Electric machine with integrated power electronics and method for producing the bond of the DC bars with the DC contacts surfaces of the power semiconductor of the power electronics

• US 7,557,477 B2
• Filed: 06/28/2006
• Issued: 07/07/2009
• Est. Priority Date: 07/09/2005
• Status: Expired due to Fees

• Current Assignee: ZF Friedrichshafen AG (Zeppelin - Stiftung der Stadt Friedrichshafen)
• Original Assignee: ZF Friedrichshafen AG (Zeppelin - Stiftung der Stadt Friedrichshafen)
• Inventors: Kett, Jürgen, Schön, Wolfgang
• Primary Examiner(s): Lam; Thanh
• Application Number:
  US11/476,446
• Publication Number:
  US 20070007829A1
• Time in Patent Office: 1,105 Days
• Field of Search: 310 71- 72, 310/68.R, 310/68.D, 310/89, 310/52, 310/64, 310/254
• US Class Current: 310/68.00D
• CPC Class Codes: H02K 11/05 Rectifiers associated with casings, enclosures or brackets
• CPC Class Codes: H02K 15/0056 Manufacturing winding connections
• CPC Class Codes: H02K 15/0081 for form-wound windings
• CPC Class Codes: H02K 2213/12 Machines characterised by the modularity of some components

Abstract

The proposed electric machine with integrated power electronics is modularly constructed, it being possibly prefabricated and separately to install the parts stator carrier (2), control (10) for the power semiconductor DC+ (4), DC bars (5), power semiconductor (8), cooling duct (12) for power electronics and electric machine, stator (1) and stator winding (3).

Claims

1. An electric machine with integrated power electronics, the electronic machine being modularly constructed and comprising:

a stator carrier (2),

a power semiconductor control (10),

a positive DC bar (4),

a negative DC bar (5),

a power semiconductor (8), and

a cooling duct (12) for cooling the integrated power electronics, and the electric machine, a stator (1) and a stator winding (3), each of which is prefabricated and separately installed in the electric machine;

wherein the positive DC bar (4) and the negative DC bar (5) are located so as to be essentially superimposed when radially viewed along a rotational axis and so as to be essentially parallel when axially viewed normal to the rotational axis, and

an insulator (14) is situated between the positive DC bar (4) and the negative DC bar (5) with contact surfaces (22A, 22B) between the insulator (14) and the positive DC bar (4) and the negative DC bar (5) so that the insulator (14), the positive DC bar (4) and the negative DC bar (5) together comprise an intermediate circular capacitor (20) for the power electronics.

2. The electric machine with integrated power electronics according to claim 1, wherein a side of the positive DC bar (4) and a side of the negative DC bar (5) facing the insulator (14) are roughened to provide sufficient contact surfaces (22A, 22B) to form the intermediate circular capacitor (20).

3. The electric machine with integrated power electronics according to claim 1, wherein the positive DC bar (4) and the negative DC bar (5) and the insulator (14) together form snap-on connections.

4. The electric machine with integrated power electronics according to claims 1, wherein an end (16) of the stator winding (3) is a link which, after insertion of the power electronic module, is bent up and soldered with the power semiconductor (8) such that when combined with a plug connection (15), a fixing of a semiconductor module is obtained between the power semiconductor (8) and the stator carrier (2).

5. The electric machine with integrated power electronics according to claim 1, wherein a bond (6) of the positive DC bar (4) and a bond (7) the negative DC bar (5) with a DC contact surface of the power semiconductor (8) is produced by an initial current supply of one of a soldered layer and a layer of any other suitable connecting medium applied on the contact surface during production of the power semiconductor (8), heat produced by an initial high ohmic resistance on the contact surface creating a band and a system being prepared for regular operation by subsequent lowering of ohmic resistance on contact power of the system.

6. The electric machine with integrated power electronics according to claim 5, wherein the bond (6) of the positive DC bar (4) and the bond (7) the negative DC bar (5) with DC contact surfaces of the power semiconductor (8) are produced by extrusion.

7. The electric machine with integrated power electronics according to claim 6, wherein the semiconductor module and the positive DC bar (4) and the negative DC bar (5) are communicate with a snap-on connections, an electric connection is produced by surface pressure on contact points and an other snap-on connection (17) is provided between one of the positive DC bar (4), the negative DC bar (5) and the power conductor (8).