WO2024256301A1 - Groupe rotor pour moteur électrique - Google Patents

Groupe rotor pour moteur électrique Download PDF

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Publication number
WO2024256301A1
WO2024256301A1 PCT/EP2024/065848 EP2024065848W WO2024256301A1 WO 2024256301 A1 WO2024256301 A1 WO 2024256301A1 EP 2024065848 W EP2024065848 W EP 2024065848W WO 2024256301 A1 WO2024256301 A1 WO 2024256301A1
Authority
WO
WIPO (PCT)
Prior art keywords
rotor
magnets
holding
package
packs
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
PCT/EP2024/065848
Other languages
German (de)
English (en)
Inventor
Marco GRIMM
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Brose Fahrzeugteile SE and Co KG
Original Assignee
Brose Fahrzeugteile SE and Co KG
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 Brose Fahrzeugteile SE and Co KG filed Critical Brose Fahrzeugteile SE and Co KG
Publication of WO2024256301A1 publication Critical patent/WO2024256301A1/fr
Anticipated expiration legal-status Critical
Pending legal-status Critical Current

Links

Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/22—Rotating parts of the magnetic circuit
    • H02K1/27—Rotor cores with permanent magnets
    • H02K1/2706—Inner rotors
    • H02K1/272—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis
    • H02K1/274—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis the rotor consisting of two or more circumferentially positioned magnets
    • H02K1/2753—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis the rotor consisting of two or more circumferentially positioned magnets the rotor consisting of magnets or groups of magnets arranged with alternating polarity
    • H02K1/278—Surface mounted magnets; Inset magnets
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/02—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
    • H02K15/03—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies having permanent magnets
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K29/00—Motors or generators having non-mechanical commutating devices, e.g. discharge tubes or semiconductor devices
    • H02K29/03—Motors or generators having non-mechanical commutating devices, e.g. discharge tubes or semiconductor devices with a magnetic circuit specially adapted for avoiding torque ripples or self-starting problems
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K2201/00—Specific aspects not provided for in the other groups of this subclass relating to the magnetic circuits
    • H02K2201/06—Magnetic cores, or permanent magnets characterised by their skew

Definitions

  • the invention relates to a rotor assembly for an electric motor, having a rotor shaft directed along an axial direction and at least two rotor packages which are arranged coaxially and offset from one another along the rotor shaft.
  • the invention further relates to a method for producing a rotor assembly and an electric motor with such a rotor assembly.
  • motor vehicles typically have a power steering system, which reduces the steering force required to operate a steering wheel when steering at a standstill or at low vehicle speeds.
  • the power steering system assists a motor vehicle user when steering by supporting the steering force applied by the vehicle user, for example with a hydraulic system or with an electric motor.
  • an electric motor arranged on the steering wheel mechanism supports and superimposes the steering movements of the vehicle user with a generated auxiliary force.
  • So-called brushless electric motors brushless direct current motors, BLDC motors
  • BLDC motors brushless direct current motors
  • Such a brushless electric motor as an electric three-phase machine basically has a fixed (stationary) stator with an electric rotating field winding, which is energized with a multi-phase three-phase current.
  • the Phases of the generated three-phase current and the associated rotating field are referred to as (motor) phases.
  • this also includes the stator coils (phase winding) assigned to each such phase with the associated connecting lines (phase end).
  • the phases are connected to one another in a star point of a star connection, for example.
  • the stator or its rotating field winding has three phases and thus at least three phase conductors or phase windings, each of which is supplied with an electric current in a phase-shifted manner in order to generate a rotating magnetic field in which a rotor, usually provided with permanent magnets and also referred to as a rotor, rotates about its axis.
  • the rotor generally has a particularly cylindrical, punched (rotor) laminated core as the central rotor core.
  • the rotor core is, for example, firmly joined to a rotor or motor shaft of the electric motor.
  • a surface permanent magnet rotor also known as an SPM rotor
  • the rotor magnets are attached or held to an outer circumference of a lateral surface of the rotor core.
  • the permanent magnets are joined to the lateral surface in a material-bonded manner, in particular by means of an adhesive or epoxy. Holding devices for fastening and/or holding the permanent magnets to the lateral surface without a material bond are also conceivable.
  • the rotor is arranged, for example, in a toothed stator with a number of radially directed stator teeth and stator slots.
  • the rotating field winding is applied in particular to the stator teeth.
  • rotors are used, particularly in the case of long active part lengths, in which the rotor magnets are arranged offset to one another along the axial direction or the rotor shaft.
  • rotor magnets arranged axially one above the other or stacked are arranged offset to one another in the tangential direction (circumferential direction/azimuthal direction).
  • Such a cogging or offset arrangement of the rotor magnets has a beneficial effect on reducing the cogging torque and thus on reducing torque ripple of the electric motor.
  • This subsequently has a beneficial effect on reducing the running noise when the electric motor is in operation. In other words, noise development is reduced, which in turn improves the acoustic properties of the rotor and the electric motor, which is particularly desirable in applications close to a vehicle interior.
  • a so-called discrete setting is possible, for example, in which a number of (individual) rotor packages equipped with rotor magnets are arranged coaxially to one another along the rotor shaft and set to one another or against one another.
  • the rotor packages are each stacked with a tangential angular offset along the axial direction.
  • the rotor packages equipped with rotor magnets are offset or rotated relative to one another in the tangential direction by a setting angle.
  • a tangential setting angle is realized from rotor package to rotor package along the axial direction or rotor shaft.
  • the angle of inclination is generated mechanically, for example, during the shaft-tight joining of the rotor packages.
  • the angle of inclination generated is subject to a variety of assembly influences, such as grippers, belts, mechanics or measurement inaccuracies, which often leads to assembly inaccuracies, which lead to deviations in the desired angle of inclination between the rotor packs.
  • This disadvantageously increases the cogging torque of the rotor or the electric motor, which results in greater noise during operation.
  • intermediate element intermediate ring
  • This intermediate element is also intended to be used to adjust the twist or offset angle between the rotor packs in a form-fitting manner.
  • SPM rotor assemblies with such intermediate elements are known, for example, from DE 10 2017 223 622 A1 and EP 4 084 296 A1.
  • the invention is based on the object of specifying a particularly suitable rotor assembly of an electric motor.
  • a discretely offset rotor assembly with an improved magnetic flux between the rotor packages is to be realized.
  • the invention is also based on the object of specifying a particularly suitable method for producing a rotor assembly and a particularly suitable electric motor.
  • the rotor assembly according to the invention is intended for an electric motor, in particular for a power steering system of a motor vehicle, and is suitable therefor and
  • the rotor assembly has a rotor shaft and a rotor with two magnet positioning rings and a sleeve-like or cuff-like magnet fixing sleeve.
  • the rotor is designed in several parts with at least two rotor packages (individual packages), with a number of rotor magnets arranged on each of the rotor packages.
  • the rotor magnets are preferably permanent magnets.
  • axial or an “axial direction” is understood to mean in particular a direction parallel (coaxial) to the rotor shaft, i.e. perpendicular to the front sides of the rotor.
  • radial or a “radial direction” is understood to mean in particular a direction oriented perpendicular (transverse) to the rotor shaft along a radius of the rotor or the rotor packs.
  • tangential or a “tangential direction” is understood to mean in particular a direction along the circumference of the rotor or the rotor packs (circumferential direction, azimuthal direction), i.e. a direction perpendicular to the axial direction and the radial direction.
  • the rotor or each of the rotor packages is joined to the rotor shaft, which is oriented along the axial direction, in a shaft-tight manner.
  • the rotor packages have a central through-opening, by means of which the rotor packages are joined to the rotor shaft, preferably in a force-locking and/or form-locking manner - for example by means of a press fit.
  • the offset of the adjacent rotor packages is in particular only achieved by the joining connection, in particular by the press fit, to the rotor shaft.
  • the adjacent rotor packages are attached to the rotor shaft with a defined offset angle, i.e. a tangential angular offset.
  • a “positive connection” or a “positive-locking mounting/connection” between at least two interconnected parts is understood here and below in particular to mean that the interconnected parts are held together at least in one direction by a direct interlocking of contours of the parts themselves or by an indirect interlocking via an additional connecting part.
  • the "blocking" of mutual movement in this direction is therefore due to the shape.
  • the rotor packages which are in particular cylindrical, are preferably designed as punched laminated core packages (rotor laminated core packages) with a number of rotor laminations stacked or layered along the axial direction.
  • the rotor packages are arranged coaxially to one another along the rotor shaft or are stacked and arranged offset to one another. The rotor packages thus form a package assembly.
  • the rotor packs are each equipped with a number of rotor magnets, which are arranged tangentially distributed on the respective outer surface of the rotor packs.
  • the rotor packs in particular have a substantially equilateral polygonal or polygonal base surface, so that the surface has a number of contact surfaces of equal area for the permanent magnets along the tangential or azimuthal direction, i.e. along the outer circumference.
  • the rotor magnets are thus designed as surface magnets, with the rotor or the rotor assembly being designed in SPM construction.
  • the rotor magnets have, for example, a rectangular or cuboid, preferably a loaf-shaped or bowl-shaped, cross-sectional shape.
  • a magnet positioning ring is provided as a retaining ring, which secures the rotor magnets against unwanted axial and radial slipping out.
  • the magnet positioning rings hold the rotor magnets along the Radial and tangential directions without material bonding, in particular form-fitting, to the lateral surfaces of the rotor cores.
  • a magnet fixing sleeve is placed or pressed onto the rotor packs or the pack assembly to fix the rotor magnets.
  • the magnet fixing sleeve is designed, for example, as a tubular, hollow cylinder, sleeve or cuff-shaped (cover or holding) casing.
  • the magnet fixing sleeve can be designed as a deep-drawn (stainless) steel part or aluminum part.
  • the magnet fixing sleeve is placed axially on the package assembly, and thus on the rotor magnets, as a magnet cover.
  • the placement is carried out in particular by means of an axial press fit, whereby it is possible, for example, that only the rotor magnets are in mechanical (touch) contact with the magnet fixing sleeve.
  • the press fit for fastening the magnet fixing sleeve is carried out in particular only by means of rotor magnets.
  • the outer circumference of the rotor magnets is larger than the outer circumference of the rotor packages and/or the magnet positioning rings, so that the rotor magnets are joined to the magnet fixing sleeve radially at an apex, for example.
  • This advantageously and easily reduces the mechanical demands on the stability and strength of the magnet positioning rings. In particular, this makes it possible to design the magnet positioning rings as cost-effective plastic injection-molded parts.
  • the magnet fixing sleeve has a certain oversize along the axial direction with regard to the axial height of the stack assembly. This means that the magnet fixing sleeve has two front collar areas (front sides) which are bent (crimped) radially inwards in a process step following the press fit. This means that the magnet fixing sleeve grips or surrounds the stack assembly - and thus the rotor - in a form-fitting manner when assembled.
  • the rotor packs have holding contours for tangentially holding the rotor magnets, which protrude radially from the outer circumference of the respective rotor pack.
  • the holding contours are thus arranged as radial separating webs between the tangentially distributed rotor magnets, with the outer circumference of the holding contours preferably being smaller than the outer circumference of the rotor magnets.
  • the rotor packs therefore have superficial radially protruding extensions between the magnetic poles, between which the rotor magnets are positioned tangentially.
  • the holding contours limit tangential misalignment of the rotor magnets.
  • the rotor packs are arranged directly or immediately adjacent to one another.
  • the front sides of adjacent rotor packs therefore touch one another.
  • the holding contours of a rotor pack form an axial stop for the rotor magnets of an adjacent rotor pack.
  • the interleaved or offset arrangement of the rotor packs results in an axial limitation between the rotor packs when viewed from the front along the axial direction by the radially protruding holding contours underneath.
  • the rotor magnets of a rotor pack are thus supported axially on the holding contours of the adjacent rotor pack on the front side.
  • the offset, immediate and direct arrangement and the holding contours mean that an intermediate element (intermediate ring) arranged between the rotor packs for offsetting the rotor packs is no longer required, which means that a magnetic flux between the rotor packs is not interrupted by an air gap (or an intermediate element). This creates a particularly suitable rotor assembly for an electric motor.
  • the rotor magnets are axially enclosed between a holding contour of an adjacent rotor pack and one of the front-side magnet positioning rings.
  • the rotor magnets of the rotor packs on the inside of the pack are axially enclosed between the holding contours of the adjacent rotor packs.
  • an axial form fit is achieved between the holding contours or the holding contours and a magnet positioning ring.
  • the rotor magnets are thus held tangentially by the holding contours of the associated rotor pack and at least on one end face axially by the holding contours of an adjacent rotor pack and optionally on the other end face axially and radially by a magnet positioning ring, with the magnet fixing sleeve fixing the rotor magnets in a form-fitting and/or force-fitting manner, in particular in the radial direction.
  • the rotor magnets are arranged on the rotor packs in a stable and reliable manner.
  • the rotor magnets are held or fastened to the casing or contact surfaces of the rotor packs without any material bond.
  • a material bond-free, tangential, radial and axial alignment and holding of the rotor magnets is achieved in the assembly of the rotor packs.
  • the angle of inclination is dimensioned such that the holding contours of adjacent rotor packs are arranged in the axial direction with as little overlap or overlap as possible. This ensures a particularly large axial support surface of the holding contours for the rotor magnets of the adjacent rotor pack.
  • material bond or a “material bond” between at least two interconnected parts is understood here and below to mean in particular that the interconnected parts are held together at their contact surfaces by material union or cross-linking, for example due to atomic or molecular bonding forces, possibly under the effect of an additive.
  • material bond-free refers to a holding or fastening of the parts in the absence or lack of such a "material bond” or a “material bond”.
  • the holding contours are designed to be trapezoidal or dovetail-shaped in cross-section. The side walls of the holding contours are oriented in particular along the radial direction.
  • the holding contours only provide a positive connection in the tangential direction for the rotor magnets of the associated rotor package. This enables a simple and cost-effective construction of the rotor packages or the laminated core stack layers. Furthermore, a particularly simple and collision-free insertion or fitting of the rotor magnets is possible.
  • the rotor assembly or the rotor or the package assembly has exactly two rotor packages. This ensures a particularly compact rotor assembly.
  • the holding contours extend essentially over the entire axial height of the respective rotor package.
  • the holding contours extend essentially without interruption, so that a stable and large-area tangential holder for the rotor magnets of the respective rotor package is realized.
  • the rotor packages are designed as punched laminated core packages, this means that essentially all rotor sheets are provided with the holding contours, and that the holding contours are arranged axially aligned and stacked on top of one another. This improves the stability of the holding contours in the axial direction, so that a particularly stable axial stop or axial contact surface is realized for the rotor magnets of the adjacent rotor package.
  • the magnet positioning rings have holding webs that protrude axially in the direction of the rotor packs, which in the joined state each rest radially in sections on a free end of a holding contour, and which each overlap two adjacently arranged rotor magnets tangentially in the radial direction.
  • the holding webs thus realize the radial form-fitting of the magnet positioning rings for the rotor magnets.
  • the arrangement of the holding contour and holding webs is essentially T-shaped, with the holding contour forming the vertical T-leg and the holding web forming the horizontal T-leg.
  • the method according to the invention is intended for producing a rotor assembly described above and is suitable and designed for this purpose.
  • a rotor shaft, at least two rotor packages, a number of rotor magnets, two magnet positioning rings and a magnet fixing sleeve are provided.
  • the rotor packages each have holding contours for tangentially holding the rotor magnets, which protrude radially from the outer circumference of the respective rotor package.
  • a first rotor package is joined to the rotor shaft in a first method step.
  • the first rotor package is pressed axially onto the rotor shaft in a form-fitting and/or force-fitting manner using a press fit.
  • one of the magnet positioning rings is arranged or placed on the front side of the first rotor package.
  • the first rotor package is fitted with a number of rotor magnets.
  • the rotor magnets are inserted tangentially and form-fittingly into the magnet holders formed between the holding contours.
  • the rotor magnets are secured against axial and radial slipping out by the magnet positioning ring.
  • the second rotor package is joined to the rotor shaft in a fourth process step.
  • the second rotor package is pressed axially onto the rotor shaft using a press fit in a form-fitting and/or force-fitting manner.
  • the second rotor package is applied or pulled onto the rotor shaft at a tangential angle to the first rotor package, so that the second rotor package is arranged offset or twisted to the first rotor package.
  • the second rotor package is provided with the rotor shaft such that the first and second rotor packages are in direct or immediate axial contact with one another at the front.
  • the defined twist or angle of inclination is set directly in the process, for example with a servo axis, so that a particularly high angular accuracy between the rotor packages is guaranteed.
  • the higher angular accuracy of the tangential angle of inclination between the rotor packages results in a particularly low cogging torque of the rotor or the rotor assembly. In particular, this reduces torque ripple during operation of the rotor, which has a beneficial effect on the acoustic properties of the rotor or an electric motor equipped with it.
  • the second rotor package is equipped with a number of rotor magnets.
  • the rotor magnets are inserted or placed into the magnet receptacles formed between the holding contours of the second rotor package and axially limited by the holding contours of the adjacent rotor package, so that the rotor magnets sit tangentially between the holding contours of the second rotor package and are supported axially on the holding contours of the adjacent rotor package.
  • the fourth and fifth process steps are repeated for each additional rotor stack.
  • the other magnet positioning ring is arranged or placed on the axially outermost second rotor stack so that the rotor magnets of this rotor stack are held axially and radially in a form-fitting manner by the magnet positioning ring.
  • the magnet fixing sleeve is placed or pulled onto the assembled rotor packs. This creates a particularly suitable process for producing a rotor assembly.
  • the magnet fixing sleeve is pressed axially onto the rotor packs and rotor magnets.
  • a press-fit connection is created between the magnet fixing sleeve and the rotor magnets.
  • the rotor magnets are held radially by a funnel when a rotor package is fitted.
  • the funnel thus ensures that the rotor magnets do not slide radially out of the magnet holders in an undesirable manner.
  • a (holding) ring is also conceivable.
  • the rotor magnets are secured at a lower end by the magnet positioning ring against axial and radial slipping out, with the funnel securing the rotor magnets in particular at an upper end, i.e. at a front side opposite the magnet positioning ring.
  • the funnel secures the rotor magnets in particular at a lower end, with the upper end being held by the second magnet positioning ring in the sixth process step.
  • the funnel is removed when the magnetic fixing sleeve is put on.
  • the funnel is moved away essentially at the same time as the magnetic fixing sleeve is put on. This ensures that the magnetic fixing sleeve is applied without collision.
  • the rotor assembly described above is part of an electric motor.
  • the electric motor according to the invention is particularly suitable and designed for a power steering system of a motor vehicle.
  • the electric motor has a stator and a rotor shaft which is mounted so as to be rotatable relative to the stator and on which the rotor packages of the rotor are fixedly supported.
  • the rotor packages of the rotor are arranged offset from one another along the rotor shaft.
  • the electric motor is particularly preferably designed as a brushless electric motor in the manner of an internal rotor.
  • the electric motor When used for power steering, the electric motor is arranged in the area of a driver's cab, whereby the rotor according to the invention ensures particularly smooth motor operation, since a particularly high angular accuracy of the setting of the rotor packages is ensured. This advantageously and easily reduces the noise generated by the electric motor, which has a beneficial effect on the user comfort of the motor vehicle.
  • Fig. 1 shows a schematic representation of an electric motor power steering system of a motor vehicle
  • Fig. 2 shows a perspective view of a rotor assembly of the power steering
  • Fig. 3 shows a perspective view of a rotor of the rotor assembly
  • Fig. 4 shows a perspective view of a rotor package of the rotor
  • Fig. 5 shows a perspective view of a magnet positioning ring of the rotor
  • Fig. 6 shows a detail of the rotor in the area of the magnet positioning ring in plan view
  • Fig. 7 shows a central region of the rotor in perspective
  • Fig. 8 shows the rotor assembly in perspective sectional view.
  • Fig. 1 shows in a schematic and simplified manner a motor vehicle 2 with a steering wheel 4 and with a steering gear 6 coupled thereto for moving wheels of the motor vehicle 2 (not shown in detail).
  • an electromotive power steering 8 is provided between the steering wheel 4 and the steering gear 6.
  • the power steering 8 is mechanically coupled on the one hand to a steering column 10 coupled to the steering wheel 4 and on the other hand to a steering gear 6.
  • the power steering 8 has two rotation sensors 12, 14 and a
  • the steering wheel 1 has a torsion bar 16 arranged between rotation sensors 12 and 14.
  • the rotation sensors 12, 14 are coupled to a controller 18 in terms of signals.
  • the controller 18 is also guided to an electric motor 20, which is coupled to the steering gear 6 in terms of drive.
  • the steering column 10 If a vehicle user turns the steering wheel 4 using a steering force, the steering column 10 is turned or rotated accordingly. This deflects the torsion bar 16, which is detected by the rotation sensors 12 and 14.
  • the rotation sensors 12 and 14 send corresponding measurement signals to the controller 18, which controls and/or regulates the electric motor 20 depending on the measurement signals.
  • the electric motor 20 generates a rectified auxiliary force to support the steering force in order to move the steering gear 6.
  • the rotor assembly 22 has a central rotor shaft 24 and a rotor 26 and a sleeve- or cuff-like magnet fixing sleeve 28.
  • the rotor 26 shown individually in Fig. 3 is in this embodiment designed in two parts with two offset rotor packs (individual packs) 30, wherein a number of permanent magnet rotor magnets 32 are arranged on each of the rotor packs 30.
  • the rotor magnets 32 are provided with reference numerals in the figures merely as an example.
  • the rotor 26 designed as an SPM rotor or each of the (SPM) rotor packages 30 is joined to the rotor shaft 24 oriented along an axial direction A in a shaft-fixed manner.
  • the rotor packages 30 shown individually in Fig. 4 have a central through-opening 34, by means of which the rotor packages 30 are joined to the rotor shaft 24 in a force-locking and/or form-locking manner by means of a press fit.
  • the offset of the adjacent rotor packages 30 is only realized by the joining connection, in particular by the press fit, with the rotor shaft 24.
  • the adjacent rotor packages 30 are connected to a defined angle of inclination, i.e. a tangential angular offset, is applied to the rotor shaft 24.
  • the approximately cylindrical rotor packages 30 are designed, for example, as punched laminated core packages (rotor laminated core packages) with a number of rotor sheets stacked or layered along the axial direction A.
  • the rotor packages 30 have a substantially equilateral octagonal base area.
  • the base area is therefore, for example, an octagon, so that the outer surface has eight contact surfaces 36 of equal area for the rotor magnets 32 along a tangential or azimuthal direction T.
  • Each rotor package 30 is therefore equipped with eight rotor magnets 32.
  • the rotor magnets 32 have a loaf-shaped cross-section (see, for example, Fig. 6), with the flat contact surface being placed on the contact surfaces 36 so that the curved surface protrudes outwards.
  • the rotor packages 30 each have eight recesses 38 that pass through the respective laminated core.
  • the recesses 38 are distributed evenly around the respective central through-opening 34 along the tangential direction T.
  • the recesses 38 have an approximately drop-shaped or diamond-shaped cross-sectional shape, with the respective tip oriented towards a center line of the respective contact surface for the rotor magnets 32.
  • the recesses 38 are provided with reference numerals in the figures merely as an example.
  • the rotor packages 30 have holding contours 40 that protrude radially from the outer circumference for tangentially holding the rotor magnets 32.
  • the holding contours 40 are thus arranged as radial separating webs between the tangentially distributed rotor magnets 32.
  • the holding contours 40 thus limit the contact surfaces 36 and reduce tangential misalignment of the rotor magnets 32.
  • the holding contours 40 have a trapezoidal or dovetail-shaped cross-sectional shape.
  • the holding contours 40 extend essentially over the entire axial height of the respective rotor package 30.
  • the loaf-shaped rotor magnets 32 are seated in the magnet holder in a form-fitting manner.
  • the holding contours 40 preferably only realize a tangential form-fitting connection for the rotor magnets 32.
  • two magnet positioning rings 42 are provided for axially and in particular radially securing the rotor magnets 32, which are placed on the outer end faces of the rotor packs 30 arranged next to one another in the joined or assembled state.
  • the rotor packs 30 lie directly or immediately axially against one another on the end faces facing one another.
  • the magnet positioning rings 42 shown individually in Fig. 5 each have a circular ring-shaped ring body 44.
  • the ring body 44 protrudes radially from the respective rotor pack 30.
  • the ring body 44 of the magnet positioning rings 42 protrudes from the rotor packs 30 along a radial direction R.
  • the ring body 44 has a radial width which is slightly smaller than the common radial dimension of the rotor pack 30 and the rotor magnets 32.
  • the ring body 44 therefore does not protrude from the rotor magnets 32 arranged on the outer surface of the rotor packs 30 along the radial direction R.
  • the vertices or vertex regions of the loaf-shaped rotor magnets 32 form the radially outermost points of the rotor 26.
  • the ring body 44 has a central circular opening for the passage of the rotor shaft 24.
  • the circular opening has an eight-pointed star shape as an inner contour, whereby eight radially inwardly projecting tooth extensions 46 are exposed on the ring body 44 on the radial inside.
  • the ring body 44 On the flat side facing the rotor packs 30, the ring body 44 has eight retaining webs 48 and eight retaining extensions 50, which are formed axially upwards on the ring body 44.
  • the retaining extensions 50 and retaining webs 48 are one-piece, i.e. one-piece or monolithically, formed onto the ring body 44.
  • the retaining webs 48 and retaining extensions 50 are provided with reference numerals in the figures merely as examples.
  • the holding extensions 50 are each formed on the radially inner tooth tips of the tooth extensions 46.
  • the pin-, cylinder-, or bolt-shaped holding extensions 50 of the magnet positioning ring 42 engage in the recesses 38 of the respective facing rotor package 30.
  • the drop or diamond shape of the recesses 38 acts like a centering aid when joining the magnet positioning ring 42 to the rotor packages 30. This means that the magnet positioning ring 42 engages axially in the respective associated rotor package 30 at least in sections by means of the holding extensions 50.
  • the holding webs 48 are arranged tangentially distributed on the outer edge or outer circumference of the ring body 44.
  • the holding webs 48 are arranged tangentially offset from the holding extensions 50, so that the holding webs 48 are placed radially on the outside of the holding contours 40 of the rotor package 30.
  • the tangential holding webs 48 each rest radially in sections on a free end of a holding contour 40.
  • the holding webs 48 which are approximately trapezoidal in cross section, thus form approximately a T-shape with the holding contours 40 for radially holding the rotor magnets 32, with the radial holding contour 40 forming the vertical T-leg and the tangential holding web 48 forming the horizontal T-leg.
  • the holding webs 48 partially overlap the rotor magnets 32 arranged adjacent to the holding web 48 in the radial direction.
  • the holding extensions 48 rest against the radially outer contour of the loaf-shaped rotor magnets 32 in such a way that the rotor magnets 32 are at least partially and radially enclosed in these contact areas.
  • the rotor magnets 32 are held in a form-fitting manner along the tangential direction T by means of the holding contours 40 and in a form-fitting manner along the radial direction R by means of the holding webs 48, with the ring body 44 realizing an axial limitation to the rotor package front side.
  • the ring body 44 of the magnet positioning ring 42 is clamped radially in a force-fitting and/or form-fitting manner to the rotor package 30 by the holding extensions 50 engaging in the recesses 38 and the holding webs 48 resting on the free ends of the holding contours 40.
  • the rotor packs 30 are arranged directly or directly adjacent to one another on the rotor shaft 24.
  • the front sides of the adjacent rotor packs 30 thus have a mechanical contact.
  • the crossed or offset arrangement of the rotor packs 30 results in an axial limitation between the rotor packs 30 when viewed from the front along the axial direction A by the radially protruding retaining contours 40 underneath.
  • the retaining contours 40 of one rotor pack 30 thus form an axial stop for the rotor magnets 32 of the other rotor pack 30 and vice versa.
  • the magnet fixing sleeve 28 for fixing the rotor magnets 32 is placed or pressed onto the rotor packages 30 or the package assembly - as can be seen in Fig. 8, for example.
  • the magnet fixing sleeve 28 is designed as a tubular, hollow cylinder, sleeve or cuff-shaped (covering or holding) casing.
  • the magnet fixing sleeve 28 can be designed as a deep-drawn (stainless) steel part or aluminum part.
  • the magnet fixing sleeve 28 is placed axially as a magnet cover on the rotor 26, and thus on the rotor magnets 32.
  • the placement takes place in particular by means of an axial press fit, wherein preferably only the rotor magnets 32 are in mechanical (touch) contact with the magnet fixing sleeve 28.
  • the magnet fixing sleeve 28 has a certain oversize along the axial direction A with regard to the axial height of the package assembly. This means that the magnet fixing sleeve 28 has two front-side collar areas (front sides) 52. The collar areas 52 are formed after the press-fit of the Magnet fixing sleeve 28 is bent radially inwards (crimped), and thus the
  • Magnet fixing sleeve 28 is axially positively secured to the rotor 26.
  • the rotor magnets 32 of the rotor assembly 22 are thus held in a form-fitting manner tangentially by the holding contours 40 of the associated rotor packet 30 and axially on one end face by the holding contours 40 of the adjacent rotor packet 30 and axially and radially on the other end face by a magnet positioning ring 42.
  • the magnet fixing sleeve 28 is pulled onto the equipped rotor 26, by means of which the rotor magnets 32 are fixed in a form-fitting and/or force-fitting manner, in particular in the radial direction.
  • the rotor magnets 32 are held on the rotor packets 30 in a stable and reliable manner and without any material bond.
  • a method for manufacturing the rotor assembly 22 is explained in more detail below. According to the method, the rotor shaft 24, the two rotor packs 30, sixteen (16) rotor magnets 32, two magnet positioning rings 42, and a magnet fixing sleeve 28 are provided.
  • a first rotor package 30 is joined to the rotor shaft 24.
  • the first rotor package 30 is pressed axially onto the rotor shaft 24 in a form-fitting and/or force-fitting manner by means of the through-opening 34 using a press fit.
  • one of the magnet positioning rings 42 is arranged or placed on the outer end face of the first rotor package 30.
  • the first rotor package 30 is fitted with eight rotor magnets 32.
  • the rotor magnets 32 are inserted tangentially in a form-fitting manner into the magnet receptacles formed between the holding contours 40.
  • the rotor magnets 32 are secured against axial and radial slipping out by the magnet positioning ring 42.
  • the rotor magnets 32 are secured against axial and radial slipping out at a lower end by the magnet positioning ring 42, with a funnel Rotor magnets 32 are held in place, in particular at an upper end, i.e. at a front side opposite the magnet positioning ring 42, or secured against slipping out.
  • the second rotor package 30 is joined to the rotor shaft 24 in a fourth process step.
  • the second rotor package 30 is pressed axially onto the rotor shaft 24 in a form-fitting and/or force-fitting manner by means of the through-opening 34 using a press fit.
  • the second rotor package 30 is applied or pulled onto the rotor shaft 24 at a tangential angle to the first rotor package 30, so that the second rotor package 30 is arranged offset or rotated to the first rotor package 30.
  • the second rotor package 30 is joined to the rotor shaft 24 in such a way that the rotor packages 30 are directly or immediately axially in contact with one another at the end.
  • the defined angle of rotation or offset is preferably set directly with a servo axis in the process, so that a particularly high angular accuracy between the rotor packages 30 is guaranteed.
  • the second rotor package 30 is equipped with eight rotor magnets 32.
  • the rotor magnets 32 are inserted or placed in the magnet receptacles formed between the holding contours 40 of the second rotor package 30 and axially delimited by the holding contours 40 of the first rotor package 30, so that the rotor magnets 32 are seated tangentially between the holding contours 40 of the second rotor package 30 and are supported axially on the holding contours 40 of the respective first rotor package 30.
  • the funnel is moved to the second rotor package 30, so that the funnel secures the rotor magnets 32 of the second rotor package 30, in particular at a lower end.
  • the other magnet positioning ring 42 is arranged or placed on the second rotor package 30, so that the rotor magnets 32 of this rotor package 30, in particular at an upper end, are held axially and radially in a form-fitting manner by the magnet positioning ring 42.
  • the magnet fixing sleeve 28 is pressed onto the equipped rotor packages 30 and the collar areas 52 are bent radially inwards.
  • the funnel is moved away or removed essentially at the same time as the magnet fixing sleeve 28 is pulled on.

Landscapes

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

Abstract

L'invention concerne un groupe rotor (22) pour un moteur électrique (20), ledit groupe rotor présentant : un arbre de rotor (24) orienté le long d'une direction axiale (A) ; au moins deux ensembles rotors (30) qui sont disposés de manière coaxiale et inclinée l'un par rapport à l'autre le long de l'arbre de rotor (24), les ensembles rotors (30) étant munis dans chaque cas d'un certain nombre d'aimants de rotor (32) qui sont disposés en étant répartis tangentiellement sur les surfaces d'enveloppe des ensembles rotors (30) ; deux bagues de positionnement d'aimants (42) destinées à assurer le maintien axial et radial par complémentarité de forme des aimants de rotor (32) sur les ensembles rotors (30), les bagues de positionnement d'aimants se trouvant sur les faces opposées des ensembles rotors (30) situés dans chaque cas le plus à l'extérieur ; et une douille de fixation d'aimants (28) montée sur les ensembles rotors (30) et destinée à assurer la fixation des aimants de rotor (32), les ensembles rotors se faisant face directement, les ensembles rotors (30) présentant des contours de maintien (40) permettant la fixation tangentielle des aimants de rotor (32) qui font saillie radialement de la périphérie extérieure de l'ensemble rotor (30) respectif, et les contours de retenue (40) d'un ensemble rotor (30) formant une butée axiale pour les aimants de rotor (32) d'un ensemble rotor (30) voisin.
PCT/EP2024/065848 2023-06-12 2024-06-10 Groupe rotor pour moteur électrique Pending WO2024256301A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102023205414.0 2023-06-12
DE102023205414.0A DE102023205414A1 (de) 2023-06-12 2023-06-12 Rotorbaugruppe für einen Elektromotor

Publications (1)

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WO2024256301A1 true WO2024256301A1 (fr) 2024-12-19

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DE (1) DE102023205414A1 (fr)
WO (1) WO2024256301A1 (fr)

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20130257211A1 (en) * 2011-04-02 2013-10-03 Nidec Corporation Rotor unit, rotating electrical machine, and method of manufacturing rotor unit
DE102017223622A1 (de) 2017-12-21 2019-06-27 Brose Fahrzeugteile GmbH & Co. Kommanditgesellschaft, Würzburg Rotor für einen Elektromotor und Elektromotor
KR20220005699A (ko) * 2020-07-07 2022-01-14 엘지이노텍 주식회사 모터
WO2022054168A1 (fr) * 2020-09-09 2022-03-17 三菱電機株式会社 Machine électrique tournante et son procédé de fabrication
EP4084296A1 (fr) 2019-12-23 2022-11-02 LG Innotek Co., Ltd. Moteur

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5040286A (en) * 1988-06-08 1991-08-20 General Electric Company Method for making permanent magnet rotor
US5881448A (en) * 1992-04-06 1999-03-16 General Electric Company Method for making permanent magnet rotor
US5627423A (en) * 1993-06-11 1997-05-06 Askoll S.P.A. Permanent-magnet rotor for electric motors and method of manufacturing the same
JP7433183B2 (ja) * 2020-09-30 2024-02-19 三菱電機株式会社 回転電機および回転電機の製造方法

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20130257211A1 (en) * 2011-04-02 2013-10-03 Nidec Corporation Rotor unit, rotating electrical machine, and method of manufacturing rotor unit
DE102017223622A1 (de) 2017-12-21 2019-06-27 Brose Fahrzeugteile GmbH & Co. Kommanditgesellschaft, Würzburg Rotor für einen Elektromotor und Elektromotor
EP4084296A1 (fr) 2019-12-23 2022-11-02 LG Innotek Co., Ltd. Moteur
KR20220005699A (ko) * 2020-07-07 2022-01-14 엘지이노텍 주식회사 모터
WO2022054168A1 (fr) * 2020-09-09 2022-03-17 三菱電機株式会社 Machine électrique tournante et son procédé de fabrication

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