Classifications

• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K5/00—Casings; Enclosures; Supports
  • H02K5/04—Casings or enclosures characterised by the shape, form or construction thereof
  • H02K5/22—Auxiliary parts of casings not covered by groups H02K5/06-H02K5/20, e.g. shaped to form connection boxes or terminal boxes
  • H02K5/225—Terminal boxes or connection arrangements
• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K11/00—Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection
  • H02K11/30—Structural association with control circuits or drive circuits
  • H02K11/33—Drive circuits, e.g. power electronics
• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
  • H02K15/0056—Manufacturing winding connections
  • H02K15/0062—Manufacturing the terminal arrangement per se; Connecting the terminals to an external circuit
• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
  • H02K15/14—Casings; Enclosures; Supports
• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K5/00—Casings; Enclosures; Supports
  • H02K5/02—Casings or enclosures characterised by the material thereof

Definitions

• the invention relates to an electric motor according to the preamble of claim 1 and a method for producing such an electric motor according to the preamble of claim 17.
• the invention has the object of providing the generic electric motor and the generic method in such a way that a secure attachment of the electric motor is ensured with structurally simple design and manufacture. This object is achieved according to the invention in the generic electric motor with the characterizing features of claim 1 and the genus in contemporary methods with the characterizing features of claim 17.
• the electronics and / or terminal housing and the stator are firmly connected by its encapsulation with each other to the stator. It forms a complete unit, so that the production of the electric motor is possible in a simple manner.
• the encapsulation is thus not only provided for the stator, but it also serves as a connecting means to connect the electronics and / or terminal housing with the wound stator. As a result, additional connecting parts between the electronics and / or terminal housing and the stator can be saved. Only a single Umspritzvor gear is required.
• the material of the encapsulation allows optimal heat dissipation from the winding region of the stator in the electronics and / or connection housing.
• the bottom of the electronics and / or connection housing is at least partially covered at the top of the encapsulation. This ensures a secure positive connection between the electronics and / or connection housing and the stator.
• the encapsulation advantageously connects the electronics and / or connection housing to the stator in a form-fitting manner.
• the electronics and / or connection housing and the stator are reliably firmly connected to each other, so that unintentional release during assembly and also during use of the electric motor is excluded.
• a reliable solid connection between the electronics and / or terminal housing and the stator is achieved in that the electronics and / or terminal housing is provided with openings for the passage of the material of the encapsulation. The material passes through the openings so that it can be seen on either side of the corresponding opening. gene having part of the electronics and / or connection housing is located.
• the positive connection achieved in this way is safe and withstands even heavy loads.
• the openings for the passage of the material of the encapsulation in the bottom of the electronics and / or Anschlußge housing is particularly advantageous.
• this material can pass through the openings into the electronics and / or connection housing and thus cover the floor, for example, on both sides, whereby a reliable positive connection between the electronics and / or terminal housing and the stator is ensured.
• the openings in the bottom of the electronics and / or terminal housing can be used ge to bring connection contacts from the stator into the interior of the electronics and / or connection housing.
• the encapsulation then encloses these terminals, so that they are properly positioned for connection to the electronics in the electronics and / or terminal housing, which greatly facilitates the installation of the electric motor.
• thermocouples Through the openings, other components, such as sensors, for. B. thermocouples, Hall sensors and the like., Are performed.
• the encapsulation covers the bottom at least partially on both the top and at the bottom.
• the upper side of the bottom of the electronics and / or connection housing is recessed in relation to a peripheral edge adjoining a jacket of the electronic and / or terminal housing.
• the recess thus formed within the electronics and / or connection housing can then serve as a receiving space for the material of the encapsulation when it passes through the openings in the bottom in the electronics and / or terminal housing.
• a reliable solid connection between the electronics and / or terminal housing and the stator is achieved when the top of the top of the floor covering encapsulation lies in a plane with the top of the peripheral edge.
• the receiving space of the electronics and / or connection housing has a coat to the bottom Runaway level bottom surface, which facilitates the installation of the electronics in the electronics and / or connection housing.
• the extending over the circumference of the jacket of the electronics and / or connection housing edge may be formed relatively narrow, so that a sufficiently large, formed by the recess volume for receiving the encapsulation is present.
• the electronics and / or connection housing preferably has a mounting flange which is at least largely free of the encapsulation.
• mounting flange openings may be provided for the passage of mounting screws, by means of which the electric motor can be attached by the customer.
• the mounting flange may be provided with mounting threads for the mounting screws.
• the mounting flange preferably extends over the circumference of the electronics and / or connection housing.
• a mounting flange is also an embodiment to be understood, in which over the circumference of the electronics and / or connection housing, for example, two or more spaced-apart projecting flange parts are provided.
• the mounting flange is integrally formed with the jacket of the electronics and / or connection housing. Then there is no additional work to connect the jacket to the mounting flange.
• the bottom is formed integrally with the jacket of the electronics and / or connection housing.
• the electronics and / or terminal housing can be produced together with the mounting flange and the floor by means of an injection molding process, partly made of aluminum.
• other materials for the electronics and / or terminal housing other, good heat dissipating properties having materials into consideration.
• the bottom of the electronics and / or connection housing is advantageously provided with a central opening, at the edge of which a ring protruding towards a stator of the stator stator connects .
• This ring can be closed over the circumference, but can also consist only of a partial ring or of individual, spaced-apart ring sections.
• the ring may cooperate with a stator bushing of the stator to align the electrical and / or terminal housing radially with respect to the stator.
• the ring is surrounded by an electrically insulating pasisolierelement.
• the ring may be formed in an advantageous embodiment so that it has a bearing seat for a rotary bearing for a rotor shaft. About the ring results in a very good heat dissipation of this electronics housing adjacent pivot bearing.
• This pivot bearing is usually subjected to higher thermal loads than the other when using the electric motor, remote from the electronics and / or terminal housing lying pivot bearing, because both the winding of the stator and housed in the electronics and / or connection housing power electronics directly adjacent to this Rotary bearings are.
• the stator of the stator is detected and then together with the electronics and / or terminal housing inserted in an injection mold. Subsequently, a thermally conductive, electrically insulating plastic is introduced into the injection molding tool. In this case, the stator is overmolded and at the same time the stator is connected to the electronics and / or connection housing to the stator unit. In this way, a one-piece complete stator, which requires no further processing.
• FIG. 1 shows an exploded view of an electronics housing, an intermediate insulating element and a stator of an EC motor according to the invention
• Fig. 2 shows an axial section through the interconnected parts according to
• FIG. 5 shows the electronics housing according to FIG. 4 in a perspective bottom view
• FIG. 6 shows an axial section of an electronics housing connected to a stator of a second embodiment of an EC motor according to the invention
• FIG. 7 shows in axial section a third embodiment of an EC motor according to the invention
• FIG. 8 is a perspective bottom view of an electronics housing of the EC motor according to FIG. 7,
• the engine is an EC motor with an electronics housing 1 which receives the electrical / electronic components required for operation of the EC motor.
• an electronics housing 1 which receives the electrical / electronic components required for operation of the EC motor.
• At the one stator 2 end facing the electronics housing 1 is provided with a radially outward Shen projecting circumferential mounting flange 3. It is used by the customer for fixing the EC motor.
• the housing 1 may, for example, a connection housing or
• Terminal box for an asynchronous or reluctance motor.
• Terminal box for an asynchronous or reluctance motor.
• the electronics housing 1 has a bottom 4 (FIGS. 1 to 5) which is provided with a central opening 5.
• the bottom 4 is surrounded by a peripheral raised edge 6 (FIGS. 3 and 4), from which a circumferential jacket 7 projects transversely.
• a circumferential jacket 7 projects transversely.
• the circumference openings 8 which serve to connect to a full injection of the stator 2 to be described later.
• further openings 9 are provided for carrying out contacts in the bottom 4. These openings 9 have only elongated outline by way of example. Also, the openings 8 need not have the illustrated circular outline.
• At the edge of the central opening 5 includes a projecting from the bottom of the bottom 4 vertically projecting ring 10, which extends only over part of the circumference of the opening 5.
• At least the jacket 7 and the mounting flange 3 are made in one piece from a metallic material, preferably made of aluminum. Before geous also the bottom 4 of the electronics housing 1 is formed integrally with the jacket 7.
• the mounting flange 3 has distributed over its circumference bushings 1 1 for mounting screws to secure the electric motor by the customer. Since the mounting flange 3 is made of metal and is integrally formed with the jacket 7 of the electronics housing 1, a secure screw connection of the EC motor is ensured. The mounting flange 3 can reliably absorb the weight of the electric motor and the attached fan, without a loosening of the screw is to be feared.
• the bushings 1 1 are, as shown by way of example Fig. 1, at the side facing away from the jacket 7 underside of the mounting flange 3 surrounded by a stationary ring 12, so that the inserted through the bushings 11 screws find a secure fit.
• the mounting flange 3 may also be provided with threads for screwing the mounting screws. Since the electronics housing 1 is advantageously made entirely of metal, there is a reliable dissipation of the heat generated when using the EC motor. Therefore, the electronics housing 1 may consist not only of the preferred aluminum, but also of other heat-dissipating metalli's materials.
• the protruding from the bottom 4 in the direction of the stator 2 ring 10 is advantageously also formed integrally with the bottom 4.
• the ring 10 is surrounded by an intermediate insulating element 13, which consists of an electrically insulating plastic. It is adapted in its shape to the design of the stator 2 and may for example be formed as a ring or as a ring segment.
• the septisolierelement 13 is annular.
• the annular Eisenisolierelement 13 abuts on the outside of the ring 10 and on the underside of the bottom 4.
• the stator 2 is formed in a known manner from auffact sitting sheet metal lamella, which are connected firmly together in a suitable manner.
• the stator 2 is provided in a known manner with a winding 14.
• the connection contacts 15 of the winding 14 protrude through the openings 9 in the bottom 4 of the electronics housing 1 and are electrically connected to an electronics 16 accommodated in the electronics housing 1 (FIG. 3).
• the stator 2 is surrounded by an existing from electrically insulating plastic inner encapsulation 17a. It serves to insulate the stator core 2 with respect to the winding 14 and may for example consist of a thermoplastic such as polyamide or PET. Provision may be made in the inner encapsulation 17a to receive contacts.
• a rotor shaft 19 (Fig. 3), which is supported in two pivot bearings 22, 23, which are housed in a respective bearing seat 20, 21.
• the bearing seats 20, 21 are located in the region above and below the stator core 2 and are formed by the inner encapsulation 17a.
• the pivot bearing 22, 23 may, as shown, be a ball bearing. Depending on the design of the EC motor, the pivot bearing 22, 23 may also be another roller bearing or a sliding bearing.
• the rotor shaft 19 protrudes beyond the bearing seat 21 and at this end advantageously carries a cooling wheel 24, which sits non-rotatably on the rotor shaft 19 and serves to cool the EC motor.
• the rotor shaft 19 carries in a known manner a rotor hood 25, which surrounds the stator 2 and has on its inner wall permanent magnets 26 which are distributed over the circumference of the rotor hood 25.
• the permanent magnets 26 surround the stator 2 to form an annular air gap 27.
• the permanent magnets 26 protrude with both ends axially over the stator 2.
• the permanent magnets 26 themselves are axially projected from the rotor cover 25 at its the mounting flange 3 end facing.
• the metallic electronics housing 1 with the mounting flange 3 and the wound stator 2 are placed in an injection mold, in which a good thermal conductivity, electrically insulating plastic 28 is injected, which forms an outer extrusion 17b.
• a plastic is advantageously a duroplastic, such as BMC (Bulk Molding Compound).
• BMC Bulk Molding Compound
• This is a fiber-matrix semi-finished product. It consists mostly of short glass fibers and a polyester or vinyl ester resin. It is also possible thermoplastics.
• the plastic forms the outer Statorumspritzung 17b.
• a firm connection between the electronics housing 1 and the stator A takes place via this injected plastic. This is achieved by the fact that the plastic passes through the openings 8, 9 (FIGS.
• the bottom 4 of the electronics housing 1 is covered with the plastic 28 so that the top 29 of the encapsulation 17b and the top 30 of the edge 6 of the bottom 4 are in a common plane (Fig. 2).
• the bottom 4 is completely covered on its underside by the plastic 28, which also surrounds the outside of the stator 2 and the lower winding of the stator stator 2.
• the bacteria insolierelement 13 which sits on the ring 10 and rests against the underside of the bottom 4 is enclosed by the plastic 28 and integrated into the composite of electronics housing 1 and stator A.
• stator unit consisting of one piece with the electronics housing 2 is created.
• the mounting flange 3 is free of the encapsulation 17a, 17b.
• the electronics 16 are installed in the electronics housing 1.
• the electrical / electronic components are seated on at least one printed circuit board 31 ( Figure 3) which is suitably secured.
• an intermediate insulation 32 is provided, which can be used, for example, as a flat insulating Lierusion is formed and is secured in a suitable manner in the electronics housing 1.
• the intermediate insulation 32 can be omitted if the insulation is formed by the outer coating 17b.
• a lid 33 is placed, which is releasably connected with screws with the jacket 7.
• two planar contact elements 34, 35 are arranged by way of example (FIG. 4), which each extend obliquely to the inner wall of the jacket 7 and are connected to the jacket 7 with their ends lying in the circumferential direction. Between the jacket 7 and the abutment elements 34, 35, receiving spaces 36 are formed, into which fastening / clamping elements are inserted, which press the components against the abutment elements 34, 35 of the jacket 7. Due to the contact between these components and the jacket 7, the resulting heat during operation of the EC motor in these components via the jacket 7 leads cleanse.
• the jacket 7 has a straight section 37, in which passage openings 38 for power lines are located, which are connected to corresponding terminals within the electronics housing 1.
• the jacket 7 is largely cylindrical. Only in the area of threaded debohrept 39 of the jacket 7 is provided with inwardly extending part-circular indentations. In the threaded holes 39 Screw ben are screwed to fasten the lid 33.
• the jacket 7 is thickened in the area of the threaded bores 39, so that the cover 33 can be reliably screwed onto the end face of the jacket 7.
• a sealing surface 40 which extends over the circumference of the shell 7 and the seal between the cover 33 (including a seal) and the shell 7 ensured (Fig. 3 and 4).
• the solid, preferably one-piece connection between the jacket 7 of the electronics housing 1 and the mounting flange 3 offers the advantage that the screw connection for the customer fan attachment is reliable, especially for heavier fans.
• the outer encapsulation 17b allows a large-scale mechanical connection of the electronics housing 1 to the stator A. If the electronics housing 1 or its jacket 7 is preferably integrally formed with the mounting flange 3, only a single component is required for this, preferably, an aluminum die-cast part. It is only an encapsulation in the manner described be required to completely overmold the stator A and at the same time produce the solid positive connection between the stator A and the electronics housing 1.
• the encapsulation 17b further has the advantage that an additional seal between the bottom 4 of the electronics housing 1 and the motor flange 28a formed by the encapsulation 17b (FIG. 2) is not required.
• the electronics housing 1 is connected to the stator A in the manner described above the encapsulation 17b, the electronics 16 and the power semiconductors can be easily mounted.
• the material of the encapsulation 17b also enables improved decoupling of the stator A from the electronics housing 1 with respect to noise. see and vibrations.
• the material of the encapsulation 17b serves as a corresponding damping mass.
• stator A and electronics housing 1 by means of extrusion coating 17b offers the advantage that mechanical machining on the electronics housing is not required. It only need the threads in the holes 39 and optionally in the bushings 1 1 are attached.
• connection between the electronics housing 1 and the stator A requires no additional connecting parts, so that the assembly of the EC motor can be easily made.
• Fig. 6 shows an embodiment that differs from the previous,sbei play in that an intermediate insulating is not seen easily.
• the encapsulation 17b encloses the bearing seat 20.
• the insects 15 and the electronics housing 1 are met.
• this embodiment is the same shape as the previous embodiment. Again, there are the same advantages as have been explained with respect to the embodiment of FIGS. 1 to 5.
• FIGS. 7 and 8 corresponds essentially to the embodiment according to FIGS. 1 to 5.
• the difference is that the bearing seat 20 for the electronic housing 1 facing pivot bearing 22 is part of the ring 10, the central opening. 5 encloses in the bottom 4 of the electronics housing.
• the free edge of the ring 10 is used for twistedg of the bearing seat 20 is bent so that an annular bearing surface 41 is formed (Fig. 8). It serves as an axial stop for the encapsulation 17b.
• the bearing seat 21 is formed by the inner encapsulation 17a.
• the ring 10 is elongated in contrast to the previous embodiments to form the bearing seat 20, there is improved heat dissipation from the pivot bearing 22 via the ring 10 in the electronics housing 1.
• the pivot bearing 22 is thermally more stressed than the pivot bearing 23, because the winding 14 and the power electronics 16 are adjacent to the pivot bearing 22.
• the heat can be optimally discharged into the electronics housing 1 via the bearing seat 20 of the ring 10.
• FIGS. 7 and 8 is the same removablebil det as the embodiment of FIGS. 1 to 5.
• FIG. 9 essentially corresponds to the exemplary embodiment according to FIG. 3.
• the rotor surrounding the stator is not shown in FIG.
• the electronics housing 1 has the radially outwardly projecting circumferential mounting flange 3, with which the EC motor can be attached by the customer.
• At least the jacket 7 and the mounting flange 3 are made in one piece from metallic material, preferably made of aluminum. As in the embodiment of FIG. 3, the bottom 4 of the Elektronikgeophu ses 1 is advantageously formed integrally with the jacket 7.
• the stator 2 is completely surrounded by the encapsulation 17b.
• the encapsulation 17b is formed so that it covers the inside 42 of the jacket 7 of the Elektronikgeophu ses 1 over part of its height.
• the encapsulation part 43 extends over less than half the height of the inner side 42 of the housing shell 7, for example.
• the encapsulation part 43 can also be made higher. It is possible to cover the entire inner side 42 with the encapsulation part 43.
• the encapsulation 43 has only a very small thickness. It is only so large that the electrical insulation of the electrical / electronic components located in the electronics compartment 44 of the electronics housing 1 is ensured with respect to the electronics housing 1.
• the overmolding part 43 has the advantage, even if it does not have sufficient insulating properties, of ensuring distances between the electrical / electronic components in the electronics compartment 44 and the electronics housing 1. In this way, the required clearances and creepage distances can be safely maintained.
• the encapsulation 43 extends over the circumference of the shell 7. However, it is possible to provide the encapsulation 43 only where electrical insulation is needed. Other areas that do not require electrical insulation are freed, so that there, for example, components that develop heat during operation can be installed in the electronics compartment 44 so that they have contact with the jacket 7. Then, the heat can be reliably delivered to these electrical / electronic components directly to the jacket.
• the encapsulation part 43 can be pulled up so far that it projects beyond the free edge of the housing jacket 7. Then, the encapsulation part 43 forms on the sealing surface 40 an edge-side seal which seals the cover 33 with respect to the jacket 7 of the electronics housing 1. In this case, a separate sealing element is not required.
• FIG. 9 is the same as the embodiment of FIG. 3.
• Fig. 10 shows a variant in which the two bearing seats 20, 21 are formed in the Vollumspritzung 17b.
• the stator 2 and the electronics housing 1 is inserted into a tool for full encapsulation.
• the plastic 28 is injected for the Vollumspritzung 17b in the tool.
• the plastic 28 then forms the encapsulation 17b, with which the stator core 2 and the electronics housing 1 are firmly connected to one another.
• the two bearing seats 20, 21 are produced in Umspritzwerkmaschinezeug.
• the Umspritzwerkmaschinezeug is designed accordingly.
• the Umspritzwerkmaschinezeug ensures the alignment of the two bearing seats 20, 21.
• the bearing seats 20, 21 may have a cylindrical outer shape or a slightly wavy outer shape.
• the embodiment is the same as the embodiment of FIG. 3.
• the described construction of the bearing seats 20, 21 in the encapsulation 17 may also be provided in the other described embodiments.
• the inner and outer encapsulation 17a, 17b may be made of different materials. However, it is also possible to produce the inner encapsulation 17a of the same material, preferably BMC, as the outer encapsulation 17b.

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• 2018
  • 2018-02-06 DE DE102018001015.6A patent/DE102018001015A1/de active Pending
• 2019
  • 2019-01-24 BR BR112020015551-9A patent/BR112020015551A2/pt unknown
  • 2019-01-24 EP EP19703007.5A patent/EP3750230A1/de active Pending
  • 2019-01-24 WO PCT/EP2019/000020 patent/WO2019154556A1/de unknown
  • 2019-01-24 JP JP2020542566A patent/JP7285266B2/ja active Active
  • 2019-01-24 US US16/967,737 patent/US11923747B2/en active Active
  • 2019-01-24 CN CN201980011965.1A patent/CN111954968B/zh active Active

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