阅读说明：本技术 电动机 (Electric motor ) 是由 弗里德里希·斯库勒 尤利安·容格 于 2018-07-11 设计创作，主要内容包括：一种适用于电动的凸轮轴调节器的电动机(2)，其包括两个不同的模块，即主马达模块和与主马达模块电和机械连接的插接器模块(4)，其中，主马达模块包括壳体罐(7)、定子(11)和借助滚动轴承(23)支承在壳体罐(7)中的转子(13)并且接入插接器模块(4)中，并且其中，在插接器模块(4)与主马达模块之间的电连接通过能通过沿模块的轴向方向接合模块来建立的连接、尤其是绝缘刺破式连接得到。(An electric motor (2) for an electric camshaft adjuster, comprising two different modules, namely a main motor module and a plug-in module (4) which is electrically and mechanically connected to the main motor module, wherein the main motor module comprises a housing pot (7), a stator (11) and a rotor (13) which is mounted in the housing pot (7) by means of a rolling bearing (23) and engages in the plug-in module (4), and wherein the electrical connection between the plug-in module (4) and the main motor module is obtained by a connection which can be established by engaging the modules in the axial direction of the modules, in particular an insulation-piercing connection.)

1. For an electric motor of an electric camshaft adjuster or for a system for variably adjusting a compression ratio, having two modules (3, 4, 5, 6), namely a main motor module (3) and a plug-in module (4, 5, 6) electrically and mechanically connected thereto, wherein the main motor module (3) comprises a housing pot (7), a stator (11) and a rotor (13) which is mounted in the housing pot (7) by means of a rolling bearing (23) and is plugged into the plug-in module (4, 5, 6), and wherein an electrical connection (37) between the plug-in module (4, 5, 6) and the main motor module (3) is obtained by means of a connection (37) which can be established by engaging the modules (3, 4, 5, 6) in the axial direction of the modules.

2. The electric motor according to claim 1, characterized in that the rolling bearing (23) is configured as a double row angular contact ball bearing.

3. The electric motor according to claim 1, characterized in that the rolling bearing (23) is configured as a four-point contact bearing.

4. The electric motor according to any one of claims 1 to 3, characterized in that the housing pot (7) has a housing base (9) which merges into an intermediate, inwardly drawn, annular shoulder (10) in which the rolling bearing (23) is held.

5. The electric motor according to claim 4, characterized in that the rolling bearing (23) is adjacent to a radial shaft seal ring (24) which is also held in the annular shoulder (10).

6. The electric motor according to any one of claims 1 to 5, characterized by a sealing ring (30) which seals the main motor module (3) both against the plug-in module (4, 5, 6) and against a screw-on face (33).

7. The electric motor according to any one of claims 1 to 6, characterized in that the plug-in module (4) comprises a sensor plate (34) cooperating with the rotor (13).

8. Electric motor according to any one of claims 1 to 7, characterized in that the plug-in module (6) comprises electronic control means (35) for operating the main motor module (3).

9. The electric motor according to any one of claims 1 to 8, characterized in that the electrical connection (37) between the plug-in module (4, 5, 6) and the main motor module (3) is configured as an insulation-piercing connection.

10. Installation kit comprising modules (3, 4, 5, 6) of an electric motor, namely a unified main motor module (3) and different plug-in modules (4, 5, 6) combinable with the main motor module (3), which plug-in modules differ from each other with respect to sensors (34) and electronic control means (35), wherein portions of insulation-piercing connections (37) are formed by the main motor module (3) and by each plug-in module (4, 5, 6), which insulation-piercing connections can be completed by engaging different modules (3, 4, 5, 6) in the axial direction of the main motor module (3).

Technical Field

The invention relates to an electric motor for an electric camshaft adjuster or for a system for variably adjusting the compression ratio of an internal combustion engine.

Background

An electric motor for an electric camshaft adjuster is known, for example, from DE 102013212933B 3. The electric motor comprises a pot-shaped first housing part made of metal and a second housing part made of plastic, which encloses the first housing part, wherein a first rolling bearing is arranged in the first housing part and a second rolling bearing is arranged in the second housing part. The rolling bearing arranged in the pot-shaped first housing part is designed as a fixed bearing. The shaft seal is located on the side of the rolling bearing facing the interior space of the housing.

Another electric motor of an electric camshaft adjuster is disclosed in US 8,220,426B 2. In this case, the motor shaft of the electric motor is also supported by two rolling bearings, i.e., ball bearings.

Disclosure of Invention

The object of the present invention is to improve an electric motor for a camshaft adjuster in relation to the prior art with respect to a particularly cost-effective, modular construction.

This object is achieved according to the invention by an electric motor for an electric camshaft adjuster or for a system for variably adjusting a compression ratio, having the features of claim 1. Furthermore, this object is achieved by a mounting kit according to claim 10 comprising different modules of an electric motor.

The electric motor for an electric camshaft adjuster or for a system for variably adjusting the compression ratio of an internal combustion engine comprises, in a basic concept known per se, a pot-shaped first housing part made of metal and a second housing part made of plastic, which is designed as a closure first housing part of a plug-in module. The pot-shaped first housing part of the electric motor according to the invention is the part of the module referred to as the main motor module. In the case of an electric motor, the rolling bearing is arranged only in the main motor module and not in the plug-in module. The main motor module contains the core functions of the electric motor, namely the magnetic circuit and the motor shaft supported by means of the rolling bearing. Preferably, a brushless direct current motor is provided, which has an energizable three-phase stator winding and a rotor equipped with permanent magnets.

The energization of the main motor module is effected by means of a plug-in module, wherein the electrical connection between the plug-in module and the main motor module is obtained by means of a connection, in particular an insulation-piercing connection, which can be established by engaging the module in the axial direction of the main motor module and thus of the entire electric motor, wherein the main motor module is plugged in, for example, by being pressed into the plug-in module. In this way, relatively complex connections, such as soldered or welded connections, are eliminated.

The electrical and mechanical interfaces between the main motor module and the connector modules are unified, so that a single type of main motor module can be combined with different types of connector modules at will. For all types of connector modules of the installation kit formed in this way, the standardized current supply to the main motor module, which can be established by means of a plug connection, is common. Optionally, the connector module further comprises a sensor, in particular in the form of a sensor board, which interacts with the rotor. Such a sensor enables detection of the rotor orientation for external manipulation of the motor. It is also possible to integrate the electronic control device into the connector module. Overall, the installation kit may thus for example comprise three types of plug-in modules:

a connector module with a rotor position sensor,

a connector module with integrated electronic control means,

a connector module without sensors or control components.

In the last case, the electric motor is operated without sensors on the outside.

The only rolling bearing of the electric motor is designed such that it can withstand axial forces, radial forces and tilting moments. For this purpose, for example, double-row angular contact ball bearings in an O-ring arrangement are suitable. Alternatively, the mentioned functions can be assumed by a four-point contact bearing. Possible designs for four-point contact bearings are described, for example, in DE 102014215523 a1 and DE 102014205689 a 1. Possible applications of four-point contact bearings are described, for example, in WO 2007/122181a 1.

Irrespective of the type of construction of the rolling bearing, the rolling bearing is preferably held in an annular shoulder which points inward from the bottom of the pot-shaped housing part, i.e. projects into the interior of the main motor module. The rolling bearing is preferably sunk into the rotor of the electric motor, so that the rolling bearing is located in or near the center of gravity of the rotor. Optionally, a shaft sealing ring is additionally arranged in the annular shoulder holding the rolling bearing, which shaft sealing ring is disposed upstream of the rolling bearing, so that the rolling bearing is located in the sealed interior of the main motor module.

For static sealing of the electric motor, a sealing ring is preferably provided, which seals the main motor module both against the connector module and against an external screw surface. In a preferred embodiment, the sealing ring contacts a metallic insert, for example a steel sheet, which belongs to the connector module and is permanently inserted, for example by injection molding, into a housing made of plastic of the connector module. The housing of the main motor module is pressed into the annular metal insert, thereby forming a permanently fixed friction-locking connection that can be maintained over the entire temperature range.

The housing of the connector module is, according to a possible embodiment, at least partially embodied as a metallic heat sink, which is made of aluminum or another light metal substance, for example. This can be of interest in particular in integrated power electronics. The targeted heat conduction of the connector modules is advantageous for the structural shape of the electric motor, in which the main motor module has a particularly simple, compact outer contour.

The electrical connection between the connector module and the main motor module can be established in a particularly simple and at the same time durable manner as an insulation-piercing connection. Against this technical background, reference is made in this context to DE 10026424C 2 and DE 102004037991 a 1.

In the present case, the initially insulated conductor to be contacted is located, for example, on the side of the main motor module. The counterpart of the insulation-piercing connection on the side of the plug-in module is designed to firstly remove the insulation of the conductors when the modules are plugged together and then to establish an electrical and mechanical connection, wherein, for example, sections of the electrical conductors belonging to the plug-in module are wrapped around the wires arranged in the main motor module in a barbed manner.

The mechanical main components of the connector module, which are essentially flat components oriented transversely to the longitudinal axis of the main motor module, are preferably produced from plastic, in particular by injection molding. In a preferred embodiment, a lead frame is embedded in the main part, which lead frame establishes an electrical connection between the contact to the main motor module on the one hand and the connector to be coupled from the outside on the other hand. If the connector module comprises a sensor arranged on a circuit board, for example, press-in contacts are provided which establish an electrical connection between the lead frame and the circuit board. The magnetized sensor magnet ring cooperating with the sensor can be fastened to the rotor, for example by means of a slot or rivet.

In the case of the use of an electric motor in an electromechanical camshaft adjuster, for example, a double-bladed drive element is fastened to the motor shaft of the main motor module, which introduces torque into the adjusting gear, optionally via a compensating clutch. Gears or other elements suitable for torque transmission, such as a single finger clutch, can likewise be connected to the motor shaft. The profile for torque transmission can likewise be integrated into the shaft, for example in the form of a flattened section.

The mechanical connection of the electric motor to the surrounding structure is preferably realized in the region of the interface between the main motor module and the plug-in module. At this interface, the pot-shaped housing of the main motor module is sunk into the connector module, which is advantageous with regard to mechanical stability and sealing by means of the single sealing ring already mentioned. A further advantage is achieved by the particularly simple geometric design of the pot-shaped housing part. The pot-shaped housing part can in particular have a continuously smooth, cylindrical peripheral side. In contrast to a main motor module having a standardized outer contour, different plug-in modules, which can be combined with the main motor module in any case, can have different outer contours, which are dependent on the functional range of the plug-in module.

Drawings

Subsequently, embodiments of the invention are explained in detail with the aid of the figures. Wherein:

fig. 1 shows an assembly for assembling an electric motor, which is built up of a main motor module and different plug-in modules;

fig. 2 shows a variant of an electric motor that can be constructed with the assembly according to fig. 1;

fig. 3 and 4 show different plug-in modules that can be combined with a main motor module;

FIGS. 5 and 6 illustrate insulation-piercing connections between a main motor module and a plug-in module;

FIG. 7 shows a cross-sectional view through the bearing arrangement and the rotor of the main motor module;

figure 8 shows in a simplified semi-transparent view an electric motor comprising a plug-in module according to figure 3,

fig. 9 shows the sealing of the motor in the mounted state in detail.

Detailed Description

Fig. 1 shows a mounting kit, generally designated by reference numeral 1, which is suitable for constructing different electric motors 2. The electric motor 2 is used in an electromechanical camshaft adjuster, which is known, for example, from the prior art mentioned.

The installation kit 1 consists of a main motor module 3 and different plug-in modules 4, 5, 6. All the core functions of the electric motor 2 are implemented in the main motor module 3. The structure of the main motor module 3 and the complete electric motor 2 is taken from fig. 2.

The housing 7 of the main motor module 3 is designed as a housing pot made of sheet metal. The outer wall of the housing 7, indicated with 8, is continuously cylindrical. The outer wall 8 is coupled to a ring-disk-shaped housing bottom 9. The inner edge of the housing base 9 is in turn connected to an annular, concentric shoulder 10 with respect to the outer wall 8, which extends in the axial direction of the main motor module 3 at least to a third of the housing pot 7. Overall, the housing 7 thus describes the shape of an annularly encircling groove, the outer edge of which is in the form of an outer wall 8 that is higher than the inner wall of a shoulder 10 in the form of an annulus.

In general, the main motor module 3 is constructed as an inner mover device, wherein a stator 11 with energizable windings 12 cooperates with a rotor 13, which is fastened on a shaft 14, i.e. a motor shaft. The rotor 13 has a pot shape open towards the housing bottom 9. The rotor base, indicated by 15, therefore faces the end side of the main motor module 3 facing away from the housing base 9. The end face of the main motor module 3 to be connected to one of the connector modules 4, 5, 6 is referred to here, which will be explained in more detail below. The rotor is equipped with permanent magnets 16. In general, the main motor module 3 functions as a brushless dc motor. The permanent magnets 16 are embedded in a hollow cylindrical section 17 of the rotor 13, which is connected to the rotor base 15 and which engages back over the annular shoulder 10, i.e. overlaps it in the axial direction. On the outside of the rotor base 15, a sensor magnet ring 18 is visible, which is fastened with a groove pin 19. The sensor magnet ring 18 optionally cooperates with the plug-in modules 4, 5, 6. Fig. 2 also shows the lower plug insulator 20 and the upper plug insulator 21. The upper plug insulator 21 is located in the region of a connecting piece 22 which projects beyond the open end side of the housing pot 7 and has a function, which will be described in more detail below, in cooperation with the plug-in modules 4, 5, 6.

For supporting the shaft 14 together with the rotor 13, a rolling bearing 23, which is designed as a double row angular contact ball bearing in the design according to fig. 2, is integrated into the main motor module 3. The rolling bearing 23 is able to withstand radial forces, axial forces and tilting moments in a manner known per se and is located in the vicinity of the center of gravity of the arrangement consisting of the shaft 14 and the rotor 13. The rolling bearing 23 is inserted into the annular shoulder 10 and ends in alignment with it on the end side (toward the center of the interior of the housing 7). Thus, a free space is formed at the opposite end side of the rolling bearing 23, into which the radial shaft seal ring 24 is fitted. The rolling bearing 23 is lubricated with grease and is therefore located within the sealed interior space of the electric motor 2. A double-bladed drive element 25 for introducing a torque into a not shown adjusting gear unit of the camshaft adjuster, which is designed as a three-shaft gear unit, is fastened to the shaft 14 projecting from the main motor module 3 and sealed by means of a radial shaft sealing ring 24.

Each plug-in module 4, 5, 6 is a substantially flat member which lies in a plane normal to the axis of rotation of the electric motor 2. The coupling section 26 of the connector modules 4, 5, 6, which is located above in the arrangement according to fig. 2, serves to couple lines for transmitting energy and/or electrical signals. In each case, the lines to be coupled to the electric motor 2 are coupled by means of a plug-in connection element, not shown, which is inserted into the coupling section 26 in a direction orthogonal to the longitudinal direction of the shaft 14, i.e. oriented towards the middle axis of the electric motor 2. This contributes to a particularly space-saving construction of the entire electric motor 2 in the axial direction.

The coupling contour of all the connector modules 4, 5, 6 is designed uniformly, which involves assembly with the main motor module 3. The steel insert 28 made of sheet metal is permanently fastened, for example by injection molding, to the housing 27 made of plastic of the connector modules 4, 5, 6. The inner diameter of the steel insert 28 corresponds to the outer diameter of the housing pot 7 plus the interference of the press fit for the permanent friction-locking connection between the metal parts 7, 28.

The steel insert 28 has the shape of an angular ring and is spaced apart from the open end side of the housing 27 facing the main motor module 3. On this end face, an annular circumferential shoulder 29 is formed between the steel insert 28 and the housing 27, which shoulder serves to receive a sealing ring 30. The different coupling elements 31 of the connector modules 4, 5, 6 for connection to the coupling section 26 of the main motor module 3 project in the axial direction beyond the steel insert 28, however in this embodiment do not project to the end sides of the connector modules 4, 5, 6. The entire connector module 4, 5, 6 can be fastened to an external screw surface 33 (fig. 9) using a metal sleeve 32 inserted into the housing 7.

The design of the electric motor 2 according to fig. 2 corresponds to the combination of the main motor module 3 with the plug-in module 4 shown above in fig. 1. The connector module 4 has a sensor in the form of a sensor board 34, which is inserted into the housing 27 and, in cooperation with the sensor magnet ring 18, provides information relating to the position and/or rotation of the rotor 13. The connection 22 and the coupling element 31 are located radially outside the sensor plate 34 with respect to the rotational axis of the motor 2. All the electrical connections between the plug-in module 4 and the main motor module 3 required for operating the electric motor 2 can be established by simply joining the plug-in module and the main motor module 3 along the mentioned modules 3, 4 and thus along the axial direction of the entire electric motor 2, wherein the main motor module 3 is plugged into the plug-in module 4. This also applies if one of the two other connector modules 5, 6 is used.

The difference between the connector module 5, which is shown in the middle in fig. 1 and separately in fig. 3, and the connector module 4 is the elimination of the sensor board 34. In this case, a sensorless external actuation of the electric motor 2 is provided.

The connector module 6, which is shown separately in fig. 4 and below in fig. 1, has an integrated electronic control unit 35, which is arranged on a circuit board 36, which is inserted into the housing 27 in a manner similar to the sensor board 34. The plug-in module 6 is enlarged compared to the plug-in modules 4, 5.

An insulation-piercing connection 37, which is explained below, for example, with reference to fig. 5 and 6, is realized by the connection 22 of the main motor module 3 and the coupling element 31 of the connector modules 4, 5, 6.

Arranged in the connection piece 22 is an insulating wire 38, through which current can be fed to the windings 12 of the main motor module 3. The coupling element 31 is designed in the form of a two-armed clamp, the arms of which are designated 39. If the connector modules 4, 5, 6 are moved from the disconnected position (fig. 5) into the position connected to the main motor module 3 (fig. 6), the two arms 39 first open when moved past the wires, wherein the insulation of the wires 38 is damaged and thus an electrical contact is established.

In fig. 7, the integration of the rolling bearing 23 into the main motor module 3 can be seen in detail. In the illustrated embodiment, the rolling bearing 23 is designed as a double-row angular contact ball bearing. Alternatively, the rolling bearing 23 may be, for example, a single row of four-point contact bearings. In each case, the rolling bearing 23 is the only bearing device of the electric motor 2. No sliding bearings or rolling bearings are present in the connector modules 4, 5, 6.

Fig. 8 shows the features of the connector module 4 in perspective. In addition to the three conductor strips 40, which transmit current for energizing the winding 12, a narrower conductor strip 41 is generally visible, which is used for signal transmission between the electric motor 2 and an external control. The wider conductor strip 40 and the narrower conductor strip 41 are guided from the coupling section 26 through the housing 27 in a correspondingly bent shape. The end of the conductor strip 40 oriented in the axial direction of the electric motor 2 is configured as a component of the insulation-displacement connection 37, as is shown in fig. 5 and 6. Conversely, press-in contacts on the sensor board 34 are formed on the end of the comparatively narrow conductor strip 41 which is likewise oriented in the axial direction.

The entire motor 2 has the sealing ring 30 as the only static seal. As can be seen from fig. 9, the sealing ring 30 has an approximately diamond-shaped cross section in this exemplary embodiment, wherein the sealing ring, in the installed state, contacts the steel insert 28, the plastic surface of the housing 27, the cylindrical outer wall 8 of the housing 7 and the screw surface 33, which is not associated with the electric motor 2. A seal between the main motor module 3 and the connector modules 4, 5, 6 and a seal between the entire electric motor 2 and the screw surface 33 are thus obtained.

List of reference numerals

1 installation kit

2 electric motor

3 main motor module

4 connector module

5 connector module

6 connector module

7 casing, casing jar

8 outer wall

9 bottom of the shell

10 annular shoulder

11 stator

12 winding

13 rotor

14 shaft

15 bottom of rotor

16 permanent magnet

17 hollow cylindrical section

18 sensor magnetic ring

19 grooved pin

Plug-in insulator below 20

21 upper plug-in insulator

22 connecting piece

23 rolling bearing

24 radial shaft seal ring

25 drive element

26 coupling section

27 housing of connector module

28 steel insert

29 shoulder

30 sealing ring

31 coupling element of a connector module

32 sleeve

33 screw surface

34 sensor, sensor board

35 electronic control device

36 circuit board

37 electrical connection, insulation piercing connection

38 wire rod

39 arm

40 conductor strip

41 conductor strip