Electrical machine and method for producing an electrical machine

1. An electrical machine ( 10 ) comprising a pole pot ( 15 ), in which a stator ( 16 ) and a rotor ( 18 ) are held, and a connector housing ( 33 ) that lies axially against an open side of the pole pot ( 15 ), the connector housing ( 33 ) having an integrated terminal connector ( 37 ) and electrical contacts ( 30 , 34 ), each of the electrical contacts ( 30 , 34 ) of the connector housing ( 33 ) being connected to respective mating electrical contacts ( 26 , 133 ) of the stator ( 16 ) to form a pair of connected contacts,

wherein the connector housing ( 33 ) has an annular circumferential wall ( 83 ) having radial windows ( 110 ), each radial window ( 110 ) being adjacent to a respective pair of connected contacts and being configured to allow a tool ( 150 ) to be inserted through the radial window ( 110 ) to connect the respective pair of connected contacts.

2. The electrical machine according to claim 1 , characterized in that the electrical contacts ( 30 , 34 ) of the connector housing ( 33 ) are welded to the mating electrical contacts ( 26 , 133 ) of the stator ( 16 ).

3. The electrical machine according to claim 1 , characterized in that the electrical contacts ( 30 , 34 ) of the connector housing ( 33 ) on one hand as contact lugs ( 34 ) project axially downward on an inner side ( 29 ) of the connector housing ( 33 ), and on an other hand as current pins ( 43 ) end at the terminal connector ( 37 ), and the mating electrical contacts ( 26 , 133 ) of the stator ( 16 ) are formed as terminal pins ( 26 ) of conductor elements ( 23 ) of an interconnection board ( 22 ) that are electrically connected to electrical windings ( 17 ) of the stator ( 16 ).

4. The electrical machine according to claim 3 , characterized in that the interconnection board ( 22 ) is arranged axially on the stator ( 16 ) and a bearing plate ( 54 ) for the mounting of the rotor ( 18 ) is fastened to the open end of the pole pot ( 15 ) axially over the interconnection board ( 22 ), wherein the terminal pins ( 26 ) protrude out of a body of plastic ( 21 ) of the interconnection board ( 22 ) axially through the bearing plate ( 54 ) into the connector housing ( 33 ).

5. The electrical machine ( 10 ) according to claim 1 , characterized in that the mating electrical contacts ( 26 , 133 ) and the electrical contacts ( 30 , 34 ) of the connector housing ( 33 ) run parallel to one another, overlapping in the axial direction ( 4 ), and at least approximately lie against one another in the circumferential direction ( 2 ).

6. The electrical machine ( 10 ) according to claim 1 , characterized in that the mating electrical contacts ( 26 , 133 ) of the stator ( 16 ) are connected to a contact plate ( 22 ) by way of resilient regions ( 38 ) and/or the electrical contacts ( 30 , 34 ) of the connector housing ( 33 ) are connected to the connector housing ( 33 ) by way of elastic regions ( 118 ).

7. The electrical machine ( 10 ) according to claim 1 , characterized in that arranged on an inner side ( 29 ) of the connector housing ( 33 ) is an interference suppression capacitor ( 111 ), which has as one of the electrical contacts ( 30 , 34 ) of the connector housing ( 33 ) a free capacitor terminal ( 134 ) which is electrically connected to the pole housing ( 15 ) by way of a bearing plate ( 54 ).

8. The electrical machine ( 10 ) according to claim 1 , characterized in that a bearing plate ( 54 ) has axial centering elements ( 60 ) and/or clearances for receiving centering mating elements ( 103 ), by means of which the connector housing ( 33 ) is exactly positioned in its rotational position with respect to an interconnection board ( 22 ) by way of the bearing plate ( 54 ), so that the electrical contacts ( 30 , 34 ) of the connector housing ( 33 ) lie against the corresponding mating electrical contacts ( 26 , 133 ) of the stator ( 16 ).

9. The electrical machine ( 10 ) according to claim 1 , characterized in that the connector housing ( 33 ) is formed from plastic and has a circular uninterrupted axial edge ( 140 ), which closes off the radial windows ( 110 ) axially downwardly.

10. The electrical machine ( 10 ) according to claim 1 , characterized in that fitted axially over the connector housing ( 33 ) is a metal cover ( 81 ), which is welded in a sealed manner to the pole pot ( 15 ), wherein a terminal connector ( 37 ) with current pins ( 43 ) protrudes axially outward oppositely from the rotor ( 18 ) through a clearance ( 39 ) in the metal cover ( 81 ).

11. A method for producing an electrical machine ( 10 ) according to claim 1 , comprising:

assembly of the stator ( 16 ) in the pole pot ( 15 ) in such a way that electrical mating contacts ( 133 ) of the stator ( 16 ) project axially upward;

placement of the connector housing ( 33 ) onto the pole pot ( 15 ) in such a way that electrical contacts ( 30 ) in the connector housing ( 33 ) project axially downward;

radial reaching of welding tools ( 150 ) through the radial windows ( 110 ) in the circumferential wall ( 83 ) of the connector housing ( 33 ); and

welding of the electrical contacts ( 30 , 34 ) of the connector housing ( 33 ) to the corresponding electrical mating contacts ( 26 , 133 ) of the stator ( 16 ).

12. The method according to claim 11 , characterized in that, for the assembly of the stator ( 16 ),

coil formers ( 36 ) with electrical windings ( 17 ) are inserted into the pole pot ( 15 ),

the rotor ( 18 ) is inserted into the pole pot ( 15 ),

the interconnection board ( 22 ) is placed onto the stator ( 16 ) and is contacted with the electrical windings ( 17 ), and

a bearing plate ( 54 ) for the rotor ( 18 ) is arranged axially above an interconnection board ( 22 ) and is securely welded to the pole pot ( 15 ), wherein electrical terminal pins ( 26 ) of the interconnection board ( 22 ) are led axially through the bearing plate ( 54 ) and protrude axially upward beyond the bearing plate ( 54 ).

13. The method according to claim 11 , characterized in that, before the placement of the connector housing ( 33 ) onto the pole pot ( 15 ),

first a magnetic sensor ( 74 , 77 ) is fastened to an inner side ( 29 ) of the connector housing ( 33 ) and terminal legs ( 106 ) of the magnetic sensor ( 74 , 77 ) are electrically contacted with insert conductors ( 116 ) of the connector housing ( 33 ), and

an interference suppression capacitor ( 111 ) is fastened to the inner side ( 29 ) of the connector housing ( 33 ), and a first capacitor terminal ( 128 ) is electrically contacted with the magnetic sensor ( 74 , 77 ).

14. The method according to claim 11 , characterized in that the electrical contacting of the mating electrical contacts ( 26 , 133 ) of the stator ( 16 ) with the electrical contacts ( 30 , 34 ) of the connector housing ( 33 ) is carried out by means of the same welding process as the electrical contacting of a free capacitor terminal ( 134 ) with an axially upwardly projecting ground contact ( 95 ) of a bearing plate ( 54 ).

15. The electrical machine ( 10 ) according to claim 1 , characterized in that arranged on an inner side ( 29 ) of the connector housing ( 33 ) is an interference suppression capacitor ( 111 ), which has as an electrical contact ( 30 ) a free capacitor terminal wire ( 134 ) which is electrically connected to the pole pot ( 15 ) by way of a bearing plate ( 54 ), wherein a interference suppression capacitor ( 111 ) is connected to a rotational position sensor ( 74 ) for the rotor ( 18 ), which is securely adhesively fixed on the inner side ( 29 ) of the connector housing ( 33 ).

16. The electrical machine ( 10 ) according to claim 1 , characterized in that a bearing plate ( 54 ) has axially angled-away centering lugs ( 100 , 102 ) and/or clearances for receiving centering mating elements ( 103 ), by means of which the connector housing ( 33 ) is exactly positioned in its rotational position with respect to an interconnection board ( 22 ) by way of the bearing plate ( 54 ), so that the electrical contacts ( 30 , 34 ) of the connector housing ( 33 ) lie against the corresponding mating electrical contacts ( 26 , 133 ) of the stator ( 16 ).

17. A method for producing an electrical machine ( 10 ) according to claim 1 , comprising:

assembly of the stator ( 16 ) in the pole pot ( 15 ) in such a way that the electrical mating contacts ( 26 , 133 ) of the stator ( 16 ) project axially upward;

placement of the connector housing ( 33 ) onto the pole pot ( 15 ) in such a way that the electrical contacts ( 30 , 34 ) in the connector housing ( 33 ) project axially downward, wherein the connector housing ( 33 ) is pressed into a cylindrical offset ( 89 ) at the open side of the pole pot ( 15 );

radial reaching of the tools ( 150 ) through radial windows ( 110 ) in the circumferential wall ( 83 ) of the connector housing ( 33 ); and

welding of the electrical contacts ( 30 , 34 ) of the connector housing ( 33 ) to the corresponding electrical mating contacts ( 26 , 133 ) of the stator ( 16 ) by means of resistance welding or laser welding.

18. The method according to claim 17 , characterized in that, for the assembly of the stator ( 16 ),

coil formers ( 36 ) with electrical windings ( 17 ) are inserted into the pole pot ( 15 ),

the rotor ( 18 ) is inserted into the pole pot ( 15 ),

an interconnection board ( 22 ) is placed onto the stator ( 16 ) and is contacted with the electrical windings ( 17 ),

a bearing plate ( 54 ) for the rotor ( 18 ) is arranged axially above the interconnection board ( 22 ) and is securely welded to the pole pot ( 15 ), wherein the mating electrical contacts ( 26 , 133 ) of the interconnection board ( 22 ) are led axially through a bearing plate ( 54 ) and protrude axially upward beyond the bearing plate ( 54 ).

19. The method according to claim 17 , characterized in that, before the placement of the connector housing ( 33 ) onto the pole pot ( 15 ),

first a magnetic sensor ( 74 , 77 ) is fastened to an inner side ( 29 ) of the connector housing ( 33 ) and terminal legs ( 106 ) of the magnetic sensor ( 74 , 77 ) are electrically contacted with insert conductors ( 116 ) of the connector housing ( 33 ),

an interference suppression capacitor ( 111 ) is fastened to the inner side ( 29 ) of the connector housing ( 33 ), and a first capacitor terminal ( 128 ) is electrically contacted with the magnetic sensor ( 74 , 77 ),

wherein a second free capacitor terminal ( 134 ) projects freely toward one of the radial windows ( 110 ) of the connector housing ( 33 ).

20. The electrical machine according to claim 1 , wherein the connector housing ( 33 ) has a circular uninterrupted axial edge ( 140 ) from which the circumferential wall ( 83 ) extends.

21. An electrical machine ( 10 ) comprising a pole pot ( 15 ), in which a stator ( 16 ) and a rotor ( 18 ) are held, and a connector housing ( 33 ) that lies axially against an open side of the pole pot ( 15 ), the connector housing ( 33 ) having an integrated terminal connector ( 37 ),

wherein the connector housing ( 33 ) has a circumferential wall ( 83 ) having windows ( 110 ) through which electrical contacts ( 30 ) of the connector housing ( 33 ) contact electrical mating contacts ( 133 ) of the stator ( 16 ),

wherein a bearing plate ( 54 ) has axial centering elements ( 60 ) and/or clearances for receiving centering mating elements ( 103 ), by means of which the connector housing ( 33 ) is exactly positioned in its rotational position with respect to an interconnection board ( 22 ) by way of the bearing plate ( 54 ), so that the electrical contacts ( 30 , 34 ) of the connector housing ( 33 ) lie against the corresponding mating electrical contacts ( 26 , 133 ) of the stator ( 16 ).

22. An electrical machine ( 10 ) comprising a pole pot ( 15 ), in which a stator ( 16 ) and a rotor ( 18 ) are held, and a connector housing ( 33 ) that lies axially against an open side of the pole pot ( 15 ), the connector housing ( 33 ) having an integrated terminal connector ( 37 ),

wherein the connector housing ( 33 ) has a circumferential wall ( 83 ) having windows ( 110 ) through which electrical contacts ( 30 ) of the connector housing ( 33 ) contact electrical mating contacts ( 133 ) of the stator ( 16 ),

wherein fitted axially over the connector housing ( 33 ) is a metal cover ( 81 ), which is welded in a sealed manner to the pole pot ( 15 ), wherein a terminal connector ( 37 ) with current pins ( 43 ) protrudes axially outward oppositely from the rotor ( 18 ) through a clearance ( 39 ) in the metal cover ( 81 ).