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DE-102024210781-A1 - Stator of an electric motor

DE102024210781A1DE 102024210781 A1DE102024210781 A1DE 102024210781A1DE-102024210781-A1

Abstract

The invention relates to a stator (8) of an electric motor (1), comprising a number of coil-carrying stator teeth (11) and a contact adapter (13) with sockets (16) into which contact elements (17) with an insulation displacement contact (18) for electrical contacting of coil sections (19) are inserted or can be inserted, and comprising a number of connection contacts (7), wherein the respective contact element (17) has a contact slot (20) into which the associated connection contact (7) is inserted, and wherein the connection contact (7) has a locking contour (21) that anchors the connection contact (7) in the associated socket (16).

Inventors

  • Anna May
  • Alexander Volkamer

Assignees

  • Brose Fahrzeugteile SE & Co. Kommanditgesellschaft, Würzburg

Dates

Publication Date
20260513
Application Date
20241108

Claims (10)

  1. Stator (8) of an electric motor (1), comprising: - a number of stator teeth (11) oriented radially concentrically to a central axis (5), which support coils (12) of a multiphase stator winding (14); - a contact adapter (13) with a number of sockets (16) into which contact elements (17) with at least one insulation displacement contact (18) for electrically contacting coil sections (19) of interconnected coils (12) are inserted or can be inserted; and with a number of terminal contacts (7) corresponding to the number of phases of the stator winding (14); - wherein the respective contact element (17) has an axially accessible contact slot (20) into which the associated terminal contact (7) is inserted or can be inserted in a clamping manner; and - wherein the terminal contact (7) has a locking contour (21) that secures the terminal contact (7) in the associated socket (16).
  2. Stator (8) after Claim 1 , characterized in that the locking contour (21) is designed as at least one hook directed backwards with respect to the insertion direction of the connecting contact (7).
  3. Stator (8) after Claim 1 or 2 , characterized in that the contact adapter (13) has an annular interconnection housing (15), on which the socket pockets (16) are axially raised.
  4. Stator (8) after one of the Claims 1 until 3 , characterized in that the respective plug pocket (16) has at least one plug slot (22), preferably opposing plug slots (22), which is aligned with the contact slot (20) of the contact element (17) located in the plug pocket (16).
  5. Stator (8) after one of the Claims 1 until 4 , characterized in that at least one of the pockets (16) of the contact adapter (13) has a first pocket section (16a) oriented in its circumferential direction (U) or tangentially to it for receiving the contact element (17) and a second pocket section (16b) extending transversely to the first pocket section (16a) or radially oriented in which the contact slot (20) of the contact element (17) for the connecting contact (7) having the locking contour (21) is arranged.
  6. Stator (8) after one of the Claims 1 until 5 , characterized in that - the at least one of the plug pockets (16) of the contact adapter (13) is closed on the outer side facing away from the contact slot (20) of the contact element (7) sitting in this plug pocket (16) along the plug-in direction of the connecting contact (7) having the locking contour (21), and/or - that at least one of the plug pockets (16) of the contact adapter (17) has a wall section (23) extending in the plug-in direction of the connecting contact (7) into which the locking contour (21) of the connecting contact (7) snaps into or, in particular, cuts into, deforming.
  7. Stator (8) after one of the Claims 1 until 6 , characterized in that the blocking contour (21) is formed at a contact end (7a), in particular knife-like, of the connecting contact (7), in particular at a narrow side or at opposite narrow sides of the connecting contact (7) or of the contact end (7a).
  8. Stator (8) after one of the Claims 1 until 7 , characterized in that the contact slot (20) of the respective contact element (7) is arranged on the axially opposite side of the insulation displacement contact (18), in particular between two insulation displacement contacts (18) spaced apart from each other.
  9. Stator (8) after one of the Claims 1 until 8 , characterized in that the or each connecting contact (7) is formed on a busbar (7c) extending in the circumferential direction (U) of the contact adapter (13), and/or that the connecting contact (7) or the respective busbar (7c) is embedded in or encased by an electrical insulation (7d), in particular a plastic overmolding.
  10. Electric motor (1) with a stator (8) according to one of the Claims 1 until 9 .

Description

The invention relates to a stator of an electric motor, comprising a number of stator teeth which support coils of a multiphase stator winding, and a contact adapter with sockets and with contact elements inserted therein and with a number of phase or terminal contacts. The invention further relates to an electric motor, in particular an auxiliary unit of a motor vehicle, with such a stator. Such an electric motor is designed as a so-called brushless electric motor (brushless DC motor, BLDC motor) with electronic commutation of the motor current. The electric motor, as an electric (three-phase) machine, has a stator and a rotor with several permanent magnets, which is fixed to a rotor shaft. The rotor shaft is rotatably mounted about a rotor axis by means of one or more bearings, with each bearing being mounted in a bearing housing of a bearing shield and/or the bottom of a (cup-shaped) motor housing. In an internal rotor motor (internal rotor motor or rotor), the stator, which coaxially surrounds the rotor, has, for example, a stator lamination stack with a number of star-arranged stator teeth. These teeth carry an electrical rotating field or stator winding in the form of individual (stator) coils wound from insulating wire. The coils are assigned to individual strands or phases of the electric motor and are interconnected in a predetermined manner, for example, in a star or delta connection. For this purpose, the coils are electrically connected to form a multiphase, in particular three-phase, rotating field or stator winding by means of a connecting element, preferably annular, mounted on the stator. Typically, each phase of the rotating field or stator winding, which is electrically offset by 120°, is electrically connected to a terminal contact, for example, through a corresponding opening in the end shield. On the side of the connecting element or bearing shield opposite the stator, (motor) electronics are typically arranged to supply current to the phases of the rotating field or stator winding. The electronics comprise a bridge circuit, provided, for example, by means of a printed circuit board, whereby each of the phase connections must be connected to the electronics. The interconnection element, also referred to below as a contact adapter, has a preferably ring-shaped, plastic housing with a number of preferably axially raised pockets for electrically conductive contact elements. To connect the coils, wire sections of the coils or their winding wire to be contacted are inserted into corresponding slots of the preferably cuboid-shaped pockets of the interconnection element or contact adapter and mechanically secured within the pocket by the contact element that can be inserted into the respective pocket. The contact elements for the coils or their wire sections are preferably designed as insulation displacement contacts. For this purpose, the contact element has one or more cutting edges which, when inserted into the socket, cut the insulation of the wire section of the coil winding located in the respective slot of the socket in such a way that, when the insulation displacement contact is inserted, a conductor of the winding wire is electrically connected to the contact element via the insulation displacement contact. On a longitudinal side axially opposite the insulation displacement contact, the contact element has an axially extending contact slot. A connecting contact, for example a rail or contact section of a busbar or a stamped grid, of the interconnection element or contact adapter, serving in particular as a phase connection, is or can be inserted into this contact slot with a clamping connection. Due to the geometric constraints, the assembly or implementation of an electrical connection between the terminal contacts or phase connections of the busbars or the stamped grid of the interconnecting element or contact adapter with its contact elements is typically automated or carried out using a so-called blind assembly process. The problem here is that the interface between the terminal contact or busbar or contact section serving as a phase connection and the contact element of the interconnecting element (contact adapter) seated in the respective socket cannot absorb axial forces, meaning that the contact is not, or at least not sufficiently, secured against movement or vibration. There is also a risk that the respective phase or connection contact is located on the side of the component facing away from the stator or the connecting element or contact adapter of the electric motor, for example, a pump block of an electrically operated brake force distribution system. The auxiliary component of the vehicle is not connected to a (connector) plug as intended. To ensure collision-free contact between the respective phase or connection contact and the (customer-supplied) connector during automated blind assembly, precise positioning of the phase or connection contacts (customer contacts) is