EP4409727A1 - Rotor pour machine électrique pourvu d'un canal de liaison - Google Patents

Rotor pour machine électrique pourvu d'un canal de liaison

Info

Publication number
EP4409727A1
EP4409727A1 EP22803171.2A EP22803171A EP4409727A1 EP 4409727 A1 EP4409727 A1 EP 4409727A1 EP 22803171 A EP22803171 A EP 22803171A EP 4409727 A1 EP4409727 A1 EP 4409727A1
Authority
EP
European Patent Office
Prior art keywords
rotor
laminated core
pockets
magnet
connecting channel
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
EP22803171.2A
Other languages
German (de)
English (en)
Inventor
Christoph Wieczorek
Markus Rubi
Alexander Schlereth
Kay Lemmert
Stephan Hellmuth
Robert Werner
Robin Büsch
Sebastian Dieterich
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.)
Valeo eAutomotive Germany GmbH
Original Assignee
Valeo eAutomotive Germany 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 Valeo eAutomotive Germany GmbH filed Critical Valeo eAutomotive Germany GmbH
Publication of EP4409727A1 publication Critical patent/EP4409727A1/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
    • H02K1/2706—Inner rotors
    • H02K1/272—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis
    • H02K1/274—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis the rotor consisting of two or more circumferentially positioned magnets
    • H02K1/2753—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis the rotor consisting of two or more circumferentially positioned magnets the rotor consisting of magnets or groups of magnets arranged with alternating polarity
    • H02K1/276—Magnets embedded in the magnetic core, e.g. interior permanent magnets [IPM]
    • H02K1/2766—Magnets embedded in the magnetic core, e.g. interior permanent magnets [IPM] having a flux concentration effect
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/02—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
    • H02K15/03—Processes 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
    • H02K15/00—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/12—Impregnating, moulding insulation, heating or drying of windings, stators, rotors or machines
    • 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
    • H02K1/2706—Inner rotors
    • H02K1/272—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis
    • H02K1/274—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis the rotor consisting of two or more circumferentially positioned magnets
    • H02K1/2753—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis the rotor consisting of two or more circumferentially positioned magnets the rotor consisting of magnets or groups of magnets arranged with alternating polarity
    • H02K1/276—Magnets embedded in the magnetic core, e.g. interior permanent magnets [IPM]

Definitions

  • the invention relates to a rotor for an electric machine, an electric machine with a rotor, a vehicle with an electric machine and a method for producing a rotor.
  • the rotor has a laminated core formed from stacked electrical laminations (rotor core) with magnet pockets arranged therein and a plurality of magnets, of which at least one is inserted in each of the magnet pockets.
  • Electrical machines with such a rotor are increasingly being used in electrically powered vehicles and hybrid vehicles, primarily as an electric motor for driving a wheel or an axle of such a vehicle.
  • Such an electric motor is usually mechanically coupled to a gear for speed adjustment.
  • the electric motor is usually electrically coupled to an inverter, which generates an AC voltage for the operation of the electric motor, for example a polyphase AC voltage, from a DC voltage supplied by a battery.
  • the rotor must ensure that the magnets maintain their position in the magnet pockets, especially at high speeds.
  • it is customary to encapsulate the magnets in the magnet pockets with an encapsulating compound, so that the magnets are securely fastened or fixed in the laminated core.
  • the encapsulation is complex and it can happen that unwanted cavities or air bubbles remain in the laminated core.
  • the invention is therefore based on the object of specifying a rotor for an electrical machine whose magnets can be cast in a particularly simple manner, with no cavities or air bubbles remaining in the laminated core of the rotor.
  • the invention provides for a rotor of the type mentioned at the outset to have a plurality of free spaces, each of which is delimited by the magnets inserted in one of the magnet pockets and the laminated core. Furthermore, the rotor has a first connecting channel, which connects a first of the free spaces, which is assigned to a first of the magnetic pockets, with a second of the free spaces, which is assigned to a second of the magnetic pockets.
  • the free spaces can be cast with a casting compound, as a result of which the magnets are fixed in the laminated core, in particular glued to the laminated core. Potting is a comparatively simple and inexpensive way of attaching the magnets.
  • both free spaces can be cast in a single process step. Consequently, different magnetic pockets are cast in the same process step.
  • a free space is assigned to a magnetic pocket can be understood here in such a way that the free space belongs to the magnetic pocket or forms part of the magnetic pocket. In other words, the free space takes up part of the volume of the magnet pocket.
  • the laminated core can be formed from the electrical laminations by these being welded, glued, stamped or fastened to one another in some other way.
  • the laminated core can have a cylindrical shape.
  • each electrical lamination can have a central opening which, in the installed state, forms an axial borehole in the laminated core through which a rotor shaft of the rotor can lead.
  • the axis of the rotor shaft or the rotor corresponds to the axial axis of the laminated core.
  • the laminated core can be composed of a plurality of laminated core segments, it being possible for one or more of the laminated core segments to be twisted relative to one or more of the other laminated core segments. In this way, the rotational behavior of the rotor can be improved.
  • the laminated cores can be twisted against each other in such a way that that the axial free spaces otherwise running parallel to the rotor axis run obliquely to the rotor axis.
  • the electrical machine can have a stator relative to which the rotor can rotate.
  • the stator can have a further laminated core (stator core), which is formed from stacked electrical laminations.
  • stator can have windings of electrical conductors, for example as coil windings or flat wire windings.
  • the machine can be equipped with a housing in which the rotor and the stator are accommodated, with the rotor shaft being able to protrude from the housing.
  • the magnets used in one of the magnet pockets are preferably lined up axially. As a result, the magnets can simply be inserted or pushed into the magnet pocket one after the other when assembling the rotor.
  • the magnets lined up axially are referred to as "magnet stacks".
  • the rotor can have several such magnet stacks, each of which is arranged in a magnet pocket. As an alternative to a magnet stack, a single magnet can also be arranged in one or more of the magnet pockets.
  • a space may be formed on one side surface of a magnet pocket, and another space may be formed on an opposite side surface of the magnet pocket. This allows the magnets arranged between the two free spaces to be fixed particularly well with the encapsulation.
  • the two free spaces can be separated from one another by a magnet or a magnet stack.
  • the volume of the free spaces is generally selected to be significantly smaller than the volume of the magnet stack in order to limit the amount of potting compound required to fill the free spaces.
  • the first free space, the second free space and the first connecting channel form a continuous channel belong, which connects a filling port with a vent port of the rotor.
  • the continuous channel can be completely filled with casting compound in a single method step.
  • the first connecting channel runs on an axial side of the laminated core. This is preferably the axial side on which the filling opening is arranged. Alternatively, it can be the opposite axial side.
  • a further embodiment of the invention provides a second connecting channel which runs on an opposite axial side of the laminated core and connects the second free space to a third of the free spaces.
  • the first connecting channel and the second connecting channel each run on a different axial side.
  • the third free space is preferably assigned to the second magnetic pocket.
  • the third free space can be assigned to a third magnetic pocket.
  • the rotor can have further connecting channels for connecting further free spaces to the free spaces mentioned so far.
  • a preferred embodiment of the invention provides that the first connecting channel and/or the second connecting channel each run in an end plate of the rotor.
  • Such an end plate is arranged on an axial side of the laminated core.
  • a connecting channel can be formed, for example, as a groove in the end plate, preferably on an inner side of the end plate.
  • the rotor according to the invention can have no end plate.
  • the first connection channel and/or the second connection channel can each run in an end plate of the laminated core.
  • Such an end plate is arranged on an axial side of the laminated core.
  • a Connection channel can be formed, for example, in a bulge of the end plate.
  • the filling opening and the ventilation opening are preferably arranged on the same axial side of the laminated core.
  • the filling opening and the ventilation opening can be arranged on different axial sides of the laminated core.
  • a particularly preferred embodiment of the rotor provides two, three or four continuous channels corresponding to the above-mentioned continuous channel, which each connect a different filling opening of the rotor to a different ventilation opening of the rotor.
  • a large part of the connection channels or even all of the connection channels can be connected in such a way that the magnets of the rotor can be cast in a few process steps or in a single process step.
  • the magnets of the rotor according to the invention are preferably cast with a casting compound that fills the free spaces. Normally the voids are completely filled with potting compound. However, it is also possible to only partially fill the free spaces with casting compound.
  • An epoxy resin or an adhesive, among others, can be used as the casting compound.
  • the invention relates to an electrical machine with a rotor of the type described.
  • the electrical machine can have a stator relative to which the rotor can be rotated.
  • the stator can have a further laminated core (stator core), which is formed from stacked electrical laminations.
  • the stator can have windings of electrical conductors, for example in the form of coil windings or flat wire windings.
  • the invention relates to a vehicle with such an electric machine, which is provided for driving the vehicle.
  • the machine can drive a wheel or an axle of the vehicle.
  • the invention relates to a method for producing a rotor for an electrical machine, with the following steps:
  • free spaces that are assigned to different magnet pockets can be cast simultaneously or in the same method step, which means that the method can be carried out particularly easily and quickly.
  • the casting compound flows out of the first free space through the connecting channel into the second free space.
  • FIG. 1 is a perspective view of a laminated core and a rotor shaft of a rotor according to the invention
  • FIG. 2 shows a section of the laminated core shown in FIG. 1,
  • FIG. 5 shows a perspective view of the rotor without the laminated core and the rotor shaft
  • Fig. 6 is a view of the arrangement shown in Fig. 5 from a different perspective
  • FIG. 7 shows a vehicle with an electric machine with the rotor.
  • the rotor 1 shown in FIG. 1 is intended for an electrical machine and comprises a cylindrical laminated core 2 composed of stacked electrical laminations.
  • the laminated core 2 encloses a rotor shaft 4 in a positive and/or non-positive manner.
  • the electrical laminations are divided into five laminated core segments, in which case the rotor 1 could also have a different number of laminated core segments or an unsegmented laminated core. Each laminated core segment is rotated by the same angle of rotation relative to an adjacent laminated core segment in the circumferential direction.
  • FIG. 2 shows a detail of the rotor 1 . It can be seen there that a plurality of magnetic pockets 3, 5 are arranged in the laminated core 2 along the circumference of the rotor 1, each of which extends from the shown axial side of the laminated core 2 to its opposite axial side. In a magnet pocket 3, 5, several cuboid magnets 6, 7 are lined up axially, forming a magnet stack. A total of 32 such magnet stacks are accommodated in the laminated core, although a different number of magnet stacks can also be used.
  • the magnetic pockets 3, 5 are of different sizes. In particular, a distinction can be made between larger magnetic pockets 3 with longer axial openings and smaller magnetic pockets 5 with shorter axial openings. In the larger magnet pockets 3, larger magnets 6 with longer axial faces are lined up axially, while in the smaller magnet pockets 5 smaller magnets 7 with shorter axial faces are lined up axially.
  • Two adjacent, larger magnet pockets 3 are arranged symmetrically to one another with respect to a radial axis (not shown) of the laminated core 2, with the two magnet pockets 3 forming a V-shape which opens radially outwards.
  • two adjacent smaller magnet pockets 5 are arranged symmetrically to one another with respect to the radial axis, with the two magnet pockets 5 also forming a V-shape.
  • each magnetic pocket 3, 5 has a free space 8 formed on one side face of the magnetic pocket 3, 5 and a free space 9 formed on an opposite side face of the magnetic pocket 3, 5, between which a magnet stack is located.
  • the free spaces 8 , 9 each run from one axial side to the opposite axial side of the laminated core 2 , with the free space 9 running radially outside of the free space 8 .
  • FIG. 3 shows the rotor 1 with a first end plate 10 and a second end plate 11 in a side view.
  • the end plates 10, 11 are arranged on opposite axial sides of the laminated core 2 and are connected to one another using clamping elements.
  • the laminated core 2 is permanently subjected to a compressive force or prestressing force. This prevents the electrical laminations of the laminated core 2 from becoming detached from one another, in particular at high speeds of the rotor 1 .
  • FIG. 4 is a perspective view of the rotor 1 with the end plates 10, 11.
  • the clamping elements are in the form of screws 12, the ends of which can be seen in FIG.
  • Each of the eight bolts 12 runs axially through the first end plate 10 , the laminated core 2 and the second end plate 11 .
  • the end plates 10, 11 and the laminated core 2 are each provided with axial bores.
  • the heads of the screws 12 (not visible) are arranged on the first end plate 10 .
  • the screws 12 are screwed with nuts.
  • FIG. 5 is a view of the rotor from the same perspective as in FIG. 4, with the laminated core 2, the rotor shaft 4 and the screws 12 not being shown. On the other hand, the two end plates 10, 11 and the axial free spaces and connecting channels filled with the casting compound are shown.
  • the second end plate 11 has a filling opening 13 which is connected to a ventilation opening 14 via the free spaces and connecting channels.
  • the free spaces and connecting channels thus form a continuous channel which extends from the filling opening 13 to the ventilation opening 14 .
  • the continuous channel includes, among other things, a free space 15 which extends axially from the filling opening 13 to the first end plate 10 and is part of a first magnetic pocket.
  • connection channel 16 formed in the first end plate 10 adjoins the first free space 15 and runs between a magnet stack (not shown in FIG. 5) arranged in the first magnet pocket and the first end plate 10 .
  • a further free space 17 connects to the connecting channel 16, which extends axially from the first end plate 10 to the second end plate 11 and is part of the first magnetic pocket.
  • the free space 17 can be referred to as "first free space”.
  • connection channel 18 connects to the free space 17.
  • the connection channel 18 is formed in the second end plate 11 and extends to another space 19. Referring to the claims, the connection channel 18 can be referred to as “first connection channel” and the space 19 as "second space”.
  • the free space 19 is part of a second magnet pocket and runs axially from the second end plate 11 to the first end plate 10.
  • a further connecting channel 20 formed in the first end plate 10 adjoins the free space 19, which connects between a magnet stack arranged in the second magnet pocket and the first end plate 10 runs.
  • the connecting duct 20 may be referred to as a "second connecting duct”.
  • the connecting channel 20 connects the free space at 19 with a further free space 25 which extends axially from the first end plate 10 to the second end plate 11 and is part of the second magnetic pocket.
  • the space 25 can be referred to as a "third space”.
  • the third free space can also be part of a third magnetic pocket.
  • connection channels and free spaces which extend up to the ventilation opening 14 , are connected to the free space 25 .
  • the continuous channel formed by the free spaces and connecting channels mentioned runs in a meandering manner between the two end plates 10, 11 and connects the filling opening 13 with the ventilation opening 14.
  • the channel is characterized in that it is cast with casting compound in a single process step can be.
  • the casting compound can be introduced or pressed into the filling opening 13 so that the casting compound flows up to the ventilation opening 14 .
  • the continuous channel extends over approximately a quarter of the circumference of the laminated core 2.
  • other embodiments of the invention are also possible in which such a channel extends over approximately half the circumference or over the entire circumference.
  • connection channels can also be formed in end plates of the laminated core, for example using curvatures in the end plates.
  • FIG. 7 schematically shows a vehicle 21 with an electric machine 22, which is used to drive the vehicle 21.
  • the electrical machine 22 has a housing 23 in which the rotor 1 and a stator 24 which surrounds the rotor 1 are accommodated.
  • the laminated core 2, in which the magnet pockets 3.5 are arranged is formed from stacked electrical laminations.
  • a second step the magnets 6, 7 are inserted into each of the magnet pockets 3.5, with free spaces remaining, which are each delimited by the magnets 6.7 inserted into one of the magnet pockets 3.5 and the laminated core 2.
  • a first connecting channel is formed, which connects a first of the free spaces, which is assigned to a first of the magnetic pockets 3.5, with a second of the free spaces, which is assigned to a second of the magnetic pockets.
  • the magnets 6, 7 inserted into the magnet pockets 3, 5 are cast with a casting compound.
  • a portion of the potting compound can flow from the first free space through the first connecting channel into the second free space.
  • a nozzle of a filling device is placed on the filling opening 13 (or each filling opening) of the first end plate 10 .
  • the casting compound is pressed into the free spaces with overpressure, so that the casting compound flows through the axially extending connecting channels, as was explained with reference to FIG. 5 and FIG. Meanwhile, air escapes from the laminated core 2 , in particular from the free spaces and connecting channels, through the ventilation opening 14 .
  • the casting compound hardens.
  • the rotor shaft 4 is inserted through an axially extending central through opening of the laminated core 2 (and corresponding openings of the end plates 10, 11) so that the laminated core 2 encloses the rotor shaft 4 and is fixed thereto.

Landscapes

  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Permanent Field Magnets Of Synchronous Machinery (AREA)

Abstract

Rotor (1) pour une machine électrique (22), comprenant : un paquet de tôles (2) qui est formé de tôles électriques empilées et à l'intérieur duquel des poches à aimants (3, 5) sont disposées, plusieurs aimants (6, 7), chacune des poches à aimants (3, 5) contenant au moins un desdits aimants, plusieurs espaces libres (8, 9, 17, 19, 25) qui sont chacun délimités par les aimants (6, 7), disposés dans l'une des poches à aimants (3, 5), et par le paquet de tôles (2), et un premier canal de liaison (18) qui relie un premier espace libre (17), qui est associé à une première poche à aimant (3), à un deuxième espace libre (19), qui est associé à une deuxième poche à aimant (5). L'invention concerne en outre une machine électrique (22) équipée d'un tel rotor (1), un véhicule (21) équipé d'une telle machine électrique (22) et un procédé de fabrication d'un tel rotor (1).
EP22803171.2A 2021-09-29 2022-09-27 Rotor pour machine électrique pourvu d'un canal de liaison Pending EP4409727A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102021210913.6A DE102021210913A1 (de) 2021-09-29 2021-09-29 Rotor für eine elektrische Maschine mit einem Verbindungskanal
PCT/EP2022/076847 WO2023052362A1 (fr) 2021-09-29 2022-09-27 Rotor pour machine électrique pourvu d'un canal de liaison

Publications (1)

Publication Number Publication Date
EP4409727A1 true EP4409727A1 (fr) 2024-08-07

Family

ID=84358672

Family Applications (1)

Application Number Title Priority Date Filing Date
EP22803171.2A Pending EP4409727A1 (fr) 2021-09-29 2022-09-27 Rotor pour machine électrique pourvu d'un canal de liaison

Country Status (5)

Country Link
US (1) US20240413683A1 (fr)
EP (1) EP4409727A1 (fr)
CN (1) CN118176644A (fr)
DE (1) DE102021210913A1 (fr)
WO (1) WO2023052362A1 (fr)

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR3147913B1 (fr) * 2023-04-14 2025-04-11 Commissariat Energie Atomique Montage réversible d’aimant permanent dans une machine électrique

Family Cites Families (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2005312259A (ja) 2004-04-26 2005-11-04 Toyota Motor Corp モータの回転子
CN101356711B (zh) * 2006-01-11 2011-04-27 株式会社三井高科技 将永磁体树脂密封到叠片转子铁芯中的方法
DE102008027758B4 (de) 2008-06-11 2010-09-09 Siemens Aktiengesellschaft Rotor für eine permanentmagneterregte dynamoelektrische Maschine
KR101220381B1 (ko) * 2010-12-01 2013-01-09 현대자동차주식회사 매입형 영구자석모터 및 이를 제작하는 방법
DE102012215084A1 (de) 2012-08-24 2014-02-27 Siemens Ag Rotor einer elektrischen Maschine und elektrische Maschine
US11128206B2 (en) * 2017-03-29 2021-09-21 Hitachi Automotive Systems, Ltd. Method of manufacturing rotor of rotating electrical machine
DE102017214309A1 (de) 2017-08-17 2019-02-21 Continental Automotive Gmbh Rotor für eine elektrische Maschine, insbesondere eines Kraftfahrzeugs, sowie Verfahren zum Herstellen eines solchen Rotors
CN109698590B (zh) 2017-10-23 2020-11-13 株洲中车机电科技有限公司 一种永磁电机转子真空灌胶方法
DE102018009844A1 (de) 2018-12-14 2019-06-27 Daimler Ag Verfahren zum Herstellen einer Blechpaketeinheit für eine elektrische Maschine, insbesondere eines Kraftfahrzeugs
JP2020096474A (ja) * 2018-12-14 2020-06-18 トヨタ自動車株式会社 回転電機のロータ
JP7183087B2 (ja) 2019-03-20 2022-12-05 株式会社東芝 回転電機
CN113162277A (zh) 2021-05-12 2021-07-23 北汽大洋电机科技有限公司 新能源永磁电机的灌胶转子总成及其电机

Also Published As

Publication number Publication date
CN118176644A (zh) 2024-06-11
US20240413683A1 (en) 2024-12-12
DE102021210913A1 (de) 2023-03-30
WO2023052362A1 (fr) 2023-04-06

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