DE102021209415A1 - Rotor for an electrical machine and method for manufacturing a rotor - Google Patents

Abstract

The present invention relates to a rotor for an electrical machine, in particular an electric motor, comprising a rotor stack (1) with at least one magnet mount (13) for accommodating at least one magnet (14), in particular a permanent magnet, the magnet (14) being secured by a mounting clamp ( 15) is fixed in the magnet receptacle (13) and a manufacturing method for the rotor, and a rotor for an electrical machine, in particular an electric motor, comprising a rotor core (2) with an opening (22) for receiving a rotor shaft, the rotor core having a plurality of laminations (21a...x) which are arranged one behind the other in the axial direction, the individual sheet metal laminations (22) being composed of a plurality of segments (211a...x) in the circumferential direction, the segments being directed towards the opening (22). Page (2211), wherein adjacent laminations (22) or sets of laminations are offset by an angle bisector (W) of the segments (221) s ind, wherein the side (2211) of the laminations or of the rotor stack facing the opening (22) for receiving a rotor shaft has a positioning geometry (2212) with a shape deviating from the circular shape and a manufacturing method of the rotor.

Description

The present invention relates to a rotor for an electrical machine, in particular an electric motor, according to claim 1, a method for manufacturing a rotor according to claims 13 to 16, a rotor for an electrical machine according to claim 17, and a method for manufacturing a rotor according to claim 21

Rotors for electrical machines are well known. They are used, for example, in permanently excited synchronous machines. Here, permanent magnets are attached to the rotor. The so-called buried design has become established for so-called electric traction drives, i.e. the magnet is in a recess or pocket in the rotor assembly.

A common type of installation is gluing, as for example from the DE201110119512 known. This type of attachment has the advantage that the magnet also has a mechanical protective layer due to the adhesive, eg against erosion of the anti-corrosion layer or brittle fracture due to stress peaks at the edges. However, there are also disadvantages of this form of installation, in particular high expenditure in the processing of the adhesive due to, for example, compliance with curing times, dispenser cleaning/maintenance, etc. In addition, an adhesive connection requires installation under compression of the rotor stack. A recycling of the high-quality, expensive magnetic materials is very difficult if not impossible due to gluing. Analogously, the above disadvantages also apply to other material connection means for magnet installation, such as from DE 10 2017 106 052 A1 known.

Due to the disadvantages mentioned, manufacturers and system builders prefer an adhesive-free or non-material magnet installation. Methods are also known in which the permanent magnets are each pressed into a depression or recess or are locked in the rotor core with elastic and/or plastic deformation. The magnet is often clamped by means of at least one clamping lug that is arranged on the base body.

However, like other fastenings by forming, clamping lugs have the disadvantage that they mechanically stress the permanent magnets at points and are therefore very heavily stressed, especially during assembly and under operating conditions of the electrical machine, which can lead to voltage peaks and damage, in particular magnet breakage or a Scratching the magnet surface and/or its coating, for example when inserting the magnet axially. Damaged coatings will no longer protect the permanent magnets from corrosion and can lead to an uneven magnetic field profile and increased leakage flux, as a result of which the cogging torque and torque ripple of the electrical machine are increased. A magnet installation with fixing lugs is, for example, from EN20111078054 known.

Also Magneteibau with additional component are known, for example from EP 2 249 460 A1 . A disadvantage here, for example, is that the gap has to be enlarged for installation, which entails an additional weakening of the rotor core. Furthermore, it is not possible or only possible to a limited extent to absorb tensile forces in the stomach pocket of the rotor assembly. Furthermore, the permeability of the material is low or there are no zones for low/high permeability.

Although usable rotors have already been proposed here, there is still a need for improvement, in particular with regard to the attachment of magnets in or on the rotor.

This is where the present invention comes in and sets itself the task of proposing an improved rotor, in particular a rotor with an improved magnet installation, which does not require a material bond but also prevents effective damage or voltage peaks to the magnet during installation and during operation. In addition, the solution should advantageously enable a homogenization of the stresses in the rotor stack by allowing the absorption of tensile forces by the fastening means. The ferromagnetic function in the area of the magnet installation pocket should be retained as best as possible or ideally be adjustable.

According to the invention, this object is achieved by a rotor having the characterizing features of claim 1 in that the magnet is fixed in the magnet receptacle by a mounting bracket.

Further advantageous refinements of the proposed invention result in particular from the features of the dependent claims. The objects or features of the various claims can in principle be combined with one another as desired.

In an advantageous embodiment of the invention, it can be provided that the rotor stack comprises a number of laminations which are arranged one behind the other in the axial direction, with the laminations in particular consisting of a plurality of segments in the circumferential direction.

In a further advantageous embodiment of the invention, it can be provided that the rotor stack comprises a plurality of magnet receptacles, which are arranged one behind the other in the circumferential direction, preferably coaxially, in the rotor stack, with each permanent magnet preferably being fixed in the at least one magnet receptacle with at least one mounting bracket.

In a further advantageous embodiment of the invention, it can be provided that the mounting bracket is characterized in that the magnet is at least partially encompassed on at least two sides, preferably on three or four sides.

In a further advantageous embodiment of the invention it can be provided that the mounting clamp has several contact points or surfaces on each side of the magnet and/or the magnet receiving wall, in particular in order to avoid stress peaks. This results in defined contact points between the magnet and the magnet holder.

In a further advantageous embodiment of the invention, it can be provided that the mounting clamp is set up to compensate for play in the gap between the magnet receptacle of the rotor core and the magnet, in particular by elastic and/or plastic deformation of the respective clamp sections. In this way, manufacturing tolerances can be compensated.

In a further advantageous embodiment of the invention, it can be provided that the mounting bracket is equipped with a temperature element for detecting the component temperatures in/on the magnet during engine operation. As a result, the mounting bracket can combine an additional function.

In a further advantageous embodiment of the invention, it can be provided that the mounting bracket has geometric features which produce a form fit in the rotor assembly when installed.

In a further advantageous embodiment of the invention, it can be provided that the mounting clamp consists of a thin sheet metal material, in particular in the range of 0.3-0.35 mm, and/or flexible sheet metal material, preferably electrical sheet metal. Electrical steel can fall off during the manufacture of other rotor or stator components, i.e. components of an electrical machine, and can thus be recycled as assembly clamps.

In a further advantageous embodiment of the invention, it can be provided that the mounting bracket has specifically adjusted properties for absorbing/conducting the magnetic flux.

In a further advantageous embodiment of the invention, it can be provided that the mounting clamp consists, at least in sections, of ferromagnetic material and/or non-ferromagnetic material, in particular with fiber reinforcement in the direction of the tensile force absorption.

In a further advantageous embodiment of the invention, it can be provided that the mounting bracket has a design that absorbs tensile forces.

Another object of the present invention is to propose an advantageous method for manufacturing a rotor according to at least one of claims 1 to 12.

According to the invention, this object is achieved by a method with the features of claim 13 in that the blank for the mounting bracket is made from an electrical steel sheet which remains from the stamping process of the stator or rotor, particularly in the area of the waste, more preferably using the magnet receptacle -Punching waste.

According to the invention, this object is achieved by a method with the features of claim 14 in that a laser process is used for irradiation to modify the ferromagnetic properties in different zones of the mounting bracket, that a laser process is used for perforating or similar preparation of the desired bending edges of the mounting bracket and/or or that a laser process is used to join the ends with the mounting bracket running around.

According to the invention, this object is achieved by a method having the features of claim 15 in that the mounting bracket is provided with an additional plastic coating or a similar coating as a buffer material in the contact areas of the magnet.

According to the invention, this object is achieved by a method having the features of claim 16 in that the mounting bracket is paired with the magnet prior to installation in the package.

The present invention also relates to a rotor according to the preamble of the claim 17 and a method of manufacturing a rotor according to claim 21.

A rotor essentially comprises a rotor stack. The rotor stack preferably comprises a plurality of laminations which are arranged one behind the other in the axial direction. The individual sheet metal laminations are segmented in the circumferential direction, i.e. they consist of several segments.

In this context, segmented stator laminations in electrical machines are known from the prior art, for example in order to increase the degree of material utilization.

The prior art is known for segmenting the rotor laminations in the rotor, for example from EP2356734B1 . In order to improve the degree of material utilization when different materials are selected for the stator and rotor, it is necessary for segmented sheets to be used on both sides. For the segmentation of rotor laminations, training against the centrifugal forces that occur is required, and the torques generated in the rotor must also be able to be transmitted. In the prior art, segment assemblies can often only be found on the stator side, while segmentation is generally dispensed with on the rotor side because of the challenges mentioned above. Here, the degree of material utilization of the rotor lamination used is often particularly poor.

A rotor for an electrical machine is also from EP1269608B1 known. 5 shows, for example, a rotor with a stator segmentation according to the prior art.

Solutions for rotor segmentation disclosed in the prior art often show complex, difficult form-fitting segment connections. There are essentially two disadvantages here.

On the one hand, the influence of the cut edges, which has a damaging effect on the sheet metal properties, is prolonged. Furthermore, such positive locking (with a narrow gap or even without play) can only be connected to one another with process reliability with difficulty.

From the EP500457A1 For example, segments arranged in an overlapping manner have become known. A positive connection between the segments is also provided.

While the slots can be used as a positioning aid in the case of segmented stators, there is no alignment geometry on the segment circumference on the rotor with a circular outside and inside diameter. In addition, with the high number of strokes of a punching and stacking tool with strip feed, the moving metal sheets accelerate quite quickly, which must be braked safely and precisely for the time of the processing step.

Although usable rotors have already been proposed here, there is still a need for improvement, in particular with regard to the connection of the segments.

This is where the present invention comes in and sets itself the task of proposing an improved rotor, in particular proposing a rotor which, in principle, does not require form-fitting connections between the segments.

According to the invention, this object is achieved by a rotor with the characterizing features of claim 17 in that adjacent laminations or laminations are arranged offset by a bisecting line of the segments and the side of the laminations or rotor lamination facing the opening for receiving a rotor shaft has a positioning geometry has a shape deviating from the circular shape. In other words, the solution is a segmented rotor design, with the segments in the laminations being offset by the bisecting line and having geometries that deviate from the circular inner shape of the rotor laminations.

Preferably, the laminations or laminations are arranged rotationally symmetrically as a multiple of the number of poles or the number of segments, i.e. for example 8 magnetic poles, i.e. 2 poles each on 4x 90° segments form a complete layer. This results in an arrangement in which layers lying one on top of the other are possible both with a congruent pitch layer and with a pitch layer offset by 45°. The latter is preferred, which, viewed axially, represents a kind of offset as in the stone composite of a wall.

As a result, the new degree of design freedom on the inner diameter of rotor stacks, as is achieved with the externally centered design by means of an axial press fit, is put to use and stacking of segments without positive locking in the pitch layers is made possible.

Further advantageous refinements of the proposed invention result in particular from the features of the dependent claims. The objects or features of the various claims can in principle be combined with one another as desired.

In an advantageous embodiment of the invention, it can be provided that the positioning geometries are aligned in the axial direction.

In a further advantageous embodiment of the invention, it can be provided that segments with the same geometry are provided. In this way, in particular identical parts can be produced and production costs can be saved.

In a further advantageous embodiment of the invention, it can be provided that the opening for receiving the rotor shaft is partially lined with a resin. In this way, a form fit, in particular, can be produced between the laminations and/or segments of the rotor, in particular independently of form fit connections between the segments.

Another object of the present invention is to propose an advantageous method for manufacturing a rotor according to at least one of claims 17 to 20.

According to the invention, this object is achieved by a method with the features of claim 22 in that adjacent laminations or laminations are arranged offset by a bisecting line of the segments, with the side of the laminations or rotor assembly facing the opening for receiving a rotor shaft having a positioning geometry has a shape deviating from the circular shape. As a result, a segmentation solution can be proposed that enables reliable and repeatable deceleration and positioning of the segment parts in the stacking stage of the punching tool.

Further advantageous refinements of the proposed invention result in particular from the features of the dependent claims. The objects or features of the various claims can in principle be combined with one another as desired.

In an advantageous embodiment of the proposed invention, it can be provided that the positioning geometries are arranged in such a way that they are aligned in the axial direction.

In a further advantageous embodiment of the proposed invention, it can be provided that segments with the same geometry are used.

In a further advantageous embodiment of the proposed invention, it can be provided that segments are assembled into complete rotor stacks in the stacking station of the stamping tool. As a result, more cost-effective production can be achieved.

In a further advantageous embodiment of the proposed invention, it can be provided that gluing and/or punched packeting methods, in particular alternating punched nub positions, are used to connect the sheet metal laminations.

• 1 ein erfindungsgemäßer Rotor, insbesondere Rotor-Blechschnitt einer 8-poligen PSM mit tangentialer Magnetanordnung und Montageklammer;
• 2 ein erfindungsgemäßer Rotor in einer vergrößerten Detaildarstellung, insbesondere Ausführungsformen von zugkraftaufnehmenden Klammerbefestigungen für Magnete;
• 3 ein erfindungsgemäßer Rotor in einer vergrößerten Detaildarstellung, insbesondere eine Detailansicht zur Ausführungsform II;
• 4 ein erfindungsgemäßer Rotor in einer vergrößerten Detaildarstellung, insbesondere Details zu ferromagnetischen Zonen der Montageklammer;
• 5 ein erfindungsgemäßer Rotor, insbesondere eine Statorsegmentierung mittels mehrlagiger Segmentanordnung;
• 6 ein erfindungsgemäßer Rotor, insbesondere eine Statorsegmentierung zur Verdeutlichung zweier um eine Winkelhalbierende des Segmentes versetzt angeordnete Blechlamelle;
• 7 ein erfindungsgemäßer Rotor, insbesondere Ausgestaltungen von Innengeometrien.

Further features and advantages of the present invention become clear from the following description of preferred exemplary embodiments with reference to the attached figures. show in it

• 1 a rotor according to the invention, in particular rotor sheet metal section of an 8-pole PSM with a tangential magnet arrangement and mounting bracket;
• 2 a rotor according to the invention in an enlarged detailed representation, in particular embodiments of tensile force-absorbing clamp attachments for magnets;
• 3 a rotor according to the invention in an enlarged detailed view, in particular a detailed view of embodiment II;
• 4 a rotor according to the invention in an enlarged detailed view, in particular details of the ferromagnetic zones of the mounting bracket;
• 5 a rotor according to the invention, in particular a stator segmentation by means of a multi-layer segment arrangement;
• 6 a rotor according to the invention, in particular a stator segmentation to illustrate two laminations arranged offset by an angle bisector of the segment;
• 7 a rotor according to the invention, in particular configurations of internal geometries.

W

Winkelhalbierende

1

Rotorpaket

11

Öffnung zur Aufnahme einer Rotorwelle

12 (a-x)

Blechlamelle

13

Magnetaufnahme

14

Magnet, insbesondere Permanentmagnet

15

Montageklammer

121 (a -x)

Segment

2

Rotorpaket

22 (a -x)

Blechlamelle

21

Öffnung

221 (a -x)

Segment

2211

zur Öffnung 22 gerichtete Seite

2212

Positioniergeometrie

The following reference symbols are used in the figures:

W

bisector

1

rotor package

11

Opening to accommodate a rotor shaft

12 (ax)

sheet metal lamella

13

magnetic recording

14

Magnet, in particular permanent magnet

15

mounting bracket

121 (a-x)

segment

2

rotor package

22 (a-x)

sheet metal lamella

21

opening

221 (a-x)

segment

2211

to the opening 22 directed side

2212

positioning geometry

Features and details that are described in connection with a method also apply in connection with the device according to the invention and vice versa, so that the disclosure of the individual aspects of the invention is or can always be referred to reciprocally. In addition, an optionally described method according to the invention can be carried out with the device according to the invention.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will also be understood that the terms "comprises" and/or "comprising" when used in this specification specify the presence, but not the presence, of the recited features, integers, steps, operations, elements, and/or components or exclude the addition of one or more other features, integers, steps, operations, elements, components and/or groups thereof. As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items.

First up 1 referenced.

A rotor according to the invention essentially comprises a rotor stack 1 with an opening 11 for receiving a rotor shaft (not shown). The rotor stack 1 preferably comprises a plurality of laminations 12 a - x, which are arranged one behind the other in the axial direction. The individual sheet metal laminations can preferably be segmented in the circumferential direction, ie consist of several segments 121a-x. The index x is intended to indicate the number of laminations or segments per lamina, it being possible in principle for there to be many or any number of laminations per rotor stack or segments per lamina.

The rotor core 1 comprises at least one magnet receptacle 13 for accommodating at least one magnet 14, in particular a permanent magnet. Correspondingly, the permanent magnet 14 is accommodated in the magnet receptacle 13 . The magnet receptacle 13 can be provided, for example, as a recess or receptacle chamber in the rotor core 1 . The rotor core 1 preferably comprises a plurality of magnet receptacles 13 which are arranged one behind the other in the circumferential direction, preferably coaxially, in the rotor core 1 .

According to the invention, it is provided that the at least one magnet 14 is fixed in the at least one magnet receptacle 13 with at least one mounting bracket 15 . Provision is preferably made for each magnet 14 to be fixed in the at least one magnet receptacle 13 with at least one mounting bracket 15 .

The mounting bracket 15 is preferably characterized in that the magnet 14 is at least partially surrounded on at least two sides.

The mounting clamp 15 is further preferably characterized in that it has several contact points or surfaces on each side of the magnet and/or the magnet receiving wall, in particular in order to avoid stress peaks.

The mounting clamp 15 is further preferably characterized in that it is set up to compensate for play in the gap between the magnet receptacle 13 and the magnet 14, in particular through an elastic change in shape of the respective clamp sections.

Provision is also preferably made for the mounting bracket 15 to have geometric features which, when installed in the rotor core 1, produce a form fit and in particular thus, for example, allow stresses from the rotor core (e.g. as a result of the effect of centrifugal force) to be introduced into the mounting bracket 15 - the mounting bracket is thus effective as a traction mechanism.

Provision is also preferably made for the mounting bracket 15 to consist, at least in sections, of a very thin, flexible sheet metal material, preferably electrical sheet metal. The mounting bracket preferably has a wall thickness of 0.3-0.35 mm. The aim is in particular to keep the gap for installation as small as possible and to fill it with a ferromagnetic clamp material in order to obtain good permeability in the direction of the poles.

Provision is also preferably made for the mounting bracket 15 to have specifically adjusted properties for absorbing/conducting the magnetic flux.

The 2 shows various configurations of the mounting bracket 15, all of which have in common a form-fitting installation and a geometry that absorbs tensile forces. The various configurations are each designated I, II a), II b) and III.

Since flux barriers arranged laterally to the magnetic poles often result in a high state of stress in the area of the remaining, thin webs towards the air gap (see Fig 2 ), a tensile force absorption by the mounting clamp 15 in this area is particularly advantageous. But this feature is also relevant for segmented rotor designs with the pitch on the pole or magnet center.

In an embodiment according to III, two identical mounting brackets 15 are used to clamp the magnet 14; a small form-fitting enclosure on the magnet sides is also possible here.

Common to all of the configurations is the goal of minimizing the installation gap by using the thinnest possible material for the mounting bracket 15, e.g.

Another common feature is the formation of embossing or beads in the respective side surfaces of the mounting bracket 15, which bring about play compensation through elastic, possibly also partially plastic deformation when the magnet is installed.

The 3 shows a detailed view of embodiment II.

The advantage of this embodiment II lies in the complete, circumferential enclosing of the magnet 14 as well as the strong form of the form fit. The tensile force absorption (in tangential direction of rotor) is given over both longitudinal sides.

The complete enclosure of the magnet acts as a mechanical protection, both during installation and during operation.

The 4 shows details of ferromagnetic zones of the mounting bracket 15, in particular 4 the good permeability desired in the pole direction, which is achieved in particular by largely filling the installation gap with the mounting bracket 15 made of ferromagnetic material. Furthermore, the pole sides are shown, in which magnetic short circuits are undesirable - see example field line in zone B. Through targeted thermal treatment, as known from EP3 016 245 B1 , the material of the mounting bracket 15 can be modified in these side areas in order to produce the lowest possible permeability there.

• - zugkraftaufnehmende Gestaltung
• - Eignung zur Aufnahme/Leitung von magnetischem Fluss - mindestens in dafür vorgesehenen Zonen der Montageklammer
• - Anzahl der umfassten Seiten des Magneten durch die Montageklammer >=2, vorzugsweise 3 oder 4
• - elastisch-plastisch spielausgleichende Klammergeometrie (mit Biege- bzw. Verformungsbereichen)
• - Verwendung Elektroblech
• - Modifikation der ferromagnetischen Eigenschaften in bestimmten Zonen der Montageklammer
• - Montageklammer aus Elektroblech mit Flusslenkungseigenschaften
• - Spielausgleich über elastisch-plastische Formänderung der Klammerabschnitte
• - zugkraftaufnehmende Gestaltung

The rotor according to the invention, in particular the mounting bracket 15, is characterized in particular by the following features, individually or in combination:

• - traction absorbing design
• - Suitability for absorbing/conducting magnetic flux - at least in the designated zones of the mounting bracket
• - Number of sides of the magnet covered by the mounting bracket >=2, preferably 3 or 4
• - elastic-plastic play-compensating clip geometry (with bending or deformation areas)
• - Use of electrical steel
• - Modification of the ferromagnetic properties in certain zones of the mounting bracket
• - Electrical steel mounting bracket with flux routing properties
• - Compensation for play via elastic-plastic deformation of the clip sections
• - traction absorbing design

• - Kombination der Montageklammer mit einem Temperaturelement zur Erfassung der Bauteiltemperaturen im/am Magnet während des Motorbetriebes
• - Nutzung der Laserprozess zur Bestrahlung zur Modifikation der ferromagnetischen Eigenschaften in verschiedenen Zonen
• - Nutzung Laserprozess zum Perforieren o.a. Vorbereitung der gewünschten Biegekanten der Montageklammer
• - Nutzung Laserprozess zum Verbinden der Enden bei umlaufender Montageklammer
• - Nicht ferromagnetische Werkstoffe / Werkstoffkombination, z.B. a) mit Faserverstärkung in Richtung der Zugkraftaufnahme; b) Klammerabschnitte teils ferromagnetischer Werkstoff (Zone A), teils nicht-ferromagn. (Zone B)

Other optional configurations of the mounting bracket 15:

• - Combination of the mounting bracket with a temperature element for recording the component temperatures in/on the magnet during engine operation
• - Use of the laser process for irradiation to modify the ferromagnetic properties in different zones
• - Use of the laser process for perforating or similar preparation of the desired bending edges of the mounting bracket
• - Use of a laser process to connect the ends with a surrounding mounting clamp
• - Non-ferromagnetic materials / combination of materials, eg a) with fiber reinforcement in the direction of tensile force absorption; b) Clamp sections partly ferromagnetic material (zone A), partly non-ferromagnetic. (Zone B)

• -verbesserte Spannungsverteilung im Rotor bzw. Rotorpaket
• -bessere Permeabilität im Einbauspalt, da dieser großteils mit Elektroblech gefüllt ist
• -sehr gute Möglichkeit zum Recycling
• -durch dünnes Klammermaterial kann Einbauspalt minimiert werden
• -homogenere Spannungsverteilung zu Zugkraftaufnahme der Montageklammer

The resulting advantages are in particular as follows:

• -Improved stress distribution in the rotor or rotor stack
• -Better permeability in the installation gap, as this is largely filled with electrical steel
• -very good way to recycle
• -The installation gap can be minimized by using thin clamp material
• -More homogeneous stress distribution for tensile force absorption of the mounting bracket

• - dass der Zuschnitt für die Montageklammer 15 aus dem Elektroblech erfolgt, welcher aus dem Stanzprozess des Stators bzw. Rotors übrig bleibt, insbesondere im Bereich des Verschnitts, in besonders günstigem Fall kann der Magnetaufnahmen-Stanzabfall Verwendung finden;
• - dass das Elektroblech für die Montageklammer 15 durch Wärmebehandlung, z.B. mittels Laser, insbesondere hinsichtlich seiner ferromagnetischer Eigenschaften in bestimmten Abschnitten, modifiziert wird. Hier kann insbesondere auf die 4 verwiesen werden;
• - dass die Montageklammer 15 in den Anlagebereichen des Magneten 14 mit einer zusätzlichen Kunststoffbeschichtung o.ä. „Puffermaterial“ versehen wird;
• - dass die Montageklammer 15 vorab des Einbaus in das Paket mit dem Magnet 14 gepaart wird. Der Einbau erfolgt über axiales Einschieben. Hierbei ist der Magnet 14 bereits von der Montageklammer 15 eingehaust und somit mechanisch geschützt.

According to the invention, it can also be provided that the production of the rotor according to the invention, in particular the assembly clamp for the rotor according to the invention, is characterized by the following process steps, individually or in combination, characterized in that

• that the blank for the mounting bracket 15 is made from the electrical steel sheet which remains from the stamping process of the stator or rotor, particularly in the area of the waste;
• - That the electrical sheet for the mounting bracket 15 is modified by heat treatment, for example by means of a laser, in particular with regard to its ferromagnetic properties in certain sections. Here, in particular, on the 4 to get expelled;
• - that the mounting bracket 15 is provided with an additional plastic coating or similar "buffer material" in the contact areas of the magnet 14;
• - That the mounting bracket 15 is paired with the magnet 14 before assembly in the package. The installation is done by pushing it in axially. In this case, the magnet 14 is already enclosed by the mounting bracket 15 and is therefore mechanically protected.

A rotor according to the invention essentially comprises a rotor stack 2 with an opening 22 for receiving a rotor shaft (not shown). The rotor stack 2 preferably comprises a plurality of laminations 21 a...x, which are arranged one behind the other in the axial direction. The individual laminations 21 are segmented in the circumferential direction, ie they consist of several segments 221a...x. The index x is intended to indicate the number of laminations or segments per lamina, it being possible in principle for there to be many or any number of laminations 21 per rotor stack 2 or segments 221 per lamina 21 .

The segments 221 have a side 2211 directed towards the opening 22 .

According to the invention, adjacent laminations 21 or sets of laminations are offset by an angle bisector W of segment 221 . Lamella packs accordingly consist of several laminations 21 arranged in the axial direction.

Due to the offset of the segment positions by an angle bisector W, it is achieved in particular that when the rotor core 2 is axially braced, there is a large frictional connection via which the torque can be transmitted. This torque is essentially determined by the relationship between the coefficient of friction and the preload force. This frictional connection also ensures that the centrifugal forces acting on the segments are absorbed and, in principle, allows the disadvantageous positive locking in the segment dividing positions to be eliminated. By doing without a form fit in the segment divisions, a simplified assembly process, shorter cutting edge length than with form fit in the division, in particular as a functional advantage, is possible. In particular, there can be an improvement in the degree of material utilization. In particular, an overlapping of the segment levels by at least one magnetic pole Wall construction is provided. An offset of the disk packs by a bisecting line of the segment in each case means a segment offset in which, for example, layers 1-3 are also aligned, but the layers 4-6 are then arranged at an angle offset in relation thereto.

According to the invention, it is further provided that the side 2211 of the laminations 21 or of the rotor stack 2 facing the opening 22 for receiving a rotor shaft has a positioning geometry 2212 with a shape deviating from the circular shape. The positioning geometry 2212 can be used for additional functions in the operation of the rotor or the electrical machine, for example for improved heat dissipation by enlarging the surface, for mechanical stabilization by casting in the gap between the rotor core and the rotor shaft in the assembled assembly and/or for the angular orientation of the sheet metal section (the poles ) to the rotor shaft. Variations are conceivable in particular with regard to the number, shape and position of the positioning geometry 2212 .

Provision can preferably be made for the positioning geometries to be aligned in the axial direction.

It can preferably be provided that segments with the same geometry are present.

The method according to the invention for producing, in particular assembling, a rotor is to be explained in more detail below. It goes without saying that only a few selected assembly steps are shown here, as they are helpful for understanding the method according to the invention. The manufacture of the rotor can further, the subject man known, include steps or intermediate steps.

According to the invention, it is provided that the side of the rotor stack facing the opening has a positioning geometry with a shape deviating from the circular shape. With this positioning geometry, which can also be referred to as braking or centering geometry, higher stroke rates/min can be achieved and ultimately the manufacturing process can be accelerated. Both preferably take place in a common progressive tool, in particular both the segment stamping (several stages) and the final packaging process.

Provision can preferably be made for the positioning geometries to be arranged in such a way that they are aligned in the axial direction.

It can preferably be provided that segments with the same geometry are used.

Provision can preferably be made for segments to be assembled into complete rotor stacks in the stacking station of the stamping tool.

To connect the sheet metal layers, so-called alternating punched nub positions can be used in addition to gluing and conventional punched packaging processes.

In the 5 a rotor according to the invention, in particular a stator segmentation, is shown by means of a multi-layer segment arrangement. The positioning geometry 2212 is shown here, for example, as a type of free form or a type of non-round. Each of the segments 221 ad has this positioning geometry 2212 on its side 2211 facing the opening 22 . The segments 221 ′, which also have this positioning geometry 2212 , form a sheet metal layer that is offset relative to the sheet metal layer of the segments 221 .

In 6 the segments 221 and a segment 221' which is offset by the angle bisector W are shown in dashed lines by way of example. A kind of wall bond is created, which gives the rotor lamination stack additional stability. Several laminations 22 can be stacked to form a lamina package. These laminated cores can then in turn be offset, preferably offset by the angle bisecting line W of the segments 221, in order to form the laminated rotor core.

In the 7 a rotor according to the invention, in particular configurations of positioning geometries 2212, is shown. The various configurations of the positioning geometries 2212 shown there are merely examples and do not occur together on a rotor assembly.

These positioning geometries 2212 can be convex or concave, for example as a groove, tongue or nose, notches or depressions or projections with a round, semi-circular or triangular shape.

QUOTES INCLUDED IN DESCRIPTION

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

Patent Literature Cited

• EN 201110119512 [0003]
• DE 102017106052 A1 [0003]
• EN 20111078054 [0005]
• EP 2249460 A1 [0006]
• EP 2356734 B1 [0030]
• EP 1269608 B1 [0031]
• EP 500457 A1 [0034]
• EP 3016245 B1 [0074]

Claims (25)

Rotor for an electrical machine, in particular an electric motor, comprising a rotor core (1) with at least one magnet mount (13) for accommodating at least one magnet (14), in particular a permanent magnet, characterized in that the magnet (14) is secured by a mounting bracket (15) is fixed in the magnet holder (13). rotor after claim 1 , characterized in that the rotor core (1) comprises a number of laminations (12 ax) which are arranged one behind the other in the axial direction, the laminations in particular being made up of a plurality of segments (121 ax) in the circumferential direction. Rotor according to at least one of the preceding claims, characterized in that the rotor core (1) comprises a plurality of magnet receptacles (13) which are arranged one behind the other in the circumferential direction, preferably coaxially, in the rotor core (1), with each magnet (14) preferably having at least a mounting bracket (15) is fixed in the at least one magnet receptacle (13). Rotor according to at least one of the preceding claims, characterized in that the mounting clamp (15) is characterized in that the magnet (14) is at least partially surrounded on at least two sides, preferably on three or four sides. Rotor according to at least one of the preceding claims, characterized in that the mounting bracket (15) has several contact points or surfaces on each side of the magnet (14) and/or the magnet receiving wall, in particular to avoid stress peaks. Rotor according to at least one of the preceding claims, characterized in that the mounting bracket (15) is set up to compensate for play in the gap between magnet receptacle (13) and magnet (14), in particular by elastic and/or plastic deformation of the respective bracket sections. Rotor according to at least one of the preceding claims, characterized in that the mounting clamp (15) is equipped with a temperature element for detecting the component temperatures in/on the magnet during engine operation. Rotor according to at least one of the preceding claims, characterized in that the assembly clamp (15) has geometric features which produce a positive fit when installed in the rotor core (1). Rotor according to at least one of the preceding claims, characterized in that the mounting clamp (15) consists of a thin sheet material, in particular in the range of 0.3 - 0.35 mm, and/or flexible sheet metal material, preferably electrical sheet metal. Rotor according to at least one of the preceding claims, characterized in that the mounting bracket (15) has specifically adjusted properties for receiving/conducting the magnetic flux. Rotor according to at least one of the preceding claims, characterized in that the assembly clamp consists, at least in sections, of ferromagnetic material and/or non-ferromagnetic material, in particular with fiber reinforcement in the direction of the tensile force absorption. Rotor according to at least one of the preceding claims, characterized in that the mounting bracket (15) has a design that absorbs tensile forces. Method for producing a rotor according to at least one of the preceding claims, characterized in that the blank for the mounting bracket (15) is made from an electrical steel sheet which remains from the stamping process of the stator or rotor, in particular in the area of the waste, more preferably below Use of the magnetic recording punch waste. Method for producing a rotor according to at least one of the preceding claims, characterized in that a laser is used to modify the ferromagnetic properties in various zones of the mounting bracket (15), for perforating or similar preparation of the desired bending edges of the mounting bracket (15) and/or for Connecting the ends when the mounting bracket (15) is used all around. Process for manufacturing a rotor according to at least one of the preceding claims, characterized in that the assembly clamp (15) is provided with an additional plastic coating or a similar coating as buffer material in the contact areas of the magnet (14). Method for manufacturing a rotor according to at least one of the preceding ones Claims, characterized in that the mounting bracket (15) is paired with the magnet (14) before installation in the magnet receptacle (13). Rotor for an electrical machine, in particular an electric motor, comprising - a rotor core (2) with an opening (22) for receiving a rotor shaft, wherein - the rotor core comprises a plurality of laminations (21 a...x) which are arranged one behind the other in the axial direction are, wherein - the individual laminations (22) are composed of a plurality of segments (211a...x) in the circumferential direction, wherein - the segments have a side (2211) directed towards the opening (22), characterized in that - adjacent laminations ( 22) or laminations are arranged offset by an angle bisector (W) of the segments (221), with the side (2211) of the laminations or of the rotor assembly facing the opening (22) for receiving a rotor shaft having a positioning geometry (2212) with one of having a shape deviating from the circular shape. rotor after Claim 17 , characterized in that the positioning geometries (2212) are aligned in the axial direction. Rotor after at least one of claims 17 or 18 , characterized in that geometrically identical segments (221) are provided. Rotor after at least one of claims 17 until 19 , characterized in that the opening (21) for receiving the rotor shaft is partially lined with a resin. Method for producing a rotor according to at least one of claims 17 until 20 , characterized in that adjacent laminations (22) or laminations are arranged offset by an angle bisector (W) of the segments (221), the side (2211) of the laminations or of the rotor assembly facing the opening (22) for receiving a rotor shaft has a positioning geometry (2212) with a shape deviating from the circular shape. procedure after Claim 21 , characterized in that the positioning geometries (2212) are arranged such that they are aligned in the axial direction. procedure after Claim 21 or 22 , characterized in that segments (221) of the same geometry are used. Process according to at least one of Claims 21 until 23 , characterized in that a segment assembly to form complete rotor stacks (2) takes place in a stacking station of a stamping tool. Process according to at least one of Claims 21 until 24 , characterized in that gluing and/or punched packeting methods, in particular alternating punched nub positions, are used to connect the laminations (22).

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