EP3243259A1

EP3243259A1 - Interconnection board of a stator for an electrical machine and method for producing same

Info

Publication number: EP3243259A1
Application number: EP15817400.3A
Authority: EP
Inventors: Konstantin Haberkorn; Tamas Csoti
Original assignee: Robert Bosch GmbH
Current assignee: Robert Bosch GmbH
Priority date: 2015-01-07
Filing date: 2015-12-28
Publication date: 2017-11-15
Also published as: WO2016110425A1; CN107112846A; CN107112846B; US10686344B2; FR3031422A1; FR3031422B1; US20180262075A1; DE102015200093A1

Abstract

An interconnection board (52) of a stator (10) of an electrical machine (12), as well as a method for producing same, by means of which an electrical winding (16) of the stator (10) can be connected to customer-specific connecting plugs (56) for power supply, wherein the interconnection board (52) has a closed ring (61) as a plastic body (62), onto which closed ring (61) exactly three holding elements (63) are integrally formed, extending in the axial direction (3), in which holding elements respective axial connector plugs (54) made of metal extend in the axial direction, wherein the axial connector plugs (54) are each integrally configured with conductive elements (58) which can be directly electrically connected to connecting wires (30, 31) of the electrical winding (16).

Description

description

title

Circuit board of a stator for an electric machine and method for producing such

The invention relates to a wiring plate of a stator for an electric machine, and to an electric machine and to a method for producing such a wiring board according to the preamble of the independent claims.

State of the art

With the DE 10 2010 000 710 AI a bearing plate of an electric machine has become known, which also serves as a circuit board for the electrical winding of a stator. The electrical winding is designed as a single-tooth winding, are wound individually wound stator segments individually and then assembled into an annular stator. Each single tooth winding here has its own winding wire beginning and - end, which are passed axially through holes in the bearing plate. These wire starts and ends are welded with conductor elements, so that the individual phases can be supplied with current via connection plugs.

In this embodiment, the conductor elements in the manufacture and in the assembly are very expensive. The inventive solution, a circuit board to be created, in which the connector plugs are securely guided in their connection with custom plugs, the interconnection plate should be independent of the end plate mountable.

Disclosure of the invention Advantages of the invention

The inventive device and the method according to the invention with the features of the independent claims have the advantage that by the formation of the holding elements for the connection plug as an integral part of the plastic plate molded axial extensions the connection plug when attaching the connector very reliable in all spatial directions are supported. In this case, both the plastic body of the interconnection plate and the conductor elements mounted thereon with their integrated connection plugs can be produced and installed very simply and inexpensively.

The measures listed in the dependent claims advantageous refinements and improvements of the embodiments specified in the independent claims are possible. The conductor elements are advantageously punched out of a metal sheet, wherein the connection plug are bent such that they extend in the axial direction of the rotor shaft. In this case, the flat plate of the connector plug extends transversely to the circumferential direction, whereas the rest of the angled conductor elements extends in a plane across the rotor shaft in the circumferential direction in a plane. In this embodiment, the middle parts of the conductor elements can very easily be supported axially on the annular plastic body of the Verschalte- plate, wherein the axially angled connector plug supported simultaneously in the axially extending support members. The conductor elements are preferably attached by means of plastic material deformation of the plastic body to this. Since the connection plugs are designed as sheet metal tabs of the bending stamped part, they can easily form an insulation displacement connection with the corresponding connection plugs.

Since the flat connector plugs extend in the radial and axial directions, they are supported particularly favorably by guide surfaces of the retaining elements, which likewise extend in the radial direction and axial direction.

In a preferred embodiment, the connection plugs have transverse webs which extend in the radial direction with the metal sheet of the connection plug. If an axial force is exerted on the connection plug when plugging in the connection plug, this force can be absorbed by axial abutment surfaces of the holding elements. As a result, regardless of the tolerance during assembly of the conductor elements, a clearly defined reference point in the axial direction for the plug connection can always be made available.

For mounting the conductor elements in the holding elements, the latter slots in the axial direction, which are at least as wide in the radial direction as the central regions of the conductor elements. As a result, the conductor elements with the angled connection plugs can be inserted axially into the holding elements, such that the angled middle region of the conductor element can extend in the circumferential direction through the slot.

In one embodiment of the Verschalteplatte a total of exactly three axial extensions are formed as a holding element, wherein in each of the holding elements in each case two adjacent connection plug are inserted, so that six different phases of the electric motor can be controlled with a total of six connection plugs. To support the two connection plugs, the holding element has a central web which extends in the radial direction and axial direction in a planar manner. At this central web can each create a connection plug at the opposite outer circumferential surfaces in the circumferential direction. In order to support the connection plugs in both circumferential directions, counter-surfaces are formed approximately parallel to the guide surfaces of the central web, against which the connection plugs - or in particular their transverse webs - are supported in the circumferential direction.

In an alternative embodiment of the Verschalteplatte, in which in an axial holding element always only one Anschuss plug is inserted, two branches of the conductor element can advantageously extend in both opposite circumferential directions. As a result, the number of parts and assembly costs can be reduced. The two branches of the conductor elements are advantageous with respect to the radial direction next to each other, however, arranged in the axial direction at different levels, so that these branches do not touch. This can be dispensed with an additional insulation. In order to To connect terelements with the radially outer connecting wires of the coil sections, have the conductor elements - or each branch of the conductor element - mounting portions. The attachment portion is advantageously formed integrally with the bending stamped part, wherein the attachment portion of the inner branch crosses the outer branch of the other conductor member axially spaced.

So that the bends in both opposite branches are axially insertable into the holding elements, the two spaced apart in the circumferential direction of the first and second guide surfaces are formed such that these surfaces with respect. The radial direction does not overlap. As a result, the two branches of the one sheet metal element of the Ansteck connector can be bent in each case in the opposite direction by about 90 ° and are inserted axially into the guide shafts of the holding elements.

In order to provide an anti-rotation device for a bearing cap, which is mounted axially on the Verschalteplatte, an axial extension of a single holding element has a different cross-section than the other two holding elements. For example, a holding element can be formed wider in the circumferential direction, in which case a single axial opening in the bearing plate is then made correspondingly wider.

Injection molding technology, the wider holding element can be realized particularly favorable by the formation of a two-part holding element. In this case, the two axial extensions each have a U-shaped cross-section, so that the free legs point toward each other in the circumferential direction. Advantageously, the end faces of the free legs form the corresponding first and second guide surfaces which are arranged spaced apart in the circumferential direction such that the connection plug can be inserted or clamped therebetween.

In order to precisely define the axial position of the connection plug, the connection plate is supported directly on the stator body by means of spacers. Since the insulating mask is arranged with the guide elements for the connecting wires between the wiring plate and the stator body, so are Tolerance deviations eliminated this Isolierlamelle. The spacers are advantageously also formed integrally with the plastic body of the Verschalteplatte, preferably as an injection molded part. The spacers extend advantageously axially relative to the holding elements at their radially outermost region whereby a deflection of the interconnection plate in the region of the connection plug when inserting the connection plug is prevented.

To fasten the conductor elements on the interconnection plate are integrally formed on the plastic body Nietstifte in the axial direction, which are thermoformed after placement of the conductor elements on the plastic body. In this case, the conductor elements have particularly favorable holes in the sheet through which the rivet pin protrudes, wherein then a riveted joint is formed.

The stator according to the invention particularly advantageously has a circuit board, in which the one-piece conductor elements, which are designed as bending punched parts, each electrically interconnects two radially opposite partial coil pairs, wherein each connection plug can be driven as a phase by the control unit. The conductor element can be advantageously punched without much waste from a sheet, since in the initial state, both branches extend approximately parallel to each other in a plane with the Ansteck plug. Only in a second step, the two branches are bent relative to the metal plate of the connector connector about 90 ° in the opposite direction to form an approximately semicircular conductor element, at its center extends axially the connector plug.

In the electric machine according to the invention, the stator is wound in such a way that two immediately adjacent stator teeth are wound with exactly one partial coil in each case, which form a partial coil pair by means of a wound through winding wire. The connecting wire of these immediately adjacent arranged partial coils is guided for all partial coil pairs in the same axial plane of the insulating lamella. In the case of a twelve-toothed stator, for example, six partial coil pairs each having six short connecting wires can be formed, whereby these six short connecting wires each have the interface. le form the mounting portions of the conductor elements. As a result, either six separate phases, each with one partial coil pair or only three phases, each with two electrically connected partial coil pairs can be formed in an optional manner. Accordingly, three connection plugs for three phases or six connection plugs for six phases in the axial direction can be formed in the circuit board.

According to the manufacturing method of the wiring board according to the invention, the three one-piece conductor elements may first be arranged with an auxiliary device into a ring such that their attachment portions cross radially. Thereafter, all three conductor elements can be axially mounted on the plastic body simultaneously with an auxiliary tool, wherein the connection plug are axially inserted respectively in the guide shafts of the axial extensions of the holding elements. This avoids that the conductor elements must be bent after their axial mounting in the radial direction.

Brief description of the drawings

Embodiments of the invention are illustrated in the drawings and explained in more detail in the following description. Show it:

Fig. 1 shows schematically an inventive winding scheme

2 shows an inventive conductor element of a wiring plate

Fig. 3 shows a first embodiment of a wound stator with Isolierla- melle

4 is a corresponding plan view of FIG .. 3

5 and 6 an embodiment of FIG. 3 with a first embodiment of a patch plate

Fig. 7 and 8 an embodiment of FIG. 3 with a second embodiment of a patch plate

9 shows the wiring plate according to FIGS. 7 and 8 without a stator, and FIG

Fig. 10 is a punched conductor element before bending. In Fig. 1, a cut-open stator 10 is shown schematically, on the

Statorzähnen 14, the winding diagram of an electrical winding 16 is shown. The stator 10 has, for example twelve stator teeth 14, wherein each stator tooth 14 is always wound exactly one partial coil 18. In each case two directly adjacent partial coils 18 are connected by means of a short connecting wire 31 to an adjacent partial coil pair 17. With the winding, for example, a first wire beginning 28 on the second stator tooth 14 is started and a connecting wire 30 is led to the fifth stator tooth 14. Immediately after the fifth stator tooth 14, the sixth stator tooth 14 is wound, so that this partial coil pair 17 is connected by means of the short connecting wire 31 of two directly adjacent partial coils 18. After the sixth stator tooth 14, the winding wire 22 is guided by means of the connecting wire 30 to the third stator tooth 14, there to form a connected by means of the connecting wire 31 part coil pair 17 with the fourth stator tooth 14. From the fourth stator tooth 14 of the winding wire 22 is guided over the connecting wire 30 to the first stator tooth 14, where the wire end 29 of the first winding strand 24 is disposed immediately adjacent to the wire beginning 28. The second winding strand 25 is wound with a second, separate winding wire 22 corresponding to the winding of the first winding strand 24, so that a further three partial coil pairs 17 arise from immediately adjacent arranged partial coils 18, which are connected by means of a short connecting wire 31. The wire beginning 28 and the wire end 29 of the two winding strands 24, 25 are each electrically connected together. In this embodiment, two coils Paarel7 are always connected to a phase 26 after winding, so that a total of exactly three phases U, V, W arise, each with four sub-coils. The first three sub-coil pairs 17 form a separate winding strand 24, which is wound from a separate winding wire 22, and with respect to the second winding strand 25 is also isolated with three sub-coil pairs 17 (as indicated by the dashed line between the sixth and seventh Stator tooth 14 is shown). Therefore, in such a winding, six separate phases 26 could be driven. In our embodiment, however, two radially exactly opposite partial coil pairs 17 of different winding strands 24, 25 are electrically connected to one another by means of conductor elements 58 of a circuit board 52 in order to reduce the electronic complexity of the control device. Such a conductor element 58, which is for example Control of the V-phase is used in Fig. 1, is shown in Fig. 2 and will be explained in more detail in the second embodiment.

In Fig. 3, a three-dimensional view of a stator 14 is now shown, which is wound according to the winding diagram of Fig. 1. The stator 14 has a stator 34, which is composed of individual laminations 36, for example. The stator body 34 in this case comprises an annular closed yoke yoke 38, on which the stator teeth 14 are formed radially inwardly. Inside, the stator 14 has a circular recess into which a rotor, not shown, can be inserted, as better seen in Fig. 4 can be seen. The stator teeth 14 extend in the radial direction 4 inwards and in the axial direction 3 along the rotor axis. In the exemplary embodiment, the stator teeth 14 are formed entangled in the circumferential direction 2 in order to reduce the cogging torque of the rotor. For this purpose, for example, the laminations 36 are rotated in the circumferential direction 2 corresponding to each other. Before the stator body 34 is wound, 39 insulating lamellae 40 are placed on both axial end faces in order to electrically insulate the winding wire 22 from the stator body 34. At least one of the two insulating lamellae 40 has an annularly closed circumference 41, from which 4 insulator teeth 42 extend in the radial direction and cover the end faces 39 of the stator teeth 14. On the annular periphery 41 of the insulating lamella 40 guide elements 44 are formed, in which the connecting wires 30, 31 are guided between the coil sections 18. For this purpose, 41 grooves 45 are formed in the circumferential direction 2, for example, on the circumference, so that the connecting wires 30, 31 are arranged in axially offset planes in order to prevent crossover of the connecting wires 30, 31. The short connecting wires 31 between the sub-coil pairs 17 are arranged in the uppermost axial plane, and in particular all six connecting wires 31 for contacting the phase connections all run in the same axial plane. For this purpose, two axial extensions 46 are always formed between two partial coils 18 of a partial coil pair 17, which are separated from one another by an intermediate radial opening 47. Thus, the short connecting wires 31 of the partial coil pairs 17 are freely accessible from all sides and, in particular in the region of the radial opening 47, are not in contact with the insulating lamella 40. The two wire starts 28 and wire ends 29 are fixed in this embodiment in a labyrinth arrangement 50, each in the circumferential direction 2 immediately adjacent to the two axial extensions 46 ange- are arranged, which are spaced by the radial opening 47. Thus, it can be seen in FIG. 3 that the wire beginning 28 of the first winding strand 24 runs parallel and immediately adjacent to the wire end 29 of the first winding strand 24 over the circumferential area of the radial opening 47. In this case, the wire beginning 28 is arranged in a first labyrinth arrangement 50 on one side of the radial opening 47, and the wire end 29 of the first winding strand 24 in a second labyrinth arrangement 50 in the circumferential direction 2 opposite to the radial opening 47. By means of this parallel arrangement of the short connecting wires 31, they can be electrically contacted in the same way as the connecting wires 31 of the wound-through partial coil pairs 17 for the purpose of phase control.

In Fig. 4 is also clearly visible that the two parallel connecting wires 31 are arranged at the same radius. The free ends of the wire beginning 28 and the wire end 29 terminate directly after the corresponding labyrinth arrangements 50, so that they do not protrude radially beyond the connecting wires 30, 31. The connecting wires 30, 31 all extend in the circumferential direction 2 along the guide elements 44 and lie radially outside of the wound on the stator teeth 14 sub-coils 18. In Fig. 4, the two motor halves 11, 13 are also schematically separated by the dash-dotted line, the left half of the engine 11 is electrically isolated from the right motor half 13. The electrical winding 16 is manufactured, for example, by means of needle windings, wherein the connecting wires 30, 31 can be guided radially outward between the sub-coils 18 by means of a winding head and can be deposited in the guide elements 44. In this embodiment, all the connecting wires 30, 31 are arranged axially on one side of the stator body 34. In an alternative, not shown embodiment, it is also possible to move a portion of the connecting wires 30, 31 on the axially opposite side of the stator 14. In this case, for example, the short connecting wires 31 for contacting the phase control can be arranged in a first insulating lamella 40, and the other connecting wires 30, which connect the different pairs of coil pairs 17 with each other, are guided on the axially oppositely disposed insulating lamella 40.

5, a first embodiment of a circuit board 52 is placed on the embodiment of the stator 10 according to FIG. 3, by means of which the electrical winding 16 is attached. is controlled. For this purpose, the circuit board 52 connection plug 54, can be added to the custom connector connector 56 of a controller. In this embodiment, exactly six terminal plugs 54 are arranged, which are each electrically connected to a partial coil pair 17 of the electrical winding 16. In this case, exactly six phases 26 are each formed by exactly one partial coil pair 17, so that the six connection plugs 54 are contacted with exactly six connecting wires 31 of adjacent partial coil pairs 17. For this purpose, the interconnection plate 52 has exactly six conductor elements 58 which have the connection plugs 54 at an axially angled end, and at the other end a fastening section 60 which is electrically connected-for example welded-to the connection wires 31. The circuit board 52 has a plastic body 62, which is formed as a closed ring 61, through which the rotor can be inserted into the stator 10. Integrally formed on the plastic body 62 are retaining elements 63 which extend away from the stator body 34 in the axial direction 3. The guide elements 58 extend in the circumferential direction 2 along the plastic body 62, wherein the angled connection plug 54 are guided within the holding elements 63 in the axial direction 3. At the other end, the conductor elements 58 on the attachment portion 60, whose free end is formed as a loop 64 which surrounds the connecting wires 31. In this case, the loop 64 is formed from a sheet material whose cross-section is approximately rectangular. In the exemplary embodiment, the conductor elements 58 are formed as bending punched parts 59 made of sheet metal, so that the loop 64 can be bent over the connecting wire 31 from the free end of the fastening section 60 during its mounting. After arranging the open loop 64 around the connecting wire 31, for example, electrodes are applied to both radially opposite surfaces of the loop 64, which are compressed in the radial direction while being energized with the connecting wire 31 for welding the loop 64. Here, the insulating varnish of the connecting wire 31 is melted, so that it comes to a metallic solid connection between the mounting portion 60 and the connecting wire 31. The loop 64 is placed around the connecting wire 31 in the area of the radial opening 47, since no guide element 44 is arranged between the connecting wire 31 and the loop 64 in this area. As a result, there is sufficient space for the application of the electrodes, so that a free leg end 65 of the loop 64 can be pressed against the mounting portion 60, whereby the loop 64 is closed. Depending on the partial coil pair 17, the loop 64 encloses only a single connecting wire 31 or simultaneously two parallel connecting wires 31 which are formed from the wire beginning 28 and the wire end 29 of a single winding strand 24, 25. The connection plugs 54 are designed, for example, as insulation displacement connections 55, which have at their free axial end 68 a notch 69, into which a wire or a clamping element of the corresponding connection plug 56 of the customer can be inserted. Furthermore, a crosspiece 70 in the radial direction 4 is formed on the connection plug 54, which is supported correspondingly on an axial stop 72 of the holding element 63. Furthermore, a first guide surface 74 and a second guide surface 75 are formed on the holding element 63, which support the connection plug 54 in both opposite circumferential directions 2. This prevents that the connection plug 54 when inserting the connection plug 56 in the circumferential direction 2 or buckle over, whereby the axial tolerances of the connector is ensured.

Conductor elements 58 are at least partially radially juxtaposed, thereby requiring that mounting portions 60 of inner conductor elements 58 radially cross outer conductor elements 58 for contacting with the bonding wires 31. Therefore, the radially inner conductor elements 58 are arranged on an axially higher path 76 of the plastic body 62, and the radially outer conductor elements 58 on an axially lower path 77. Here are formed as sheet metal strips middle portions 78 of the conductor elements 58 surface on the plastic body 62 and are connected for example by means of rivet or locking elements with this. For this purpose, axial rivet pins 79 are formed on the plastic body 62, for example, which pass through corresponding axial openings 80 of the conductor elements 58. By means of heat-in particular ultrasound-the ends of the rivet pins 79 can be formed into a rivet head 81, which forms a positive connection with the conductor elements 58.

In the exemplary embodiment of FIGS. 5 and 6, two connection plugs 54 are always arranged in a common holding element 63, wherein these are separated from one another in the circumferential direction 2 by a middle web 82 of the holding element 63. In this case, the central web 82 forms on both sides in each case a first, second guide surface 74, 75 for the Each adjoining connection plug 54. The respectively opposite the central web 82 second and first guide surfaces 75, 74 are formed by corresponding mating surfaces 83 extending in the radial direction 4 and axial direction 3. In the region of the holding elements 63 - these axially opposite - spacer 84 are formed, which supported the interconnection plate 52 axially relative to the stator 34. In the embodiment of Figures 5 and 6, exactly one holding member 63 has a greater width 85 in the circumferential direction 2, as the other two holding elements 63. This creates a rotation for a bearing cap, not shown, which axially with correspondingly shaped axial openings on the Hal teelemente 63 is added.

FIG. 6 shows how the two connection plugs 54 bear against the middle web 82 on both sides. Each angled in opposite circumferential directions 2 closes the respective central portion 78 of the webs 76, 77 are arranged, they do not touch, so that they electrically against each other conductor element 58 at. Since the radially adjacent conductor elements 58 are isolated on axially different.

The inner ring of the plastic body 62 is slightly wavy, so that a punch tool can be attached to the inner ends of the stator teeth 14 directly on the side surfaces. As a result, the stator 10 can be pressed into a motor housing (not shown).

In Fig. 7, an alternative wiring board 52 is placed on the embodiment of the stator 10 of FIG. 3 as a further embodiment, by means of which the electrical winding 16 is driven. This embodiment corresponds to the control with exactly three phases U, V, W according to the schematic representation in Fig. 1. In this embodiment, the circuit board 52 has exactly three connector 54, can be added to the custom connector connector 56 of a controller , Each connection plug 54 is part of a conductor element 58, which electrically connects a first partial coil pair 17 to a second - in particular radially exactly opposite - the partial coil pair 17. These are starting from the in

Axial direction 3 extending terminal connector 54, a first branch 90 and a second branch 91 arranged angled in the circumferential direction 2. The two branches 90, 91 together form approximately a semicircle, and extend along the annular plastic body 62, wherein at their end remote from the connection plug 54 En- the fixing portions 60 for electrical contacting with the connecting wires 30, 31 of the partial coils 18 have. The first branch 90 of a first conductor element 58 is arranged radially inside the second branch 91 of a second conductor element 58. The attachment portion 60 of the first inner branch 90 therefore crosses the second outer branch 91 of the second conductor member 58 in the radial direction 4 without touching it. In this case, the radially inner branches 90 are arranged on an axially higher track 76 than the radially outer branches 91, which are arranged on an axially lower track 77 of the plastic body 62. Trained as sheet metal strip conductor elements 58 are flat against the plastic body 62 and are connected for example by means of rivet connections 79, 81 or locking elements with this. For this purpose, for example, on the plastic body 62 axial rivet pins 79 are formed, which engage in corresponding axial openings 80 of the conductor elements 58. By means of heat - in particular ultrasound - the ends of the rivet pins 79 can be converted to a rivet head 81, which forms a positive connection with the conductor elements 58. For example, each branch 90, 91 is fastened to the interconnection plate 52 by means of two rivet heads 81, as can be seen particularly well in FIG. Retaining elements 63 are integrally formed on the plastic body 62 again, which extend away from the stator body 34 in the axial direction 3 and receive the connection plug 54. For example, as shown in FIG. 5, the connection plugs 54 are also formed as an insulation displacement connection 55, which has a notch 69 at its free axial end 68 into which a wire or a clamping element of the corresponding connection plug 56 of the customer can be inserted. The holding elements 63 are formed in two parts in this embodiment. A radially inner axial extension 92 forms a first guide surface 74 in a first circumferential direction 2 and a radially outer axial extension 93 forms the second guide surface 75 for the opposite circumferential direction 2. The two Axialfortsätze 92, 93 are arranged offset in the circumferential direction 2, so that between the Guide surfaces 74, 75 of the connection plug 52 extends in the axial direction 3. The axial extensions 92, 93 each have a support surface 95 with respect to the radial direction 4, on which the connection plug 52 is radially supported. For this purpose, the axial extensions 92, 93 have, for example, an L-shaped or U-shaped cross-section 96 transversely to the axial direction 3. With respect to the axial direction 3, the radially extending transverse web 70 is supported on axial stops 72 of the retaining element 63. The axial extensions 92, 93 are offset in the radial direction 4 so far that they do not overlap in the radial direction 4. As a result, in the holding element ment 63 in both circumferential directions 2 each openings 98 are formed, from which the two branches 90, 91 in opposite circumferential directions 2 emerge from the holding element 63. So that the conductor elements 58 can be mounted axially in the holding elements 63, the openings 98 are open in the axial direction 3 upwards. The angled portions 100 of the branches 90, 91 to the connection plug 54 are arranged radially next to one another and on axially different planes, so that the branches 90, 91 on the axially different tracks 76, 77 of the plastic body 62 can extend.

It can be seen from FIG. 8 that the branches 90, 91 are arranged radially in the region of the stator teeth 14 and radially inside the guide elements 44 of the insulating lamella 40. The three holding elements 63 are distributed uniformly in the circumferential direction 2 in approximately 120 ° spacing. A holding element 63 again has a greater width 85 in the circumferential direction 2 to prevent rotation. For this purpose, the two axial extensions 92, 93 are U-shaped, so that their free legs 87 in the circumferential direction 2 show each other. The end faces 88 of the free legs 87 in this case form guide surfaces 106 in the circumferential direction 2 (which correspond to the first and second guide surfaces 74, 75), between which the connection plugs 54 are arranged.

As can be seen in particular in FIG. 9, integrally formed with the holding elements 63 are formed axially opposite to these spacers 84 on the plastic body 62, which rest axially against the stator body 34. The free ends of the attachment portions 60 are again formed as loops 64 as in Fig. 5, which are still open prior to assembly of the conductor elements 58, and after the assembly, the connecting wires 31 enclose.

In Fig. 10, a conductor member 58 is shown as bending punched parts 59 made of sheet metal after punching before it is bent. In this initial state, the two branches 90, 91 both in the same circumferential direction 2, whereby sheet material is saved. The two planned bends 100 are arranged axially offset in the bent state, at which the two branches 90, 91 are then bent in opposite circumferential directions 2. The arcuate branches 90, 91 here have slight radial offsets 102 to accommodate the radial widening 104 at the apertures 80. The attachment portions 60 are shown in FIG. 5 pre-bent as an open loop 64 and after being placed on the connecting wires 30, 31 radially compressed to form a closed loop 64. For this purpose, 64 electrodes are again applied to both radially opposite surfaces of the loop, which are compressed in the radial direction 4 while, for example, for welding the Loop 64 are energized with the connecting wire 31, 30. Thus, the fastening portions 60 and their electrical contact with the winding 16 can be carried out in the same manner as in the embodiment according to FIGS. 5 and 6. In this case, the loop 64 only encloses a single connecting wire 31 or simultaneously, depending on the partial coil pair 17 two parallel juxtaposed connecting wires 31 which are formed from the wire beginning 28 and the wire end 29 of a single winding strand 24, 25.

For mounting the conductor elements 58 into the holding elements 63 of the plastic body 62, first all three conductor elements 58 are arranged in an annular manner with their branches 90, 91, so that the attachment sections 60 of the inner branches 90 radially overlap the outer branches 91. Then, all three conductor elements 58 are inserted axially together at the same time in the axial direction 3 between the guide surfaces 74, 75, 106. This is preferably done by means of an auxiliary tool that can simultaneously position and hold all three conductor elements 58. During axial insertion, the rivet pins 79 of the plastic body 62 pass through the axial openings 80 of the conductor elements 58. Thereafter, the ends of the rivet pins 79 can be converted into rivet heads 81 in order to positively connect the conductor elements 58 to the plastic body 62. This plastic material conversion takes place for example by means of hot stamping with hot punches and / or by means of ultrasound.

Claims

claims

1. interconnection plate (52) of a stator (10) of an electrical machine (12), by means of which an electrical winding (16) of the stator (10) with custom connection plugs (56) for the power supply is connectable, wherein the interconnection plate (52 ) as a plastic body (62) has a closed ring (61) on which integrally exactly three in the axial direction (3) extending holding elements (63) are formed, in which axially each axial connection plug (54) extend axially from metal, wherein the axial connection plug (54) are each formed integrally with conductor elements (58) which are electrically connectable directly to connecting wires (30, 31) of the electrical winding (16).

Second interconnecting plate (52) according to claim 1, characterized in that the conductor elements (58) are formed as bending punched parts (59) of sheet metal, whose axially angled extensions are formed as insulation displacement connection (55) which form the connection plug (54) , wherein the sheet metal of the connection plug (54) extends in the radial direction (4), and the conductor elements (58) extend flat in a plane in the circumferential direction (2) - wherein in particular the holding elements (63) have first and second guide surfaces ( 74, 75) extending in the axial direction (3) and radial direction (4) to support the terminal connectors (54) in the circumferential direction (2).

3. interconnection plate (52) according to claim 1 or 2, characterized in that the holding elements (63) axial stops (72) extending in the circumferential direction (2) and radial direction (4) to transverse webs (70) of the connection Support plug (54) in the axial direction (3) - in particular when inserting the corresponding connection plug (56).

Circuit board (52) according to one of the preceding claims, characterized in that the holding elements (63) have openings (98) in the circumferential direction (2) which extend over their entire axial extent, wherein the angled conductor elements (58) through the openings ( 98) are led out of the holding elements (63).

Circuit board (52) according to one of the preceding claims, characterized in that in each case two connection plugs (54) are arranged adjacent to a common holding element (63), wherein the holding element (63) has a center web (82) extending in the radial direction (4) at the same time the first guide surface (74) with respect to the one circumferential direction (2) for the one connection plug (54) and the second guide surface (75) with respect to the opposite circumferential direction (2) for the other connection plug (54) In particular, all six connection plugs (54) are each connected to a different phase (26) of the electrical winding (16).

Circuit plate (52) according to one of the preceding claims, characterized in that, starting from the axial connection plug (54), the conductor element (58) extends in a first and a second branch (90, 91) in opposite circumferential directions (2), wherein angled portions (100) of the branches (90, 91) are formed radially adjacent to one another.

Circuit board (52) according to any one of the preceding claims, characterized in that the two angled angular regions (100) are arranged axially on different planes, and the first and the second branch (90, 91) of the conductor element (58) on axially different annular tracks (76, 77) of the plastic body (62) abut.

Circuit board (52) according to one of the preceding claims, characterized in that the first branch (90) of the one conductor element (58) radially inwardly and axially above the second branch (91) of a another conductor element (58) is arranged, and extending from the first branch (90) radially outwardly a fixing portion (60) which crosses the second branch (91) of the other conductor element (58) contactlessly with the radially outside of the first and second branch (90, 91) arranged connecting wires (30, 31) to be contacted.

9. Interconnecting plate (52) according to one of the preceding claims,

characterized in that the support member (63) for a single terminal plug (54) has a first guide surface (74) with respect to the one circumferential direction (2) and a second guide surface (75) spaced circumferentially (2) with respect to the opposite circumferential direction (2), wherein the first and second guide surfaces (74, 75) in the radial direction (4) do not overlap.

10. Wiring plate (52) according to one of the preceding claims,

characterized in that a single holding element (63) in the circumferential direction (2) and / or radial direction (4) is wider than the other two holding elements (63), so that a bearing cap for a rotor of the electric machine (12) with corresponding axial Breakthroughs for the holding elements (63) in a unique angular position on the Verschaltungsplatte (52) can be pushed - in particular the one wider trained holding element (63) in the circumferential direction (2) opposite, radially offset from one another arranged U-shaped axial extensions (92, 93 ), and in the circumferential direction (2) facing each other free legs (87) each having end faces (88) which form the first and second guide surface (74, 75, 106) for a single connection plug (54).

11. Wiring plate (52) according to one of the preceding claims,

characterized in that integrally formed on the plastic body (62) axially opposite to the holding element (63) on the radially outer edge a spacer (84) with which the interconnection plate (52) axially relative to the stator (10) - in particular directly at the axially outermost lamination (36, 39) - is abstütztbar.

12. interconnection plate (52) according to any one of the preceding claims, characterized in that the conductor elements (58) - in particular closed over its circumference - openings (80) in the sheet metal, by the fixing of which axial rivet pins (79) of the plastic body (62 ), whose free ends are formed in particular by means of hot embossing to rivet heads (81).

13. stator (10) having a circuit board (52) according to any one of the preceding claims, characterized in that in each case one phase (26) of a first winding strand (24) with the corresponding phase (26) of a second winding strand (25) of the electrical winding (16) are connected together with exactly one connection plug (54), so that in total on the interconnection plate (52) exactly three connection plugs (54) are formed, wherein the two branches (90, 91) of a single conductor element (58 ) With the fastening portions (60) two radially opposite partial coil pairs (17) at the connecting wires (30, 31) electrically contact.

14. Electrical machine (12) with a rotor and a stator (10), comprising a circuit board (52) according to any one of the preceding claims, characterized in that two immediately adjacent sub-coils (18) by means of a connecting wire (31) directly connected are, wherein the connecting wire (31) as a wound winding wire (22) is formed without interruption, wherein on the uppermost lamination (36) of the stator (10) on its outer periphery (41) formed closed insulating lamella (40) is arranged Guiding elements (44) for the connecting wires (30, 31) between the individual partial coils (18), which are arranged in axially different planes, wherein all the connecting wires (31) between the immediately adjacent partial coil pairs (17) of a phase (26, U, V, W) are disposed in an axially uppermost plane, and electrically connected to the attachment portions (60) of the conductor members (58) are.

15. A method for producing a circuit board (52) according to any one of the preceding claims, characterized in that by means of injection molding first the annular plastic body (62) with the three integrally formed thereon retaining elements (63) is made, and then the three identical connection plug (54) with the angled thereto conductor elements (58) - in particular all simultaneously - axially along the first and second guide surface (74, 75, 106) are inserted into the holding elements (63), so that the fixing portions (60) of the first branches ( 90) radially over the second branches (91) of the conductor elements (58).