DE102020216115A1 - Process for processing at least one component of an electrical machine - Google Patents

Abstract

Method for processing at least one component of an electrical machine, in particular a pancake motor, wherein in a partially assembled state in which at least two components of the electrical machine are assembled to form a subassembly (3, 14, 15), a material thickness in at least one area of the subassembly (3 , 14, 15) of the electrical machine, in particular in the area of an air gap (8) between the rotor (4) and stator (9), is removed in a defined manner.

Description

The invention relates to a method for processing at least one component of an electrical machine, in particular a disk motor, for example for use in a motor vehicle.

Methods for processing components of electrical machines are known in principle from the prior art. For example, it is known to manufacture and process individual components of the electrical machine separately and then to join them together during the manufacture of the electrical machine. Furthermore, it is known that each of the individual components has a certain tolerance, which arises, for example, as a result of production or as a result of the assembly process.

In unfavorable circumstances, individual deviations of individual components in the assembled state can increase or a certain tolerance range must be maintained for each of the individual components, so that reliable functioning of the electric machine is guaranteed even under unfavorable tolerance conditions or groupings of components with corresponding deviations. For example, such a tolerance can affect the air gap between the rotor and stator in the electrical machine, for example the air gap between the rotor and stator in a pancake motor. Both the rotor and the stator can be manufactured as separate individual parts and checked for their dimensional accuracy. These two parts are then joined together so that a combination of the individual tolerances and the influence of the assembly must be taken into account, both due to production and assembly.

Due to the large number of parts and the possible deviations caused by production and assembly, there are a large number of possible combinations, so that individual dimensions, orientations or gap dimensions are difficult to adhere to exactly or corresponding gaps or distance dimensions have to be designed larger than necessary.

The invention is based on the object of specifying a method for machining at least one component of an electrical machine that is improved in comparison thereto.

The object is achieved by a method having the features of claim 1. Advantageous configurations are the subject matter of the dependent claims.

The method for processing at least one component of an electrical machine described in this application can also be referred to as a method for producing an electrical machine or at least one subassembly of an electrical machine, since ultimately an electrical machine is to be produced, the processing of the at least a component or subgroup a specific tolerance or distance, orientation or the like is to be set.

As described above, the invention relates to a method for machining at least one component of an electrical machine, in particular a disc motor. The invention is based on the finding that in a partially assembled state in which at least two components of the electrical machine are assembled to form a subassembly, a material thickness is removed in a defined manner in at least one area of the subassembly of the electrical machine, in particular in the area of an air gap between the rotor and stator becomes.

The present invention therefore proposes, in deviation from an individual processing of each component, first of all adopt or produce a partial assembly state in which at least two components are already joined together and form a subassembly. The two components are thus assembled into the subassembly, which subassembly forms part of the finished electrical machine. By assuming or producing the partial assembly state, influences on the tolerances of the individual components that can result from the corresponding assembly process are already assumed or excluded, since the assembly of the at least two components into the subassembly has already been completed and therefore no influences on the further tolerances has more. In other words, it is proposed that the material thickness should only be removed in a defined manner when the at least two components are assembled to form the subassembly, instead of machining each individual component prior to assembly by removing the defined material thickness to its nominal dimensions.

Thus, among other things, a distance dimension, a thickness and/or an evenness of the subgroup can be processed or adjusted and set in a targeted manner by a material thickness being removed in a defined manner in order to achieve the corresponding dimension. For example, a defined air gap between the rotor and stator of the electrical machine can be achieved in this way by machining the rotor and/or stator at least in a partially assembled state, instead of each individual component edit separately. Here, in particular, a surface of conductor areas and/or magnet areas located on the rotor or the stator can be processed so that they have a defined evenness and/or thickness and/or a distance from one another, so that ultimately a defined air gap during operation of the electrical machine remains guaranteed. In this case, it is irrelevant whether the rotor has conductor areas or magnet areas and the stator has correspondingly, conversely, magnet areas or conductor areas. The arrangement of the magnetic areas and conductor areas on the rotor or stator can be selected or reversed as desired.

Provision can also be made here for at least two subassemblies to be processed separately or in an at least partially assembled state, in particular a partially assembled state, before the assembly of the two subassemblies. According to this embodiment, it is provided that not only can at least two components be assembled into a subassembly and thus assume a partially assembled state in order to be processed in the partially assembled state, but also at least two components already assembled into subassemblies can be processed separately or also in a partially assembled state will. In other words, each of the at least two subgroups can be processed separately before the two subgroups are assembled together, or it is also possible to first at least partially join the two subgroups and produce a partially assembled state and to carry out the machining in the partially assembled state in which the two subgroups are joined together or arranged next to each other and thus together form a new subgroup.

In the context of the description, a partial assembly state is understood to mean, in particular, a state in which the assembly in relation to the end product or the finished electrical machine has not yet been fully completed, but the two subgroups are already connected to one another or oriented relative to one another. The partially assembled state can thus be a state in which the two sub-assemblies are placed together or fully connected to one another, but the end product is not necessarily yet complete. For example, although the two subgroups may be placed next to each other, the final alignment or orientation of the subgroups may not be complete. Starting from the partially assembled state, further components can also be arranged or assembled on the subassembly.

In the partially assembled state, the two subgroups can already be in contact with one another, for example, and are therefore no longer completely separated or separately from one another. A subgroup in such a partially assembled state can in particular be a rotor already arranged on a rotor shaft, which forms a first subgroup, wherein a stator or two stator halves can form a further subgroup and have a defined arrangement in relation to the rotor shaft and the rotor arranged thereon can, but the electrical machine is not fully assembled, for example, an axial displacement of the rotor and the stator can be made or the housing can still be fully assembled and the like.

In the previously described removal of the material thickness in the at least one area, material is ground off according to a further embodiment. As described above, this can be done in the at least one conductor area and/or the at least one magnet area, which, as also described above, can be arranged optionally on the rotor or the stator. When the material thickness is removed, in particular if this is done by grinding, a partial assembly state can be selected in which the at least one magnet area is not yet magnetized or not yet completely magnetized. This is particularly useful because no magnetic chips are generated by the material removal. In any case, it is also possible to carry out a cleaning step after the material thickness has been removed, for example by blowing out and/or washing out.

According to a further embodiment of the method, it can be provided that the material is removed by means of a removal device, with a relative movement being generated between a removal element, in particular a surface of an abrasive, and the surface of the conductor area and/or magnet area. The removal device thus provides at least one removal element or has one that is brought into contact with the surface of the conductor area and/or the magnet area, with a relative movement being generated so that the removal element removes material from the surface of the conductor area and/or the magnet area can remove defined. The removal element can be designed in particular as a grinding element or have one and can be brought into contact with a surface of the grinding element with the surface of the conductor area and/or the magnetic area during the relative movement.

The relative movement can be generated on the one hand by actively moving the conductor area and/or the magnet area, for example by moving the rotor and/or Moving the stator, in particular moving the electrical machine in a partially assembled state in which the rotor is already at least partially assembled on the stator. It is also possible to move the removal element individually or in combination with the conductor area and/or the magnet area in order to remove the defined material thickness. For example, a subassembly of the rotor and stator can be moved as a whole about the axis of rotation of the rotor, so that both the conductor areas and the magnet areas move relative to the removal element. Here, the removal element can stand still or also be moved, for example in a continuous movement, for example using a belt-like grinding element.

The rotation of the sub-group of rotor and stator, which has the conductor areas and the magnet areas, ensures in particular that each area of the conductor areas and magnet areas is guided past the removal element and thus a defined resulting material thickness can be ensured over the corresponding areas. By forming the subgroup, it is again achieved that, compared to separate processing of the conductor areas and magnet areas, the partially assembled state has already been assumed, i.e. tolerances resulting from assembly are already taken into account during processing and these do not result in a change in the after processing Affect orientation or arrangement or defined dimensions of the subgroup.

According to a further embodiment, the material thickness can be removed in a conductor area of the stator or of the rotor or in a magnet area of the stator or rotor. As described above, any choice of conductor areas and magnet areas is possible, so that they can be arranged either on the stator or on the rotor. By removing the material thickness, it is ensured that the conductor area and magnet area have the desired dimensions, so that the rotor can be oriented with a defined air gap to the stator. By forming the subgroups, in particular a subgroup in which the stator is already arranged on the rotor shaft and the air gap forms in a defined manner, it can be ensured that the defined material thickness is removed in such a way that the air gap is maintained in a defined manner. Here, the air gap is created through defined machining of the partially assembled subassemblies or it is ensured that this is maintained, so that it is not necessary to machine the individual components separately and then join them.

The at least one subgroup can also be contacted to remove the material thickness on at least one bearing and/or on a flange by means of a receiving device of a removal device. As previously described, the subassembly can be formed by assembling at least two components together. Here, the subassembly can be contacted on at least one bearing and/or on at least one flange by means of a receiving device of a removal device. The receiving device can, for example, clamp or otherwise accommodate the bearing or the flange of the subassembly and thus ensure a defined orientation and positioning of the subassembly. For example, the subassembly can be the already partially assembled rotor, the rotor bearing of which can be clamped in the receiving device. Such a saving or inclusion makes it easier for the removal device to rotate the rotor about the rotor shaft in order to remove the material thickness, in particular when contacting a removal element.

For this purpose, it can be provided that, in order to remove the material thickness, a removal element, in particular having two removal surfaces, is introduced into the air gap between the conductor area and the magnet area, in particular in both air gaps between the two conductor areas and the two magnet areas, and a relative movement is generated. As previously described, the rotor may have conductive portions or magnetic portions and the stator may have magnetic portions or conductive portions, respectively. The rotor is designed in such a way that it has conductor areas or magnet areas on its disk-like upper side and underside, i.e. those surfaces which are essentially perpendicular to the axis of rotation, and the two stator halves have magnetic areas or conductor areas corresponding to the rotor. The rotor rotates in the electrical machine accordingly, forming an air gap with respect to the stator, so that the air gap ultimately forms between the conductor areas and magnet areas. A removal element can be specifically introduced into this air gap for processing the subassembly, so that the relative movement between the removal element and the conductor area and magnet area can remove material that protrudes beyond the defined air gap.

In particular, a removal element having two removal surfaces can be used, for example a double-sided grinding element, which simultaneously contacts the magnet area and the conductor area in the same air gap. Two such removal elements can be used here so that both air gaps, i.e. between the top (first) stator half and the top (first side) of the rotor and the bottom (second) stator half and the bottom (second side) of the rotor, can be adjusted at the same time. When adapting or removing the material thickness, the defined air gap between rotor and stator can be set in a targeted manner and by generating the relative movement between the removal element and the magnetic areas and the conductor areas, material can be removed in such a way that the air gap is reached in a targeted manner. If the air gap has already been reached or if the air gap has already formed, no further removal of material takes place, so that the processing also includes checking the existing material thickness.

Here it is possible to move the removal element, the magnetic area, the conductor area or any combination relative to one another. It is also possible to exert a defined contact pressure on the individual components so that they are pressed against the removal element in order to improve the removal of material.

According to a further embodiment of the method, it can be provided that at least two subgroups are oriented relative to one another, in particular in relation to an axis of rotation of the electrical machine, and/or are positioned by means of at least one, in particular at least three, orientation device having orientation means in an at least partially assembled state , in particular with regard to at least one radial and/or one axial air gap. The orientation device is therefore provided for allowing and purposefully setting an alignment or orientation and/or positioning of the subgroups relative to one another in the partially assembled state or a partially assembled state. In particular, the orientation device can provide at least three orientation means, for example adjusting screws received in threaded bores, which are arranged in such a way that orientation in at least three directions is possible. The adjusting screws are screwed into corresponding threaded bores which are aligned in such a way that by screwing in the adjusting screws a displacement of at least one sub-assembly to the at least one other sub-assembly is possible.

In this case, positioning or changing the orientation is possible both in the radial direction and in the axial direction. For example, the air gap between the rotor and the stator can therefore be adjusted both in the radial direction and in the axial direction. The orientation device can also be used to align the orientation of the rotor shaft in relation to the stator or a target orientation of the axis of rotation of the electrical machine. In particular, the orientation device can have adjusting screws such that a bearing can be positioned relative to the associated bearing flange, for example rotated in all three spatial directions and axially and radially displaced in all three spatial directions. For this purpose, for example, at least three threaded bores pointing axially inward and at least three threaded bores pointing radially inward and corresponding adjusting screws can be provided, which can be referred to as axial adjusting screws and radial adjusting screws.

Said adjusting screws can protrude through the associated bearing flange and thus touch either the bearing directly or a component bearing the bearing, which can be movably adjusted with the bearings, with an end face. The bearings can be moved and the working air gap between the rotor and stator can be positioned and oriented by setting the adjusting screws of the orientation device in a defined manner. In particular, spacers can be used that specify an ideal position. Once the ideal position has been reached, the adjusting screws can be fixed, in which case further components can then optionally be attached for additional fixation, for example by welding or soldering or gluing or riveting or screwing or using an outer ring which connects both stator halves to one another on the outer circumference and the air gap radially completes. The setting described can also be made without a spacer.

As described, before a final orientation and/or positioning, at least one spacer can be introduced between the at least two subgroups, the dimension of which corresponds to a target orientation and/or a target distance. The spacers can, for example, be shaped in such a way that they can be introduced into the air gap between the conductor areas and the magnet areas and thus specify the defined target distance for the air gap. Once the spacers have been introduced, the two subgroups are oriented in a defined manner relative to one another, so that the previously described orientation can then be carried out using the orientation device. Once the orientation is complete, the position taken can be fixed, as also previously described. The spacers can then be removed.

In addition to the method, the invention relates to a device for processing at least one Component of an electrical machine, in particular of a pancake motor, wherein at least one removal device having at least one removal element is provided, which can be coupled or is coupled to a drive device which is designed to cause a relative movement between a subassembly of an electric machine accommodated in a receiving device of the device and the Create Abtragelement to remove material from the subgroup.

As already described, the receiving device can receive the relevant subassembly directly on a bearing or a flange, for example a rotor bearing or a rotor flange, which is connected to the rotor shaft. In this case, it is possible, by turning the rotor shaft, to set the magnetic areas or conductor areas on the rotor in motion. Contact with a stationary or moving removal element makes it possible to grind the conductor areas or magnet areas accordingly or to remove material in general. In this case, pressure can be exerted on the rotor shaft in order to establish a defined contact with the removal element. It is also possible to machine both axial surfaces of the rotor at the same time, i.e. in particular both axial conductor areas or magnetic areas at the same time. The processing can in particular include the production of a defined flatness, as well as an adjustment of the thickness of the conductor areas or magnet areas in such a way that an air gap between the rotor and the stator can be set correctly.

The device can also be used to process magnetic areas or conductor areas located in the stator or in at least one half of the stator, in particular to remove or grind material.

In addition, the invention relates to a method for machining at least one component of an electrical machine, in particular a pancake motor, wherein in a partially assembled state in which at least two components of the electrical machine are assembled to form a subassembly, at least two such subassemblies are formed using at least one, in particular at least three, orientation means having orientation device in an at least partially assembled state are oriented relative to each other, in particular in relation to an axis of rotation of the electrical machine, and / or positioned, in particular in relation to at least one radial and / or axial air gap.

The orientation device is therefore provided for allowing and purposefully setting an alignment or orientation and/or positioning of the subgroups relative to one another in the partially assembled state or a partially assembled state. In particular, the orientation device can provide at least three orientation means, for example adjusting screws received in threaded bores, which are arranged in such a way that orientation in at least three directions is possible. The adjusting screws are screwed into corresponding threaded bores which are aligned in such a way that by screwing in the adjusting screws a displacement of at least one sub-assembly to the at least one other sub-assembly is possible. The previous description with reference to the orientation device, in particular the adjusting screws, threaded holes and spacers, can be transferred completely to this method.

In addition, the invention also relates to a device for processing at least one component of an electrical machine, in particular a disc motor, which device has at least one orientation device which is designed to align at least two subgroups, in particular by means of at least three orientation devices of the orientation device in an at least partially assembled state relative to one another to orient, in particular in relation to an axis of rotation of the electrical machine, and / or to position, in particular in relation to at least one radial and / or axial air gap.

Furthermore, the invention relates to a method for machining at least one component of an electrical machine, in particular a disc motor, wherein in a partially assembled state in which at least two components of the electrical machine are assembled to form a subassembly, a deformation force is exerted by means of at least one deformation device, in particular in an axial direction parallel deformation direction, is applied to the rotor, wherein the deformation force exceeds a plastic deformation threshold.

In addition, the invention relates to a device for machining at least one component of an electrical machine, in particular a disc motor, the device having a deformation device which is designed to apply a deformation force to the rotor, in particular in a deformation direction running parallel to the axial direction, the Deformation force exceeds a plastic deformation threshold.

The method and the device aimed at deforming the rotor also obviously contribute to flatness and runout a pancake motor or, in general, an electrical machine. Provision is made here in particular for the rotor and stator of the electrical machine to be clamped separately in a holding device in the region of the rotor shaft. In this case, the rotor and/or the stator can also be rotated about the rotor shaft. In particular, the device is assigned a detection device which is designed to detect an axial runout in the region of the rotor and/or the stator. In particular, a deviation from a target axial position or target center position of the magnetic areas and/or the conductor areas of the electrical machine. The detection device can be, for example, a dial gauge or any other type, for example in the form of an, in particular electronic, probe.

In other words, an axial deviation can be determined by which the electrical machine deviates from an ideal target center run or a target center position, in particular between the stator halves. If the rotor has an axial runout, for example, the distance between the rotor and the upper or lower stator or the upper or lower stator half changes when the rotor rotates relative to the stator. This means that the size of the air gaps is not constant over one revolution of the rotor.

This axial runout or the axial deviation can be detected by the detection device. The detection device can also be operated manually by an operator. Alternatively, it is possible to output the deviation as a control signal and to process it, in particular in an automated manner. A corresponding control signal can then be fed to the deforming device, which has, for example, two stamping devices that can be moved in the deforming direction, i.e. in a direction running essentially parallel to the axial direction, in order to contact and deform the rotor or the stator.

Ultimately, a force, namely the deformation force described, can be applied to the rotor and/or stator by the deformation device in order to deform the rotor and/or stator in a defined manner. The stamping devices described ultimately press axially (from above or below) onto the rotor or the stator in order to deform it, in particular above a defined plastic threshold at which the rotor and/or stator plastically deform. The axial deviation can therefore be "pressed out" by the deformation device. In particular, the plastic threshold can be defined in such a way that an elastic “springing back” occurs when the shaping force applied to the rotor and/or stator by the deformation device is cancelled. Ultimately, the plastic threshold must be defined in such a way that the stamp pushes the rotor and/or the stator further than the target central position requires, so that the ideal position is reached after a “spring back”. The plastic threshold can accordingly have or take into account a deformation range and an elastic range.

As described, two stamping devices can be provided, of which only one stamping device is active in each case, namely depending on the direction in which the deviation from the desired central position has to be corrected.

Of course, all the advantages, details and features that have been described in relation to the methods can be fully transferred to the devices. The individual methods and devices can be combined with one another as desired. This means in particular that each of the methods and the associated device can be carried out separately or in any combination with one or both of the other methods or devices. For example, the removal of material can be provided separately or in combination with the orientation device and/or the deformation device. Analogously, the orientation device or the deformation device can be used separately or in any combination with one of the other two devices.

• 1 einen Ausschnitt einer Vorrichtung zur Bearbeitung einer Komponente einer elektrischen Maschine nach einem ersten Ausführungsbeispiel;
• 2 einen Ausschnitt einer elektrischen Maschine;
• 3 einen Ausschnitt einer Vorrichtung zur Bearbeitung einer Komponente einer elektrischen Maschine nach einem zweiten Ausführungsbeispiel;
• 4 einen Ausschnitt einer elektrischen Maschine nach einem dritten Ausführungsbeispiel; und
• 5 die elektrische Maschine von 4 in einer perspektivischen Darstellung; und
• 6 eine Vorrichtung zur Bearbeitung einer Komponente einer elektrischen Maschine nach einem vierten Ausführungsbeispiel.

The invention is explained below using exemplary embodiments with reference to the figures. The figures are schematic representations and show:

• 1 a section of a device for processing a component of an electrical machine according to a first embodiment;
• 2 a section of an electrical machine;
• 3 a section of a device for processing a component of an electrical machine according to a second embodiment;
• 4 a section of an electrical machine according to a third embodiment; and
• 5 the electric machine of 4 in a perspective view; and
• 6 a device for machining a component of an electrical machine according to a fourth exemplary embodiment.

1 shows a device 1 for processing components of an electrical machine, for example a pancake motor. The device 1 has a receiving device 2 which is designed to receive a subassembly 3 of the electrical machine. The subassembly 3 of the electrical machine is in a partially assembled state, ie in a partially assembled state of at least two components of the electrical machine. In the embodiment shown, the subassembly 3 comprises a rotor 4 and a rotor shaft 5 already assembled together.

The receiving device 2 has a clamping device for receiving the rotor shaft 5, by means of which the rotor shaft 5 or alternatively a flange or a bearing of the rotor 4 can be clamped. Conductor areas 6 are arranged on the rotor 4 in the axial direction in relation to the axis of rotation of the rotor 4 . An air gap 8 forms between the conductor areas 6 and the stator-side magnet areas 7 in the assembled electric machine, in which the rotor 4 can rotate around the rotor shaft 5 or with the rotor shaft 5 . The air gap 8 is best in 2 shown, which shows an exemplary electrical machine. The arrangement of the conductor areas 6 and the magnet areas 7 should only be understood as an example. It is also possible that the conductor areas 6 are arranged on the stator 9 and the magnet areas 7 on the rotor 4 . The air gap 8 therefore designates the clear dimension between the surface of the rotor 4, in particular the conductor areas 6, and the respective first or second stator half of the stator 9, for example an upper and lower half of the stator 9.

The device 1 also has a removal device 10 with at least one removal element 11 , the device 1 being designed to generate a relative movement between the subgroup 3 and the removal element 11 . In the exemplary embodiment shown, the device 1 has a drive device 12 for this purpose, with the drive device 12 in the exemplary embodiment shown being coupled to the receiving device 2 only by way of example, so that the subassembly 3 received in the receiving device 2, in particular the rotor shaft 5 and the one on the rotor shaft 5 arranged rotor 4 can be rotated. In particular, it is possible to rotate the rotor shaft 5 and the rotor 4 about the axis of rotation of the rotor 4 and thus to move them relative to the removal element 11 of the removal device 10 . The relative movement between the conductor areas 6 and the removal element 11 makes it possible to remove defined material from the subassembly 3 , in particular the conductor areas 6 of the rotor 4 .

The device 1 also has a positioning device 13 which is designed to position the removal element 11 relative to the subgroup 3 in order to set the defined dimension that the subgroup 3 should have in the area in which the material is removed. For example, a defined material thickness can be set, with the device 1 removing material until the desired material thickness is reached in the relevant area. The positioning device 13 can be designed as a linear guide, for example as a spindle drive, and thus position the subgroup 3 relative to the removal element 11 .

As an alternative to the described variant, it is also possible to fix the subgroup 3 and instead to carry out a movement on the part of the removal device 10, for example by rotating or moving the at least one removal element 11 relative to the subgroup 3. A combination of the movements can also be used here the subgroup 3 and the at least one removal element 11 are performed. Furthermore, it is also possible to provide at least one removal element 11 on each axial side of the sub-assembly 3, for example in addition to the one in 1 shown variant, a further Abtragelement 11 above the rotor 4, so that both conductor areas 6 can be processed on both axial sides of the rotor 4 at the same time.

In the 1 The device 1 shown is only to be understood as an example. In particular, it is also possible to process further subgroups 3 of an electrical machine, for example to remove material in at least one area of one half of the stator 9 .

3 shows a device 1 according to a second embodiment. Basically, the benefits, details and features that are related to 1 and 2 have been described, according to the design 3 transferrable and vice versa. According to 3 a sub-group 14, which consists of two sub-groups 3, 15, is processed. The subgroup 3 has already been described above and is composed at least of the rotor 4 and the rotor shaft 5 . The sub-assembly 15 comprises at least one stator half and the magnet areas 7 which are arranged on the stator half of the stator 9 . The subassembly 14 is therefore in a partially assembled state, since the subassembly 3 and the subassembly 15 are already arranged next to one another, but the final assembled state has not yet been reached.

In 3 it can also be seen that removal elements 11 are introduced into the air gap 8 between the subgroup 3 and the subgroup 15, ie between the stator 9 and the rotor 4. In this embodiment, two removal elements 11 are introduced into the air gap 8, one of which any number of removal elements 11 can be used. As before regarding 1 has been described, a relative movement between the subassembly 14 and the removal element 11 is generated. This can be done in particular by rotating the subassembly 14 about the rotor shaft 5 . For this purpose, in particular, the subgroups 3 and 15 are fixed so that they rotate together about an axis located in the rotor shaft 5 . Alternatively or additionally, it is also possible to move the removal elements 11 relative to the subgroup 14 .

The removal elements 11 are preferably designed in such a way that each removal element 11 is double-sided, i.e. has removal surfaces on both sides. As a result, the material thickness can be adjusted or processed on the stator side and on the rotor side. The removal elements 11 can also be designed to be compressible. It is possible that a spacer is introduced between the subgroups 3, 15, i.e. in the air gap 8 or otherwise, or that the two subgroups 3, 15 are otherwise objected to, so that a target distance or a target positioning of the subgroup 14 is achieved. In this state, in particular, the processing can take place, so that material is removed from the subgroups 3, 15 until the air gap 8 is reached in a defined manner. The spacers can then be removed or the subassembly 14 can be fixed. The electrical machine can then be fully assembled or the subassembly 14 can be joined to at least one other subassembly.

the 4 and 5 12 also show a device 1 which has an orientation device 16 which is designed to orient the subassembly 3, in particular to orient a bearing 17, 18 relative to the associated bearing flange 19, 20. For this purpose, the orientation device 16 has threaded bores 23, 24 in which adjusting screws 21, 22 are accommodated. This makes it possible for the orientation of the bearings 17, 18 and the rotor shaft 5 as well as the axial and radial position of the bearings 17, 18 to be adjusted relative to the associated bearing flange 19, 20. As a result, the air gap 8, ie the magnetic working air gap of the electrical machine, can be maintained or adjusted. For this purpose, the bearings 17, 18 in particular can be rotated in all three spatial directions relative to the associated bearing flange 19, 20 and displaced axially and radially in all three spatial directions. For this purpose, the screws 21, 22 must be screwed in accordingly. In this exemplary embodiment, the device 1 can be understood as a component of the electrical machine.

It is optionally possible to introduce spacers (not shown) when adjusting the orientation device 16, for example in the air gap 8, which correspond to the clear dimension of the target air gap and thus position the rotor 4 relative to the stator 9 in its target position or in an (axial) Keep your distance. In 5 Threaded holes 23, 24 are shown into which corresponding set screws 21, 22 can be screwed in order to carry out the positioning as previously described. By screwing the adjusting screws 21, 22 into the at least three radially inward-pointing threaded bores 24 and the at least three axially inward-pointing threaded bores 23, the target position can be adjusted, in particular as long as the spacers are arranged in the air gap 8.

The adjusting screws 21, 22 protrude through the corresponding bearing flange 19, 20 and touch the bearing 17, 18 or a bearing 17, 18 bearing component which is movably connected together with the bearings 17, 18 with the end face. The adjusting screws 21, 22 can thus be tightened or fixed, so that the rotor 4 and the stator 9 are fixed in their desired position, in particular the subgroups 3, 15 are adjusted to one another. The spacers can then be removed and, if necessary, other components can be attached to fix the desired position, in particular by welding or soldering or gluing or riveting or screwing or by an outer ring that is attached to the radially outer circumference and connects both stator halves of the stator 9 to one another and thus the electrical machine closes off radially to the outside.

The methods and devices related to the 1-3 as well as the 4 , 5 described may each be used separately or in combination. In particular, the material thickness can be removed as the last step in the machining of the electrical machine, ie an orientation, as described, is carried out before the material thickness is removed. Further joining or assembly steps can follow the removal of the material thickness.

6 shows a device 1 according to a fourth embodiment. The device 1 has a deformation device 25 and a holding device 26 which is designed to accommodate, in particular to clamp, the rotor 4 together with the rotor shaft 5 . In other embodiments it is also possible to use an in 6 clamp not shown stator or individual stator halves and apply the method that is described below in relation to the rotor 4, analogously to the stator.

In this embodiment variant, the rotor 4 is clamped in the holding device 26 so that it can rotate, ie the rotor 4 is accommodated in the holding device 26 so that it can rotate about its axis of rotation. Only half of the device 1 or of the rotor 4 is shown in the figure, since it is constructed symmetrically about the axis of rotation. The deformation device 25 has two punch devices 27, each of which has a movable punch 28 and an actuator 29, with which actuator 29 the punch 28 can be moved, in particular in the direction of deformation. It is thus possible on the part of the deformation device 25 to apply a deformation force to the rotor 4 and to deform it in a targeted manner, depending on an axial deviation of the rotor 4, in particular if the rotor 4 has a so-called “axial runout”.

For example, in this exemplary embodiment, the device 1 is assigned a detection device 30 , for example a probe, which is designed to detect an axial deviation of the rotor 4 . For example, a so-called target central position of the rotor 4 lies between the two stamp devices 27. If the rotor 4 has an axial runout, the rotor 4 deviates from the target central position at least in one circumferential position. The rotor 4 can thus expediently be rotated about its axis of rotation (shown in dashed lines), with the detection device 30 being in contact with the surface of the rotor 4 and thus being able to detect deviations in the axial position of the surface of the rotor 4 .

If such a deviation is detected, one of the two stamping devices 27 can be used to deform the rotor 4 accordingly. For this purpose, the actuators 29 can receive corresponding control signals from the detection device 30 . A control device (not shown) can also be provided, which records the measured values of the detection device 30 and generates corresponding control signals and outputs them to the stamp devices 27 . For example, if the rotor 4 deviates “downwards”, the lower stamping device 27 can be used to “press out the deviation upwards”.

In the exemplary embodiment shown, it is assumed that the rotor 4 deviates “upwards”. Here, the deformation force is exerted on the rotor 4 with the upper stamping device 27 . The stamp 28 makes contact with the surface of the rotor 4 and transfers the deformation force to the rotor 4, so that the latter is plastically deformed. In this case, it is determined by means of the detection device 30 how far the rotor 4 has to be deformed. In particular, it can be taken into account that when the force transmitted from the stamping device 27 to the rotor 4 is removed, a defined “springing back” of the rotor 4 takes place. This can be taken into account when defining the plastic threshold, so that when the deformation force is removed after plastic deformation has taken place, the target central position is reached. The detection device 30 can track the detected axial position of the rotor 4 until the ideal position is reached. The target center position can then be checked by rotating the rotor 4 at least once completely around the axis of rotation and determining the axial position. If necessary, the deformation can be repeated at at least one other point.

With regard to the preceding devices 1, the in 6 described device 1 are made in particular as the first processing of the component of the electrical machine. Optionally, before or after the orientation in relation to 4 , 5 has been described. Finally, the defined material thickness can be removed 1-3 be made. The individual devices 1 can in particular also stand for themselves, ie can be used independently of other devices 1 . In particular, each of the devices 1 can be used when assembling a corresponding electric machine without using any of the other devices 1 . The order in which the individual devices 1 are used can also be selected as desired. This results in corresponding combinations or sequences of application.
Details, advantages and features shown in the individual exemplary embodiments can, of course, be combined with one another as desired, interchanged with one another and transferred to one another.

Reference List

1

contraption

2

recording facility

3

subgroup

4

rotor

5

rotor shaft

6

conductor area

7

magnet area

8th

air gap

9

stator

10

removal device

11

removal element

12

drive device

13

positioning device

14

subgroup

15

subgroup

16

orientation device

17

warehouse

18

warehouse

19

bearing flange

20

bearing flange

21

adjusting screw

22

adjusting screw

23

threaded hole

24

threaded hole

25

deformation device

26

holding device

27

stamp device

28

Rubber stamp

29

actuator

30

detection device

Claims (14)

Method for machining at least one component of an electrical machine, in particular a pancake motor, characterized in that in a partially assembled state in which at least two components of the electrical machine are assembled to form a subassembly (3, 14, 15), a material thickness in at least one area of the Subgroup (3, 14, 15) of the electrical machine, in particular in the area of an air gap (8) between the rotor (4) and stator (9), is removed in a defined manner. procedure after claim 1 , characterized in that at least two sub-assemblies (3, 14, 15) are processed separately or in an at least partially joined state, in particular a partially assembled state, prior to the assembly of the two sub-assemblies (3, 14, 15). procedure after claim 1 or 2 , characterized in that when the material thickness is removed, material is ground off in the at least one area. procedure after claim 3 , characterized in that the material is removed by means of a removal device (10), a relative movement being generated between a removal element (11), in particular a surface of a grinding element, and the surface of the conductor area (6) and/or magnet area (7). Method according to one of the preceding claims, characterized in that the material thickness is removed in a conductor area (6) of the stator (9) or rotor (4) or in a magnet area (7) of the stator (9) or rotor (4). Method according to one of the preceding claims, characterized in that the at least one subgroup (3, 14, 15) for removing the material thickness is attached to at least one bearing (17, 18) and/or to a flange (19, 20) by means of a receiving device ( 2) a removal device (10) is contacted. Method according to one of the preceding claims, characterized in that to remove the material thickness in the air gap (8) between the conductor area (6) and the magnet area (7), in particular in both air gaps (8) between the two conductor areas (6) and the two magnet areas (7), a removal element (11), in particular having two removal surfaces, is introduced and a relative movement is generated. Method according to one of the preceding claims, characterized in that at least two subgroups (3, 14, 15) are oriented relative to one another in an at least partially assembled state, in particular in relation to one Axis of rotation of the electrical machine, and / or are positioned, in particular with respect to at least one radial and / or an axial air gap (8). Method according to one of the preceding claims, characterized in that before orientation and/or positioning, spacers are introduced between the at least two subgroups (3, 14, 15), the dimensions of which correspond to a target orientation and/or a target distance. Method for processing at least one component of an electrical machine, in particular a pancake motor, characterized in that in a partially assembled state in which at least two components of the electrical machine are assembled to form a subassembly (3, 14, 15), at least two subassemblies (3, 14 , 15) by means of at least one orientation device (16), in particular having at least three orientation means, are oriented relative to one another in an at least partially assembled state, in particular in relation to a rotational axis of the electrical machine, and/or are positioned, in particular in relation to at least one radial axis and/or an axial air gap (8). Method for processing at least one component of an electrical machine, in particular a pancake motor, characterized in that in a partially assembled state in which at least two components of the electrical machine are assembled to form a subassembly (3, 14, 15), by means of at least one deformation device (25) a deformation force, in particular in a deformation direction running parallel to the axial direction, is applied to the rotor (4), the deformation force exceeding a plastic deformation threshold. Device (1) for machining at least one component of an electrical machine, in particular a disc rotor motor, characterized by at least one removal device (10) which has at least one removal element (11) and which can be coupled or is coupled to a drive device (12) which is designed to to generate a relative movement between a subassembly (3, 14, 15) of an electrical machine accommodated in a receiving device (2) of the device (1) and the removal element (11) in order to remove material from the subassembly (3, 14, 15). Device (1) for processing at least one component of an electrical machine, in particular a disc rotor motor, characterized by at least one orientation device (16) which is designed to align at least two subgroups (3, 14, 15), in particular by means of at least three orientation devices of the orientation device ( 16) to be oriented relative to one another in an at least partially assembled state, in particular in relation to an axis of rotation of the electrical machine, and/or to be positioned, in particular in relation to at least one radial and/or one axial air gap (8). Device (1) for processing at least one component of an electrical machine, in particular a disc rotor motor, characterized by a deformation device (25) which is designed to apply a deformation force, in particular in a deformation direction running parallel to the axial direction, on the rotor (4), wherein the deformation force exceeds a plastic deformation threshold.

Images