Motor winding connections

0001The invention relates to a method for automatically Contacting of the windings of the stator of an electric motor, the particular for driving a centrifugal pump or a is fan used, the stator during assembly in the axial direction via the rotor can be pushed and wherein the Ends of the windings are led to a contact carrier, the on the rear in mounting direction front end of the Windings is disposed.

0002Electric motors for driving pumps and fans are in Known various designs. It is, for example, known from the series production of small centrifugal pumps Aggregate to design so that its individual parts such as rotor, Stator and housing in the axial direction can be assembled, an automation of the manufacturing process to favor. One problem with this so-called "in-line" However, manufacturing is the connection of the motor windings to the External contacts. In this manufacturing step is a manual Intervention yet inevitable.

0003Manual labor is so far in particular always necessary when it comes to the sometimes long ends of the windings to and take over a certain distance at a lead connection point. In addition, for example, be the provided ends of the coils by hand with wire and led to a clipboard. The interconnection to an Star or delta connection is then made via jumpers the clipboard.

0004There are known other engines in which the winding ends sorted by hand and arranged in a on the stator Power distribution are performed. is on the connector strip Terminal box plugged in which the crosswise connection happens. is When interconnecting in such terminal boxes it is known to series production contacting PCBs to use, where the intersection of the conductor tracks is realized. The use of such printed circuit boards problematic as the thereon printed conductors only can be designed at great expense for high currents.

0005The object of the invention is therefore a process for the to establish contact with the stator windings, which is can be fully automated and for contacting of windings with wire cross-sections of between about 0.1 mm²and up to 2 mm² suitable is. At the same time, the object of to provide invention a canned motor pump, with the automated contact their stator finished "in-line" leaves.

0006These objects are achieved by a method according to claim 1 and achieved by a pump of claim 9.

0007A particular advantage of the inventive method, that the contact means of the gripper detected ends can fully automate, since the ends can be automatically found and implemented. Thus, the production to be rationalized, what tangible to Reduction of production costs contribute. Specifically, by the method of the previously performed manually Search and gripping the wire ends automatically. Since the gripper with its crest or his fork close to the winding attaches, where the location of the wire ends relatively well defined is, the ends can be securely detected. This advantage takes wear, especially in long wire ends to.

0008The manufacturing of stators and thus also of the electrical Machines can advantageously without manual intervention together with the connection of the motor windings to the External contacts or to the electronic module mechanically "in-line" happen. The process is particularly suitable for rigid wires having a comparatively large cross-section wire, so that especially for high currents Motors designed to easy and inexpensive way completely in series production can be built automatically. For the novel Method, it is irrelevant whether the first detected ends be or first contact carrier or the Chamber block cap is placed.

0009Particularly advantageously, the process can at stators Insert whose pole shanks are wound individually and are then combined to form a stator. It is advantageous if the ends of the relatively stiff wire of one end face of the stator with a slight inclination by protrude outside, so that a made of plastic disk-shaped chamber block cap between the funnel-shaped loose wire ends on the front side can be placed, without causing the wire ends are clamped. Of the decisive operation involves gripping the wire at Withdrawal from the winding and a lead of the detected wire to the site of contact.

0010The greatly simplified manufacturing and the use of insulation displacement contacts makes the renunciation of some components possible and thus contributes to a reduction in manufacturing costs at. With fewer components, in particular by saving the previously required fasteners, also is a given improved reliability of the engine. there makes the use of insulation displacement contacts welding or brazing of joints ensures redundant and thus a particularly reliable contact. The automatic Interconnection can at any electrical equipment, ie both in the manufacture of motors as well as the Production of generators occur. particularly advantageous the process can be for contacting the twelve ends Insert a three-phase machine, whose six windings three pairs of coils are connected together.

0011The stamped sheet metal insulation displacement contacts are se known and may vary depending on the to bewerkstelligenden Contact be designed accordingly. The insulation displacement contacts are resilient and have a slotted Fitting on. Upon contacting the wire insulation intersected by the insulation displacement terminal. It is not necessary to strip the winding wire. The insulation displacement contacts can according to the request for Wire cross-sections of about 0.1 mm² to 2 mm² used will.

0012In an advantageous embodiment, the contact carrier be designed such that both a connection of the coils in is possible delta connection and in star connection. The arrangement of the wires may be on the face of the be made in accordance with the contact carrier requirements. The crossover of the wire ends is unlike the Use of conductive contact elements due to the isolation on the one hand not a problem, and on the other hand are viewed intersecting wires in different guide grooves on their intersections a different height level exhibit. The stripping of the winding wires are at Contact the insulation displacement contacts at the points where the cutting of contacts access.

0013In a particularly advantageous embodiment, the Stator to six wound coils with wrappers layer by layer on frame-shaped in particular of plastic Brackets made wound and a magnetic field generate in the radial direction. Depending on two opposite Coils by means of an insulation displacement contact to a Pair of coils connected together. Advantageously, the Coil of stiff but flexible wire with relatively large cross section is wound so that two ends of a relatively long protrude like fingers stiff on one side of the coil. Such wire ends can easily grasped by machine, by Recesses brought out in the chamber block cap, on the be appropriate length cut and aligned.

0014Advantageously, the manufacturing facility with a Arm equipped, at the end of a ridge is maintained. This Comb is brought up to the respective coil and grasps the ends close to the coil. The arm then performs the end over the face of the chamber block cap. The so ausgericheten Ends are joined together with the insulation displacement contacts. The insulation displacement contacts are either on the are chamber block cap mounted and the wire ends in this is inserted or the ends are fixed before a mounted insulation displacement contact from outside to the ends becomes. The manufacturing facility also enables Removing the separated pieces of wire so that a possible Short-circuit is prevented.

0015In order to ensure contact to the motor electronics, have some insulation displacement contacts plug on that via respective counterparts with the control electronics can be connected. For a simple Ferigung it is also particularly advantageous if in the chamber block cap Guide grooves are provided, into which the ends of the Windings are inserted. This guide, which Depth is larger than the diameter of the wire to provide the Wire ends maintenance, safety and security against damage against short circuits with other wires at the crossing points.

0016In a particular embodiment at the Chamber block cap pins provided corresponding in engage recesses in the stator and in the electronics and one hand, a centering of the three components to and on the other hand ensure a twisting against each other to prevent. By the pins can be press-fit to a be omitted, leading to a further simplification of the Manufacturing contributes. It is particularly advantageous that kind provide fixation in a canned motor, as thus likewise the containment shell in a recess of Chamber block cap is an exact fit centered and its Vibrations are damped. The vibration-damped Split case helps to reduce the running noise.

0017In a particular embodiment, the chamber block cap centered on the motor housing or the electronics housing cover and turn inside the containment shell via a particular Dämfungselement centered, said that the Dämfungselement Dampens vibrations.

0018A particular embodiment of an engine according to the The method according to the invention is manufacturable, is in the Drawings 1 to 3 shown in greater detail below and is described. Show it:<dl tsize="7"><dt><b>figure 1</b></dt><dd>a section through a by an electric motor powered centrifugal pump,</dd><dt><b>figure 2</b></dt><dd>a section through the chamber block cap Electric motor with a delta connection.</dd><dt><b>figure 3</b></dt><dd>a section through the chamber block cap Electric motor with a star connection and</dd></dl>

0019In Figure 1 is a three-phase motor for driving a Centrifugal pump with a central intake 21 shown. The A centrifugal pump has an impeller 1, in a pump housing 2 is arranged. The rotor 3 of the motor by a Containment shell 4 separated from the stator. 5 The stator windings of 6 surrounded pole shanks 7 are close to the containment shell. 4 In the drawing it can be seen that the windings or coils 6 on frame-shaped brackets 8 made of plastic in layers are wound. The stator 5 is of a motor housing 9 surround. The windings can also directly to removable Pole legs be wound up in the assembly to Pole ring are introduced.

0020The ends 10a, 10b of in this case six coils 6 project to the impeller 1 back remote from the pump out and pierce recesses in the windings 6 covering the contact support 11 made of plastic, which in this Case is constructed as a chamber block cap. The contact carrier 11 is based on the insertion direction (arrow A) from the rear on the containment shell 4 be placed, wherein the containment shell 4 a central hole 19 (Figure 2) in the contact carrier 11 passes through. On the outer, opposite the intake End side of the contact carrier 11, the ends 10a and 10b two opposite coils 6a and 6b by about 90 ° parallel to the bent of Stirmnfläche Kontaltträgers 11th The ends 10a and 10b extend in guides 13, which is on the chamber block cap are, and are at a location near of a coil 6b summarized. At the point where both Ends are 10a and 10b come into mutual contact electrically by an inserted insulation displacement contact 12 and mechanically interconnected.

0021As seen in Figure 2, are two opposing to reel in this way through the insulation displacement contact 12a a pair of coils connected. In addition, two are adjacent Coils 6 a further three insulation displacement contacts 12b connected to each other, so that a delta connection the six coils 6 results. The insulation displacement contacts 12b in this case designed such that it to a connector 14 (Figure 1) have contact with the electronics not shown. The electronics is covered by an electronics housing 15th From Figure 1 it is seen that all components of the let aufeinandersezuen pump in the axial direction.

0022In contrast to the delta connection shown in Figure 2 shows the circuit according to Figure 3, a star connection. at these are the end 18 of the three coil pairs 6 to a central star point 16 with an insulation displacement contact 17 interconnected at the chamber block cap 11th The contact 17 may together gesetzer than three individual sheets triangular cylinders be constructed.

0023In this embodiment, the chamber block cap 11, Pins 20 in recesses of the patch Motor housing 15 and engage in grooves of the stator 3 and the resulting twisting of the stator 3 with respect to the housing prevent.

0024The method for manufacturing the stator 3 with attached Chamber block cap 11 includes the following steps. First the six coils 6 wound on the frame 8 such that all the ends come 10 to lie at one end face. Then the individual windings are merged and in this case twelve finger-like protruding wire ends with the Receiving member of the gripper, or the form of a comb comprising a fork as a threading aid, detected and with the Grippers along the geometry of the contact support on the spot the contact out. The placement of the contact carrier can take place before or after gripping. The ends then on the face by means of insulation displacement contacts (12) each conductively connected. In an intermediate step, the ends are cut to the required length.

0025For engaging the ends (10a, 10b), the receiving member of the Gripper as close as possible to the surface of the winding zoom out, where the ends have a defined position taking. In a special embodiment, the dern out gripper can rest on the surface of the winding will. Following the gripping of the ends (10a, 10b), the closed receiving member advantageously so that the Ends can not slip out of the gripper. To the gaps between the teeth of the female organ closed, so that the ends of the ridge in the radial direction are held.