WO2010040534A2 - Rotor de machine électrique et utilisation associée, dispositif et procédé de fabrication de ce rotor - Google Patents

Rotor de machine électrique et utilisation associée, dispositif et procédé de fabrication de ce rotor Download PDF

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Publication number
WO2010040534A2
WO2010040534A2 PCT/EP2009/007240 EP2009007240W WO2010040534A2 WO 2010040534 A2 WO2010040534 A2 WO 2010040534A2 EP 2009007240 W EP2009007240 W EP 2009007240W WO 2010040534 A2 WO2010040534 A2 WO 2010040534A2
Authority
WO
WIPO (PCT)
Prior art keywords
rotor
main body
mounting flange
rotor main
shaft
Prior art date
Application number
PCT/EP2009/007240
Other languages
German (de)
English (en)
Other versions
WO2010040534A3 (fr
Inventor
Bernd Schottdorf
Franz Weissgerber
Original Assignee
Pro Diskus Ag
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 Pro Diskus Ag filed Critical Pro Diskus Ag
Priority to EP09778872A priority Critical patent/EP2332236A2/fr
Publication of WO2010040534A2 publication Critical patent/WO2010040534A2/fr
Publication of WO2010040534A3 publication Critical patent/WO2010040534A3/fr

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Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/22—Rotating parts of the magnetic circuit
    • H02K1/28—Means for mounting or fastening rotating magnetic parts on to, or to, the rotor structures
    • 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
    • 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
    • H02K1/2793—Rotors axially facing stators
    • H02K1/2795—Rotors axially facing stators the rotor consisting of two or more circumferentially positioned magnets
    • 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

Definitions

  • the present invention relates generally to electrical machines, and more particularly to rotors for electric machines.
  • Electric machines both in the form of electric motors and generators, are increasingly being used in areas of alternative power generation and supply.
  • conventional electrical machines u.a. due to size, weight and efficiency in many cases not suitable.
  • the patent DE 10 2006 036 707 B3 discloses a carrier ring made of fiber-reinforced plastic with cutouts for insertion of permanent magnets.
  • One or more carrier rings can form a rotor construction.
  • FIG. 1 of US 4,674,178 shows a rotor hub having a recess comprising a body of cured fibrous material.
  • the body fills the depression and is cylindrical.
  • the body is formed by winding a fiber, such as a carbon fiber, in a curable resin, such as an epoxy, around the rotor structure.
  • the side plates are formed of a suitable magnetic material.
  • the rotor hub center portion is formed of a magnetic material, but may be formed of a non-magnetic material.
  • the fastening flange is not made of fiber composite material, but only certain components of the rotor hub are formed of hardened fiber material.
  • Fig. 14 shows an overview diagram of such conventional methods from Neitzel and Mitschang. The diagram is divided on the Horizontal axis the shape complexity of a fiber-plastic composite and on the vertical axis an approximate component size.
  • the diagram in FIG. 14 provides information about component types and processing methods.
  • the shape complexity of round or oval tubes is low, but their component size can vary from small to large.
  • the fiber processing methods flow forming and injection molding are increasingly used in components of high shape complexity and small to medium size components, whereas the resin injection method according to Neitzel and Mitschang is more likely to be selected with high shape complexity and large component size.
  • the resin injection method according to Neitzel and Mitschang is more likely to be selected with high shape complexity and large component size.
  • a disadvantage of all processes is the processing costs and the high energy requirement, for example, when using an autoclave for curing fiber-plastic composites.
  • Object of the present invention is to overcome the above-mentioned disadvantages of the prior art.
  • a rotor for an electric machine is provided with a rotor main body made of
  • Fiber composite material exists. There is also an on the
  • Rotor main body arranged mounting flange
  • Fiber composite material Preferably, the
  • the mounting flange may be arranged flat on a front and / or a rear side of the rotor main body.
  • the rotor is cylindrical and the front side thereof is a circular surface, i. the cylinder cover, which is also the circular back, i. the cylinder bottom, opposite.
  • the ratio of rotor main body diameter to rotor main body thickness is high, i. the rotor main body is advantageously flat and therefore lighter in weight.
  • a mounting flange can be arranged on the front and / or rear of the rotor.
  • the attachment flange preferably increases the thickness of the rotor main body toward the center thereof.
  • the mounting flange may be configured to transmit torque from the rotor main body to the shaft disposed on the mounting flange. This results in an assembly of preferably interconnected components, wherein the Components include the rotor main body, the mounting flange and the shaft.
  • the mounting flange may be formed positively with the shaft.
  • the shaft Preferably, the
  • Fit e.g., press fit
  • a backlash e.g., backlash
  • mechanical wear and losses e.g., mechanical wear and losses
  • At least one fiber of a fiber material forms the rotor main body and the mounting flange.
  • the at least one fiber is wound, laid, tensioned, or otherwise arranged so that a solid such as the rotor main body and / or the fixing body can be integrally formed.
  • the rotor main body and / or the mounting flange can have high stability. If the rotor main body and the mounting flange are in common with each other, e.g. formed integrally, so preferably an additional connection operation of two components can be avoided and a solid cohesion and rapid production can be achieved.
  • Mounting flange at least one component, which is formed from plate-like fiber composite semi-finished product.
  • the mounting flange is formed from one or more flat stacked components.
  • a component is a generic component that is easy and quick to produce.
  • Under plate-like fiber composite semi-finished product is preferably understood to mean a plate formed from fiber composite raw material, which can be easily brought into a desired shape by conventional machining processes.
  • the advantage of fiber composite semi-finished products is the saving of fiber composite manufacturing tools, knowhow, and infrastructure.
  • the finishing process from the fiber composite semi-finished product to the mounting flange is advantageously short, inexpensive and can be handled with current machine tools.
  • Under plate-like fiber composite semi-finished product are preferably also prefabricated rods, spars, pipes, mats and sandwich panels, each having fiber composite material to understand.
  • the at least one fiber forms a thickening towards the center of the rotor.
  • a thickening towards the center of the rotor is produced.
  • the thickening can form a mounting flange.
  • the present invention provides a method for producing a rotor according to the invention and uses of the rotor according to the invention.
  • 3a shows an enlarged portion of a
  • Fig. 3b shows an enlarged portion of a
  • 4a is a side view of a rotor main body with cover layers
  • 4b is a side view of a rotor main body with a mounting flange
  • Fig. 10a further storage devices, and 10b
  • Fig. 11 shows a "negative mold for manufacturing rotor
  • Fig. 12 shows a further negative mold for
  • Rotor manufacture 13 is a flowchart for various methods of production
  • Fig. 14 is a diagram according to the prior art
  • Fig. 16 is a hybrid system
  • 17a shows an electrical circuit arrangement of a and 17b motor-generator device.
  • the rotor main body may include one or a plurality of centrally disposed to the center of the rotor main body shots.
  • the rotor may comprise a plurality of magnets, which are arranged in at least one of the receptacles, wherein at least two magnets are arranged in at least one of the receptacles.
  • at least one of the magnets is a permanent magnet.
  • the material of the magnet has rare
  • the material of the magnet can have neodymium and / or a chemical compound with neodymium.
  • the material of the magnet may additionally or alternatively the chemical Compound neodymium-iron-boron or samarium-cobalt include.
  • the centrally arranged receptacles are holes passing through the rotor main body.
  • At least one cover layer is provided, wherein the at least one cover layer may be arranged on the rotor main body such that the magnets arranged in the central receptacles are at least partially covered.
  • At least one of the cover layers may have fiber composite material.
  • the magnets are covered in such a way by at least one of the cover layers that they are not removable from the recordings.
  • At least one cover layer is arranged on a front surface and / or a rear surface _ of the rotor main body.
  • the fiber composite material of the rotor can be carbon
  • Epoxy resin and / or polypropylene Epoxy resin and / or polypropylene.
  • At least one fiber for the fiber composite material may be designed to be laid in / on a forming means. It can also be provided that the semifinished product comprising fiber composite material for forming the rotor main body is used. Preferably, at least one fiber for the fiber composite material is designed such that it is placed in / on a shaping means.
  • the invention provides the use of the rotor in an electrical machine as a drive for an air, water or land vehicle 1 or a generator in a power generating device before.
  • Power generation apparatus may include wind and hydro power plants and / or be configured to convert rotational forces generated by a vehicle and / or torques into electrical energy.
  • the invention provides a designed as a hub motor and / or generator for a vehicle electrical machine.
  • a rotor for an electric machine is provided with a rotor main body made of fiber composite material.
  • a mounting flange disposed on the rotor main body may also be made of fiber composite material.
  • the rotor main body and the mounting flange are integrally formed of fiber composite material and collectively referred to as a rotor.
  • the mounting flange may be arranged flat on a front and a rear side of the rotor main body.
  • the rotor is cylindrical and the front side, ie the cylinder cover, a circular surface which is opposite to the likewise circular rear side, ie the cylinder bottom.
  • the ratio rotor main body diameter to rotor main body thickness is high, ie the rotor main body is advantageously flat and therefore has a low Weight.
  • a mounting flange can be arranged on the front and / or rear of the rotor.
  • the attachment flange preferably increases the thickness of the rotor main body toward the center thereof.
  • the mounting flange may be configured to transmit torque from the rotor main body to the shaft disposed on the mounting flange. This allows e.g. an assembly of preferably interconnected components, wherein the
  • Components include the rotor main body, the mounting flange and the shaft.
  • the mounting flange may be formed positively to the shaft.
  • At least one fiber of a fiber material may be the
  • Rotor main body and the mounting flange form.
  • the at least one fiber is wound, laid, tensioned, or otherwise arranged so that a solid such as the rotor main body and / or the fixing body can be integrally formed.
  • the mounting flange may comprise at least one component which is formed from plate-like fiber composite semi-finished product.
  • the mounting flange is formed from one or more flat stacked components.
  • a component is an easily available, simply constructed component which can be produced easily and quickly.
  • Under plate-like fiber composite semi-finished product is preferably understood to mean a plate formed from fiber composite raw material, which can be easily brought into a desired shape by conventional machining processes.
  • the finishing process from the fiber composite semi-finished product to the mounting flange is advantageously short, inexpensive and can be handled with current machine tools.
  • Under plate-like fiber composite semi-finished product may also or alternatively be prefabricated rods, spars, pipes, mats and sandwich panels, each of which may comprise fiber composite material understood.
  • the at least one fiber towards the center of the rotor can form a thickening.
  • a natural thickening towards the center of the rotor is produced.
  • the thickening can form a mounting flange.
  • the at least one fiber can be guided as a loop around the at least one receptacle and thereby leave at most one side of the at least one receptacle free.
  • a loop so leads around a receptacle, which has four sides, for example, that three of these sides are looped.
  • the at least one fiber can at least partially wrap around at least two adjacent receptacles.
  • the rotor main body may comprise at least one flange hole and / or a central shaft receiving and / or shaft passage, which may be at least partially wrapped by at least one fiber.
  • the at least one fiber may at least partially wrap around the circumference of the rotor main body.
  • the at least one fiber wraps around at least two locations of the rotor main body, wherein a location includes a receptacle, a central shaft receptacle, a flange hole or a specific area of the rotor main body.
  • a location includes a receptacle, a central shaft receptacle, a flange hole or a specific area of the rotor main body.
  • the at least one fiber comprises an endless fiber and / or piecewise thickening fibers.
  • the continuous fiber has the advantage that it is easy to work as a wound starting material.
  • thickening fibers allow the manufacture of a rotor main body of constant and uniform thickness.
  • a disk-shaped rotor main body is formed by at least one fiber
  • a natural material thickening to the center of the rotor main body may form a hub, a mounting flange or a shaft connection.
  • at least one flange hole can serve as a balancing means for the rotor main body, in particular if it is disc-shaped.
  • a method of manufacturing a rotor for an electric machine includes making a rotor main body as a rotor only of fiber composite material, and disposing a mounting flange made only of fiber composite material on the rotor main body.
  • a rotor-shaft assembly for an electric machine which has a shaft and a rotor arranged on the shaft with a Comprising fiber composite material having rotor main body, wherein the shaft and the rotor main body are coupled by means of at least one longitudinal pin connection.
  • the rotor-shaft assembly has a flange which is connected to the rotor main body, wherein the rotor main body and the flange are coupled by means of at least one of the longitudinal pin connections with the shaft.
  • the longitudinal pin connection comprises at least one longitudinal pin made of a predetermined material, which is exchangeable with another longitudinal pin.
  • the predetermined material may be an elastic material.
  • the longitudinal pin connection shears the at least one longitudinal pin at high torque.
  • the longitudinal pin connection allow startup and / or brake slip and / or mechanical damping.
  • a hybrid system is provided with an engine unit or other rotary drive unit, a gear unit and an electric motor unit with a shaft, wherein the gear unit, the torque of the engine unit or other rotary drive unit with the torque of
  • Electric motor unit summed and the electric motor unit comprises at least one fiber composite material having rotor, which is coupled by a longitudinal pin connection to the shaft of the electric motor unit.
  • the longitudinal pin connection for coupling the rotor main body to the shaft may comprise at least one longitudinal pin of a predetermined material, which is exchangeable against a longitudinal pin of another predetermined material.
  • the predetermined Material be an elastic material.
  • the longitudinal pin connection shears off at high torque.
  • an embodiment of the hybrid system is provided which allows startup and / or brake slip and / or mechanical damping.
  • a method for producing a rotor-shaft arrangement comprises the following steps: providing a rotor main body comprising fiber composite material
  • a rotor-shaft arrangement described above, a hybrid system described above and / or an electric machine described above as and / or for a drive for an air, water or land vehicle or as a generator in a power generating device is provided the power generating device comprises wind and hydro power plants.
  • a storage arrangement with a rotatably arranged on a rotational axis rotor of fiber composite material and at least one rotor bearing provided, which is in a radially spaced from the axis of rotation of the region in operative connection with the rotor.
  • at least one of the bearings and in particular two bearings can be in operative connection with a radially outer region of the rotor. It can also be provided that at least two of the bearings on different sides of the rotor are in operative connection with this.
  • at least one of the bearings is operatively connected to the shaft.
  • at least one of the bearings is provided on or within a stator of the electric motor. At least one of the bearings, which is operatively connected to a radially outer region of the rotor, may be a sliding bearing.
  • a magnetic bearing may be provided.
  • magnets in particular permanent magnets, may be provided on or within the rotor for the magnetic bearing.
  • the magnetic bearing can be actively controlled.
  • a circular arrangement of a group of permanent magnets on or within the rotor and a corresponding circular arrangement of a group of external stationary permanent magnets or field coils in the vicinity of the rotor at repulsive field force exerts a radial centering effect on the rotor and relieved a radial bearing.
  • the shaft is supported by at least two bearings.
  • an electric machine with a stator, a rotor, a shaft and a bearing arrangement is provided.
  • a method of manufacturing a bearing assembly for an electric motor wherein a fiber composite rotor, shaft, and rotor bearing is provided, and wherein the rotor, shaft, and rotor bearing are arranged such that the rotor is rotatably disposed about an axis of rotation and wherein the at least one rotor bearing is in operative connection with the rotor in a region spaced radially from the axis of rotation.
  • a use of the storage device described above is provided in an electric machine as a drive for an air, water or land vehicle or as a generator in a power generating device, in particular in wind and hydroelectric power plants.
  • a method of manufacturing a fiber composite rotor having a rotor main body for an electric motor comprising the steps of: combining fibers of a fiber material with a matrix into a fiber amount, introducing the fiber amount with diffused fibers into one of the shapes of the fibers Rotor main body corresponding negative mold, compressing the introduced in the negative mold amount of fiber and
  • the fibers of the fiber material are formed by cutting, cutting or the like of an endless fiber into fiber parts of a certain length.
  • these fiber parts are combined with a matrix.
  • the matrix is preferably a binder or bonding agent that forms certain advantageous physical and mechanical properties in connection with the fibers.
  • a matrix may be selected, for example, from the group of thermosets (for example unsaturated polyester resins, vinyl ester resins, epoxy resins) or from the group of thermoplastics (for example polypropylene, polyamide, polyethylene terephthalate, polyphenylene sulfide, polyether ether ketone).
  • thermosets for example unsaturated polyester resins, vinyl ester resins, epoxy resins
  • thermoplastics for example polypropylene, polyamide, polyethylene terephthalate, polyphenylene sulfide, polyether ether ketone
  • Diffusely arranged fibers advantageously allow rapid and inexpensive processing, since no intermediate step for aligning or deliberately arranging the fibers is necessary.
  • the merging of the fibers with the matrix occurs either before the
  • the curing of the fiber mixture is preferably a process that causes a phase transition of the matrix from liquid to solid.
  • this phase transition is irreversible and reversible for thermoplastics. Curing means in this case
  • the resulting after curing fiber composite component is hard or stiffened; Depending on the matrix and fiber type, it can have different mechanical and physical properties such as high toughness, low weight, electrical conductivity, high flexibility, etc.
  • the fiber composite material and / or the fiber may comprise carbon.
  • Carbon is a particularly lightweight and durable material that has many uses as fiber material
  • Forms can form and through interaction with one
  • Binder such a form permanently.
  • Carbon fiber composite material manufactured rotor main body is light and can still withstand acting forces and moments.
  • the amount of fiber can be heated by means of a microwave source.
  • the fiber composite material comprises carbon
  • the electrical conductivity of carbon may be used to be heated by a microwave source. This has the advantage over conventional autoclave processes of reduced energy requirements to cure the fiber mixture.
  • the amount of fiber may preferably be below a predetermined pressure during heating by a microwave in a negative mold, or the amount of fiber was pressed under predetermined pressure before being heated in the negative mold.
  • a predetermined pressure rather than a negative mold, may be caused by the gas pressure surrounding the fiber. This has the advantage that the amount of fiber reaches a high density of material and thereby low volume.
  • the material of the Negative form also fiber composite material and in particular carbon has.
  • a negative mold for producing a rotor main body wherein at least one fiber is in or on the negative mold and a binder or connecting means interconnects portions of the at least one fiber.
  • An electric machine may include a stator and a rotor including the rotor main body according to any one of the above solutions.
  • such an electric machine is a pancake electric motor / generator with permanently excited rotor and serves as a drive for an air, water or land vehicle or as a generator in a power generating device, wherein the power generating device according to a Au Installationsform wind and hydroelectric plants comprises.
  • FIG. 1 shows an electric machine including a stator 102 and a rotor main body 104.
  • the rotor main body 104 may be disk-shaped, cylindrical, frusto-conical or double-frusto-conical.
  • a mounting flange may be arranged on the rotor main body 104, wherein an arrangement of the rotor main body 104 with a mounting flange as a rotor is referred to.
  • FIG. 1 shows two magnets 106 visible in the sectional view of the rotor main body 102, for example permanent magnets, of which a plurality of rings are arranged in or on the rotor main body 104, and stator windings (not shown) provided in the stator 102.
  • Fig. 1 shows a shaft 108, for example, by the Mounting flange with the rotor main body 104 is connected so that a rotational movement of the shaft 108 leads to a rotational movement of the rotor main body 104 and vice versa.
  • the shaft 108 may be, for example, a rod-shaped component made of solid material or a hollow cylindrical component, wherein the cross section of such a component may be completely or partially circular, rectangular, elliptical or toothed and is designed as a joint, hollow, gimbal or flexible shaft.
  • FIG. 1 illustrates two bearings 110 that radially support the shaft 108 so that the shaft 108 and associated rotor main body 104 are radially held in position even when rotated about its axis of rotation.
  • the magnets 106 mounted on the rotor main body 104 magnetically interact with the stator windings on the stator 102 to cause the rotor main body 100 and the shaft 108 connected thereto to rotate about the rotor axis.
  • the mode of action of the electric machine is reversed
  • Shaft 108 and its associated rotor main body 104 results in an electromagnetic interaction between the magnets 106 and the stator windings arranged on the rotor main body, whereby electric current is finally generated.
  • a rotor 104 as an external component surrounds a stator as an internal component.
  • Fig. 2 shows a rotor main body 200 provided in a disc shape and a predetermined thickness.
  • the material of the rotor main body 200 comprises fiber composite material, preferably carbon fiber composite material.
  • the rotor main body 200 further includes 172 (by way of example only) rectangular receptacles 202 centered around the rotation axis of the rotor main body 200 and close to the outer periphery thereof.
  • Centrally located flange holes 204 and the shaft passage 206 centrally located in the rotor main body 200 provide connection to a shaft (not shown).
  • the centrally arranged flange holes 204 are arranged between the centrally located shaft passage 206 and the close to the outer edge of the rotor main body 200 receptacles 202.
  • the number and arrangement of the flange holes 204 may depend in particular on forces and moments to be transmitted.
  • the rectangular receptacles 202 serve to receive magnets, in particular permanent magnets.
  • at least one magnet can be arranged in all, a plurality, in particular two, three, four, five, eight, eleven or 16, or in exactly one shot.
  • an arbitrary number of receptacles 202 are provided for the rotor main body 200, for example, just one shot, two, three, four, five, eight, 13, 16, 65 or 172 shots.
  • FIG. 3a shows an enlarged view of a partial region of a rotor main body 200.
  • the receptacles 302 on the outer edge of the rotor main body each receive a magnet 304.
  • the magnets 312 magnetically interact with the stator windings (not shown) disposed on the stator to thereby generate current (as far as the electric machine functions as a generator) or thereby initiate rotational movement of the rotor (if the electric machine works as a motor).
  • the north pole of the magnet 312 is denoted by N.
  • two smaller magnets 312, 314 are arranged alongside one another in the receptacles 302.
  • the smaller magnets 312, 314 are separately magnetized magnets.
  • the two smaller magnets 312, 314 have the total volume of one of the magnets 304 shown there. It is exploited the property that in the production of magnets smaller ferromagnetic body can be magnetized better than larger in the rule.
  • two smaller magnets usually have a higher magnetization than a comparable magnet whose volume corresponds to the sum of the volumes of the two smaller magnets when magnetized in the same magnetic field in the same way as the two smaller magnets.
  • the magnets located in a recording with the same total volume and the same total weight have a greater magnetization than a comparably produced, twice as large magnet in a receptacle, as for example in Fig. 3a see is.
  • a rotor with more powerful magnets with the same volume and weight can be provided. Because the rotor main body comprises fiber composite material, the weight of the rotor is further reduced as compared to an equally powerful conventionally manufactured rotor.
  • At least two magnets or similar formulations should also be understood to mean those arrangements in which at least two ferromagnetic bodies were magnetized as separate bodies, but then after their Magnetization or after a first magnetization process, which can be followed by further magnetization processes, are joined together to form a body, in particular by gluing together or other methods for joining objects.
  • the advantages of using magnets which have been magnetized as smaller bodies, which are shown here, also apply to such exemplary embodiments.
  • the north poles of two magnets 312, 314 always point either to the center or to the edge of the motor.
  • Other examples include
  • Arrangements in which the north poles of the two magnets in a receptacle point in different directions further include arrangements in which the magnets of a receptacle are not are arranged at their longitudinal edges, but adjacent to their short edge surfaces.
  • three, four or more smaller individual magnets are arranged in at least one receptacle. While in the example shown in Fig. 3b, the north pole of the magnets always points in different directions in adjacent photographs, examples are also included in which the north poles of the magnets always point in the same direction. Furthermore, examples may be provided in which the poles of the individual magnets are arranged arbitrarily directed.
  • Fig. 4a shows a rotor main body 402 and a shaft 404 in a side view.
  • the rotor main body 402 has rectangular receptacles 406, one of which can be seen in section above the line of symmetry.
  • cover sheets 412, 414 made of carbon fiber composite plate-like semi-finished product.
  • the cover layers 412, 414 cover the rectangular receptacles 406 and optionally arranged therein magnets, of which in the sectional view, a magnet 420 is visible.
  • the receptacles 406 of the rotor main body 402 are holes therethrough. It will be in the
  • the two cover layers 412 and 414 are attached to the rotor main body and prevent falling out of the magnets.
  • the cover layers 412, 414 comprise fiber composite material.
  • the receptacles 406 merely represent recesses that are not holes passing through the rotor main body. In such a case, it can be provided that only one cover layer 412 for fastening the magnets 420 to the rotor main body 402 is arranged.
  • Fig. 4b shows a mounting flange 400. Further, Fig. 4b shows a side view of the rotor main body 104 shown in Fig. 1 and a shaft 404.
  • the rotor main body 402 which is shown above the shaft 404 in sectional view, has a rectangular socket 406, as in Figs Fig. 1, on.
  • the cover layers 412 and 414 cover the rectangular receptacles 406 and magnets disposed therein, e.g. Permanent magnets, of which in the sectional view, a permanent magnet 420 is visible.
  • two inner and outer mounting flange disks 418 and 422 are arranged on the front side 408 and rear side 410 thereof.
  • the inner mounting flange disks 418 are attached directly to the rotor main body 402 by an adhesive (not shown), and have a smaller diameter than the rotor main body 402 and a larger diameter than the outer mounting flange disks 422.
  • the outer mounting flange disks 422 are in turn provided with an adhesive (not shown) each with one of them adjacent inner mounting flange 418 connected.
  • the mounting flange discs 418 and 422 are made of plate-like carbon fiber composite semi-finished components. The entire mounting flange establishes a positive and non-positive connection to the shaft 404.
  • the rotor main body 402 and / or the buildin 't Trents- can flange disks 418 and 422 have a rectangular, elliptical, annular cross section or the like.
  • the mounting flange disks 418 and 422 may be integrally formed with each other and disposed on the rotor main body 402, or the mounting flange disks 418 and 422 are integrally formed with the rotor main body 402.
  • the mounting flange disks 418 and 422 provide the rotor main body with an area and volume greater interface with the shaft 404, thereby enhancing the transmission of forces and moments between the rotor main body 402 and the shaft 404.
  • Fig. 5 shows a rotor 500. From the outside in turn in Fig. 5 can be seen: a rotor main body 502, a integrally formed with the rotor main body 502 frusto-conical mounting flange 504, provided in the mounting flange 504 shaft passage 506 with groove 508 embedded therein and a provided with a driving lug 510 shaft 512 in cross-sectional view.
  • the shaft 512 is disposed by suitable fit in the shaft passage 506 of the mounting flange 504.
  • the interchangeable the cam lug 510 engages the groove 508 and allows torques and forces to be transmitted between the shaft 512 and the rotor main body 502 so that the shaft 512, the rotor main body 502 and the mounting flange 504 engage in the same angular velocity at both can rotate through the double arrow 514 indicated directions of rotation.
  • FIG. 6 shows a section of a rotor main body 600.
  • Exemplary carbon fiber shims 602, 604, 606, 608, 610 are illustrated in the sector-shaped section of the rotor main body 600 shown in FIG.
  • a shaft feedthrough carbon fiber loop 602 passes around a shaft passage 612 and around a receptacle 614.
  • a mounting flange hole carbon fiber loop 610 passes around a mounting flange hole 616 and a plurality of receptacles 614.
  • a multi-receptacle carbon fiber loop 606, 608 guides around a plurality of receptacles 614.
  • Carbon fiber rings can be combined with each other, in series, alternately, according to a predetermined sequence pattern and, for example, by a continuous carbon fiber 618 can be realized.
  • the following fiber loop guides are possible: fiber loops are wound in eight, helical, or drum shape around one or more receivers 614 and / or one or more mounting flange holes 616 and / or the shaft bushing 612 and / or the outer edge of the rotor main body 600 or fiber loops are inserted into geodesic lines between two or more locations comprising one or more receptacles 614 and / or one or more mounting flange 616 and / or the shaft passage 612 and / or the outer edge of the rotor main body 600.
  • the fiber loops 606, 608 and 610 shown in Fig. 6 are drawn only schematically as closed, they may also be designed as opened on one side loops or at a position with overlapping parts of an endless fiber 618.
  • Such an endless carbon fiber 618 is supplemented at the outer peripheral portion of the rotor main body 600 with additional piece-wise carbon fibers to make a predetermined thickness of the rotor main body 600.
  • the endless carbon fiber 618 thickens the rotor main body 600 along its vertical axis to a natural hub.
  • FIG. 7 shows a rotor 700 of an electric machine and a hub 704 made of continuous carbon fiber.
  • the shaft passage formed by the hub 704 positively receives a shaft 702.
  • four holes are coupled with longitudinally disposed pins 706 disposed thereon.
  • Longitudinal pins may be, in particular, cylinder-pin-like, conical-pin-type or kerbwind-type longitudinal pins. Shaft and hub thus form a coupled connection.
  • the number and arrangement of the longitudinal pins 706 at the junction of shaft 702 and hub 704 may depend in particular on the forces and moments to be transmitted. In the example shown in Fig. 7, four longitudinal pins were used. However, any number of longitudinal pins can realize the pin connection, in particular a longitudinal pin, two, three, four, five, eleven or 18 longitudinal pins.
  • the material of the longitudinal pins 706 is elastic and shears off at high torque.
  • the longitudinal pins 706 provide on the one hand start-up, brake slip and rotational damping and on the other hand at the same time a safety function to protect the rotor 700 and the shaft 702 from excessive torque. In addition, it is possible to replace a worn longitudinal pin 706 with a new one.
  • FIG. 8 shows an electric machine 800.
  • a stator 801 surrounds a rotor main body 802.
  • the rotor main body 802 is formed integrally with a mounting flange 804 which is connected to a shaft 808 through a lug 806.
  • the driving lug 806 engages in a recessed into the mounting flange 810 a.
  • the shaft 408 is supported radially and / or axially on both sides of the stator 801 by two stationary rolling bearings 812.
  • the stator 801 in FIG. 8 includes electric stator coils (not shown) whose magnetic field interacts with a magnetic field of permanent magnets 814 arranged in an outer area of the rotor main body.
  • Permanent magnets 814 are disposed in hollow seats 817 of the rotor main body 802 and are closed to the outside by cover layers 816 and 818 disposed on both sides of the rotor main body 802.
  • the mounting flange 804 provides a large engagement surface for the driving lug 806 engaging in the groove 810, thereby enabling the transmission of forces and torques between the shaft 808 and the rotor main body 802
  • the mounting flange 804 allows, for example, a transmission of higher forces and moments, as in an in Fig. 1 shown in comparable dimensions running electrical machine 100 is possible.
  • the bearings 812 shown in Fig. 8 provide support for the shaft 808 and the rotor main body 802 connected thereto via the mounting flange 804. However, if only the bearings 812 are provided as the bearings, rapid rotation of the rotor main body 802 occurs without bearing in axial directions vibrations. It would be desirable to realize a bearing which ensures that the rotor main body 802 does not leave its axially provided position, in particular at its edges, during such rotational movement and / or in the event of vibrations, oscillations or similar movements.
  • Fig. 9a shows a schematic storage device.
  • a rotor 904 is connected to a shaft 902 via a suitable rotor-shaft arrangement.
  • the rotor 904 made of carbon fiber composite material in this case includes receptacles 906, 908 for magnets (not shown).
  • the rotor 904 is supported by two radial bearings 912, 914.
  • the radial bearings 912, 914 ensure that the shaft 902 and the rotor 904 attached thereto are held in their intended position in the radial direction R.
  • further bearings 916, 918 are provided according to the invention in the example shown in FIG. 9a, which support the rotor on both sides and provide axial support of the rotor 904.
  • the thrust bearings 916, 918 ensure that the rotor 904 and the shaft 902 connected thereto also at Operation of the electric machine are held in a predetermined axial position A.
  • Fig. 9b shows a bearing assembly with bearings 922, 924 supporting the shaft axially.
  • bearings 926, 928 are provided. These bearings 926, 928 are at a radially outer portion of the rotor 904 with this in operative connection.
  • bearings 926, 928 may be disposed in and / or on a stator (not shown). Such an arrangement of the bearings 926, 928 is particularly suitable for preventing vibration of the rotor from its axial position.
  • bearings 936, 938 are provided.
  • the outboard portion of the rotor 904 with this operatively connected bearing 936 and 938 support the rotor 904 in the axial and / or radial direction.
  • Fig. 9d shows another example of a storage arrangement.
  • a bearing 948 provided on the outer portion of the rotor supports the rotor 904 so as to axially support the rotor 904.
  • Another bearing 944 in turn supports the shaft 902 and its associated rotor 904 so as to be radially supported.
  • FIG. 10 a shows an inner side surface 1022 of a stator of an electrical machine 1000, a cross section 1024 the stator in the schematic representation shown, a shaft 1002, a rotor 1004 connected to the shaft, housings 1006, 1008 for magnets (not shown) in the rotor 1004 and inventively provided bearing 1012, 1014, 1016, 1018.
  • the shaft 1002 is doing supported radially by the provided bearings 1012, 1014.
  • bearings 1016, 1018 are provided in the example shown, which are arranged on the stator and support the rotor 1004 axially.
  • the radially supporting bearings 1012, 1014 may be rolling bearings and the axially supporting bearings 1016, 1018 may be plain bearings. Due to the arrangement in FIG. 10a, the rotor 1004 can be operated at a diameter of preferably about two meters, four meters, six meters and more, stable and with a small stator gap at high rotational speeds, so that a good magnetic interaction between the magnets and the Stator can be used.
  • the bearings 1012, 1014 realize a radial bearing of shaft 1002.
  • a magnetic bearing is preferably provided for the axial bearing of the rotor 1004.
  • further magnets 1030 and 1032 are arranged both on or in the rotor 1004 and on or in the stator.
  • the magnets 1030 mounted centrally on or in the rotor 1004 and the stationary magnets 1032 arranged correspondingly to these in the vicinity of the rotor 1004 act on one another in an attractive and / or repulsive manner.
  • a radial centering effect is additionally produced on the rotor 1004, so that the radially supporting bearings 1012, 1014 are relieved.
  • Another embodiment provides additionally or alternatively other equivalent storage "in front, for example, air bearings.
  • Fig. 11 shows a negative mold 1100 for rotor production.
  • the female mold 1100 is designed along a longitudinal section mirror symmetrical to the axis of symmetry 1102 and has a negative mold outer edge 1104, a carbon fiber recess 1106, the receptacles 202 (of Fig. 2) corresponding pins 1108, a carbon fiber recess 1106 and the mounting flange holes 204 (of Fig. 2) corresponding pins 1110 on.
  • Disposed in the center of the female mold 1100 is a washer 1112 corresponding to the shaft passage 206 (of Fig. 2).
  • the negative mold outer edge 1104, the pins 1108, the pins 1110 and the disk 1112 are integrally formed with the female mold 1100.
  • the material of the female mold 1100 is made of aluminum or carbon fiber composite material and can be closed by a negative mold closing lid (not shown).
  • Carbon fibers 1114 are used e.g. deposited, stretched or laminated by a fiber lay-off device (not shown) into the carbon fiber recess 306 according to a predetermined pattern.
  • Fig. 12 shows a negative mold 1200 for rotor production.
  • the negative mold 1200 is shown in cross section in FIG.
  • carbon fibers 1202 are shown lying in the negative mold 1200, also shown in cross-section.
  • the location and orientation of the carbon fibers 1202 in the negative mold 1200 is merely qualitative.
  • the carbon fibers 1202 may have any position and orientation in the negative mold 1200.
  • the negative mold 1200 is symmetrical to the axis 1204, so that only one half of the negative mold 200 is explained in more detail.
  • the negative mold 1200 in FIG. 2 comprises tenons 1206 which correspond in shape and volume to the receptacles 406 shown in FIGS. 4a, 4b, respectively. Furthermore, the negative mold 1200 in the center comprises a pin 1208, which corresponds to a shaft passage. The pins 1206 and the pin 1208 are formed integrally with the female mold 1200. The remaining space between the pins 1206, the pin 1208 and the negative mold 1200 itself forms a stepped cylindrical trough whose shape and volume corresponds to a rotor.
  • This rotor includes a rotor main body corresponding to a rotor main body portion 1210 in the female mold 1200, and a mounting flange unilaterally and integrally formed with the rotor main body corresponding to a mounting flange portion 1212 in the female mold 200.
  • the material of the negative mold 1200 may be e.g. Aluminum or fiber composite material.
  • Fig. 13 shows a flow chart for a rotor manufacturing process.
  • the flowchart provides four alternative procedures for making a rotor main body 1300 consisting of only carbon fiber composite material.
  • Process 1302 includes the sequential steps of placing carbon fiber into a negative mold 1304, introducing epoxy resin into the negative mold carbon fiber 1306, and curing 1308 the carbon fiber and epoxy resin mixture at a predetermined pressure P H and a predetermined temperature T H
  • the methodology 1310 includes the step to mill and drill plate-like carbon fiber composite semi-finished product 1312 so that the rotor main body is formed.
  • Process 1314 includes the sequential steps of laminating fiber prepreg into a negative mold 1316 and curing 1318 the fiber prepreg at a predetermined pressure P H and a predetermined temperature T H.
  • Process 1320 includes the sequential steps of blending carbon fibers with polypropylene 1322, the mixture of carbon fiber with polypropylene in a negative mold to introduce or press 1324 and the mixture at a predetermined pressure P H and a predetermined temperature T H harden 1326th
  • FIG. 15 shows an electric machine 1500 in which three of the stators 1502, 1504 and 1506 shown in FIG. 8, each having rotatably mounted therein rotors 1508, 1510 and 1512, are arranged in series on a shaft 1514.
  • Such a stator-rotor subunit of a stator and a rotor in this case corresponds to the electrical machine 800 shown in FIG. 8.
  • the shaft 1514 of the electric machine 1500 shown in FIG. 15 is supported radially and / or axially by two fixed rolling bearings 1516 similarly as shown in FIG. Since the diameter of the stator-rotor subunit shown in FIG. 15 is larger than the thickness of the stator-rotor subunit, the electric machine 1500 with two, three or more stator-rotor subunits arranged in series can achieve a more compact design, ie a ratio of Machine diameter to machine thickness of about 1: 1 and thereby the power and torque are increased.
  • a housing 1518 enclosing the stator-rotor subunits shown in FIG. 15, which protects the electric machine 1500 from inward and outward influences (eg, dust, heat, moisture, electromagnetic radiation, etc.). protects.
  • inward and outward influences eg, dust, heat, moisture, electromagnetic radiation, etc.
  • FIG. 16 shows a hybrid system.
  • the device Ml represents a motor-generator device according to one of the aforementioned embodiments.
  • motor M2 is a conventional internal combustion engine or comparable.
  • the torques of the two motor-acting devices Ml and M2 are summed in a planetary gear 1602 and output from the hybrid system.
  • FIGS. 17a and 17b show an electrical circuit arrangement of a motor-generator device.
  • 17a shows a circuit arrangement in a state in which the motor-generator device as a generator G1 converts mechanical energy into electrical energy and stores it in a battery 1702.
  • a rectifier or commutator may be connected between battery 1702 and generator Gl if the generator supplies Gl power.
  • Fig. 17b shows a circuit arrangement in a state in which the motor-generator device as motor Ml acts to convert electrical energy from a battery 1702 into mechanical energy.
  • a vehicle drive may be implemented which, upon braking the vehicle, feeds kinetic energy back into a battery 1702 and selectably converts electrical energy of the battery 1702 into kinetic energy.
  • a rotor-shaft arrangement of the motor-generator device can be designed so that drive and brake slip by elastic longitudinal pins allow soft starting and braking in the hybrid system and provided by the elastic longitudinal pins damping behavior of a backward non-constant rotation of the internal combustion engine via the planetary gear 1502 prevented on the motor-generator device.
  • this may in particular as a drive device or other use in an aircraft (in particular a passenger aircraft, a powered aircraft, a glider with or without auxiliary engine or an electric machine for an airship ), Watercraft (in particular a ship or boat, for example a motorboat or a sailboat with or without an auxiliary engine) or land vehicle (especially a car, a motorcycle, a truck, a locomotive, a forklift) are used, the low weight and the high Stability of the rotor main body made of fiber composite allows high start-up and braking acceleration of the drive device.
  • an aircraft in particular a passenger aircraft, a powered aircraft, a glider with or without auxiliary engine or an electric machine for an airship
  • Watercraft in particular a ship or boat, for example a motorboat or a sailboat with or without an auxiliary engine
  • land vehicle especially a car, a motorcycle, a truck, a locomotive, a forklift
  • an electric machine for driving pumps as a servomotor; lawnmowers, cranes, tanks; as a (servo) engine in aircraft, ship and car models; at vending machines (eg ATMs) Toys, household appliances and electrical appliances (eg CD, DVD players, hard drives) possible.
  • vending machines eg ATMs
  • Toys household appliances and electrical appliances (eg CD, DVD players, hard drives) possible.
  • the electric machine can take a combination of generator function and motor function, and e.g. in an electric vehicle or vehicle with
  • Hybrid drive optionally when braking the vehicle

Landscapes

  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Manufacture Of Motors, Generators (AREA)
  • Permanent Field Magnets Of Synchronous Machinery (AREA)
  • Connection Of Motors, Electrical Generators, Mechanical Devices, And The Like (AREA)
  • Iron Core Of Rotating Electric Machines (AREA)

Abstract

L'invention concerne une machine électrique (100; 800; 1000; 1500) comportant un stator (102; 801; 1502, 1504, 1506) et un rotor (500; 700; 904; 1004; 1508, 1510, 1512), le rotor présentant un corps principal de rotor (200; 402; 502; 600; 802; 1300) en matériau composite renforcé par des fibres et une bride de fixation (400; 504; 804) placée sur le corps principal de rotor (200; 402; 502; 600; 802; 1300), cette bride étant en matériau composite renforcé par des fibres. L'invention porte également sur un procédé de fabrication de ce rotor et sur son utilisation.
PCT/EP2009/007240 2008-10-08 2009-10-08 Rotor de machine électrique et utilisation associée, dispositif et procédé de fabrication de ce rotor WO2010040534A2 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP09778872A EP2332236A2 (fr) 2008-10-08 2009-10-08 Rotor de machine électrique et utilisation associée, dispositif et procédé de fabrication de ce rotor

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102008050806.3 2008-10-08
DE102008050806A DE102008050806A1 (de) 2008-10-08 2008-10-08 Rotor für eine elektrische Maschine sowie Verwendung desselben und Vorrichtung und Verfahren zu dessen Herstellung

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WO2010040534A2 true WO2010040534A2 (fr) 2010-04-15
WO2010040534A3 WO2010040534A3 (fr) 2010-08-12

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EP (1) EP2332236A2 (fr)
DE (1) DE102008050806A1 (fr)
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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2773023A1 (fr) * 2013-02-27 2014-09-03 Yasa Motors Ltd Moteur à flux axial
EP2802062A1 (fr) * 2013-05-08 2014-11-12 Phase Motion Control S.p.A. Générateur électrique destiné à un générateur d'énergie éolienne

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4835840A (en) * 1986-06-16 1989-06-06 General Electric Company Method of making an improved disc rotor assembly
GB2302455A (en) * 1995-06-17 1997-01-15 Urenco A rotor
WO2001011755A1 (fr) * 1999-08-09 2001-02-15 Perm Motor Gmbh Machine electrique a flux axial
EP1369976A1 (fr) * 2002-06-04 2003-12-10 Magnet-Motor Gesellschaft für magnetmotorische Technik mbH Machine électrique
US20060138890A1 (en) * 2004-12-14 2006-06-29 Nissan Motor Co., Ltd. Rotor structure of an axial gap rotating electrical device

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4674178A (en) * 1985-10-16 1987-06-23 Sundstrand Corporation Method of fabricating a permanent magnet rotor
DE102006036707B3 (de) 2006-08-05 2008-02-28 Marquardt, Rainer, Prof.-Dr.-Ing. Trägheitsarmer Direktantrieb

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4835840A (en) * 1986-06-16 1989-06-06 General Electric Company Method of making an improved disc rotor assembly
GB2302455A (en) * 1995-06-17 1997-01-15 Urenco A rotor
WO2001011755A1 (fr) * 1999-08-09 2001-02-15 Perm Motor Gmbh Machine electrique a flux axial
EP1369976A1 (fr) * 2002-06-04 2003-12-10 Magnet-Motor Gesellschaft für magnetmotorische Technik mbH Machine électrique
US20060138890A1 (en) * 2004-12-14 2006-06-29 Nissan Motor Co., Ltd. Rotor structure of an axial gap rotating electrical device

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2773023A1 (fr) * 2013-02-27 2014-09-03 Yasa Motors Ltd Moteur à flux axial
EP2802062A1 (fr) * 2013-05-08 2014-11-12 Phase Motion Control S.p.A. Générateur électrique destiné à un générateur d'énergie éolienne

Also Published As

Publication number Publication date
EP2332236A2 (fr) 2011-06-15
DE102008050806A1 (de) 2010-04-22
WO2010040534A3 (fr) 2010-08-12

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