WO2015048956A2

WO2015048956A2 - Positioning an overmolded stator for a clutch actuator or a transmission actuator and introducing a rotor position magnet into such an actuator

Info

Publication number: WO2015048956A2
Application number: PCT/DE2014/200462
Authority: WO
Inventors: Julian Botiov; Markus Dietrich; Vincent Gautier; Jürgen GERHART; Jie Zhou
Original assignee: Schaeffler Technologies AG & Co. KG
Priority date: 2013-10-01
Filing date: 2014-09-09
Publication date: 2015-04-09
Also published as: DE112014004555A5; KR102214250B1; WO2015048958A2; CN105658982B; DE112014004527A5; CN105658982A; WO2015048957A2; DE112014004551A5; WO2015048956A3; KR20160065843A; WO2015048957A3; WO2015048958A3

Abstract

The invention relates to an actuator for a motor vehicle, having a housing, having an electromagnetic drive device having a stator and a rotor that can be rotated relative to said stator, wherein the rotor is connected via a converter unit to a release element, wherein the converter element converts the rotational movement of the rotor into a translational movement of the release element, and having an electronic control unit that is electrically connected to the drive device and controls the drive device, wherein the drive device has an overmolding consisting of an electrically insulating material, at least on the side facing the control unit.

Description

Positioning a molded stator for a clutch actuator or a gear actuator and introducing a rotor magnet in such an actuator

The invention relates to an actuator / actuator for a motor vehicle, such as a car, truck, bus or agricultural utility vehicle, with a housing, with a stator and a rotor rotatable relative to this stator having, electromagnetic drive means, wherein the rotor via a transducer unit with a trigger element (such as a piston or a gear of a transmission, such as a planetary gear, or a nut) is connected, wherein the transducer unit converts the rotational movement of the rotor into a translational movement of the trigger element, and with an electrically connected to the drive means, the drive means controlling , electronic control unit.

Such actuators, which can be used, for example, as clutch actuators or planetary gear actuators in a belt drive and are used in particular in motor vehicles such as buses, cars, lorries or agricultural utility vehicles, are already known from the prior art. For example, WO 201 1/127888 A2 discloses a hydrostatic actuator with a master cylinder, in particular in a motor vehicle, comprising a housing and a piston which can be displaced axially in the housing and acts on a pressure chamber filled with pressure medium. The piston is driven by a rotary drive electric motor with a stator and a rotor by means of a planetary gear mechanism which converts the rotary drive into an axial movement. The Planetenwälzgetriebe is centered in the housing and a driven by the electric motor spindle is supported by a single radial bearing relative to the housing.

Since the control unit is to be arranged spatially immediately adjacent to the drive device, certain signs of wear during operation can lead to such a loss of function. For example. For example, substances such as equipment may, from the drive means, enter the housing space receiving the control unit over time, thereby affecting the electrical contacts, eventually leading to damage or even separation of these contacts. Furthermore, it may happen in an already advanced state of wear of the control unit, that not all functions of the control unit can be reliably performed due to the additional vibrations occurring in operation and applied to the actuator. For example, the rotational position sensor could The control unit, the rotational position of the rotor may no longer reliably play.

It is an object of the following invention to overcome the disadvantages known from the prior art and to increase the reliability of the actuator, wherein the actuator should be cheaper and to manufacture by a smaller number of components. The assembly of the actuator should be simplified.

This object is achieved in that the drive device has at least on the side facing the control unit one of an electrically insulating material, preferably plastic, in the form of an encapsulation or encapsulation existing geometry.

Such an encapsulation has the effect that the drive device, which is usually designed as an electric motor and which comprises the stator and the rotor, is arranged with a distance from the control unit by means of a kind of spacer. An encapsulation can be precisely adjusted in terms of thickness. The encapsulation layer is thus arranged spatially between the drive device and the control unit and serves as a spatial separation. This makes it possible to provide as reproducible as possible alignment of these two components for mass production, wherein the actuator can be used over a longer life cycle.

Further advantageous embodiments are claimed in the subclaims and are explained in more detail below.

If the encapsulation on the stator and / or the rotor material, force or positively connected, the encapsulation can be connected directly to a portion of the output device. The actuator is characterized particularly space-saving ausgestaltbar.

According to a further embodiment, it is also advantageous if the stator is encapsulated on its side facing the control unit with a stator separation layer which at least partially forms the encapsulation, wherein the stator separation layer is preferably cup-shaped and a continuous bottom region of the stator separation layer in the axial direction between the control unit and the side of the stator facing the control unit is arranged and a sidewall region of the stator separator layer adjoining the bottom region surrounds the stator on a radially outer peripheral side. As a result, the encapsulation can be configured partially or completely as an envelope of a stator, which then has a type Forming stator separation layer, which separates the stator spatially from the control unit receiving portion of the housing. By this separation, the stator and the accommodating space in the housing including the driving means (ie, the electric motor) can be sealed by the housing space accommodating the control unit. As a result, the penetration of particles and liquids (oil, water, salt water, etc.), in particular wear particles and fluid fractions, in the control unit receiving area of the housing can be avoided. The life of the drive device and primarily the reliability, but also the control unit, are thereby substantially increased and implemented in a space-saving manner by the cup-shaped design.

It is also advantageous if at least one axially extending first positioning pin is formed on the stator separation, which extends to the control unit and on which the control unit is held relative to the drive means in the axial and / or radial direction, preferably a circuit board and / or a housing cover of the control unit is held directly by the at least one first positioning pin. This makes it possible to correctly attach the control unit together with the board in one step, in particular in the axial direction to the stator and to center / centered align. As a result, the assembly is further simplified and high positioning accuracy between sensor components in the control unit and mech. Ensures elements in the electric motor unit.

It is also advantageous if at least one second positioning pin extending in the axial direction is formed on the stator separating layer, which extends toward the control unit and wherein a heat dissipation housing part is held in the axial and / or radial direction on the at least one second positioning pin. As a result, it is also possible to design a heat dissipating part embodied as a housing part, which is simultaneously placed in the correct axial and / or radial direction relative to the stator and, moreover, also centered relative to the rotor, so that the best possible heat dissipation can take place. The Wärmeableitteil, which is usually made of aluminum, thus optimally cooling acts on the stator. As a result, the performance of the actuator is further increased.

It is also expedient if the stator has a bearing carrier, such as a bearing outer ring of a roller bearing, wherein an inner peripheral surface of the stator separator, the stator separator to the rotor rotational axis centering on a radially outer retaining ring of the bearing carrier. As a result, the stator together with the stator housing is also optimally centered on the rotor, ie on the axis of rotation of the rotor, whereby on the one hand the torque uniformity of the electric motor is optimized and on the other hand the ease of assembly is increased. According to another embodiment, it is also advantageous if the rotor is encapsulated on its side facing the control unit with a Umspritzung at least partially forming Rotorumspritzung, wherein the Rotorumspritzung is preferably pot-shaped, and wherein a bottom portion of the Rotorumspritzung in the axial direction between the control unit and the control unit side facing the rotor is arranged and adjoining the bottom region side wall portion of the rotor injection surrounds the rotor on a radial outer peripheral side. Such a rotor encapsulation, which can be provided optionally in addition to the stator separation layer or instead of the stator separation layer, can also be provided with an encapsulation of the rotor. Such Rotorumspritzung has the advantage that this example. Can be applied to a front end of the rotor, thus ensuring the most accurate and optimal positioning and recording a position magnet in the rotor and the usually directly mounted on the board of the control unit rotor position sensor metrologically optimized to place the rotor. As a result, a very compact design of an actuator is created, in particular in the embodiment of the electric motor as a brushless DC motor. The rotor magnet can be further included directly in this Rotorumspritzung and its distance to the control unit on the position in the encapsulation are arbitrarily set in the axial direction. As a result, the housing space is exploited even more intense.

It is also advantageous if, in this context, a magnet receiving cap is connected to the rotor extrusion which rotatably receives a magnet holder ring arranged centrally to accommodate the axis of rotation of the rotor for receiving a position magnet, wherein the magnet receiving cap is formed integrally with the rotor encapsulation or plugged into the rotor encapsulation, such as locked, is. As a result, an optimized for receiving the position magnets area on the Rotorumspritzung be ausgestaltbar, the position magnets in this area, eg. About a press fit, centered and fixed in the axial direction to ensure optimum distance to the control unit. As a result, the rotational position of the rotor is detected as reliable as possible. In this case, the magnet receiving cap serves as a balance between the thermal expansion coefficients of the material of the Rotorumspritzung and the magnet in both a sintered, as well as a plastic-sprayed magnet.

In this context, it is also advantageous if the magnet retaining ring with rib-shaped projections on its inner peripheral surface is ausgestaltbar, wherein the position magnet is rotatably pressed in the magnet retaining ring, snapped and / or glued. This is one implemented particularly easy to produce centering and mounting the position magnet, whereby the manufacturing cost of the actuator can be further reduced and the assembly forces for the pressing / and or locking by reducing the contact surface are further reduced.

If the position magnet continues to be a plastic-bonded or sintered magnet and / or the position magnet is located on a board and / or the rotor has a laminated core and a hub part, then the inventive actuator can be produced even more efficiently.

In other words, the invention relates to a compact design of a BLDC (brushless DC (DC)) rotor (internal rotor) with an integrated rotor magnet. This design allows optimal mechanical centering and attachment of the rotor magnet together with the rotor unit and at the same time a space-optimized integration of the rotor magnet on the rotor facing away from the control electronics front side of the rotor. In the proposed design, the safety with respect to a relative angular rotation between the rotor magnet and the position of the permanent magnet in the stator continues to increase in a very compact design. Conventional BLDC motors in actuators with high demands on position accuracy usually require a sensor-based commutation. A very common and accurate method of commutation, which at the same time offers relatively low costs for series solutions, is the commutation of the EC motor (electrically commutated motor) by an AMR / GMR sensor (magnetoresistive, giant magnetoresistive effect based sensors).

A front-side or diametrically two-pole magnetized (rotor-mounted) magnet is normally mounted on the output shaft (where the rotor of the EC motor is also mounted). The integration can be made by a press fit on the (rotor) shaft, or by gluing (shaft front side). Thus, the rotor magnet in the tangential direction is rigidly connected to the (output / rotor) shaft. Through this connection, the rotor magnet transmits the exact rotation angle from the rotor in the direction of the sensor module in the electronic module / control unit, which is important for the commutation of the current direction in the stator of the EC motor with a high efficiency. This sensor module usually has a NF-incremental interface (incremental interface). In order to enable the integration of the rotor magnet on the shaft, one needs the corresponding interface on the shaft of the rotor. This means, for example, that in the case of a press fit, an additional length is required for the press fit (on the inner or outer diameter). Furthermore, a small portion of the magnetic flux from the rotor magnet is shorted by the shaft material and thus you may get a lower flux density in the sensor area. In a BLDC rotor design for an actuator, it is necessary to provide a very compact design, in that preferably no shaft protrudes in the direction of the control electronics. The goal is to make the integration of the rotor magnet within the rotor space. In this case, the axial position of the magnetic front side, which faces the control electronics, must be calibrated to compensate for axial tolerances in the assembly.

The rotor magnet can be further integrated in a board, which is part of the overmolding of the rotor. The encapsulation of the rotor also serves as burst protection / mechanical fixation of the permanent magnets in the rotor and as an interface for the integration of the rotor magnet. The rotor magnet is pressed in / pressed in a board in the encapsulation of the rotor package. Press-fitting can be combined optionally with a snap-in function with a hook geometry in the rotor extrusion coating, or with an adhesive process for fixing in a specific position in the axial direction. Depending on the requirements for magnetic circuit design (sensor position, minimum / maximum magnetic flux density in the sensor area as a function of the radial and axial tolerances, etc.), the rotor magnet may be designed as a plastic-bonded or sintered magnet. In this case, if the rotor magnet is additionally adhesively bonded, the result is that after the adhesive dispensing, the axial position of the rotor magnet is adjusted to a specific reference in the actuator assembly. Thus, one could possibly compensate for higher tolerances in the axial direction in the production process. Alternatively, a laminated rotor package can also be implemented. As injection molding more accurate diameter tolerances on a certain number of ribs in the scope are much easier to control, you can provide the interface for the pressing of the rotor magnet with ribs. In two other variants for the mounting of the rotor magnet in the Umspritzung is a clip for locking in position (without compensation of the axial tolerances in the axial direction in the manufacturing process) and pressing in the axial direction with respect to a specific reference in Aktor- / Aktuatorzusammenbau (with compensation the axial tolerances in the axial direction in the manufacturing process) can be used. In the second variant, a certain amount of adhesive is laid in the mounting interface of the rotor magnet and after pressing (preferably slight interference fit between magnet and plastic material of the encapsulation) of the adhesive will harden and finally secure the position of the rotor magnet. The rotor magnet can also be fixed in a plastic carrier, which is fixed by means of clip geometry on the rotor hub. A certain number of clips / clips of the rotor magnetic bearing Gers (also referred to as magnetic holding cap) meet along the circumference in openings in the rotor hub and / or the rotor encapsulation and engage in the pressing.

The invention therefore relates to a compact design of a BLDC (brushless DC) rotor (internal rotor) with an integrated rotor magnet (RL magnet). This design allows optimal mechanical centering and attachment of the rotor magnet together with the rotor unit and at the same time a space-optimized integration of the rotor magnet on the rotor facing away from the control electronics front side of the rotor. In the proposed design, the safety against a relative angular rotation between rotor magnet and position increases the permanent magnet in the stator in a very compact design. The rotor magnet can be pressed in different ways into the encapsulation of the rotor / the rotor package, wherein ribs in the encapsulation, a latching function with hook geometry, and / or a combination of these previous possibilities are provided with an adhesive process / is. It is also possible to use a plastic-bonded or sintered magnet as a rotor magnet. The magnet is on a board and is pressed in with it. Also, the rotor is made of laminated core and hub part and has an integrated (rotor position) magnet.

The invention also relates to a Statorumspritzung, which is made with a plastic or with a non-conductive material. The encapsulation achieves a separation from the electronics, so that no particles from the electronics area (LCU "Local Control Unit") can penetrate into the motor area, the encapsulation furthermore has a receptacle for the end area of the rotor. For example, the cover or the electronics has a position sensor which detects at least the radial position of the rotor, for example by magnetic field lines of a magnet provided by means of positioning pins / holes and / or spacer pins The cast-in stator is accommodated by a housing with heat-dissipating elements, for which purpose corresponding positioning pins are provided on the stator and / or encapsulation sides, in order to increase the efficiency of the actuator with respect to the utilized installation space of the electric motor, according to the invention, the space tolerance reduced, in particular with respect to the air gap of the electric motor. For this purpose, the encapsulation is designed with an inner diameter, which is supported on a positioning aid (edge) of the ball bearing for the rotor. By doing this relative positioning of the stator to the motor, the necessary tolerances can be reduced. The functional area of the inside diameter Sers Umspritzung for centering is preferably distributed over a certain number of ribs on the diameter circumference. Thus, on the one hand, the tolerances of the centering diameter are increased via individual ribs (injection molding condition) and, on the other hand, the assembly forces are thereby reduced (smaller contact area).

The invention will now be explained in more detail below with the aid of drawings, in which different embodiments are shown.

Show it:

1 shows a longitudinal section through an actuator according to the invention after a first

Embodiment, wherein the section is performed along a plane in which the axis of rotation of the rotor is running, and the actuator is shown in an axial region of the drive device designed as an electric motor,

2 is an exploded isometric view of the stator-rotor control unit assembly of the drive device, the stator being shown from the side facing the control unit, and holes of a board of the control unit being aligned with positioning pins of the stator.

Fig. 3 is an isometric view of a housing cover closing the circuit board of the control unit to a side facing away from the stator of the board, the housing cover from a bottom, i. one of the board in the operating state side facing, is shown,

4 shows an exploded isometric view of the housing cover-board assembly, wherein the relative position of these two components is illustrated in the operating state,

5 is an exploded isometric view of the heat sink housing stator assembly with the heat sink housing portion centered and secured to the stator by bolts;

FIG. 6 shows the heat dissipation body part stator assembly shown in FIG. 5 in an assembled state. FIG. a longitudinal sectional view according to FIG. 1, wherein the actuator is shown in a slightly larger area and in particular the board of the control unit can be seen, a detailed view of marked in Fig. 7 area VIII, wherein the centering between a bearing carrier and the stator separation layer shown is an isometric view of a designed as a rotor encapsulation Umsprit- tion that is injected in an operating state of the actuator to one end of a rotor, and in which Rotorumspritzung the rotor magnet is inserted in a magnet receiving cap of Rotorumspritzung an isometric view of the already in Fig. 9 shown Rotorumspritzung, wherein in particular the inner peripheral surface of the magnet receiving cap can be seen particularly well, a side view of the Rotorumspritzung shown in Fig. 9, this side view representing the Rotorumspritzung in a plane which is parallel to the rotor axis of rotation is performed, a cross section through the rotor according to the invention in the injection line along the line shown in FIG. Xll-Xll, ie along a plane to which the axis of rotation of the rotor is oriented orthogonally in the operating state, performed in Fig. 12 particularly clearly the 9, wherein the rear side of the rotor encapsulation, ie the side facing the rotor in the operating state of the actuator, is shown, is a longitudinal section of the rotor encapsulation along that in FIG 13 is a sectional view of the rotor XIV-XIV, in which a laminated core of the rotor is inserted, wherein the longitudinal section is performed in a plane in which the rotor axis of rotation is running,

15 is a front view of the rotor injection shown in FIGS. 9 to 14, FIG. 16 is an isometric view of the rotor encapsulation and the rotor already shown in longitudinal section in FIG. 14, FIG.

17 shows an isometric view of a rotor encapsulation according to the invention according to a further embodiment, wherein in particular a front side of the rotor encapsulation, i. a side which faces away from the rotor in the operating state is shown,

FIG. 18 shows a side view of the rotor encapsulation shown in FIG. 17, this side view illustrating the rotor encapsulation in a plane aligned parallel to the rotor axis of rotation, FIG.

FIG. 19 is a cross-sectional view taken along the section line in FIG. 18. FIG

XIX-XIX, i. along a plane to which the axis of rotation of the rotor is oriented orthogonally in the operating state,

Fig. 20 is a rear view of the rotor encapsulation of Figs. 17-19, wherein the back side of the rotor encapsulation, i. which is shown in the operating state of the actuator facing the rotor side,

21 is a longitudinal sectional view of the rotor encapsulation along the section line XXI-XXI marked in FIG. 20, FIG.

22 is a front view of the rotor injection shown in FIGS. 17 to 21,

FIG. 23 is an isometric longitudinal sectional view of that already illustrated in FIG. 21

Rotor injection and the rotor,

24 is a longitudinal sectional view of another embodiment of a rotor encapsulation according to the invention, wherein the attachment of the rotor magnet to the magnet receiving cap has been made with a positive connection,

Fig. 25 is a longitudinal sectional view of another embodiment of a rotor encapsulation according to the invention, wherein between the rotor magnet and the Rotorumspritzung an adhesive for adhesive attachment of the magnet is provided, and 26 is a longitudinal sectional view of a further embodiment of a rotor encapsulation according to the invention, wherein the magnet receiving cap is clipped / plugged into the rotor extrusion.

The figures are merely schematic in nature and are only for the understanding of the invention. The same elements are provided with the same reference numerals.

In Fig. 1, an embodiment of an actuator 1 according to the invention is shown. This actuator 1 is particularly optimized for use in motor vehicles, such as cars, trucks, buses or agricultural vehicles. It may, for example, be designed as an actuator 1 for actuating a clutch (i.e., as a clutch actuator) or as an actuator 1 for actuating a planetary gear (planetary gear actuator / PGA), in particular for actuating a belt pulley drive. In general, such a structural design of the combination electric motor / control unit can be used on all types of actuators in the motor vehicle engine compartment, which use a conversion of rotational in translational motion, or a rotational movement. The highly integrated control unit offers enormous advantages in terms of functional reliability and compactness of the solution.

The actuator 1 is constructed and constructed essentially in its assembly, such as the hydrostatic actuator shown in WO 201 1/127888, wherein it essentially relates to the drive device 3 described in more detail below and its spatial connection / disconnection to the electronic control device. Control unit 6 different. The actuator of WO 201 1/127888 is considered integrated herein. The actuator 1 has, as well as the WO 201 1/127888, a housing 2, which is preferably designed in several parts. Enclosed by the housing 2 and accommodated in the housing 2 is an electromagnetic drive device 3, which is designed as an electric motor 3 and therefore also referred to below as an alternative electric motor 3. The drive device 3 / the electric motor 3 has a stator 4 with a plurality of fixed magnetizable elements and a rotor 5 which is rotatably mounted relative to the stator 4. The rotor 5 is further connected via a designed as a converter unit spindle drive, which is not shown here, with a movable in the axial direction of the trigger element 42. Upon rotation of the rotor 5 about its axis of rotation of the spindle drive acts as a converter unit and the rotational movement / rotation of the rotor 5 is converted into an axial movement / translational movement of the trigger element 42. The triggering element 42 is designed in the in Fig. 1 as a mother. The rotor 5 in turn may be directly an integral part of a rotating rod 38 of the spindle drive or alternatively, as explained in more detail below, be designed as a separate component and, for example, be connected by means of a laminated core with the spindle rod 38 / pushed onto this. In any case, the rotor 5 rotatably drives the spindle rod 38 of the spindle drive. This spindle rod 38, which in its end remote from the rotor 5 (not shown here) has a spindle-like external thread engages with this external thread in an internal thread of the nut / the trigger element 42, so that this upon rotation of the spindle rod 38 in the axial direction, ie translationally is moved / moved. This translatory movement leads to a switching movement of the actuator 1. As an alternative to a nut, the triggering element 42 can also be designed as a gear of a transmission, for example a planetary gear. For example. could the trigger member 42 has a planet gear, which meshes with the external thread of the spindle rod 38 and 38 drives a ring gear upon rotation of the rod by the rotor 5, which ring gear in turn displaces a piston in the axial direction, which cooperates piston with a pressure chamber and thus also a Switching movement of the actuator 1 causes.

In the operating state of the actuator 1, i. In a ready assembled and assembled state of the actuator 1, the electric motor 3 is connected by means of an electronic control unit 6 to a power source. The control unit 6 comprises at least one circuit board 7, which is electrically conductively connected to the electric motor 3, so that the electric motor 3 is completely controllable by the electronic unit. The board 7 is shown particularly clearly in Fig. 2. The control unit 6 is, as can be seen particularly well in FIG. 7, arranged in the axial direction adjacent to the rotor 5 and the stator 4 / the electric motor 3.

In the embodiment according to FIG. 1, according to the invention, an encapsulation 8 is provided on the stator 4, which encapsulation 8 is designed as a separate material layer, referred to below as a stator separation layer 9. The stator separation layer 9 is configured substantially cup-shaped in the cured state and accordingly has an annular side wall region 10, which surrounds the stator 4 radially from the outside and fits tightly against it. At one end of this side wall portion 10 includes a bottom portion 1 1 at. This bottom portion 1 1 extends in the radial direction continuously inward (to the middle of the electric motor 3 back) and thus represents a kind of continuous floor, which is sealed. The bottom portion 1 1 adjoins the end of the side wall portion 10 facing the control unit 6, so that the bottom portion 11 is disposed axially between the electric motor 3 and the control unit 6 / the board 7. The electric motor 3 is still on the Stator separation layer 9 on the housing 2 and / or on a housing-fixed component, that it is sealed by the stator separation layer 9 to the control unit 6, ie the housing space in which the control unit 6 and the board 7 is received. For electrical coupling of the stator 4 to the control unit 6, an electrically conductive contact wire and / or punched grid pin is preferably carried out in the bottom region 1 1, which is also surrounded by the stator separation layer 9 sealing, so that only electrical energy

(Current / voltage) between the control unit 6 and the electric motor 3 can flow back and forth.

In addition, the encapsulation 8 has on its side facing the control unit 6 a plurality of first positioning pins 12 extending in the axial direction. These first positioning pins 12 are distributed along the circumference of the stator 4 on the bottom portion 1 1. Each of these first positioning pins 12 extends substantially in the axial direction (toward the control unit 6 in the operating state) and is designed to extend substantially parallel to the adjacent first positioning pins 12. Each of the first positioning pins 12 is in a hole 13, which is designed as a bore / through hole, the board 7 can be inserted, so that the board 7 is secured in the radial direction and in the axial direction by simultaneous abutment of the board face to stops 14 of the first positioning pins 12 , The first positioning pins 12 each have a rod-shaped projection / rod portions 15, which extends from the stop 14 in the axial direction to the board and is inserted into a hole 13 of the board 7. The rod regions 15 furthermore have a projection extending along the circumference, for example an annular projection. This annular projection is latched after its passage through the hole 13 of the board 7 behind the board 7 and fixes the board 7 via a positive connection. This positive connection may alternatively be performed somewhat differently to the one extending along the circumference projection. For example. For example, a plurality of circumferentially extending projections / annular projections could be disposed axially adjacent to the rod portion 15, for example, to form a kind of Christmas tree structure. In addition to the positive connection or, alternatively, the rod region 15 can also have a substantially constant diameter over its length, in which case the circuit board 7 is glued to the stop 14 and / or the rod region 15. The board 7 has three holes 13, in the three first positioning pins 12 are inserted.

From the side facing away from the electric motor 3, as can be seen particularly well in FIGS. 3 and 4, a housing cover 16 is fixed on the circuit board 7 and / or on the stator 4. Also, this housing cover 16 preferably also has substantially in axial Direction extending positioning pins 17, hereinafter referred to as third positioning pins 17, on. These third positioning pins 17 can also engage in holes 13 of the board 7 and / or be inserted and there in the axial direction and radial direction (material, non-positive or positive) are held, so that a relative assurance of the housing cover 16 relative to the control unit 6 / the board 7 is done. The housing cover 16 also preferably has pin receptacles 19, which receive and hold at least some of the ends of the rod regions 15 of the first positioning pins 12 projecting through the circuit board 7.

As further particularly evident in FIGS. 5 and 6, a heat dissipating part 18 is arranged between the stator separation layer 9 and the circuit board 7. This heat dissipating part 18, which is usually made of aluminum, has integrated, radially inwardly extending projections, which are designed as tabs 39 and through which a plurality of bores 20 are made. On the one hand, these holes 20 serve as through-holes for screws 21. On a side facing away from the stator 4 each of these through-holes is a screw head of a screw 21 on the tab 39. The screws 21 are in turn screwed into threaded bores 22 in the stator separation layer 9 or in the stator 4, or preferably in the tabs of a metallic case of the stator 4. As a result, a better strength of the screw connection against vibration loads is achieved. On the other hand, the bores 20 are used to accommodate further positioning pins 23, which are also molded onto the stator separating layer 9. These positioning pins 23 are hereinafter referred to as second positioning pins 23. These second positioning pins 23 extend substantially in the axial direction and preferably comprise a latching device, in the form of a projection extending along the circumference, for example an annular projection which is locked into the respective bore 20 at least in the operating state. As a result, a positive retention of the heat dissipation portion 18 with respect to the encapsulation 8 and thus the stator 4 is likewise possible.

In FIGS. 7 and 8, the centering between the stator separating layer 9 / the encapsulation 8 and the rotor 5 is once again shown more clearly. As can be clearly seen herein, the rotor 5 is mounted rotatably relative to the stator 4 by means of a roller bearing 24. For optimal centering of the stator 4 relative to the rotor 5, a bearing carrier 25 is pressed onto an outer ring of the rolling bearing 24, which bearing carrier 25 is held fixed to the housing (as a component fixed to the housing). Again on the bearing bracket 25, namely on an axially extending annular portion 26 of the bearing support 25 of the side wall portion 10 of the stator separation layer 9 is pushed. In this case, the side wall region 10 rests with a radial inner side on a radial outer side of the annular region 26 of the bearing carrier 25. These Both circumferential surfaces are tolerance matched such that the stator separator layer 9 performs with the bearing support 25 at least in some areas along the circumference of an interference fit. Thus, the stator separation layer 9 is supported on the bearing carrier 25.

In addition to the (first) encapsulation 8, which is configured as a stator separation layer 9, the rotor 5 can also be designed with an encapsulation 28, a second encapsulation 28. The first encapsulation 8 and the second encapsulation 28 may be integrally connected with one another to form an encapsulation. However, the first and second encapsulation 8, 28 may also, as is preferably provided in FIGS. 1 to 26, be designed in two parts, namely in the form of the first and the second encapsulation 8 and 28. The second encapsulation 28 is designed as a rotor encapsulation 29 executed and sprayed on a front end of the rotor 5. This rotor sleeve 29 further serves to receive a rotor magnet / position magnet 30th This position magnets 30, as can be seen particularly well in Fig. 1, is arranged centrally to a sensor 31, which sensor 31 is in turn mounted directly on the board 7, namely on a front side of the board 7, which faces the electric motor 3 in the operating state. Between the sensor 31 and position magnet 30, in turn, the bottom portion 1 1 of the first encapsulation 8 is running. The sensor 31 is configured as a rotational position sensor and detects the rotational position of the rotor 5 in the usual way by means of the rotationally fixed via the rotor extrusion 29 to the rotor 5 associated with the rotor 5. The various embodiments of the rotor extrusion 29 are illustrated in connection with FIGS. 9 to 26. The Rotorumspritzung 29 is always configured substantially pot-shaped and arranged with an annular side wall portion 32 extending around the rotor 5 around. At the side wall portion 32 includes at an axial end, which faces in the operating state of the control unit 6, a bottom portion 33 at. The bottom portion 33 is substantially inwardly in the radial direction and is in a radial center region, i. a portion located radially inward of the side wall portion 32 is connected to a magnetic retaining cap 27 including a magnet retaining ring 34. The magnetic retaining ring 34 in turn extends substantially in the axial direction. In the Magnethaltering 34 then the position magnet 30 is held against rotation.

According to a first embodiment of the rotor extrusion 29 illustrated in FIGS. 9 to 16, for the purpose of the positional magnetic fixing, the inner circumferential surface 35 has a plurality of circumferentially distributed inwardly projecting projections / retaining projections 36. The inner diameter of these holding projections 36 is matched to the outer diameter of the annular position magnet 30 such that the position magnet 30 with the Magnet retaining ring 34 enters a press fit. The position magnet 30 is thus pressed into the magnet retaining ring 34 of the rotor extrusion 29. With its inner peripheral surface 35, the magnet retaining ring 34 holds the position magnet 30 rotationally fixed. The magnet retaining ring 34 is also integrally connected to the bottom portion 33.

As further shown in FIG. 12, a plurality of side wall portions 32 are provided

Embedded rotor drive magnets embedded and thus fixed along the circumference, wherein the polarity of the adjacent magnets along the circumference in each case differs.

As can furthermore be seen in FIG. 14, the rotor 5 according to this embodiment is designed as a laminated core 37 at its front end which projects into the rotor extrusion 29. The laminated core 37 has a plurality of adjacent discs and is held in the rotor extrusion 29. The laminated core 37 and the rotor extrusion 29 and the rotor drive magnets therefore form the rotor 5. The rod 38 of the spindle drive is in the operating condition, as it can be seen, for example, in Fig. 1, inserted into the laminated core 37 and held in rotation therewith. This embodiment is also particularly good in FIG.

16 to recognize.

As an alternative to the configuration only as a laminated core 37, it is also possible, as shown in FIGS.

17 to 23 is executed, the rotor overmold 29 instead of only on a laminated core 37 and radially on the outside of a rotor pot 40 with a pressed-sheet package aufzuspritzen which combination of rotor pot 40 and laminated core then also in the operating state rotatably connected to the spindle rod 38, e.g. by a press fit and / or a welded joint. This alternative embodiment has the advantage that a space for storage in the inner region of the rotor 5 is thereby created free.

Furthermore, it is alternatively or in addition to that realized in FIGS. 9 to 23

Press fit between the position magnet 30 and magnet retaining ring 34 also possible to attach the position magnet 30 in the magnet retaining ring 34 different rotation. For example. by means of a clip / snap connection, via a locking of arranged on the inner peripheral surface 35 or on the outer peripheral surface of the bearing magnet 30 projections in grooves / annular grooves of the outer peripheral surface of the bearing magnet 30 or the inner peripheral surface 35 of the Magnethalterings 34, as shown in Fig. 24. Furthermore, as shown in FIG. 25, it is also possible to additionally or alternatively fix the position magnet 30 to the magnet retaining ring 34 by means of an adhesive bond. Further, instead of embodying the magnet receiving cap 27 (as described in FIGS. 1 to 25) integrally with the bottom portion 33, it is also possible to perform as a ring separate from the bottom portion 33, as shown in FIG. This separate ring is then provided with a clip connection, such as one or more, annular projections, which projection engages in an undercut and the magnet receiving cap 27 then holds on this clip holder in the Rotorumspritzung 29 rotationally. In turn, the position magnet 30 is then inserted into the magnet receiving cap 27. It is also possible to arrange a bursting protection 41 radially around the rotor extrusion 29 in order to protect the encapsulation from erosion.

The rotor extrusion 29 and / or the stator separation layer 9 are made of an electrically insulating material, such as a plastic, and applied to the drive device 3 by means of a plastic casting process, such as an injection molding process.

List of Symbols Actuator

casing

Drive device / electric motor

stator

rotor

control unit

circuit board

Encapsulation / first encapsulation

Statortrennschicht

Sidewall region

floor area

first positioning pin

hole

attack

bar area

housing cover

third positioning pin

Heat-dissipating part / heat-dissipating housing part Pin holder

drilling screw

threaded hole

second positioning pin

roller bearing

bearing bracket

ring area

Magnetic receiving cap

Coating / second encapsulation Rotor overmolding

position solenoid

sensor

Sidewall region

floor area

Magnetic retaining ring

Inner circumferential surface

retaining projection

laminated core

pole

flap

rotor pot

Burst protection Łuslöseelement

Claims

claims

1 . Actuator (1) for a motor vehicle, comprising a housing (2), an electromagnetic drive device (3) having a stator (4) and a rotor (5) rotatable relative to this stator (4), wherein the rotor (5) is connected via a transducer unit to a triggering element (42), wherein the transducer unit converts the rotational movement of the rotor (5) into a translatory movement of the triggering element (42), and to a driving device (3) electrically connected to the drive device (3) controlling, electronic control unit (6), characterized in that the drive device (3) at least on the control unit (6) facing side of a consisting of an electrically insulating material Ums- pritzung (8, 28).

2. Actuator (1) according to claim 1, characterized in that the encapsulation (8, 28) on the stator (4) and / or the rotor (5) is material, force or positively connected.

3. Actuator (1) according to any one of claims 1 and 2, characterized in that the

Stator (4) is encapsulated on its side facing the control unit with a Umspritzung (8) at least partially forming stator separation layer (9), wherein the stator separation layer (9) is preferably designed pot-shaped and a continuous bottom portion (1 1) of the stator separation layer (9) is arranged in the axial direction between the control unit (6) and the control unit (6) facing side of the stator (4) and a to the bottom region (1 1) adjoining side wall region (10) of the stator separation layer (9) to the stator (4) surrounds a radial outer peripheral side.

4. Actuator (1) according to claim 3, characterized in that on the stator separation layer (9) at least one axially extending first positioning pin (12) is formed, which extends to the control unit (6) and on which the control unit ( 6) is held relative to the drive device (3) in the axial and / or radial direction, wherein preferably a circuit board (7) and / or a housing cover (16) of the control unit (6) of the at least one first positioning pin (12) is held directly , Actuator (1) according to one of Claims 3 and 4, characterized in that at least one second positioning pin (23) extending in the axial direction is formed on the stator separation layer (9) and extends to the control unit (6) and on which at least one second positioning pin (9) a Wärmeableitgehäuseteil (18) is held in the axial and / or radial direction.

Actuator (1) according to one of claims 3 to 5, characterized in that the stator (4) has a bearing carrier (25), such as a bearing outer ring of a rolling bearing (24), wherein on a radially outer retaining ring of the bearing support (25). an inner peripheral surface of the stator separation layer (9), the stator separation layer (9) to the rotor axis of rotation centering, is applied.

Actuator (1) according to one of claims 1 to 6, characterized in that the rotor (5) on its the control unit (6) facing side with the encapsulation (28) at least partially forming Rotorumspritzung (29) is encapsulated, the Rotorumspritzung (29) is preferably designed pot-shaped, and wherein a bottom portion (33) of the rotor extrusion (29) in the axial direction between the control unit (6) and the control unit (6) facing side of the rotor (5) is arranged and a to the bottom portion (33) subsequent side wall region (32) of the rotor extrusion (29) surrounds the rotor (5) on a radially outer peripheral side.

Actuator (1) according to claim 7, characterized in that a magnet receiving cap (27) with the Rotorumspritzung (29) is connected, for receiving a position magnet (30) rotatably receives a centrally to the axis of rotation of the rotor (5) arranged Magnethaltering (34) wherein the magnet receiving cap (27) is formed approximately integrally with the rotor extrusion (29) or plugged into the rotor extrusion (29) as if engaged.

Actuator (1) according to claim 8, characterized in that the Magnethaltering (34) with rib-shaped projections (36) on its inner peripheral surface (35) is ausgestaltbar, wherein the position magnet (30) rotatably pressed in the Magnethaltering (34), snapped and / or is glued.

10. Actuator (1) according to any one of claims 7 and 8, characterized in that the

Positioning magnet (30) is a plastic-bonded or sintered magnet, and / or the position magnet (30) is located on a board, and / or the rotor (5) has a laminated core (37) and a hub part.