposed contacting elements are located in two parallel levels on the outer surface of the connecting body. The intermediate layer or layers can be realized, for example, by means of a plastic overmold. Preferably, there are a total of (n*m)*2 positions at which the contacting elements are exposed. The number of strands, i.e. the parameter m, is preferably m = 3, and the number of coils, i.e. the parameter n, is preferably n = 2.

According to the invention, it is further provided that the first contact elements are positioned in an arcuate arrangement. This is intended to of the present invention in particular mean that in a plan view of the connecting body, i.e. in a view of the second contacting elements in the direction of the first contacting elements, or of the contacting component from above, the first contacting elements are arranged or positioned in an arc shape. For example, the connecting element can also have an arc-shaped cross section. The arc-shaped cross section is then in a plane parallel to that in which at least the first contacting elements are arranged.

This design makes it possible to make particularly simple contact between the stator or the conductor ends and the contacting component. Because an arc shape is provided, the first contacting elements can follow the shape of a stator or a stator winding. Accordingly, as described in more detail below, it is particularly preferred if the arc shape is adapted to the circular shape of the stator winding or corresponds to it.

The stator can therefore be formed in a uniform and conventional manner, so that no twisting or bending or banding of the conductor ends of the stator winding is necessary. The contacting arrangement can therefore very easily contact existing stator systems and can therefore be easily implemented without any changes to the stator design being necessary. In fact, the stator design can be the same regardless of the power class.

This means that different performance data or performance characteristics of the electrical machine can be easily adapted by exchanging the contacting components with different switching structures. In the case of the contacting components specified in each case, the contacting elements and the connecting body are preferably dimensioned for the respective area of application, i.e. they have the necessary insulation properties and current strengths, for example.

In addition, the structure can be very simple, so that the contacting component can be designed very cost-effectively and the contacting component according to the invention requires only a small installation space and is lightweight. This is a great advantage, especially for use in motor vehicles.

Preferably, at least the connecting body, optionally together with the first and/or second contacting elements, can be at least partially overmolded with a plastic. In this embodiment, leakage currents can be prevented particularly effectively and safely. In this embodiment in particular, it is thus possible for the power supply unit to also be designed using 800 V technology, which can be advantageous in terms of application. Care should be taken to ensure that corresponding contact positions of the contacting elements remain free from the overmold.

It may further be preferred that the electrical switching structure is selected from star connections or delta connections. More precisely, star connections can be provided for high peak torques at low speeds and delta connections for high continuous torques at high speeds. In addition, there are also series and parallel connections in star or delta configuration as well as double star and double delta connections as further refined gradations. In addition to the four winding schemes explained above (star-parallel; star series; delta-parallel; delta series), the contacting kit according to the invention can contain further contacting sets which, for example, implement the following winding schemes: double star, i.e. two independent star connections without parallel/series connection of the coils; double delta, i.e. two independent delta connections without parallel/series connection of the coils; double star, i.e. two independent star connections with series connections of coils, for multi-pole electrical machines; or double delta, i.e. two independent delta connections, each with parallel connections of coils, for multi-pole electrical machines. However, all circuits are to be viewed as gradations or designs of star connections or delta connections.

It may also be preferred that the arcuate arrangement has a radian dimension in a range from greater than or equal to π/4 to less than or equal to π, for example from greater than or equal to π/3 to less than or equal to π/2. In particular, this design ensures that corresponding conductor ends can be accommodated without any problems. This is because, in particular, in such a radian dimension or angular range, the contacting component can be placed on conventional stators without any problems, with the corresponding conductor ends to be connected lying in this range.

With reference to further advantages and technical features of the contacting component, reference is made to the description of the arrangement, the method, the figures as well as the description of the figures.

Also described is an arrangement comprising a stator and a contacting component for an electric drive of a motor vehicle, wherein the contacting component is contacted with conductor ends of electrical conductors of a stator coil of the stator, and wherein the contacting component is designed as described.

This essentially describes the contacting component described above, which is arranged on a stator or is in contact with it. For this purpose, the first contacting elements are preferably in contact with conductor ends of electrical conductors of the stator coil of the stator. For this purpose, the contacting elements can have a receptacle into which the conductor ends are pushed, or can also be fixed in place in some other way.

This offers the advantages described above in particular. In detail, a particularly simple contact between the stator or the conductor ends and the contacting component can be made, whereby in particular a conventional stator without complex bending or twisting of the conductor ends can be used. Accordingly, it can be advantageous for the conductor ends of the stator to run untwisted from the winding straight axially into the contacting elements. A particularly simple adaptation can be achieved by adapting an arcuate arrangement of the first contact elements to the circular shape of the stator coil or corresponding to it.

It can also be provided that the arrangement also has a power supply device which is contacted with the second contacting elements. In particular, the power supply device can comprise a battery and a converter, the latter being contacted with the second contacting elements. The power supply device, in particular a battery, can preferably be designed using 800 V technology. This design allows a particularly wide range of applications and is particularly possible if the connecting body, optionally together with the first and/or second contacting elements, is at least partially overmolded with a plastic.

With regard to further advantages and technical features of the arrangement, reference is made to the description of the contacting component, the method, the figures and the description of the figures.

1. a) Bereitstellen einer Mehrzahl an Kontaktierungsbauteilen, wobei die Kontaktierungsbauteile eine zueinander unterschiedliche elektrische Schaltstruktur aufweisen, und wobei die Kontaktierungsbauteile ausgebildet sind wie beschrieben;
2. b) Definieren einer Leistungscharakteristik des Elektromotors;
3. c) Auswählen eines Kontaktierungsbauteil basierend auf der Leistungscharakteristik; und
4. d) Kontaktieren der Statorspule mit dem Kontaktierungsbauteil.

Furthermore, a method is described for contacting a stator coil of a stator of an electric motor for an electric drive for a motor vehicle with a power supply device, comprising the method steps:

1. a) providing a plurality of contacting components, wherein the contacting components have a mutually different electrical switching structure, and wherein the contacting components are designed as described;
2. b) Defining a performance characteristic of the electric motor;
3. c) selecting a contacting component based on the performance characteristics; and
4. d) Contacting the stator coil with the contacting component.

According to this method, in particular the simple and universally applicable design of an arrangement as described above is realized.

According to method step a), a plurality of contacting components are provided, wherein the contacting components have a different electrical switching structure from one another, and wherein the contacting components are designed as described. For example, the electrical switching structure can be selected from the group consisting of star circuits or delta circuits, each containing possible gradations or configurations as described in detail above.

Subsequently, a performance characteristic of the electric motor can be defined according to method step b). For this purpose, for example, a speed-dependent performance, a torque profile or even an efficiency in different performance ranges can be considered, without being limited to this. In particular, the performance characteristic of the electric motor can be adapted in a suitable manner to the electrical switching structures present in the contacting components.

In this regard, it may be preferred that the electrical switching structure has, for example, star connections, if necessary for high peak torques at low speeds, and delta connections, if necessary for high continuous torques at high speeds. In addition, there are also series and parallel connections in star or delta configurations, as well as double star and double delta connections as further refined gradations. In addition to the four winding schemes explained above (star-parallel; Star series; delta parallel; delta series), the contacting kit according to the invention can contain further contacting kits which, for example, implement the following winding schemes: double star, i.e. two independent star connections without parallel/series connection of the coils; double delta, i.e. two independent delta connections without parallel/series connection of the coils; double star, i.e. two independent star connections, each with series connections of coils, for multi-pole electrical machines; or double delta, i.e. two independent delta connections, each with parallel connections of coils, for multi-pole electrical machines.

It is therefore subsequently possible for a contacting component to be selected based on the performance characteristics in accordance with method step c) and for the stator coil to be contacted with the contacting component in accordance with method step d). Accordingly, the contacting component can also be contacted with an energy transmission unit, such as in particular an accumulator via a converter.

It is therefore possible to design an arrangement as described above in a simple manner and to use conventional stators. This makes it possible to have a "shelf solution" in which the contacting component is selected depending on the power of the electric motor and is connected to the electric motor or stator and also to a power supply unit. In this case, a particularly simple contact between the stator or the conductor ends and the contacting component is possible, whereby in particular a conventional stator can be used without complex bending or twisting of the conductor ends.

With regard to further advantages and technical features of the method, reference is made to the description of the arrangement, the contacting component, the figures and the description of the figures.

• 1 zeigt eine schematische Ansicht einer Ausgestaltung eines Kontaktierungsbauteils gemäß der Erfindung;
• 2 zeigt eine weitere schematische Ansicht der Ausgestaltung aus 1;
• 3 zeigt eine schematische Ansicht einer teilweisen umspritzen Ausgestaltung aus 1;
• 4 zeigt eine schematische Ausgestaltung einer Anordnung aus dem Kontaktierungsbauteil gemäß 1 mit einem Stator eines Elektromotors;
• 5 zeigt eine schematische Ansicht einer weiteren Ausgestaltung eines Kontaktierungsbauteils gemäß der Erfindung;
• 6 zeigt eine weitere schematische Ansicht der Ausgestaltung aus 5;
• 7 zeigt eine schematische Ansicht einer weiteren Ausgestaltung eines Kontaktierungsbauteils gemäß der Erfindung;
• 8 zeigt eine weitere schematische Ansicht der Ausgestaltung aus 7;
• 9 zeigt eine schematische Ansicht einer weiteren Ausgestaltung eines Kontaktierungsbauteils gemäß der Erfindung;
• 10 zeigt eine weitere schematische Ansicht der Ausgestaltung aus 9.

The invention is explained in more detail below with reference to the figures, whereby individual or multiple features of the figures may be a feature of the invention on their own or in combination. Furthermore, the figures are only to be seen as examples and in no way restrictive.

• 1 shows a schematic view of an embodiment of a contacting component according to the invention;
• 2 shows another schematic view of the design from 1 ;
• 3 shows a schematic view of a partially overmolded embodiment of 1 ;
• 4 shows a schematic design of an arrangement of the contacting component according to 1 with a stator of an electric motor;
• 5 shows a schematic view of a further embodiment of a contacting component according to the invention;
• 6 shows another schematic view of the design from 5 ;
• 7 shows a schematic view of a further embodiment of a contacting component according to the invention;
• 8 shows another schematic view of the design from 7 ;
• 9 shows a schematic view of a further embodiment of a contacting component according to the invention;
• 10 shows another schematic view of the design from 9 .

In the 1 and 2 an embodiment of a contacting component 10 according to an embodiment of an invention is shown in different views. The contacting component 10 serves in particular for contacting a stator 12 for an electric motor with an energy transmission unit for an electric drive of a motor vehicle.

The contacting component 10 has a plurality of first contacting elements 14 for contacting conductor ends 16 of electrical conductors 18 of the stator coil 20. The contacting component 10 also has a plurality of second contacting elements 22 for contacting a power supply device. This makes it possible to electrically connect the stator coil 20 and thus an electric motor to a power supply unit, such as in particular a rechargeable battery.

For connecting the first contacting elements 14 and the second contacting elements 22, a connecting body 24 is also shown, on which the first contacting elements 14 and the second contacting elements 22 are arranged, for example fixed. The connecting body 24 has an arcuate cross-section and further comprises a switching structure 26, by means of which the first contacting elements 14 and the second contacting elements 22 are connected to one another. In the 1 and 2 A star-parallel connection is shown in more detail. The arcuate arrangement of the contacting elements 14 is also shown.

In the 3 is the design according to 1 shown, wherein the connecting body 24, together with a part of the first contacting elements 14 and the second contacting elements 22, are overmolded with a plastic 28, whereby a contact area remains free. Suitable plastics 28 for overmolding basically include electrically non-conductive plastics 28, such as polyamide, polypropylene or the like.

In the 4 an arrangement 30 of a stator 12 and a contacting component 10 is shown, wherein the contacting component 10 is attached to the stator 12 and contacts it. The stator 12 comprises, in a manner known per se, the stator coil 20, which is constructed from conductors 18 with conductor ends 16. It is shown that the conductor ends 16 are in contact with the contacting component 10 or the first contacting elements 14. With regard to the design of the conductors 18 or the conductor ends 16, the stator 12 can be designed in a conventional manner. In particular, it can be provided that the conductor ends 16 of the stator 12 run untwisted from the winding of the stator coil 20 straight axially into the contacting elements 14. The fact that the arc shape is additionally adapted to the circular shape of the stator coil 20 enables particularly simple contacting.

In the other figures, further embodiments of the contacting element 10 are shown, whereby reference is made in principle to the above description of the embodiment according to 1 is referred to.

In detail, the 5 and 6 a contacting component with an electrical switching structure 26 in a serial star shape, show the 7 and 8 a contacting component 10 with an electrical switching structure 26 in a parallel triangular shape and show the 9 and 10 a contacting component 10 with an electrical switching structure 26 in a serial triangular form.

1. a) Bereitstellen einer Mehrzahl an Kontaktierungsbauteilen 10, wobei die Kontaktierungsbauteile 10 eine zueinander unterschiedliche elektrische Schaltstruktur 26 aufweisen, und wobei die Kontaktierungsbauteile 10 ausgebildet sind wie beschrieben;
2. b) Definieren einer Leistungscharakteristik des Elektromotors;
3. c) Auswählen eines Kontaktierungsbauteils 10 basierend auf der Leistungscharakteristik; und
4. d) Kontaktieren der Statorspule 20 mit dem Kontaktierungsbauteil 10.

By selecting the respective contacting components 10 based on their electrical switching structure 26 based on a definition of a performance characteristic of the electric motor comprising the stator 12, an adaptation to the performance characteristic can be made possible in a simple manner. Accordingly, the present invention makes it possible to provide a method for contacting a stator coil 20 of a stator 12 of an electric motor for an electric drive for a motor vehicle with a power supply device, comprising the method steps:

1. a) providing a plurality of contacting components 10, wherein the contacting components 10 have a mutually different electrical switching structure 26, and wherein the contacting components 10 are designed as described;
2. b) Defining a performance characteristic of the electric motor;
3. c) selecting a contacting component 10 based on the performance characteristics; and
4. d) Contacting the stator coil 20 with the contacting component 10.

List of reference symbols

10

Contacting component

12

stator

14

first contact element

16

Ladder end

18

Director

20

Stator coil

22

second contact element

24

Connecting body

26

Switching structure

28

plastic

30

arrangement

QUOTES INCLUDED IN THE DESCRIPTION

This list of documents listed 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 accepts no liability for any errors or omissions.

Cited patent literature

• DE 102017209479 A1 [0004]

Claims (10)

Contacting component (10) for contacting a stator (12) for an electric motor with an energy transmission unit for an electric drive of a motor vehicle, wherein the contacting component (10) has a plurality of first contacting elements (14) for contacting conductor ends (16) of electrical conductors (18) of a stator coil (20) of the stator (12) and a plurality of second contacting elements (22) for contacting the energy supply device, characterized in that the contacting component (10) has a connecting body (24) for connecting the first contacting elements (14) and the second contacting elements (22), wherein the connecting body (24) has a switching structure (26) by means of which the first contacting elements (14) and the second contacting elements (22) are interconnected, wherein the first contact elements (14) are positioned in an arcuate arrangement. Contacting component (10) according to Claim 1 , characterized in that at least the connecting body (24) is at least partially encapsulated with a plastic (28). Contacting component (10) according to Claim 1 or 2 , characterized in that the electrical switching structure (26) is selected from star connections or delta connections. Contacting component (10) according to one of the Claims 1 until 3 , characterized in that the arcuate arrangement has a radian measure in a range from greater than or equal to π/4 to less than or equal to π. Arrangement (30) comprising a stator (12) and a contacting component (10) for an electric drive of a motor vehicle, characterized in that the contacting component (10) is contacted with conductor ends (16) of electrical conductors (18) of a stator coil (20) of the stator (12), wherein the contacting component (10) is designed according to one of the Claims 1 until 4 . Arrangement (30) according to Claim 5 , characterized in that the arcuate arrangement is adapted to the circular shape of the stator coil (20). Arrangement (30) according to Claim 6 , characterized in that the conductor ends (16) of the stator (12) extend untwisted from the winding straight axially into the first contacting elements (14). Arrangement (30) according to Claim 5 or 6 , characterized in that the arrangement (30) further comprises a power supply device which is contacted with the second contacting elements (22). Method for contacting a stator coil (20) of a stator (12) of an electric motor for an electric drive for a motor vehicle with a power supply device, comprising the method steps: a) providing a plurality of contacting components (10), wherein the contacting components (10) have a mutually different electrical switching structure (26), and wherein the contacting components (10) are designed according to one of the Claims 1 until 4 ; b) defining a performance characteristic of the electric motor; c) selecting a contacting component (10) based on the performance characteristic; and d) contacting the stator coil (20) with the contacting component (10). Procedure according to Claim 9 , characterized in that the electrical switching structures (26) are selected from star connections or delta connections.

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