WO2019072472A1 - Élément secondaire pour machine électrique - Google Patents

Élément secondaire pour machine électrique Download PDF

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Publication number
WO2019072472A1
WO2019072472A1 PCT/EP2018/074483 EP2018074483W WO2019072472A1 WO 2019072472 A1 WO2019072472 A1 WO 2019072472A1 EP 2018074483 W EP2018074483 W EP 2018074483W WO 2019072472 A1 WO2019072472 A1 WO 2019072472A1
Authority
WO
WIPO (PCT)
Prior art keywords
recess
secondary element
axial
bolt
permanent magnet
Prior art date
Application number
PCT/EP2018/074483
Other languages
German (de)
English (en)
Inventor
Andre Grübel
Matthias Ebert
Walter Wolf
Freio Stalf
Original Assignee
Zf Friedrichshafen 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 Zf Friedrichshafen Ag filed Critical Zf Friedrichshafen Ag
Publication of WO2019072472A1 publication Critical patent/WO2019072472A1/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
    • H02K1/27—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]
    • 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
    • H02K15/12—Impregnating, heating or drying of windings, stators, rotors or machines

Definitions

  • the present invention relates to an electric machine with a primary element and a secondary element, which are rotatably supported against each other.
  • the invention relates to a secondary element of a permanent-magnet electric machine.
  • An electric machine comprises a primary element and a secondary element which are rotatably mounted about an axis of rotation against each other. Permanent magnets are provided on the secondary element and the primary element carries a coil winding with one or more phases.
  • the machine may include a permanent magnet DC machine or a permanent magnet synchronous machine. Depending on the application and wiring, the machine can work as a motor or as a generator.
  • the secondary element usually comprises a laminated core, which is formed as an axial stack of mutually insulated sheets.
  • the permanent magnets can be accommodated in axial recesses of the secondary element.
  • the permanent magnets are arranged radially as far outside as possible in order to maximize a convertible torque of the machine.
  • the permanent magnets on the laminated core and the laminated core must be fixed in itself. For this purpose, various proposals have been made.
  • US 7 612 480 B2 shows a rotor with permanent magnets for an electric machine.
  • the magnets are housed in axial pockets of a flux pack.
  • magnetic flux barriers are provided in the form of recesses, which may be filled with a material having increased magnetic resistance.
  • KR 1999 0 065 556 proposes to form support disks on both sides of a rotor of a brushless DC motor by means of injection molding, the support disks being connected to one another by means of axial bolts which are likewise formed by means of injection molding.
  • KR 1998 0 045 807 U relates to the rotor of a brushless DC motor. It is proposed to inject magnetic powder in synthetic resin into axial bores of the rotor for the production of the rotor.
  • An object underlying the invention is to provide an improved secondary element for an electrical machine and an improved method for producing the secondary element.
  • the invention solves this problem by means of the subjects of the independent claims. Subclaims give preferred embodiments again.
  • a rotating electrical machine comprises a secondary element and an axis of rotation about which the secondary element can be rotatably mounted relative to a primary element.
  • a secondary element for the electric machine comprises a laminated core with an axial recess; wherein in the recess a permanent magnet is mounted; and wherein a bolt produced by means of injection molding technology extends axially through the recess, which comprises a head with an enlarged cross-section at at least one axial end.
  • a secondary element in particular forms one or the electromagnetically active rotor component of an electrical machine and comprises a laminated core with permanent magnets arranged thereon.
  • the permanent magnet can be securely fixed in the recess.
  • a remaining space between the permanent magnet and the limitation of the recess are filled in the injection molding, so that the permanent magnet can be positively secured and, if the injection molding material allows, by adhesion also cohesively in the recess on the laminated core.
  • the laminated core can be stabilized in the axial direction by the bolt. A tendency of a particular lying at one axial end sheet of the laminated core to be removed from the other sheets, can be effectively counteracted.
  • the bolt can be designed so that it absorbs large axial forces.
  • the laminated core can be axially biased and the bolt can take over the biasing force after curing or setting. Ingress of dust or a particularly corrosive liquid in the secondary element can be prevented by an improved filling of gaps by the injection molding material.
  • the bolt is preferably produced from a thermoplastic.
  • the thermoplastic can be processed more easily in an injection molding machine. A cleaning effort in a distribution system, as it may be required in a thermosetting, can be omitted. A sprue obtained during injection molding of a secondary element can be used for the injection molding of another secondary element.
  • the thermoplastic can harden on cooling, so that can be dispensed with a furnace hardening. Heating of the laminated core prior to injection may be omitted.
  • the thermoplastic may be cheaper than a thermoset.
  • the thermoplastic can have a long-term temperature resistance of eg 150 ° C.
  • the curing process can be carried out simply and rapidly by cooling; a time-consuming or costly polymerization process for curing can be dispensed with.
  • a high-temperature thermoplastic is preferably used.
  • One possible thermoplastic includes injection-moldable polyphenylene sulfide (PPS), which can be operated in continuous operation at approx. 200 - 240 ° C, depending on the mechanical load.
  • PPS polyphenylene sulfide
  • the thermoplastic may also be suitably chosen depending on a cycle time or cycle time available for manufacturing a secondary element in an injection molding machine.
  • the laminated core may have a further axial recess, through which a further bolt extends, which comprises at least one axial end of a head with an enlarged cross-section.
  • the two recesses are preferably arranged radially offset from one another. As a result, both the axial and the radial strength of the secondary element can be further increased.
  • the recess may be widened at an axial end, wherein the bolt is flush with the laminated core.
  • a rotor can be formed from a plurality of secondary elements.
  • the expansion may include one or only a few sheets of the laminated core.
  • a sheet is usually about 0.3 - 0.5 mm thick, so that the head can be formed flat in the axial direction. In the region of the head, one or more axially close sheets may be held by adhesion to the bolt. In the radial direction, there is preferably positive locking of the metal sheets to the bolt.
  • the expansion can be formed stepwise in one or more stages, or also continuously, for instance conical or pyramidal.
  • a respective head is attached to both axial ends of the bolt. Each head can be sunk axially by corresponding widening of the recess, so that it terminates axially flush with an end face of the laminated core.
  • An axially over the laminated core projecting head of the bolt may be rounded in the radial direction or in the circumferential direction.
  • the head can be optimized for flow, so that a resistance originating from the bolt head, for example when the secondary element moves in a fluid, can be reduced.
  • An acoustic load, if the fluid comprises a gas, can thereby be reduced.
  • the recess may be larger in the circumferential direction than the permanent magnet.
  • a magnetic flux barrier in the circumferential direction may be provided on the permanent magnet, which may improve the electromagnetic properties at the transition between the permanent magnet and the laminated core.
  • the River barrier can be filled with thermoplastic.
  • the flow barrier may form a shank of the bolt extending axially through the lamination stack.
  • a method of manufacturing a secondary element comprises steps of producing a laminated core having an axial recess; the introduction of a permanent magnet in the axial recess; and injecting a thermoplastic into the axial recess to overmold the permanent magnet in the recess, thereby forming a bolt extending axially through the recess and having a head with an enlarged cross-section at at least one axial end.
  • the method can be used for the rapid and secure production of a secondary element for an electrical machine.
  • the electric machine can be used in particular as a control, drive or traction motor on a motor vehicle.
  • a hot runner manifold system and a hot runner nozzle, optionally with a needle valve can be used.
  • the injection can also be done by means of a cold runner manifold in a tandem tool (three-plate tool).
  • the thermoplastic may be injected at a circumferential boundary of the recess from a direction obliquely in or against the circumferential direction.
  • a free jet through which, for example, air or other surrounding fluid can be incorporated into the injection molding compound, can thus be prevented.
  • thermoplastic can be injected at an axial boundary of the permanent magnet in the axial direction. Thereby, two bolts circumferentially located at opposite ends of the permanent magnet can be formed simultaneously.
  • the permanent magnet can be pressed in the axial direction during injection in order to fix it.
  • a pressing member may include a flow barrier that allows only a predetermined flow of injection molding material in the plane of rotation about the axis of rotation. Hydraulic forces during injection molding can be better controlled.
  • the laminated core can be supported in force-controlled manner during the injection in the region of the permanent magnet from radially outside.
  • the performance of the secondary element may depend on how close the permanent magnet is to a radially outer boundary of the laminated core.
  • each recess may be a permanent magnet and at both ends in and against the circumferential direction, a bolt can be formed, which can act as a barrier at the same time.
  • each pin is associated with a spray nozzle, in another embodiment, two circumferentially adjacent bolts - which belong to recesses of different permanent magnets - produced by a common spray nozzle.
  • Heads of the bolts can be formed integrated with each other. In general, it is preferred that a head is formed on the axial side of the bolt, from which the injection takes place by means of a spray nozzle.
  • the laminated core may have a further axial recess and during injection, a further, extending through the further recess bolts are formed.
  • the bolt may have a common head with a bolt which extends through the recess with the permanent magnet.
  • the further bolt may be located radially further inward or farther out than the bolt passing through the recess for the permanent magnet.
  • the head of the further bolt may be made integral with the heads of two other bolts.
  • FIG. 1 shows a secondary element for an electrical machine.
  • FIG. 2 shows a detail of the secondary element of FIG. 1 in a first embodiment
  • FIG. 3 shows a detail of the secondary element of FIG. 1 in a second embodiment
  • FIG. 4 shows a first sectional view through a secondary element according to FIG. 2;
  • FIG. 5 shows a second sectional view through a secondary element according to FIG. 2;
  • FIG. 6 shows a third sectional view through a secondary element according to FIG. 2;
  • FIG. 7 shows a first sectional view through a secondary element according to FIG. 3;
  • FIG. 8 shows a second sectional view through a secondary element according to FIG. 3;
  • FIG. 9 shows a third sectional view through a secondary element according to FIG. 3.
  • FIG. 10 shows a perspective sectional view of a secondary element according to FIG. 2;
  • Fig. 1 1 is a perspective sectional view of a secondary element according to Figure 3;
  • 12 shows schematic representations of variants of the production of a secondary element;
  • FIG. 13 illustrates a flowchart of a method for manufacturing a secondary element for an electric machine.
  • FIG. 1 shows a secondary element 100 for an electrical machine.
  • the secondary element 100 comprises an axis of rotation 105 around which it can be rotatably mounted in the electric machine relative to a primary element.
  • the axis of rotation 105 serves here primarily as a reference axis for radial or axial locations or expansions.
  • the secondary element 100 may be part of a rotor of the electric machine.
  • the secondary element can be assembled with a radially inner support element, which can be mounted relative to the primary element, which may be comprised by a stator of the machine, about the axis of rotation 105, for example by means of a sliding or roller bearing.
  • the secondary element 100 comprises a laminated core 1 10, which is formed from a plurality of sheets 1 15, which are stacked in the axial direction.
  • the sheets 15 are preferably magnetically and / or electrically isolated from one another, for example by means of axially interposed paper layers.
  • axial first recesses 120 are arranged.
  • a recess 120 is preferably formed by a part of the recess 120 is introduced into each sheet 1 15 during its manufacture, and the sheets 1 15 are then stacked such that the parts of the recess 120 are axially aligned.
  • One or more lying at one axial end of the laminated core 1 10 sheets 1 15 may be slightly different shaped with an enlarged recess 120, as explained in more detail below.
  • a permanent magnet 125 may be attached in each first recess 120.
  • a plurality of permanent magnets 125 can be lined up in the axial direction; In the present discussion, for simplification, only one permanent magnet 125 per first recess 120 is assumed.
  • the first recesses 120 are preferably of the same size and regularly distributed on the circumference. More preferably, the first recesses 120 are closed radially on the outside, an embodiment with an at least partial opening radially au Shen, however, is also possible.
  • the permanent magnets 125 are held in a form-fitting manner in the first recesses 120.
  • FIGS. 2 and 3 each show a detail of the secondary element 100 of FIG. 1 in various embodiments.
  • the first recess 120 is preferably larger in the circumferential direction than the permanent magnet 125, so that in the circumferential direction before and / or behind the permanent magnet 125 each have a cavity which extends axially through the laminated core 1 10 and the function of a magnetic flux barrier 130th can fulfill.
  • An axial contour of the permanent magnet 125 is preferably rectangular, optionally with rounded edges. In this case, the permanent magnet 125 is more preferably greater in the circumferential direction than in the radial direction, for example in a ratio of approximately 5: 1 or greater.
  • a shoulder 135 formed on the radially inner side of the laminated core 1 10, to hold the permanent magnet 125 positively in the circumferential direction.
  • the shape of a cross-section through the flow barrier 130 can be selected substantially freely, in the present case it has a substantially trapezoidal shape, preferably with rounded corners.
  • the plastic 140 preferably comprises a thermoplastic, as described in more detail below with particular reference to a method. It is further proposed that the plastic 140 completely axially passes through the laminated core 1 10, in particular in the region of a flow barrier 130, and thus forms a bolt 145. At one or both axial ends of the bolt 145 may carry a head 150 whose cross-section is larger than the cross section in the adjacent pin area, so that the head 150 axially rests against one of the sheets 1 15 and so forms a positive connection.
  • the bolt 145 can fix the plates 1 15 of the laminated core 1 10 axially, in the radial direction or in the circumferential direction by positive engagement with each other.
  • the plastic 140 in particular in the area of the bolt 145, can contribute to securing the permanent magnet 125 in the first recess 120.
  • second axial recesses 155 may pass through the lamination stack, with the second recesses 155 preferably lying on a circumference having a radius smaller or greater than the circumference on which the first recesses 120 lie. In the circumferential direction, the second recesses 155 may lie between bolts 145 of the same first recess 120.
  • the second recesses 155 can also be injected with plastic 140 so that further axial bolts 145 can form.
  • a head 150 is formed on at least one axial end of a bolt which lies in a second recess 155, as in the case of the bolts 145 in a first recess 120.
  • FIG. 2 shows an embodiment of the secondary element 100, in which a head 150 is assigned in each case to only one bolt 145.
  • a head 150 may be attached to the axial end de a bolt 145 are formed, on which the plastic 140 is injected into the first recess 120, and / or at the opposite axial end.
  • FIG. 3 shows an embodiment of the secondary element 100, in which a head 145 axially covers two circumferentially adjacent bolts 150 of different first recesses 120, so that both bolts 145 can be injection-molded from only one injection nozzle for plastic 140.
  • the head 150 may also cover a bolt 145 in a second recess 155 and one or two bolts 145 in a first recess 120.
  • FIGS. 4, 5 and 6 show sectional views through a secondary element 100 in the embodiment of FIG. 2.
  • Cutting planes run parallel to the axis of rotation 105 and in FIG. 4 through a second recess 155, in FIG. 5 through a first recess 120 and in FIG circumferentially adjacent first recesses 120.
  • first bolts 145 On bolts 145, which extend through the first recess 110, hereinafter referred to as first bolts 145, heads 150 are only attached to axial ends of one side (in the illustration on the left). In this case, the heads 150 first pin 145 may be connected to each other, as shown in Figure 5. On the opposite side no heads 150 are provided in the illustrated embodiment, and the bolts 150 preferably ends flush with the axially last plate 1 15 of the laminated core 1 10. This allows the secondary element 100 on this axial side close to another element of the electric machine be packed, in particular to another secondary element 100, which also has a flat axial end surface.
  • the bolt 145 extending through the second recess 155 hereinafter referred to as the second bolt 145, carries on one axial side (in the illustration on the left) a head 150 projecting over the laminated core 1 10 and on the other axial rail 150.
  • the second recess 155 is widened in the axial end region by an axially outer plate lying 1 15 has a portion of the second recess 155 with a larger cross-section than an axially further inside sheet metal 15 1.
  • only a plate 15 carries an enlarged second recess 155, so that a step between the bolt 145 and the head 150 results.
  • the second recess 155 may also be continuously widened over one or more sheets 15.
  • Such recessed head 150 may also be provided at an opposite axial end of the second bolt 145. Furthermore, a countersunk head 150 can also be formed on one or both sides of a first bolt 145.
  • FIGS. 7, 8 and 9 show sectional views through a secondary element 100 in the embodiment of FIG. 3, with views corresponding to FIGS. 4, 5 and 6 being selected.
  • two heads 150 of first bolts 145 of adjacent first recesses 120 are connected to one another at their heads 150, as can be seen in particular in FIG.
  • the second recesses 155 may be distributed around the rotation axis 105 such that they lie between first bolts 145 of different first recesses 120.
  • a head 150 preferably covers two first and one second bolts 145 axially.
  • FIG. 10 shows a perspective sectional view of a secondary element 100 according to the embodiment of FIG. 2. It becomes clear how a first bolt 145 passes through the flow barrier 130 and at the same time overmoulds the associated permanent magnet 125 in the first recess 120.
  • Figure 1 1 shows a perspective sectional view of a secondary element 100 according to the embodiment of Figure 3.
  • connection in a plane of rotation about the axis of rotation 105, there is provided a connection between axial ends of first bolts 145, which connection can be on the axial side, not raised Head 150 is formed or at the time during the production of no plastic 140 is injected. In other embodiments, such a connection may also be used.
  • FIG. 12 shows schematic representations of variants of the production of a secondary element.
  • the illustrated variants may be used in particular in connection with a manufacturing method which is described in more detail below with reference to FIG. It should be noted that details and features of the individual variants may be combined with each other, and that each variant may be adapted according to the requirements for the secondary element 100 or a manufacturing method described herein.
  • FIG. 12 a shows a first variant in which an injection molding tool 1200 is used, which has two spray nozzles 1205 for the ejection of the first recess 120.
  • the spray nozzles 1205 are each arranged in the region of a flow barrier 130 of the same permanent magnet 125 and inject plastic 140, in particular a thermoplastic, from the same axial side of the secondary element 100.
  • the injection directions of the spray nozzles 1205 are preferably inclined in the direction of a circumferential boundary of the first recess 120 and more preferably arranged so that plastic 140 comes as soon as possible after coming out of a spray nozzle 1205 in contact with the laminated core 1 10.
  • heads 150 are not formed on either the upper side or the lower side of the first bolts 145, but the first bolts 145 may be connected in a region between the spray nozzles 1205 via the permanent magnets 1256.
  • the permanent magnets 125 can be fixed by being pressed axially in the injection molding tool 1200, preferably with a predetermined Force.
  • the secondary element 100 is supported on the radially outer side during the injection molding, in particular in regions which lie radially outside a permanent magnet 125. The support is preferably force-controlled.
  • FIG. 12b shows a second variant, in which only one spray nozzle 1205 is provided for the ejection of the first recess 120.
  • the spray nozzle is positioned above the permanent magnet 125, from where the plastic 130 in the horizontal direction, ie in a plane of rotation about the axis of rotation 105, is distributed to the flux barriers 130.
  • a vent 1210 can be arranged in the injection molding tool 1200.
  • FIG. 12c shows another variant similar to that of FIG. 12b but providing for the formation of raised heads 150 at upper ends of the first bolts 145.
  • the heads 150 are not exactly at the upper ends of the first pin 145 here, but are offset from each other.
  • FIG. 12 d shows a further variant in which the heads are offset from one another in contrast to the variant of FIG. 12 c.
  • FIG. 12e again shows a further variant in which two spray nozzles are used as in the variant of FIG. 12a, and mutually offset heads 150 are formed as in the variant of FIG. 12c.
  • FIG. 12f shows a variant analogous to that of FIG. 12e, but in which the heads are designed to be offset from each other as in the variant of FIG. 12c.
  • FIG. 12g shows a last variant, which substantially corresponds to that of FIG. 12b without vent 1210 or that of FIGS. 12c, 12d without heads 150.
  • FIG. 13 shows a flowchart of a method 1300 for producing a secondary element 100 for an electrical machine.
  • the method 1300 can in particular be carried out using a special injection molding tool 1200 according to one of the variants of Figure 12.
  • sheets 1 15 are punched into a laminated core 1 10.
  • a stamped package can be used, are embossed in the axially adjacent sheets 1 15 during punching.
  • Such an embossment can be recognized, for example, as a rectangle in FIG. 11 in the circumferential direction between two second bolts 145.
  • the sheets 1 15 may all be congruent or congruent or one or more sheets 1 15 in the vicinity of an axial end of the laminated core 1 10 may differ, in particular in cross section of the first or second recess 120, 155.
  • permanent magnets 125 can be inserted into the first recesses 120.
  • the insertion is preferably carried out from the axial direction.
  • the permanent magnets 125 are not yet magnetic at this time and will be magnetized later.
  • a step 1315 the secondary element 100 is inserted into a suitably equipped injection molding tool 120 and the injection molding tool 120 is closed.
  • the secondary element 100 in the injection molding tool 120 can be axially and / or radially supported. In the axial direction, a predetermined contact pressure on the laminated core 1 10 can be exercised.
  • plastic 140 in particular a hot thermoplastic, is injected into the injection molding tool 120 so that the permanent magnets 125 are encapsulated in their first recesses 120 and at the same time first bolts 145 and optionally second bolts 145 made of plastic 140 are formed on the secondary element 100.
  • a cooling of the thermoplastic material 140 can be carried out at least to the extent that sufficient strength for demoulding is provided.
  • the injection molding tool 120 can be opened and the secondary element 100 removed.
  • another cooling phase can follow.
  • the secondary element can be supplemented with one or more further elements to form a rotor for an electrical machine.

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

Abstract

L'invention concerne une machine électrique tournante comprenant un élément secondaire (100) et un axe de rotation (105) autour duquel l'élément secondaire (100) peut être monté pour pouvoir tourner par rapport à un élément primaire. Un élément secondaire (100) destiné à une telle machine électrique comprend un paquet de tôles (110) doté d'une cavité axiale (120), un aimant permanent (125) étant logé dans la cavité (120), et un boulon (145) moulé par injection s'étendant axialement à travers la première cavité (120), lequel boulon comprend à au moins une extrémité axiale une tête (150) de section transversale supérieure.
PCT/EP2018/074483 2017-10-09 2018-09-11 Élément secondaire pour machine électrique WO2019072472A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102017217937.6A DE102017217937A1 (de) 2017-10-09 2017-10-09 Sekundärelement für eine elektrische Maschine
DE102017217937.6 2017-10-09

Publications (1)

Publication Number Publication Date
WO2019072472A1 true WO2019072472A1 (fr) 2019-04-18

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CN112865364A (zh) * 2020-12-31 2021-05-28 西门子电动汽车动力总成系统(上海)有限公司 电机部件、电机、机动车辆及组装电机部件的方法
DE102021111346A1 (de) 2021-05-03 2022-11-03 Dr. Ing. H.C. F. Porsche Aktiengesellschaft Verfahren zum Herstellen eines Blechpakets einer elektrischen Maschine
DE102022115983B4 (de) 2022-06-27 2024-01-25 Hiwin Mikrosystem Corp. Kernstruktur des Motorrotors

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