Rotor, manufacturing assembly for producing rotor, method for producing rotor, and electric machine

By designing offset holes that deviate from the circular shape in the rotor stack of the electric motor, adjusting the relative offset of the rotor body, the problems of load pulsation and torque fluctuation under high torque conditions are solved, and higher operating stability and service life are achieved, while reducing production costs.

CN119968763APending Publication Date: 2025-05-09SCHAEFFLER TECHNOLOGIES AG & CO KG
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Patent Information

Application Number
CN202380064527.8
Authority / Receiving Office
CN · China
Patent Type
Applications(China)
Current Assignee / Owner
Priority Date
2022-09-21
Filing Date
2023-08-29
Publication Date
2025-05-09

AI Technical Summary

Technical Problem

In the prior art, the rotor of the electric motor is prone to load pulsation and torque fluctuations under high torque conditions, affecting the synchronization characteristics and operating stability.

Method used

By designing offset holes that deviate from the circular shape in the rotor laminate, the relative offset of the rotor body is adjusted using the first and second offset holes to ensure that the rotor laminate has the highest possible accuracy and stability when rotating.

Benefits of technology

It realizes reducing load pulsation and torque fluctuations under high torque conditions, improves the smooth operation and service life of the rotor, while reducing production costs and improving production accuracy.

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Abstract

The invention relates to a rotor (1) for an electric machine (2), in particular for use in a powertrain (3) of a motor vehicle (4) driven in a hybrid or all-electric manner. The rotor (1) is made of a plurality of rotor bodies (6), which are made of stacked rotor laminations (5) and which are equipped with permanent magnets (8). The rotor bodies (6) are rotated relative to each other about a common axis of rotation (7), whereby the rotor (1) has an offset angle a defined by the total rotation of the rotor bodies (6), and each of the rotor laminations (5) has at least one first offset hole (9) through which a first rod-shaped tool (21) can be axially engaged, and the relative offset of the two axially adjacent rotor bodies (6) can be adjusted by means of the first offset hole. First offset holes (9) are arranged in the rotor (1) in a flush manner with respect to each other such that a first channel (10) extending axially through the rotor (1) is formed, said first offset holes (9) having a contour (11) deviating from the circular shape and having a longitudinal extension (12) in the radial direction.
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Description

Technical Field

[0001] The invention relates to a rotor for an electric machine, in particular for use in a powertrain of a motor vehicle driven in a hybrid or fully electric manner, wherein the rotor is made of a plurality of rotor bodies made of stacked rotor laminations and the rotor bodies are equipped with permanent magnets, wherein the rotor bodies rotate relative to each other about a common rotation axis, wherein the rotor has an offset angle α defined by the total rotation of the rotor bodies. The invention also relates to a manufacturing assembly for producing the rotor, a method for producing the rotor and an electric machine. Background Art

[0002] Electric motors are increasingly being used to drive motor vehicles, creating an alternative to fossil fuel-intensive internal combustion engines. Considerable efforts have been made to improve the suitability of electric drives for everyday use and also to provide users with the driving comfort they are accustomed to.

[0003] Permanent magnet synchronous motors (PSM) are already used in many industrial applications and are also increasingly used in the automotive industry in the process of electrification. Such permanent magnet synchronous motors usually have a stator to be energized and a permanent magnet rotor. The permanent magnet synchronous motor is constructed as both an inner rotor and an outer rotor (the stator is arranged inside). In order to achieve the best possible synchronous characteristics, the electrical winding of the stator is divided into a plurality of winding sections arranged one after another in the circumferential direction according to the current phase used. Modern synchronous motors are usually operated with a 3-phase network, in which high torques can be provided. In this case, the number of electrical sub-windings is an integer multiple of three. The number of magnetic poles formed on the rotor is adapted to the winding method of the electrical coils on the stator. The ratio between the number of poles on the rotor and the number of electrodes formed on the stator also affects the synchronous characteristics of the motor. Two adjacent poles on the rotor each form a pole pair.

[0004] Due to the magnetic forces acting on the permanent magnet synchronous motor, a noticeable "cogging effect" occurs when the rotor is rotated manually in the de-energized state. However, more problematic for the operating characteristics of such synchronous motors are similar effects which occur when the motor is powered and under load and which are referred to in this context as load pulsations, torque fluctuations or "ripple torque". If the number of poles is high enough, the load pulsations are barely noticeable when the motor is idling (when no torque or only low torque is available). However, when the engine is operated at high torque reduction, the load pulsations are clearly noticed as periodic torque fluctuations. The torque fluctuations usually follow sinusoidal oscillations, which correspond to the higher harmonics of the torque variations occurring at the pole pairs.

[0005] Since such load pulsations are disruptive in many applications, especially when high synchronization characteristics are required, various methods exist in the prior art to reduce the load pulsations. For example, attempts are made to counteract the load pulsations by changing the value of the current fed to the motor in the opposite direction. This type of electronic control can lead to a reduction in load pulsations in engines running at relatively low speeds and to constant load reductions in very fast-acting control circuits. However, if the motor control system has to compensate for rapidly changing load conditions at high speeds, conventional control circuits are no longer able to regulate the load pulsations simultaneously with reasonable effort.

[0006] Another solution sought in practical implementation is to reduce the load pulsations by tilting the poles of the rotor relative to the poles of the stator. In a permanent magnet synchronous motor, the permanent magnets arranged on the rotor are tilted relative to the axis of rotation. This tilting means that the entire cross-sectional area of ​​the poles does not face each other at any time, which on the one hand leads to a reduction in the maximum torque, but on the other hand also has a balancing effect with respect to the load pulsations.

[0007] Rotors for electric machines with such reduced torque ripple are known in the prior art. For example, the website https: / / etn-demeter.eu / rotor-shaping-technologies-for-permanent-magnet-electrical-machines / provides different concepts for rotors with reduced torque ripple.

[0008] A concept for reducing torque ripple known from the prior art as rotor skew is that a rotor having a plurality of rotor segments arranged in a row in the axial direction and rotated relative to one another by a certain angle can each be rotated relative to one another by a certain angle.

[0009] Various rotor skews are known. In the case of linear skew, the skew of magnetic poles of the same polarity extends linearly from the first rotor section to the last rotor section in the axial direction. V-shaped rotor skews are also known, in which the course of the magnetic poles resembles a V-shape.

[0010] The rotor of an electric motor is in many cases assembled using rotor laminations or rotor lamination stacks. As already explained above, for the correct operation of the electric motor, a defined offset or relative angular position of the rotor laminations or rotor lamination stacks with respect to one another is of considerable importance for the coordinated synchronization of the electric machine. Therefore, when assembling the rotor, this offset must be set reliably and correctly, and the rotor laminations or rotor lamination stack must be connected to the rotor shaft of the rotor with this specified offset. Furthermore, it should be ensured that once the offset has been correctly set, it is maintained even when the electric motor is in operation.

[0011] From DE 102018112195 A1 it is known to provide a cup-shaped or hat-shaped opening in the rotor laminations, preferably in all rotor laminations, for anchoring to one another, said opening having a depression on one side of the rotor lamination and a projection on the other side of the rotor lamination, the dimensions of the depression and projection being coordinated with one another for fastening to one another. This means that the presence of the depression or projection on the respective side of the rotor lamination simplifies the realization of an offset of the individual rotor laminations / rotor lamination stacks with respect to one another.

[0012] There is a continuing need to reduce the torque ripple of a rotor by means of rotor skew.

[0013] However, in conventional processes for joining lamination stacks, the lamination stacks are typically heated, for example during a plastic injection molding process, which causes the lamination stacks to thermally expand. As a result, the required tolerances for rotation of the individual rotor lamination stacks relative to each other may not be met. Summary of the invention

[0014] Therefore, the object of the present invention is to provide a rotor which can reduce the torque ripple and thus increase the smooth operation and service life of the rotor. The object of the present invention is also to achieve a rotor which can be produced cost-effectively and can ensure the highest possible precision when the individual rotor lamination stacks rotate relative to each other. Furthermore, the object of the present invention is to achieve an improved manufacturing assembly for producing a rotor and an optimized method for producing a rotor. The object of the present invention is also to provide an electric machine which is very quiet in operation and can be produced cost-effectively.

[0015] This object is achieved by a rotor for an electric machine, in particular for an electric machine for use in a powertrain of a motor vehicle driven in a hybrid or fully electric manner, wherein the rotor is made of a plurality of rotor bodies, which are made of stacked rotor laminations and are equipped with permanent magnets, wherein the rotor bodies rotate relative to each other about a common rotation axis, wherein the rotor has an offset angle α defined by the total rotation of the rotor bodies, wherein each of the rotor laminations has at least one first offset hole, through which a first rod-shaped tool can be axially engaged and by means of which the relative offset of two axially adjacent rotor bodies can be adjusted, and wherein the first offset holes are arranged in the rotor in a flush manner relative to each other so that a first channel extending axially through the rotor is formed, wherein the first offset hole has a profile that deviates from a circular shape and has a longitudinal extension in a radial direction.

[0016] This has the advantage that the rotor laminations can be positioned with sufficient accuracy in the circumferential direction to meet the required tolerances for rotation between the lamination stacks. Furthermore, the lamination stacks can be easily joined and different linear expansions of the lamination stacks and the tool at different temperatures can be compensated. Therefore, the rotor according to the invention has an offset hole pattern in the rotor laminations, by means of which the offset of the rotor body can be defined very accurately.

[0017] First, the individual elements of the claimed subject matter of the present invention are explained in accordance with their relevance or mentioned order in the claims, and then particularly preferred embodiments of the subject matter of the present invention are described.

[0018] The rotor is the rotating (turning) part of the electric machine. The rotor comprises in particular a rotor shaft and one or more rotor bodies formed by a rotor lamination stack arranged in a non-rotatable manner on the rotor shaft. The rotor shaft may be hollow, which on the one hand reduces weight and on the other hand allows a lubricant or coolant to be supplied to the rotor body.

[0019] For the purposes of the present invention, a rotor body is understood to mean a rotor without a rotor shaft. The rotor body is therefore made in particular of the rotor lamination stack and permanent magnets inserted into pockets of the rotor lamination stack or fixed to the circumference of the rotor lamination stack and any axial cover parts for closing the pockets.

[0020] The permanent magnets can preferably be inserted into pockets of the rotor lamination stack. Each pocket can be provided with a single larger rotor magnet designed as a bar magnet or with a plurality of smaller permanent magnet elements.

[0021] The rotor has a plurality of rotor bodies. Particularly preferably, the rotor bodies are formed substantially of identical parts, in particular substantially identically. It is highly preferred that the rotor bodies are formed of identical, in particular substantially identical rotor laminations. Therefore, the rotor body is particularly preferably formed by a rotor lamination stack, which is composed of a plurality of lamination-type individual sheets or rotor laminations, usually made of electrical steel, which are layered and stacked one on top of the other to form a stack, which is referred to as a rotor lamination stack. The individual laminations can be held together in the rotor lamination stack by gluing, welding or screwing. The rotor lamination stack can also particularly have permanent magnets, which are inserted into pockets of the rotor lamination stack or are fixed to the rotor lamination stack in the circumferential direction.

[0022] The rotor according to the invention is intended for use in an electric machine. Electric machines are generally used to convert electrical energy into mechanical energy and / or mechanical energy into electrical energy. Electric machines generally comprise a stationary part, called a stator or armature, and a part, called a rotor, arranged to be movable relative to the stationary part.

[0023] In the case where the electrical machine is designed as a rotating machine, a distinction is made in particular between radial flux machines and axial flux machines. A radial flux machine is characterized in that the magnetic field lines extend in the radial direction in the air gap formed between the rotor and the stator, while in the case of an axial flux machine the magnetic field lines extend in the axial direction in the air gap formed between the rotor and the stator. In conjunction with the present invention, the rotor according to the invention is preferably intended for use in a radial flow machine. The stator of a radial flux machine usually has a cylindrical structure and usually comprises electrical laminations which are electrically insulated from one another and are constructed in a layered manner and are stacked to form a lamination stack. Grooves distributed on the circumference or recesses closed in the circumferential direction are embedded in the electrical laminations extending parallel to the rotor axis and accommodate the stator winding or parts of the stator winding. Depending on the configuration towards the surface, the grooves can be closed with closing elements, such as closing wedges or covers, etc., to prevent the stator winding from separating.

[0024] The rotor according to the invention is intended in particular for use in an electric machine within the powertrain of a motor vehicle driven in a hybrid or fully electric manner.

[0025] In particular, the electric machine is dimensioned such that a vehicle speed of more than 50 km / h, preferably more than 80 km / h, and in particular more than 100 km / h can be achieved. The electric motor particularly preferably has an output of more than 30 kW, preferably more than 50 kW, and in particular more than 70 kW. Furthermore, it is preferred that the electric machine provides a speed of more than 5000 rpm, particularly preferably more than 10000 rpm, very particularly preferably more than 12500 rpm.

[0026] For the purposes of this application, a motor vehicle is a land vehicle that moves by machine power and is not constrained by railway tracks. The motor vehicle may for example be selected from the group of a passenger car, a truck, a scooter, a light motor vehicle, a motorcycle, a motor bus / coach or a tractor.

[0027] In the context of the present application, the powertrain of a motor vehicle is understood to mean all components of the motor vehicle which generate power for driving the motor vehicle and transmit the power to the road via the wheels.

[0028] According to another preferred improvement of the present invention, it can also be provided that the offset holes are arranged on a common pitch circle D1 coaxially positioned with the rotor.

[0029] Advantageous embodiments of the invention are specified in the dependent claims. The features listed individually in the dependent claims can be combined with one another in a technically meaningful manner and can define further embodiments of the invention. In addition, the features indicated in the claims are described and explained in more detail in the description, wherein further preferred embodiments of the invention are shown.

[0030] According to a preferred embodiment of the invention, it can be provided that each of the rotor laminations has at least one second offset hole, through which a second rod-shaped tool can be axially engaged and by means of which the relative offset of two axially adjacent rotor bodies can be adjusted, and the second offset holes are arranged in the rotor in a flush manner relative to each other so that a second channel extending axially through the rotor is formed, wherein the second offset hole has a profile that deviates from a circular shape and has a longitudinal extension in the radial direction.

[0031] An advantage of this design is that a geometrically unique arrangement of the rotor laminations can be defined by the two offset holes.

[0032] Most preferably, the first offset hole and the second offset hole are arranged on a common pitch circle D1 offset by 180° from one another, which allows a particularly good compensation of thermal expansions within the stator laminations.

[0033] According to another further preferred development of the present invention, it can also be provided that the first offset holes and / or the second offset holes of the rotor core are designed to be substantially identical, which is particularly advantageous in terms of manufacturing technology.

[0034] Furthermore, according to an equally advantageous embodiment of the invention, it can be provided that the first offset hole and / or the second offset hole is designed as an elongated hole, wherein the elongated hole has a substantially rectangular cross section, to which a semicircular cross section adjoins on both sides in the radial direction. This design has proven to be particularly advantageous for the production of offset rotors.

[0035] According to another particularly preferred embodiment of the invention, it can be provided that the rectangular cross section has a length L in the radial direction and the semicircular cross sections each have a diameter DS, wherein the length L is between L=0.1*DS and L=0.2*DS. This makes it possible to achieve the effect that very precise tolerances can be maintained in the circumferential direction while maintaining sufficient space in the radial direction to compensate for thermal expansion of the material.

[0036] It is further preferred that the radial extension of the elongated hole is less than 0.1*(D1+DS), whereby sufficiently good thermal expansion compensation can be provided.

[0037] The object of the invention can also be achieved by a manufacturing assembly for producing a rotor according to any one of claims 1 to 5, the manufacturing assembly comprising a first rod-shaped tool and a plurality of rotor bodies made of stacked rotor laminations, wherein the rotor bodies are equipped with permanent magnets and rotate relative to each other about a common rotation axis, wherein the rotor has an offset angle α defined by the total rotation of the rotor bodies, wherein each of the rotor laminations has at least one first offset hole, through which the first rod-shaped tool can be axially engaged and by means of which the relative offset of two axially adjacent rotor bodies can be adjusted, and wherein the first offset holes are arranged in the rotor in a flush manner relative to each other so that a first channel extending axially through the rotor is formed,

[0038] The first offset hole has a profile that deviates from a circular shape and extends longitudinally in the radial direction, and the first rod-shaped tool is engaged through the first offset hole with play in the radial direction and substantially without play in the circumferential direction when inserted into the first offset hole.

[0039] In addition, the object of the present invention can also be achieved by a method for producing a rotor, the method comprising the following steps:

[0040] providing a first rod-shaped tool, and

[0041] providing a plurality of rotor bodies made of stacked rotor laminations, wherein the rotor bodies can be equipped with permanent magnets and can rotate relative to one another about a common rotation axis, wherein the rotor has an offset angle α defined by the total rotation of the rotor bodies, wherein each of the rotor laminations has at least one first offset hole, through which a first rod-shaped tool can be axially engaged and by means of which a relative offset of two axially adjacent rotor bodies can be adjusted, and wherein the first offset holes are arranged in the rotor in a flush manner relative to one another, such that a first channel extending axially through the rotor is formed, wherein the first offset holes have a profile deviating from a circular shape and having a longitudinal extension in the radial direction,

[0042] Push the rotor laminations through the first offset holes onto the first rod-shaped tool.

[0043] In this context, it may also be advantageous to further develop the method such that the rotor lamination is pushed at a rotor lamination temperature of 15° C. to 35° C. Preferably, when pushing the rotor lamination, the first tool and the second tool have a temperature of 50° C. to 100° C., preferably 65° C. to 85° C. During molding, the rotor lamination and the tools are then preferably heated to a temperature between 150° C. and 200° C., preferably between 160° C. and 180° C.

[0044] The object of the invention is also achieved by an electric machine, in particular for a powertrain of a motor vehicle driven in a hybrid or fully electric manner, comprising a rotor according to any one of claims 1 to 5 . BRIEF DESCRIPTION OF THE DRAWINGS

[0045] The invention is explained in more detail below with reference to the accompanying drawings without limiting the general concept of the invention.

[0046] In the attached picture:

[0047] Figure 1 shows a schematic axial cross-section of the motor,

[0048] Figure 2 A front view of a rotor lamination stack showing a rotor,

[0049] Figure 3 A detailed view of the offset hole is shown,

[0050] Figure 4 shows a perspective view of a manufacturing assembly for a rotor,

[0051] Figure 5 A motor vehicle having an electric powertrain is shown in a schematic block diagram. DETAILED DESCRIPTION

[0052] Figure 1 There is shown a rotor 1 mounted for rotation relative to a stator 23 for an electric machine 2 for use in a powertrain 3 of a motor vehicle 4 driven in a hybrid or fully electric manner, as also shown in FIG. Figure 5 In the embodiment shown, the electrical machine 2 is designed as a radial flux machine.

[0053] The rotor 1 is made of three rotor bodies 6a, 6b, 6c, which are made of stacked rotor laminations 5 and are equipped with permanent magnets 8, which can be combined with Figure 2 See.

[0054] The rotor bodies 6 a , 6 b , 6 c rotate relative to each other about a common rotation axis 7 , wherein the rotor 1 has an offset angle α defined by the total rotation of the rotor bodies 6 .

[0055] As from Figure 2As can be seen in the figure, each of the rotor laminations 5 has a first offset hole 9, through which a first rod-shaped tool 13 can be axially engaged and by means of which the relative offset of two axially adjacent rotor bodies 6 can be adjusted, and the first offset holes 9 are arranged in the rotor 1 in a flush manner relative to each other, so that a first channel 10 extending axially through the rotor 1 is formed, which can be seen from Figure 2 and Figure 3 seen in the combination.

[0056] The first offset hole 9 has a contour 11 which deviates from a circular shape and has a longitudinal extension 12 in the radial direction.

[0057] Furthermore, each of the rotor laminations 5 has at least one second offset hole 14 through which the second rod-shaped tool 21 can be axially engaged and by means of which the relative offset of two axially adjacent rotor bodies 6 can be adjusted, and which are arranged in the rotor 1 in a flush manner relative to one another so that a second channel 15 is formed which extends axially through the rotor 1. The second offset hole 14 has a contour 16 which deviates from a circular shape and has a longitudinal extension 17 in the radial direction.

[0058] The first offset holes 9 and the second offset holes 14 of the rotor laminations 5 are substantially identical and are arranged on a common pitch circle D1 located coaxially with the rotor 1 .

[0059] Therefore, the rotor deflection of the individual rotor bodies 6a, 6b, 6c is influenced by the deflection holes 9, 14 arranged on the common pitch circle D1. Depending on the desired deflection angle of the rotor 1, the deflection holes are inserted into the rotor bodies 6a, 6b, 6c at different angles (angle 1, angle 2) on the pitch circle D1. Since only individual deflection holes are needed to ensure the rotation of the stator bodies 6a, 6b, 6c, they can be designed as elongated holes 18, such as in Figure 2 can be seen in.

[0060] When designing the elongated hole 18, the width of the elongated hole 18 is designed to have as little play as possible for the tool 13, 21. The tolerances are determined by the expansion of the tool 13, 21 at temperature and the manufacturing tolerances. The tolerances are in the range of <2.5% of the diameter of the round tool 13, 21. The radial length of the elongated hole 18 is determined by the different thermal expansions of the base plate 24 with the tool 13, 21 and the rotor lamination 5. A radial extension of the elongated hole of less than 0.1*(D1DS) has proven to be particularly advantageous.

[0061] In the embodiment shown, the first offset hole 9 and the second offset hole 14 are designed as elongated holes 18, wherein the elongated hole 18 has a substantially rectangular cross section 19, and the semicircular cross section 20 adjoins the rectangular cross section on both sides in the radial direction, as shown in FIG. Figure 3 The rectangular cross section 19 has a length L in the radial direction and the semicircular cross sections 20 each have a diameter DS, wherein the length L is between L=0.1*DS and L=0.2*DS.

[0062] Figure 4 shows the use for producing Figures 1 to 3 The manufacturing assembly 22 of the rotor 1 known from FIG. The manufacturing assembly 22 has a first rod-shaped tool 13 with a circular cross section and a second rod-shaped tool 21 with a circular cross section. In the embodiment shown, the first tool 13 and the second tool 21 are substantially identical. The diameter of the tools 13, 21 is selected so that the tools 13, 21 can penetrate the offset holes 9, 14. The tools 13, 21 extend orthogonally out of the plane of the base plate 24 so that the rotor laminations 5 rest on the base plate 24 when they are placed above the tools 13, 21 by means of the offset holes 9, 14.

[0063] Using the manufacturing assembly 22, the rotor 1 may be produced as follows:

[0064] First, a first rod-shaped tool 13 and a second rod-shaped tool 21 are provided. Figure 4 Then, a plurality of rotor bodies 6 made of stacked rotor laminations 5 are provided, wherein the rotor bodies 6 can be equipped with permanent magnets 8 and can rotate relative to each other about a common rotation axis 7, wherein the rotor 1 has an offset angle α defined by the total rotation of the rotor bodies 6. The rotor laminations 5 correspond to Figures 2 to 3 The rotor laminations 5 are then pushed onto the rod-shaped tools 13 , 21 through the first offset holes 9 , 14 .

[0065] The rotor lamination 5 is pushed at a rotor lamination 5 temperature of 15° C. to 35° C. Preferably, when pushing the rotor lamination 5, the first tool 13 and the second tool 21 have a temperature of 50° C. to 100° C., preferably 65° C. to 85° C. During molding, the rotor lamination 5 and the tools 13, 21 are then preferably heated to a temperature between 150° C. and 200° C., preferably between 160° C. and 180° C.

[0066] The terms "radial", "axial", "tangential" and "circumferential direction" used in this application always refer to the axis of rotation of the rotor of the electric machine. The terms "left", "right" and "above", "below", "above" and "below" are used here only to clarify the area of ​​the illustration currently described in the text. The following embodiments of the invention may also be arranged in different ways. The present invention is also not limited to the embodiments shown in the drawings. Therefore, the above description should not be regarded as restrictive, but as illustrative. The attached claims should be understood to mean that the stated features are present in at least one embodiment of the invention. This does not exclude the presence of other features. In the case where the claims and the above description define a "first" feature and a "second" feature, this designation is used to distinguish between two features of the same type without limiting the order of priority.

[0067] Reference numerals list

[0068] 1 Rotor

[0069] 2 Motor

[0070] 3 Powertrain

[0071] 4 Motor vehicles

[0072] 5 Rotor laminations

[0073] 6 Rotor body

[0074] 7 Axis of rotation

[0075] 8 permanent magnets

[0076] 9 Offset hole

[0077] 10 channels

[0078] 11. Outline

[0079] 12 Vertical extension

[0080] 13 Tools

[0081] 14 Offset hole

[0082] 15 channels

[0083] 16. Outline

[0084] 17 Vertical extension

[0085] 18 Long hole

[0086] 19 Section

[0087] 20 Section

[0088] 21 Tools

[0089] 22 Manufacturing Components

[0090] 23 Stator

[0091] 24 Base plate

Claims

1. A rotor (1) for an electric machine (2), in particular for use in a powertrain (3) of a motor vehicle (4) driven in a hybrid or fully electric manner, in, The rotor (1) is made of a plurality of rotor bodies (6), the rotor bodies are made of stacked rotor laminations (5), and the rotor bodies (6) are equipped with permanent magnets (8). wherein the rotor bodies (6) rotate relative to each other about a common rotation axis (7), wherein the rotor (1) has an offset angle α defined by the total rotation of the rotor bodies (6), It is characterized in that Each of the rotor laminations (5) has at least one first offset hole (9), through which a first rod-shaped tool (13) can be axially engaged and by means of which the relative offset of two axially adjacent rotor bodies (6) can be adjusted, and the first offset holes (9) are arranged in the rotor (1) in a flush manner relative to each other so that a first channel (10) is formed which extends axially through the rotor (1), The first offset hole (9) has a profile (11) that deviates from a circular shape and has a longitudinal extension (12) in the radial direction.

2. The rotor (1) according to claim 1, It is characterized in that Each of the rotor laminations (5) has at least one second offset hole (14), through which a second rod-shaped tool (21) can be axially engaged and by means of which the relative offset of two axially adjacent rotor bodies (6) can be adjusted, and the second offset holes (14) are arranged in the rotor (1) in a flush manner relative to each other so that a second channel (15) extending axially through the rotor (1) is formed, Therein, the second offset hole (14) has a contour (16) which deviates from a circular shape and has a longitudinal extension (17) in the radial direction.

3. The rotor (1) according to claim 1 or 2, It is characterized in that The first offset holes (9) and / or the second offset holes (14) of the rotor laminations (5) are substantially identical.

4. A rotor (1) according to any one of the preceding claims, It is characterized in that The first offset hole (9) and / or the second offset hole (14) is designed as an elongated hole (18), wherein the elongated hole (18) has a substantially rectangular cross section (19) to which a semicircular cross section (20) adjoins on both sides in the radial direction.

5. The rotor (1) according to claim 4, It is characterized in that The rectangular cross section (19) has a length L in the radial direction and the semicircular cross sections (20) each have a diameter DS, wherein the length L is between L=0.1*DS and L=0.2*DS.

6. A manufacturing assembly (22) for producing a rotor (1) according to any one of claims 1 to 5, comprising: a first rod-shaped tool (13), and A plurality of rotor bodies (6) made of stacked rotor laminations (5), wherein the rotor bodies (6) are equipped with permanent magnets (8) and rotate relative to each other about a common rotation axis (7), wherein the rotor (1) has an offset angle α defined by the total rotation of the rotor bodies (6), Each of the rotor laminations (5) has at least one first offset hole (9), through which the first rod-shaped tool (13) can be axially engaged and by means of which the relative offset of two axially adjacent rotor bodies (6) can be adjusted, and wherein the first offset holes (9) are arranged in the rotor (1) in a flush manner relative to one another so that a first channel (10) extending axially through the rotor (1) is formed, wherein the first offset hole (9) has a profile (11) which deviates from a circular shape and has a longitudinal extension (12) in the radial direction, Furthermore, the first rod-shaped tool (13) is engaged through the first offset hole (9) with play in the radial direction and substantially without play in the circumferential direction when inserted into the first offset hole (9).

7. A method for producing a rotor (1), the method comprising the following steps: A first rod-shaped tool () is provided and A plurality of rotor bodies (6) made of stacked rotor laminations (5) are provided, wherein: The rotor bodies (6) can be equipped with permanent magnets (8) and can be rotated relative to each other about a common rotation axis (7), wherein the rotor (1) has an offset angle α defined by the total rotation of the rotor bodies (6), wherein each of the rotor laminations (5) has at least one first offset hole (9), through which a first rod-shaped tool (13) can be axially engaged and by means of which the relative offset of two axially adjacent rotor bodies (6) can be adjusted, and wherein the first offset holes (9) are arranged in the rotor (1) in a flush manner relative to each other so that a first channel (10) extending axially through the rotor (1) is formed, wherein the first offset hole (9) has a contour (11) that deviates from a circular shape and has a longitudinal extension (12) in the radial direction, The rotor laminations (5) are pushed through the first offset holes (9) onto the first rod-shaped tool (13).

8. The method according to claim 7, It is characterized in that The rotor stack (5) is pushed at a rotor stack temperature of 15°C to 35°C.

9. The method according to claim 7 or 8, It is characterized in that When pushing the rotor laminations (5), the first tool (13) and / or the second tool (21) has a temperature of 50°C to 100°C, preferably 65°C to 85°C.

10. An electric machine (2), in particular for use in a powertrain (3) of a motor vehicle (4) driven in a hybrid or fully electric manner, comprising a rotor (1) according to any one of claims 1 to 5.

Citation Information

Patent Citations

  • Packaging and interlocking of rotor laminations for an electric machine, electric machine and method for manufacturing a rotor

    DE102018112195A1