WO2022258380A2

WO2022258380A2 - Rotor segment, magnet cover, rotor, generator, wind turbine and molding device and method for producing a rotor segment

Info

Publication number: WO2022258380A2
Application number: PCT/EP2022/064216
Authority: WO
Inventors: Stephan Jöckel; Andreas Recktenwald; Jakob BLÄSI
Original assignee: Wobben Properties Gmbh
Priority date: 2021-06-10
Filing date: 2022-05-25
Publication date: 2022-12-15
Also published as: WO2022258380A3; DE102021114933A1; EP4352857A2

Abstract

The invention relates to a rotor segment (200) of a rotor (121) of a generator (1), in particular a segmented rotor (121) of a segmented generator (1), for a wind turbine (100), comprising: a magnet carrier segment (210) having an annular or partially annular geometry, wherein the magnet carrier segment (210) extends in a radial direction (R) between a radially outer magnet carrier outer face (211) and a magnet carrier inner face (212) which is located radially inwards in relation to the magnet carrier outer face; and at least one rotor laminated core (220) which is designed to receive at least one magnet unit (230), wherein the at least one rotor laminated core (220) extends in the radial direction (R) between a radially outer laminated core outer face (221) and a laminated core inner face (222) which is located radially inwards in relation to the laminated core outer face; characterized in that a connecting element (240) is located between the magnet carrier segment (210) and the at least one rotor laminated core (220), which connecting element is in the form of a cast part and/or foamed part and is connected to the laminated core outer face (221) of the at least one rotor laminated core (220) and to the magnet carrier inner face (212) of the magnet carrier segment (210).

Description

Rotor segment, magnet cover, rotor, generator, wind turbine, and molding apparatus and method for manufacturing a rotor segment

The invention relates to a rotor segment of a rotor of a generator for a wind turbine. The invention particularly relates to a rotor segment of a segmented rotor of a segmented generator for a wind turbine. The rotor segment comprises a magnet carrier segment with a ring-shaped or partially ring-shaped geometry, the magnet carrier segment extending in a radial direction between a radially outer magnet carrier outer surface and a magnet carrier inner surface which is radially inner in relation to the magnet carrier outer surface, and at least one rotor laminated core, which is used for receiving at least one magnet unit is formed, the at least one rotor laminated core extending in the radial direction between a radially outer laminated core surface and a laminated core inner surface located radially in relation to the laminated core outer surface.

Furthermore, the invention relates to a magnet cover for covering at least one magnet unit of a rotor segment.

The invention also relates to a rotor, in particular a segmented rotor, and a generator, in particular a segmented generator, for a wind energy plant. Furthermore, the invention relates to a wind energy installation.

Finally, the invention relates to a molding device and a method for manufacturing a rotor segment. It is known to produce a rotor segment or a rotor of a generator for a wind turbine from a magnet carrier segment and a rotor sheet metal package. For the production of the rotor segment or the rotor, it is known to arrange the rotor sheet metal package on the magnet carrier segment. In particular, the rotor laminated core is arranged with its radially outer outer surface of the laminated core on the radially inner inner surface of the magnet carrier. For this purpose, both the rotor laminated core and the magnet carrier segment are machined beforehand and then assembled at the machined fitting surfaces or functional surfaces and welded together.

This type of production of a rotor segment or rotor requires a comparatively large number of production steps and, in particular, requires a high level of (manufacturing) accuracy to be achieved. In particular, the machined mating surfaces or functional surfaces must meet tight tolerances in terms of their dimensions, shape and position. Both the comparatively high number of manufacturing steps required and the high demands on the accuracy to be achieved are responsible for a significant part of the costs. If the high levels of accuracy are not achieved in terms of production technology, this can lead to the rotor, i.e. the generator, running out of true and to increased noise emissions. It is therefore necessary to use machine tools, such as lathes, with which the required manufacturing accuracies can be achieved. However, such machine tools are very expensive - especially when components with large diameters are to be produced.

Another disadvantage of this type of production is that a corresponding material allowance has to be provided on the rotor laminated core and/or the magnet carrier segment for machining. This in turn leads to comparatively high material costs for a rotor segment or rotor produced in this way. However, thanks to the expensive manufacturing process and the high levels of accuracy that can be achieved as a result, an air gap between the rotor and stator of a generator can be adjusted comparatively well in terms of roundness, cylindricity and squareness, and thus a comparatively high generator output can be achieved despite the power losses that conventional steel magnet covers cause. The German Patent and Trademark Office has researched the following prior art in the priority application for the present application: DE 10 2013 101 956 A1, DE 10 2004 035 382 A1, DE 10 2018 111 906 A1, DE 10 2015 203 257 A1, WO 2012/ 103 882 A2, EP 2 790 297 A1, DE 10 2009 025 929 A1, US 5 306 123 A, DE 10 2010 041 593 A1, DE 20 2011 050 715 U1, EP 2 713480 A1, EP 3 829 030 A1.

The invention is therefore based on the object of providing a rotor segment, a magnet cover, a rotor, a generator, a wind energy installation, as well as a molding device and a method for producing a rotor segment, which address the problems mentioned. In particular, the invention is based on the object of providing a rotor segment, a magnet cover, a rotor, a generator, a Wndener- gieanlage as well as a molding device and a method for producing a rotor segment, which a cheaper and faster production of a rotor segment, a magnet cover, a rotor, a generator and/or a wind energy system. In particular, the invention is also based on the object of providing a rotor segment, a magnet cover, a rotor, a generator, a Wndenergie- plant and a molding device and a method for producing a rotor segment, which manufacture a rotor segment, a magnet cover, a rotor , A generator and / or a Wndenergieanlage allow the weight is reduced compared to conventional solutions. Furthermore, the invention is preferably based on the object of providing a rotor segment, a magnet cover, a rotor, a generator, a Wndenergieanlage and a molding device and a method for producing a rotor segment, which enable improved vibration damping and/or reduced noise emissions . Finally, the invention is also based in particular on the object of providing a rotor segment, a magnet cover, a rotor, a generator, a wind turbine, as well as a molding device and a method for producing a rotor segment, which has an improved air gap in terms of roundness, cylindricity and squareness and reduced power losses between Enable rotor and stator.

According to one aspect of the invention, the object is achieved by a rotor segment according to claim 1 . The rotor segment is characterized in that a connecting element is arranged between the magnet carrier segment and the at least one rotor laminated core, which is designed as a cast and/or foam part and connected to the at least one rotor laminated core on the outer surface of the laminated core and the magnet carrier segment on the Magnet carrier inner surface is connected.

Unless expressly stated otherwise, information about an axial direction, a circumferential direction and a radial direction in the description relates to a Understand the axis of rotation of a generator. The axial direction corresponds to a direction parallel, ie along the axis of rotation. The circumferential direction corresponds to a direction essentially tangential to the axis of rotation, ie orthogonal to the axial direction and the radial direction. The radial direction corresponds to a direction radial to the axis of rotation, ie orthogonal to the axial direction and circumferential direction.

The rotor segment preferably extends in the radial direction between a radially inner flange for fastening the rotor segment to a rotor base body flange of a bearing unit and the radially outer magnet carrier segment. The rotor segment preferably extends with a rotor bearing section between the radially inner flange for fastening the rotor segment to the rotor G round body flange of the bearing unit and the radially outer magnet carrier segment. It is to be understood that the rotor segment can be of multi-part or integral design. In particular, it should be understood that the rotor segment can be formed integrally from individual rotor elements that are welded or screwed together. The rotor segment is preferably partially ring-shaped in relation to the axis of rotation in a circumferential direction. In particular, the rotor segment has a partially annular geometry. Furthermore, the rotor segment can be designed as a ring. Such a rotor segment extends in the circumferential direction with a certain degree of arc between first and second separation interfaces. A rotor segment preferably extends in the circumferential direction by at least 15°, 30°, 45°, 60°, 90°, 120°, 180° or 360° and/or by a maximum of 15°, 30°, 45°, 60°, 90° °, 120°, 180° or 360°. In the axial direction, the rotor segment extends by at least 0.5m, 1m, 1.5m, 2m, 2.5m, 3m or more and/or by a maximum of 0.5m, 1m, 1.5m, 2m, 2.5m, 3m or less.

The first and second separation interfaces extend substantially orthogonally to the circumferential direction. In particular, the first and second separation interfaces define first and second separation interface planes within which the axis of rotation extends. In particular, the first and/or second separating interface extend in such a way that the first and/or second separating interface plane extend in a radial direction in relation to the axis of rotation. In particular, the first and/or second parting interface planes, which extend in the radial direction with respect to the axis of rotation, intersect in an axis that is or defines the axis of rotation. In particular, the axis of rotation lies in the first and/or second separation interface planes, which extend in the radial direction in relation to the axis of rotation. The first and/or second separation interface of a rotor segment has a connection device. The connecting device at the first and/or second separation interface is designed to connect adjacent rotor segments that are arranged to form a rotor to one another. The connecting device of the first and/or second separation interface is designed in particular to mechanically connect adjacent rotor segments. The mechanical connection can be designed as a non-positive and/or material-to-material and/or form-fitting connection. The first and/or second separation interface preferably has a flange connection and/or a screw connection as a connecting device for fastening rotor segments that are adjacent in the circumferential direction.

The magnet carrier segment has a ring-shaped or part-ring-shaped geometry. In particular, the magnet carrier segment can be designed as a ring. The magnet carrier segment extends in the radial direction between a radially outer magnet carrier outer surface and a radially inner magnet carrier surface in relation to the magnet carrier outer surface. The magnet carrier segment extends in the circumferential direction between the first and second separation interfaces. The magnet carrier segment can essentially have the dimensions described for the rotor segment in the axial direction and circumferential direction.

The magnet carrier segment preferably comprises the material steel or essentially consists of the material steel. In particular, the magnet carrier segment is a steel construction. The magnet carrier segment is preferably a rolled and/or bent steel construction. In addition or as an alternative, the magnet carrier segment is a welded steel construction. Preferably, the magnet carrier segment is not a steel construction produced by machining. In particular, the magnet carrier segment does not have any high-precision, machined fitting surfaces or functional surfaces for the connection to the at least one laminated rotor core.

The at least one rotor laminated core has a ring-shaped or part-ring-shaped geometry. In particular, the at least one rotor laminated core can be designed as a ring. The at least one rotor laminated core is designed to accommodate at least one magnet unit. The at least one rotor laminated core extends in the radial direction between a radially outer laminated core outer surface and a laminated core inner surface which is radially inward in relation to the laminated core outer surface. The at least one laminated rotor core preferably extends in the circumferential direction between the first and second separation interface. In particular, the at least one rotor laminated core can correspond to the dimensions of the rotor segment in the circumferential direction. Two, three, four or more rotor lamination stacks are preferably arranged next to one another in the circumferential direction, so that they extend between the first and second separation interface. The at least one rotor laminated core preferably extends in the circumferential direction by at least 15°, 30°, 45°, 60°, 90°, 120°, 180° or 360° and/or by a maximum of 15°, 30°, 45° , 60°, 90°, 120°, 180° or 360°.

In the axial direction, the at least one rotor laminated core extends by at least 0.25m, 0.5m, 1m, 1.5m, 2m, 2.5m, 3m or more and/or by a maximum of 0.25m, 0.5m, 1 m,

1 .5m, 2m, 2.5m, 3m or less.

The at least one rotor laminated core includes a plurality of rotor laminations. In particular, the at least one rotor laminated core includes a plurality of stacked and braced rotor laminations. In particular, the rotor laminations are stacked on top of one another in the axial direction. The rotor laminations can be spaced apart from one another in the axial direction. In particular, adjacently arranged rotor laminations can form or define a gap through which, for example, cooling air can flow. The rotor laminations are in particular steel laminations or iron laminations.

It may be preferred that the at least one rotor lamination stack has alignment stops. The alignment stops are designed to align the at least one rotor laminated core compared to the forming device described herein on the one hand with greater accuracy and on the other hand also quickly and easily. The alignment stops can in particular be designed as elevations, for example pins, convex projections or the like, and/or depressions, for example grooves, concave depressions or the like.

In a preferred embodiment, the generator has an external rotor. In this preferred embodiment, the at least one rotor laminated core is arranged on the inside in the radial direction in relation to the magnet carrier segment. In particular, the at least one rotor laminated core is arranged in such a way that the outer surface of the laminated core faces the magnet carrier inner surface of the magnet carrier segment. In particular, the at least one rotor laminated core and the magnet carrier segment are arranged at a distance from one another in the radial direction. The distance in the radial direction between the at least one rotor laminated core and the magnet carrier segment, in particular the outer surface of the laminated core and the inner surface of the magnet carrier is at least 10mm, 20mm, 30m, 40m, 50m, 75mm or 100mm and/or at most 10mm, 20mm, 30m, 40m, 50m, 75mm or 100mm.

A connecting element is arranged between the at least one laminated rotor core and the magnet carrier segment. The connecting element has a ring-shaped or part-ring-shaped geometry. In particular, the connecting element can be designed as a ring. The connecting element extends in the circumferential direction between the first and second separation interfaces. In the circumferential direction, the connecting element can essentially have the dimensions described for the rotor segment. In the axial direction, the connecting element can essentially have the dimensions described for the at least one laminated rotor core in the circumferential direction.

The connecting element is designed to connect the magnet carrier segment to the at least one rotor laminated core. In particular, the connecting element is designed for the non-positive and/or form-fitting and/or material-to-material connection of the magnet carrier segment to the at least one rotor laminated core. In particular, the connection between the at least one laminated rotor core and the magnet carrier segment is produced by a connecting element foamed and/or cast between the at least one laminated rotor core and the magnet carrier segment. The connecting element is preferably foamed and/or cast in the vertical direction from bottom to top between the magnet carrier segment and the at least one rotor laminated core. This has the advantage that any trapped air or the like can escape upwards.

The connecting element preferably comprises a material or the connecting element consists of a material which differs from the material of the at least one rotor lamination stack and/or the magnet carrier segment.

In particular, the material of the connecting element is suitable for temperatures of at least -40°C, -30°C, -20°C, -10°C, 0°C, +10°C, +20°C, +30°C, + 40°C, +50°C, +60°C, +70°C, +80°C, +90°C, +100°C or more suitable. Additionally or alternatively, the material of the connecting element is preferably for temperatures of at most -40°C, -30°C, -20°C, -10°C, 0°C, +10°C, +20°C, +30° C, +40°C, +50°C, +60°C, +70°C, +80°C, +90°C, +100°C or less suitable. The material of the connecting element preferably has a modulus of elasticity of at least 100 MPa, 200 MPa, 300 MPa, 400 MPa, 500 MPa, 600 MPa, 700 MPa, 800 MPa, 900 MPa, 1000 MPa, 1100 MPa, 1200 MPa, 1300 MPa, 1400 MPa 1500MPa or more. Additionally or alternatively, the material of the connecting element has in particular a modulus of elasticity of at least 100 MPa, 200 MPa, 300 MPa, 400 MPa, 500 MPa, 600 MPa, 700 MPa, 800 MPa, 900 MPa, 1000 MPa, 1100 MPa, 1200 MPa, 1300 MPa, 1400MPa 1500MPa or less.

The material of the connecting element preferably has a tensile strength of at least 1 MPa, 5 MPa, 6 MPa, 7 MPa, 8 MPa, 9 MPa, 10 MPa, 15 MPa, 20 MPa, 30 MPa or more. Additionally or alternatively, the material of the connecting element has in particular a tensile strength of at least 1 MPa, 5 MPa, 6 MPa, 7 MPa, 8 MPa, 9 MPa, 10 MPa, 15 MPa, 20 MPa, 30 MPa or less.

The material of the connecting element preferably has a compressive strength of at least 1 MPa, 5 MPa, 6 MPa, 7 MPa, 8 MPa, 9 MPa, 10 MPa, 15 MPa, 20 MPa, 30 MPa or more. Additionally or alternatively, the material of the connecting element has in particular a compressive strength of at least 1 MPa, 5 MPa, 6 MPa, 7 MPa, 8 MPa, 9 MPa, 10 MPa, 15 MPa, 20 MPa, 30 MPa or less.

In particular, the material of the connecting element corresponds to the building material class or Euroclass E according to the assessment standard of DIN EN 13501. It can be preferred that the material of the connecting element is a material of a building material class or the Euro class according to the assessment standard of DIN EN 13501, which compared to materials of building material class E contributes less to fire behavior.

This arrangement of the connecting element designed as a cast and/or foam part between the at least one laminated rotor core and the magnet carrier segment significantly reduces the requirements for the manufacturing accuracy to be achieved in the magnet carrier segment and/or the at least one laminated rotor core. This is because the outer surface of the laminated core and the inner surface of the magnet carrier no longer have to be in the form of mating surfaces or functional surfaces, as was previously necessary. Rather, the cast and/or foam mass of the connecting element compensates for possible manufacturing inaccuracies in the at least one laminated rotor core and the magnet carrier segment. This significantly reduces the manufacturing cost of the rotor segment. This effect is additionally reinforced by the fact that expensive machine tools, which were previously required to to achieve the required manufacturing accuracies become superfluous. Furthermore, this accelerates the manufacturing process, since time-consuming manufacturing processes, which enable high manufacturing accuracy, are eliminated.

Furthermore, the damping property of the rotor segment can be adjusted in a targeted manner by means of the connecting element. In this way, on the one hand, the mechanical load on the rotor segment or rotor or generator can be reduced, that is to say the service life can be increased and operating costs reduced, and the noise emissions of the rotor segment or rotor or generator can be reduced.

The material preferably has high inherent damping. Furthermore, through the use of the connecting element according to the invention, an improved air gap between the rotor and stator of a generator in terms of roundness, cylindricity and squareness can be produced due to the modified manufacturing process. In particular, manufacturing inaccuracies, i.e. larger tolerances, can easily be compensated for by the connecting element. Because the connecting element is designed as a cast part and/or foam part, it can have variable thicknesses in the radial direction, which compensate for the manufacturing inaccuracies, i.e. larger tolerances.

For further advantages, design variants and design details of the rotor segment according to the invention and its developments, reference is also made to the following description of the corresponding features and developments of the magnet cover, the rotor, the generator, the wind turbine and the shaping device, as well as the method for producing a rotor segment or rotor .

According to a preferred embodiment of the rotor segment, the connecting element comprises plastic, in particular polyurethane, and/or is particularly preferably designed as a polyurethane foam part and/or polyurethane cast part. This preferred embodiment has the advantage that manufacturing inaccuracies can be compensated for without great effort. Furthermore, this has the advantage that the magnet carrier segment and the at least one rotor laminated core can be manufactured with less effort, ie at lower costs. Furthermore, the connecting element has a vibration-damping effect and thus reduces vibrations. As a result, on the one hand, the mechanical stress during operation decreases, which leads to lower operating costs; on the other hand, the noise emission decreases as a result. Finally, this preferred allows Embodiment produce an improved air gap between the rotor and stator of a generator in terms of roundness, cylindricity and squareness.

Since the magnet carrier segment and the at least one rotor laminated core comprise materials with a higher melting temperature than plastic, the magnet carrier segment and the at least one rotor laminated core can advantageously serve as a mold for the connecting element to be cast or foamed.

For further advantages of this preferred development of the rotor segment, reference is also made to the advantages of the rotor segment according to the invention.

According to a further preferred development, the connecting element is connected to the inner surface of the magnet carrier and/or the outer surface of the laminated core in a materially bonded manner, in particular adhesively, and/or in a form-fitting manner.

As a result, a particularly stable and low-noise connection can be produced. For further advantages of this preferred development of the rotor segment, reference is also made to the advantages of the rotor segment according to the invention. In a further preferred embodiment of the rotor segment, it is provided that the magnet carrier segment has a first connecting device on the inside surface of the magnet carrier, the first connecting device having one or more first connecting projections and/or one or more first connecting depressions, for the positive connection of the connecting element to the magnet carrier segment. The one or more first connecting projections are preferably welded to the magnet carrier segment, in particular to the inner surface of the magnet carrier.

In addition or as an alternative, it is provided that the at least one rotor laminated core has a second connecting device on the outer surface of the laminated core, the second connecting device having one or more second connecting projections and/or one or more second connecting recesses, for the positive connection of the connecting element to the at least one rotor lamination package.

In addition or as an alternative, it is further provided that the connecting element is located in the radial direction between a radially outer connecting element outer surface and a radially inner connection in relation to the connecting element outer surface. connecting element inner surface, wherein the connecting element preferably has a first connecting device on the connecting element outer surface, the first connecting device having one or more first connecting projections and/or one or more first connecting depressions, for positively locking connection of the connecting element to the magnet carrier segment, and/or preferably a second one on the connecting element inner surface Having connecting device, the second connecting device having one or more second connecting projections and / or one or more second connecting recesses, for positive connection of the connecting element with the at least one rotor laminated core.

Preferably, the first and/or second connecting projections have an I-shaped and/or L-shaped and/or T-shaped cross section or the like. Furthermore, it is preferred that the first and/or second connection recesses have an I-shaped and/or L-shaped and/or T-shaped cross section or the like. In particular, the one or more first connecting projections and/or the one or more first connecting depressions are arranged equidistantly from one another in the circumferential direction. It can also be preferred that the one or more second connecting projections and/or the one or more second connecting recesses are arranged equidistantly from one another in the circumferential direction. The magnet carrier segment preferably has a plurality of first connecting projections with a T-shaped cross section. In particular, the rotor laminated core has a plurality of second connection depressions with a T-shaped cross section on the outer surface of the laminated core. In particular, the plurality of second connection depressions are designed as a T-shaped groove. According to this preferred embodiment, the connection between the at least one laminated rotor core and the magnet carrier segment or the at least one laminated rotor core and the magnet carrier segment with the connecting element is further improved. In particular, this further extends the service life of the rotor segment. For further advantages of this preferred development of the rotor segment, reference is also made to the advantages of the rotor segment according to the invention. According to a further preferred development, it is provided that the connecting element has greater damping than the magnet carrier segment and/or the at least one rotor laminated core.

This preferred embodiment enables a further reduction in vibrations. Consequently, this preferred embodiment leads to a reduced mechanical load, i.e. a longer service life, and reduces the noise emission of the rotor or generator. For further advantages of this preferred development of the rotor segment, reference is also made to the advantages of the rotor segment according to the invention.

According to a further preferred development, the rotor segment comprises at least one magnet unit, which is arranged on the at least one rotor laminated core, in particular on the inner surface of the laminated core. Additionally or alternatively, the rotor segment includes at least one magnet cover for covering the at least one magnet unit. In addition or as an alternative, it is provided that the rotor laminated core has fastening connections on the inner surface of the laminated core, which are designed to fasten the at least one rotor laminated core with one or more magnet covers, in particular for non-positive and/or positive fastening, wherein preferably the at least one magnet unit is arranged between the rotor laminated core and the magnet cover. The magnet cover has in particular features and advantages of the magnet cover according to the invention or its preferred embodiments - as described below - on.

This preferred embodiment enables the magnet units to be attached, secured and preserved in a particularly cost-effective manner on the at least one rotor laminated core. In particular, power losses can be minimized in a particularly advantageous manner. For further advantages of this preferred development of the rotor segment, reference is also made to the advantages of the rotor segment according to the invention.

The object is achieved according to a further aspect of the invention by a magnet cover for covering at least one magnet unit, having a cover unit which extends in the circumferential direction between a first and second end and between an inner cover surface lying on the inside in the radial direction and an outer cover surface lying on the outside in the radial direction , a first side wall located at the first end, and a second side wall located at the second end. with the first and second sidewalls angling from the lid exterior surface, with an intermediate wall disposed between the first and second sidewalls and angling from the lid exterior surface.

In particular, the first and/or second side wall and/or the intermediate wall extend inwards in the radial direction, starting from the inner surface of the cover. Furthermore, the first and/or second side wall and/or the intermediate wall extend perpendicular to the inner surface of the lid.

In particular, a radial transition from the cover unit to the first and/or second side wall and/or intermediate wall is provided. In particular, the radial transition from the inner surface of the lid to the first and/or second side wall and/or intermediate wall has a radius of at least 0.5 mm, 1 mm, 2 mm, 3 mm, 4 mm, 5 mm or more and/or a maximum radius of 0, 5mm, 1mm, 2mm, 3mm, 4mm, 5mm or less. Furthermore, the radial transition from the outer surface of the lid to the first and/or second side wall and/or intermediate wall preferably has a radius of at least 0.5 mm, 1 mm, 2 mm, 3 mm, 4 mm, 5 mm or more and/or a maximum radius of 0 .5mm, 1mm, 2mm, 3mm, 4mm, 5mm or less.

Magnet units arranged in two rows usually form a pole pair. The magnet cover according to the invention has the advantage that such a pair of poles can be fastened and secured to a laminated rotor core with a single magnet cover and can be preserved against environmental influences. Furthermore, the assembly of the magnet cover according to the invention is faster in comparison to conventional magnet covers, which are each to be fastened to a rotor laminated core for a magnet unit. In particular, the intermediate wall increases the stability of the magnet cover, which increases its service life and thus the service life of the rotor segment or rotor and generator. Furthermore, this configuration changes the vibration behavior of the magnet cover in such a way that the noise emission of the rotor or generator can be minimized.

For further advantages, design variants and design details of the magnet cover according to the invention and its developments, reference is also made to the above description of the corresponding features and developments of the rotor segment. According to a preferred development, it is provided that the magnet cover extends in the axial direction between a first and second opening arrangement and has an insertion funnel unit for inserting magnet units at one of the two opening arrangements. In addition or as an alternative, it is preferably provided that the cover unit has a wall thickness that is smaller than a wall thickness of the first and/or second side wall and/or smaller than a wall thickness of the intermediate wall. In addition or as an alternative, it is provided that the wall thickness of the first and/or second side wall is smaller than the wall thickness of the intermediate wall. Furthermore, it is additionally or alternatively provided in this preferred embodiment that the first and/or second side wall and/or the intermediate wall each have a fastening section for fastening the magnet cover to a laminated rotor core.

The first and second opening arrangements are preferably connected to one another by two shafts. The first side wall, the intermediate wall and a section of the cover unit form a first shaft. The second side wall, the intermediate wall and another section of the lid unit form a second shaft. The shafts are designed to accommodate the magnet units.

The insertion funnel unit is designed to insert magnet units into the magnet covers more quickly and easily. For this purpose, the insertion funnel unit preferably has funnel feed walls arranged inclined relative to the first and/or second side wall and/or the cover unit. In particular, the insertion funnel unit has a

Funnel opening cross section, which decreases towards one of the two opening arrangements in the axial direction. In particular, the funnel opening cross section can decrease linearly.

The magnet cover or the cover unit preferably extends in the circumferential direction by at least 30 mm, 40 mm, 50 mm, 60 mm, 70 mm, 80 mm, 90 mm, 100 mm, 110 mm, 120 mm, 130 mm, 140 mm, 150 mm, 160 mm, 170 mm, 180 mm, 190 mm, 200 mm or similar - the more. Additionally or alternatively, the cover unit preferably extends in the circumferential direction by a maximum of 30 mm, 40 mm, 50 mm, 60 mm, 70 mm, 80 mm, 90 mm, 100 mm, 110 mm, 120 mm, 130 mm, 140 mm, 150 mm, 160 mm, 170 mm, 180 mm, 190 mm, 200 mm or less . The magnet cover preferably extends in the radial direction with a height of at least 5 mm, 10 mm, 20 mm, 30 mm, 40 mm, 50 mm or more. In addition or as an alternative, it is also preferred that the magnet cover extends in the radial direction with a maximum height of 5 mm, 10 mm, 20 mm, 30 mm, 40 mm, 50 mm or less. The first and/or second side wall and/or intermediate wall and/or cover unit preferably has a wall thickness of at least 0.5 mm, 1 mm, 1.5 mm, 2 mm, 3 mm, 4 mm, 5 mm or more. Additionally or alternatively, the wall thickness of the first and/or second side wall and/or the intermediate wall and/or the cover unit is a maximum of 0.5 mm, 1 mm, 1.5 mm, 2 mm, 3 mm, 4 mm, 5 mm or less. The wall thickness of the cover unit is preferably 1 mm, the first and second side wall is 2 mm and the intermediate wall is 3 mm.

The fastening section of the first and/or second side wall and/or the intermediate wall is designed for a positive connection with a laminated rotor core. The fastening section preferably has a circular cross section. It can also be preferred that the respective fastening section has an L-shaped or T-shaped cross section. In particular, it can be preferred that the respective fastening section has a polygonal cross section, for example a triangular and/or rectangular cross section. In particular, the fastening sections are designed for a positive connection in the radial direction with the at least one laminated rotor core. The first and/or second side wall and/or intermediate wall preferably have fastening sections of identical design. It can be preferred that the first and/or second side wall and/or intermediate wall have fastening sections that differ from one another. The attachment section of the first and/or second side wall and/or the intermediate wall preferably has a width of at least 0.5 mm, 1 mm, 1.5 mm, 2 mm, 3 mm, 4 mm, 5 mm, 7 mm, 10 mm or more in the circumferential direction. Additionally or alternatively, the width of the first and/or second side wall and/or the intermediate wall is at most 0.5 mm, 1 mm, 1.5 mm, 2 mm, 3 mm, 4 mm, 5 mm, 7 mm, 10 mm or less. In particular, the attachment portion of the first and second side walls has a width of 5mm and the attachment portion of the intermediate wall has a width of 7mm.

In particular, a radial transition from the first and/or second side wall and/or intermediate wall to the respective fastening section is provided. In particular, the radial transition from the respective fastening section to the first and/or second side wall and/or intermediate wall has a radius of at least 0.5 mm, 1 mm, 2 mm, 3 mm, 4 mm, 5 mm or more and/or a maximum radius of 0 .5mm, 1mm, 2mm, 3mm, 4mm, 5mm, 10mm or less. The magnet cover according to the invention enables a simple and secure attachment of the magnet cover to a rotor laminated core in a particularly advantageous manner. Furthermore, this magnet cover enables a particularly advantageous preservation of the magnet units to be covered with the magnet cover. Furthermore, this preferred embodiment makes it possible to provide a magnet cover that is both stable and comparatively light, which can contribute to reducing the weight of the rotor or generator. For further advantages of this preferred development of the magnet cover, reference is also made to the advantages of the magnet cover according to the invention and its preferred developments. According to a further preferred embodiment of the magnet cover, this is made in one piece; and/or is this made of plastic, in particular of a fiber composite plastic, or includes this; and/or is it designed as a compression molded part and/or an injection molded part.

A magnet cover designed in this way enables magnet units to be attached and secured cost-effectively on a laminated rotor core and allows them to be preserved. In particular, magnet covers made of plastic are much less lossy in terms of generator output compared to magnet covers made of steel. In particular, such magnet covers can be produced in a particularly cost-effective manner. For further advantages of this preferred development of the magnet cover, reference is also made to the advantages of the magnet cover according to the invention and its preferred developments.

According to a further aspect of the invention, the object is achieved with a molding device according to claim 10 for the production of a rotor segment. The molding device comprises a ring-shaped or partially ring-shaped negative mold, which extends in a radial direction between a radially outer negative outer surface and a negative inner surface that is inner in relation to the radially outer negative outer surface, characterized in that the negative mold comprises a non-magnetic material or essentially consists of a non-magnetic material; and the molding device has soft-magnetic elements which can be arranged on the negative inner surface for closing the magnetic flux for the production of the rotor segment.

The non-magnetic material is, for example, stainless steel or glass fiber reinforced plastic. However, other structure-bearing non-magnetic materials can also be considered as non-magnetic materials. The negative mold is designed to align rotor lamination stacks for the production of a rotor segment described herein. For this purpose, the laminated rotor cores are preferably arranged next to one another in the circumferential direction, so that they extend by 180° in the circumferential direction. In particular, the negative mold is designed to align and stack rotor laminations of a laminated rotor core to be produced on the negative mold. In this respect, the negative mold has a shape that corresponds to the contour of the inner surface of the laminated core. The negative outer surface preferably has a shape that corresponds to the contour of the magnet covers, in particular the cover units of the magnet covers. This is because, when producing the rotor segment, the magnetic forces of the magnet units cause the cover units of the magnet covers to lie against the negative outer surface with the cover outer surface. As a result, the magnet units interacting with the stator during operation are aligned or centered with respect to the axis of rotation.

The molding device according to the invention therefore causes a magnetic force to act in the direction of the soft magnetic elements of the molding device according to the invention, which are on the inside in the radial direction, during the production of a rotor segment according to the invention by inserting magnet units between magnet covers and the at least one rotor lamination stack. This has the advantage that an improved air gap in terms of roundness, cylindricity and perpendicularity between rotor and stator is made possible, which minimizes power losses of the generator.

For further advantages, design variants and design details of the molding device according to the invention and its further developments, reference is also made to the above description of the corresponding features and further developments of the rotor segment and the magnet cover and to the following description of the corresponding features and further developments of the method for manufacturing a rotor segment .

According to a preferred development, the shaping device comprises an alignment device for stacking and aligning the individual rotor laminations of the at least one rotor laminated core at a distance defined in the radial direction from the shaping device. In addition or as an alternative, the shaping device preferably comprises a feeding device which is designed to feed one or more magnet units to the magnet cover. In particular, the feed device has at least one feed magazine and/or an insertion aid device. The Einschiebehilfevorrichtung is particularly designed for feeding and inserting the magnet units between the Magnet cover and the at least one rotor laminated core to be in engagement with the insertion funnel unit.

Preferably, the alignment device comprises or consists essentially of a non-magnetic material. In particular, the alignment device has an outer surface that includes or consists essentially of a non-magnetic material. The non-magnetic material is, for example, stainless steel or glass fiber reinforced plastic. However, other structure-bearing non-magnetic materials can also be considered as non-magnetic materials.

In particular, the alignment device comprises alignment elements which essentially extend in a radial direction. The alignment elements are designed to align the at least one rotor laminated core of the rotor segment to be produced as described herein with respect to the forming device on the one hand with greater accuracy and on the other hand also quickly and easily. In particular, the alignment elements are designed to engage in the alignment stops of the at least one laminated rotor core with a precise fit. In particular, the alignment elements are designed to align the at least one laminated rotor core with respect to the forming device via the alignment stops of the at least one laminated rotor core. For this purpose, the alignment elements can in particular have elevations, for example pins, convex projections or the like, and/or depressions, for example grooves, concave depressions or the like.

The alignment elements can be spring loaded. It can also be preferred that the alignment elements extend outwards in the radial direction, starting from the negative mold, in particular from the radially outer negative outer surface. In particular, it can be provided that the negative mold forms the alignment elements integrally. The alignment elements cause the at least one rotor laminated core to be pressed away from the forming device in the radial direction in order to produce the rotor segment, so that a gap is created between the magnet units and the at least one rotor laminated core or its inner surface. The magnet units and the casting compound for fastening the magnet units to the at least one laminated rotor core can be introduced into this gap. In particular, the casting compound can consist of the material of the connecting element. In particular, the gap can be filled with the material of the connecting element for fastening the magnet units to the at least one rotor laminated core at the same time as the connecting element is produced. For advantages of this preferred development of the shaping device, reference is made to the advantages of the shaping device according to the invention and its further preferred developments.

In a further preferred development of the molding device, the soft-magnetic elements can be moved back and forth radially in the radial direction between an assembly position and a standby position, with the soft-magnetic elements being arranged in the assembly position on the negative inner surface to close the magnetic flux to produce the rotor segment and in the standby position for opening the magnetic flux to remove the molding device from the manufactured rotor segment, the soft magnetic elements are not arranged on the negative inner surface, in particular are arranged spaced apart from the negative inner surface in the radial direction.

In particular, the soft magnetic elements are retracted from the mounting position to the standby position in the radial direction or pushed from the standby position to the mounting position in the radial direction. Here, for example, the forming device can have a hydraulic device that effects the movement of the soft magnetic elements between the mounting position and the standby position. The hydraulic device is designed to overcome the very large magnetic forces acting on the forming device through the magnet units of the rotor segment to be produced. For example, the hydraulic device may include one, two or more double-acting cylinders that may be coupled to the soft magnetic members and configured to radially reciprocate the soft magnetic members in the radial direction between the standby position and the mounting position.

By moving the soft magnetic elements from the assembly position to the standby position, the acting magnetic forces are greatly reduced, since the negative mold, in particular the outer surface of the molding device, is made of a non-magnetic material, such as stainless steel or glass fiber reinforced plastic. This makes it possible to remove the manufactured rotor segment from the molding device. For this purpose, the rotor segment is removed from the molding device in a vertical direction or in an axial direction.

For advantages of this preferred development of the shaping device, reference is made to the advantages of the shaping device according to the invention and its further preferred developments. The object is achieved according to a further aspect of the invention by a rotor of a generator, in particular by a segmented rotor of a segmented generator, for a wind turbine, comprising a rotor segment described above and/or a rotor segment produced with a molding device described above. The segmented rotor for a wind turbine comprises two or more rotor segments. The two or more rotor segments are preferably arranged in a ring shape. In particular, the two or more rotor segments are arranged coaxially to an axis of rotation of the segmented generator.

Preferably, the two or more rotor segments extend with the same degree of arc in the circumferential direction. In particular, the rotor segments extend according to the following formula, depending on the number of the respective segments: 360 “/(number of segments). According to this, for example, the rotor segments of a segmented rotor, which comprises two rotor segments, extend in the circumferential direction by 180°, with three rotor segments it would be 120°, with four rotor segments it would be 90° etc. It may also be preferred that the rotor segments which a segmented rotor is assembled, extend in the circumferential direction with a different degree of arc. For example, a segmented rotor can be formed from three rotor segments. In such a segmented rotor, for example, a first rotor segment can extend in the circumferential direction at 180°, a second rotor segment at 120° and a third rotor segment at 60°. Any other extensions in the circumferential direction of the rotor segments are conceivable, provided they result in an extension of 360° in the circumferential direction.

For further advantages, design variants and design details of the rotor according to the invention and its developments, reference is also made to the above description of the corresponding features and developments of the rotor segment, the magnet cover and the shaping device.

According to a further aspect of the invention, the object is achieved by a generator, in particular a segmented generator, for a wind energy installation, comprising a rotor as described above. The generator is preferably designed as an external rotor. According to a further aspect of the invention, the object is achieved by a wind energy installation comprising a generator as described above.

According to a further aspect of the invention, the object is achieved by a method for producing a rotor segment of a rotor of a generator, in particular a segmented rotor of a segmented generator, for a wind turbine, preferably for producing a rotor segment according to one of the preceding claims, comprising the steps:

providing a shaping device, in particular a shaping device described above, and - providing at least one rotor laminated core which is designed to accommodate at least one magnet unit, the at least one rotor laminated core being located in the radial direction between a radially outer laminated core surface and a relative to the outer surface of the laminated core extends radially inwardly from the inner surface of the laminated core, the provision of the at least one rotor laminated core being a stacking and aligning of rotor laminations to form at least one rotor

Laminated core in relation to a radially outer negative outer surface of the shaping device at a distance defined in a radial direction from the shaping device, in particular by means of an alignment device of the shaping device. The provision of the shaping device comprises in particular providing the shaping device of the soft-magnetic elements in an assembly position. This has the effect that the magnetic forces due to the soft-magnetic elements are almost eliminated, so that the frictional forces when pushing in are minimized.

The stacking of rotor laminations to form at least one rotor laminated core is preferably an overlapping stacking of rotor laminations to form at least one rotor laminated core. The rotor laminations are preferably stacked in the axial direction. In particular, the rotor laminations can be stacked and aligned using a centering tool. For this purpose, the centering tool can be introduced in the axial direction into centering openings in the rotor laminations. According to a preferred development, the method comprises the steps:

smearing the radially outer negative outer surface of the mold assembly with a release agent; and or axial pre-tightening of the at least one rotor laminated core with one or more tie rods; and or

Fastening, in particular pushing in, one or more magnet covers on the at least one rotor laminated core, in particular fastening the one or more magnet covers on fastening connections of a laminated core inner surface of the at least one rotor laminated core; and/or arranging, in particular pushing in, at least one magnet unit between the at least one rotor laminated core and the one or more magnet covers; and/or - releasing the pre-tensioning of the at least one rotor lamination stack; and/or radial knocking of the detached rotor laminations of the at least one rotor lamination stack on the forming device and/or independent centering of the detached rotor laminations of the at least one rotor lamination stack as a result of the magnetic forces; and/or - final bracing of the at least one rotor laminated core with the one or more tie rods; and or

Aligning, in particular tapping, the at least one laminated rotor core, in particular the rotor laminations, to the shaping device, in particular to the alignment device, for centering the at least one laminated rotor core, in particular the at least one magnet unit; and or

providing at least one magnet carrier segment, the magnet carrier segment extending in a radial direction between a radially outer magnet carrier outer surface and a radially inner magnet carrier surface in relation to the magnet carrier outer surface; and/or - arranging the at least one magnet carrier segment coaxially with respect to the

Rotor laminated core, in particular slipping the magnet carrier segment over the at least one rotor laminated core, preferably in a vertical direction, so that an annular air gap extends between the at least one magnet carrier segment and the at least one rotor laminated core, with in particular the at least one rotor laminated core is arranged coaxially with the magnet carrier segment in relation to an axis of rotation of the rotor segment, with the at least one rotor laminated core preferably being arranged radially on the inside in the radial direction relative to the magnet carrier segment and the outer surface of the laminated core and the inner surface of the magnet carrier facing one another are spaced facing each other; and or Gluing the at least one magnet unit to the at least one rotor laminated core and/or the one or more magnet covers with a casting compound; and or

Arranging, in particular foaming and/or pouring, preferably in a vertical direction from bottom to top, in particular against the force of gravity

Connecting element between the radially outer magnet carrier segment and the at least one radially inner rotor laminated core, so that the connecting element is connected to the at least one rotor laminated core on the outer surface of the laminated core and the magnet carrier segment on the inner surface of the magnet carrier, the connecting element being in particular cast - and or

foam part is formed and/or the connecting element is preferably arranged by a casting and/or foaming process, the connecting element preferably comprising plastic, in particular polyurethane, and/or particularly preferably being formed as a polyurethane foam part and/or polyurethane cast part; and or

curing of the potting compound and/or the connecting element; and/or moving the soft magnetic elements from an assembly position to a standby position, in particular in the radial direction, to open the magnetic flux to remove the molding device from the manufactured rotor segment, the soft magnetic elements in the standby position not being at the

are arranged on the negative inner surface, in particular are arranged at a distance from the negative inner surface in the radial direction; and/or demolding the manufactured rotor segment.

Arranging the at least one magnet carrier segment coaxially in relation to the rotor laminated core includes, in particular, arranging a flange of the magnet carrier segment on a flange of the molding device. In particular, the coaxial arrangement of the at least one magnet carrier segment in relation to the rotor laminated core is also a positioning of the at least one magnet carrier segment in relation to the rotor laminated core. Preferably, the at least one magnet carrier segment is arranged coaxially in relation to the rotor laminated core in such a way that an average annular gap of about 30 mm is formed between the magnet carrier inner surface and the laminated core outer surface.

Gluing the at least one magnet unit to the at least one rotor laminated core and/or the one or more magnet covers includes in particular gluing the at least one magnet unit to the at least one Rotor laminated core and / or the one or more magnet covers with a potting compound. It can be preferred that the casting compound consists of the material of the connecting element. In particular, it is preferred that the at least one magnet unit is glued to the at least one rotor laminated core and/or the one or more magnet covers and the arrangement, in particular foaming and/or casting, of a connecting element between the radially outer magnet carrier segment and the at least one The radial inner rotor core is made synchronously with the same material and in a common process step.

The soft magnetic elements are moved from an assembly position to a standby position and/or vice versa, preferably using a hydraulic device, so that the magnetic forces acting between the magnet units of the rotor segment to be produced and the forming device are minimized.

The individual steps of the method are preferably carried out in the order mentioned. However, it may also be preferred to go through the steps in a different order. In particular, it can be preferred that individual steps are run through several times.

For the advantages, design variants and design details of these further aspects of the invention and their respective developments, reference is also made to the remaining description of the corresponding advantages, design variants and design details of the respective remaining aspects and their preferred developments.

Preferred embodiments of the invention are described by way of example with reference to the accompanying figures. Show it:

Figure 1: a schematic representation of a wind power plant;

Figure 2a,b: a schematic three-dimensional view and a schematic side view of a preferred embodiment of a rotor;

FIG. 3a: a schematic side view of a preferred embodiment of a rotor to be manufactured with a molding device in an assembly position; FIG. 3b, c: a schematic detailed view of the shaping device shown in FIG. 3a in a longitudinal and cross-sectional view;

FIG. 4: a schematic plan view of a preferred embodiment of a rotor segment to be produced with a molding device; FIG. 5: a schematic plan view of a preferred embodiment of a magnet cover;

FIGS. 5a, b: schematic isometric representations of a further preferred embodiment of a magnet cover;

FIGS. 6a,b,c schematic isometric representations of a further preferred embodiment of a magnet cover in a full view and in two different detailed views;

FIGS. 7a, b schematic isometric representations of a preferred embodiment of a feeding device in a full view and in a detailed view;

FIG. 8 shows a schematic isometric illustration of a magnet cover arranged on a negative mold according to a preferred embodiment illustrated in FIGS. 6a-c;

FIGS. 9a, b show various detailed views of the arrangement shown in FIG. 8;

FIG. 10: a schematic flowchart of a preferred method for producing a rotor segment of a rotor; and FIG. 11: a schematic flowchart of a further preferred method for producing a rotor segment of a rotor.

1 shows a schematic representation of a wind energy plant according to the invention. The wind turbine 100 has a tower 102 and a nacelle 104 on the tower 102 . An aerodynamic rotor 106 with three rotor blades 108 and a spinner 110 is provided on the nacelle 104 . During operation of the wind energy installation, the aerodynamic rotor 106 is caused to rotate by the wind and thus also rotates electrodynamic rotor 121 or rotor of a generator 120 about an axis of rotation, which is directly or indirectly coupled to the aerodynamic rotor 106. The electrical generator 120 is arranged in the nacelle 104 and generates electrical energy. The pitch angles of the rotor blades 108 can be changed by pitch motors on the rotor blade roots 109 of the respective rotor blades 108 .

Fig. 2a, b show a schematic three-dimensional view and a schematic side view of a preferred embodiment of a rotor 121 according to the invention. The rotor 121 has two rotor segments 200 designed in the form of a partial ring according to the invention. The rotor segments 200 each extend by 180°. The rotor segments 200 are connected to one another at the separation interfaces. The separation interfaces extend in separation interface planes in which the axis of rotation lies.

The rotor segments 200 each have a magnet carrier segment 210 . The magnet carrier segment 210 is a rolled steel construction. The magnet carrier segment 210 extends in the axial direction A over a width of approximately 2 m. It is particularly clear from FIG. 2b that the rotor segment 200 extends in the radial direction R between a radially inner flange for fastening the rotor segment to a rotor base body flange of a bearing unit and the radially outer magnet carrier segment 210 .

The respective rotor segment 200 also has a plurality of rotor laminated cores 220 . In the preferred embodiment shown schematically, the rotor segments 200 have four rotor laminated cores 220, which extend in the circumferential direction U by 45°. The rotor laminated cores 220 extend in the axial direction A over a width of approximately 1 m.

The magnet carrier segment 210 and the rotor laminated cores 220 are spaced apart in the radial direction R from one another. A connecting element 240 is arranged between the magnet carrier segment 210 and the rotor lamination packets 220 . The connecting element 240 extends in the axial direction A over the width of the rotor lamination stacks 220. In the circumferential direction U, the connecting element 240 extends by 180° between the separation interfaces.

The connecting element 240 is an injection molded part and/or foam molded part made of polyurethane. This has the advantage that the magnet carrier segment can be manufactured with less manufacturing accuracy, ie faster and more cost-effectively, and at the same time an improved air gap between the rotor and stator in terms of cylindricity, roundness and squareness is made possible at an early stage. These manufacturing advantages can be achieved by means of the molding device 300 according to the invention, which FIG. 3a shows in a preferred embodiment in a schematic side view. Figures 3b and 3c are schematic detail views of the molding apparatus shown in Figure 3a in longitudinal and cross section.

The molding device 300 has a ring-shaped negative mold 310, which extends in the radial direction R between a radially outer negative outer surface 311 and a negative inner surface 312 that is inner in relation to the radially outer negative outer surface - this is in detail Fig. 3b, 3c and 4 refer to. The molding device has soft magnetic elements 320 . The soft magnetic elements 320 can be moved back and forth in the radial direction R between a mounting position and a standby position.

In the assembly position--shown in FIGS. 3a, 3b, 3c and 4--the soft-magnetic elements 320 are in contact with the negative inner surface 312. This has the effect that the magnetic flux for producing the rotor segment with magnet units is closed when these are inserted between the magnet cover and the at least one rotor lamination packet. As a result, the magnet cover lies flat with the cover unit and the magnet units on the molding device. In the standby position, the soft magnetic elements 320 are arranged at a distance from the negative inner surface 312 . The effect of this is that the magnetic flux is open and the finished rotor segment can be removed from the molding device for further processing or assembly. The standby position for the middle soft-magnetic element is shown in dotted form in the detailed illustration of the shaping device in FIG. 3b. The soft magnetic elements 320 are moved back and forth in a radial direction between the mounting position and the standby position by means of a hydraulic device. In the present case, the hydraulic device for moving the soft-magnetic elements 320 between the mounting position and the standby position has a double-acting cylinder which is coupled to the soft-magnetic elements. This is shown schematically in FIGS. 3b and 3c.

It can be seen that the shaping device also has an alignment device 330 for stacking and aligning the individual rotor laminations of the at least one rotor lamination stack 220 at a distance defined in the radial direction from the shaping device 300 having. In particular, the alignment device comprises alignment elements which essentially extend in a radial direction. The alignment elements are designed to align the at least one laminated rotor core of the rotor segment to be produced in relation to the forming device on the one hand with greater accuracy and on the other hand also quickly and easily. The alignment elements can, for example, be formed integrally on the negative outer surface, as shown in FIG. 3b, or be spring-loaded, as shown in FIG. This causes the at least one rotor laminated core to be pressed away from the forming device in the radial direction in order to produce the rotor segment, so that a gap is created between the magnet units and the at least one rotor laminated core or its inner surface.

4 and 3b are schematic plan views of two preferred embodiments based on the rotor segment 200 shown schematically in side view in Figures 3a, b and a preferred embodiment of the shaping device 300 shown schematically in side view in Figures 3a, b.

The magnet carrier segment 210 has a first connecting device 213 with a plurality of first connecting projections on the inner surface 212 of the magnet carrier. The several first connecting projections enable a positive connection of the connecting element 240 to the magnet carrier segment 210. These first connecting devices 213 have a T-shaped cross section. On the outer surface 221 of the laminated core, the rotor cores 220 have a second connecting device 223 with a plurality of second connecting recesses. The several second connection depressions enable a form-fit connection of the connection element 240 to the rotor lamination stacks 220. Correspondingly, the connection element 240 has on a connection element outer surface 241 a first connection device 213 with a plurality of first T-shaped connection depressions for the form-fit connection of the connection element to the magnet carrier segment 210. A connecting element inner surface 242 of the connecting element 240, which is on the inside in relation to the connecting element outer surface 241 in the radial direction, has a second connecting device 223 with a plurality of second T-shaped connecting projections for the positive connection of the connecting element 240 with the at least one rotor laminated core 220 Thus, the connecting element 240 is cohesive, in particular adhesive, and form-fitting with the Magnet carrier inner surface 212 of the magnet carrier segment 210 and the laminated core outer surface 221 of the rotor laminated cores 220 connected.

The rotor segment also includes a plurality of magnet covers 250 for covering magnet units 230. The magnet covers 250 are attached to the core inner surface 222 of the rotor cores 220. For this purpose, the rotor sheet metal packets 220 at the

Sheet metal package inner surface 222 fastening terminals 224 on. In the present case, the fastening connections 224 are designed as grooves into which the magnet covers 250 are pushed in the axial direction A. The rotor segment 200 also includes magnet units 230 which are arranged on the inner surface of the laminated core 222 of the rotor laminated cores 220 . The magnet units 230 are inserted between the rotor laminated cores 220 and 250 magnet covers.

5 is a schematic plan view of such a magnet cover 250 according to the invention. The magnet cover 250 has a cover unit 251 which extends in the circumferential direction U between a first and second end and between an inner cover surface lying on the inside in the radial direction R and an outer cover surface lying on the outside in the radial direction R. The lid assembly 251 further includes a first side wall 252 located at the first end and a second side wall 253 located at the second end. The first and second side walls 252, 253 extend essentially perpendicularly, starting from the outer surface of the lid. An intermediate wall 254 is arranged between the first and second side walls and extends essentially perpendicularly, starting from the outer surface of the lid.

The magnet cover 250 is formed in one piece. The magnet cover 250 is made of a fiber composite resin as a compression molding. It can be seen that the cover unit 251 has a wall thickness which is smaller than a wall thickness of the first and second side walls 252, 253 and smaller than a wall thickness of the intermediate wall 254. It can also be seen that the wall thickness of the first and/or second side wall 252, 253 is smaller than the wall thickness of the intermediate wall 254. To attach the magnet cover 250 to the rotor laminated core 220, the first and second side wall 252, 253 and the intermediate wall 254 have a fastening section. In the case of the magnet cover 250, a radial transition from the cover unit 251 to the first and second side walls 252, 253 and the intermediate wall 254 is provided. In particular, the radial transition from the inner surface of the cover to the first and second side walls 252, 253 and the intermediate wall 254 has a radius of 3 mm. Furthermore, the radial transition from the lid outer surface to the first and second side walls 252, 253 has a radius of 1 mm. Furthermore, the magnet cover 250 has a radial transition with a radius of 1 mm from the first and second side walls 252, 253 and the intermediate wall 254 to the respective fastening section. The magnet cover 250 extends in the radial direction over a height of 30 mm and in the circumferential direction U over a width of 90 mm.

The magnet cover 250 shown in FIG. 5 and also in FIG. 4 has fastening sections for connection to the at least one laminated rotor core 220 . The fastening sections have a circular cross section and enable a form-fitting connection to the at least one laminated rotor core 220 in the radial direction.

Furthermore, the fastening sections can also have a different cross-section and can, for example, be polygonal, somewhat rectangular and/or triangular. 5a and 5b show a further preferred embodiment of the magnet cover 250 as a sectional view (FIG. 5a) and in a plan view in the axial direction A (FIG. 5b). This further embodiment of the magnet cover 250 differs from the embodiment of the magnet cover 250 shown in Fig. 5 essentially only in that the magnet cover has a triangular and two rectangular fastening elements in cross section for connection to the at least one rotor laminated core 220. 6a, 6b and 6c show schematic isometric representations of a further preferred embodiment of a magnet cover 250 in a full view and in two different detailed views. It can be seen in FIG. 6a that the magnet cover 250 extends in the axial direction A between a first and second opening arrangement 250a, 250b. An insertion funnel unit 255 is arranged on the first opening arrangement 250a. The insertion funnel unit 255 facilitates the insertion of magnet units 230 into the magnet covers 250. For this purpose, the insertion funnel unit 255 is inclined relative to the first and second side walls 252, 253 and the cover unit 254, i.e. the funnel feed walls of the insertion funnel unit 255 are opposite the first and second side walls 252, 253 and the lid unit 254 are arranged inclined. It can be seen in particular in FIGS. 6b and 6c how the insertion funnel unit 255 defines a funnel opening cross section which decreases linearly in the axial direction in the direction of the first opening arrangement 250a; the funnel opening cross section thus tapers in the direction of the first opening arrangement. It can be preferred that the shaping device 300 has a feed device, as shown by way of example in the schematic isometric illustrations in FIGS. 7a and 7b. Such a feeding device 340 is designed to quickly and easily feed one or more magnet units 230 to the magnet cover 250 . For this purpose, the feed device 340 in the present case has a feed magazine 341 and an insertion aid device 342 . Magnet units 230 can be arranged in the feed magazine 341 and then fed between the magnet cover 250 and the laminated core of the rotor. The feeding of the magnet units 230 between the magnet cover 250 and the rotor lamination stack is facilitated by the insertion aid device 342 in that the insertion aid device 342 for feeding and inserting the magnet units 230 between the magnet cover 250 and the at least one rotor lamination stack engages with the insertion funnel unit 255 stands.

Such an engagement of the insertion aid device 342 with the insertion funnel unit 255 is shown in FIGS. 8 and 9a as well as 9b. FIG. 8 shows a schematic isometric full view of a magnet cover 250 arranged on a negative mold 310, as was described in detail with reference to FIGS. 6a-6c. It can be seen that the feed device 340 is arranged in the axial direction above the negative mold 310 and the magnet covers 250 arranged in the negative mold 310 . As a result, the feeding device 340 grips the insertion funnel unit 255. The feeding device 340 engaged with the insertion funnel unit 255 is shown in detail in FIGS. 9a and 9b.

FIG. 10 shows a schematic flowchart of a preferred method 1000 for producing a rotor segment 200 of a rotor 121 . The method 1000 first comprises providing 1010 a shaping device 300 as described above. Method 1000 further comprises providing 1020 at least one rotor lamination stack 220 which is designed to receive at least one magnet unit 230, wherein the providing 1020 the at least one rotor lamination stack 220 includes stacking and aligning rotor laminations to form at least one rotor lamination stack 220 in relation to a radially outer negative outer surface 311 of the shaping device 300 at a distance defined in a radial direction R from the shaping device 300 with an alignment device 330 of the shaping device 300.

FIG. 11 shows a schematic flow chart of a further preferred method 1000 for producing a rotor segment 200 of a rotor 121 . The method 1000 includes the following steps: Coating 1030 the radially outer negative outer surface of the molding device with a release agent and axially pre-clamping 1040 the at least one rotor lamination stack with one or more tie rods.

Method 1000 also includes fastening 1050, in particular pushing in, one or more magnet covers 250 to the at least one rotor core 220, in particular fastening the one or more magnet covers 250 to fastening connections 224 of a core inner surface 222 of the at least one rotor core 220.

Furthermore, the method 1000 includes arranging 1060, in particular pushing in, at least one magnet unit 230 between the at least one rotor laminated core 220 and the one or more magnet covers 250.

This is followed by a release 1070 of the pre-stressing of the at least one rotor lamination stack, a radial tapping 1080 of the released rotor lamination sheets of the at least one rotor lamination stack on the forming device and/or independent centering of the released rotor lamination sheets of the at least one rotor lamination sheet package as a result of the magnetic forces, and a final bracing 1090 of the at least one rotor laminated core with the one or more tie rods; and or

The method also includes aligning1100, in particular tapping, the at least one laminated rotor core 220, in particular the rotor laminations, to the forming device 300, in particular to the alignment device 330, to center the at least one laminated rotor core 220, in particular the at least a magnet unit 230.

The method then includes providing 1200 at least one magnet carrier segment 210, the magnet carrier segment 210 extending in a radial direction R between a radially outer magnet carrier outer surface 211 and a magnet carrier inner surface 212 which is radially inner in relation to the magnet carrier outer surface 211.

According to the execution of the method, the at least one magnet carrier segment 210 is arranged coaxially in relation to the rotor laminated core 220, in particular the magnet carrier segment 210 is slipped over the at least one rotor laminated core 220, so that between the at least one magnet carrier segment and to the at least one rotor lamination stack an annular air gap extends, with the at least one rotor lamination stack 220 being arranged coaxially to the magnet carrier segment 210 in relation to an axis of rotation of the rotor segment, with the at least one rotor lamination stack 220 preferably being in the radial direction R is arranged radially on the inside relative to the magnet carrier segment 210 and the laminated core outer surface 221 and the magnet carrier inner surface 212 are arranged spaced apart, facing one another.

Adhesive bonding 1400 of the at least one magnet unit 230 to the at least one laminated rotor core 220 and/or the one or more magnet covers 250 with a casting compound is then provided.

The method also includes arranging 1500, in particular foaming and/or casting, a connecting element 240 between the radially outer magnet carrier segment 210 and the at least one radially inner laminated rotor core 220, so that the connecting element 240 is connected to the at least one laminated rotor core 220 on the outer surface of the laminated core 221 and the magnet carrier segment 210 on the magnet carrier inner surface 212, with the connecting element 240 being designed in particular as a cast and/or foam part and/or the connecting element 240 being arranged preferably by a casting and/or foaming process , wherein the connecting element 240 preferably comprises plastic, in particular polyurethane, and/or is particularly preferably designed as a polyurethane foam part.

The casting compound and the connecting element are then cured 1600 .

Furthermore, the method 1000 includes a method 1700 of the soft magnetic elements 320 from an assembly position to a standby position to open the magnetic flux to see the removal of the molding device 300 from the manufactured rotor segment 200, wherein the soft magnetic elements 320 are not in the standby position are arranged on the negative inner surface 312, in particular are arranged at a distance from the negative inner surface 312 in the radial direction R.

Finally, the method includes demolding 1800 the manufactured rotor segment 200. REFERENCE LIST

100 wind turbine 102 tower 104 nacelle 106 aerodynamic rotor

108 rotor blade

109 Rotor blade roots

110 spinner 120 (electrical) generator 121 (electrodynamic) rotor 200 rotor segment 210 magnet carrier segment 211 magnet carrier outer surface 212 magnet carrier inner surface 213 first connecting projections

220 rotor lamination stack 221 lamination stack outer surface 222 lamination stack inner surface 223 second connection recesses 224 fastening connections

230 magnet unit

240 fastener

241 fastener outer surface

242 Fastener Inner Face 250 Magnet Cover

250a,b first and second port arrays

251 lid unit

252 first side panel

253 second side wall 254 intermediate wall

255 insertion funnel unit

300 molding device

310 negative mold

311 negative outer surface 312 negative inner surface

320 soft magnetic elements 330 Alignment Device

340 feeder

341 feed magazine

342 Insertion aid A axial direction

R radial direction

U circumferential direction

Claims

EXPECTATIONS

1 rotor segment (200) of a rotor (121) of a generator (1), in particular a segmented rotor (121) of a segmented generator (1), for a wind turbine (100), comprising a magnet carrier segment (210) with an annular or part-annular geometry, wherein the magnet carrier segment (210) extends in a radial direction (R) between a radially outer magnet carrier outer surface (211) and a magnet carrier inner surface (212) lying radially inward in relation to the magnet carrier outer surface, and at least one rotor laminated core (220) which is used for receiving at least one magnet unit (230) is formed, the at least one rotor laminated core (220) being located in the radial direction (R) between a radially outer laminated core surface (221) and a laminated core inner surface (221) located radially inward in relation to the laminated core outer surface ( 222) extends, characterized in that between the magnet carrier segment (210) and the at least one rotor Ble ch package (220) a connecting element (240) is arranged, which is designed as a cast and/or foam part and with the at least one rotor laminated core (220) on the laminated core outer surface (221) and the magnet carrier segment (210) on the Magnet carrier inner surface (212) is connected.

2 rotor segment (200) according to the preceding claim 1, wherein the connecting element (240) plastic, in particular polyurethane, comprises and / or is particularly preferably designed as a polyurethane foam part and / or polyurethane cast part. 3 rotor segment according to any one of the preceding claims, wherein the connecting element (240) materially, in particular adhesively, and / or positively connected to the magnet carrier inner surface (212) and / or the laminated core outer surface (221).

4. Rotor segment according to one of the preceding claims, wherein the magnet carrier segment (210) on the magnet carrier inner surface (212) has a first connecting device (213), comprising one or more first connecting projections and/or one or more first connecting depressions, for the positive connection of the connecting element (240) to the magnet carrier segment (210); and/or the at least one rotor laminated core (220) has a second connecting device (223) on the outer surface (221) of the laminated core, having one or more second connecting projections and/or one or more second connecting recesses, for the positive connection of the connecting element (240 ) with the at least one rotor laminated core (220); and/or - the connecting element (240) extends in the radial direction (R) between a radially outer connecting element outer surface (241) and a connecting element inner surface (242) lying radially inward in relation to the connecting element outer surface (241), and wherein preferably o on the connecting element outer surface ( 241) has a first connecting device (213), having one or more first connecting projections (213) and/or one or more first connecting depressions, for the positive connection of the connecting element to the magnet carrier segment (210), and/or o on the connecting element inner surface ( 242) has a second connecting device (223), having one or more second connecting projections and/or one or more second connecting recesses (223), for the positive connection of the connecting element (240) to the at least one rotor laminated core (220). 5. rotor segment (200) according to any one of the preceding claims, wherein the connecting element (240) has a greater damping than the magnet carrier segment (210) and / or the at least one rotor laminated core (220).

6. Rotor segment according to one of the preceding claims, comprising at least one magnet unit (230) which is attached to the at least one rotor laminated core (220), in particular to the inner surface of the laminated core

(222) is located; and/or comprising at least one magnet cover (250) for covering the at least one magnet unit (230); and/or wherein the rotor laminated core (220) has fastening connections (224) on the laminated core inner surface (222) for fastening the at least one Rotor laminated core (220) with one or more magnet covers (250), in particular a magnet cover (250) according to any one of claims 7-9, are formed, in particular for non-positive and / or positive attachment, wherein preferably the at least one magnet unit ( 230) between the rotor laminated core (220) and the magnet cover (250) is arranged.

7. Magnet cover (250) for covering at least one magnet unit (230) of a rotor segment (200), having a cover unit (251) which extends in the circumferential direction between a first and second end and between a cover inner surface lying on the inside in the radial direction and an in radially outward lid outer surface, a first sidewall (252) located at the first end and a second sidewall (253) located at the second end, the first and second sidewalls (252, 253) extending from extending angularly from the outer surface of the lid, characterized in that an intermediate wall (254) is disposed between the first and second side walls (252, 253) and extends angularly from the outer surface of the lid. 8. Magnet cover (250) according to the preceding claim 7, wherein the magnet cover (250) extends in the axial direction (A) between a first and second opening arrangement (250a, 250b) and at one of the two opening arrangements (250a, 250b) an insertion funnel unit ( 255) for introducing magnet units, and/or - the cover unit (251) has a wall thickness which is less than one

wall thickness of the first and/or second side wall (252, 253) and/or is smaller than a wall thickness of the intermediate wall (254); and/or the wall thickness of the first and/or second side wall (252, 253) is smaller than the wall thickness of the intermediate wall (254); and/or - the first and/or second side wall (252, 253) and/or the intermediate wall

(254) each have a fastening section for fastening the magnet cover (250) to a rotor laminated core (220).

9. magnet cover (250) according to any one of the preceding claims 7 or 8, wherein the magnet cover is formed in one piece; and/or is made of plastic, in particular made of a fiber composite plastic, or comprises it; and/or is designed as a compression molded part and/or an injection molded part. 10. Molding device (300) for producing a rotor segment (200) according to one of the preceding claims 1-6, comprising a ring-shaped or partially ring-shaped negative mold (310) which extends in a radial direction (R) between a radially outer negative outer surface (311) and a negative inner surface (312) which is on the inside in relation to the radially outer negative outer surface, characterized in that the negative mold (310) comprises a non-magnetic material or essentially consists of a non-magnetic material; and the forming device (300) has soft magnetic elements (320) on the negative inner surface (312) for closing the magnetic flux to

Production of the rotor segment (200) can be arranged.

11. Forming device (300) according to the preceding claim, comprising an alignment device (330) for stacking and aligning the individual rotor laminations of the at least one rotor lamination stack (220) at a distance defined in the radial direction from the forming device (300); and/or a feed device (340), which is designed to feed one or more magnet units (230) to the magnet cover (250), the feed device (340) in particular having: o at least one feed magazine (341) and/or o an insertion aid device (342 ) designed to be in engagement with the insertion funnel unit (255) for feeding and inserting the magnet units (230) between the magnet cover (250) and the at least one rotor laminated core. 12. Molding device (300) according to either of the preceding claims 10-11, wherein the soft-magnetic elements (320) can be moved back and forth radially in the radial direction (R) between a mounting position and a standby position, the soft-magnetic elements ( 320) in the mounting position on the negative inner surface (312) to close the magnetic flux to produce the rotor segment (200) and in the standby position for opening the magnetic flux to remove the molding device (300) from the manufactured rotor segment (200), the soft magnetic elements (320) are not arranged on the negative inner surface (312), in particular in the Radial direction (R) spaced from the negative inner surface (312) are arranged.

13. Rotor (121) of a generator (120), in particular segmented rotor (121) of a segmented generator (120), for a wind turbine (100), comprising a rotor segment (200) according to any one of the preceding claims 1-6 and / or rotor segment (200) manufactured with the molding device (300) according to any one of the preceding claims 10-12.

14. Generator (120), in particular segmented generator (120), for a Wndener- gieanlage (100), comprising a rotor (121) according to the preceding claim.

15. Wndenergieanlage (100) comprising a generator (120) according to the preceding claim.

16. Method (1000) for producing a rotor segment (200) of a rotor (106) of a generator (1), in particular a segmented rotor (106) of a segmented generator (1), for a Wndenergieanlage (100), preferably for producing a rotor segment according to one of the preceding claims 1-6, characterized by the steps:

providing a molding apparatus (300) according to any one of the preceding claims 10-12, and

Providing at least one rotor laminated core (220) which is designed to accommodate at least one magnet unit (330), the at least one rotor laminated core (220) being located in the radial direction (R) between a radially outer laminated core outer surface (221) and a laminated core inner surface (222) that is radially inward in relation to the laminated core outer surface (221), wherein the provision of the at least one rotor laminated core (220) involves stacking and aligning rotor laminations to form at least one rotor laminated core (220 ) in relation to a radially outer negative outer surface (311) of the molding device (300) at a distance defined in a radial direction from the molding device (300), in particular by means of an alignment device (330) of the molding device (300). 17. Method (1000) according to the preceding claim, comprising the steps of:

smearing the radially outer negative outer surface (311) of the mold assembly (300) with a release agent; and/or axial pre-tensioning of the at least one rotor laminated core with one or more tie rods; and or

Fastening, in particular pushing in, one or more magnet covers (250) on the at least one rotor laminated core (220), in particular fastening the one or more magnet covers (250) on fastening connections (224) of a laminated core inner surface (222) of the at least one rotor laminated core (220); and or

Arranging, in particular pushing in, at least one magnet unit (230) between the at least one rotor laminated core (220) and the one or more magnet covers (250); and/or releasing the pre-tensioning of the at least one rotor lamination stack; and/or the radial tapping of the loosened rotor laminations of the at least one rotor lamination stack on the shaping device and/or independent centering of the loosened rotor laminations of the at least one rotor lamination stack as a result of the magnetic forces; and/or - final bracing of the at least one rotor laminated core with the one or more tie rods; and or

Alignment, in particular tapping, of the at least one laminated rotor core (220), in particular the rotor laminations, on the shaping device (300), in particular on the alignment device (330), for centering the at least one laminated rotor core (220) , in particular the at least one

magnet unit (230); and or

Providing at least one magnet carrier segment (210), the magnet carrier segment (10) extending in a radial direction (R) between a radially outer magnet carrier outer surface (211) and a magnet carrier inner surface (212) lying radially inward in relation to the magnet carrier outer surface (211); and/or arranging the at least one magnet carrier segment (210) coaxially in relation to the rotor laminated core (220), in particular slipping the magnet carrier segment (210) over the at least one rotor laminated core (220), preferably in a vertical direction that extends between the at least one magnet support segment and the at least one rotor laminated core, an annular air gap, in particular the at least one The rotor lamination stack (220) is arranged coaxially with the magnet carrier segment (210) in relation to an axis of rotation of the rotor segment, with the at least one rotor lamination stack (220) preferably being radial in the radial direction (R) relative to the magnet carrier segment (210). is arranged on the inside and the laminated core outer surface (221) and the magnet carrier inner surface (212) are arranged facing each other spaced; and/or gluing the at least one magnet unit (230) to the at least one rotor laminated core (220) and/or the one or more magnet covers (250) with a casting compound; and/or - arranging, in particular foaming and/or casting, preferably in a vertical direction from bottom to top, in particular against the force of gravity, of a connecting element (240) between the radially outer magnet carrier segment (210) and the at least one radially inner rotor lamination stack (220), so that the connecting element (240) is connected to the at least one rotor laminated core (220) on the outer surface (221) of the laminated core and the magnet carrier segment (210) on the magnet carrier inner surface (212), the connecting element (240 ) is designed in particular as a cast and/or foam part and/or the connecting element (240) is preferably arranged by a casting and/or foaming process, with the connecting element (240) preferably

Plastic, in particular polyurethane, comprises and/or is particularly preferably designed as a polyurethane foam part and/or polyurethane cast part; and or

curing of the potting compound and/or the connecting element; and/or - moving the soft magnetic elements (320) from an assembly position to a standby position, in particular in the radial direction, to open the magnetic flux to remove the molding device (300) from the manufactured rotor segment (200), the soft magnetic elements (320) are not arranged on the negative inner surface (312) in the standby position, in particular are arranged spaced apart from the negative inner surface (312) in the radial direction (R); and/or demolding the manufactured rotor segment.