Classifications

• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K1/00—Details of the magnetic circuit
  • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
  • H02K1/22—Rotating parts of the magnetic circuit
  • H02K1/28—Means for mounting or fastening rotating magnetic parts on to, or to, the rotor structures
• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K1/00—Details of the magnetic circuit
  • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
  • H02K1/22—Rotating parts of the magnetic circuit
  • H02K1/28—Means for mounting or fastening rotating magnetic parts on to, or to, the rotor structures
  • H02K1/30—Means for mounting or fastening rotating magnetic parts on to, or to, the rotor structures using intermediate parts, e.g. spiders
• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
  • H02K15/02—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K7/00—Arrangements for handling mechanical energy structurally associated with dynamo-electric machines, e.g. structural association with mechanical driving motors or auxiliary dynamo-electric machines
  • H02K7/003—Couplings; Details of shafts

Definitions

• Rotor of a rotary electric machine a method of manufacturing a rotor of a rotary electric machine, and a rotary electric machine
• the invention relates to a method for firmly mechanically connecting two components, a rotor of an electrical rotary machine, a method for producing a rotor of an electrical rotary machine, and an electrical rotary machine.
• Another method for connecting sheet metal parts is riveting with different versions of a respective rivet.
• Methods of this type can also be used in the production of rotors for rotary electric machines.
• a rotor of an electrical rotary machine usually includes a laminated core for receiving magnets or magnets already integrated therein.
• a laminated core is usually closed off axially by rotor end plates.
• connection between a rotor end plate and the shaft must be able to transmit high torques and high speeds due to the effect of the mass moment of inertia of a respective rotor end plate.
• connection between the rotor end plate and the shaft must be absolutely free of play, since rotor end plates usually have cutouts that are used to transmit signals for eddy current sensors.
• balancing bores are often arranged in rotor end plates in order to balance the entire rotor subassembly.
• Rotor end plates are preferably made of suitable aluminum alloy because in this embodiment eddy current losses in relation to the stator and the weight are minimized.
• a common method for firmly arranging the rotor end plate on the shaft is to shrink it onto the shaft with a non-positive fit.
• a steel ring can be arranged on the shaft by means of radial pressure.
• the rotor end plate and the steel ring are assembled in such a way that the rotor end plate and the steel ring are pressed against one another axially and are also in this axial prestress in the assembled state.
• the steel ring thus represents an axial securing of the rotor end plate, it can only partially absorb the torsional moment introduced by the rotor end plate.
• the present invention is based on the object of providing a method for firmly mechanically connecting two components, a rotor of an electric rotary machine, a method for producing a rotor of an electric rotary machine and an electric rotary machine that is more efficient and ensure the fixing of rotor end plates on the shaft of a rotor in a space-saving manner.
• This object is achieved by the method for firmly mechanically connecting two components according to claim 1, by a rotor of a rotary electric machine according to claim 4, by a method for manufacturing a rotor of a rotary electric machine according to claim 9 and by a rotary electric machine according to claim 10
• Advantageous refinements of the method for firmly mechanically connecting two components are specified in subclaims 2 and 3.
• Advantageous configurations of the rotor of the electric Rotati onsmaschine are specified in the dependent claims 5 to 8.
• the invention relates to a method for firmly mechanically connecting two components, in which a first component and a second component are provided, at least one pin is produced in the first component by pressing into the material of the first component, and at least one in the second component through-hole is produced, a pin of the first component is introduced into a through-hole of the second component, and a pressure force is applied to the pin with a pressure element in the axial direction of the pin and/or an impulse is applied and with a counter-pressure element in the through-hole in the opposite direction in the axial direction a counter-pressure force is applied in the direction of pressure of the pressure force on the pin and/or a counter-impulse is applied, so that material of the pin located axially between the pressure element and the pressure element is displaced radially and forms a frictional connection with a hole wall of the through-hole.
• the frictional connection with the hole wall of the through hole creates a bearing stress or bearing pressure there, which ensures a permanent mechanical connection between the pin and the through hole and consequently between the two components in the axial direction.
• the two components are connected to one another in a non-positive and positive manner.
• the axial direction denotes the direction in which the pin is formed, ie its longitudinal direction.
• the radial direction refers to the direction running transversely thereto, ie transversely to the longitudinal direction of the pin and transversely to the effective direction of the pressure forces applied by the pressure element and the counter-pressure element.
• the method according to the invention is designed in a similar manner to clinching or clinching, although in the method according to the invention the undercut produced during clinching does not necessarily have to be produced in the material of the matrix, which corresponds here to the second component.
• the method according to the invention can also be referred to as riveting.
• journal before the journal expands radially, it can form a loose fit in relation to the through hole. This facilitates the introduction of the pin into the through hole.
• the bearing face of the hole is only realized through the radial expansion of the spigot.
• radial axial
• circumferential direction refer to the axis of rotation of the shaft or to the longitudinal axis of a respective pin.
• the method according to the invention can be carried out in such a way that the formation of the pin takes place at the same time as the pin is introduced into the through-hole of the second component.
• An alternative procedure would be to produce the pin before it is introduced into the through-hole, in particular at the same time as a punching process to form the outer contour of the first component.
• the pin is produced from the material of the first component by means of the compressive force.
• the pressure element is not only used to realize the radial widening of the pin, but also to produce the pin at all. Accordingly, the production of the spigot and the radial expansion of the spigot can essentially be carried out in one process by using the pressure element to produce the spigot in the through-hole of the second component and at the same time or immediately thereafter in the through-hole through the counter-pressure element against the pressure exerted by the pressure ckelement realized compressive force a counter-pressure force is applied, which leads to the radi alen expansion of the pin.
• a further aspect of the present invention is a rotor of an electrical rotary machine, comprising a shaft and a laminated core arranged coaxially on the shaft for receiving magnets or at least one electrical conductor, the laminated core having a rotor end plate on at least one axial side, and the Rotor has a torque transmission element which is connected to a shaft of the shaft in a torque-proof manner and which has a higher strength than the rotor end plate.
• the rotor end plate is connected to the torque transmission element by means of the method according to the invention for firmly mechanically connecting two components connected, wherein the rotor end plate is the first component or the second component, and the torque-transmitting element is the other component.
• the laminated core can already have the magnets or electrical conductors, or it can be set up to accommodate magnets or electrical conductors.
• a rotor end plate is arranged axially on both sides of the laminated core.
• the relevant strength of the torque transmission element is in particular the compressive strength and/or shear strength.
• the torque transmission element is a ring which is non-rotatably connected to the shaft, or that the torque transmission element is an integral part of the shaft.
• the non-rotatable connection of the torque transmission element to the shaft can be realized in particular in that the torque transmission element is snapped onto the shank of the shaft.
• the torque transmission element can be an integral part of the shaft, in particular a set formed by the shaft.
• the torque transmission element can be connected to the shaft by means of a press fit.
• This embodiment relates to the Vari ante of the torque transmission element, in which this is non-rotatably connected to the shaft as an extra element.
• the torque transmission element is the first component and that the rotor end plate is the second component, or that the rotor end plate is the first component and that the torque transmission element is the second component.
• the pin is produced from the material of the torque transmission element and is introduced into the through-hole of the rotor end plate.
• This embodiment occurs in particular special in the embodiment in which the torque transmission element is arranged as an extra component on the shaft.
• the pin is produced from the material of the rotor end plate and is introduced into the through hole of the torque transmission element.
• This embodiment occurs in particular in the configuration in which the torque transmission element is an integral part of the shaft.
• both components have contact surfaces running essentially perpendicularly to the axis of rotation of the shaft Components rest against each other, press against each other if necessary.
• the material of the torque-transmitting element can be steel, and the rotor end plate can consist at least predominantly of an aluminum alloy, although it should not be ruled out that the rotor end plate can be made of another material, such as also steel.
• Another aspect of the present invention is a method for manufacturing a rotor of a rotary electric machine, in which the following steps are carried out:
• a shaft, at least one rotor end plate and at least one torque transmission element and a laminated core for accommodating magnets or at least one electrical conductor are provided;
• the rotor end plate is connected to the torque transmission element by means of the method according to the invention for firmly mechanically connecting two components, the rotor end plate being the first component or the second component, and the torque transmission element being the other component, and after this step the laminated core is mounted coaxially the shaft is arranged so that an axial termination of the laminated core is formed by the rotor end plate.
• This method can be carried out in different configurations.
• the torque transmission element is present as an extra component in the form of a ring
• a Subassembly of rotor end plate and torque transmission element is produced according to the method according to the invention for firmly mechanically connecting two components, and then this subassembly is firmly connected to the shaft of the shaft, in particular by warm fitting the ring or the torque transmission element onto the shaft.
• the shaft may have been previously cooled.
• the laminated core can be firmly mechanically connected to the end plate of the rotor in the circumferential direction and/or in the axial direction.
• the rotor end plate and the torque transmission element and possibly also a respective laminated core are automatically centered in relation to one another by their inner diameter or radial limitations by the arrangement on the shaft.
• the invention provides an electric rotary machine that includes a rotor according to the invention.
• FIG. 1 A rotor produced according to the invention in a sectional view.
• the rotor shown in FIG. 1 comprises a shaft 10 on whose shaft 11 a plurality of laminated cores 20 are arranged.
• These laminated cores 20 can be connected to the shaft 10 in a torque-proof manner, for example by means of a suitable torque transmission connection, such as with a spline, not shown here.
• the laminated cores 20 are penetrated by magnets 21 in the embodiment shown here.
• the rotor comprises a rotor end plate 30 on both axial sides of the laminated core 20. Both rotor end plates are provided with balancing holes 43 according to the embodiment shown here.
• the rotor end plates 30 are attached to the shaft 10 in different variants.
• the rotor includes a torque transmission element 40 in the form of a ring.
• This torque transmission element 40 is a first component 50, which is non-rotatably connected to the rotor end plate 30, which forms a second component 60 here.
• the non-rotatable connection is achieved by directing a compressive force 70 onto the first component 50 or the torque-transmitting element 40 by means of a pressure element (not shown here) in such a way that a pin is located on the side of the torque-transmitting element 40 opposite the impact of the compressive force 70 51 trained.
• the second component 60 or the rotor end plate 30 has a through hole 61 which is designed to be complementary in terms of the shape and size of the cross section of the pin 51 and also the position of the pin 51 .
• the pin 51 can have been formed with a contact surface 41 on a contact surface 31 of the rotor end plate 30 before the torque transmission element 40 bears against it, and only when the two contact surfaces 31, 41 bear on one another enter the through hole 61.
• Torque transmission element 40 and rotor end plate 30 are centered automatically at their inner diameter or inner radial boundary edge through shaft 13 of shaft 10.
• a counter-pressure force 71 opposing the pressure force 70 is applied to the pin 51 in the axial direction, so that the material of the pin 51 undergoes a radial displacement 72 .
• the torque transmission element 40 which is designed here as an extra ring, is fastened with a press fit 42 on the shank 11 of the shaft.
• This press fit 42 can be realized in particular by warm fitting of the torque transmission element 40 .
• the rotor end plate 30 is also fixed on the left-hand side of the rotor shown by means of this non-positive connection.
• a torque transmission element 40 is also present here, but this is in the form of a shoulder 12 of the shaft 10 .
• the torque transmission element 40 is an integral part of the shaft 10 here.
• the torque-transmitting element 40 includes a contact surface 41 which bears axially against a contact surface 31 of the rotor end plate 30 .
• the rotor end plate 30 is designed as a first component 50
• the torque transmission element 40 designed as a step 12 is designed as a second component.
• a pin 51 is formed by the action of the compressive force 70 on the rotor end plate 30 on the side opposite the action of the compressive force 70 .
• the torque transmission element 40 and the paragraph 12 has an axially extending through hole 61, which with respect Shape and size of the cross section of the pin 51 and also the position of the pin 51 is designed to be complementary.
• the application of a counter-pressure force 71 to the axial end face of the pin 51 causes the material of the pin 51 to experience a radial displacement 72 and thus presses against the wall of the through-hole 61 and thus realizes a non-positive connection.
• the shoulder 12 is also used for the arrangement of clutch plates, not shown here, by means of the splines 13.
• the shoulder 12 has several radial bores 14 to enable fluid flows for the purpose of cooling and/or lubrication aggregates in the vicinity of the rotor.
• the rotor shown can be assembled in such a way that first the rotor end plate 30 on the right-hand side is firmly connected to the shoulder 12 of the shaft 10 designed as a torque transmission element 40 . Thereafter, the laminated cores 20 can be positioned on the shaft 10 .
• a subassembly comprising the rotor end plate and the torque transmission element 40 in the form of the ring, which is present as an extra component, can be arranged on the shaft 10 axially opposite the rotor end plate 30 on the right-hand side. This subassembly can be prefabricated before assembly on the shaft 10 by the described fixing of the rotor end plate 30 and the torque transmission element 40 to one another.
• a respective torque transmission element 40 can be made of steel in particular and consequently can have a higher strength than a rotor end plate 30 made of an aluminum alloy, and due to the fact that a plurality of pin-through-hole connections are realized circumferentially around the shaft 10 can be, a high mechanical strength of the connection between rotor end plate 30 and shaft 10 is guaranteed.

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• Engineering & Computer Science (AREA)
• Power Engineering (AREA)
• Manufacturing & Machinery (AREA)
• Iron Core Of Rotating Electric Machines (AREA)
• Manufacture Of Motors, Generators (AREA)

Applications Claiming Priority (2)

Publications (1)

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ID=81327740

Family Applications (1)

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• 2021
  • 2021-04-09 DE DE102021108893.3A patent/DE102021108893A1/de active Pending
• 2022
  • 2022-03-23 EP EP22714352.6A patent/EP4320707A1/de active Pending
  • 2022-03-23 WO PCT/DE2022/100221 patent/WO2022214131A1/de active Application Filing
  • 2022-03-23 CN CN202280027401.9A patent/CN117157855A/zh active Pending
  • 2022-03-23 US US18/285,893 patent/US20240195247A1/en active Pending

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