DE102020116721A1 - Rotor for a permanent magnet excited electrical machine - Google Patents

Abstract

The invention relates to a rotor (50) for an electrical machine excited by permanent magnets, having a rotor sleeve (10), an annular, anisotropic and multi-pole permanent magnet (20) accommodated in the rotor sleeve (10), and a shaft (30), with intermediate spaces between the rotor sleeve ( 10), permanent magnet (20) and shaft (30) are filled with injection molding material (40) and the components are thus connected to one another in a torque-proof manner, with the rotor sleeve (10) and/or the permanent magnet (20) and/or the shaft (30) and/or at least one positioning element (14, 24) is arranged on the injection molding material (40), which is aligned in relation to the angular position of the magnetic poles of the permanent magnet (20).

Description

The invention relates to a rotor for a permanent magnet excited electrical machine according to the preamble of claim 1.

Such a rotor can, for example, be part of an electric motor excited by permanent magnets for driving a fuel pump which is used to deliver the fuel from the tank to the motor.

Fuel pumps are often arranged directly in the fuel tank, the electric motor being flushed with fuel inside the pump housing.

Since the fuel is aggressive and corrosive, all metal parts and electrical components of the electric motor, especially the rotor components, must be protected from contact with the fuel.

Here it is known to completely encapsulate the rotor with plastic, for example according to DE 10 2008 053 233 A1 , or to arrange the rotor in a rotor sleeve sealed with plastic, as shown in DE 10 2011 105 324 A1 or DE 10 2013 007 563 A1 is revealed. The rotor sleeve consists for example of a corrosion-resistant and non-magnetic metal and encapsulates the rotor components, in particular the rotor magnet.

A hollow cylindrical and multi-pole ring magnet, for example, can be used as the rotor magnet, which is preferably injection-molded from a magnet material embedded in plastic.

In order to increase the magnetic flux density of the ring magnet, it is known that the ring magnet consists of an anisotropic magnetic material which is oriented in a preferred magnetic direction.

The magnetic pre-alignment is achieved by applying the magnetic material in a correspondingly shaped magnetic field during the injection molding process of the ring magnet. The more the injection molding compound of the ring magnet was magnetized during the injection process, the better the pre-alignment of the magnets obtained.

After completion of the rotor, the ring magnet is finally magnetized in a magnetization device, whereby it is important here to align the rotor or the ring magnet built into the rotor in the magnetization device according to the preferred magnetic direction of the ring magnet so that correct magnetization can take place.

Only if this pre-alignment is taken into account in the final magnetization process, i. H. If the ring magnet is positioned in the correct position in the magnetization device, so that the magnet is aligned in such a way that the preferred direction introduced during the injection molding process coincides with the magnetizing field of the magnetization device, an optimally magnetized magnet is obtained.

It is the object of the invention to specify a rotor for an electrical machine and a method for producing this rotor, which enables the rotor to be easily aligned in a magnetization device in accordance with the previously impressed preferred magnetic direction.

According to the invention, this object is achieved by a rotor with the features of claim 1 and a method for producing the rotor with the features of claim 10. A method for magnetizing the rotor is specified in claim 13.

Preferred embodiments of the invention and further advantageous features are specified in the dependent claims.

The claimed rotor comprises a rotor sleeve, a ring-shaped, anisotropic and multi-pole permanent magnet received in the rotor sleeve and a shaft arranged concentrically to the permanent magnet and the rotor sleeve, with gaps between the rotor sleeve, the permanent magnet and the shaft in an injection mold being filled with injection molding material using an injection molding process and the components are thereby non-rotatably connected to one another. The injection molding material is preferably an electrically insulating and solvent-resistant material, such as. B. a suitable plastic is used.

According to the invention, at least one positioning element is arranged on the rotor sleeve and / or on the permanent magnet and / or on the shaft and / or on the injection-molded material of the rotor, which is aligned with respect to the angular position of the magnetic poles of the permanent magnet.

In a preferred embodiment of the invention, the permanent magnet has at least one positioning element on at least one of its end faces or one of its inner and / or outer circumferential surfaces for correct positioning in the rotor sleeve and / or in the injection mold.

Additionally or alternatively, the rotor sleeve has at least one positioning element on at least one of its end faces or one of its inner and / or outer circumferential surfaces for the correct positioning of the rotor magnet in the rotor sleeve and / or for the correct positioning of the rotor sleeve in the injection mold.

With the invention it is achieved that the permanent magnet or the magnetic poles of the permanent magnet can be aligned correctly in relation to the rotor sleeve and / or the injection mold, so that the orientation of the magnetic poles can be seen on at least one positioning element arranged on the rotor. In particular, the rotor is provided with at least one positioning element, by means of which the finished rotor can be placed in the correct position in a magnetization device, so that its magnetic poles are correspondingly aligned with the magnetization coils.

The positioning element is visible on the finished rotor and can be arranged either on a component of the rotor sleeve or on the injection molding material located on the rotor.

In one embodiment of the invention, the positioning element is designed on the rotor sleeve in the form of a projection and / or a recess and / or a flat.

A positioning element on the permanent magnet is used to align the magnetic poles of the permanent magnet with respect to the rotor sleeve and can also be designed in the form of a projection and / or a recess and / or a flat.

When assembling the rotor, the positioning element on the permanent magnet interacts with a positioning element on the rotor sleeve and / or on the injection mold.

The positioning element on the rotor sleeve interacts with a positioning element on the injection mold and enables the correct positioning of the rotor sleeve in the injection mold.

After the rotor components consisting of the rotor sleeve, permanent magnet and shaft have been provided with the injection molding material in the injection mold, a further embodiment of the invention provides that at least one positioning element for correct positioning of the rotor is provided on at least one end face and / or one circumferential surface of the injection molding material of the rotor is arranged in a magnetization device.

The permanent magnet of the rotor is finally magnetized in the magnetization device.

The permanent magnet comprises an anisotropic magnet material bound in plastic and is injection molded, the magnet material having a preferred magnetic direction which is achieved during the injection molding process of the permanent magnet by magnetically pre-aligning the magnet material.

The rotor can be positioned in the magnetization device using the positioning element in such a way that the magnetic poles of the permanent magnet are aligned in the correct position with respect to the magnet coils of the magnetization device. Each magnetic pole in the magnetization device is magnetized taking into account the impressed magnetic pre-alignment.

The rotor sleeve of the rotor is preferably made of metal, preferably a non-magnetic and corrosion-resistant metal.

The invention also relates to a method for producing a rotor for a permanent magnetically excited electrical machine using a rotor sleeve, a hollow cylindrical anisotropic and multi-pole permanent magnet and a shaft, the rotor sleeve and / or the permanent magnet and / or the shaft and / or the injection molding material of the Rotor is provided with at least one positioning element and the positioning element is aligned with respect to the angular position of the magnetic poles of the permanent magnet.

• Anordnen des Permanentmagneten in der Rotorhülse derart, dass die Magnetpole des Permanentmagneten mittels mindestens eines am Permanentmagnet und/oder der Rotorhülse angeordneten Positionierungselements in Umfangsrichtung lagerichtig zur Rotorhülse ausgerichtet sind,
• Einlegen der Anordnung von Rotorhülse und Permanentmagnet in eine Spritzgussform derart, dass die Magnetpole des Permanentmagneten mittels mindestens eines am Permanentmagneten und/oder der Rotorhülse angeordneten Positionierungselements in Bezug auf die Spritzgussform in Umfangsrichtung lagerrichtig ausgerichtet sind,
• Einlegen der Welle in die Spritzgussform derart, dass die Welle durch die Anordnung von Rotorhülse und Permanentmagnet konzentrisch hindurchgeführt ist,
• Füllen von Zwischenräumen zwischen der Rotorhülse, dem Permanentmagneten und der Welle mit einem Spritzgussmaterial, sodass Rotorhülse, Permanentmagnet und Welle zu einem Rotor verbunden werden,
• Einlegen des Rotors in eine Magnetisierungsvorrichtung derart, dass die Magnetpole des Permanentmagneten mit Hilfe mindestens eines an der Rotorhülse und/oder dem Spritzgussmaterial angeordneten Positionierungselements in Bezug auf die Magnetisierungsvorrichtung in Umfangsrichtung ausgerichtet sind, und Magnetisieren des Permanentmagneten des Rotors in der Magnetisierungsvorrichtung.

In a preferred embodiment of the invention, the method has the following steps:

• Arranging the permanent magnet in the rotor sleeve in such a way that the magnetic poles of the permanent magnet are aligned with the rotor sleeve in the correct position in the circumferential direction by means of at least one positioning element arranged on the permanent magnet and / or the rotor sleeve,
• Insertion of the arrangement of rotor sleeve and permanent magnet into an injection mold in such a way that the magnetic poles of the permanent magnet are aligned in the correct position in the circumferential direction by means of at least one positioning element arranged on the permanent magnet and / or the rotor sleeve in relation to the injection mold,
• Insertion of the shaft into the injection mold in such a way that the shaft is guided concentrically through the arrangement of rotor sleeve and permanent magnet,
• Filling the gaps between the rotor sleeve, the permanent magnet and the shaft with an injection molding material so that the rotor sleeve, permanent magnet and shaft are connected to form a rotor,
• Insertion of the rotor into a magnetization device in such a way that the magnetic poles of the permanent magnet are aligned with the magnetization device in the circumferential direction with the aid of at least one positioning element arranged on the rotor sleeve and / or the injection molding material, and magnetization of the permanent magnet of the rotor in the magnetization device.

The method according to the invention ensures that the permanent magnet, which is already pre-magnetized during its production, and its magnetic poles are initially connected in the correct position to the other rotor components, in particular the rotor sleeve, and that the overmolding or filling of the rotor spaces with injection molding material is also in the correct position in relation to the Magnetic poles of the permanent magnet takes place and that the rotor is designed and the permanent magnet is arranged with its magnetic poles in the rotor in such a way that the rotor can be placed in the correct position in a magnetization device. In the magnetization device, the pre-magnetized magnetic poles of the permanent magnet receive their final magnetization, the rotor in the magnetization device being aligned in accordance with the preferred direction of the pre-magnetization of the magnetic poles.

A projection, a recess, a flat or a combination of these features can be used as a positioning element on the components of the rotor including the injection molding material. The positioning element on the components interacts with a corresponding positioning element in the magnetization device.

The positioning element is preferably arranged on at least one of the two end faces of the rotor, the rotor components, the injection molding material and / or an inner and / or outer peripheral surface of one of the rotor components or the injection molding material.

• 1A zeigt einen Längsschnitt durch eine Rotorhülse gemäß der Erfindung.
• 1B zeigt die Vorderansicht der Rotorhülse von 1A.
• 2A zeigt eine Seitenansicht eines Permanentmagneten gemäß der Erfindung.
• 2B zeigt eine Vorderansicht des Permanentmagneten von 2A.
• 2C zeigt eine Rückansicht des Permanentmagneten von 2A.
• 3A zeigt einen Längsschnitt durch den Zusammenbau der Rotorhülse und des Permanentmagneten.
• 3B zeigt eine Vorderansicht auf den Zusammenbau in 3A.
• 3C zeigt eine Rückansicht des Zusammenbaus von 3A.
• 4A zeigt einen Längsschnitt durch den fertigen Rotor gemäß der Erfindung.
• 4B zeigt eine Vorderansicht auf den Rotor von 4A.
• 4C zeigt eine Rückansicht des Rotors von 4A.
• 4D zeigt eine Seitenansicht des Rotors von 4A.
• 5A zeigt einen Längsschnitt durch eine Rotorhülse gemäß einer zweiten Ausgestaltung der Erfindung.
• 5B zeigt eine Vorderansicht der Rotorhülse von 5A.
• 5C zeigt eine Rückansicht der Rotorhülse von 5A.
• 6 zeigt einen Permanentmagneten gemäß einer zweiten Ausgestaltung der Erfindung.
• 7 zeigt einen Teil einer Spritzgussform.
• 8A zeigt eine Rückansicht der in die Spritzgussform eingelegten Rotorhülse.
• 8B zeigt einen Schnitt durch die in die Spritzgussform eingelegte Rotorhülse.
• 9A zeigt eine Rückansicht des in die Spritzgussform eingelegten Zusammenbaus der Rotorhülse und des Permanentmagneten.
• 9B zeigt einen Schnitt durch den in die Spritzgussform eingelegten Zusammenbaus der Rotorhülse und des Permanentmagneten.
• 10 zeigt einen Schnitt durch die in die Spritzgussform eingelegte Rotorhülse, den Permanentmagneten und die Welle.
• 11A zeigt eine Vorderansicht des fertigen Rotors gemäß der zweiten Ausgestaltung der Erfindung.
• 11B zeigt einen Schnitt entlang der Linie BB von 11A.
• 11C zeigt einen Schnitt entlang der Linie CC von 11A.
• 12 zeigt einen Schnitt durch einen Elektromotor gemäß der Erfindung.

The invention is described in more detail below with reference to the drawings, further features and advantages of the invention becoming apparent.

• 1A shows a longitudinal section through a rotor sleeve according to the invention.
• 1B FIG. 14 shows the front view of the rotor sleeve of FIG 1A .
• 2A shows a side view of a permanent magnet according to the invention.
• 2 B FIG. 13 shows a front view of the permanent magnet of FIG 2A .
• 2C FIG. 13 shows a rear view of the permanent magnet of FIG 2A .
• 3A shows a longitudinal section through the assembly of the rotor sleeve and the permanent magnet.
• 3B Fig. 13 shows a front view of the assembly in fig 3A .
• 3C FIG. 13 shows a rear view of the assembly of FIG 3A .
• 4A shows a longitudinal section through the finished rotor according to the invention.
• 4B FIG. 13 shows a front view of the rotor from FIG 4A .
• 4C FIG. 14 shows a rear view of the rotor of FIG 4A .
• 4D FIG. 14 shows a side view of the rotor of FIG 4A .
• 5A shows a longitudinal section through a rotor sleeve according to a second embodiment of the invention.
• 5B FIG. 13 shows a front view of the rotor sleeve of FIG 5A .
• 5C FIG. 14 shows a rear view of the rotor sleeve of FIG 5A .
• 6th shows a permanent magnet according to a second embodiment of the invention.
• 7th shows part of an injection mold.
• 8A shows a rear view of the rotor sleeve inserted into the injection mold.
• 8B shows a section through the rotor sleeve inserted into the injection mold.
• 9A shows a rear view of the assembly of the rotor sleeve and the permanent magnet inserted into the injection mold.
• 9B shows a section through the assembly of the rotor sleeve and the permanent magnet placed in the injection mold.
• 10 shows a section through the rotor sleeve inserted into the injection mold, the permanent magnet and the shaft.
• 11A shows a front view of the finished rotor according to the second embodiment of the invention.
• 11B FIG. 6 shows a section along the line BB from FIG 11A .
• 11C FIG. 13 shows a section along the line CC of FIG 11A .
• 12th shows a section through an electric motor according to the invention.

1A shows a section through a first embodiment of a rotor sleeve 10 as part of a rotor according to the invention. The rotor sleeve 10 is cup-shaped and has a circumferential edge on its open side 12th on.

How to get in the 1B recognizes, includes the edge 12th the rotor sleeve 10 two, preferably at an angle of 180 degrees opposite, radially extending slots 14th . The slots 14th can also include a different angle between them, and there can also be more or less than two slots 14th to be available.

The bottom of the rotor sleeve 10 has an opening 16 on, which is about half the diameter of the rotor sleeve 10 has, wherein the opening is preferably circular.

The opening points at its edge 16 two approximately semicircular indentations opposite each other at an angle of 180 degrees 18th on that in terms of the slots 14th of the edge 12th the rotor sleeve 10 are aligned. The indentations 18th are each at the same circumferential angle as the slots 14th . The indentations 18th can also include a different angle between them, and there can also be more or fewer than two indentations 18th to be available. The number and the angular spacing of the indentations 18th can with the number of slots 14th match, but does not have to.

The rotor sleeve 10 consists preferably of a non-magnetic and corrosion-resistant metal or of plastic.

2A shows a side view of a permanent magnet 20th according to the invention, which is designed as a hollow cylindrical ring magnet and a central opening 22nd exhibits, as from the 2 B and 2C can be seen.

Like from the front view of the permanent magnet 20th according to 2 B can be seen are on the front face of the permanent magnet 20th , preferably at the edge of the opening 22nd , two projections lying opposite each other preferably at an angle of 180 degrees 24 arranged in the axial direction from the end face of the permanent magnet 20th protrude. The protrusions 24 can also include a different angle between them, and there can also be more or less than two projections 24 to be available. The number and angular spacing of the protrusions 24 preferably corresponds to the number and the angular spacing of the indentations 18th at the opening 16 at the bottom of the rotor sleeve 10 .

As can be seen from the rear view of the permanent magnet 20th according to 2C results, there are also two projections, preferably at an angle of 180 degrees, opposite one another on the rear face 26th arranged, which can, for example, have a slightly greater axial length than the projections 24 on the front face of the permanent magnet 20th .

The protrusions 24 and 26th on the permanent magnet 20th are each on the same circumferential angle of the permanent magnet 20th arranged, but preferably not on the same radius.

The permanent magnet 20th consists preferably of anisotropic magnetic material bound in plastic and is manufactured in an injection molding process.

The magnetic material has a preferred magnetic direction, which is achieved during the injection molding process by magnetically pre-aligning the magnetic material.

In the example shown is the ring magnet 20th magnetized in the circumferential direction with six magnetic poles, as in the 2 B and 2C is indicated. The six magnetic poles are each at an angle of 60 degrees around the circumference of the permanent magnet 20th arranged distributed. The magnetic poles are with respect to the protrusions 24 , 26th aligned in the circumferential direction.

A magnetic north pole is, for example, at the same circumferential angle as one of the projections 24 , 26th , and a south magnetic pole is on the same circumferential angle as the respective opposing protrusions 24 , 26th which are at an angle of 180 degrees opposite to the above magnetic north pole.

3A shows a longitudinal section through the assembly of the rotor sleeve 10 and the permanent magnet 20th .

The outside diameter of the cylindrical permanent magnet 20th is slightly larger than the inner diameter of the rotor sleeve 10 , so that the two parts can preferably be joined together by means of an interference fit by using the permanent magnet 20th into the rotor sleeve 10 is pressed in until the front face of the permanent magnet 20th on the bottom surface of the rotor sleeve 10 is applied.

The one on the front face of the permanent magnet 20th existing in cross-section semicircular projections 24 fit into the semicircular indentations 18th on the perimeter of the opening 16 on the bottom surface of the rotor sleeve 10 and reach into these indentations 18th one.

The protrusions 24 , 26th on the end faces of the permanent magnet 20th preferably have a semicircular shape in cross section, or they can also be rectangular or polygonal. This applies accordingly to the indentations 18th on the bottom surface of the rotor sleeve 10 .

The protrusions 24 on the permanent magnet 20th cause together with the indentations 18th the rotor sleeve a positioning of the permanent magnet 20th in the circumferential direction with respect to the rotor sleeve 10 so that the permanent magnet 20th and in particular its magnetic poles in a defined installation position in the circumferential direction with respect to the rotor sleeve 10 are aligned.

It doesn't matter if the permanent magnet 20th in a position rotated by 180 degrees into the rotor sleeve 10 is inserted as the rotor sleeve 10 to one of the indentations 18th intersecting plane of symmetry is formed symmetrically. The length of the rotor sleeve 10 is greater than the length of the permanent magnet 20th so that the protrusions 26th on the rear face of the permanent magnet 20th inside the rotor sleeve 10 are located and on the inner circumference of the rotor sleeve 10 abut, the projections 26th an axial distance to the outer edge 12th the rotor sleeve 10 exhibit.

In the front view in 3B you can see that the protrusions 24 of the permanent magnet 20th precisely fitting into the indentations 18th the rotor sleeve 10 intervene, causing the permanent magnet 20th in the rotor sleeve 10 is oriented so that the magnetic poles are exactly at an angle with the slots 14th of the edge 12th the rotor sleeve 10 are aligned. For example, a magnetic north pole and a magnetic south pole lie on the same circumferential angle as each of the slots 14th .

In 3C you can see that the protrusions 26th on the rear face of the permanent magnet 20th also in relation to a respective north magnetic pole and a south magnetic pole and also in relation to the slots 14th the rotor sleeve 10 are aligned.

4A shows a section through the overall assembly of the rotor according to the invention 50 .

This was done by assembling the rotor sleeve 10 and the permanent magnet 20th placed in an injection mold and, for example, by means of the two projections 24 aligned on the front face of the permanent magnet in the injection mold. An orientation of the assembly of the rotor sleeve 10 and the permanent magnet in the injection mold by means of the on the edge 12th the rotor sleeve 10 arranged slots 14th is also possible.

After that there will be a wave 30th by assembling the rotor sleeve 10 and the permanent magnet 20th inserted through and to the central opening 22nd of the permanent magnet 20th centered with both ends of the shaft 30th from assembling the rotor sleeve 10 and permanent magnet 20th stand out.

Eventually there will be gaps between the shaft 30th , the ring magnet 20th and the rotor sleeve 10 with an injection molding material 40 filled.

The injection mold is designed so that, among other things, the space between the shaft 30th and the opening on the bottom 16 the rotor sleeve with injection molding material 40 is filled out. On the front of the rotor 50 , i.e. in the area of the bottom of the rotor sleeve 10 , becomes a disc-shaped protrusion 42 made of injection molding material 40 formed in 4B can be seen in frontal view. The protrusions 24 of the rotor magnet 20th are made of injection molding material 40 surround and are preferably no longer visible.

The disc-shaped protrusion 42 made of injection molding material 40 is approximately circular disk-shaped and preferably has two flat areas on the outer circumference 44 facing each other at an angle of 180 degrees.

The rotor components are placed in the injection mold and aligned in such a way that the flats 44 des made of injection-molded material 40 formed disc-shaped projection 42 90 degrees opposite the slots 14th the rotor sleeve 10 are rotated.

That means the flats 44 of the disc-shaped projection 42 due to the alignment with respect to the rotor sleeve 10 also in relation to the magnetic poles of the permanent magnet 20th of the rotor 50 are aligned. The wave 30th is made of injection molding material 40 surround and protrudes above the surface of the disc-shaped projection 42 out.

4C shows the rear view of the finished rotor 50 , with the wave 30th and the inner peripheral surface of the permanent magnet 20th of injection molding material 40 are surrounded as well as the Ledges 26th of the permanent magnet 20th . Besides, the edge is 12th the rotor sleeve 10 with injection molding material 40 encased, however, the slots 14th preferably remain free of injection molding material. The slots 14th and / or the flats 44 on the injection molding material 40 serve for the subsequent positioning of the rotor 50 in a magnetizing device.

4D Figure 3 shows a side view of the completed rotor 50 .

The wave 30th can be flattened on one or both sides 32 have in relation to the magnetic poles of the permanent magnet 20th can, but need not be aligned.

A second embodiment of the invention is in the 5A until 11C shown.

5A shows a longitudinal section through a rotor sleeve 110 , which is constructed similarly to the rotor sleeve of the previous embodiment.

The rotor sleeve 110 is cup-shaped and has an open end with a circumferential edge 112 as well as a closed end with a bottom surface, which according to the 5B and 5C a central, roughly circular opening 116 having.

The surrounding edge 112 has two slots facing each other at an angle of 180 degrees 114 on. The slots 114 are in the radial direction in the edge 112 brought in.

On the perimeter of the circular opening 116 in the bottom of the rotor sleeve 110 are opposite semicircular indentations at an angle of 180 degrees 118 intended.

Perpendicular to the line connecting the two semicircular indentations 118 points the opening 116 two approximately rectangular recesses on its circumference 117 on.

The radially outer straight edges of these recesses 117 wise tongues 119 on by the bottom surface of the rotor sleeve 110 at an angle of about 90 degrees towards the interior of the rotor sleeve 110 are bent and into the interior of the rotor sleeve 110 stretch in.

In 6th is the one for the rotor sleeve 110 matching cylindrical ring magnet 120 shown, which has an approximately cylindrical central opening 122 having the inner peripheral surface of the opening 122 two flats facing each other at an angle of 180 degrees 124 having. The ring magnet 120 is pre-magnetized and has, for example, six magnetic poles, each at an angle of 60 degrees over the circumference of the permanent magnet 120 are arranged distributed. The magnetic poles are in 6th indicated.

The flats 124 on the peripheral surface of the opening 122 are oriented so that, for example, a north pole and a south pole of the permanent magnet 120 is assigned to one of the opposing flat areas.

7th shows part of an injection mold 160 , which has a central hole as an opening 162 and an approximately annular disk-shaped recess arranged concentrically therewith 164 .

The annular disc-shaped recess 164 forms an annular bottom surface, with two pins opposite each other at an angle of 180 degrees about half the diameter of the bottom surface 166 protrude from this floor area.

At the same circumferential angle as these pins 166 are located on the outer peripheral surface of the annular disk-shaped recess 164 slight indentations 168 .

8A Figure 13 shows a rear view of the rotor sleeve 110 that is in the injection mold 160 is inserted.

The pencils 166 of the injection mold fit exactly into the indentations 118 at the edge of the opening 116 in the bottom surface of the rotor sleeve 110 so that the rotor sleeve 110 in terms of the injection mold 160 is positioned and aligned.

It does not matter whether the rotor sleeve 110 in a position rotated by 180 degrees into the injection mold 160 is inserted because the rotor sleeve 110 to one of the indentations 118 intersecting plane of symmetry is formed symmetrically.

8B shows a longitudinal section of the injection mold 160 inserted rotor sleeve 110 . It can be seen that the bottom surface of the rotor sleeve 110 rests on the surface of the injection mold. The annular disc-shaped recess 164 in the injection mold 160 is below and concentric to the opening 116 in the bottom surface of the rotor sleeve 110 arranged. Between the injection mold 160 and the bottom of the rotor sleeve 110 there remains a space created by the depression 164 in the injection mold 160 is formed.

9A shows another step in the manufacture of the rotor 150 where the permanent magnet 120 into the one in the injection mold 160 positioned rotor sleeve 110 is inserted or pressed in.

The permanent magnet 120 has a slightly larger outer diameter than the inner diameter of the rotor sleeve 110 .

This allows the permanent magnet 120 into the rotor sleeve 110 are pressed in so far that the face of the permanent magnet 120 on the inner bottom surface of the rotor sleeve 110 is applied.

The tongues 119 on the bottom surface of the rotor sleeve 110 are dimensioned and arranged such that they are located on the inner circumference of the opening 122 of the ring magnet 120 invest. An alignment of the permanent magnet 120 in relation to the rotor sleeve 110 and the injection mold 116 takes place in that the rotor magnet is only pressed into the rotor sleeve in such a way that the tongues are attached 119 the rotor sleeve 110 on the inside of the flats 124 of the permanent magnet 120 invest.

This will make the magnetic poles of the permanent magnet 120 in relation to the tongues 119 the rotor sleeve 110 and consequently in relation to the rotor sleeve 110 precisely aligned.

The magnetic poles of the permanent magnet are also aligned at precise angles 120 in terms of the injection mold 160 , because the rotor sleeve 110 already in terms of the injection mold 160 was aligned. 10 shows a longitudinal section of the injection mold 160 inserted rotor sleeve 110 including that in the rotor sleeve 110 fixed permanent magnets 120 and a wave 130 coming through the central opening 122 of the permanent magnet 120 is passed through and aligned concentrically to this. An end to the wave 130 extends through the central opening 162 the injection mold 160 while the other end of the shaft 130 over the open end of the rotor sleeve 110 protrudes.

In the 10 Arrangement of the rotor components shown 110 , 120 and 130 is now in the injection mold 160 with an injection molding material 140 encapsulated, and there are gaps between the rotor components 110 , 120 , 130 with the injection molding material 140 (not shown) filled.

An injection mold similar to the injection mold 160 can also be used for the in the 1A until 4D illustrated rotor 50 be used. In this case, the injection mold 160 for positioning the arrangement of the rotor sleeve 10 and permanent magnet 20th ( 3A) instead of the pens 16 corresponding holes in which the projections 24 of the permanent magnet 20th engage and the the arrangement of the rotor sleeve 10 and permanent magnet 20th Align in the correct position in the injection mold.

A finished rotor component results after the injection molding process 150 like it in the 11A until 11C is shown.

11A Figure 3 shows a front view of the rotor 150 with the rotor sleeve 110 and the wave 130 , the gap between the rotor sleeve 110 or the opening 116 in the bottom surface of the rotor sleeve 110 and the wave 130 with injection molding material 140 is filled.

The permanent magnet 120 can no longer be seen after the injection molding process because it is in the rotor sleeve 110 added and made of injection molding material 140 is surrounded.

The injection molding material 140 forms on the front of the rotor sleeve 110 an elevation in the form of a disk-shaped projection 142 , which in its cross-sectional shape the shape of the opening 116 the bottom surface of the rotor sleeve 110 including the rectangular recesses 117 and indentations 118 is equivalent to.

The protruding area 142 of the injection molding material 140 has two opposite parallel flat sides in the form of flats 144 on the flat sides of the rectangular recesses 117 the rotor sleeve 110 correspond. Hence the flats 144 of the protrusion 142 of the injection molding material 140 with respect to the magnetic poles of the permanent magnet 120 aligned, ie a north pole and a south pole are each located on the same circumferential angle as a respective flat 144 of the injection molding material 140 .

11B shows a section through the rotor 150 along the line BB of 11A , taking the rotor sleeve 110 , the permanent magnet 120 and the wave 130 and detects the gaps between these components through the injection molding material 140 are filled.

The one through the injection molding material 140 formed disc-shaped projection 142 can be seen.

11C shows a section of the rotor rotated by 90 degrees 150 along the line CC in 11A with rotor sleeve 110 , Permanent magnet 120 , Wave 130 and the injection molding material filling the spaces 140 .

It can be seen that in the injection molding material opposing depressions at an angle of 180 degrees 146 are arranged by the pins 166 on the injection mold 160 were generated. These pens 166 are in relation to the magnetic poles of the rotor 150 aligned.

As positioning elements of the rotor 150 in relation to the magnetic poles of the permanent magnet 120 can be aligned, both the flats 144 of the injection molding material 140 as well as the depressions 146 Used in the injection molding material that is 90 degrees to the flats 144 are arranged twisted. Furthermore, the positioning elements on the edge 112 the rotor sleeve 110 existing slots 114 be used.

All of these positioning elements 114 , 144 and 146 are aligned with respect to the magnetic poles and in a certain angular position with respect to the magnetic poles of the rotor 150 arranged.

The wave 130 can, but does not have to be aligned with respect to the magnetic poles, for example by having a flattened shaft end 132 , which is oriented at a certain angle with respect to the magnetic poles.

At least one of these positioning elements 114 , 144 , 146 or 132 showing the orientation of the magnetic poles of the permanent magnet 120 are shown below for the alignment of the rotor 150 Used in a magnetization device to make a final magnetization of the magnetic poles of the permanent magnet 120 of the rotor 150 perform.

12th shows an electric motor with one according to the invention with a rotor 50 , the one with injection molding material 40 surrounded permanent magnets 20th having. Such an electric motor can be used, for example, to drive a gasoline pump.

List of reference symbols

10

Rotor sleeve

12th

edge

14th

slot

16

opening

18th

indentation

20th

Permanent magnet

22nd

opening

24

head Start

26th

head Start

30th

wave

32

Flattening of the shaft

40

Injection molding material

42

disc-shaped projection

44

Flattening

50

rotor

60

Electric motor

110

Rotor sleeve

112

edge

114

slot

116

opening

117

Recess

118

indentation

119

tongue

120

Permanent magnet

122

opening

124

Flattening

130

wave

132

Flattening of the shaft

140

Injection molding material

142

disc-shaped projection

144

Flattening

146

deepening

150

rotor

160

Injection mold

162

opening

164

deepening

166

pen

168

indentation

QUOTES INCLUDED IN THE DESCRIPTION

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Patent literature cited

• DE 102008053233 A1 [0005]
• DE 102011105324 A1 [0005]
• DE 102013007563 A1 [0005]

Claims (15)

Rotor (50, 150) for an electrical machine excited by permanent magnets, with a rotor sleeve (10, 110), an annular, anisotropic and multi-pole permanent magnet (20, 120) accommodated in the rotor sleeve (10, 110) and one concentric to the permanent magnet (20 , 120) and the rotor sleeve (10, 110) arranged shaft (30, 130), with gaps between the rotor sleeve (10, 110), the permanent magnet (20, 120) and the shaft (30, 130) in an injection mold (160 ) filled with injection molding material (40, 140) by using an injection molding process and the components are thereby non-rotatably connected to one another, characterized in that on the rotor sleeve (10, 110) and / or on the permanent magnet (20, 120) and / or on the Shaft (30, 130) and / or on the injection molding material (40, 140) at least one positioning element (14, 18, 24, 26, 32, 44, 114, 118, 119, 132, 144, 146) is arranged, which in Relation to the angular position of the magnetic poles of the permanent magnet (20, 120) is aligned. Rotor after Claim 1 , characterized in that at least one positioning element (24, 26, 124) for the correct positioning of the permanent magnet (20, 120) in the rotor sleeve (10 , 110) and / or is arranged in the injection mold (160), and / or that at least one positioning element (14, 114, 18, 118, 119) for the correct positioning of the permanent magnet (20, 120) in the rotor sleeve (10, 110) and / or at least one positioning element (14, 114, 18, 118) for the correct positioning of the rotor sleeve (10, 110) in the injection mold (160 ) is arranged. Rotor after one of the Claims 1 or 2 , characterized in that the positioning element (24, 26, 124) on the permanent magnet (20, 120) is designed in the form of a projection (24, 26) and / or in the form of a recess and / or a flat (124). Rotor after one of the Claims 1 until 3 , characterized in that the positioning element (14, 114, 18, 118) on the rotor sleeve (10, 110) is designed in the form of an indentation (18, 118) and / or slots (14, 114) and / or a flattening. Rotor after one of the Claims 1 until 4th , characterized in that the positioning element (24, 26, 124) on the permanent magnet (20, 120) interacts with a positioning element (18, 119) on the rotor sleeve (10, 110) and / or on a positioning element on the injection mold (160) . Rotor after one of the Claims 1 until 5 , characterized in that the positioning element (14, 114, 118) on the rotor sleeve (10, 110) interacts with a positioning element (166) on the injection mold (160). Rotor after one of the Claims 1 until 6th , characterized in that at least one positioning element (44, 144, 146) for the correct positioning of the rotor (50, 150) in a Magnetizing device is arranged. Rotor after one of the Claims 1 until 7th , characterized in that the positioning element (44, 144, 146) is designed on the injection molding material (40, 140) of the rotor (50, 150) in the form of a projection and / or a recess and / or a flat. Rotor after one of the Claims 1 until 8th , characterized in that the positioning element (44, 144, 146) of the injection molding material (40, 140) of the rotor (50, 150) interacts with a positioning element on the magnetization device. A method for producing a rotor (50, 150) for a permanent magnetically excited electrical machine using a rotor sleeve (10, 110), an annular, anisotropic and multi-pole pre-magnetized permanent magnet (20, 120) and a shaft (30, 130), characterized that the rotor sleeve (10, 110) and / or the permanent magnet (20, 120) and / or the shaft (30, 130) and / or the injection molding material (40, 140) with at least one positioning element (14, 18, 24, 44, 114, 118, 119, 144, 146) is provided and the positioning element (14, 18, 44, 114, 118, 119, 144, 146) is aligned with respect to the angular position of the magnetic poles of the permanent magnet (20, 120) . Procedure according to Claim 10 , characterized by the steps of: arranging the permanent magnet (20, 120) in the rotor sleeve (10, 110) such that the magnetic poles of the permanent magnet (20, 120) by means of at least one on the rotor sleeve (10, 110) and / or the permanent magnet (20, 120) arranged positioning element (14, 24, 26, 114, 124, 119) are aligned in the circumferential direction in the correct position to the rotor sleeve (10, 110), Insertion of the arrangement of rotor sleeve (10, 110) and permanent magnet (20, 120) into an injection mold (160) in such a way that the magnetic poles of the permanent magnet (20, 120) by means of at least one on the permanent magnet (20, 120) and / or the rotor sleeve (10, 110) arranged positioning element (14, 24, 44, 114, 118, 144) are aligned in the correct position in the circumferential direction in relation to the injection mold (160), inserting the shaft (30, 130) into the injection mold in such a way that the shaft (30, 130) is passed concentrically through the arrangement of rotor sleeve (10, 110) and permanent magnet (20, 120), filling of gaps between the rotor sleeve (10, 110), the permanent magnet (20, 120) and the shaft (30 , 130) with an injection molding material (40, 140), so that the rotor sleeve (10, 110), permanent magnet (20, 120) and shaft (30, 130) are connected to form a rotor (50, 150), inserting the rotor (50, 150) in a magnetization device in such a way that the magnetic poles of the permanent magnet (20, 12 0) of the rotor (50, 150) with the aid of at least one positioning element (14, 44, 114, 144, 146) arranged on the rotor sleeve (10, 110) and / or the injection molding material (40, 140) in relation to the magnetization device in Are aligned circumferentially, and magnetizing the permanent magnet (20, 120) of the rotor (50, 150) in the magnetizing device. Method according to one of the Claims 10 or 11th , characterized in that a projection and / or a recess and / or a flat is used as the positioning element (14, 24, 44, 114, 124, 144, 146, 166), which is located on at least one end face or an inner and / or outer peripheral surface of the permanent magnet (20, 120) and / or the rotor sleeve (10, 110) and / or the injection molding material (40, 140) and / or the injection mold (160) is arranged. Method for magnetizing a rotor (50, 150) of an electrical machine, characterized in that a rotor (50, 150) according to one of the Claims 1 until 10 is used. Procedure according to Claim 12 , characterized in that at least one positioning element (14, 44, 114, 144, 146) present on the rotor (50, 150) is used to align the magnetic poles of the rotor (50, 150) with respect to magnetizing coils of the magnetizing device. Electric motor with a rotor according to one of the Claims 1 until 9 .

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