Rotor and method for manufacturing a rotor

Abstract

The invention relates to a rotor, in particular for a current-excited synchronous machine, comprising a rotor base body having a plurality of rotor teeth, which are wound with conductor material to form a winding, the conductor material having conductor ends, which are pressed in an axial direction onto a stop by means of a contact element in order to establish an electrically conductive connection, and the contact element or the stop is designed to electrically conductively connect at least two conductor ends in a circumferential direction.

Description

Technical Field

[0001] The present invention relates to a rotor, particularly for a current-excited or separately excited synchronous motor, and a method for manufacturing the rotor. Background Technology

[0002] Rotors of this type are wound with a conductor material, such as copper wire. The conductor ends of this winding must be interconnected. Similarly, the windings must be electrically connected, for example, to a current collector for power supply. It has been found that the contact at the conductor ends is not without problems. During operation, due to the high speed, very high forces act on the rotor. The crimped connections in these areas often cannot withstand this load. Furthermore, the assembly is usually surrounded by a casting material for mechanical stabilization. Cracks may form in this casting material during cooling or later during operation. If these cracks propagate towards the conductor ends or connecting wires, this can cause the wires to break at these locations. Summary of the Invention

[0003] Therefore, the objective of this invention is to provide a method for manufacturing a rotor and a rotor, wherein, in particular, the electrical contacts of one or more windings should be optimized.

[0004] According to the invention, the rotor of a motor, particularly a current-excited or separately excited motor, especially a synchronous motor, comprises a rotor base having or configured with a plurality of rotor teeth wound with a conductor material to form a winding. The conductor material has conductor ends (also referred to as connecting wires), which are axially pressed against a stop by contact elements to establish a conductive connection. The contact elements or stops are designed to conductively connect at least two conductor ends in the circumferential direction. Pressing the conductor ends against the stops or stop elements advantageously allows for reliable and, in particular, protective electrical contact at the conductor ends. "Pressing" should be understood in particular as the contact elements being form-locked or form-locked and force-locked onto the conductor ends, with the stops providing support and, for example, positional fixation of the conductor ends.

[0005] According to a preferred embodiment, the conductor material is copper wire, which has, for example, a circular, especially circular, cross-section. The conductor end has a length of, for example, a few millimeters to a few centimeters, such as 5 mm to 30 mm. Suitably, the clamping of the conductor end is carried out over its entire length, achieving a very protective contact through the application of force over a large area. Suitably, the force applied during clamping is along the rotor axis, i.e., along the axial direction of the rotor. The stop or stop element is perpendicular or substantially perpendicular to the rotor axis. The contact element is designed to press the conductor end, or connecting wire, against the stop, especially to clamp it. For this purpose, for example, the contact element moves along the rotor shaft toward the rotor base. According to a preferred embodiment, the rotor base is a rotor lamination assembly, which is composed of multiple laminations stacked together.

[0006] According to a preferred embodiment, the rotor substrate or rotor lamination assembly is surrounded by a castable material to form an ummantelung. Suitably, this castable material forms a cladding or layer surrounding the rotor lamination assembly, on which conductor material is disposed. It has proven particularly advantageous that the stop portion is constructed directly by the castable material, which is applied by injection molding according to a preferred embodiment. According to one embodiment, the stop portion is formed by a planar or substantially planar stop surface, which is preferably oriented perpendicular to the rotor axis. In this respect, it should be mentioned that the aforementioned conductor ends, or connecting wires, are also suitably oriented such that they are perpendicular to or substantially perpendicular to the rotor axis. In particular, they are also additionally radial to the rotor axis. In other words, the orientation of the conductor ends can also be described as radial.

[0007] According to one embodiment, the contact element or stop includes at least one conductor element, thereby enabling a conductive connection between the at least two conductor ends in the circumferential direction. The at least one conductor element may be a bus or at least one (copper) wire. According to one embodiment, the conductor element is cast into the covering portion. Alternatively, the at least one conductor element is cast into the contact element. Upon compression, a form-locking contact or a form-locking and force-locking contact of the at least one conductor element is advantageously achieved.

[0008] According to one embodiment, the contact element is made of plastic. According to a preferred embodiment, the contact element has a ring-shaped design. According to one embodiment, the contact element has a groove-shaped area in which a conductor element can be disposed, or multiple conductor elements may be disposed if possible.

[0009] According to a preferred embodiment, the contact element is fixed in an axial position by a stop element. Additionally, a force can also be introduced by the stop element to clamp the connecting wire. To position the stop element on the rotor shaft, a mating region, such as a thread, is suitably provided, designed to work in conjunction with the stop element. The mating region is specifically provided and designed to introduce force onto the contact element via the stop element. Additionally or alternatively, the mating region is suitably designed to allow the stop element to be fixed along the rotor axis, thereby thus fixing the contact element in an axial position as well. According to a preferred embodiment, the stop element is also made of a plastic material. According to a preferred embodiment, the stop element also has a ring-shaped design.

[0010] According to one embodiment, the contact element or stop has a plurality of, particularly radially arranged, recesses for positioning and locating the conductor end. As already mentioned, the conductor end, or connecting wire, is also suitably arranged radially accordingly. The recesses are suitably adapted to the aforementioned orientation of the conductor end. If the conductor end has a different orientation, the recesses are also suitably constructed / oriented differently. Suitably, the recesses can achieve reliable and stress-free positioning or pre-positioning of the conductor end, and in particular, can also achieve fixation. The conductor end is currently advantageously press-fixed. Advantageously, the contact element can not only achieve simple contact, but also positioning or fixation of the conductor end. Advantageously, when setting the contact element, the conductor end is pressed into the recess.

[0011] According to one embodiment, the recess can be provided on the stop portion. Alternatively, the recess can also be constructed on the contact element. Combinations are also currently considered.

[0012] Advantageously, at least two of the recesses are connected by a conductor element. Therefore, a conductive connection can be provided circumferentially between the two recesses, or between the conductor ends disposed within the recesses. When the contact element is provided or during compression, the conductor ends contact the conductor element to conduct current circumferentially.

[0013] The clamping is understood here as follows: the conductor end is pressed against the stop via a contact element by an axial force. This achieves contact between either the conductor element present in the stop or the conductor element present in the contact element. The clamping is understood as making contact such that a sufficiently large frictional engagement is generated, which reliably fixes the conductor end and the at least one conductor element relative to each other. To further enhance the frictional engagement, the contact element and / or the stop and / or the recess and / or the conductor end may undergo at least slight plastic deformation during clamping.

[0014] According to one embodiment, one or more intermediate elements are provided in at least one recess or in multiple recesses, said intermediate element being designed to deform upon compression for connection with a conductor element. According to a preferred embodiment, the intermediate element is a metal insert element, which may be disposed within the recess. The intermediate element is also suitably formed into a groove or the like to allow the conductor element to be inserted therein. Upon compression, the intermediate element deforms, thereby achieving reliable fixation of the conductor end.

[0015] A conductive connection to the at least one conductor element is suitably provided by an intermediate element. In other words, the intermediate element and the conductor element are suitably placed against each other.

[0016] According to one embodiment, the contact element and / or the cover are designed to provide a conductive connection along the rotor axis to the current collector or slip ring module. Suitably, for this purpose, corresponding electrical conductor elements are provided in the contact element and / or the cover, said conductor elements being, for example, in the form of a bus and / or a conductor material (such as (copper) wire).

[0017] According to one embodiment, the contact element is configured as a current collector or includes such a current collector. A current collector is a component, according to one embodiment, disposed on the rotor shaft of the rotor, and on which the conductor ends / connecting wires of the windings converge and interconnect. The current collector is suitably electrically connected to the rotor's slip ring in a suitable manner. Suitably, the current collector itself can currently be configured as a contact element. Alternatively, the slip ring module may also include or be configured with such a contact element.

[0018] The present invention also relates to a method for manufacturing a rotor, the method comprising the following steps:

[0019] - A rotor body is provided and wound with a conductor material to form a winding, the winding having conductor ends;

[0020] -The conductor end is pressed against the stop by a contact element;

[0021] - A conductive connection is created between at least two conductor ends by means of a contact element or a stop.

[0022] Advantageously, the conductor elements are pressed against the stop by an axial force. Suitablely, appropriate contact elements are used for this purpose. Suitablely, conductor elements are provided in the contact elements or also in the stop, which enable current conduction in the circumferential direction. Therefore, the conductor ends can be safely and reliably interconnected. Particularly advantageously, the conductor ends are supported over a large area by the contact elements. This not only achieves protective force introduction but also, in particular, provides large-area shielding for these sensitive areas of the winding. Therefore, to mechanically stabilize the winding, it is common practice to perform injection encapsulation or surrounding casting with a casting material after winding, which in this case involves, for example, thermosetting or thermoplastic plastics. It is not uncommon for cracks to appear in the casting material during cooling or later during operation. If these cracks propagate towards the connecting wires or conductor ends, this can be problematic because there is a risk of contact failure in the conductor end region. By using contact elements, these areas are advantageously protected and the aforementioned problems are avoided. Attached Figure Description

[0023] Other advantages and features will be apparent from the following description of the rotor implementation with reference to the accompanying drawings.

[0024] In the attached image:

[0025] Figure 1 A front view of a rotor with conductor ends, which must be interconnected, is shown.

[0026] Figure 2 It shows that it is basically composed of Figure 1 A view of a known rotor, in which contact elements are arranged;

[0027] Figure 3 A schematic detail diagram showing one embodiment of the rotor;

[0028] Figure 4 As shown in Figure 3 The cross-section is shown in a rough outline. Detailed Implementation

[0029] Figure 1The diagram shows a front view of a rotor 10 viewed along its rotor axis R. The rotor has a plurality of, currently six, rotor teeth 12, each having rotor slots 14 formed therebetween. The rotor teeth 12 are wrapped with a conductor material 20, such as copper wire. The conductor material 20 forms conductor ends or connecting wires 22, which are arranged generally radially or radially relative to the rotor axis R. Reference numeral 24 schematically shows a current collector 24 comprising two terminals 25. The challenge presented herein is to electrically connect the respective conductor ends 22, or rather, to electrically connect the conductor ends 22 to the terminals 25 of the current collector 24. According to the invention, this is done via a contact element 40, as in... Figure 2 It is shown in a general outline.

[0030] Figure 2 It shows that it is basically composed of Figure 1 A view of the known rotor 10, wherein a contact element 40 is arranged along the rotor axis R, the contact element currently having three conductor elements 42. These conductor elements allow the respective conductor ends to contact each other or with terminals (see...). Figure 1 Contact. To better understand this contact, set Figure 3 and 4 .

[0031] Figure 3 A schematic detail diagram shows a cross-section of the rotor along its axis R. The winding or conductor material 20 can be seen, with conductor ends 22 extending away from this winding or conductor material. Figure 1 and 2 The region is shown from the front, specifically along the rotor axis R. It can be seen that the conductor end 22 rests against the stop 50. The conductor end 22 is pressed against the stop 50 by a contact element 40. The contact element 40 has a recess or groove 46 in which the conductor end 22 is disposed. In the embodiment shown schematically here, an intermediate element 44 is disposed in the recess or groove 46. The contact element 40 has a conductor element 42 designed and configured for use in the circumferential direction (see also...). Figure 2 A conductive connection is established. To reliably hold the contact element 40 in this position, a stop element 48 is provided. The rotor shaft 60 is schematically shown using reference numeral 60. In the present illustration, the stop 50 is implemented directly through a cover portion of the rotor base, not shown further herein. According to a preferred embodiment, the rotor base comprises a plurality of laminations stacked into a rotor assembly. Typically, this rotor assembly is surrounded by a cover portion made of plastic material. It has proven advantageous to construct the stop 50 directly through this cover portion. A cross-section is shown in dashed lines. Figure 4 It is shown in a general outline.

[0032] Figure 4 As shown in Figure 3 A schematic cross-section is shown. The stop element 50 and the groove or recess 46, in which the intermediate element 44 is disposed, can be seen. The conductor element 42, used for conducting current in the circumferential direction, is shown in dashed lines. The conductor end is marked with reference numeral 22. The intermediate element 44 is, for example, a metal component made of copper, which is malleable when the contact element is disposed on the stop 50, thereby providing more reliable mechanical and electrical contact.

[0033] List of reference numerals

[0034] 10 rotors

[0035] 12 rotor teeth

[0036] 14 rotor slots

[0037] 20 Conductor Materials

[0038] 22 conductor ends

[0039] 24 collector elements

[0040] 25 connector

[0041] 40 contact elements

[0042] 42 Conductor Elements

[0043] 44 intermediate components

[0044] 46 recesses and grooves

[0045] 48 Stopping elements

[0046] 50 stop section

[0047] 60 rotor shaft

[0048] R rotor axis

Claims

1. A rotor (10) comprising a rotor base having a plurality of rotor teeth (12). The rotor teeth (12) are wound with a conductor material (20) to form a winding. The conductor material (20) has a conductor end (22), which is axially pressed against a stop (50) by a contact element (40) to establish a conductive connection. The contact element (40) or the stop (50) is designed to electrically connect at least two conductor ends (22) in the circumferential direction. The contact element (40) or the stop (50) includes at least one conductor element (42), thereby enabling a conductive connection to be provided in the circumferential direction between the at least two conductor ends (22). The contact element (40) or the stop (50) has a plurality of radially arranged recesses (46) for positioning and locating the conductor end (22), and An intermediate element (44) is provided in at least one recess (46), the intermediate element being designed to deform upon compression for connection with a conductor element (42).

2. The rotor (10) according to claim 1, wherein, The rotor base is surrounded by casting material to form a covering portion, and the covering portion forms the stop portion (50).

3. The rotor (10) according to claim 1, wherein, The contact element (40) is fixed in axial position by a stop element (48).

4. The rotor (10) according to any one of claims 1 to 3, wherein, The intermediate element (44) provides a conductive connection to the at least one conductor element (42).

5. The rotor (10) according to any one of claims 1 to 3, wherein, The contact element (40) is designed to provide a conductive connection along the rotor axis (R) to the current collector or slip ring module.

6. The rotor (10) according to claim 2, wherein, The covering is designed to provide a conductive connection along the rotor axis (R) to the current collector or slip ring module.

7. The rotor (10) according to any one of claims 1 to 3, wherein, The contact element (40) is configured as a current collector.

8. The rotor (10) according to any one of claims 1 to 3, wherein, The rotor is the rotor of a synchronous motor used for current excitation.

9. A method for manufacturing a rotor (10), the method comprising the following steps: - A rotor body is provided and wound with a conductor material (20) to form a winding having conductor ends (22). -The conductor end (22) is pressed against the stop portion (50) by the contact element (40); - An conductive connection is formed between at least two conductor ends (22) by means of a contact element (40) or a stop (50). The contact element (40) or the stop (50) includes at least one conductor element (42), thereby enabling a conductive connection to be provided in the circumferential direction between the at least two conductor ends (22). The contact element (40) or the stop (50) has a plurality of radially arranged recesses (46) for positioning and locating the conductor end (22), and An intermediate element (44) is provided in at least one recess (46), the intermediate element being designed to deform upon compression for connection with a conductor element (42).

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