WO2021043716A1

WO2021043716A1 - Electric motor

Info

Publication number: WO2021043716A1
Application number: PCT/EP2020/074217
Authority: WO
Inventors: Thomas - c/o Vitesco Technologies GmbH MANN; Uwe - c/o Vitesco Technologies GmbH SCHEIN
Original assignee: Vitesco Technologies GmbH
Priority date: 2019-09-05
Filing date: 2020-08-31
Publication date: 2021-03-11
Also published as: DE102019213538A1

Abstract

An electric motor according to the invention, in particular a brushless DC motor, has at least one connecting element (31-33), which is connected to at least one winding wire (2) of a stator (1) of the electric motor, and an external connection (31) for energizing this winding wire (2), wherein the connecting element (31- 33) is produced, in particular formed, from a further wire.

Description

description

Electric motor

The present invention relates to an electric motor, in particular a brushless DC motor, a method for producing the electric motor and the use of a connecting element as a connecting element of the electric motor.

According to in-house practice, electrically conductive stamped and bent parts, so-called lead frames, are used to energize the winding wires of brushless DC motors (stators).

The object of the present invention is to improve an electric motor or its manufacture.

This object is achieved by an electric motor with the features of claim 1. Claims 7, 8 provide the use of a connecting element as a connecting element of an electric motor described here and a method for producing an electric motor described here under protection. The sub-claims relate to advantageous developments.

According to one embodiment of the present invention, an electric motor has a stator with one or more winding wires. In one embodiment, an (electro) magnetic field generated by energizing this winding wire or these winding wires causes a rotor of the electric motor to rotate or the electric motor is provided for this purpose, in particular set up or is used for this purpose. The winding wire or one or more of the winding wires form in one embodiment a coil or one or more coil windings of the electromotor, in one embodiment it is or is or are or are wound around one or more pole teeth.

In one embodiment, the stator is a one-piece stator and / or the electric motor is a brushless direct current motor. For this purpose, the present invention, in particular due to its construction and / or mode of operation, can be used with particular advantage. According to one embodiment of the present invention, the electric motor has one or more, in particular (each) separate and / or one or more part (s), connecting element (s), which (each) with the winding wire or one or more of the winding wires, in particular electrically conductive, connected, in particular fastened to it, is / are or will / are, in particular (in each case) with one or more winding wires arranged next to one another in one embodiment, in particular adjacent or spaced apart, winding wires tend, and which (each) has / have an external connection via which the winding wire connected to this connecting element or the winding wires connected to this connecting element can be or are energized or which is provided, in particular set up or used for this purpose becomes. In one embodiment, a first such connecting element is connected to a first winding of the electric motor (stator) and at least one further such connecting element is connected to a further winding of the electric motor (stator).

As a result, in one embodiment, desired external connections can advantageously be made available and / or winding wire (end) tolerances can be compensated.

According to one embodiment of the present invention, the or one or more of the connecting element (s) is / are or will be / are made from a, in particular special metallic and / or electrically conductive wire, in one embodiment formed, in particular by means of bending and / or pressing, which is referred to as a further wire to distinguish it from the winding wire or wires. The other wire is available as a semi-finished product. According to one embodiment of the present invention, a connecting element produced in this way is used as the connecting element or connecting element described here of an electric motor described here or is provided for this purpose, in particular set up.

As a result, in one embodiment, the production of the electric motor, in particular compared to the leadframes mentioned at the outset, can be improved, in particular production costs can be reduced and / or process reliability and / or speed can be increased. Additionally or alternatively, the electric motor can improve it, in particular its tree space and / or weight can be reduced and / or its performance and / or reliability increased. In one embodiment, the connecting element or one or more of the connecting elements (each) have at least one hook with two opposing legs, between which the winding wire connected to this connecting element or one or more of the winding wires connected to this connecting element, in particular Winding wire end (s), is / are or will / will be arranged. In one embodiment, this winding wire makes contact or one or more of these winding wires contact the hook, in particular one or both of the opposing legs, is / are or will / will be connected to or attached thereto in one embodiment, electrically conductive and / in one embodiment or cohesively, in particular by means of welding, in one embodiment resistance welding or hotstaking.

As a result, in one embodiment, the connection, in particular its reliability and / or process reliability and / or speed, can be improved, in particular resistance welding or hotstaking.

In a further development, the winding wire or one or more winding wires (each) under tensile stress, in particular while maintaining a winding tension, is / are or is / are arranged between the legs of the corresponding hook or connected thereto. Additionally or alternatively, the winding wire or one or more winding wires (in each case) is / are or will / will be arranged between the legs of the corresponding hook, in particular bent into the hook, with reshaping, in particular bending.

As a result, in one embodiment, the connection, in particular its reliability and / or process reliability and / or speed, can be (further) improved, in particular resistance welding or hotstaking.

In one embodiment, the connecting element or one or more of the connecting elements (each) have at least one leg which forms an angle of at most 30 ° with an axis of rotation of the electric motor, in particular is parallel to the axis of rotation, and / or at least one leg which forms an angle of at least 60 ° with one or the axis of rotation of the electric motor, in particular that is transverse to the axis of rotation (oriented).

As a result, in one embodiment, desired external connections can advantageously be made available and / or tolerances of the winding wires can be compensated. In one embodiment, the two legs of the hook are or are angled against one another, in particular by at least 120 °. Additionally or alternatively, in one embodiment, the leg, which forms an angle of at most 30 ° with the axis of rotation, and the leg, which forms an angle of at least 60 ° with the axis of rotation, are angled against each other, in particular by at least 60 ° °.

As a result, desired external connections can advantageously be made available in one embodiment and / or tolerances of the winding wires can be compensated and / or the connection, in particular its reliability and / or process reliability and / or speed, can be improved.

In one embodiment, the connecting element or one or more of the connecting elements (in each case) at least in sections has a circular cross-section, in particular a circular cross-section. Additionally or alternatively, in one embodiment, the connecting element or one or more of the connecting elements (each) at least partially has a flattened cross-section, in particular a cross-section with at least one flat or planar side, in particular the hook and / or external connection.

As a result, desired external connections can advantageously be made available in one embodiment and / or the connection, in particular its reliability and / or process reliability and / or speed, can be (further) improved, in particular resistance welding or hotstaking.

In one embodiment, in particular for this purpose, at least a portion of the white direct wire with a circular cross-section is formed into a flattened cross-section, in particular by means of pressing. As a result, particularly inexpensive round wires can be used as semi-finished products in one embodiment. In another embodiment, the further wire has a continuously flattened cross-section. As a result, flat wires, in particular square wires, can be used as semifinished products in one embodiment, thereby (further) improving process reliability and / or speed.

In one embodiment, the connecting element or are or are one or more of the connecting elements (each) connected to the winding wire or one or more of the winding wires in a materially bonded manner, in a further development welded, in one embodiment by means of resistance welding or so- called hotstaking or insulated or enameled wire welding, in which an (electrical) insulation, in particular a plastic insulation, of the winding wire is locally burned off in one operation and this is welded to the connecting element at the same time or afterwards. The further wire, from which the connecting element (s) is / is or are / are made, in one embodiment has (electrical) insulation, in particular plastic insulation, which in one embodiment simplifies the laying of the connecting element can be, in another embodiment the further wire is bare or the connecting element has an electrically conductive outer side, whereby in one embodiment the connection with the winding wire or the winding wires can be improved.

As a result, in one embodiment, the connection, in particular its reliability and / or process reliability and / or speed, can be (further) improved.

In one embodiment, the electric motor has a holder, in particular a holder on the stator or a one-part or multi-part cover, in particular a housing cover, on which the or one or more of the connecting element (s) are positively and / or frictionally engaged , in one embodiment by clamping and / or cohesively, in one embodiment by molding, in particular injection molding or overmolding, is / are or will / will be, in one embodiment one or the leg of the connecting element, the with the rotation axis of the electric motor forms an angle of at least 60 ° and / or we have at least one kink arranged in the bracket.

During or through resistance welding, in one embodiment, in particular metallic, bare parts are or are connected to one another, in particular in that current flows through both connection partners. During or through hotstaking, one or more insulated, in particular lacquered, winding wires are or are connected in one embodiment without prior stripping (with the or one of the connecting element (s), in particular its hook), in particular in the current through the or the connecting element (s), in particular its hook, flows. Further advantages and features emerge from the subclaims and the exemplary embodiments. For this shows, partly schematically:

Fig. 1: an electric motor according to an embodiment of the present inven tion; and

Fig. 2: a cover of an electric motor according to a further embodiment of the present invention.

Fig. 1 shows an electric motor according to an embodiment of the present invention in a perspective view.

The electric motor has a stator with several pole teeth 1, which are wound with winding wire.

Winding wire ends 2 protrude upward from the stator in the direction of an axis of rotation (vertical in FIG. 1).

The electric motor has three structurally identical connecting elements, which are each connected to two of these winding wire ends 2, have an external connection 31 for energizing them, and are formed from a further wire which initially has a circular cross-section.

The connecting elements each have a hook with two opposing legs 32, 33, between which the two winding wire ends 2 connected to this connecting element are arranged or are, in one embodiment are or are bent in while maintaining a winding tension. In the area of the legs 32, 33 the further wire or the connecting element is flattened by pressing. In a modification not shown, a flat wire can also be used as an additional wire instead of a round wire.

These legs 32, 33 form an angle of approximately 90 ° with the axis of rotation of the electric motor. The connecting elements each have a further leg which is or is angled against this and forms an angle of approximately 0 ° with the axis of rotation of the electric motor and the respective external connection 31. The opposing legs 32, 33 and the two winding wire ends 2 arranged between them are or are each welded by means of resistance welding or hotstaking.

The legs 32, which form an angle of approximately 90 ° with the axis of rotation of the electric motor, are attached to a bracket 4 of the stator in a form-fitting and / or frictional connection, for example by (a) clamping. For this purpose, they each have at least one kink.

In an embodiment shown in Fig. 2, they are instead attached in an analogous manner form-fitting and / or frictional locking to a bracket 4 of a cover 5 of the electric motor, for example by (a) clamping. The embodiment of FIG. 2 otherwise corresponds to the embodiment of FIG. 1, so that reference is made to the description thereof, only the cover 5 with the connecting elements with their legs 31-33 being shown for clarity in FIG. 2.

In a modification of the embodiment of FIG. 1 or 2, which is not shown, connecting elements, in particular their legs 32, can also be or are materially attached to the holder 4 or the cover 5, for example by injection molding or overmolding.

Although exemplary embodiments were explained in the preceding description, it should be pointed out that a large number of modifications are possible. It should also be noted that the exemplary statements are only examples that are not intended to limit the scope of protection, the applications and the structure in any way. Rather, the preceding description provides the person skilled in the art with guidelines for the implementation of at least one exemplary embodiment, with various changes, in particular with regard to the function and arrangement of the components described, being able to be made without leaving the scope of protection as he did results from the claims and these equivalent combinations of features. List of reference symbols

1 stator (pole tooth)

2 winding wire ends

31 connecting element legs 32 connecting element (hook) legs

33 connecting element (hook) leg

4 bracket

5 lids

Claims

1. Electric motor, in particular brushless DC motor, with at least one connecting element (31-33) which is connected to at least one winding wire (2) of a stator (1) of the electric motor and an external connection (31) for energizing this winding wire (2) , wherein the connecting element (31-33) made of a further wire, in particular special shaped, is.

2. Electric motor according to claim 1, characterized in that the connec tion element (31-33) has at least one hook with two opposing legs (32, 33), between which the at least one winding wire (2) is arranged.

3. Electric motor according to one of the preceding claims, characterized in that the connecting element (31-33) has at least one leg (31) which forms an angle of at most 30 ° with an axis of rotation of the electric motor, and / or at least one leg (32 , 33) which forms an angle of at least 60 ° with an axis of rotation of the electric motor.

4. Electric motor according to one of the preceding claims, characterized in that the connecting element (31-33) at least from sections has a circular cross-section and / or that the connecting element (31-33), in particular the hook (32, 33) and / or the external connection (31), at least in sections, has a flattened cross section.

5. Electric motor according to one of the preceding claims, characterized in that the connecting element (31-33) and the at least one winding wire (2) are materially connected to one another, in particular welded, in particular by means of resistance welding or hot staking.

6. Electric motor according to one of the preceding claims, characterized by a holder (4), in particular on the stator (1) or a cover (5) on which the at least one connecting element (31-33), in particular a leg (32), of the an angle with an axis of rotation of the electric motor of at least 60 ° and / or has at least one kink arranged in the holder (4), is fastened in a form-fitting, frictional and / or cohesive manner.

7. Use of a connecting element (31-33) which is made from a wire, in particular reshaped, as the connecting element of an electric motor according to one of the preceding claims.

8. A method for producing an electric motor, in particular a brushless direct current motor, according to any one of the preceding claims, characterized in that the at least one connecting element (31-33) is connected to the at least one winding wire (2) of the stator (1), in particular cohesively connected , in particular welded, is, in particular special by means of resistance welding or hotstaking.

9. The method according to the preceding claim, characterized in that the connecting element (31-33) has at least one hook with two opposing legs (32, 33), between which the at least one winding wire (2), in particular under tension and / or reshaping, is arranged, and / or at least one leg (31) which forms an angle of at most 30 ° with an axis of rotation of the electric motor, and at least one leg (32, 33) which has an angle of at least 60 ° with an axis of rotation of the electric motor ° forms.

10. The method according to the preceding claim, characterized in that at least two of these legs (31-33) are angled against each other.

11. The method according to any one of the preceding claims, characterized in that at least a portion of the connecting element (31-33) is shaped with a circular cross-section to a flattened cross-section.