WO2023274635A1 - Rotor doté d'une ouverture de remplissage comprenant un guide - Google Patents

Rotor doté d'une ouverture de remplissage comprenant un guide Download PDF

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Publication number
WO2023274635A1
WO2023274635A1 PCT/EP2022/063987 EP2022063987W WO2023274635A1 WO 2023274635 A1 WO2023274635 A1 WO 2023274635A1 EP 2022063987 W EP2022063987 W EP 2022063987W WO 2023274635 A1 WO2023274635 A1 WO 2023274635A1
Authority
WO
WIPO (PCT)
Prior art keywords
rotor
laminated core
magnet
guide
end plate
Prior art date
Application number
PCT/EP2022/063987
Other languages
German (de)
English (en)
Inventor
Markus Rubi
Alexander Schlereth
Kay Lemmert
Sebastian Dieterich
Stephan Hellmuth
Robert Werner
Robin Büsch
Christoph Wieczorek
Original Assignee
Valeo Eautomotive Germany Gmbh
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Valeo Eautomotive Germany Gmbh filed Critical Valeo Eautomotive Germany Gmbh
Publication of WO2023274635A1 publication Critical patent/WO2023274635A1/fr

Links

Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/22—Rotating parts of the magnetic circuit
    • H02K1/27—Rotor cores with permanent magnets
    • H02K1/2706—Inner rotors
    • H02K1/272—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis
    • H02K1/274—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis the rotor consisting of two or more circumferentially positioned magnets
    • H02K1/2753—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis the rotor consisting of two or more circumferentially positioned magnets the rotor consisting of magnets or groups of magnets arranged with alternating polarity
    • H02K1/276—Magnets embedded in the magnetic core, e.g. interior permanent magnets [IPM]
    • H02K1/2766—Magnets embedded in the magnetic core, e.g. interior permanent magnets [IPM] having a flux concentration effect
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/02—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
    • H02K15/03—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies having permanent magnets

Definitions

  • the invention relates to a rotor for an electric machine, an electric machine with a rotor, a vehicle with an electric machine and a method for producing a rotor.
  • Such a rotor has a laminated core formed from stacked electrical laminations (rotor core) with magnetic pockets arranged therein. Furthermore, the rotor has several magnets, at least one of which is inserted into each of the magnet pockets.
  • Electric machines with such a rotor are increasingly being used in electrically powered vehicles and hybrid vehicles, primarily as electric motors for driving a wheel or an axle of such a vehicle.
  • Such an electric motor is usually mechanically coupled to a gear for speed adjustment.
  • the electric motor is usually electrically coupled to an inverter, which converts a DC voltage supplied by a battery into an AC voltage for the operation of the
  • Electric motor generates, for example, a multi-phase AC voltage.
  • Compressive force or bias can be realized.
  • the compressive force can applied to the core using two end plates located on the axial sides of the core.
  • the magnets maintain their position in the magnet pockets, especially at high speeds.
  • the casting compound is introduced into the laminated core through filling openings, which are arranged in one of the end plates.
  • the invention is therefore based on the object of specifying a rotor for an electrical machine with a laminated core whose electrical laminations and magnets can be securely fastened without casting compound undesirably accumulating on an axial side of the laminated core.
  • the invention provides for a rotor of the type mentioned at the outset to have a plurality of free spaces, each of which is delimited by the magnets inserted in one of the magnet pockets and the laminated core. Furthermore, the rotor has a first end plate, which is arranged on an axial side of the laminated core and has a filling opening, through which one of the free spaces is uncovered. A guide for introducing a casting compound into the free space is formed in the filling opening. Furthermore, one at the opposite axial side of the laminated core arranged a second end plate.
  • a compressive force can be applied to the axial sides of the lamination stack, so that the electrical laminations of the lamination stack are securely fastened.
  • a casting compound can be introduced into the free space through the filling opening in the first end plate, with which the magnets are cast in the magnetic pocket encompassing the free space.
  • the guide ensures that the casting compound reaches the free space completely, without part of the casting compound undesirably accumulating on the axial side of the laminated core. After the casting compound has hardened, the magnets are securely fastened in the magnet pocket.
  • the casting compound when the casting compound is introduced into the free space, the casting compound flows along the guide axially into the interior of the laminated core.
  • the guide prevents the casting compound from running undesirably on the surface of the laminated core. The guide thus increases process reliability when casting the magnets.
  • the end plate can have a plurality of such filling openings with a guide, which are distributed along the circumference of the first end plate and through each of which one of the free spaces formed in the laminated core is uncovered.
  • the laminated core can be formed from the electrical laminations by these being welded, glued, stamped or fastened to one another in some other way.
  • the laminated core can have a cylindrical shape.
  • each electrical lamination can have a central opening which, in the assembled state, forms an axial borehole in the laminated core through which a rotor shaft of the rotor can pass can lead.
  • the axis of the rotor shaft or the rotor corresponds to the axial axis of the laminated core.
  • the laminated core can be composed of a plurality of laminated core segments, each of which has a plurality of electrical laminations.
  • one or more of the laminated core segments can be rotated relative to one or more of the other laminated core segments.
  • the rotational behavior of the rotor can be improved.
  • end plates can also be arranged on the axial sides of the laminated core.
  • the electrical machine can have a stator relative to which the rotor can rotate.
  • the stator can have a further laminated core (stator core), which is formed from stacked electrical laminations.
  • stator can have windings of electrical conductors, for example as coil windings or flat wire windings.
  • the magnet pockets can be distributed along the circumference of the laminated core, for example at equal distances from one another.
  • the magnetic pockets and the magnets arranged in them can each have different sizes.
  • the magnets arranged in one of the magnet pockets are lined up axially, for example. As a result, the magnets can simply be inserted or pushed into the magnet pocket one after the other when assembling the rotor.
  • the magnets lined up axially are referred to as "magnet stacks".
  • the rotor can have several such magnet stacks, each of which is arranged in a magnet pocket.
  • only a single magnet can be arranged in one or more magnet pockets instead of a plurality of magnets.
  • the guide seals the fill port from a gap created between one of the magnets located in the magnetic pocket comprising the first free space is inserted, and the first end plate is formed. This prevents the casting compound from penetrating into the intermediate space from which the casting compound could be distributed on the laminated core.
  • the gap can be formed, for example, with a depression opposite the magnet on the inside of the first end plate, or by the magnet not quite reaching the axial side of the laminated core because it sits a little too deep in the laminated core due to manufacturing tolerances.
  • the guide has a projection that protrudes axially into the free space. With the projection, the potting compound is guided into a deeper area of the free space, so that the potting compound reaches the free space in a particularly safe and controlled manner.
  • the projection extends from one side surface of the free space to an opposite side surface of the free space.
  • the projection is thus designed to be particularly wide, which prevents the sealing compound from penetrating between the two side faces onto the laminated core.
  • the projection rests against a side surface of the magnet that delimits the free space. This avoids that the potting compound between the projection and the
  • a side face of the guide facing the magnet is spaced axially from the magnet. This avoids an axial pressure of the first end plate via the guide on the magnet, which could lead to damage to the magnet.
  • another of the free spaces is exposed through the filling opening and the guide is designed for introducing the casting compound into the further free space. When casting compound is simultaneously introduced into both free spaces through the filling opening, this ensures that the casting compound reaches the free spaces completely without part of the casting compound undesirably accumulating on the axial side of the laminated core.
  • the guide can seal the filling opening from a further gap formed between a second one of the magnets, which is inserted into the magnet pocket comprising the further gap, and the first end plate. Furthermore, the guide can have a further projection which protrudes axially into the further free space. The additional projection can extend from a side surface of the additional free space to an opposite side surface of the additional free space. Furthermore, the additional projection can delimit the additional free space
  • the guide is arranged on the radially outer side of the filling opening.
  • the guide can be arranged differently, for example on the radially inner side of the filling opening.
  • the first end plate is integral with the guide. This reduces the number of components and separate assembly of the guide is no longer necessary.
  • the first end plate and the second end plate can be connected to each other using clamping members.
  • the laminated core is permanently subjected to a pretensioning force by the tensioning elements. The electrical steel sheets are thereby pressed together and an unwanted loosening of the electrical steel sheets is avoided even at high speeds.
  • the clamping elements are preferably designed as screws, which can each be secured with a nut on the laminated core.
  • the screws are supported with their screw heads on one of the end plates.
  • the clamping elements can also be designed as threaded rods which are screwed to both sides with nuts. The clamping elements are tensioned by tightening the nuts, so that a specific pretensioning force is exerted on the laminated core, which prevents the stacked electrical laminations of the laminated core from becoming detached from one another.
  • the laminated core can also be braced without screwing.
  • the magnets are cast with a casting compound introduced into the free spaces.
  • a casting compound introduced into the free spaces.
  • the casting compound can be, inter alia, an epoxy resin, a mixture of an epoxy resin and a hardener, or an adhesive.
  • the invention relates to an electrical machine with a rotor of the type described.
  • the electrical machine can have a stator relative to which the rotor can be rotated.
  • the stator can have a further laminated core formed from stacked electrical laminations.
  • the stator may have windings of electrical conductors, for example as
  • the machine with be equipped with a housing in which the rotor and the stator are accommodated, it being possible for the rotor shaft to protrude from the housing.
  • the invention relates to a vehicle with such an electric machine, which is provided for driving the vehicle.
  • the machine can drive a wheel or an axle of the vehicle.
  • the invention relates to a method for producing a rotor for an electrical machine, with the following steps: forming a laminated core, in which magnet pockets are arranged, from stacked electrical laminations,
  • Free spaces is uncovered, on an axial side of the laminated core, wherein a guide for introducing a casting compound into the free space is formed in the filling opening,
  • part of the casting compound can be introduced into the laminated core through the filling opening along the guide.
  • the casting is carried out with a nozzle of a metering device under overpressure.
  • the duration of the procedure can be shortened.
  • the nozzle is placed on the filling opening.
  • the nozzle can be placed on the outside of the laminated core.
  • the nozzle is placed on the guide.
  • the nozzle can be inserted precisely into the filling opening.
  • the nozzle is placed on the laminated core.
  • the nozzle can be inserted with a precise fit into a passage opening formed between the filling opening and the guide.
  • FIG. 1 is a perspective view of a rotor according to the invention
  • FIG. 2 is a perspective view of a laminated core and a rotor shaft of the rotor
  • FIG. 3 shows a section of the laminated core
  • FIG. 4 shows a section of a first end plate of the rotor
  • Fig. 5 is a sectional view of a portion of the rotor
  • FIG. 6 shows a vehicle with an electric machine with the rotor.
  • FIG. 1 shows a perspective view of a rotor 1 according to the invention, which belongs to an electrical machine which is provided for driving a vehicle.
  • the rotor 1 has a rotor shaft 4 , a laminated core 2 , a first end plate 9 and a second end plate 10 .
  • the laminated core 2 encloses the rotor shaft 4 and is composed of axially stacked electrical laminations, which are identical trained stamped parts.
  • the laminated core 2 can have a plurality of laminated core segments, one of the laminated core segments being rotated somewhat in the circumferential direction relative to another of the laminated core segments.
  • the end plates 9, 10 are arranged on opposite axial sides of the laminated core 2 and connected to one another using clamping elements. As a result, the laminated core 2 is permanently subjected to a compressive force or prestressing force. This prevents the electrical steel sheets from becoming detached from one another, particularly at high speeds of the rotor 1.
  • the clamping elements are designed as screws 11 .
  • Each of the eight screws 11 runs axially through the first end plate 9, the laminated core 2 and the second end plate 10.
  • the end plates 9, 10 and the laminated core 2 are each provided with axial bores.
  • the heads of the screws 11 are arranged on the first end plate 9 and on the second end plate 10 the screws 11 are screwed with nuts (not visible).
  • FIG. 2 shows a perspective view of the laminated core 2 and the rotor shaft 4 of the rotor 1 and FIG. 3 shows a section of the laminated core in the axial direction.
  • a plurality of magnet pockets 3, 5 are arranged in the laminated core 2 along its circumference, each of which extends from the shown axial side of the laminated core 2 to its opposite axial side.
  • a magnet pocket 3, 5 several cuboid magnets 6, 7 are lined up, forming a magnet stack.
  • a total of thirty-two such magnet pockets 3, 5 or magnet stacks are accommodated in the laminated core, with a different number of magnet pockets or magnet stacks also being able to be used.
  • the magnetic pockets 3, 5 are of different sizes. In particular, between larger magnetic pockets 3 with longer axial openings and smaller
  • Magnetic pockets 5 are distinguished with shorter axial openings.
  • larger magnet pockets 3 are larger magnets 6 with longer axial End faces lined up axially, while in the smaller magnet pockets 5 smaller magnets 7 with shorter axial end faces are lined up axially.
  • Two adjacent larger magnet pockets 3 are arranged symmetrically to each other with respect to a radial axis (not shown) of the laminated core 2, forming a V-shape.
  • two adjacent smaller magnet pockets 5 are arranged symmetrically to each other with respect to the radial axis, also forming a V-shape.
  • a different arrangement of the magnetic pockets can also be used.
  • each magnetic pocket 3, 5 has a free space 8 formed on one side surface of the magnetic pocket 3, 5 and a free space 8 formed on the opposite side surface of the magnetic pocket 3, 5, which are separated from one another by a magnet stack.
  • the free spaces 8 run parallel to one another from the axial side shown to the opposite axial side of the laminated core 2.
  • the 4 shows a section of the first end plate 9 in the axial direction.
  • the first end plate 9 has a filling opening 12 through which two of the free spaces 8 are exposed.
  • the two free spaces 8 each belong to a different magnet pocket 3.
  • the filling opening 12 has two approximately parallel sides which are connected to one another by two circle segments. As an alternative to this, the filling opening can also have a different shape.
  • a guide 20 is formed in the filling opening 12 and axially covers a region of the laminated core 2 and the two free spaces 8 .
  • the guide 20 has a V-shaped cutout through which another area of the laminated core 2 and the two free spaces 8 is exposed.
  • a through opening is thus formed, which is delimited radially on the inside by the filling opening 12 and radially on the outside by the guide 20 .
  • FIG. 5 is a sectional view of an area of the rotor along line VV in FIG.
  • the projection 15 seals the filling opening 12 from a first intermediate space 19 which is formed between a magnet 6 arranged on the first end plate 9 and the end plate 9 .
  • the projection 15 thus seals the filling opening 12 radially outwards. This prevents the potting compound introduced into the filling opening 12 from reaching the end face of the magnet 6 facing the end plate 9 or other points on the axial side of the laminated core 2 .
  • the gap 19 is formed as a depression of the inside of the first end plate 9, which serves to avoid pressure of the end plate 9 on the magnet 6, which could damage the magnet 6.
  • an intermediate space can also be formed in that the magnet does not quite reach the axial side of the laminated core due to manufacturing tolerances.
  • a special feature of the intermediate space 19 shown here is that it extends up to a ventilation opening which is arranged radially on the first end plate 9 and is used for venting the laminated core 2 when the casting compound is introduced.
  • the projection 15 extends from a side face of the free space 8 to an opposite side face of the free space 8 . Furthermore, the projection 15 bears against a side face of the magnet 6 that delimits the free space 8 .
  • a side face of the guide 20 facing the magnet 6 is spaced axially from the magnet 6 , in particular from its end face facing the first end plate 9 .
  • a method according to the invention for producing the rotor 1 is described below. The following process steps are carried out in the process:
  • the laminated core 2, in which the magnetic pockets 3, 5 are arranged is assembled from stacked electrical laminations.
  • Magnet stack remain two free spaces 8, which are each limited by the magnet stack and the laminated core 2.
  • the first end plate 9 is arranged on an axial side of the laminated core 2 .
  • the first end plate 9 has several
  • Filling openings 12 is uncovered by one of the spaces 8 in each case.
  • a guide 20 for introducing casting compound into the associated free space 8 is formed in each filling opening 12 .
  • the second end plate 10 is arranged on the opposite axial side of the laminated core 2 .
  • the two end plates 9, 10 are braced with the screws 11 and the associated nuts.
  • the rotor 1 thus completed is oriented vertically with the first end plate 9 facing upwards.
  • the magnets 6, 7 are cast with a casting compound, in that the free spaces 8 are filled with the casting compound.
  • the casting compound is introduced into the free spaces 8 through the filling openings 12 along the guides 20 .
  • the nozzle 16 of a metering device is placed on the laminated core 2 through a filling opening 12 (compare FIG. 5).
  • the shape of the nozzle corresponds to the shape of the passage opening remaining between the filling opening 12 and the guide 20 .
  • the nozzle 20 comprises a hollow cylinder with a hollow channel 17 and has an enlarged one at its free end
  • the nozzle can be placed on the filling opening on the outside of the first end plate. In a further alternative, the nozzle is placed on the guide through the filling opening.
  • a casting compound is then pressed with the nozzle under overpressure into the associated free space 8 .
  • magnets 6 are encapsulated in the magnet pocket 3 which encompasses the free space 8 .
  • the casting compound first flows through the free space 8 axially downwards to the second end plate 10.
  • the casting compound then flows through a connecting channel to another free space 8 on the opposite side of the magnet pocket 3.
  • the casting compound then flows through the other free space 8 axially up to the axial side of the laminated core 2.
  • Air present in the magnet pocket 3 can escape through a ventilation opening in the first end plate 9 and be replaced with the casting compound.
  • the machine 22 has a housing 23 in which the rotor 1 and a stator 24 surrounding the rotor 1 are accommodated.

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

Abstract

L'invention se rapporte à un rotor (1) destiné à une machine électrique (22), comprenant un noyau feuilleté cylindrique (2), constitué de feuilles électriques empilées et comprenant des poches d'aimant (3, 5) disposées en son sein ; de multiples aimants (6, 7), dont au moins un est inséré dans chaque poche d'aimant (3, 5) ; de multiples zones libres (8), dont chacune est délimitée par les aimants (6, 7) insérés dans l'une des poches d'aimant (3, 5) et le noyau feuilleté (2) ; une première plaque d'extrémité (9) disposée sur une face axiale du noyau feuilleté (2) et comprenant une ouverture de remplissage (12) au moyen de laquelle une première zone libre des zones libres (8) est exposée ; un guide (20) formé dans l'ouverture de remplissage (12) permettant d'introduire un composé d'enrobage dans la première zone libre (8) ; et une deuxième plaque d'extrémité (10) disposée sur la face axiale opposée du noyau feuilleté (2).
PCT/EP2022/063987 2021-06-30 2022-05-24 Rotor doté d'une ouverture de remplissage comprenant un guide WO2023274635A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102021206836.7A DE102021206836A1 (de) 2021-06-30 2021-06-30 Rotor mit einer Einfüllöffnung mit einer Führung
DE102021206836.7 2021-06-30

Publications (1)

Publication Number Publication Date
WO2023274635A1 true WO2023274635A1 (fr) 2023-01-05

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Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/EP2022/063987 WO2023274635A1 (fr) 2021-06-30 2022-05-24 Rotor doté d'une ouverture de remplissage comprenant un guide

Country Status (2)

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DE (1) DE102021206836A1 (fr)
WO (1) WO2023274635A1 (fr)

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102008027758A1 (de) * 2008-06-11 2009-12-17 Siemens Aktiengesellschaft Rotor für eine permanentmagneterregte dynamoelektrische Maschine
WO2019034331A1 (fr) * 2017-08-17 2019-02-21 Continental Automotive Gmbh Rotor pour moteur électrique, en particulier d'un véhicule automobile, et procédé de fabrication dudit rotor
WO2020196768A1 (fr) * 2019-03-28 2020-10-01 アイシン精機株式会社 Procédé de fabrication d'un noyau de moteur

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP6082687B2 (ja) 2013-11-21 2017-02-15 本田技研工業株式会社 ロータの製造方法及び端面板
DE102018009844A1 (de) 2018-12-14 2019-06-27 Daimler Ag Verfahren zum Herstellen einer Blechpaketeinheit für eine elektrische Maschine, insbesondere eines Kraftfahrzeugs

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102008027758A1 (de) * 2008-06-11 2009-12-17 Siemens Aktiengesellschaft Rotor für eine permanentmagneterregte dynamoelektrische Maschine
WO2019034331A1 (fr) * 2017-08-17 2019-02-21 Continental Automotive Gmbh Rotor pour moteur électrique, en particulier d'un véhicule automobile, et procédé de fabrication dudit rotor
WO2020196768A1 (fr) * 2019-03-28 2020-10-01 アイシン精機株式会社 Procédé de fabrication d'un noyau de moteur
EP3952075A1 (fr) * 2019-03-28 2022-02-09 Aisin Corporation Procédé de fabrication d'un noyau de moteur

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