DE102008050832A1 - Storage device for a rotor and a shaft for an electric machine - Google Patents

Abstract

The invention relates to a bearing arrangement comprising a rotor (500; 700; 904; 1004; 1508, 1510, 1512) rotatably mounted on a rotational axis of fiber composite material and at least one rotor bearing (916, 918; 926, 928). The at least one rotor bearing (916, 918, 926, 928) is in operative connection with the rotor (500, 700, 904, 1004, 1508, 1510, 1512) in a region spaced radially from the axis of rotation.

Description

The The present invention relates generally to electrical machines and in particular rotors for electric machines.

electrical Machines, both in the form of electric motors and generators, are increasingly being used in areas of alternative energy production and supply used. Here are conventional electrical Machines and a. due to size, weight and efficiency in many cases not suitable.

The patent DE 10 2006 036 707 B3 discloses a carrier ring of fiber reinforced plastic with cutouts for insertion of permanent magnets. One or more carrier rings can form a rotor construction.

The international application WO 01/11755 A1 describes similarly DE 10 2006 036 707 B3 a arranged on a shaft ironless disc-shaped rotor having permanent magnets which are embedded in a fiber or fabric-reinforced plastic. The permanent magnets are each positively connected to the surrounding plastic. The plastic forms a dimensionally stable unit together with the permanent magnets and the machine shaft.

Furthermore, this describes Handbook Composites by Manfred Neitzel and Peter Mitschang, Hanser Verlag, 2004, 1st edition , various conventional methods for processing fiber-reinforced plastic composites. 14 shows an overview diagram of such conventional methods from Neitzel and Mitschang. The diagram divides the shape complexity of a fiber-plastic composite on the horizontal axis and an approximate component size on the vertical axis.

The diagram in 14 gives particular information about component types and processing methods. For example, the shape complexity of round / oval tubes is low, but their component size can vary from small to large. The fiber processing methods flow forming and injection molding are increasingly used in components of high shape complexity and small to medium size components, whereas the resin injection method according to Neitzel and Mitschang is more likely to be selected with high shape complexity and large component size. As further information, it can be seen from the diagram which processing method is suitable for a particular component. Accordingly, according to Neitzel and Mitschang the forming of structural components and shells, the winding, for example, more suitable for pressure vessels and round / oval tubes. However, a disadvantage of all methods is the processing costs and high energy requirements, for example, when using an autoclave for curing fiber-reinforced plastic composites.

task the present invention, it is the above-mentioned disadvantages of Prior art overcome.

to This object is achieved by the present invention Articles, methods and use according to the independent claims ready. Variants and preferred embodiments of the invention will become apparent from the dependent claims, the following Description and the drawings.

Especially is a storage arrangement with a rotatable on a rotation axis arranged rotor made of fiber composite material and at least one Rotor bearing provided in a radially from the axis of rotation spaced area is in operative connection with the rotor. there is at least according to a preferred embodiment one of the bearings and in particular two bearings on a radially outside lying region of the rotor with this in operative connection. Also can be provided that at least two of the bearings at different Sides of the rotor are in operative connection with this. After a Solution is at least one of the bearings with the shaft in Operatively connected. Furthermore, it can be provided that at least one of the bearings on or within a stator of the electric motor is provided. At least one of the bearings, attached to a radial outer region of the rotor with this in operative connection stands, it can be a sliding bearing.

It can be provided for the storage device, a magnetic bearing be, for the magnets, in particular permanent magnets on may be provided in or within the rotor. The Magnetic storage can according to another embodiment also be actively controllable. Preferably, it can be provided that a circular arrangement of a group of permanent magnets on or within the rotor and a corresponding circular Arrangement of a group of external fixed Permanent magnets or field coils near the rotor with repulsive field force a radial centering effect on the rotor exercises and relieves a radial bearing. Furthermore, preferred be provided that the shaft supported by at least two bearings is.

According to one Another solution is an electric machine with a Stator, a rotor, a shaft and an inventive Storage arrangement provided.

In addition, a method of manufacture ment of a bearing arrangement for an electric motor, wherein a rotor made of fiber composite material, a shaft and a rotor bearing is provided, and wherein the rotor, the shaft and the rotor bearing are arranged such that the rotor is arranged rotatably about a rotation axis and wherein the at least one Rotor bearing is in a radially spaced from the axis of rotation region with the rotor in operative connection.

After all is a use of the storage device described above in an electric machine as a drive for an air, Water or land vehicle or as a generator in a power generating device, intended especially for wind and hydroelectric power plants.

below will be further preferred exemplary embodiments of the invention explained in more detail with reference to schematic drawings. there demonstrate:

1 an electric machine,

2 a rotor main body,

3a an enlarged portion of a rotor main body,

3b an enlarged portion of a rotor main body,

4a a side view of a rotor main body with cover layers,

4b a side view of a rotor main body with a mounting flange,

5 a rotor,

6 a section of a rotor main body,

7 a rotor-shaft arrangement,

8th an electric machine,

9a . 9b 9c and 9d various storage devices,

10a and 10b other storage devices,

11 a negative mold for rotor production,

12 another negative mold for rotor production,

13 a flowchart for different production methods,

14 a diagram according to the prior art

15 an electric machine,

16 a hybrid system, and

17a and 17b an electrical circuit arrangement of a motor / generator device.

In front referring to the drawing, detailed explanation, In the following, general remarks on the present invention are variants and embodiments thereof and alternative or to find optional additional aspects.

It is a rotor for an electric machine having a rotor main body provided, comprising fiber composite material. In this case, the rotor main body one or a plurality of concentric with the center of the rotor main body arranged recordings include. Furthermore, the rotor may have a plurality comprise magnets arranged in at least one of the receptacles are, wherein in at least one of the receptacles at least two magnets are arranged. Preferably, at least one the magnets around a permanent magnet.

Preferably the material of the magnet has rare earth metals or one chemical compound with rare earth metals on. additional or alternatively, the material of the magnet may be neodymium and / or a have chemical compound with neodymium. The material of the magnet can or alternatively the chemical compound neodymium-iron-boron or Include samarium cobalt.

It is provided that in each of the shots either no magnet or exactly two magnets are arranged. After another solution the invention are the centrally arranged recordings by the Rotor main body through holes.

Preferably At least one cover layer is provided, wherein the at least one Cover layer may be arranged on the rotor main body such that arranged in the central receptacles magnets at least partially covered. At least one of the cover layers can fiber composite material exhibit. According to one embodiment The magnets can thus by at least one covered the cover layers that they can not be removed from the shots are.

To a further embodiment can at a Front surface and / or a rear surface of the Rotor main body each arranged at least one cover layer be.

The Fiber composite material of the rotor may be carbon, epoxy resin and / or Polypropylene.

Of Another is an electric machine with a stator and a provided rotor according to the invention.

at the manufacturing process can at least one fiber for the fiber composite material is designed such that it in / on a formative means are laid. It can also be provided that Semi-finished fiber composite material for forming the rotor main body is used. Preferably, at least one fiber for the Fiber composite material designed such that it in / on a shaping Means is laid.

Also the invention provides the use of the rotor in an electrical Machine as drive for an air, water or land vehicle or as a generator in a power generating device. The power generation device may include wind and hydro power plants and or be designed by a vehicle generated rotational forces and / or moments convert into electrical energy.

Furthermore sees the invention as a hub motor and / or generator for a vehicle engine running.

Further is a rotor for an electric machine with a rotor main body provided, which consists of fiber composite material. One on the rotor main body arranged mounting flange can also be made of fiber composite material consist. Preferably, the rotor main body and the Mounting flange in one piece made of fiber composite material consisting and are referred to together as a rotor.

Of the Mounting flange can be flat on a front and a Rear side of the rotor main body may be arranged. Preferably, the rotor is cylindrical and the front side a circular area, d. H. the cylinder cover, the also circular back, d. H. the cylinder bottom, opposite. advantageously, is the ratio of rotor main body diameter to rotor main body thickness high, d. H. the rotor main body is advantageously flat and therefore has less weight. If the rotor should be connected to a shaft at its center, it is preferred if the rotor is thicker in the middle. This can at the front and / or rear of the rotor a mounting flange to be ordered. The mounting flange preferably increases the thickness of the rotor main body toward the center thereof.

Of the Mounting flange may be configured a torque from the rotor main body to be transmitted to the shaft, which is arranged on the mounting flange is. This allows z. B. an assembly of preferably interconnected components, the components comprising the rotor main body, include the mounting flange and the shaft.

Of the Mounting flange can form-fitting to the shaft be. Preferably, the mounting flange has a fitting hole, in which the shaft is fitted. Preferably, a tight fit (eg press fit) used to make a fastening game, mechanical Avoid wear and loss as well as imbalances in the rotor or reduce.

At least a fiber of a fiber material may be the rotor main body and form the mounting flange. Preferably, the at least one Fiber wound, laid, stretched or arranged in a different way, that a solid like the rotor main body and / or the fastening body formed in one piece can be. This can have the advantage that rotor main body and the mounting flange improved, high stability exhibit. Are the rotor main body and the mounting flange with each other d. H. integrally formed, so can an additional Joining process of two components omitted and a solid cohesion and a quick production can be achieved.

The mounting flange may comprise at least one component which is formed from plate-like fiber composite semi-finished product. Preferably, the mounting flange is formed from one or more flat stacked components. Advantageously, such a component is an easily available, simply constructed component which can be produced easily and quickly. By means of components with different sizes and different mechanical properties, advantageously a mounting flange can be assembled in a "modular system" and formed in an application-specific manner. Under plate-like fiber composite semi-finished product is preferably understood to mean a plate formed from fiber composite raw material, which can be easily brought into a desired shape by conventional processing methods. The finishing process from the fiber composite semi-finished product to the mounting flange is advantageously short, inexpensive and can be handled with current machine tools. Under plate-like fiber composite semifinished products can preferably also or alternatively prefabricated rods, spars, pipes, mats and sandwich panels, each of which may have fiber composite material understood.

The At least one fiber towards the center of the rotor can cause a thickening form. Preferably arises at a uniform radial guided arrangement of at least one fiber, a natural thickening towards the center of the rotor. Advantageously, the thickening form a mounting flange.

It is a rotor of an electric machine having a rotor main body provided, which consists of fiber composite material. The rotor points at least one receptacle for the arrangement of at least one magnet on. The at least one fiber extends along at least two adjacent sides of the at least one receptacle. The advantage a rotor made of fiber composite material is lower Weight and higher stability compared to conventional rotors made of soft iron material.

The at least one fiber may act as a loop around the at least one receptacle be guided and at the most one side of at least leave a recording free. Preferably, a loop performs so for a recording that has four pages, for example three of these sides are entwined.

The at least one fiber can have at least two adjacent images at least partially wrap around.

Of the Rotor main body can at least one flange hole and / or a central shaft and / or shaft bushing which at least partially surround at least one fiber can or can be.

The at least one fiber may at least partially surround the circumference of the rotor main body entwine.

Preferably The at least one fiber wraps around at least two points of the Rotor main body, wherein a location a receptacle, a central shaft mount, a flange hole or a specific area of the rotor main body. The advantage of a in Looped fiber is a higher stability of the rotor. Lead the noose around a place, can there an improved tensile strength to another location in the rotor main body getting produced. A loop guide from inner points of the rotor main body to its outer locations For example, the centrifugal force acts on external locations of the rotor main body.

Preferably The at least one fiber comprises an endless fiber and / or piecewise Thickening fibers. The continuous fiber has the advantage that it as wound-up starting material is easy to work. additionally Thickening fibers allow the manufacture of a rotor main body with constant and uniform thickness.

Becomes a disc-shaped rotor main body by at least a fiber formed, so can a natural material thickening to the center of the rotor main body a hub, a mounting flange or form a shaft connection. Advantageously, at least a flange hole as a balancing means for the rotor main body serve, especially if this disc-shaped is.

Preferably comprises a method for producing a rotor for a electric machine that a rotor main body as a rotor only made of fiber composite material, and one made only of fiber composite material existing mounting flange arranged on the rotor main body becomes.

Further is a rotor-shaft arrangement for an electric machine provided, which has a shaft and a rotor arranged on the shaft with a fiber composite material having rotor main body wherein the shaft and the rotor main body by means of at least one longitudinal pin connection are coupled. Prefers it can be provided that the rotor-shaft arrangement has a flange, which is connected to the rotor main body, wherein the rotor main body and the flange by means of at least one of the longitudinal pin connections coupled with the shaft. The longitudinal pin connection preferably comprises at least one longitudinal pin made of a predetermined material, which is interchangeable with another longitudinal pin. Preferably the predetermined material is an elastic material. Furthermore, it may be provided that the longitudinal pin connection the shears off at least one longitudinal pin at high torque. Furthermore, the longitudinal pin connection startup and / or brake slip and / or allow mechanical damping.

Further is a hybrid system with an internal combustion engine unit or a another rotary drive unit, a transmission unit and an electric motor unit provided with a shaft, wherein the gear unit, the torque the internal combustion engine unit or another rotary drive unit with sums the torque of the electric motor unit and the electric motor unit comprising at least one fiber composite rotor, the by a longitudinal pin connection to the shaft of the electric motor unit is coupled.

Furthermore, the longitudinal pin connection to Coupling of the rotor main body with the shaft comprise at least one longitudinal pin of a predetermined material, which is exchangeable against a longitudinal pin of another predetermined material. In this case, the predetermined material may be an elastic material. Furthermore, it can be provided that the longitudinal pin connection shears off at high torque. In addition, an embodiment of the hybrid system is provided which allows startup and / or brake slip and / or mechanical damping.

Of Another is an electric machine with a stator and the provided above rotor-shaft assembly.

• – Bereitstellen eines Faserverbundmaterial aufweisenden Rotorhauptkörpers
• – Bereitstellen einer Welle
• – Anordnen des Rotorhauptkörpers und der Welle, so dass die Welle und der Rotorhauptkörper mittels wenigstens einer Längsstiftverbindung gekoppelt sind.

Furthermore, a method for producing a rotor-shaft arrangement is provided, which comprises the following steps:

• - Providing a fiber composite material having rotor main body
• - Provide a wave
• Arranging the rotor main body and the shaft such that the shaft and the rotor main body are coupled by means of at least one longitudinal pin connection.

Of Another is a rotor-shaft assembly described above, one above described hybrid system and / or an electrical described above Machine as one and / or for a drive for one Air, water or land vehicle or as a generator in a power generating device provided, wherein the power generating device wind and hydroelectric power plants includes.

Further is a storage arrangement with a rotatable on a rotation axis arranged rotor made of fiber composite material and at least one Rotor bearing provided in a radially from the axis of rotation spaced area is in operative connection with the rotor. there At least one of the bearings and in particular two bearings on one radially outer region of the rotor with this in Active compound stand. It can also be provided that at least two of the bearings on different sides of the rotor with this in Active compound stand. After a solution is at least one of the bearings with the shaft in operative connection. Furthermore, can be provided that at least one of the bearings on or within a stator of the electric motor is provided. At least one the bearing, which at a radially outer region of the Rotor is in operative connection with this, can be a plain bearing be.

For One of the storage devices described above may be a magnetic bearing be provided for the magnets, in particular permanent magnets, may be provided on or within the rotor. The magnetic bearing can be actively controlled. Preference can be given here be provided that a circular arrangement of a Group of permanent magnets on or inside the rotor and a corresponding circular arrangement of a group from outside fixed permanent magnets or Field coils near the rotor with repulsive field force a radial centering effect on the rotor and a radial bearing relieved. Furthermore, it may be preferred that the shaft through at least two bearings is supported.

Of Another is an electric machine with a stator, a rotor, a shaft and a bearing assembly according to one of the preceding Claims provided.

About that In addition, there is a method of manufacturing a storage arrangement provided for an electric motor, wherein a rotor made Fiber composite material, a shaft and a rotor bearing is provided and wherein the rotor, the shaft and the rotor bearing arranged such are that the rotor is rotatably disposed about a rotation axis and wherein the at least one rotor bearing in a radially from the axis of rotation spaced area is in operative connection with the rotor.

Farther is a method for producing an electrical described above Machine provided, wherein for the preparation of the storage arrangement the method described above is used.

After all is a use of the storage device described above in an electric machine as a drive for an air, Water or land vehicle or as a generator in a power generating device, intended especially for wind and hydroelectric power plants.

It is also a method of making a fiber composite material existing rotor with a rotor main body for an electric motor is provided, comprising the following steps: Merging fibers of a fiber material with a Matrix to a Fasergemenge, introducing the Fasergemenges with diffuse arranged fibers in one of the shape of the rotor main body corresponding negative mold, compressing the introduced in the negative mold Fiber amounts and curing of the compressed fiber amount, that is preferably at a predetermined temperature and predetermined Pressure happens.

Preferably, the fibers of the fiber material are formed by cutting, cutting or the like of an endless fiber into fiber parts of a certain length. Preferably, these fiber parts with egg merge matrix. The matrix is preferably a binder or bonding agent that forms certain advantageous physical and mechanical properties in connection with the fibers.

A Matrix can, for example, from the group of thermosets (eg. unsaturated polyester resins, vinyl ester resins, epoxy resins) or from the group of thermoplastics (eg polypropylene, polyamide, Polyethylene terephthalate, polyphenylene sulfide, polyether ether ketone) come.

Diffuse arranged fibers advantageously allow a fast and inexpensive processing, since no intermediate step to Aligning or targeted placement of the fibers is necessary. Preferably happens the merging of the fibers with the matrix either before introduction into the negative mold as a fiber mixture or the diffusely arranged fibers are after introduction into the negative mold merged with a liquid matrix.

The Curing the fiber mixture is preferably a process a phase transition of the matrix of liquid after firm causes. For thermosets this phase transition is For example, irreversible, reversible in thermoplastics. Curing means In this context, not necessarily that after the hardened fiber composite component hard or is stiffened; it can vary depending on the type of matrix and fiber have mechanical and physical properties, such. B. high toughness, low weight, electrical conductivity, high flexibility etc.

The Fiber composite material and / or the fiber may include carbon. carbon is a particularly lightweight and durable material, which can form many forms as fiber material and by interaction with a binder permanently retains such a shape. A rotor main body made of carbon fiber composite material is light and can still act on forces and moments withstand.

The Fiber amount can be heated by means of a microwave source become. If the fiber composite material comprises carbon, the electrical conductivity of carbon to be used by a microwave source to be heated. This has compared to conventional Autoclave processes the advantage of reduced energy needs to to cure the fiber mixture.

The Fiber amount may preferably be during heating by a microwave in a negative mold are at a predetermined pressure, or the amount of fiber submerged before heating in the negative mold pressed predetermined pressure. Alternatively, a predetermined Pressure instead of a negative form mediated by the amount of fiber surrounding gas pressure are caused. This has the advantage that the amount of fiber a high density of material and thereby low volume reached.

There most carbon types have a negative coefficient of thermal expansion is for the curing step of in It is preferable for a quantity of fiber introduced in a negative mold that the Material of the negative mold also fiber composite material and in particular Carbon has.

Furthermore is a negative mold for manufacturing a rotor main body provided, wherein at least one fiber is in or on the negative mold and a binder or bonding agent portions of at least connects a fiber together.

A electric machine may comprise a stator and a rotor, the rotor main body according to one of the above Solutions includes. Preferably, such is an electrical Machine a pancake electric motor / generator with Permanently excited rotor and serves as a drive for an air, Water or land vehicle or as a generator in a power generating device, wherein the power generating device according to a Solution includes wind and hydro power plants.

1 shows an electric machine, which is a stator 102 and a rotor main body 104 includes. The rotor main body 104 may be disc-shaped, cylindrical, frusto-conical or doppelkegelstumpfförmig. On the rotor main body 104 may additionally be arranged a mounting flange, wherein an arrangement rotor main body 104 is referred to as a rotor with a mounting flange.

Further shows 1 two in the sectional view of the rotor main body 102 visible magnets 106 , z. B. permanent magnets, of which a plurality of annular in or on the rotor main body 104 are arranged, as well as in the stator 102 provided stator windings (not shown). Further shows 1 a wave 108 , for example, through the mounting flange with the rotor main body 104 connected so that a rotational movement of the shaft 108 to a rotational movement of the rotor main body 104 leads and vice versa. The wave 108 can z. B. be a rod-shaped member made of solid material or a hollow cylindrical member, wherein the cross section of such a component may be completely or partially circular, rectangular, elliptical or toothed and designed as a joint, hollow, gimbal or flexible shaft.

Furthermore, it represents 1 two camps 110 that represents the wave 108 support radially so that the shaft 108 and the rotor main body connected thereto 104 be held radially in its position even when rotating about its axis of rotation.

Will the electric machine 100 operated as a motor, so they occur on the rotor main body 104 attached magnets 106 such with the stator windings on the stator 102 in magnetic interaction, causing a rotation of the rotor main body 100 and the wave associated with it 108 comes around the rotor axis. When operating the electric machine as a generator, however, the mode of action of the electric machine is reversed: a rotation of the shaft 108 and the rotor main body connected thereto 104 results in an electromagnetic interaction between the magnets arranged on the rotor main body 106 and the stator windings, which eventually generates electrical current.

Due to the arrangement in 1 For example, the rotor main body 104 with a diameter of preferably greater than two meters, four meters, six meters and more stable and with a small stator gap 112 rotate at high speeds in the stator, allowing a good magnetic interaction between the magnets 106 and the stator is exploited.

In addition, a reversal of the mechanically moving components in 1 possible. That is a rotor 104 as an external component surrounds a stator as an internal component.

2 shows a rotor main body 200 which is disc-shaped and provided with a predetermined thickness. The material of the rotor main body 200 includes fiber composite material, preferably carbon fiber composite material. The rotor main body 200 continues to include 172 (only exemplary number) rectangular recordings 202 centered about the axis of rotation of the rotor main body 200 and are arranged near its outer edge. Centrally arranged flange holes 204 and the center of the rotor main body 200 lying shaft passage 206 provide connectivity to a shaft (not shown). The centrally arranged flange holes 204 are between the central shaft passage 206 and close to the outer periphery of the rotor main body 200 lying recordings 202 arranged. The number and arrangement of the flange holes 204 may depend in particular on forces and moments to be transmitted.

The rectangular pictures 202 serve for receiving magnets, in particular permanent magnets. In each case at least one magnet can be arranged in all, a plurality, in particular two, three, four, five, eight, eleven or 16, or in exactly one shot. Thereby, for the rotor main body 200 an arbitrary number of shots 202 provided, for example, exactly one shot, two, three, four, five, eight, 13, 16, 65 or 172 shots.

3a shows in an enlarged view a portion of a rotor main body 200 , The pictures 302 on the outer edge of the rotor main body each take a magnet 304 on. During operation of the electric machine, the magnets occur 312 in magnetic interaction with the stator windings (not shown) arranged on the stator and thereby generate current (insofar as the electric machine acts as a generator) or thereby trigger a rotational movement of the rotor (if the electric machine works as a motor). In 3a (and also in 3b ) is the north pole of the magnets 312 denoted by N.

In the in 3b example shown will now be in the shots 302 instead of one, two smaller magnets each 312 . 314 arranged alongside one another. With the smaller magnets 312 . 314 these are separately magnetized magnets. Compared to 3a have the two smaller magnets 312 . 314 Total volume of one of the magnets shown there 304 , It takes advantage of the fact that in the production of magnets smaller ferromagnetic body can be magnetized better than larger in the rule. Thus, two smaller magnets usually have a higher magnetization than a comparable magnet whose volume corresponds to the sum of the volumes of the two smaller magnets when magnetized in the same magnetic field in the same way as the two smaller magnets.

With the in 3b shown example can be achieved that the magnets located in a recording with the same total volume and the same total weight have a greater magnetization than a comparably manufactured, twice as large magnet in a recording, as z. In 3a you can see. It can thus provides a rotor with more powerful magnets at the same volume and weight. Because the rotor main body comprises fiber composite material, the weight of the rotor is further reduced as compared to an equally powerful conventionally manufactured rotor.

If there is talk of at least two magnets being arranged in at least one receptacle, then "at least two magnets" or similar formulations should also be understood as meaning those arrangements in which at least two ferromagnetic bodies magnetize as separate bodies Then, after their magnetization or after a first magnetization process, which can be followed by further magnetization processes, are assembled into a body, in particular by gluing together or other methods for joining objects. The advantages presented here of using magnets which have been magnetized as smaller bodies also come into play in such embodiments.

In the in 3b Example shown show the north poles of two magnets 312 . 314 always either to the middle or to the edge of the engine. Other examples include arrangements in which the north poles of the two magnets in a receptacle point in different directions. Other examples further include arrangements in which the magnets of a receptacle are arranged not adjacent to their longitudinal edges but adjacent to their short edge surfaces. In further examples, three, four or more smaller individual magnets are arranged in at least one receptacle. While in the in 3b As shown in the example shown, the north pole of the magnets in adjacent photographs always points in different directions, examples are also included in which the north poles of the magnets always point in the same direction. Furthermore, examples may be provided in which the poles of the individual magnets are arranged arbitrarily directed.

4a shows a rotor main body 402 and a wave 404 in a side view. The rotor main body 402 points as in 3 shown, rectangular shots 406 on, one of which can be seen in the sectional view above the symmetry line. On the front and back of the rotor main body 402 are two cover layers 412 . 414 arranged, which are made of plate-like semi-finished carbon fiber composite material. The cover layers 412 . 414 cover the rectangular shots 406 and optionally arranged therein magnets, of which in the sectional view of a magnet 420 is visible.

In the recordings 406 of the rotor main body 402 These are through holes. It will be in the shots 406 each two of the magnets described above (not shown) are arranged. The two cover layers 412 and 414 are attached to the rotor main body and prevent falling out of the magnets. In one example, the topsheet layers 412 . 414 Fiber composite on. This ensures that the magnets holding top layers 412 . 414 have low weight.

Other examples provide that the shots 406 represent only recesses that are not passing through the rotor main body holes. In such a case, it may be provided that only one cover layer 412 for fixing the magnets 420 on the rotor main body 402 is arranged.

4b shows a mounting flange 400 , Further shows 4b a side view of the in 1 shown rotor main body 104 and a wave 404 , The rotor main body 402 , above the shaft 404 is shown in sectional view, has a rectangular recording 406 , as in 1 shown on. At the front and back 408 respectively. 410 of the rotor main body 402 are two cover layers 412 and 414 arranged, which are made of plate-like semi-finished carbon fiber composite material and both sides of the outer edge 416 of the rotor main body 402 up to an inner mounting flange disc 418 pass. The cover layers 412 and 414 cover the rectangular shots 406 and arranged therein magnets, for. B. permanent magnets, of which in the sectional view a permanent magnet 420 is visible.

To the center of the rotor main body 402 are at the front 408 and back 410 two inner and outer mounting flange discs 418 and 422 arranged. The inner mounting flange washers 418 are directly on the rotor main body 402 attached by an adhesive (not shown) and have a smaller diameter than the rotor main body 402 and a larger diameter than the outer mounting flange washers 422 on. The outer mounting flange washers 422 are in turn by an adhesive (not shown) each with an adjacent inner mounting flange disc 418 connected. The mounting flange washers 418 and 422 are made of plate-like carbon fiber composite semi-finished components. The entire mounting flange provides a positive and non-positive connection to the shaft 404 ago.

Relating to 4b Explanatory terms with the component "disc" are not to be understood as limiting to cylindrical components. Rather, the rotor main body 402 and / or the mounting flange discs 418 and 422 have a rectangular, elliptical, annular cross-section or the like. The mounting flange washers 418 and 422 can be formed integrally with each other and to the rotor main body 402 be arranged or the mounting flange discs 418 and 422 are with the rotor main body 402 integrally formed.

The mounting flange washers 418 and 422 give the rotor main body an area and volume larger interface to the shaft 404 , whereby the transmission of forces and Mo between the rotor main body 402 and the wave 404 is improved.

5 shows a rotor 500 , From the outside are in turn in 5 to see: a rotor main body 502 , one with the rotor main body 502 integrally formed frusto-conical mounting flange 504 , one in the mounting flange 504 provided shaft passage 506 with groove embedded in it 508 and one with a driving nose 510 provided shaft 512 in cross-section. The wave 512 is by suitable fit in the shaft bushing 506 of the mounting flange 504 arranged. The interchangeable provided on the shaft drive lug 510 reaches into the groove 508 and allows transmission of torques and forces between the shaft 512 and the rotor main body 502 , so the wave 512 , the rotor main body 502 and the mounting flange 504 with an average of the same angular velocity in the two by the double arrow 514 can rotate in the direction indicated.

6 shows a section of a rotor main body 600 , In the sector-shaped section of the in 6 shown rotor main body 600 are exemplary carbon fiber loops 602 . 604 . 606 . 608 . 610 illustrated. There is a shaft feedthrough carbon fiber loop 602 around a shaft passage 612 and a shot 614 , A mounting flange hole carbon fiber loop 610 leads around a mounting flange hole 616 and several shots 614 , A multi-pickup carbon fiber loop 606 . 608 leads to a number of shots 614 , Above-mentioned carbon fiber loops can be combined with each other, in series, alternately, according to a predetermined flow pattern and, for example, by a continuous carbon fiber 618 will be realized. In addition, the following fiber loop guides are possible: fiber loops are in eight, helical, or Fassbandform to one or more recordings 614 and / or one or more mounting flange holes 616 and / or the shaft passage 612 and / or the outer periphery of the rotor main body 600 Wrapped or fiber loops are wrapped in geodesic lines between two or more locations containing one or more shots 614 and / or one or more mounting flange holes 616 and / or the shaft passage 612 and / or the outer periphery of the rotor main body 600 include.

In the 6 shown fiber loops 606 . 608 and 610 are drawn only schematically as closed, they can also as opened on one side loops or at a position with overlapping parts of a continuous fiber 618 be executed. Such an endless carbon fiber 618 becomes at the outer edge portion of the rotor main body 600 supplemented by additional piecewise carbon fibers to a predetermined thickness of the rotor main body 600 manufacture. To the center of the rotor main body 600 The endless carbon fiber thickens out 618 the rotor main body 600 along its vertical axis to a natural hub.

7 shows a rotor 700 an electric machine and a hub made of continuous carbon fiber 704 , The through the hub 704 formed shaft bushing takes a form-fitting shaft 702 on. At the transition from wave 702 and hub 704 are four holes with longitudinally arranged therein form-fitting pins 706 coupled. The longitudinal pins may be, in particular, cylinder-pin-like, conical-pin-type or kerbstift-type longitudinal pins. Shaft and hub thus form a coupled connection. The number and arrangement of the longitudinal pins 706 at the transition from wave 702 and hub 704 may depend in particular on the forces and moments to be transmitted. At the in 7 Example shown four longitudinal pins were used. However, any number of longitudinal pins can realize the pin connection, in particular a longitudinal pin, two, three, four, five, eleven or 18 longitudinal pins. The material of the longitudinal pins 706 is elastic and shears off at high torque. Thus, the longitudinal pins provide 706 on the one hand start-up, brake slip and rotational damping and on the other hand at the same time a safety function to the rotor 700 and the wave 702 to protect against excessive torque. It is also possible a worn longitudinal pin 706 to exchange with a new one.

8th shows an electric machine 800 , In 8th engages a stator 801 a rotor main body 802 , The rotor main body 802 is integral with a mounting flange 804 trained by a mate nose 806 with a wave 808 connected is. The driving nose 806 engages in a recessed in the mounting flange groove 810 one. The wave 408 will be on both sides of the stator 801 by two fixed bearings 812 radially and / or axially supported.

The stator 801 in 8th includes electric stator coils (not shown) whose magnetic field is applied with a magnetic field of permanent magnets arranged in an outer area of the rotor main body 814 interacts. The permanent magnets 814 are in hollow shots 817 of the rotor main body 802 arranged and through on both sides of the rotor main body 802 arranged cover layers 816 and 818 completed to the outside.

The mounting flange 804 provides a large attack surface for in the groove 810 engaging driver nose 806 and thereby allows the transmission of forces and torques zwi the wave 808 and on the rotor main body 802 arranged mounting flange 804 ,

The mounting flange 804 allows, for example, a transmission of higher forces and moments, as in an in 1 shown executed in comparable dimensions electric machine 100 is possible.

In the 8th shown bearings 812 ensure a storage of the shaft 808 and with her over the mounting flange 804 connected rotor main body 802 , But are only the bearings as bearings 812 provided, so in rapid rotational movements of the rotor main body 802 does not rotate in axial directions. It would be desirable to realize a storage that ensures that the rotor main body 802 does not leave its axially provided position, in particular at its edges, during such a rotational movement and / or in the event of vibrations, oscillations or similar movements.

9a shows a schematic storage device. In the embodiment shown is a rotor 904 via a suitable rotor-shaft arrangement with a shaft 902 connected. The rotor 904 Carbon fiber composite material includes recordings 906 . 908 for magnets (not shown). Furthermore, the rotor 904 through two radial bearings 912 . 914 stored. During operation of the electric machine, vibrations and / or vibrations occur on the rotor 904 and the wave 902 , The radial bearings 912 . 914 make sure the shaft 902 and the rotor attached to it 904 be held in their intended position in the radial direction R.

In addition to the radial bearings 912 . 914 the wave 902 are at the in 9a shown example further inventories 916 . 918 provided, which support the rotor on both sides and for an axial bearing of the rotor 904 to care. The thrust bearings 916 . 918 make sure the rotor 904 and the wave associated with it 902 be maintained in a predetermined axial position A during operation of the electric machine. Depending on the specific characteristics of the electrical machine used, it is possible to use the thrust bearings 916 . 918 next to the wave 902 or near the edge of the rotor 904 to arrange.

9b shows a storage arrangement with bearings 922 . 924 that support the shaft axially. Preferably, further bearings 926 . 928 intended. These bearings 926 . 928 are located on a radially outer region of the rotor 904 in operative connection with this. Preferably, such bearings 926 . 928 be arranged in and / or on a stator (not shown). Such an arrangement of bearings 926 . 928 is particularly suitable for preventing vibration of the rotor from its axial position.

In the example of 9c are only bearings 936 . 938 intended. The outer area of the rotor 904 with this operatively connected bearing 936 and 938 support the rotor 904 in the axial and / or in the radial direction.

9d shows another example of a storage arrangement. A provided on the outer region of the rotor bearing 948 stores the rotor 904 such that the rotor 904 is axially supported. Another camp 944 again stores the wave 902 and the rotor connected to it 904 such that they are radially supported.

The of 10a shown schematic representation shows an inner side surface 1022 a stator of an electric machine 1000 , a cross section 1024 through the stator in the schematic representation shown, a shaft 1002 , a rotor connected to the shaft 1004 , Recordings 1006 . 1008 for magnets (not shown) in the rotor 1004 and inventively provided bearings 1012 . 1014 . 1016 . 1018 , The wave 1002 is doing through the provided stock 1012 . 1014 radially supported. In addition, bearings are in the example shown 1016 . 1018 provided, which are arranged on the stator and the rotor 1004 support axially. Preferably, it may be in the radially supporting bearings 1012 . 1014 around rolling bearings and the axially supporting bearings 1016 . 1018 to trade in plain bearings. Due to the arrangement in 10a can the rotor 1004 be operated at a diameter of preferably about two meters, four meters, six meters and more, stable and with a small stator gap at high speeds, so that a good magnetic interaction between the magnets and the stator can be used.

In the example of realize bearings 1012 . 1014 a radial bearing of shaft 1002 , For the axial bearing of the rotor 1004 a magnetic bearing is preferably provided. These are both on or in the rotor 1004 as well as on or in the stator more magnets 1030 respectively. 1032 arranged. The centric act on or in the rotor 1004 attached magnets 1030 and the corresponding to these near the rotor 1004 arranged stationary magnets 1032 attractive and / or repulsive to each other. In the case of a repulsive force action, a radial centering effect is additionally produced on the rotor 1004 so that the radially supporting bearings 1012 . 1014 be relieved. Another example provides, in addition or alternatively, another equivalent bearing, for. B. Air storage.

11 shows a negative form 1100 to the Ro torherstellung, The negative form 1100 is along a longitudinal section mirror-symmetrical to the axis of symmetry 1102 designed and has a negative mold outer edge 1104 , a carbon fiber recess 1106 , the recordings 202 (from 2 ) corresponding pin 1108 , a carbon fiber recess 1106 and the mounting flange holes 204 (from 2 ) corresponding pins 1110 on. In the middle of the negative mold 1100 is a slice 1112 arranged, which the shaft passage 206 (from 2 ) corresponds.

The negative mold outside edge 1104 , the cones 1108 , the pencils 1110 and the disc 1112 are integral with the negative mold 1100 educated. The material of the negative mold 1100 is made of aluminum or carbon fiber composite material and can be closed by a negative mold closing lid (not shown).

carbon fibers 1114 (Thickness of the fibers 1114 in 3 only schematically) z. B. from a Faserablegevorrichtung (not shown) in the carbon fiber recess 306 filed, stretched or laminated according to a predetermined pattern.

12 shows a negative form 1200 for rotor production. The negative form 1200 is in 12 shown in cross section. To illustrate are - also shown in cross section - carbon fibers 1202 in the negative form 1200 lying down. The location and orientation of the carbon fibers 1202 in the negative form 1200 is only qualitative. The carbon fibers 1202 can be any position and orientation in the negative mold 1200 exhibit. The negative form 1200 is symmetrical to the axis 1204 so that only one half of the negative mold 200 is explained in more detail.

The negative form 1200 in 2 includes cones 1206 , which in form and volume in each case the in 4a . 4b shown shots 406 correspond. Furthermore, the negative mold comprises 1200 in the middle a pen 1208 , which corresponds to a shaft passage. The cones 1206 and the pen 1208 are integral with the negative mold 1200 educated. The remaining space between the pins 1206 , the pen 1208 and the negative mold 1200 itself forms a stepped cylindrical trough whose shape and volume corresponds to a rotor. This rotor includes a rotor main body that is a rotor main body portion 1210 in the negative form 1200 and a mounting flange unilaterally and integrally formed with the rotor main body, which is a mounting flange portion 1212 in the negative form 200 equivalent.

The material of the negative mold 1200 can z. As aluminum or fiber composite material.

13 shows a flowchart for a rotor manufacturing method, according to an embodiment of the invention. The flowchart provides four alternative processes involving a rotor main body consisting of only carbon fiber composite material 1300 manufacture. The procedure 1302 includes the successive steps of laying carbon fiber in negative form or clamping 1304 , Insert epoxy resin into the carbon fiber in the negative mold 1306 and curing the mixture of carbon fiber and epoxy resin at a predetermined pressure PH and a predetermined temperature T _H 1308 , The procedure 1310 includes the step of milling and drilling a plate-like carbon fiber composite semi-finished product 1312 so that the rotor main body is formed. The procedure 1314 includes the sequential steps to laminate fiber prepreg in negative mold 1316 and curing the fiber prepreg at a predetermined pressure PH and a predetermined temperature T _H 1318 , The procedure 1320 The sequential steps involves mixing carbon fibers with polypropylene 1322 to place the mixture of carbon fiber with polypropylene in a negative mold or to press 1324 and cure the mixture at a predetermined pressure PH and a predetermined temperature T _H 1326 ,

It can be two, several or all of all of the procedures also partially are combined with each other.

15 shows an electric machine 1500 , at the three of in 8th shown stators 1502 . 1504 and 1506 each having a rotor rotatably mounted therein 1508 . 1510 and 1512 on a wave 1514 arranged in series. Such a stator-rotor subunit of a stator and a rotor corresponds to the in 8th shown electric machine 800 ,

The wave 1514 the in 15 shown electric machine 1500 will, similar to in 8th shown by two fixed bearings 1516 radially and / or axially supported. Since the diameter of in 15 shown stator-rotor subunit is greater than the thickness of the stator-rotor subunit, the electric machine 1500 with two, three or more series-arranged stator-rotor subunits achieve a more compact design, ie a ratio of machine diameter to machine thickness of about 1: 1 and thereby the power and torque can be increased.

For arranging the electric machine in a system is a in 15 shown stator-rotor subunits enveloping housing 1518 provided that the electric machine 1500 inward and outward from influences (eg dust, heat, humidity, electromagnetic radiation, etc.) protects.

Another aspect is in 16 showing a hybrid system. In this case, the device M1 represents a motor-generator device according to one of the aforementioned exemplary embodiments. In contrast, the motor M2 is a conventional internal combustion engine or comparable. The torques of the two motor-acting devices M1 and M2 are in a planetary gear 1602 summed and released from the hybrid system.

17a and 17b show an electrical circuit arrangement of a motor / generator device. It shows 17a a circuit arrangement in a state in which the motor-generator device acting as a generator G1 converts mechanical energy into electrical energy and in a battery 1702 stores. In addition, in the circuit arrangement, a rectifier or commutator between battery 1702 and generator G1 be switched if the generator G1 supplies power.

17b shows a circuit arrangement in a state in which the motor / generator device as a motor M1 acting electrical energy from a battery 1702 converted into mechanical energy.

In an application of the circuit arrangement 17a and 17b on the hybrid system of 16 can be realized a vehicle drive, the kinetic energy when braking the vehicle in a battery 1702 restores and selects electrical energy of the battery 1702 converted into kinetic energy. A rotor-shaft arrangement of the motor-generator device can be designed so that drive and brake slip by elastic longitudinal pins allow a soft start and deceleration in the hybrid system and provided by the elastic longitudinal pins damping behavior of retroactively unconstantially rotating the engine via the planetary gear 1502 prevents the motor-generator device.

at one of the devices described above, in particular in a of the electrical machines described above, this particular as a drive device or for other use in one Aircraft (in particular a passenger aircraft, an airplane, a glider with or without an auxiliary engine or an electric machine for an airship), watercraft (especially a ship or boat, for example a motorboat or a sailboat with or without auxiliary engine) or land vehicle (especially a car, a motorcycle, a truck, a locomotive, a forklift) are used, wherein the low weight and high stability of the fiber composite material Rotor main body high start-up and braking acceleration allows the drive device. Besides that is an application of such an electric machine for driving Pump; as a servomotor; at lawnmowers, cranes, tanks; as a (servo) engine in aircraft, ship and car models; at vending machines (eg ATMs) toys, household appliances and electrical appliances (eg CD, DVD players, hard disks) possible.

Furthermore The electric machine can be a combination of generator function and take over engine function and z. B. in an electric vehicle or vehicle with hybrid drive optionally when braking the vehicle Feeding energy into an electric battery or while accelerating the vehicle's electrical energy from the battery as an engine again convert into kinetic energy.

QUOTES INCLUDE IN THE DESCRIPTION

This list The documents listed by the applicant have been automated generated and is solely for better information recorded by the reader. The list is not part of the German Patent or utility model application. The DPMA takes over no liability for any errors or omissions.

Cited patent literature

• - DE 102006036707 B3 [0003, 0004]
• WO 01/11755 A1 [0004]

Cited non-patent literature

• - Handbuch Composite Materials by Manfred Neitzel and Peter Mitschang, Hanser Verlag, 2004, 1st Edition [0005]

Claims (16)

Storage arrangement with a rotatably mounted on a rotation axis rotor ( 500 ; 700 ; 904 ; 1004 ; 1508 . 1510 . 1512 ) made of fiber composite material and at least one rotor bearing ( 916 . 918 ; 926 . 928 ), which in a radially spaced from the axis of rotation axis with the rotor ( 500 ; 700 ; 904 ; 1004 ; 1508 . 1510 . 1512 ) is in operative connection. Storage arrangement according to claim 1, wherein at least one of the bearings at a radially outer region of the rotor ( 500 ; 700 ; 904 ; 1004 ; 1508 . 1510 . 1512 ) is in operative connection with this. Storage arrangement according to claim 1 or 2, comprising at least two bearings ( 916 . 918 ; 926 . 928 ). Storage arrangement according to claim 3, wherein at least two of the bearings ( 916 . 918 ; 926 . 928 ) on different sides of the rotor ( 500 ; 700 ; 904 ; 1004 ; 1508 . 1510 . 1512 ) are in operative connection with this. Storage arrangement according to claim 3 or 4, wherein at least one of the bearings ( 916 . 918 ; 926 . 928 ) with the wave ( 108 ; 404 ; 512 ; 702 ; 808 ; 902 ; 1002 ; 1514 ) is in operative connection. Storage arrangement according to one of the preceding claims, wherein at least one of the bearings ( 916 . 918 ; 926 . 928 ) on or within a stator ( 102 ; 801 ; 1502 . 1504 . 1506 ) of the electric motor is provided. Storage arrangement according to one of the preceding claims, wherein at least one of the bearings ( 916 . 918 ; 926 . 928 ), which at a radially outer region of the rotor ( 500 ; 700 ; 904 ; 1004 ; 1508 . 1510 . 1512 ) is in operative connection with this, a sliding bearing is. Storage arrangement according to one of the preceding Claims that provide a magnetic bearing. Storage arrangement according to claim 8, wherein permanent magnets ( 1030 ) on or within the rotor ( 500 ; 700 ; 904 ; 1004 ; 1508 . 1510 . 1512 ) are provided for the magnetic bearing. Storage arrangement according to claim 8, wherein the magnetic bearing is actively controllable. Storage arrangement according to one of the preceding claims, wherein a circular arrangement of a group of permanent magnets ( 1030 ) on or within the rotor ( 500 ; 700 ; 904 ; 1004 ; 1508 . 1510 . 1512 ) and a corresponding circular arrangement of a group of outer permanent magnets ( 1032 ) or field coils near the rotor ( 500 ; 700 ; 904 ; 1004 ; 1508 . 1510 . 1512 ) with repulsive field force a radial centering effect on the rotor ( 500 ; 700 ; 904 ; 1004 ; 1508 . 1510 . 1512 ) and relieves a radial bearing. Storage arrangement according to one of the preceding claims, wherein the shaft ( 108 ; 404 ; 512 ; 702 ; 808 ; 902 ; 1002 ; 1514 ) by at least two bearings ( 922 . 924 ) is supported. Electric machine ( 100 ; 800 ; 1000 ; 1500 ) with: - a stator ( 102 ; 801 ; 1502 . 1504 . 1506 ), - a rotor ( 500 ; 700 ; 904 ; 1004 ; 1508 . 1510 . 1512 ), - a wave ( 108 ; 404 ; 512 ; 702 ; 808 ; 902 ; 1002 ; 1514 ) and - a storage arrangement according to one of the preceding claims. Method for producing a storage arrangement for an electrical machine ( 100 ; 800 ; 1000 ; 1500 ), comprising the following steps: - providing a fiber composite material having rotor ( 500 ; 700 ; 904 ; 1004 ; 1508 . 1510 . 1512 ), - providing a wave ( 108 ; 404 ; 512 ; 702 ; 808 ; 902 ; 1002 ; 1514 ), - providing a rotor bearing ( 916 . 918 ; 926 . 928 ) and - arrangement of the rotor ( 500 ; 700 ; 904 ; 1004 ; 1508 . 1510 . 1512 ), the wave ( 108 ; 404 ; 512 ; 702 ; 808 ; 902 ; 1002 ; 1514 ), and the rotor bearing ( 916 . 918 ; 926 . 928 ) such that the rotor ( 500 ; 700 ; 904 ; 1004 ; 1508 . 1510 . 1512 ) is arranged rotatably about a rotation axis and the at least one rotor bearing ( 916 . 918 ; 926 . 928 ) in a radially spaced from the axis of rotation axis with the rotor ( 500 ; 700 ; 904 ; 1004 ; 1508 . 1510 . 1512 ) is in operative connection. Use of the storage arrangement according to one of Claims 1 to 12 in an electric machine as a drive for an air, water or land vehicle or as a generator in a power generating device. Use according to claim 15, wherein the power generating device Wind and hydro power plants.