Electrical machine, and methods for producing an electrical machine

Patent metadata

Field	Value
Publication number	US-11075565-B2
Application number	US-201716087758-A
Country	US
Kind code	B2
Filing date	Mar 20, 2017
Priority date	Mar 24, 2016
Publication date	Jul 27, 2021
Grant date	Jul 27, 2021

Abstract

The invention relates to an electrical machine ( 10 ), in particular an electronically commutated EC motor, and to methods for producing an electrical machine ( 10 ) of this type having a pole pot ( 15 ), in which a stator ( 16 ) and a rotor ( 18 ) are received, and a plug housing ( 33 ) with an integrated connector plug ( 37 ) is arranged axially on the open side of the pole pot ( 15 ), wherein a rotor shaft ( 20 ) of the rotor ( 18 ) protrudes with a free end ( 80 ) axially out of the pole pot ( 15 ) into the plug housing ( 33 ), and a magnetic signal generator ( 75 ) for rotational position detection is arranged at the free end ( 80 ), which magnetic signal generator ( 75 ) interacts with a magnetic field sensor ( 77 ) which lies axially opposite it, wherein the magnetic field sensor ( 77 ) is configured as a wired single-part component and is fastened directly to the inner side ( 29 ) of the plug housing ( 33 ) without the use of a printed circuit board.

First claim

The invention claimed is:

1. An electrical machine ( 10 ), having a pole pot ( 15 ), in which a stator ( 16 ) and a rotor ( 18 ) are accommodated, and a plug housing ( 33 ) with an integrated plug-in connector ( 37 ) is arranged axially on an open side of the pole pot ( 15 ), wherein a rotor shaft ( 20 ) of the rotor ( 18 ) projects with a free end ( 80 ) axially out of the pole pot ( 15 ) into the plug housing ( 33 ), and a magnetic signal generator ( 75 ) for rotational position detection is arranged at the free end ( 80 ), which magnetic signal generator ( 75 ) interacts with a magnetic field sensor ( 77 ) in axial opposition thereto, characterized in that the magnetic field sensor ( 77 ) is configured as a wired single-part component, and is fastened directly to an inner side ( 29 ) of the plug housing ( 33 ), without the use of a circuit board, and a receiving frame ( 119 ) is configured circumferentially around the magnetic field sensor ( 77 ), and forms a positive fit with the magnetic filed sensor ( 77 ) wherein the magnetic field sensor ( 77 ) comprises a sensor housing ( 79 ), configured to an approximately rectangular design, one corner of which is beveled.

2. The electrical machine as claimed in claim 1 , characterized in that the magnetic field sensor ( 77 ) is directly adhesively bonded to the inner side ( 29 ).

3. The electrical machine as claimed in claim 1 , characterized in that guide ribs ( 104 ) are molded onto the inner side ( 29 ), by means of which the magnetic field sensor ( 77 ) is maintained in an exact position in relation to the signal generator ( 75 ).

4. The electrical machine ( 10 ) as claimed in claim 1 , characterized in that at least one compression rib ( 105 ) is molded onto the inner side ( 29 ), by means of which the magnetic field sensor ( 77 ) is secured, pending the curing of the adhesive ( 120 ).

5. The electrical machine ( 10 ) as claimed in claim 1 , characterized in that a receiving frame ( 119 ) is configured circumferentially around the magnetic field sensor ( 77 ), and forms a positive fit with the magnetic field sensor ( 77 ).

6. The electrical machine ( 10 ) as claimed in claim 1 , characterized in that further contact lugs ( 34 ) project axially on the inner side ( 29 ) which, on one side, are routed to the plug-in connector ( 37 ) in the form of power pins ( 43 ) and, on an other side, are electrically connected to the terminal pins ( 26 ) of an interconnection board ( 22 ), which energizes the electrical windings ( 17 ) of the stator ( 16 ).

7. The electrical machine ( 10 ) as claimed in claim 1 , characterized in that a magnet holder ( 78 ) is press-fitted to the free end ( 80 ) of the rotor shaft ( 20 ), in which a sensor magnet ( 76 ) is arranged by way of a signal generator ( 75 ).

8. The electrical machine ( 10 ) as claimed in claim 1 , characterized in that a bearing plate ( 54 ) for the rotor shaft ( 20 ) is arranged axially between the plug housing ( 33 ) and the interconnection board ( 22 ), wherein the bearing plate ( 54 ) comprises axial centering elements ( 60 ) and/or cut-outs for the accommodation of centering mating elements, by means of which the plug housing ( 33 ) is positioned above the bearing plate ( 54 ) in its rotational position with respect to the interconnection board ( 22 ).

9. The electrical machine ( 10 ) as claimed in claim 1 , characterized in that the plug housing ( 33 ) is formed of plastic, and with an outer radial edge ( 112 ) bears axially on the pole pot ( 15 ), and a metal cover ( 81 ) is axially attached above the plug housing ( 33 ), which is welded to the pole pot ( 15 ) in a leak-tight manner, wherein the plug-in connector ( 37 ) projects outwards through a cut-out ( 39 ) in the metal cover ( 81 ).

10. The electrical machine ( 10 ) as claimed in claim 1 , characterized in that the magnetic field sensor ( 77 ) comprises a plurality of terminal legs ( 106 ) which are electrically connected to insert conductors ( 116 ) in the plug housing ( 33 ) by resistance or laser welding, wherein the insert conductors ( 116 ) terminate in the form of sensor pins ( 41 ) in the plug-in connector ( 37 ).

11. The electrical machine ( 10 ) as claimed in claim 1 , characterized in that a magnet holder ( 78 ) is press-fitted to the free end ( 80 ) of the rotor shaft ( 20 ), in which a 2-pole sensor magnet ( 76 ) is arranged by way of a signal generator ( 75 ), and is adhered therein.

12. The electrical machine ( 10 ) as claimed in claim 1 , characterized in that a bearing plate ( 54 ) for the rotor shaft ( 20 ) is arranged axially between the plug housing ( 33 ) and the interconnection board ( 22 ), wherein the bearing plate ( 54 ) comprises axial centering lugs ( 100 , 102 ) which are bent over in the axial direction ( 4 ) and/or cut-outs for the accommodation of centering mating elements, by means of which the plug housing ( 33 ) is positioned above the bearing plate ( 54 ) in its rotational position with respect to the interconnection board ( 22 ).

13. The electrical machine ( 10 ) as claimed in claim 1 , characterized in that the magnetic field sensor ( 77 ) comprises a plurality of terminal legs ( 106 ) which are electrically connected to insert conductors ( 116 ) in the plug housing ( 33 ), wherein the insert conductors ( 116 ) terminate in the form of sensor pins ( 41 ) in the plug-in connector ( 37 ).

14. The electrical machine ( 10 ) as claimed in claim 13 , characterized in that the insert conductors ( 116 ) project axially on the inner side ( 29 ) of the plug housing ( 33 ), and the terminal legs ( 106 ), in a plane transverse to the axial direction ( 4 ), are brought out of the sensor housing ( 79 ) of the magnetic field sensor ( 77 ).

15. The electrical machine ( 10 ) as claimed in claim 13 , characterized in that the insert conductors ( 116 ) or the terminal legs ( 106 ) are bent over, as a result of which the insert contacts ( 30 ) and the terminal legs ( 106 ) are configured in a mutually parallel arrangement in the contacting region ( 107 ).

16. The electrical machine ( 10 ) as claimed in claim 13 , characterized in that, on the inner side ( 29 ), a capacitor contact ( 108 ) is configured as an insert component, which is electrically connected to the insert conductors ( 116 ) for the terminal legs ( 106 ), and the capacitor contact ( 108 ) is connected to an interference suppression capacitor ( 111 ) which is arranged on the inner side ( 29 ) of the plug housing ( 33 ).

17. The electrical machine ( 10 ) as claimed in claim 13 , characterized in that, on the inner side ( 29 ), a capacitor contact ( 108 ) is configured as an insert component, which is electrically connected to the insert conductors ( 116 ) for the terminal legs ( 106 ), and the capacitor contact ( 108 ) is connected to an interference suppression capacitor ( 111 ) which is arranged on the inner side ( 29 ) of the plug housing ( 33 ), and is adhesively bonded in a capacitor locator ( 126 ).

18. A method for producing an electrical machine ( 10 ) as claimed in claim 13 , characterized in that, firstly, the magnetic field sensor ( 77 ) is fastened to the inner side ( 29 ) of the plug housing ( 33 ) and the terminal legs ( 106 ) thereof are welded to insert conductors ( 116 ) in the plug housing ( 33 ) and, further to the fitting of the plug housing ( 33 ) on the pole pot ( 15 ), the contact lugs ( 34 ) on the plug housing ( 33 ) for the supply of power to the electrical winding ( 17 ) are welded to the corresponding terminal pins ( 26 ) on the interconnection board ( 22 ).

19. The method for producing an electrical

Assignees

• Bosch Gmbh Robert

Inventors

• Stubner Armin
• Meyer Christian
• Gmuend Torsten
• Poddey Christian
• Ritt Jean-Marc

Classifications

• H02K29/08

  using magnetic effect devices, e.g. Hall-plates, magneto-resistors (H02K29/12 takes precedence) · CPC title

• H02K3/522

  for generally annular cores with salient poles · CPC title

• H02K15/14

  Casings; Enclosures; Supports · CPC title

• H02K2203/09

  Machines characterised by wiring elements other than wires, e.g. bus rings, for connecting the winding terminations · CPC title

• H02K2211/03

  Machines characterised by circuit boards, e.g. pcb · CPC title