EP4352857A2 - Segment de rotor, couvercle magnétique, rotor, générateur, éolienne et dispositif de moulage et procédé de fabrication d'un segment de rotor - Google Patents

Segment de rotor, couvercle magnétique, rotor, générateur, éolienne et dispositif de moulage et procédé de fabrication d'un segment de rotor

Info

Publication number
EP4352857A2
EP4352857A2 EP22733519.7A EP22733519A EP4352857A2 EP 4352857 A2 EP4352857 A2 EP 4352857A2 EP 22733519 A EP22733519 A EP 22733519A EP 4352857 A2 EP4352857 A2 EP 4352857A2
Authority
EP
European Patent Office
Prior art keywords
rotor
magnet
laminated core
segment
magnet carrier
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP22733519.7A
Other languages
German (de)
English (en)
Inventor
Stephan Jöckel
Andreas Recktenwald
Jakob BLÄSI
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Wobben Properties GmbH
Original Assignee
Wobben Properties GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Wobben Properties GmbH filed Critical Wobben Properties GmbH
Publication of EP4352857A2 publication Critical patent/EP4352857A2/fr
Pending legal-status Critical Current

Links

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
    • H02K1/27—Rotor cores with permanent magnets
    • H02K1/2786—Outer rotors
    • H02K1/2787—Outer rotors the magnetisation axis of the magnets being perpendicular to the rotor axis
    • H02K1/2789—Outer rotors the magnetisation axis of the magnets being perpendicular to the rotor axis the rotor consisting of two or more circumferentially positioned magnets
    • H02K1/2791—Surface mounted magnets; Inset magnets
    • 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
    • H02K15/03—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies having permanent magnets
    • 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
    • H02K7/18—Structural association of electric generators with mechanical driving motors, e.g. with turbines
    • H02K7/1807—Rotary generators
    • H02K7/1823—Rotary generators structurally associated with turbines or similar engines
    • H02K7/183—Rotary generators structurally associated with turbines or similar engines wherein the turbine is a wind turbine
    • H02K7/1838—Generators mounted in a nacelle or similar structure of a horizontal axis wind turbine

Definitions

  • the invention relates to a rotor segment of a rotor of a generator for a wind turbine.
  • the invention particularly relates to a rotor segment of a segmented rotor of a segmented generator for a wind turbine.
  • the rotor segment comprises a magnet carrier segment with a ring-shaped or partially ring-shaped geometry, the magnet carrier segment extending in a radial direction between a radially outer magnet carrier outer surface and a magnet carrier inner surface which is radially inner in relation to the magnet carrier outer surface, and at least one rotor laminated core, which is used for receiving at least one magnet unit is formed, the at least one rotor laminated core extending in the radial direction between a radially outer laminated core surface and a laminated core inner surface located radially in relation to the laminated core outer surface.
  • the invention relates to a magnet cover for covering at least one magnet unit of a rotor segment.
  • the invention also relates to a rotor, in particular a segmented rotor, and a generator, in particular a segmented generator, for a wind energy plant. Furthermore, the invention relates to a wind energy installation.
  • the invention relates to a molding device and a method for manufacturing a rotor segment. It is known to produce a rotor segment or a rotor of a generator for a wind turbine from a magnet carrier segment and a rotor sheet metal package. For the production of the rotor segment or the rotor, it is known to arrange the rotor sheet metal package on the magnet carrier segment.
  • the rotor laminated core is arranged with its radially outer outer surface of the laminated core on the radially inner inner surface of the magnet carrier.
  • both the rotor laminated core and the magnet carrier segment are machined beforehand and then assembled at the machined fitting surfaces or functional surfaces and welded together.
  • This type of production of a rotor segment or rotor requires a comparatively large number of production steps and, in particular, requires a high level of (manufacturing) accuracy to be achieved.
  • the machined mating surfaces or functional surfaces must meet tight tolerances in terms of their dimensions, shape and position. Both the comparatively high number of manufacturing steps required and the high demands on the accuracy to be achieved are responsible for a significant part of the costs. If the high levels of accuracy are not achieved in terms of production technology, this can lead to the rotor, i.e. the generator, running out of true and to increased noise emissions. It is therefore necessary to use machine tools, such as lathes, with which the required manufacturing accuracies can be achieved. However, such machine tools are very expensive - especially when components with large diameters are to be produced.
  • German Patent and Trademark Office has researched the following prior art in the priority application for the present application: DE 10 2013 101 956 A1, DE 10 2004 035 382 A1, DE 10 2018 111 906 A1, DE 10 2015 203 257 A1, WO 2012/ 103 882 A2, EP 2 790 297 A1, DE 10 2009 025 929 A1, US 5 306 123 A, DE 10 2010 041 593 A1, DE 20 2011 050 715 U1, EP 2 713480 A1, EP 3 829 030 A1.
  • the invention is therefore based on the object of providing a rotor segment, a magnet cover, a rotor, a generator, a wind energy installation, as well as a molding device and a method for producing a rotor segment, which address the problems mentioned.
  • the invention is based on the object of providing a rotor segment, a magnet cover, a rotor, a generator, a Wndener- giestrom as well as a molding device and a method for producing a rotor segment, which a cheaper and faster production of a rotor segment, a magnet cover, a rotor, a generator and/or a wind energy system.
  • the invention is also based on the object of providing a rotor segment, a magnet cover, a rotor, a generator, a Wndenergy- plant and a molding device and a method for producing a rotor segment, which manufacture a rotor segment, a magnet cover, a rotor , A generator and / or a Wndenergystrom allow the weight is reduced compared to conventional solutions.
  • the invention is preferably based on the object of providing a rotor segment, a magnet cover, a rotor, a generator, a Wndenergystrom and a molding device and a method for producing a rotor segment, which enable improved vibration damping and/or reduced noise emissions .
  • the invention is also based in particular on the object of providing a rotor segment, a magnet cover, a rotor, a generator, a wind turbine, as well as a molding device and a method for producing a rotor segment, which has an improved air gap in terms of roundness, cylindricity and squareness and reduced power losses between Enable rotor and stator.
  • the object is achieved by a rotor segment according to claim 1 .
  • the rotor segment is characterized in that a connecting element is arranged between the magnet carrier segment and the at least one rotor laminated core, which is designed as a cast and/or foam part and connected to the at least one rotor laminated core on the outer surface of the laminated core and the magnet carrier segment on the Magnet carrier inner surface is connected.
  • the axial direction corresponds to a direction parallel, ie along the axis of rotation.
  • the circumferential direction corresponds to a direction essentially tangential to the axis of rotation, ie orthogonal to the axial direction and the radial direction.
  • the radial direction corresponds to a direction radial to the axis of rotation, ie orthogonal to the axial direction and circumferential direction.
  • the rotor segment preferably extends in the radial direction between a radially inner flange for fastening the rotor segment to a rotor base body flange of a bearing unit and the radially outer magnet carrier segment.
  • the rotor segment preferably extends with a rotor bearing section between the radially inner flange for fastening the rotor segment to the rotor G round body flange of the bearing unit and the radially outer magnet carrier segment.
  • the rotor segment can be of multi-part or integral design.
  • the rotor segment can be formed integrally from individual rotor elements that are welded or screwed together.
  • the rotor segment is preferably partially ring-shaped in relation to the axis of rotation in a circumferential direction.
  • the rotor segment has a partially annular geometry.
  • the rotor segment can be designed as a ring.
  • Such a rotor segment extends in the circumferential direction with a certain degree of arc between first and second separation interfaces.
  • a rotor segment preferably extends in the circumferential direction by at least 15°, 30°, 45°, 60°, 90°, 120°, 180° or 360° and/or by a maximum of 15°, 30°, 45°, 60°, 90° °, 120°, 180° or 360°.
  • the rotor segment extends by at least 0.5m, 1m, 1.5m, 2m, 2.5m, 3m or more and/or by a maximum of 0.5m, 1m, 1.5m, 2m, 2.5m, 3m or less.
  • the first and second separation interfaces extend substantially orthogonally to the circumferential direction.
  • the first and second separation interfaces define first and second separation interface planes within which the axis of rotation extends.
  • the first and/or second separating interface extend in such a way that the first and/or second separating interface plane extend in a radial direction in relation to the axis of rotation.
  • the first and/or second parting interface planes which extend in the radial direction with respect to the axis of rotation, intersect in an axis that is or defines the axis of rotation.
  • the axis of rotation lies in the first and/or second separation interface planes, which extend in the radial direction in relation to the axis of rotation.
  • the first and/or second separation interface of a rotor segment has a connection device.
  • the connecting device at the first and/or second separation interface is designed to connect adjacent rotor segments that are arranged to form a rotor to one another.
  • the connecting device of the first and/or second separation interface is designed in particular to mechanically connect adjacent rotor segments.
  • the mechanical connection can be designed as a non-positive and/or material-to-material and/or form-fitting connection.
  • the first and/or second separation interface preferably has a flange connection and/or a screw connection as a connecting device for fastening rotor segments that are adjacent in the circumferential direction.
  • the magnet carrier segment has a ring-shaped or part-ring-shaped geometry.
  • the magnet carrier segment can be designed as a ring.
  • the magnet carrier segment extends in the radial direction between a radially outer magnet carrier outer surface and a radially inner magnet carrier surface in relation to the magnet carrier outer surface.
  • the magnet carrier segment extends in the circumferential direction between the first and second separation interfaces.
  • the magnet carrier segment can essentially have the dimensions described for the rotor segment in the axial direction and circumferential direction.
  • the magnet carrier segment preferably comprises the material steel or essentially consists of the material steel.
  • the magnet carrier segment is a steel construction.
  • the magnet carrier segment is preferably a rolled and/or bent steel construction.
  • the magnet carrier segment is a welded steel construction.
  • the magnet carrier segment is not a steel construction produced by machining.
  • the magnet carrier segment does not have any high-precision, machined fitting surfaces or functional surfaces for the connection to the at least one laminated rotor core.
  • the at least one rotor laminated core has a ring-shaped or part-ring-shaped geometry.
  • the at least one rotor laminated core can be designed as a ring.
  • the at least one rotor laminated core is designed to accommodate at least one magnet unit.
  • the at least one rotor laminated core extends in the radial direction between a radially outer laminated core outer surface and a laminated core inner surface which is radially inward in relation to the laminated core outer surface.
  • the at least one laminated rotor core preferably extends in the circumferential direction between the first and second separation interface.
  • the at least one rotor laminated core can correspond to the dimensions of the rotor segment in the circumferential direction.
  • Two, three, four or more rotor lamination stacks are preferably arranged next to one another in the circumferential direction, so that they extend between the first and second separation interface.
  • the at least one rotor laminated core preferably extends in the circumferential direction by at least 15°, 30°, 45°, 60°, 90°, 120°, 180° or 360° and/or by a maximum of 15°, 30°, 45° , 60°, 90°, 120°, 180° or 360°.
  • the at least one rotor laminated core extends by at least 0.25m, 0.5m, 1m, 1.5m, 2m, 2.5m, 3m or more and/or by a maximum of 0.25m, 0.5m, 1 m,
  • the at least one rotor laminated core includes a plurality of rotor laminations.
  • the at least one rotor laminated core includes a plurality of stacked and braced rotor laminations.
  • the rotor laminations are stacked on top of one another in the axial direction.
  • the rotor laminations can be spaced apart from one another in the axial direction.
  • adjacently arranged rotor laminations can form or define a gap through which, for example, cooling air can flow.
  • the rotor laminations are in particular steel laminations or iron laminations.
  • the at least one rotor lamination stack has alignment stops.
  • the alignment stops are designed to align the at least one rotor laminated core compared to the forming device described herein on the one hand with greater accuracy and on the other hand also quickly and easily.
  • the alignment stops can in particular be designed as elevations, for example pins, convex projections or the like, and/or depressions, for example grooves, concave depressions or the like.
  • the generator has an external rotor.
  • the at least one rotor laminated core is arranged on the inside in the radial direction in relation to the magnet carrier segment.
  • the at least one rotor laminated core is arranged in such a way that the outer surface of the laminated core faces the magnet carrier inner surface of the magnet carrier segment.
  • the at least one rotor laminated core and the magnet carrier segment are arranged at a distance from one another in the radial direction.
  • the distance in the radial direction between the at least one rotor laminated core and the magnet carrier segment, in particular the outer surface of the laminated core and the inner surface of the magnet carrier is at least 10mm, 20mm, 30m, 40m, 50m, 75mm or 100mm and/or at most 10mm, 20mm, 30m, 40m, 50m, 75mm or 100mm.
  • a connecting element is arranged between the at least one laminated rotor core and the magnet carrier segment.
  • the connecting element has a ring-shaped or part-ring-shaped geometry.
  • the connecting element can be designed as a ring.
  • the connecting element extends in the circumferential direction between the first and second separation interfaces. In the circumferential direction, the connecting element can essentially have the dimensions described for the rotor segment. In the axial direction, the connecting element can essentially have the dimensions described for the at least one laminated rotor core in the circumferential direction.
  • the connecting element is designed to connect the magnet carrier segment to the at least one rotor laminated core.
  • the connecting element is designed for the non-positive and/or form-fitting and/or material-to-material connection of the magnet carrier segment to the at least one rotor laminated core.
  • the connection between the at least one laminated rotor core and the magnet carrier segment is produced by a connecting element foamed and/or cast between the at least one laminated rotor core and the magnet carrier segment.
  • the connecting element is preferably foamed and/or cast in the vertical direction from bottom to top between the magnet carrier segment and the at least one rotor laminated core. This has the advantage that any trapped air or the like can escape upwards.
  • the connecting element preferably comprises a material or the connecting element consists of a material which differs from the material of the at least one rotor lamination stack and/or the magnet carrier segment.
  • the material of the connecting element is suitable for temperatures of at least -40°C, -30°C, -20°C, -10°C, 0°C, +10°C, +20°C, +30°C, + 40°C, +50°C, +60°C, +70°C, +80°C, +90°C, +100°C or more suitable.
  • the material of the connecting element is preferably for temperatures of at most -40°C, -30°C, -20°C, -10°C, 0°C, +10°C, +20°C, +30° C, +40°C, +50°C, +60°C, +70°C, +80°C, +90°C, +100°C or less suitable.
  • the material of the connecting element preferably has a modulus of elasticity of at least 100 MPa, 200 MPa, 300 MPa, 400 MPa, 500 MPa, 600 MPa, 700 MPa, 800 MPa, 900 MPa, 1000 MPa, 1100 MPa, 1200 MPa, 1300 MPa, 1400 MPa 1500MPa or more. Additionally or alternatively, the material of the connecting element has in particular a modulus of elasticity of at least 100 MPa, 200 MPa, 300 MPa, 400 MPa, 500 MPa, 600 MPa, 700 MPa, 800 MPa, 900 MPa, 1000 MPa, 1100 MPa, 1200 MPa, 1300 MPa, 1400MPa 1500MPa or less.
  • the material of the connecting element preferably has a tensile strength of at least 1 MPa, 5 MPa, 6 MPa, 7 MPa, 8 MPa, 9 MPa, 10 MPa, 15 MPa, 20 MPa, 30 MPa or more. Additionally or alternatively, the material of the connecting element has in particular a tensile strength of at least 1 MPa, 5 MPa, 6 MPa, 7 MPa, 8 MPa, 9 MPa, 10 MPa, 15 MPa, 20 MPa, 30 MPa or less.
  • the material of the connecting element preferably has a compressive strength of at least 1 MPa, 5 MPa, 6 MPa, 7 MPa, 8 MPa, 9 MPa, 10 MPa, 15 MPa, 20 MPa, 30 MPa or more. Additionally or alternatively, the material of the connecting element has in particular a compressive strength of at least 1 MPa, 5 MPa, 6 MPa, 7 MPa, 8 MPa, 9 MPa, 10 MPa, 15 MPa, 20 MPa, 30 MPa or less.
  • the material of the connecting element corresponds to the building material class or Euroclass E according to the assessment standard of DIN EN 13501. It can be preferred that the material of the connecting element is a material of a building material class or the Euro class according to the assessment standard of DIN EN 13501, which compared to materials of building material class E contributes less to fire behavior.
  • This arrangement of the connecting element designed as a cast and/or foam part between the at least one laminated rotor core and the magnet carrier segment significantly reduces the requirements for the manufacturing accuracy to be achieved in the magnet carrier segment and/or the at least one laminated rotor core. This is because the outer surface of the laminated core and the inner surface of the magnet carrier no longer have to be in the form of mating surfaces or functional surfaces, as was previously necessary. Rather, the cast and/or foam mass of the connecting element compensates for possible manufacturing inaccuracies in the at least one laminated rotor core and the magnet carrier segment. This significantly reduces the manufacturing cost of the rotor segment. This effect is additionally reinforced by the fact that expensive machine tools, which were previously required to to achieve the required manufacturing accuracies become superfluous. Furthermore, this accelerates the manufacturing process, since time-consuming manufacturing processes, which enable high manufacturing accuracy, are eliminated.
  • the damping property of the rotor segment can be adjusted in a targeted manner by means of the connecting element.
  • the mechanical load on the rotor segment or rotor or generator can be reduced, that is to say the service life can be increased and operating costs reduced, and the noise emissions of the rotor segment or rotor or generator can be reduced.
  • the material preferably has high inherent damping. Furthermore, through the use of the connecting element according to the invention, an improved air gap between the rotor and stator of a generator in terms of roundness, cylindricity and squareness can be produced due to the modified manufacturing process. In particular, manufacturing inaccuracies, i.e. larger tolerances, can easily be compensated for by the connecting element. Because the connecting element is designed as a cast part and/or foam part, it can have variable thicknesses in the radial direction, which compensate for the manufacturing inaccuracies, i.e. larger tolerances.
  • the connecting element comprises plastic, in particular polyurethane, and/or is particularly preferably designed as a polyurethane foam part and/or polyurethane cast part.
  • plastic in particular polyurethane
  • the connecting element has a vibration-damping effect and thus reduces vibrations.
  • the mechanical stress during operation decreases, which leads to lower operating costs; on the other hand, the noise emission decreases as a result.
  • this preferred allows Embodiment produce an improved air gap between the rotor and stator of a generator in terms of roundness, cylindricity and squareness.
  • the magnet carrier segment and the at least one rotor laminated core comprise materials with a higher melting temperature than plastic, the magnet carrier segment and the at least one rotor laminated core can advantageously serve as a mold for the connecting element to be cast or foamed.
  • the connecting element is connected to the inner surface of the magnet carrier and/or the outer surface of the laminated core in a materially bonded manner, in particular adhesively, and/or in a form-fitting manner.
  • the magnet carrier segment has a first connecting device on the inside surface of the magnet carrier, the first connecting device having one or more first connecting projections and/or one or more first connecting depressions, for the positive connection of the connecting element to the magnet carrier segment.
  • the one or more first connecting projections are preferably welded to the magnet carrier segment, in particular to the inner surface of the magnet carrier.
  • the at least one rotor laminated core has a second connecting device on the outer surface of the laminated core, the second connecting device having one or more second connecting projections and/or one or more second connecting recesses, for the positive connection of the connecting element to the at least one rotor lamination package.
  • the connecting element is located in the radial direction between a radially outer connecting element outer surface and a radially inner connection in relation to the connecting element outer surface.
  • connecting element inner surface wherein the connecting element preferably has a first connecting device on the connecting element outer surface, the first connecting device having one or more first connecting projections and/or one or more first connecting depressions, for positively locking connection of the connecting element to the magnet carrier segment, and/or preferably a second one on the connecting element inner surface Having connecting device, the second connecting device having one or more second connecting projections and / or one or more second connecting recesses, for positive connection of the connecting element with the at least one rotor laminated core.
  • the first and/or second connecting projections have an I-shaped and/or L-shaped and/or T-shaped cross section or the like.
  • the first and/or second connection recesses have an I-shaped and/or L-shaped and/or T-shaped cross section or the like.
  • the one or more first connecting projections and/or the one or more first connecting depressions are arranged equidistantly from one another in the circumferential direction.
  • the one or more second connecting projections and/or the one or more second connecting recesses are arranged equidistantly from one another in the circumferential direction.
  • the magnet carrier segment preferably has a plurality of first connecting projections with a T-shaped cross section.
  • the rotor laminated core has a plurality of second connection depressions with a T-shaped cross section on the outer surface of the laminated core.
  • the plurality of second connection depressions are designed as a T-shaped groove.
  • the connection between the at least one laminated rotor core and the magnet carrier segment or the at least one laminated rotor core and the magnet carrier segment with the connecting element is further improved. In particular, this further extends the service life of the rotor segment.
  • the connecting element has greater damping than the magnet carrier segment and/or the at least one rotor laminated core.
  • This preferred embodiment enables a further reduction in vibrations. Consequently, this preferred embodiment leads to a reduced mechanical load, i.e. a longer service life, and reduces the noise emission of the rotor or generator.
  • a reduced mechanical load i.e. a longer service life
  • reduces the noise emission of the rotor or generator for further advantages of this preferred development of the rotor segment, reference is also made to the advantages of the rotor segment according to the invention.
  • the rotor segment comprises at least one magnet unit, which is arranged on the at least one rotor laminated core, in particular on the inner surface of the laminated core. Additionally or alternatively, the rotor segment includes at least one magnet cover for covering the at least one magnet unit.
  • the rotor laminated core has fastening connections on the inner surface of the laminated core, which are designed to fasten the at least one rotor laminated core with one or more magnet covers, in particular for non-positive and/or positive fastening, wherein preferably the at least one magnet unit is arranged between the rotor laminated core and the magnet cover.
  • the magnet cover has in particular features and advantages of the magnet cover according to the invention or its preferred embodiments - as described below - on.
  • This preferred embodiment enables the magnet units to be attached, secured and preserved in a particularly cost-effective manner on the at least one rotor laminated core.
  • power losses can be minimized in a particularly advantageous manner.
  • a magnet cover for covering at least one magnet unit, having a cover unit which extends in the circumferential direction between a first and second end and between an inner cover surface lying on the inside in the radial direction and an outer cover surface lying on the outside in the radial direction , a first side wall located at the first end, and a second side wall located at the second end. with the first and second sidewalls angling from the lid exterior surface, with an intermediate wall disposed between the first and second sidewalls and angling from the lid exterior surface.
  • first and/or second side wall and/or the intermediate wall extend inwards in the radial direction, starting from the inner surface of the cover. Furthermore, the first and/or second side wall and/or the intermediate wall extend perpendicular to the inner surface of the lid.
  • a radial transition from the cover unit to the first and/or second side wall and/or intermediate wall is provided.
  • the radial transition from the inner surface of the lid to the first and/or second side wall and/or intermediate wall has a radius of at least 0.5 mm, 1 mm, 2 mm, 3 mm, 4 mm, 5 mm or more and/or a maximum radius of 0, 5mm, 1mm, 2mm, 3mm, 4mm, 5mm or less.
  • the radial transition from the outer surface of the lid to the first and/or second side wall and/or intermediate wall preferably has a radius of at least 0.5 mm, 1 mm, 2 mm, 3 mm, 4 mm, 5 mm or more and/or a maximum radius of 0 .5mm, 1mm, 2mm, 3mm, 4mm, 5mm or less.
  • Magnet units arranged in two rows usually form a pole pair.
  • the magnet cover according to the invention has the advantage that such a pair of poles can be fastened and secured to a laminated rotor core with a single magnet cover and can be preserved against environmental influences. Furthermore, the assembly of the magnet cover according to the invention is faster in comparison to conventional magnet covers, which are each to be fastened to a rotor laminated core for a magnet unit.
  • the intermediate wall increases the stability of the magnet cover, which increases its service life and thus the service life of the rotor segment or rotor and generator. Furthermore, this configuration changes the vibration behavior of the magnet cover in such a way that the noise emission of the rotor or generator can be minimized.
  • the magnet cover extends in the axial direction between a first and second opening arrangement and has an insertion funnel unit for inserting magnet units at one of the two opening arrangements.
  • the cover unit has a wall thickness that is smaller than a wall thickness of the first and/or second side wall and/or smaller than a wall thickness of the intermediate wall.
  • the wall thickness of the first and/or second side wall is smaller than the wall thickness of the intermediate wall.
  • the first and/or second side wall and/or the intermediate wall each have a fastening section for fastening the magnet cover to a laminated rotor core.
  • the first and second opening arrangements are preferably connected to one another by two shafts.
  • the first side wall, the intermediate wall and a section of the cover unit form a first shaft.
  • the second side wall, the intermediate wall and another section of the lid unit form a second shaft.
  • the shafts are designed to accommodate the magnet units.
  • the insertion funnel unit is designed to insert magnet units into the magnet covers more quickly and easily.
  • the insertion funnel unit preferably has funnel feed walls arranged inclined relative to the first and/or second side wall and/or the cover unit.
  • the insertion funnel unit has a
  • Funnel opening cross section which decreases towards one of the two opening arrangements in the axial direction.
  • the funnel opening cross section can decrease linearly.
  • the magnet cover or the cover unit preferably extends in the circumferential direction by at least 30 mm, 40 mm, 50 mm, 60 mm, 70 mm, 80 mm, 90 mm, 100 mm, 110 mm, 120 mm, 130 mm, 140 mm, 150 mm, 160 mm, 170 mm, 180 mm, 190 mm, 200 mm or similar - the more.
  • the cover unit preferably extends in the circumferential direction by a maximum of 30 mm, 40 mm, 50 mm, 60 mm, 70 mm, 80 mm, 90 mm, 100 mm, 110 mm, 120 mm, 130 mm, 140 mm, 150 mm, 160 mm, 170 mm, 180 mm, 190 mm, 200 mm or less .
  • the magnet cover preferably extends in the radial direction with a height of at least 5 mm, 10 mm, 20 mm, 30 mm, 40 mm, 50 mm or more.
  • the magnet cover extends in the radial direction with a maximum height of 5 mm, 10 mm, 20 mm, 30 mm, 40 mm, 50 mm or less.
  • the first and/or second side wall and/or intermediate wall and/or cover unit preferably has a wall thickness of at least 0.5 mm, 1 mm, 1.5 mm, 2 mm, 3 mm, 4 mm, 5 mm or more. Additionally or alternatively, the wall thickness of the first and/or second side wall and/or the intermediate wall and/or the cover unit is a maximum of 0.5 mm, 1 mm, 1.5 mm, 2 mm, 3 mm, 4 mm, 5 mm or less.
  • the wall thickness of the cover unit is preferably 1 mm, the first and second side wall is 2 mm and the intermediate wall is 3 mm.
  • the fastening section of the first and/or second side wall and/or the intermediate wall is designed for a positive connection with a laminated rotor core.
  • the fastening section preferably has a circular cross section. It can also be preferred that the respective fastening section has an L-shaped or T-shaped cross section. In particular, it can be preferred that the respective fastening section has a polygonal cross section, for example a triangular and/or rectangular cross section.
  • the fastening sections are designed for a positive connection in the radial direction with the at least one laminated rotor core.
  • the first and/or second side wall and/or intermediate wall preferably have fastening sections of identical design.
  • first and/or second side wall and/or intermediate wall have fastening sections that differ from one another.
  • the attachment section of the first and/or second side wall and/or the intermediate wall preferably has a width of at least 0.5 mm, 1 mm, 1.5 mm, 2 mm, 3 mm, 4 mm, 5 mm, 7 mm, 10 mm or more in the circumferential direction. Additionally or alternatively, the width of the first and/or second side wall and/or the intermediate wall is at most 0.5 mm, 1 mm, 1.5 mm, 2 mm, 3 mm, 4 mm, 5 mm, 7 mm, 10 mm or less.
  • the attachment portion of the first and second side walls has a width of 5mm and the attachment portion of the intermediate wall has a width of 7mm.
  • a radial transition from the first and/or second side wall and/or intermediate wall to the respective fastening section is provided.
  • the radial transition from the respective fastening section to the first and/or second side wall and/or intermediate wall has a radius of at least 0.5 mm, 1 mm, 2 mm, 3 mm, 4 mm, 5 mm or more and/or a maximum radius of 0 .5mm, 1mm, 2mm, 3mm, 4mm, 5mm, 10mm or less.
  • the magnet cover according to the invention enables a simple and secure attachment of the magnet cover to a rotor laminated core in a particularly advantageous manner. Furthermore, this magnet cover enables a particularly advantageous preservation of the magnet units to be covered with the magnet cover.
  • this preferred embodiment makes it possible to provide a magnet cover that is both stable and comparatively light, which can contribute to reducing the weight of the rotor or generator.
  • this preferred embodiment of the magnet cover this is made in one piece; and/or is this made of plastic, in particular of a fiber composite plastic, or includes this; and/or is it designed as a compression molded part and/or an injection molded part.
  • a magnet cover designed in this way enables magnet units to be attached and secured cost-effectively on a laminated rotor core and allows them to be preserved.
  • magnet covers made of plastic are much less lossy in terms of generator output compared to magnet covers made of steel.
  • such magnet covers can be produced in a particularly cost-effective manner.
  • the object is achieved with a molding device according to claim 10 for the production of a rotor segment.
  • the molding device comprises a ring-shaped or partially ring-shaped negative mold, which extends in a radial direction between a radially outer negative outer surface and a negative inner surface that is inner in relation to the radially outer negative outer surface, characterized in that the negative mold comprises a non-magnetic material or essentially consists of a non-magnetic material; and the molding device has soft-magnetic elements which can be arranged on the negative inner surface for closing the magnetic flux for the production of the rotor segment.
  • the non-magnetic material is, for example, stainless steel or glass fiber reinforced plastic. However, other structure-bearing non-magnetic materials can also be considered as non-magnetic materials.
  • the negative mold is designed to align rotor lamination stacks for the production of a rotor segment described herein.
  • the laminated rotor cores are preferably arranged next to one another in the circumferential direction, so that they extend by 180° in the circumferential direction.
  • the negative mold is designed to align and stack rotor laminations of a laminated rotor core to be produced on the negative mold.
  • the negative mold has a shape that corresponds to the contour of the inner surface of the laminated core.
  • the negative outer surface preferably has a shape that corresponds to the contour of the magnet covers, in particular the cover units of the magnet covers. This is because, when producing the rotor segment, the magnetic forces of the magnet units cause the cover units of the magnet covers to lie against the negative outer surface with the cover outer surface. As a result, the magnet units interacting with the stator during operation are aligned or centered with respect to the axis of rotation.
  • the molding device according to the invention therefore causes a magnetic force to act in the direction of the soft magnetic elements of the molding device according to the invention, which are on the inside in the radial direction, during the production of a rotor segment according to the invention by inserting magnet units between magnet covers and the at least one rotor lamination stack.
  • This has the advantage that an improved air gap in terms of roundness, cylindricity and perpendicularity between rotor and stator is made possible, which minimizes power losses of the generator.
  • the shaping device comprises an alignment device for stacking and aligning the individual rotor laminations of the at least one rotor laminated core at a distance defined in the radial direction from the shaping device.
  • the shaping device preferably comprises a feeding device which is designed to feed one or more magnet units to the magnet cover.
  • the feed device has at least one feed magazine and/or an insertion aid device.
  • the Einschiebe Anlagenvorraum is particularly designed for feeding and inserting the magnet units between the Magnet cover and the at least one rotor laminated core to be in engagement with the insertion funnel unit.
  • the alignment device comprises or consists essentially of a non-magnetic material.
  • the alignment device has an outer surface that includes or consists essentially of a non-magnetic material.
  • the non-magnetic material is, for example, stainless steel or glass fiber reinforced plastic. However, other structure-bearing non-magnetic materials can also be considered as non-magnetic materials.
  • the alignment device comprises alignment elements which essentially extend in a radial direction.
  • the alignment elements are designed to align the at least one rotor laminated core of the rotor segment to be produced as described herein with respect to the forming device on the one hand with greater accuracy and on the other hand also quickly and easily.
  • the alignment elements are designed to engage in the alignment stops of the at least one laminated rotor core with a precise fit.
  • the alignment elements are designed to align the at least one laminated rotor core with respect to the forming device via the alignment stops of the at least one laminated rotor core.
  • the alignment elements can in particular have elevations, for example pins, convex projections or the like, and/or depressions, for example grooves, concave depressions or the like.
  • the alignment elements can be spring loaded. It can also be preferred that the alignment elements extend outwards in the radial direction, starting from the negative mold, in particular from the radially outer negative outer surface. In particular, it can be provided that the negative mold forms the alignment elements integrally.
  • the alignment elements cause the at least one rotor laminated core to be pressed away from the forming device in the radial direction in order to produce the rotor segment, so that a gap is created between the magnet units and the at least one rotor laminated core or its inner surface.
  • the magnet units and the casting compound for fastening the magnet units to the at least one laminated rotor core can be introduced into this gap.
  • the casting compound can consist of the material of the connecting element.
  • the gap can be filled with the material of the connecting element for fastening the magnet units to the at least one rotor laminated core at the same time as the connecting element is produced.
  • the soft-magnetic elements can be moved back and forth radially in the radial direction between an assembly position and a standby position, with the soft-magnetic elements being arranged in the assembly position on the negative inner surface to close the magnetic flux to produce the rotor segment and in the standby position for opening the magnetic flux to remove the molding device from the manufactured rotor segment, the soft magnetic elements are not arranged on the negative inner surface, in particular are arranged spaced apart from the negative inner surface in the radial direction.
  • the soft magnetic elements are retracted from the mounting position to the standby position in the radial direction or pushed from the standby position to the mounting position in the radial direction.
  • the forming device can have a hydraulic device that effects the movement of the soft magnetic elements between the mounting position and the standby position.
  • the hydraulic device is designed to overcome the very large magnetic forces acting on the forming device through the magnet units of the rotor segment to be produced.
  • the hydraulic device may include one, two or more double-acting cylinders that may be coupled to the soft magnetic members and configured to radially reciprocate the soft magnetic members in the radial direction between the standby position and the mounting position.
  • the soft magnetic elements By moving the soft magnetic elements from the assembly position to the standby position, the acting magnetic forces are greatly reduced, since the negative mold, in particular the outer surface of the molding device, is made of a non-magnetic material, such as stainless steel or glass fiber reinforced plastic.
  • the rotor segment is removed from the molding device in a vertical direction or in an axial direction.
  • a rotor of a generator in particular by a segmented rotor of a segmented generator, for a wind turbine, comprising a rotor segment described above and/or a rotor segment produced with a molding device described above.
  • the segmented rotor for a wind turbine comprises two or more rotor segments.
  • the two or more rotor segments are preferably arranged in a ring shape.
  • the two or more rotor segments are arranged coaxially to an axis of rotation of the segmented generator.
  • the two or more rotor segments extend with the same degree of arc in the circumferential direction.
  • the rotor segments extend according to the following formula, depending on the number of the respective segments: 360 “/(number of segments).
  • the rotor segments of a segmented rotor which comprises two rotor segments, extend in the circumferential direction by 180°, with three rotor segments it would be 120°, with four rotor segments it would be 90° etc.
  • the rotor segments which a segmented rotor is assembled extend in the circumferential direction with a different degree of arc.
  • a segmented rotor can be formed from three rotor segments.
  • a first rotor segment can extend in the circumferential direction at 180°, a second rotor segment at 120° and a third rotor segment at 60°. Any other extensions in the circumferential direction of the rotor segments are conceivable, provided they result in an extension of 360° in the circumferential direction.
  • the object is achieved by a generator, in particular a segmented generator, for a wind energy installation, comprising a rotor as described above.
  • the generator is preferably designed as an external rotor.
  • the object is achieved by a wind energy installation comprising a generator as described above.
  • the object is achieved by a method for producing a rotor segment of a rotor of a generator, in particular a segmented rotor of a segmented generator, for a wind turbine, preferably for producing a rotor segment according to one of the preceding claims, comprising the steps:
  • the at least one rotor laminated core being located in the radial direction between a radially outer laminated core surface and a relative to the outer surface of the laminated core extends radially inwardly from the inner surface of the laminated core, the provision of the at least one rotor laminated core being a stacking and aligning of rotor laminations to form at least one rotor
  • Laminated core in relation to a radially outer negative outer surface of the shaping device at a distance defined in a radial direction from the shaping device, in particular by means of an alignment device of the shaping device.
  • the provision of the shaping device comprises in particular providing the shaping device of the soft-magnetic elements in an assembly position. This has the effect that the magnetic forces due to the soft-magnetic elements are almost eliminated, so that the frictional forces when pushing in are minimized.
  • the stacking of rotor laminations to form at least one rotor laminated core is preferably an overlapping stacking of rotor laminations to form at least one rotor laminated core.
  • the rotor laminations are preferably stacked in the axial direction.
  • the rotor laminations can be stacked and aligned using a centering tool.
  • the centering tool can be introduced in the axial direction into centering openings in the rotor laminations.
  • the method comprises the steps:
  • Fastening in particular pushing in, one or more magnet covers on the at least one rotor laminated core, in particular fastening the one or more magnet covers on fastening connections of a laminated core inner surface of the at least one rotor laminated core; and/or arranging, in particular pushing in, at least one magnet unit between the at least one rotor laminated core and the one or more magnet covers; and/or - releasing the pre-tensioning of the at least one rotor lamination stack; and/or radial knocking of the detached rotor laminations of the at least one rotor lamination stack on the forming device and/or independent centering of the detached rotor laminations of the at least one rotor lamination stack as a result of the magnetic forces; and/or - final bracing of the at least one rotor laminated core with the one or more tie rods; and or
  • the magnet carrier segment extending in a radial direction between a radially outer magnet carrier outer surface and a radially inner magnet carrier surface in relation to the magnet carrier outer surface; and/or - arranging the at least one magnet carrier segment coaxially with respect to the
  • Rotor laminated core in particular slipping the magnet carrier segment over the at least one rotor laminated core, preferably in a vertical direction, so that an annular air gap extends between the at least one magnet carrier segment and the at least one rotor laminated core, with in particular the at least one rotor laminated core is arranged coaxially with the magnet carrier segment in relation to an axis of rotation of the rotor segment, with the at least one rotor laminated core preferably being arranged radially on the inside in the radial direction relative to the magnet carrier segment and the outer surface of the laminated core and the inner surface of the magnet carrier facing one another are spaced facing each other; and or Gluing the at least one magnet unit to the at least one rotor laminated core and/or the one or more magnet covers with a casting compound; and or
  • connecting element between the radially outer magnet carrier segment and the at least one radially inner rotor laminated core, so that the connecting element is connected to the at least one rotor laminated core on the outer surface of the laminated core and the magnet carrier segment on the inner surface of the magnet carrier, the connecting element being in particular cast - and or
  • the connecting element is preferably arranged by a casting and/or foaming process, the connecting element preferably comprising plastic, in particular polyurethane, and/or particularly preferably being formed as a polyurethane foam part and/or polyurethane cast part; and or
  • the negative inner surface are arranged on the negative inner surface, in particular are arranged at a distance from the negative inner surface in the radial direction; and/or demolding the manufactured rotor segment.
  • Arranging the at least one magnet carrier segment coaxially in relation to the rotor laminated core includes, in particular, arranging a flange of the magnet carrier segment on a flange of the molding device.
  • the coaxial arrangement of the at least one magnet carrier segment in relation to the rotor laminated core is also a positioning of the at least one magnet carrier segment in relation to the rotor laminated core.
  • the at least one magnet carrier segment is arranged coaxially in relation to the rotor laminated core in such a way that an average annular gap of about 30 mm is formed between the magnet carrier inner surface and the laminated core outer surface.
  • Gluing the at least one magnet unit to the at least one rotor laminated core and/or the one or more magnet covers includes in particular gluing the at least one magnet unit to the at least one Rotor laminated core and / or the one or more magnet covers with a potting compound.
  • the casting compound consists of the material of the connecting element.
  • the at least one magnet unit is glued to the at least one rotor laminated core and/or the one or more magnet covers and the arrangement, in particular foaming and/or casting, of a connecting element between the radially outer magnet carrier segment and the at least one
  • the radial inner rotor core is made synchronously with the same material and in a common process step.
  • the soft magnetic elements are moved from an assembly position to a standby position and/or vice versa, preferably using a hydraulic device, so that the magnetic forces acting between the magnet units of the rotor segment to be produced and the forming device are minimized.
  • the individual steps of the method are preferably carried out in the order mentioned. However, it may also be preferred to go through the steps in a different order. In particular, it can be preferred that individual steps are run through several times.
  • Figure 1 a schematic representation of a wind power plant
  • Figure 2a,b a schematic three-dimensional view and a schematic side view of a preferred embodiment of a rotor
  • FIG. 3a a schematic side view of a preferred embodiment of a rotor to be manufactured with a molding device in an assembly position
  • FIG. 3b, c a schematic detailed view of the shaping device shown in FIG. 3a in a longitudinal and cross-sectional view
  • FIG. 4 a schematic plan view of a preferred embodiment of a rotor segment to be produced with a molding device
  • FIG. 5 a schematic plan view of a preferred embodiment of a magnet cover
  • FIGS. 5a, b schematic isometric representations of a further preferred embodiment of a magnet cover
  • FIGS. 6a,b,c schematic isometric representations of a further preferred embodiment of a magnet cover in a full view and in two different detailed views;
  • FIGS. 7a, b schematic isometric representations of a preferred embodiment of a feeding device in a full view and in a detailed view;
  • FIG. 8 shows a schematic isometric illustration of a magnet cover arranged on a negative mold according to a preferred embodiment illustrated in FIGS. 6a-c;
  • FIGS. 9a, b show various detailed views of the arrangement shown in FIG. 8;
  • FIG. 10 a schematic flowchart of a preferred method for producing a rotor segment of a rotor
  • FIG. 11 a schematic flowchart of a further preferred method for producing a rotor segment of a rotor.
  • the wind turbine 100 has a tower 102 and a nacelle 104 on the tower 102 .
  • An aerodynamic rotor 106 with three rotor blades 108 and a spinner 110 is provided on the nacelle 104 .
  • the aerodynamic rotor 106 is caused to rotate by the wind and thus also rotates electrodynamic rotor 121 or rotor of a generator 120 about an axis of rotation, which is directly or indirectly coupled to the aerodynamic rotor 106.
  • the electrical generator 120 is arranged in the nacelle 104 and generates electrical energy.
  • the pitch angles of the rotor blades 108 can be changed by pitch motors on the rotor blade roots 109 of the respective rotor blades 108 .
  • Fig. 2a, b show a schematic three-dimensional view and a schematic side view of a preferred embodiment of a rotor 121 according to the invention.
  • the rotor 121 has two rotor segments 200 designed in the form of a partial ring according to the invention.
  • the rotor segments 200 each extend by 180°.
  • the rotor segments 200 are connected to one another at the separation interfaces.
  • the separation interfaces extend in separation interface planes in which the axis of rotation lies.
  • the rotor segments 200 each have a magnet carrier segment 210 .
  • the magnet carrier segment 210 is a rolled steel construction.
  • the magnet carrier segment 210 extends in the axial direction A over a width of approximately 2 m. It is particularly clear from FIG. 2b that the rotor segment 200 extends in the radial direction R between a radially inner flange for fastening the rotor segment to a rotor base body flange of a bearing unit and the radially outer magnet carrier segment 210 .
  • the respective rotor segment 200 also has a plurality of rotor laminated cores 220 .
  • the rotor segments 200 have four rotor laminated cores 220, which extend in the circumferential direction U by 45°.
  • the rotor laminated cores 220 extend in the axial direction A over a width of approximately 1 m.
  • the magnet carrier segment 210 and the rotor laminated cores 220 are spaced apart in the radial direction R from one another.
  • a connecting element 240 is arranged between the magnet carrier segment 210 and the rotor lamination packets 220 .
  • the connecting element 240 extends in the axial direction A over the width of the rotor lamination stacks 220. In the circumferential direction U, the connecting element 240 extends by 180° between the separation interfaces.
  • the connecting element 240 is an injection molded part and/or foam molded part made of polyurethane. This has the advantage that the magnet carrier segment can be manufactured with less manufacturing accuracy, ie faster and more cost-effectively, and at the same time an improved air gap between the rotor and stator in terms of cylindricity, roundness and squareness is made possible at an early stage.
  • FIG. 3a shows in a preferred embodiment in a schematic side view.
  • Figures 3b and 3c are schematic detail views of the molding apparatus shown in Figure 3a in longitudinal and cross section.
  • the molding device 300 has a ring-shaped negative mold 310, which extends in the radial direction R between a radially outer negative outer surface 311 and a negative inner surface 312 that is inner in relation to the radially outer negative outer surface - this is in detail Fig. 3b, 3c and 4 refer to.
  • the molding device has soft magnetic elements 320 .
  • the soft magnetic elements 320 can be moved back and forth in the radial direction R between a mounting position and a standby position.
  • the soft-magnetic elements 320 are in contact with the negative inner surface 312. This has the effect that the magnetic flux for producing the rotor segment with magnet units is closed when these are inserted between the magnet cover and the at least one rotor lamination packet. As a result, the magnet cover lies flat with the cover unit and the magnet units on the molding device. In the standby position, the soft magnetic elements 320 are arranged at a distance from the negative inner surface 312 . The effect of this is that the magnetic flux is open and the finished rotor segment can be removed from the molding device for further processing or assembly.
  • the standby position for the middle soft-magnetic element is shown in dotted form in the detailed illustration of the shaping device in FIG. 3b.
  • the soft magnetic elements 320 are moved back and forth in a radial direction between the mounting position and the standby position by means of a hydraulic device.
  • the hydraulic device for moving the soft-magnetic elements 320 between the mounting position and the standby position has a double-acting cylinder which is coupled to the soft-magnetic elements. This is shown schematically in FIGS. 3b and 3c.
  • the shaping device also has an alignment device 330 for stacking and aligning the individual rotor laminations of the at least one rotor lamination stack 220 at a distance defined in the radial direction from the shaping device 300 having.
  • the alignment device comprises alignment elements which essentially extend in a radial direction.
  • the alignment elements are designed to align the at least one laminated rotor core of the rotor segment to be produced in relation to the forming device on the one hand with greater accuracy and on the other hand also quickly and easily.
  • the alignment elements can, for example, be formed integrally on the negative outer surface, as shown in FIG. 3b, or be spring-loaded, as shown in FIG.
  • FIGS. 4 and 3b are schematic plan views of two preferred embodiments based on the rotor segment 200 shown schematically in side view in Figures 3a, b and a preferred embodiment of the shaping device 300 shown schematically in side view in Figures 3a, b.
  • the magnet carrier segment 210 has a first connecting device 213 with a plurality of first connecting projections on the inner surface 212 of the magnet carrier.
  • the several first connecting projections enable a positive connection of the connecting element 240 to the magnet carrier segment 210.
  • These first connecting devices 213 have a T-shaped cross section.
  • the rotor cores 220 On the outer surface 221 of the laminated core, the rotor cores 220 have a second connecting device 223 with a plurality of second connecting recesses.
  • the several second connection depressions enable a form-fit connection of the connection element 240 to the rotor lamination stacks 220.
  • connection element 240 has on a connection element outer surface 241 a first connection device 213 with a plurality of first T-shaped connection depressions for the form-fit connection of the connection element to the magnet carrier segment 210.
  • a connecting element inner surface 242 of the connecting element 240 which is on the inside in relation to the connecting element outer surface 241 in the radial direction, has a second connecting device 223 with a plurality of second T-shaped connecting projections for the positive connection of the connecting element 240 with the at least one rotor laminated core 220
  • the connecting element 240 is cohesive, in particular adhesive, and form-fitting with the Magnet carrier inner surface 212 of the magnet carrier segment 210 and the laminated core outer surface 221 of the rotor laminated cores 220 connected.
  • the rotor segment also includes a plurality of magnet covers 250 for covering magnet units 230.
  • the magnet covers 250 are attached to the core inner surface 222 of the rotor cores 220.
  • the rotor segment 200 also includes magnet units 230 which are arranged on the inner surface of the laminated core 222 of the rotor laminated cores 220 .
  • the magnet units 230 are inserted between the rotor laminated cores 220 and 250 magnet covers.
  • the magnet cover 250 has a cover unit 251 which extends in the circumferential direction U between a first and second end and between an inner cover surface lying on the inside in the radial direction R and an outer cover surface lying on the outside in the radial direction R.
  • the lid assembly 251 further includes a first side wall 252 located at the first end and a second side wall 253 located at the second end.
  • the first and second side walls 252, 253 extend essentially perpendicularly, starting from the outer surface of the lid.
  • An intermediate wall 254 is arranged between the first and second side walls and extends essentially perpendicularly, starting from the outer surface of the lid.
  • the magnet cover 250 is formed in one piece.
  • the magnet cover 250 is made of a fiber composite resin as a compression molding. It can be seen that the cover unit 251 has a wall thickness which is smaller than a wall thickness of the first and second side walls 252, 253 and smaller than a wall thickness of the intermediate wall 254. It can also be seen that the wall thickness of the first and/or second side wall 252, 253 is smaller than the wall thickness of the intermediate wall 254.
  • the first and second side wall 252, 253 and the intermediate wall 254 have a fastening section. In the case of the magnet cover 250, a radial transition from the cover unit 251 to the first and second side walls 252, 253 and the intermediate wall 254 is provided.
  • the radial transition from the inner surface of the cover to the first and second side walls 252, 253 and the intermediate wall 254 has a radius of 3 mm.
  • the radial transition from the lid outer surface to the first and second side walls 252, 253 has a radius of 1 mm.
  • the magnet cover 250 has a radial transition with a radius of 1 mm from the first and second side walls 252, 253 and the intermediate wall 254 to the respective fastening section.
  • the magnet cover 250 extends in the radial direction over a height of 30 mm and in the circumferential direction U over a width of 90 mm.
  • the magnet cover 250 shown in FIG. 5 and also in FIG. 4 has fastening sections for connection to the at least one laminated rotor core 220 .
  • the fastening sections have a circular cross section and enable a form-fitting connection to the at least one laminated rotor core 220 in the radial direction.
  • the fastening sections can also have a different cross-section and can, for example, be polygonal, somewhat rectangular and/or triangular.
  • 5a and 5b show a further preferred embodiment of the magnet cover 250 as a sectional view (FIG. 5a) and in a plan view in the axial direction A (FIG. 5b).
  • This further embodiment of the magnet cover 250 differs from the embodiment of the magnet cover 250 shown in Fig. 5 essentially only in that the magnet cover has a triangular and two rectangular fastening elements in cross section for connection to the at least one rotor laminated core 220.
  • 6a, 6b and 6c show schematic isometric representations of a further preferred embodiment of a magnet cover 250 in a full view and in two different detailed views.
  • the magnet cover 250 extends in the axial direction A between a first and second opening arrangement 250a, 250b.
  • An insertion funnel unit 255 is arranged on the first opening arrangement 250a.
  • the insertion funnel unit 255 facilitates the insertion of magnet units 230 into the magnet covers 250.
  • the insertion funnel unit 255 is inclined relative to the first and second side walls 252, 253 and the cover unit 254, i.e. the funnel feed walls of the insertion funnel unit 255 are opposite the first and second side walls 252, 253 and the lid unit 254 are arranged inclined. It can be seen in particular in FIGS.
  • the shaping device 300 has a feed device, as shown by way of example in the schematic isometric illustrations in FIGS. 7a and 7b.
  • a feeding device 340 is designed to quickly and easily feed one or more magnet units 230 to the magnet cover 250 .
  • the feed device 340 in the present case has a feed magazine 341 and an insertion aid device 342 .
  • Magnet units 230 can be arranged in the feed magazine 341 and then fed between the magnet cover 250 and the laminated core of the rotor.
  • the feeding of the magnet units 230 between the magnet cover 250 and the rotor lamination stack is facilitated by the insertion aid device 342 in that the insertion aid device 342 for feeding and inserting the magnet units 230 between the magnet cover 250 and the at least one rotor lamination stack engages with the insertion funnel unit 255 stands.
  • FIGS. 8 and 9a Such an engagement of the insertion aid device 342 with the insertion funnel unit 255 is shown in FIGS. 8 and 9a as well as 9b.
  • FIG. 8 shows a schematic isometric full view of a magnet cover 250 arranged on a negative mold 310, as was described in detail with reference to FIGS. 6a-6c. It can be seen that the feed device 340 is arranged in the axial direction above the negative mold 310 and the magnet covers 250 arranged in the negative mold 310 . As a result, the feeding device 340 grips the insertion funnel unit 255. The feeding device 340 engaged with the insertion funnel unit 255 is shown in detail in FIGS. 9a and 9b.
  • FIG. 10 shows a schematic flowchart of a preferred method 1000 for producing a rotor segment 200 of a rotor 121 .
  • the method 1000 first comprises providing 1010 a shaping device 300 as described above.
  • Method 1000 further comprises providing 1020 at least one rotor lamination stack 220 which is designed to receive at least one magnet unit 230, wherein the providing 1020 the at least one rotor lamination stack 220 includes stacking and aligning rotor laminations to form at least one rotor lamination stack 220 in relation to a radially outer negative outer surface 311 of the shaping device 300 at a distance defined in a radial direction R from the shaping device 300 with an alignment device 330 of the shaping device 300.
  • FIG. 11 shows a schematic flow chart of a further preferred method 1000 for producing a rotor segment 200 of a rotor 121 .
  • the method 1000 includes the following steps: Coating 1030 the radially outer negative outer surface of the molding device with a release agent and axially pre-clamping 1040 the at least one rotor lamination stack with one or more tie rods.
  • Method 1000 also includes fastening 1050, in particular pushing in, one or more magnet covers 250 to the at least one rotor core 220, in particular fastening the one or more magnet covers 250 to fastening connections 224 of a core inner surface 222 of the at least one rotor core 220.
  • the method 1000 includes arranging 1060, in particular pushing in, at least one magnet unit 230 between the at least one rotor laminated core 220 and the one or more magnet covers 250.
  • the method also includes aligning1100, in particular tapping, the at least one laminated rotor core 220, in particular the rotor laminations, to the forming device 300, in particular to the alignment device 330, to center the at least one laminated rotor core 220, in particular the at least a magnet unit 230.
  • the method then includes providing 1200 at least one magnet carrier segment 210, the magnet carrier segment 210 extending in a radial direction R between a radially outer magnet carrier outer surface 211 and a magnet carrier inner surface 212 which is radially inner in relation to the magnet carrier outer surface 211.
  • the at least one magnet carrier segment 210 is arranged coaxially in relation to the rotor laminated core 220, in particular the magnet carrier segment 210 is slipped over the at least one rotor laminated core 220, so that between the at least one magnet carrier segment and to the at least one rotor lamination stack an annular air gap extends, with the at least one rotor lamination stack 220 being arranged coaxially to the magnet carrier segment 210 in relation to an axis of rotation of the rotor segment, with the at least one rotor lamination stack 220 preferably being in the radial direction R is arranged radially on the inside relative to the magnet carrier segment 210 and the laminated core outer surface 221 and the magnet carrier inner surface 212 are arranged spaced apart, facing one another.
  • Adhesive bonding 1400 of the at least one magnet unit 230 to the at least one laminated rotor core 220 and/or the one or more magnet covers 250 with a casting compound is then provided.
  • the method also includes arranging 1500, in particular foaming and/or casting, a connecting element 240 between the radially outer magnet carrier segment 210 and the at least one radially inner laminated rotor core 220, so that the connecting element 240 is connected to the at least one laminated rotor core 220 on the outer surface of the laminated core 221 and the magnet carrier segment 210 on the magnet carrier inner surface 212, with the connecting element 240 being designed in particular as a cast and/or foam part and/or the connecting element 240 being arranged preferably by a casting and/or foaming process , wherein the connecting element 240 preferably comprises plastic, in particular polyurethane, and/or is particularly preferably designed as a polyurethane foam part.
  • the casting compound and the connecting element are then cured 1600 .
  • the method 1000 includes a method 1700 of the soft magnetic elements 320 from an assembly position to a standby position to open the magnetic flux to see the removal of the molding device 300 from the manufactured rotor segment 200, wherein the soft magnetic elements 320 are not in the standby position are arranged on the negative inner surface 312, in particular are arranged at a distance from the negative inner surface 312 in the radial direction R.
  • the method includes demolding 1800 the manufactured rotor segment 200.
  • spinner 120 (electrical) generator 121 (electrodynamic) rotor 200 rotor segment 210 magnet carrier segment 211 magnet carrier outer surface 212 magnet carrier inner surface 213 first connecting projections

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

Abstract

L'invention concerne un segment de rotor (200) d'un rotor (121) d'un générateur (1), en particulier un rotor segmenté (121) d'un générateur segmenté (1), pour une éolienne (100) comprenant un segment de support d'aimant (210) présentant une géométrie annulaire ou partiellement annulaire, le segment de support d'aimant (210) s'étendant dans une direction radiale (R) entre une surface extérieure de support d'aimant (211) située radialement à l'extérieur et une surface intérieure de support d'aimant (212) située radialement à l'intérieur par rapport à la surface extérieure de support d'aimant, et au moins un paquet de tôles de rotor (220) qui est conçu pour recevoir au moins une unité magnétique (230), le ou les paquets de tôles de rotor (220) s'étendant dans la direction axiale (R) entre une surface extérieure de paquet de tôles radialement à l'extérieur (221) et une surface intérieure de paquet de tôles située radialement à l'intérieur (222) disposée radialement vers l'intérieur par rapport à la surface extérieure du paquet de tôles ; l'invention étant caractérisée en ce qu'un élément de liaison (240) est situé entre le segment de support d'aimant (210) et le ou les paquets de tôles de rotor (220), ledit élément de liaison (240) se présentant sous la forme d'une pièce coulée et/ou d'une pièce en mousse et étant relié à la surface extérieure de paquet de tôles (221) du ou des paquets de tôles de rotor (220) et à la surface intérieure de support d'aimant (212) du segment de support d'aimant (210).
EP22733519.7A 2021-06-10 2022-05-25 Segment de rotor, couvercle magnétique, rotor, générateur, éolienne et dispositif de moulage et procédé de fabrication d'un segment de rotor Pending EP4352857A2 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102021114933.9A DE102021114933A1 (de) 2021-06-10 2021-06-10 Rotorsegment, Magnetabdeckung, Rotor, Generator, Windenergieanlage sowie Formvorrichtung und Verfahren zur Herstellung eines Rotorsegments
PCT/EP2022/064216 WO2022258380A2 (fr) 2021-06-10 2022-05-25 Segment de rotor, couvercle magnétique, rotor, générateur, éolienne et dispositif de moulage et procédé de fabrication d'un segment de rotor

Publications (1)

Publication Number Publication Date
EP4352857A2 true EP4352857A2 (fr) 2024-04-17

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Family Applications (1)

Application Number Title Priority Date Filing Date
EP22733519.7A Pending EP4352857A2 (fr) 2021-06-10 2022-05-25 Segment de rotor, couvercle magnétique, rotor, générateur, éolienne et dispositif de moulage et procédé de fabrication d'un segment de rotor

Country Status (3)

Country Link
EP (1) EP4352857A2 (fr)
DE (1) DE102021114933A1 (fr)
WO (1) WO2022258380A2 (fr)

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DE4323656A1 (de) * 1993-07-15 1995-01-19 Vacuumschmelze Gmbh Verfahren zum Verkleben von Dauermagnetwerkstoffen
JP2000152541A (ja) * 1998-11-12 2000-05-30 Sawafuji Electric Co Ltd アウタロータ型多極発電機用ロータにおける磁鋼片固定方法
US7262526B2 (en) * 2002-06-20 2007-08-28 Kabushiki Kaisha Toshiba Rotor for permanent magnet motor of outer rotor type
DE102004035382A1 (de) 2004-07-21 2006-03-16 Schmalfuß, Udo, Dipl.-Ing. Modularer Generator für getriebelosen Antrieb von Rotoren mit geringer Drehzahl
DE102009025929A1 (de) 2009-06-05 2010-12-09 Ulrich Spevacek Läuferaufbau für eine permanentmagneterregte, rotierende elektrische Maschine
DE102009031371B4 (de) * 2009-07-01 2011-05-26 Siemens Aktiengesellschaft Läufer und Verfahren zur Herstellung eines Läufers einer elektrischen Maschine
GB201016324D0 (en) * 2010-09-28 2010-11-10 Nexxtdrive Ltd An electrical machine and a rotor for an electrical machine
DE102010041593A1 (de) 2010-09-29 2012-03-29 Siemens Aktiengesellschaft Magnetpolabdeckung einer elektrischen Maschine
WO2012103882A2 (fr) 2011-01-31 2012-08-09 Ixetic Bad Homburg Gmbh Rotor pour un moteur électrique et moteur électrique
DE202011050715U1 (de) 2011-07-13 2011-11-16 Lloyd Dynamowerke Gmbh & Co. Kg Aufnahmeelement zum Aufnehmen von Magneten in einer elektrischen Maschine sowie Bauteil mit einem solchen Aufnahmeelement
EP2713480B1 (fr) 2012-09-27 2018-01-31 Siemens Aktiengesellschaft Rotor d'un générateur à aimant permanent
DE102013101956A1 (de) 2013-02-27 2014-08-28 Wittenstein Ag Rotor
EP2790297B1 (fr) 2013-04-08 2017-08-02 Siemens Aktiengesellschaft Rotor pour une machine électrique
DE102015203257A1 (de) 2015-02-24 2016-08-25 Robert Bosch Gmbh Rotor für eine elektrische Maschine mit vorteilhafter Drehmomentübertragung sowie entsprechende elektrische Maschine
DE102018111906A1 (de) 2018-05-17 2019-11-21 Schaeffler Technologies AG & Co. KG Rotor oder Stator mit segmentierten Funktionsblechpaketen, Elektromaschine und Verfahren zum Herstellen eines Rotors oder Stators
EP3829030A1 (fr) 2019-11-29 2021-06-02 Siemens Gamesa Renewable Energy A/S Module d'aimant permanent pour machine à aimant permanent

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Publication number Publication date
WO2022258380A2 (fr) 2022-12-15
DE102021114933A1 (de) 2022-12-15
WO2022258380A3 (fr) 2023-02-23

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