Method for manufacturing an electric machine rotor with lamination core axial fixation function by friction welding and rotor

Abstract

The invention relates to a method for producing an electric machine rotor (1) having a rotor support (10) and a laminated core (4). In order to simplify the production of the rotor (1) and thus to reduce the production costs, the following steps are provided: positioning the laminated core (4) at least on a first component (2) of the rotor support (10), wherein the laminated core (4) at least partially radially surrounds the first component (2) with respect to an axis of rotation (12) of the electric machine; and welding the respective axial end faces of the first component (2) and of a second component (3) of the rotor support (4) to form the rotor support (10) by friction welding, wherein the laminated core (4) is fixed on the rotor support (10) by means of fastening elements (5) which axially surround the laminated core (4) on both sides by reducing the axial extension of the first component (2) and / or of the second component (3) with respect to the axis of rotation (12).

Description

Technical Field

[0001] A first aspect of the invention relates to a method for manufacturing an electric motor rotor having a rotor support and a laminated iron core. A second aspect of the invention relates to a rotor manufactured according to this method. The invention also relates to an electric motor rotor having a rotor support and a laminated iron core, the laminated iron core at least partially radially surrounding the rotor support about the axis of rotation of the motor. Background Technology

[0002] DE 10 2007 032 131 A1 discloses a rotor support for an electric motor, which is composed of at least two parts by friction welding. This makes it easier to manufacture the rotor support from multiple parts that may be made of different materials. Summary of the Invention

[0003] The objective of this invention is to further simplify the manufacture of motor rotors and thus reduce manufacturing costs.

[0004] According to the present invention, this task is accomplished through the subject matter of the technical solutions described below. Advantageous embodiments with suitable improvements are the subject matter of other technical solutions described below.

[0005] The first aspect of the present invention relates to a method for manufacturing an electric motor rotor having a rotor support and a laminated iron core, comprising the following steps:

[0006] - The laminated core is positioned at least on a first member of the rotor support, wherein the laminated core radially surrounds the first member at least partially about the axis of rotation of the motor, and

[0007] - The rotor support is formed by welding the corresponding axial end faces of the first and second components of the rotor support by friction welding, wherein the laminated core is fixed to the rotor support by means of fasteners that surround the laminated core on both sides in the axial direction by reducing the axial extension dimension of the first and / or second components about the axis of rotation.

[0008] In other words, the laminated core is oriented relative to the first member before the first and second members are assembled into the rotor support. Here, the laminated core may already be in its final position relative to the first member. The final position here refers to the position the laminated core will also be in relative to the first member later, after the first and second members are welded to form the rotor support. In other designs, the laminated core may be partially positioned on the first member of the rotor support and partially on the second member. In other words, the laminated core is thus partially positioned as a first part on the first member and as a second part on the second member. The portions of the laminated core then at least partially radially surround the members. Thus, the laminated core is also indirectly assembled when the respective end faces of the first and second members are welded. In other words, the first and second portions of the laminated core are advantageously assembled by welding the first and second members together. Optionally, the laminated core can be fixed after being positioned on the first member to prevent slippage before or during welding. This fixing is particularly releasable. Therefore, the fixing can be released after welding. For example, this fixing is done by means of clamps or the like.

[0009] When the corresponding axial end faces of the first and second components are welded by friction welding, the first and second components are rotated relative to each other. Either the first or second component can be rotated while the other component remains stationary. Alternatively, the rotation of the first and second components in opposite directions can be specified. Friction between the components generates heat. In particular, the corresponding end faces of the components rub against each other. Therefore, frictional heat may occur in each component, especially on each end face. Through the frictional heat and heat generated by the respective components, the respective materials of the first and second components soften and / or become deformable. This allows for the assembly or welding of the respective components. In particular, the materials of the first and second components, especially in the respective end face regions, are metallic. Here, the respective metallic materials, or more generally, the respective materials of the first and second components, are different. Friction welding is particularly advantageous for assembling different, especially metallic materials. For example, the respective materials of the first and second components are different grades of steel. Therefore, the first component can be made of a steel or alloy different from that of the second component. In other designs, the first and / or second components can be composed of respective component blanks. In this case, a combination of different component blanks made of different materials is also conceivable.

[0010] In the case of laminated iron cores used in motors or current rotor laminated iron cores, errors within a few millimeters often occur due to manufacturing limitations. In other words, the axial extension dimension of the laminated iron core can vary by several millimeters. This must be taken into account when securing such a laminated iron core to the rotor support. This method allows for particularly simple radial securing of the laminated iron core to the rotor support because the axial extension dimension of the rotor support is adapted to the axial extension dimension of the laminated iron core by friction welding. In other words, the rotor support is adapted in terms of its axial extension dimension to the laminated iron core, which has already been positioned at least on the first member during welding, by reducing the axial extension dimension of the first and / or second member during friction welding. For example, it is specified that each fastener surrounds the laminated iron core on both sides and thus applies a resultant force to the laminated iron core, wherein the respective forces applied by the fasteners extend at least substantially axially and are opposite to each other. In other words, by each of the fasteners, a force can be applied to the laminated iron core within the surrounding area, which is at least substantially axially directed towards the corresponding other fastener. Therefore, the laminated iron core is clamped between the fasteners by the respective forces of the fasteners.

[0011] For fasteners, the following are different implementation methods that will be explained in detail in conjunction with various improvement schemes.

[0012] According to an improved embodiment, at least a first fastener is positioned on the first member, for example, before welding the first and second members. For example, before the first and second members are welded, the first fastener is positioned on the first member by force-transmitting fit and / or form fit and / or friction fit. Advantageously, the placement of the first fastener on the first member also occurs before positioning the laminated core on the first member. In this case, the first fastener can be used as a support when positioning the laminated core on the first member. In other words, in this case, the first fastener can be used for the orientation of the laminated core, particularly in the axial direction, during lamination core positioning. Advantageously, an integral design of the first fastener and the first member can also be achieved. In other words, the first member can be designed such that it forms the first fastener. Generally, the first fastener (and a second fastener) can be provided by radially raising the first member about the axis of rotation. In other words, the first (and second) fasteners can be used to increase the radius of the first member in their respective regions, whether integrally formed with or separately from the first member.

[0013] According to an improved embodiment, the first component is constructed from two component blanks by friction welding, wherein a weld protrusion is optionally formed by friction welding, which forms the first fastener. In other words, the first component can be constructed by joining two component blanks. The joining of the two component blanks is particularly carried out by friction welding. When the two component blanks are assembled into the first component, a weld or weld protrusion can be formed. The weld protrusion can optionally form the first fastener. The assembly of the two component blanks, particularly by friction welding, to form the first component can be carried out before or after the lamination core is positioned on the first component. For example, it can be specified that the lamination core is first positioned on one of the two component blanks and then the component blank is joined to the other component blank by welding. With the weld protrusion, the radius of the first component can be locally, especially in the area where the two component blanks meet. In this way, the weld protrusion allows the lamination core to be at least partially surrounded on both sides in the axial direction. Because the first component is assembled from two component blanks, the manufacturing of the rotor can be further simplified. In addition, different materials, especially metals, can be used. Weld protrusion is a particularly simple way to provide the first fastener without requiring another separate component.

[0014] According to an improved embodiment, the second component and the first component blank of the two component blanks are designed as flanges, and the second component blank of the two component blanks is designed at least substantially as a hollow cylinder. The second component blank is positioned within a laminated core, and the opposing end faces of the first component blank and the second component blank are friction-welded to each other. Within this embodiment, the laminated core is positioned only on a portion of the first component, i.e., the second component blank. Here, the laminated core can be inserted into the second component blank, or the second component blank can be inserted into the laminated core. Then, the second component blank is friction-welded not only to the first component blank at its opposing end face to form the first component, but also to the second component to form a rotor support or rotor. Welding of the second component blank to the first component blank and the second component can be performed simultaneously. However, it is preferred that the second component blank is first friction-welded to the first component blank, and then to the second component. Particularly advantageous within this embodiment is that two fasteners surrounding the laminated core axially on both sides are formed by their respective weld protrusions. One of the weld protrusions can be formed by welding the first and second component blanks, and the other weld protrusion can be formed by welding the second component blank to the second component or by welding the first component to the second component. In this way, a particularly simple and low-cost rotor machining is guaranteed.

[0015] According to an improved embodiment, at least one second fastener, particularly in the form of a weld protrusion, is formed during or immediately after welding the first and second components. The advantages of the weld protrusion as a fastener have been clearly explained. As already described, two fasteners can be designed with corresponding weld protrusions. Since at least the second fastener, and specifically the second fastener, is formed during welding, it is formed by friction welding. In other words, the second fastener, particularly the weld protrusion, is formed during or by friction welding to clamp the laminated core. The clamping of the laminated core can advantageously be carried out, particularly when the first fastener has been placed on the first component before welding the first and second components as described above. In this case, the possibility of movement of the laminated core in a spatial direction parallel to the axis is limited. By forming the second fastener, the laminated core is then also fixed in the opposite spatial direction parallel to the axis. In this way, the gradual fixing and, consequently, particularly accurate orientation of the laminated core can be guaranteed. The formation of the weld protrusion as the second fastener can also be carried out immediately after welding, provided that the components are still hot.

[0016] Preferably, the reduction in the axial extension dimension of the first and / or second components is achieved by applying axial pressure during and / or after friction welding. The second fastener can be formed by applying pressure during or after the welding of the first and second components until the laminated core is secured or clamped axially. In other words, the reduction in the axial extension dimension of the first and / or second components can be carried out by applying pressure until the axial extension dimension of the rotor support thus formed is adapted to the laminated core. In particular, the material of the first and / or second components is recombinated or deformed by reducing the axial extension dimension and / or applying pressure, thereby forming the second fastener, particularly the weld protrusion.

[0017] Alternatively, especially when the first and second components already have their respective fasteners before welding, the laminated core can be clamped by applying pressure. It is generally stipulated that the first and second components already have their respective fasteners before welding, wherein the axial fixation of the laminated core is achieved by clamping the laminated core due to the reduction of the axial extension dimension of the first and / or second components. In other words, the distance between the corresponding fasteners of the first and second components can be reduced by reducing the axial extension dimension of the first and / or second components. By reducing this distance, the laminated core can be clamped between the fasteners. The reduction of the axial extension dimension is particularly achieved by the aforementioned axial pressure. In other words, the fasteners of the first and second components can move closer to each other by shortening the axial extension dimension of the first and / or second components due to pressure applied during welding. Axial pressure, in particular, generates pressure on the laminated core from the fasteners. In other words, the aforementioned opposing forces on the laminated core from the fasteners can be generated by applying pressure.

[0018] According to an improved embodiment, a laminated iron core is clamped between respective fasteners already installed on the first and second components before welding, forming a cavity between each fastener and the rotor support, wherein the cavity surrounds the welded end faces of the first and second components. In other words, each fastener is pressed onto the laminated iron core. This creates a cavity between each fastener and the rotor support, and optionally, the laminated iron core. In other words, each cavity can be defined by its respective fastener, rotor support, and laminated iron core. Here, the cavity or size of the first and / or second component can be selected such that it surrounds or closes the welded end faces of the first and second components, i.e., the weld between the first and second components. This ensures protection of easily corroded welds.

[0019] A second aspect of the invention relates to an electric motor rotor manufactured by the method of the invention. In particular, the rotor is characterized by the performance obtained by manufacturing it using the method of the invention.

[0020] A third aspect of the invention relates to an electric motor rotor having a rotor support and a laminated iron core, the laminated iron core at least partially radially surrounding the rotor support about the motor's rotation axis. The invention specifies that the rotor support has respective fasteners that axially surround the laminated iron core on both sides and are axially fixed to the rotor support; at least one of these fasteners is designed as a weld protrusion. In particular, the electric motor rotor is also manufactured using the method of the invention. Specifically, at least one weld protrusion is manufactured or formed by friction welding. In particular, the weld protrusion is formed by assembling or welding the first and second components of the rotor support.

[0021] In another design, it can be specified that the two fasteners are provided by their respective weld protrusions. For example, it can be specified that the first weld protrusion of the two weld protrusions is formed by assembling the first component from two component blanks by means of friction welding. The second weld protrusion of the two weld protrusions can be formed by assembling the first component and the second component by means of friction welding.

[0022] The method for manufacturing an electric motor rotor according to the first or second aspect of the present invention and the rotor are closely related to each other. Therefore, the features, improvements, and advantages described with respect to the method of the present invention also apply to the rotor of the present invention, and vice versa. For the sake of brevity, the features of the method are not described with respect to the rotor. Attached Figure Description

[0023] Other advantages, features, and details of the invention will become apparent from the following description of preferred embodiments, taken in conjunction with the figures. The features and combinations of features mentioned above in the specification, as well as the features and combinations of features mentioned below in the description of the drawings and / or shown individually in the figures, may be used not only in their respective specified combinations, but also in other combinations or individually, without departing from the scope of the invention, wherein:

[0024] Figure 1 A cross-sectional schematic diagram along the axis of rotation of the rotor or motor is shown for a motor rotor according to the first embodiment, which consists of at least two components and a stack of laminations.

[0025] Figure 2 A second embodiment of such a rotor is shown, wherein one of the components is composed of two component blanks;

[0026] Figure 3 An alternative embodiment of the rotor is shown, wherein fasteners independent of welds are provided on the first and second components;

[0027] Figure 4 An embodiment of a rotor having an oil cavity integrated into a component of the rotor is shown;

[0028] Figures 5A-5D Different embodiments of components for the rotor are shown;

[0029] Figures 6A-6D Different embodiments of the component blanks for the rotor are shown. Detailed Implementation

[0030] Figure 1-4A cross-sectional view is shown of a rotor 1 and a motor (not shown) according to different embodiments. The rotor 1 has a rotation axis 12, which also corresponds to the rotation axis of the motor. Each rotor 1 has a rotor support 10 composed of a first component 2 and a second component 3, and a laminated iron core 4. Depending on the embodiment, the first component 2 may be composed of two first component blanks 8 and second component blanks 9. Each rotor 1 has a rotationally symmetric structure about the rotation axis 12. In other words, in Figure 1-4 The respective cross-sectional views only show the portion located above the axis of rotation 12 in the cross-sectional view.

[0031] According to Figure 1 In this embodiment, the rotor support 10 consists of a first member 2 and a second member 3. In particular, during the manufacture of the rotor 1, it is specified that the laminated core 4 is positioned on the first member 2 of the rotor support 10 such that the laminated core 4 at least partially radially surrounds the first member 2 about the axis of rotation 12. In other words, the first member 2 can be inserted into the laminated core 4, and therefore it is specifically specified that, regardless of component errors, the inner diameter of the laminated core 4 corresponds to the outer diameter of the first member 2. Component errors here can be adapted to the errors achievable during the machining of the laminated core 4 and / or the first member 2. In other words, it can be specified that the laminated core 4 is moved above the first member 2 during positioning. When positioning the laminated core 4, it can be positioned on the first of two fasteners 5. Specifically, the laminated core 4 is positioned such that it contacts the corresponding fastener 5. In this example, the first fastener is provided by a fastener 7 fixedly mounted on the first member 2. Such a fastener 7 is, for example, a clamp, a support ring, or a center nut. The fastener 7 can provide a stop for positioning the laminated core 4. Optionally, a spring can be provided between the laminated iron core 4 and the fastener 7 (in accordance with...) Figure 1 (This is not the case in the example). Such a spring can, for example, be similar to or correspond to spring 13.

[0032] After positioning the laminated iron core 4 relative to the first component 2, the first component 2 and the second component 3 are welded together to form the rotor support 10. Welding is performed, in particular, by friction welding or by friction welding methods. This results in a weld that is circumferentially surrounding the axis of rotation 12. The weld here forms a weld protrusion 6, which has a radius about the axis of rotation 12 that is larger than that of the first component 2 and the second component 3. The weld protrusion 6 forms a second fastener therein. A spring element 13, such as a disc spring, can optionally be provided between the weld protrusion 6 and the laminated iron core 4. Two fasteners 5, in this example the weld protrusion 6 and a pre-fixed fastener 7, together surround the laminated iron core 4 from both sides. In other words, the laminated iron core 4 is framed or surrounded by the fasteners 5. The fasteners 5 can collectively apply a retaining force to the laminated iron core 4. In this example, this retaining force is controlled by means of the spring element 13.

[0033] During friction welding, the first component 2 and the second component 3 are pressed or compressed with a predetermined force. In other words, an axial force is applied to the first component 2 and the second component 3 during friction welding. Through this axial force, the first component 2 and the second component 3 can be pressed together. Through this force and friction welding, the axial extension of at least one of the first component 2 and the second component 3 about the axis of rotation 12 can be reduced. In other words, during friction welding, the axial extension of at least one of the first component 2 and the second component 3 is reduced. In other words, the material of at least one of the two components is deformed or displaced by the heat and pressure during friction welding, thus forming the weld protrusion 6. For example, the first component 2 and the second component 3 can be made of the same substance or material, especially metal. In this case, the weld protrusion 6 can be formed, particularly by reducing the axial extension of the first component 2 and the second component 3. Alternatively, it can be specified that the first component 2 and the second component 3 are made of different materials. In this case, it can be specified that the weld protrusion 6 is made of the material of only one of the first component 2 and the second component 3. But in this case, it can also be specified that the weld protrusion is formed of different materials of the first component 2 and the second component 3.

[0034] In this case, the final step of axially extending and reducing the size of the first component 2 and the second component 3 used to form the weld protrusion 6 can be performed, for example, while the material is still heated by friction welding but the first component 2 and the second component 3 are no longer rotating, so that the weld protrusion 6 itself no longer twists or is no longer in the rotational motion of friction welding relative to the lamination core 4 as a fastener 5.

[0035] By reducing the axial extension dimensions of the first component 2 and / or the second component 3, the length of the rotor support 10 can be adapted to the axial extension dimension of the laminated core 4 during the welding of the first component 2 and the second component 3. This is advantageous because the laminated core 4 typically has a large error in its axial extension dimension, thus requiring complex axial fixation of the laminated core 4 in manufacturing according to the prior art. This is achieved by forming a weld protrusion 6 during welding, which automatically adapts to the axial extension dimension of the laminated core 4. In other words, the weld protrusion 6 is designed with respect to its position and / or shape such that it optimally surrounds the laminated core 4 in a manner that serves as a second fastener on the corresponding side. Figure 1 In this example, the laminated core 4 contacts the pre-positioned fastener 7, which acts as a stop, during welding. For this purpose, the laminated core 4 can also be additionally and temporarily fixed to the first member 2 to prevent slippage during welding. During welding, the weld protrusion 6 is formed on the side of the laminated core 4 opposite to the fastener 7, surrounding the laminated core 4. By forming the weld protrusion 6, the laminated core 4 is clamped, particularly between the weld protrusion 6 and the pre-fixed fastener 7. This ensures the axial fixation of the laminated core 4.

[0036] Figure 2 Implementation examples and according to Figure 1 The difference in the embodiment is that the first component 2 is composed of a first component blank 8 and a second component blank 9. Figure 2 Rotor support 10 and Figure 1 The differences between the rotor support 10 and the manufacturing methods on which they are based are briefly shown below. In this embodiment, the two fasteners 5 are provided by their respective welds or weld protrusions 6. In other words, the laminated core 4 is surrounded on both sides by the two weld protrusions 6 or clamped between the two weld protrusions 6. The assembly of the first component blank 8 and the second component blank 9 into the first component 2 can be performed before or simultaneously with welding to the second component 3. In other words, it can be specified that the first component 2 is first formed by combining the first component blank 8 and the second component blank 9, especially by welding or friction welding. Then, the laminated core can be positioned on the first component 2. In this case, the positioning of the laminated core 4 on the first component 2 and the welding of the first component 2 to the second component 3 are performed, especially with respect to... Figure 1 The same manner has been shown in the embodiments. In this case, the only difference is that the fastener 7, which is placed earlier, is also provided by the weld protrusion 6. In other words, in this case, the weld protrusion 6, which is formed by welding, in particular friction welding, the first component blank 8 and the second component blank 9 to form the first component 2, acts as or serves as a stop when positioning the laminated core 4.

[0037] Or, according to Figure 2In this embodiment, it can be specified that two weld protrusions 6 are formed simultaneously. In particular, it is specified that the first component blank 8, the second component blank 9, and the second component 3 are simultaneously welded to each other, especially by friction welding. In other words, the first component blank 8 and the second component blank 9 are welded to form the first component 2, while the first component 2 and the second component 3 are simultaneously welded to form the rotor support 10. In particular, it can be specified that the laminated core 4 is positioned relative to the second component blank 9 such that the laminated core 4 at least partially surrounds the second component blank 9 in the radial direction. The second component blank 9 is preferably designed as a hollow cylinder. Alternatively, it can be specified that it is designed as a hollow shaft. Subsequently, welding can be performed on both sides of the second component blank 9 to the first component blank 8 or the second component 3. In particular, the second component blank 9 is preferably welded to the first component blank 8 at its first end face by friction welding, and the second component blank 9 is preferably welded to the second component 3 at its second end face by friction welding. Therefore, on both sides of the laminated core 4, each weld protrusion 6 is formed, especially simultaneously, as its respective fastener 5. Friction welding is performed, especially under axial force. Therefore, in this case, the axial extension dimensions of the second component 3 and / or the first component blank 8 and / or the second component blank 9 can be reduced. By correspondingly changing or reducing the axial extension dimensions, the resulting rotor support 10 is adapted to the axial extension dimension of the laminated core 4. The laminated core 4 is clamped between two weld protrusions 6 and thus axially fixed. This is particularly automated through friction welding and the formation of weld protrusions 6 with corresponding positions and / or shapes.

[0038] Unlike according to Figure 1 and Figure 2 In the implementation method, the fastener 5 is based on Figure 3 In this embodiment, the arm 11 is designed to be at least partially parallel to the axis of rotation 12 and its circumference is greater than the inner circumference of the laminated core 4. Here, the laminated core is also clamped or surrounded by fasteners 5. According to... Figure 3 The implementation method can be similar to Figure 2 The manufacturing process involves first forming the first component 2 by assembling the first component blank 8 and the second component blank 9, and then welding the first component 2 to the second component 3. Alternatively, it can be similar to... Figure 2 In one embodiment, the first component blank 8, the second component blank 9, and the second component 3 can be welded to each other simultaneously. Here, a spring element 13 is arranged between each of the respective arms 11 and the laminated iron core 4. However, this is only exemplary and is to be understood as optional.

[0039] Compared with the prior implementation method (according to Figure 1 and 2The difference lies in the fact that the weld protrusion 6, or these weld protrusions 6, are not designed or used as fasteners 5 here. Instead, the weld protrusion 6 is used here only to accommodate excess material from the first component 2 and the second component 3 or to reduce the axial extension dimensions of the first component 2 and the second component 3, or the second component 3 and the first component blank 8 and the second component blank 9, during friction welding. In other words, welding or friction welding is also performed here under axial pressure. Under axial pressure, the arms 11 are pressed onto the laminated core 4, optionally by means of springs 13 respectively disposed therebetween. By appropriately selecting the axial pressure and welding conditions, a predetermined clamping force of the arms 11 on the laminated core 4 can be achieved. The axial extension dimension of the rotor support 10 is thus adapted to the axial extension dimension of the laminated core 4. Errors in the laminated core 4 can be compensated for by adjusting the rotor support 10. In this embodiment, friction welding is therefore not used to form the weld protrusion 6 as a fastener 5, but rather to assemble the rotor support 10 and adjust the axial extension dimension of the rotor support 10.

[0040] Here, the final step of axial extension dimension reduction can also be carried out immediately after friction welding, so that the material at the friction welding part is still hot and deformable, but the first component 2 and the second component 3 can no longer rotate relative to the laminated iron core 4, so the arm 11 no longer rotates relative to the laminated iron core 4 during axial compression.

[0041] Figure 4 Show Figure 3 Another design of the implementation. Here, the second component blank 9 is designed to have varying wall thickness or different inner radii in the axial direction. This design of the second component blank 9 allows for oil distribution on the inner surface of the rotor support 10. The weld protrusion 6 serves as an oil film limiting mechanism in this case.

[0042] Figures 5A-5D Different embodiments of the first component 2 or the first component blank 8 are shown. According to... Figure 1 An alternative design for the first component 2 in the embodiments can, for example, be according to... Figure 5A The first component 2 of the embodiment takes the form of this. In this case, the shaft protruding from the rotor 1 can be designed as a hollow shaft. Generally, the rotor support 10 or the rotor 1 in combination with any drive shaft or driven shaft is possible and is explicitly specified. The design of the rotor support 10 as a hollow or solid shaft is also explicitly specified.

[0043] Figures 5B-5DDifferent embodiments for the first component blank 8 are shown. The second component 3 and the first component blank 8 can be designed to be identical or mirror-symmetrical. For example, the axis of symmetry can be perpendicular to the axis of rotation 12. The second component blank 9 can therefore be arranged between two identical or two mirror-symmetrical parts, i.e., between the second component 3 and the first component blank 8. Correspondingly, the two identical or mirror-symmetrical parts can be designed as corresponding flanges, which surround the hollow shaft located therebetween, i.e., the second component blank 9. The flanges can optionally have rolling teeth. Figure 5B The diagram shows a design where the protruding shaft is hollow. Figure 5C It shows how it is applied in, for example Figure 2 In the embodiments, such as the first component blank 8 or the second component 3. Figure 5C It shows how it is applied in, for example Figure 3 and 4 In the embodiments, such as the first component blank 8 or the second component 3.

[0044] Finally, Figures 6A-6D The diagram shows different embodiments of the second component blank 9. For example, one can conceive of a hollow cylinder with a regular shape and a smooth inner and outer circumferential surface. Figure 6A Alternatively, it can be specified that the outer and / or inner peripheral surfaces have textures. Figure 6B The outer texture structure 19 is shown. As already stated regarding... Figure 4 As shown in the embodiments, the wall thickness of the hollow shaft or hollow cylinder of the second component blank 9 can be varied. This is in Figure 6C The image is shown in the middle. The outer texture structure 19 is also shown in this embodiment. Figure 6D Another exemplary outline of a textured structure 18 in the form of a thread is shown. In this case, the textured structure 18 is arranged, for example, on the inner circumferential surface. However, an alternative or additional textured structure 18 may also be specified on the outer circumferential surface. Different second component blanks 9 may, for example, be various extruded profiles. In other words, this second component blank 9 or these second component blanks 9 can be formed by extrusion. Extrusion is here a very advantageous method for manufacturing components in large quantities.

[0045] Here, a particularly advantageous and highly automated method of machining the rotor 1 is obtained. Thus, the large axial extension error of the laminated core 4 can be compensated by the shrinkage of the rotor support 10 during assembly from the first component 2 and the second component 3, or from the first component 2 and the first component blank 8 and the second component blank 9. This compensation is, for example, at least in part, achieved by forming suitable weld protrusions 6 in appropriate shape or location. Alternatively or additionally, the compensation can be achieved by shortening the distance between the two fasteners 5, especially the two arms 11, through friction welding and thus the shortening of the rotor support 10 or its components.

[0046] List of reference numerals

[0047]

Claims

1. A method for manufacturing an electric machine rotor (1) having a rotor carrier (10) and a laminated core (4), the method having the following steps: - positioning the laminated core (4) at least on the first component (2) of the rotor support (10), wherein the laminated core (4) at least partially radially surrounds the first component (2) with respect to an axis of rotation (12) of the electric machine, and - the first component (2) of the rotor carrier (10) and the respective axial end face of the second component (3) of the rotor carrier (10) are welded by friction welding to form the rotor carrier (10), wherein the laminated core (4) is fixed on the rotor carrier (10) by means of fastenings (5) which axially surround the laminated core (4) on both sides by reducing the axial extension of the first component (2) and / or the second component (3) with respect to the axis of rotation (12), wherein at least one of the fastenings (5) is designed in the form of a weld bead (6).

2. The method of claim 1, wherein, At least a first of the fastenings (5, 7) is arranged on the first component (2) before the first component (2) and the second component (3) are welded.

3. The method of claim 2, wherein, The first component (2) is composed of two component blanks by the friction welding, wherein the weld bead (6) forming the first fastening (5) is optionally formed by the friction welding.

4. The method of claim 3, wherein, The second component (3) and a first of the two component blanks (8) are designed as a flange, and a second of the two component blanks (9) is at least substantially designed as a hollow cylinder, wherein the second component blank (9) is arranged in the laminated core (4) when positioned, and the first component blank (8) and the second component (3) are friction welded to opposite end faces of the second component blank (9).

5. The method according to one of the preceding claims, characterized in that, At least a second of the fastenings (5) is formed during or after the welding of the first component (2) and the second component (3).

6. The method according to any one of claims 1 to 4, characterized in that, The reduction of the axial extension of the first component (2) and / or the second component (3) is achieved by axial pressing during and / or after the friction welding.

7. The method according to any one of claims 1 to 4, characterized in that, The first component (2) and the second component (3) each have a respective fastening (5, 11) before the welding, wherein the axial fixation of the laminated core (4) is achieved by clamping of the laminated core (4) as a result of the reduction of the axial extension of the first component (2) and / or the second component (3).

8. The method of claim 7, wherein, By clamping the laminated core (4), a respective cavity is formed between the respective fastening (5, 11) and the rotor carrier (10), wherein the cavity surrounds the welded end faces of the first component (2) and the second component (3).

9. The method of claim 5 wherein, At least a second of the fastenings (5) is a weld bead (6).

10. An electric machine rotor (1) manufactured by the method according to one of the preceding claims.

11. An electric machine rotor (1) having: - a rotor carrier (10), and - a laminated core (4) which at least partially radially surrounds the rotor carrier (10) with respect to an axis of rotation (12) of the electric machine, characterized in that - The rotor support (10) has fastening elements (5) which axially surround the laminated core (4) on both sides and axially fix the laminated core on the rotor support (10), wherein at least one of the fastening elements (5) is designed as a weld bead (6).

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