DE102024115076A1 - Electric motor, comprising a stator and a rotor shaft rotatably mounted relative to the stator, as well as a protective cover and an angle sensor - Google Patents

Abstract

Electric motor, comprising a stator and a rotor shaft rotatably mounted relative to the stator, as well as a protective cover and angle sensor for detecting the rotational position of the rotor shaft, wherein a support part is attached to the protective cover, to which a sensor plug housing of the angle sensor is connected in a rotationally fixed manner, wherein the support part has a yoke region, a first leg region, a second leg region and tab regions, wherein the tab regions adjoin the respective end regions of the first leg region, the second leg region and the yoke region, wherein a press-in nut is pressed into each of the tab regions.

Description

The invention relates to an electric motor, comprising a stator and a rotor shaft rotatably mounted relative to the stator, as well as a protective cover and angle sensor.

It is generally known that a stationary housing of an angle sensor, which is designed to detect the rotational position of a shaft, is connected to a stationary part by means of a torque support. The measured values recorded by the angle sensor are transmitted digitally or analogously by means of a sensor line, i.e. an electrical line.

From the JP 2019 - 146 346 A The closest state of the art is an electric motor.

From the DE 10 2017 112 231 A1 A method for anchoring connecting elements in a permanently deformable flat material is known.

From the DE 10 2004 042 478 A1 A method for the torsion-proof fastening of a functional element in a component is known.

From the DE 10 2015 012 796 A1 a drive is known.

From the DE 10 2019 003 071 B3 A planar double-cardanic stator coupling is known.

From the JP 2001 - 169 512 A The attachment of an angle sensor to a motor is known.

The invention is therefore based on the object of connecting an electric motor with an angle sensor in a stable manner.

According to the invention, the object is achieved in the electric motor according to the features specified in claim 1 or 2.

Important features of the invention in the electric motor according to claim 1 are that the electric motor has a stator and a rotor shaft rotatably mounted relative to the stator as well as a protective cover and an angle sensor for detecting the rotational position of the rotor shaft,
wherein a support part is attached to the protective cover, to which a sensor plug housing of the angle sensor is connected in a rotationally fixed manner,
wherein the support member has a yoke portion, a first leg portion, a second leg portion and tab portions,
wherein the tab regions adjoin the respective end regions of the first leg region, the second leg region and the yoke region,
wherein a press-in nut is pressed into each of the tab areas.

The advantage here is that the support part can be designed to be flat and is therefore rigid in the circumferential direction relative to the axis of rotation of the rotor shaft. This means that the sensor connector housing of the angle sensor can be connected in a torsionally rigid manner to the protective cover and thus to the motor housing, stator and/or a housing part of the electric motor.

The housing of the angle sensor can also be connected to the fan cover of the electric motor by means of a torque support to dissipate torque.

The U-shaped design of the support part, with a yoke area connecting the two leg areas, makes it easier to thread the sensor cable through and allows axial tolerances to be compensated.

The tab areas are preferably of the same shape, i.e. they merge into one another through a mathematical rotation of 90° or 180° or 270°.

The ability to vibrate is suppressed particularly well when the press-in nuts arranged on the tab areas are located at the corners of a square which is rotated by an angle to a second square which contains parts of the outer edges of the leg areas and the yoke area in its outer edge. The axis of rotation is arranged and aligned coaxially to the axis of rotation of the rotor shaft.
Important features of the electric motor according to claim 2 are that the electric motor has a stator and a rotor shaft rotatably mounted relative to the stator as well as a protective cover and angle sensor for detecting the rotational position of the rotor shaft,
wherein a support part is attached to the protective cover, to which a sensor plug housing of the angle sensor is connected in a rotationally fixed manner,
wherein the support member has a yoke portion, a first leg portion, a second leg portion and tab portions,
wherein the yoke region adjoins both the first and the second leg region, wherein a first tab region (24) is arranged at the end region of the first leg region facing away from the yoke region,
wherein a second tab region (25) is arranged at the end region of the yoke region facing the first leg region,
wherein a third tab region (24) is arranged at the end region of the yoke region facing the second leg region,
wherein a fourth tab area (25) is provided on the yoke area facing away from the end region of the second leg region,
wherein a press-in nut is pressed into each of the tab areas.

The advantage here is that the support part can be designed to be flat and is therefore rigid in the circumferential direction relative to the axis of rotation of the rotor shaft. This means that the angle sensor can be connected in a torsionally rigid manner to the protective cover and thus to the motor housing, stator and/or a housing part of the electric motor.

The U-shaped design of the support part, which has a yoke area connecting the two leg areas, makes threading relative to the rotor shaft easier on the one hand and allows axial tolerances to be compensated on the other.

The tab areas are preferably of the same shape, i.e. they merge into one another through a mathematical rotation of 90° or 180° or 270°.

The ability to vibrate is suppressed particularly well when the press-in nuts arranged on the tab areas are located at the corners of a square which is rotated by an angle to a second square which contains parts of the outer edges of the leg areas and the yoke area in its outer edge. The axis of rotation is arranged and aligned coaxially to the axis of rotation of the rotor shaft.

In an advantageous embodiment, the support part is made from a metal sheet as a stamped part. The advantage here is that it is inexpensive to manufacture and allows a large torque to be dissipated. In addition, the support part can be made very rigid in the circumferential direction despite being made from a metal sheet. In the axial direction, however, the support part is not rigid, but rather so elastic that tolerances can be compensated and tension can be avoided. In addition, vibrations can be efficiently dampened in the axial direction.

In an advantageous embodiment, the support part is U-shaped. The advantage here is that it is easy to manufacture because the rotor shaft can simply be threaded into the opening of the U-shape.

In an advantageous embodiment, the support part, including its yoke region, the leg regions and the tab regions, is formed in one piece, in particular in one part. The advantage here is that the support part can be produced simply and inexpensively, in particular by punching out a metal sheet.

In an advantageous embodiment, the support part is flat, in particular it is quasi-two-dimensional, with the normal direction of the plane receiving the support part being aligned parallel to the axis of rotation of the rotor shaft. The advantage here is that even with a small wall thickness of the support part, it has a high torsional rigidity, so that transverse forces that are transmitted to the sensor connector housing via a cable, for example, can be dissipated.

In an advantageous embodiment, all edges of the first square connecting the centers of gravity of the press-in nuts each have a non-zero angle, in particular with an angle value between 10° and 30°, to all edges of the second square, the edges of which contain at least partial areas of the outer edges of the yoke area and the two leg areas, in particular with respect to the axis of rotation of the rotor shaft, in particular radially outer edges. The advantage here is that the oscillation capability of the support part is reduced.

In an advantageous embodiment, the tab areas and/or the press-in nuts are arranged radially outside the sensor connector housing, in particular with respect to the axis of rotation of the rotor shaft. It is advantageous that the first square encompasses the second square, in particular that the first square contains the second square.

In an advantageous embodiment, each of the press-in nuts has an internal thread whose screw axis is aligned parallel to the axial direction and/or the direction of the axis of rotation of the rotor shaft. It is advantageous that the support part is arranged in a plane whose normal direction is aligned parallel to the direction of the axis of rotation of the rotor shaft. This enables a torsionally rigid connection of the sensor connector housing to the protective cover.

In an advantageous embodiment, a first longitudinal slot is introduced into the first leg region and a second longitudinal slot is introduced into the second leg region, in particular wherein the two longitudinal slots extend parallel to one another and/or are aligned. The advantage here is that the sensor connector housing can be connected to the support part in a form-fitting manner without play and thus a rigid connection can be achieved.

In an advantageous embodiment, the longitudinal slots are each rectangular or cuboid-shaped, in particular with the respective edges of the two longitudinal slots parallel to each other or are aligned perpendicular to each other. The advantage here is that a secure and positive connection can be achieved.

In an advantageous embodiment, pin areas formed on the sensor connector housing are inserted into the longitudinal slots and pressed in with no play. The advantage here is that a stable connection can be achieved. The respective pin area can be formed in a correspondingly cuboid shape and can thus be pressed into the respective longitudinal slot by means of a press fit.

In an advantageous embodiment, the protective cover is attached to a bearing flange of the electric motor,
wherein the bearing flange accommodates a bearing which rotatably supports the rotor shaft,
The stator is connected to the bearing flange in a rotationally fixed manner. The advantage here is that the air flow driven by a fan wheel is used efficiently and the angle sensor can be supported and/or attached to the protective cover.

In an advantageous embodiment, a fan wheel having fan blades that is connected to the rotor shaft in a rotationally fixed manner is surrounded radially by the protective cover. The advantage here is that the air flow is sucked in through grid openings in the protective cover to the fan cover arranged inside the protective cover, past the angle sensor, and is conveyed by the fan cover along a bearing flange and/or stator on the side of the fan cover facing away from the angle sensor.

In an advantageous embodiment, the threaded area, in particular the external thread area, of a respective screw is screwed into the respective internal thread area of a respective press-in nut,
wherein the screw protrudes through an opening in the protective cover, in particular through a grille opening of a fan grille of the protective cover,
The screw head of the screw rests on the side of the protective cover facing away from the press-in nut. The advantage here is that the support part is attached to the

The sensor connector housing is connected to the support part by pressing the pin areas of the sensor connector housing into the longitudinal slots of the support part, without play and with a positive fit in the circumferential direction. The rotor shaft is connected in a rotationally fixed manner to a rotatably mounted part of the angle sensor, the housing of which is held in a rotationally fixed manner by a torque support that is connected to the fan cover.

Further advantages arise from the subclaims. The invention is not limited to the combination of features in the claims. The person skilled in the art will recognize further useful combination options of claims and/or individual claim features and/or features of the description and/or the figures, in particular from the task and/or the task arising from comparison with the prior art.

• In der 1 ist ein ein Stützteil 1 aufweisender, B-seitiger Bereich eines Elektromotors explodiert in Schrägansicht dargestellt, wobei der Stator und Rotor des Elektromotors nicht gezeigt sind.
• In der 2 ist das Stützteil 1 in Draufsicht dargestellt.
• In der 3 ist der Elektromotor mitsamt seines Stators 30, seiner Lüfterhaube 35 und seiner Schutzhaube 3 explodiert in Schrägansicht dargestellt.

The invention will now be explained in more detail using schematic illustrations:

• In the 1 a B-side region of an electric motor having a support part 1 is shown exploded in an oblique view, wherein the stator and rotor of the electric motor are not shown.
• In the 2 the support part 1 is shown in plan view.
• In the 3 the electric motor together with its stator 30, its fan cover 35 and its protective cover 3 is shown exploded in an oblique view.

As shown in the figures, the electric motor has a protective cover 3 which is placed over the stator or over a bearing flange connected to the stator and is fastened to the stator or bearing flange, in particular by means of screw parts.

An angle sensor has a sensor connector housing 2, with the sensor itself being arranged at an axial distance therefrom within the protective cover 3. The sensor itself has a sensor housing and a shaft part that is arranged to rotate relative to the sensor housing. The shaft part protrudes from the angle sensor to the stator and is connected in a rotationally fixed manner to the rotor shaft of the electric motor.

The angle sensor can be used to detect the rotational position of the rotor shaft. The sensor cable of the angle sensor runs as a cable inside the protective cover 3 to the sensor connector housing 2, where the sensor cable is attached to connection devices and connected to an external cable.

To dissipate transverse forces and corresponding torques, the sensor connector housing 2 is connected to the support part 1 in a rotationally fixed manner. For this purpose, the support part 1 has longitudinal slots 23 into which pin areas formed on the sensor connector housing 2 protrude. The pin areas are pressed into the longitudinal slots 23 without play.

Each longitudinal slot 23 is arranged in a respective leg region (21, 22) of the support part 1.

The first of the leg regions 21 is connected to the second of the leg regions 22 via a yoke region 20.

The support part 1 is manufactured as a stamped part from a sheet metal and is U-shaped, wherein the U-shape is formed from the yoke region 20 and the first leg region 21 as well as the second leg region 22.

A tab region 25, which projects in particular radially outward, is formed on the end region of the yoke region 20 facing the first leg region 21.

A tab region 24, which projects in particular radially outward, is formed on the end region of the yoke region 20 facing the second leg region 22.

A tab region 24, which projects in particular radially outward, is formed on the end region of the first leg region 21 facing away from the yoke region 20.

A tab region 25, which projects in particular radially outward, is formed on the end region of the second leg region 22 facing away from the yoke region 20.

In each of the tab areas (24, 25) a press-in nut is arranged in an axially continuous recess, which is connected in a rotationally fixed manner to the respective tab area (24, 25).

In particular, the centres or centres of gravity of the press-in nuts are at the corners of a first imaginary, 2 not shown, in particular mathematical, first square. The center of this first square is arranged in the axis of rotation of the rotor shaft.

The support part 1, together with the yoke region 20, the first leg region, the second leg region 22 and the four aforementioned tab regions (24, 25), is formed in one piece, in particular in one part.

The support part 1 is connected to the protective cover 3 by means of the screws 4, which are screwed into the press-in nuts 26. For this purpose, the protective cover 3 has continuous openings, in particular grille openings of a fan grille, through which the screws 4 protrude.

The longitudinal slots 23 are rectangular. In particular, the yoke region 20, the first leg region 21 and the second leg region 22 are also rectangular.

The edges of the square whose corners coincide with the centers of gravity of the press-in nuts 23 are not parallel to the outer edges of the yoke region 20, the first leg region and the second leg region, but they have a non-zero angle thereto.

The outer edges, i.e. outer edges of the leg areas (21, 22) and the yoke area 20 are in 2 shown in plan view and thus, as in 2 evident, from a second, imaginary, in the 2 not fully shown square. The center of this second square is located in the axis of rotation of the rotor shaft.

The tab region 24 arranged at the end region of the first leg region 21 facing away from the yoke region 20 passes through a 90° anti-clockwise rotation into the tab region 25 arranged at the end region of the yoke region 20 facing the first leg region 21, and through a further 90° anti-clockwise rotation it passes into the tab region 24 which is arranged at the end region of the yoke region 20 facing the second leg region 22. Through a further 90° rotation it then passes into the end region of the second leg region 22 facing away from the yoke region 20.

The screws 4 protrude through the grid openings of the protective hood 3 and are screwed into the press-in nuts 26 so that the respective screw head of the respective screw 4 rests on the protective hood 3 and on the side of the protective hood 3 facing away from the screw head the support part 1 rests on the protective hood and on the side of the support part 1 facing away from the screw head the press-in nuts 23 protrude from the support part 1, into the internal thread of which the screws 4 are screwed with their thread area.

In particular, the outer edge of the sensor connector housing adjacent to the protective cover 3 has a circular contour, wherein the maximum diameter of the circular contour is arranged radially inside the press-in nuts 23 but radially outside the second square.

As in 3 As can be seen, the bearing flange 36, to which the fan cover 35 and the protective cover 3 are attached, is connected to the stator 30. The rotatably mounted part of the angle sensor 31 is rotationally fixedly connected to the rotor shaft 37 by means of a coupling 32.

The housing of the angle sensor 31 is connected to the fan cover via the torque support 33 and is thus held in position with low vibration.

The sensor connector housing 2 of the angle sensor is designed in two parts, i.e. it is composed of a lower part and an upper part.

The fan wheel 38 with fan blades is rotationally fixedly connected to the rotor shaft 37.

In further embodiments according to the invention, the protective cover is not made of metal, but as a plastic injection-molded part.

list of reference symbols

1

support part, especially torque support

2

sensor connector housing of the angle sensor

3

protective cover

4

screw

20

yoke area

21

first thigh area

22

second thigh area

23

longitudinal slot

24

tab area

25

tab area

26

press-in nut

30

stator

31

angle sensor

32

coupling

33

torque support

34

sensor cable

35

fan cover

36

bearing flange

37

rotor shaft

38

fan wheel with fan blades

QUOTES INCLUDED IN THE DESCRIPTION

This list of documents listed by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions.

Cited patent literature

• JP 2019 - 146 346 A [0003]
• DE 10 2017 112 231 A1 [0004]
• DE 10 2004 042 478 A1 [0005]
• DE 10 2015 012 796 A1 [0006]
• DE 10 2019 003 071 B3 [0007]
• JP 2001 - 169 512 A [0008]

Claims (15)

Electric motor, having a stator and a rotor shaft rotatably mounted relative to the stator, as well as a protective cover and angle sensor for detecting the rotational position of the rotor shaft, wherein a support part is attached to the protective cover, to which a sensor plug housing of the angle sensor is connected in a rotationally fixed manner, wherein the support part has a yoke region, a first leg region, a second leg region and tab regions, wherein the tab regions adjoin the respective end regions of the first leg region, the second leg region and the yoke region, wherein a press-in nut is pressed into each of the tab regions. Electric motor, comprising a stator and a rotor shaft rotatably mounted relative to the stator, as well as a protective cover and angle sensor for detecting the rotational position of the rotor shaft, wherein a support part is attached to the protective cover, to which a sensor plug housing of the angle sensor is connected in a rotationally fixed manner, characterized in that the support part has a yoke region, a first leg region, a second leg region and tab regions, wherein the yoke region adjoins both the first and the second leg regions, wherein a first tab region (24) is arranged at the end region of the first leg region facing away from the yoke region, wherein a second tab region (25) is arranged at the end region of the yoke region facing the first leg region, wherein a third tab region (24) is arranged at the end region of the yoke region facing the second leg region, wherein a fourth tab region (25) is arranged at the end region of the second leg region facing away from the yoke region, wherein in each of the tab regions a press-in nut is pressed in. electric motor after claim 1 or 2 , characterized in that the support part is made of a metal sheet as a stamped part. Electric motor according to one of the preceding claims, characterized in that the support part is U-shaped. Electric motor according to one of the preceding claims, characterized in that the support part together with its yoke region, the leg regions and the tab regions is formed in one piece, in particular in one part. Electric motor according to one of the preceding claims, characterized in that the support part is flat, in particular is quasi-two-dimensional, wherein the normal direction of the plane receiving the support part is aligned parallel to the axis of rotation of the rotor shaft. Electric motor according to one of the preceding claims, characterized in that all edges of the first square connecting the centers of gravity of the press-in nuts each have a non-vanishing angle, in particular with an angle value between 10° and 30°, to all edges of the second square, the edges of which contain at least partial regions of the outer, in particular with respect to the axis of rotation of the rotor shaft, in particular radially outer, edges of the yoke region and the two leg regions. Electric motor according to one of the preceding claims, characterized in that the tab areas and/or the press-in nuts are arranged radially outside the sensor connector housing, in particular with respect to the axis of rotation of the rotor shaft. Electric motor according to one of the preceding claims, characterized in that each of the press-in nuts has an internal thread whose screw axis is aligned parallel to the axial direction and/or direction of the axis of rotation of the rotor shaft. Electric motor according to one of the preceding claims, characterized in that a first longitudinal slot is introduced in the first leg region and a second longitudinal slot in the second leg region, in particular wherein the two longitudinal slots extend and/or are aligned parallel to one another. Electric motor according to one of the preceding claims, characterized in that the longitudinal slots are each aligned rectangularly or cuboid-shaped, in particular wherein the respective edges of the two longitudinal slots are aligned parallel to one another or perpendicular to one another. Electric motor according to one of the preceding claims, characterized in that pin areas formed on the sensor connector housing are inserted into the longitudinal slots and pressed in with a form-fitting fit without play. Electric motor according to one of the preceding claims, characterized in that the protective cover is fastened to a bearing flange of the electric motor, wherein the bearing flange accommodates a bearing which rotatably supports the rotor shaft, wherein the stator is connected to the bearing flange in a rotationally fixed manner. Electric motor according to one of the preceding claims, characterized in that a fan wheel having fan blades which is connected to the rotor shaft in a rotationally fixed manner is radially surrounded by the protective cover, wherein a fan cover (35) is arranged within the protective cover, which radially surrounds the fan wheel together with the fan blades, wherein the angle sensor is supported on the fan cover (35) by means of a torque support. Electric motor according to one of the preceding claims, characterized in that the threaded area, in particular the external thread area, of a respective screw is screwed into the respective internal thread area of a respective press-in nut, wherein the screw projects through an opening in the protective hood, in particular through a grille opening of a fan grille of the protective hood, wherein the screw head of the screw rests on the side of the protective hood facing away from the press-in nut.

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