DE102022212459A1 - Rotor with clamping cavities for an electric machine - Google Patents

Abstract

The present invention relates to a method for producing a rotor (1) for an electric machine (2) for a motor vehicle (3), comprising:
- providing a laminated core (5) extending around a rotor longitudinal axis (4) from several discs (6) arranged next to one another,
- arranging an electrically insulating clamping means (13) in clamping cavities (12) of the rotor teeth (9) such that the clamping means (13) is arranged outside a winding space (10) of the laminated core (5) and the disks (6) of the laminated core (5) are clamped together by the clamping means (13), and
- Arranging the winding wire (11) in the winding space (10) such that the bracing means (13) is secured by the winding wire (11) against removal from the laminated core (5).
The invention further relates to a rotor (1), an electric machine (2) and a motor vehicle (3).

Description

The present invention relates to a method for producing a rotor for an electric machine for a motor vehicle. The invention further relates to a rotor for an electric machine for a motor vehicle, an electric machine for a motor vehicle with a generic rotor and a motor vehicle with a generic electric machine.

Many different methods are known for producing rotors for electrical machines, in which laminated cores made of several disks of electrical steel are wound with a winding wire. The winding wire is arranged by winding in a winding space of the laminated core, which is formed by the rotor teeth and pole caps of the laminated core.

When the winding is created, the winding wire is wound around the laminated core under tension. The high wire tension exerts a correspondingly high force on the laminated core. Depending on the connection technology used, laminated cores are more or less compressible and are therefore comparable to a stack of disc springs.

During the winding process, the winding wire is wound successively around the individual poles of the laminated core, so that the poles are exposed to a corresponding inhomogeneous and temporally changing external load. This means that an asymmetrical deformation of the laminated core can be caused when the winding is created. This can lead to problems such as dimensional accuracy of the rotor, imbalance, subsequent settling effects of the winding during operation of the electric machine, uneven tensions in the individual winding layers of the winding or the like.

To reduce such deformation of the laminated core, it is known to apply an axial compressive force to the laminated core. In order not to hinder the winding process, it is therefore usual to introduce the compressive force into the laminated core via the outer disks near the longitudinal axis of the rotor. This means that the compressive force is introduced unevenly over one end face of the laminated core in the area of a central passage through the laminated core for arranging the rotor shaft.

To better distribute this compressive force across the laminated core, such a process requires a particularly rigid design of the laminated core's pole caps. To prevent the laminated core from tipping over, clamping mandrels can also be inserted into the central opening of the laminated core on both sides to accommodate the rotor shaft. As an alternative to clamping mandrels, the laminated core can sometimes also be arranged on the rotor shaft before the winding is created, for example shrunk or pressed on. In addition, welding the disks of the laminated core at the edge of the winding space, in particular at a groove base formed between adjacent pole caps, is known.

From the document EN 10 2020 113 110 A1 A method for producing a rotor for an electric machine is known in which the laminated core is first stabilized by wrapping winding wire around it and then a cooled rotor shaft is pushed into the heated laminated core. Improved dimensional stability of the laminated core is achieved by using particularly rigid end plates.

The document EN 10 2019 207 865 A1 discloses a method for producing a winding on a stator base body of a stator. A wire tension of the winding wire or a bending deflection of a hollow winding needle is recorded using appropriate measuring equipment and kept below a predetermined limit value via a control loop. This is intended to ensure that the winding has as uniform a formation as possible.

Known methods for producing windings have the disadvantage that at high wire tensions there is still an increased risk of excessive deformation of the disks of the laminated core. At lower wire tensions there is a risk that the winding will become too loose. If the laminated core is compressed in the area of the inner bushing, there is still a risk of the disks bending in the area of the pole caps due to the tensions generated by the winding. Welding the disks can have a negative effect on the rotor from an electromagnetic point of view and is also very costly.

It is therefore the object of the present invention to eliminate or at least partially eliminate the disadvantages described above in a rotor for an electric machine for a motor vehicle. In particular, it is the object of the present invention to provide a method for producing a rotor for an electric machine for a motor vehicle, a rotor for an electric machine for a motor vehicle, an electric machine for a motor vehicle and a motor vehicle with an electric or hybrid drive system, which in a simple and cost-effective manner achieve a reduced deformation of the disks of the sheet metal part. kets when generating the winding and/or have a lower imbalance and/or a higher dimensional accuracy and/or ensure a uniform and stable winding.

The above object is solved by the patent claims. Accordingly, the object is solved by a method for producing a rotor for an electric machine for a motor vehicle with the features of independent claim 1, by a rotor for an electric machine for a motor vehicle with the features of independent claim 8, an electric machine for a motor vehicle with the features of independent claim 10 and by a motor vehicle with an electric or hybrid drive system with the features of independent claim 11. Further features and details of the invention emerge from the subclaims, the description and the drawings. Features and details that are described in connection with the method according to the invention naturally also apply in connection with the rotor according to the invention, the electric machine according to the invention and the motor vehicle according to the invention and vice versa, so that with regard to the disclosure of the individual aspects of the invention, reference is or can always be made to each other.

• - Bereitstellen eines sich um eine Rotorlängsachse erstreckenden Blechpakets aus mehreren nebeneinander angeordneten Scheiben, wobei das Blechpaket einen Paketinnenbereich mit einer koaxial zur Rotorlängsachse ausgebildeten zentralen Durchführung und mehrere vom Paketinnenbereich in radiale Richtung nach außen abstehende Rotorzähne aufweist, wobei zwischen benachbarten Rotorzähnen jeweils ein Wicklungsraum zur Anordnung einer Wicklung aus Wicklungsdraht ausgebildet ist, wobei in den Rotorzähnen eine Verspannkavität zur Anordnung eines Verspannmittels ausgebildet ist,
• - Anordnen eines elektrisch isolierenden Verspannmittels in den Verspannkavitäten derart, dass das Verspannmittel überwiegend oder vollständig außerhalb des Wicklungsraums angeordnet ist und die Scheiben des Blechpakets durch das Verspannmittel parallel zur Rotorlängsachse miteinander verspannt sind, und
• - Anordnen des Wicklungsdrahts im Wicklungsraum des Blechpakets derart, dass das Verspannmittel durch den Wicklungsdraht vor einem Entfernen vom Blechpaket gesichert ist.

According to a first aspect of the invention, the object is achieved by a method for producing a rotor for an electric machine for a motor vehicle. The method comprises:

• - Providing a laminated core extending around a rotor longitudinal axis from a plurality of discs arranged next to one another, wherein the laminated core has a core inner region with a central passage formed coaxially to the rotor longitudinal axis and a plurality of rotor teeth protruding outward from the core inner region in the radial direction, wherein a winding space for arranging a winding made of winding wire is formed between adjacent rotor teeth, wherein a clamping cavity for arranging a clamping means is formed in the rotor teeth,
• - arranging an electrically insulating bracing means in the bracing cavities such that the bracing means is arranged predominantly or completely outside the winding space and the disks of the laminated core are braced together by the bracing means parallel to the rotor longitudinal axis, and
• - Arranging the winding wire in the winding space of the laminated core in such a way that the tensioning means is secured by the winding wire against removal from the laminated core.

First, the laminated core extending around the rotor's longitudinal axis is provided. The laminated core has a plurality of disks that are arranged next to one another coaxially to the rotor's longitudinal axis and are combined to form the laminated core. The disks form the inner region of the laminated core with the central passage that is coaxial to the rotor's longitudinal axis. The central passage is designed to pass through a rotor shaft of the rotor. The laminated core can thus be mounted on the rotor shaft, for example in a press fit. The inner region of the core is preferably hollow-cylindrical or at least hollow-cylindrical.

The laminated core has a plurality of rotor teeth that extend radially outward from the inner region of the core and thus protrude radially from the inner region of the core. The rotor teeth are preferably formed by the disks of the laminated core. The rotor teeth preferably have a tooth cap on a tooth end facing away from the longitudinal axis of the rotor, which has a larger configuration in the circumferential direction than a central tooth region of the rotor tooth arranged between the inner region of the core and the tooth end. The tooth cap can also be referred to as the pole cap of the rotor. Adjacent rotor teeth are preferably arranged at a distance from one another on the inner region of the core.

Grooves are formed between the adjacent rotor teeth, which bind a part, in particular a large part, of the winding space. The winding space is designed to arrange the winding of the rotor from winding wire. The winding space is preferably at least partially limited in the radial direction by the tooth cap. The winding space also extends over the front sides of the rotor teeth, so that the winding can be arranged around the individual rotor teeth on the laminated core. In this way, winding heads of the winding can be formed on the front sides.

The disks of the laminated core are preferably all or at least predominantly made of sheet metal made of electrical sheet metal or another metal. Such electrically conductive disks are preferably coated with an electrical insulator, such as baking varnish. Alternatively or additionally, an electrical insulator, such as paper, can be arranged between two adjacent disks. According to the invention, one or more of the disks can be made of another material, such as a plastic or a fiber composite material with conductive and/or non-conductive reinforcing fibers, which are embedded in a matrix material, such as a resin or the like. In this way, the bending stiffness of the laminated core can be increased.

The two front-side disks of the laminated core, each arranged on the front side of the laminated core, can be designed according to the invention as sheet metal disks made of electrical sheet metal or another metal. The front-side disks preferably have a greater thickness than the other disks of the laminated core. It is preferred according to the invention that the front-side disks have a greater bending stiffness than the other disks.

The bracing cavity is formed in the rotor teeth. The bracing means for bracing the disks of the laminated core can be arranged in the bracing cavity. The bracing cavity preferably has a cavity width that is smaller than a winding space width of the winding space formed adjacent to the bracing cavity. According to the invention, it can alternatively be provided that the cavity width corresponds to the winding space width. A cavity depth preferably corresponds to a bracing means thickness of the bracing means or, for a multi-layer arrangement of the bracing means in the bracing cavity, is a whole multiple of the bracing means thickness. Preferably, at least one cavity section of the bracing cavity has a longitudinal extension in the axial direction, i.e. parallel to the rotor longitudinal axis.

The electrically insulating clamping means is arranged in the clamping cavity in such a way that the clamping means is arranged predominantly or completely outside the winding space. Accordingly, according to the invention, it can be provided that part of the clamping means protrudes into the winding space. In this case, it is preferred that the clamping means protrudes into the winding space in such a way that the subsequent winding process is not hindered by the clamping means. According to the invention, several clamping cavities and several clamping means can be provided. According to the invention, a clamping means can be arranged in several clamping cavities. Likewise, according to the invention, it can be provided that several clamping means are arranged in one clamping cavity. Preferably, a lateral limitation of the winding space is provided by the clamping means. More preferably, the clamping cavity is completely filled by the clamping means. According to the invention, the clamping means can be designed as a clamp, for example with a U-shaped longitudinal cut for gripping the rotor tooth from three sides, as a bandage for wrapping the rotor tooth or the like. In the context of the invention, an electrically insulating bracing means is understood to mean a bracing means which is designed to be electrically insulating at least on one side that contacts the laminated core. Preferably, a side of the bracing means facing the winding space is also designed as an electrical insulator. Preferably, a core region of the bracing means is also designed as an electrical insulator. Alternatively, the core region can also be designed to be electrically conductive.

In addition, the clamping means is arranged in the clamping cavity in such a way that the disks of the laminated core are clamped together by the clamping means parallel to the rotor longitudinal axis. A force required to clamp the disks can be generated, for example, by arranging the clamping means, such as by tightening and fixing the clamping means, elastically bending and springing back the clamping means on the laminated core or the like. Preferably, the clamping means is designed to hold the clamping of the laminated core without further support, for example by the winding, an external clamping tool or the like. Alternatively or additionally, the force required to clamp the disks can be generated according to the invention via an additional pressure device which compresses the laminated core in the axial direction. In this case, a clamping means with a particularly high bending stiffness is preferred in order to hold the laminated core securely in the compressed state. The pressure device is preferably removed from the laminated core after the clamping means has been fixed to the laminated core, so that the laminated core is only held in the clamped state by the clamping means.

After the bracing means have been arranged in the bracing cavity, the winding wire is arranged in the winding space. According to the invention, the winding wire is arranged in the winding space in such a way that the bracing means is secured against removal from the laminated core by the winding wire. The winding wire is preferably arranged in the winding space in such a way that the bracing means is arranged between the winding wire and the laminated core and cannot be removed from the laminated core by a linear movement. The bracing means ensures that the bracing of the laminated core can be adjusted independently of a wire tension of the winding wire, so that the wire tension can be selected almost freely during the winding process. The winding wire is preferably arranged in the winding space after the laminated core has been arranged on the rotor shaft. Alternatively, it can also be provided that the laminated core is arranged on the rotor shaft first and then the winding wire in the winding space. The arrangement of the winding wire The winding wire is preferably wound around the rotor teeth, whereby the winding wire is preferably designed to be easily plastically deformable. The arrangement is preferably carried out in such a way that the winding wire touches the bracing means or clamps itself to the laminated core. The bracing means remains on the finished rotor.

A method according to the invention for producing a rotor for an electric machine for a motor vehicle has the advantage over conventional methods that a winding can be produced on the laminated core using simple means and in a cost-effective manner, whereby bending of the sheet metal disks due to the compression of the laminated core by the clamping means is avoided. A particularly uniform winding can thus be produced. In addition, the method according to the invention makes it easier to avoid settling effects of the winding. The rotor produced in this way therefore has significantly improved dimensional stability and significantly lower imbalance compared to conventional rotors.

According to a preferred further development of the invention, a method can provide a laminated core in which the clamping cavity extends in the axial direction and in the circumferential direction around a rotor tooth, wherein the rotor tooth is surrounded by the clamping means along the clamping cavity when the clamping means is arranged. The clamping cavities extending in the axial direction preferably extend along the winding space and have a longitudinal opening opening into the winding space. The clamping cavities extending in the circumferential direction preferably extend along the winding space provided for the winding heads and have a longitudinal opening opening into the winding space. The clamping means can be arranged, for example, by pushing the clamping means into the clamping cavity in the circumferential direction, in particular by pushing two clamping means in opposite directions on both sides of a rotor tooth. Alternatively or additionally, the bracing means can be arranged, for example, by wrapping the bracing means around the rotor tooth in the area of the bracing cavity. This has the advantage that the lamination stack can be easily compressed and held together using simple means and in a cost-effective manner.

According to the invention, it is preferred that a laminated core is provided in which the clamping cavity extends in the axial direction and in the radial direction around a rotor tooth, wherein the rotor tooth is surrounded by the clamping means along the clamping cavity when the clamping means is arranged. A first clamping cavity extending in the axial direction preferably extends along the central passage and has a longitudinal opening opening into the central passage. A second clamping cavity extending in the axial direction preferably extends along a tooth end of the rotor tooth, such as a pole cap, and is preferably open radially outward. The clamping cavities extending in the radial direction preferably extend along the front rotor teeth and preferably have a longitudinal opening pointing away from the laminated core in the axial direction. The clamping means can be arranged, for example, by pushing the clamping means into the clamping cavity in the radial direction, in particular from one side onto a rotor tooth. Alternatively or additionally, the bracing means can be arranged, for example, by wrapping the bracing means around the rotor tooth in the area of the bracing cavity. This has the advantage that the lamination stack can be easily compressed and held together using simple means and in a cost-effective manner.

It is also preferred to use a bracing means which comprises a fibre-reinforced plastic or is formed from a fibre-reinforced plastic. For example, dry reinforcing fibres can be placed or wound into the bracing cavity and then provided with matrix material. Alternatively or additionally, partially or fully impregnated reinforcing fibres can also be used. Carbon fibres, glass fibres and/or aramid fibres can be used as reinforcing fibres, for example. Thermoplastic plastic, a thermosetting plastic, a resin such as epoxy resin or the like can be used as the matrix material. This has the advantage that the dimensional stability of the rotor and the quality of the winding can be further improved and imbalances can be further reduced using simple means and in a cost-effective manner.

In a particularly preferred embodiment of the invention, a method can be provided for a rotor shaft to be arranged in a press fit on the laminated core before the winding wire is arranged in the winding space. The rotor shaft is preferably arranged by pushing the rotor shaft into the central passage of the laminated core, preferably along the rotor's longitudinal axis. The press fit is preferably created by temperature, so that the rotor shaft is preferably cooled and/or the laminated core is heated before it is arranged in the laminated core. According to the invention, the rotor shaft can be arranged in the laminated core before or after the winding is created. This has the advantage that the dimensional accuracy of the rotor and the quality of the winding can be further improved and imbalances can be further reduced using simple means and in a cost-effective manner.

Preferably, the rotor shaft is arranged on the laminated core after the laminated core has been clamped by the clamping means. When using an additional pressure device, it is preferred in this context that the pressure device continues to exert pressure on the laminated core in the axial direction, so that the arrangement of the rotor shaft causes no or only minimal displacement or bending of the disks of the laminated core and any overloading of the reinforcing means is avoided. In addition, the reinforcing means can be designed to be particularly small in this case, i.e. for relatively low forces. This has the advantage that the dimensional accuracy of the rotor and the quality of the winding can be further improved and imbalances can be further reduced using simple means and in a cost-effective manner.

According to a preferred embodiment of the invention, a method can be used to arrange the winding wire in the winding space of the laminated core with a defined longitudinal wire tension of the winding wire. The longitudinal wire tension is preferably continuously monitored during the creation of the winding and adjusted if necessary so that the longitudinal wire tension is always between a predetermined minimum wire tension value and a predetermined maximum wire tension value. The longitudinal wire tension is preferably adjusted using hysteresis and/or damping and/or delay control or the like so that voltage oscillations are better avoided. This has the advantage that the quality of the winding can be further improved using simple means and in a cost-effective manner.

According to a second aspect of the invention, the object is achieved by a rotor for an electric machine for a motor vehicle. The rotor has a laminated core made up of several disks arranged next to one another, the laminated core having an inner region of the core with a central passage formed coaxially to the longitudinal axis of the rotor and several rotor teeth protruding outward from the inner region of the core in the radial direction. A winding space is formed between adjacent rotor teeth, a rotor winding of the rotor made of winding wire being arranged in the winding space, a rotor shaft of the rotor extending coaxially to the longitudinal axis of the rotor extending through the central passage. According to the invention, a clamping cavity is formed in the rotor teeth, the disks of the laminated core being clamped together by an electrically insulating clamping means arranged in the clamping cavity.

The laminated core extends around the longitudinal axis of the rotor and has a plurality of disks that are arranged next to one another coaxially to the longitudinal axis of the rotor and are combined to form the laminated core. The disks each have a longitudinal section of the central passage and thus together form the central passage formed in the interior of the core, through which the rotor shaft is inserted.

The rotor teeth protrude outwards in the radial direction from the inner area of the package. A groove is formed between every two adjacent rotor teeth. The winding spaces or at least parts of the winding spaces are provided by the grooves. The winding spaces also extend around the rotor teeth of the front disks of the laminated core. The rotor winding made of winding wire is arranged in the winding spaces. The rotor teeth are designed as pole caps or each have a pole cap at their ends pointing away from the rotor's longitudinal axis.

The disks of the laminated core are preferably all or at least predominantly made of sheet metal disks made of electrical sheet metal or another metal. Such electrically conductive disks are preferably coated with an electrical insulator, such as baking varnish. Alternatively or additionally, an electrical insulator, such as paper, can be arranged between two adjacent inner disks. According to the invention, one or more of the inner disks can be made of another material, such as a plastic or a fiber composite material with conductive and/or non-conductive reinforcing fibers, which are embedded in a matrix material, such as a resin or the like. The flexural rigidity of the laminated core can thus be increased.

The clamping cavity is formed in the rotor teeth. The clamping means, by means of which the disks of the laminated core are clamped together, is arranged in the clamping cavity. The clamping means is thus designed to transmit a force with at least one force component acting in the axial direction to the laminated core, so that the disks are thereby pressed against each other. The clamping means can, for example, be wound or pushed into the clamping cavity and preferably clamped. The clamping cavity and the clamping means are preferably coordinated with one another in such a way that the bracing means does not protrude into the winding space. Preferably, the bracing cavity and the bracing means are coordinated with one another in such a way that the bracing means completely fills the bracing cavity or at least separates it from the winding space. The rotor winding is preferably arranged in the winding space in such a way that the bracing means is secured by the rotor winding against removal from the bracing cavity.

The rotor according to the invention for an electric machine for a motor vehicle offers all the advantages that have already been described for a method for producing a rotor for an electric machine for a motor vehicle according to the first aspect of the invention. Accordingly, the rotor according to the invention has the advantage over conventional rotors that a winding is produced on the laminated core using simple means and in a cost-effective manner, whereby bending of the sheet metal disks due to the compression of the laminated core by the clamping means is avoided. The rotor according to the invention therefore has a particularly uniform winding. In addition, settling effects of the winding are better avoided with the rotor according to the invention. The rotor according to the invention therefore has significantly improved dimensional stability and significantly lower imbalance compared to conventional rotors.

The rotor is particularly preferably manufactured by a method according to the invention. Accordingly, the laminated core is clamped during the manufacture of the rotor by arranging the electrically insulating clamping means in the clamping cavity. The winding can thus subsequently be arranged on the clamped laminated core, so that the wire tension can be controlled independently or at least essentially independently of the clamping force of the clamping of the laminated core. In other words, it is therefore not necessary for the laminated core to be clamped by the winding.

This has the advantage that a rotor with a particularly high dimensional accuracy, a lower imbalance and a particularly uniform winding with no or only very slight settling effects is provided using simple means and in a cost-effective manner.

According to a third aspect of the invention, the object is achieved by an electric machine for a motor vehicle. The electric machine has a stator extending around a rotor longitudinal axis. According to the invention, the electric machine has a rotor according to the invention. The rotor is arranged coaxially to the stator. The rotor is preferably surrounded by the stator in the circumferential direction. The stator preferably has stator teeth, stator slots formed between two adjacent stator teeth and a stator winding arranged in the stator slots. The stator winding preferably has a winding head on each of the two end faces of the stator.

The electric machine for a motor vehicle according to the invention offers all the advantages that have already been described for a method for producing a rotor for an electric machine for a motor vehicle according to the first aspect of the invention and for a rotor for an electric machine for a motor vehicle according to the second aspect of the invention. Accordingly, the electric machine according to the invention has the advantage over conventional electric machines that a particularly uniform winding is provided on the laminated core of the rotor using simple means and in a cost-effective manner, and the laminated core has experienced little or no deformation as a result of the winding. In addition, the winding of the rotor of the electric machine according to the invention has greatly reduced settling effects compared to windings of rotors of conventional electric machines. The rotor of the electric machine according to the invention therefore has significantly improved dimensional stability and significantly lower imbalance.

According to a fourth aspect of the invention, the object is achieved by a motor vehicle. The motor vehicle has an electric or hybrid drive system. According to the invention, the drive system has an electric machine according to the invention.

The motor vehicle according to the invention offers all the advantages that have already been described for a method for producing a rotor for an electric machine for a motor vehicle according to the first aspect of the invention, for a rotor for an electric machine for a motor vehicle according to the second aspect of the invention and for an electric machine for a motor vehicle according to the third aspect of the invention. Accordingly, the motor vehicle according to the invention has the advantage over conventional motor vehicles that a particularly uniform winding is provided on the laminated core of the rotor of the electric machine of the drive system of the motor vehicle using simple means and in a cost-effective manner, and the laminated core has experienced no or only very slight deformation as a result of the winding. In addition, the winding of the rotor according to the invention of the electric machines according to the invention of the motor vehicle according to the invention has a particularly uniform winding compared to windings of rotors of electric machines. ous motor vehicles has greatly reduced settling effects. The rotor according to the invention of the electric machine according to the invention of the motor vehicle according to the invention therefore has considerably improved dimensional stability and a significantly lower imbalance.

• 1 in einer stirnseitigen Draufsicht ein Blechpaket während der Durchführung einer bevorzugten ersten Ausführungsform des erfindungsgemäßen Verfahrens,
• 2 in einer perspektivischen Darstellung das Blechpaket aus 1,
• 3 in einer perspektivischen Darstellung ein Blechpaket während der Durchführung einer bevorzugten zweiten Ausführungsform des erfindungsgemäßen Verfahrens,
• 4 in einer Schnittdarstellung das Blechpaket aus 3,
• 5 in einer perspektivischen Darstellung ein Blechpaket während der Durchführung einer bevorzugten dritten Ausführungsform des erfindungsgemäßen Verfahrens,
• 6 in einer Schnittdarstellung das Blechpaket aus 5,
• 7 in einer Seitenansicht eine Elektromaschine gemäß einer bevorzugten Ausführungsform der Erfindung,
• 8 in einer Seitenansicht eine bevorzugte Ausführungsform eines erfindungsgemäßen Kraftfahrzeugs, und
• 9 in einem Ablaufdiagramm eine bevorzugte Ausführungsform eines erfindungsgemäßen Verfahrens.

A method according to the invention, a rotor according to the invention, an electric machine according to the invention and a motor vehicle according to the invention are explained in more detail below with reference to drawings. They each show schematically:

• 1 in a frontal plan view of a laminated core during the implementation of a preferred first embodiment of the method according to the invention,
• 2 in a perspective view the sheet metal package from 1 ,
• 3 in a perspective view a laminated core during the implementation of a preferred second embodiment of the method according to the invention,
• 4 in a sectional view the laminated core from 3 ,
• 5 in a perspective view a laminated core during the implementation of a preferred third embodiment of the method according to the invention,
• 6 in a sectional view the laminated core from 5 ,
• 7 in a side view an electric machine according to a preferred embodiment of the invention,
• 8th in a side view a preferred embodiment of a motor vehicle according to the invention, and
• 9 in a flow chart a preferred embodiment of a method according to the invention.

Elements with the same function and mode of operation are in the 1 to 9 each provided with the same reference symbols.

In 1 the laminated core 5 is shown schematically in a frontal plan view during the implementation of a preferred first embodiment of the method according to the invention. 2 shows the sheet package 5 from 1 in a perspective view. In the state shown, the laminated core 5 is arranged on a rotor shaft 14, which is arranged in a central passage 9 of the laminated core 5. Alternatively, the laminated core 5 can also be provided without a rotor shaft 14, wherein the rotor shaft 14 is preferably arranged on the laminated core 5 after the winding has been produced. The laminated core 5 is composed of several disks 6. The laminated core 5 has several rotor teeth 9, which extend in the radial direction R away from an inner region 7 of the laminated core 5. Between two adjacent rotor teeth 9 there is a winding space 10 for arranging a winding wire 11 (cf. 4 ). A circumferential clamping cavity 12 is formed in each of the rotor teeth 9. The clamping cavity 12 thus has two sections extending in the circumferential direction U and two sections extending in the axial direction A. Two clamping means 13 designed as elastically deformable clamps are arranged in a clamping cavity 12, by means of which the disks 6 of the laminated core 5 are clamped together in the axial direction A. The clamping means 13 completely fill the clamping cavity 12 and, together with the rotor tooth 9, form a mutually aligned lateral wall of a winding space 10.

In 3 the laminated core 5 is shown schematically in a perspective view during the implementation of a preferred second embodiment of the method according to the invention. 4 shows the sheet package 5 from 3 schematically in a sectional view. The laminated core 5 differs from the one in 1 and 2 shown laminated core 5 in a formation of the clamping cavities 12 and the clamping means 13. In 3 It is clearly visible that the clamping means 13 arranged in the clamping cavities 12 also extend in the axial direction A. 4 shows that the clamping cavities 12 also extend in the circumferential direction U. The clamping cavities 12 do not extend as in 1 around the front discs 6, but run between a front disc 6 and an adjacent disc 6. The bracing means 13 is designed as a bandage, for example made of a fiber composite material, such as preferably a fiber-reinforced thermoplastic, a fiber-reinforced thermoset, CFRP or the like. The bracing means 13 completely fills the bracing cavity 12 and forms a lateral wall of a winding space 10. Furthermore, in 4 a winding made of winding wire 11 arranged in the winding spaces 10 is shown. The winding covers the bracing means 13 and thus secures it against detachment from the laminated core 5.

In 5 the laminated core 5 is shown schematically in a perspective view during the implementation of a preferred third embodiment of the method according to the invention. 6 shows the sheet package 5 from 5 schematically in a sectional view. The laminated core 5 differs from the one in 1 and 2 shown laminated core 5 in a training the clamping cavities 12 and the clamping means 13. In 6 It is clearly visible that the clamping means 13 arranged in the clamping cavities 12 extend in the axial direction A in the area of the rotor shaft 14 and in the protruding end area of the rotor teeth 9. Furthermore, the clamping cavities 12 extend in the radial direction R through the front disks 6. In 5 the rotor winding made of winding wire 11 is already completely arranged on the laminated core 5. The rotor winding secures the bracing means 13 on the rotor tooth 9.

In 7 the electric machine 2 according to a preferred embodiment of the invention is shown schematically in a side view. The electric machine 2 has a stator 15 which extends coaxially to the rotor longitudinal axis 4. A rotor 1 according to the invention is arranged in the stator 15. The rotor 1 extends coaxially to the rotor longitudinal axis 4. An end region of the rotor shaft 14 extending coaxially to the rotor longitudinal axis 4 protrudes laterally from the stator 15.

8th shows the preferred embodiment of the motor vehicle 3 according to the invention schematically in a side view. The motor vehicle 3 has an electric drive system 16 with an electric machine 2 according to the invention and a traction battery 17. The electric machine 2 has a stator 15 and a rotor 1 according to the invention.

In 9 the preferred embodiment of a method according to the invention is shown schematically in a flow chart. In a first method action 100, a laminated core 5 extending around a rotor longitudinal axis 4 is provided from a plurality of disks 6. The laminated core 5 has a core inner region 7 with a central passage 8 formed coaxially to the rotor longitudinal axis 4 and a plurality of rotor teeth 9 protruding outward from the core inner region 7 in the radial direction R. Between adjacent rotor teeth 9, a winding space 10 is formed for arranging a winding made of winding wire 11. In addition, a bracing cavity 12 for arranging a bracing means 13 is formed in the rotor teeth 9.

In a second method action 200, an electrically insulating bracing means 13 is arranged in the bracing cavities 12 such that the bracing means 13 is arranged predominantly or completely outside the winding space 10 and the disks 6 of the laminated core 5 are braced together by the bracing means 13 parallel to the rotor longitudinal axis 4. To support this, it can be provided that the laminated core 5 is pressed together in the axial direction A by an additional pressure device during the arrangement of the bracing means 13. This allows the forces required to arrange the bracing means 13 to be reduced.

In a third method action 300, the winding wire 11 is arranged in the winding space 10 of the laminated core 5 in such a way that the clamping means 13 is secured by the winding wire 11 against being removed from the laminated core 5. In this case, the winding wire 11 can, for example, rest against the clamping means 13, for example by forming a contact pressure or without pressure. Alternatively, the winding wire 11 can be arranged at a distance from the clamping means 13. The arrangement of the winding wire 11 preferably takes place with a predefined wire tension, which is selected independently of a pressing pressure of the laminated core 5.

List of reference symbols

1

rotor

2

Electric machine

3

Motor vehicle

4

Rotor longitudinal axis

5

Sheet metal package

6

Discs

7

Package interior

8th

central implementation

9

Rotor tooth

10

Winding space

11

Winding wire

12

Clamping cavity

13

Bracing

14

Rotor shaft

15

stator

16

Drive system

17

Traction battery

100

first procedural action

200

second procedural action

300

third procedural action

400

fourth procedural action

500

fifth procedural action

A

axial direction

R

radial direction

QUOTES INCLUDED IN THE DESCRIPTION

This list of documents listed 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 accepts no liability for any errors or omissions.

Cited patent literature

• DE 102020113110 A1 [0007]
• DE 102019207865 A1 [0008]

Claims (11)

Method for producing a rotor (1) for an electric machine (2) for a motor vehicle (3), comprising: - providing a laminated core (5) extending around a rotor longitudinal axis (4) from a plurality of disks (6) arranged next to one another, wherein the laminated core (5) has a core inner region (7) with a central passage (8) formed coaxially to the rotor longitudinal axis (4) and a plurality of rotor teeth (9) protruding outward from the core inner region (7) in the radial direction (R), wherein a winding space (10) for arranging a winding made of winding wire (11) is formed between adjacent rotor teeth (9), wherein a bracing cavity (12) for arranging a bracing means (13) is formed in the rotor teeth (9), - arranging an electrically insulating bracing means (13) in the bracing cavities (12) such that the bracing means (13) is arranged predominantly or completely outside the winding space (10) and the Disks (6) of the laminated core (5) are clamped together by the clamping means (13) parallel to the rotor longitudinal axis (4), - arranging the winding wire (11) in the winding space (10) of the laminated core (5) such that the clamping means (13) is secured by the winding wire (11) against removal from the laminated core (5). Procedure according to Claim 1 , characterized in that a laminated core (5) is provided, in which the bracing cavity (12) extends in the axial direction (A) and in the circumferential direction (U) around a rotor tooth (9) in each case, wherein the rotor tooth (9) is surrounded by the bracing means (13) along the bracing cavity (12) when the bracing means (13) is arranged. Procedure according to Claim 1 or 2 , characterized in that a laminated core (5) is provided, in which the bracing cavity (12) extends in the axial direction (A) and in the radial direction (R) around a rotor tooth (9) in each case, wherein the rotor tooth (9) is surrounded by the bracing means (13) along the bracing cavity (12) when the bracing means (13) is arranged. Method according to one of the preceding claims, characterized in that a clamping means (13) is used which comprises a fiber-reinforced plastic or is formed from a fiber-reinforced plastic. Method according to one of the preceding claims, characterized in that before arranging the winding wire (11) in the winding space (10), a rotor shaft (14) is arranged in a press fit on the laminated core (5). Procedure according to Claim 5 , characterized in that the rotor shaft (14) is arranged on the laminated core (5) after the laminated core (5) has been clamped by the clamping means (13). Method according to one of the preceding claims, characterized in that the arrangement of the winding wire (11) in the winding space (10) of the laminated core (5) takes place with a defined longitudinal wire tension of the winding wire (11). Rotor (1) for an electric machine (2) for a motor vehicle (3), comprising a laminated core (5) made up of a plurality of disks (6) arranged next to one another, the laminated core (5) having a core inner region (7) with a central passage (8) formed coaxially to the longitudinal axis (4) of the rotor and a plurality of rotor teeth (9) protruding outward from the core inner region (7) in the radial direction (R), a winding space (10) being formed between adjacent rotor teeth (9), a rotor winding of the rotor (1) made up of winding wire (11) being arranged in the winding space (10), a rotor shaft (14) of the rotor (1) extending coaxially to the longitudinal axis (4) of the rotor extending through the central passage (8), characterized in that a clamping cavity (12) is formed in the rotor teeth (9), the disks (6) of the laminated core (5) being held together by an electrically insulating material arranged in the clamping cavity (12). Bracing means (13) are clamped together. Rotor (1) after Claim 8 , characterized in that the rotor (1) is produced by a method according to one of the Claims 1 until 7 is manufactured. Electric machine (2) for a motor vehicle (3), comprising a stator (15) extending around a rotor longitudinal axis (4), characterized in that the electric machine (2) has a rotor (1) according to one of the Claims 8 or 9 having. Motor vehicle (3) comprising an electric or hybrid drive system (16), characterized in that the drive system (16) comprises an electric machine (2) according to Claim 10 having.

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