Rotor for permanently excited electric machine comprising multi-part rotor plate stack and shroud ring, permanently excited electric machine and method for producing rotor

Abstract

The invention relates to a rotor (1) for a permanently excited electric machine, comprising: an embedded permanent magnet arrangement comprising a plurality of permanent magnets (12) for exciting a rotor flux; and a rotor plate stack (27) for holding and guiding a rotor magnetic flux of the permanent magnet arrangement, comprising a plurality of axial magnetic pockets (28) arranged distributed in the circumferential direction, in which the permanent magnets (12) are arranged, wherein the rotor stack (27) is formed in multiple parts with a core partial stack (2) and with a plurality of segment partial stacks (3) arranged in a circumferentially distributed manner on an outer side (7) of the core partial stack (2), the core partial stack (2) having a plurality of circumferentially distributed first receiving regions (6) for the permanent magnets (12) on the outer side (7), the core-part stack (2) has at least one first receiving region (6) for a permanent magnet (12), the core-part stack (2) has at least one section-part stack (3) on the inner side (9), each section-part stack has at least one second receiving region (10) for a permanent magnet (12) on the inner side (9), each first and each second receiving region (6, 10) forming a magnetic pocket (28), and the rotor (1) has a shroud ring (14) surrounding the multi-part rotor stack (27) for the force-fitting connection of the section-part stack (3) to the core-part stack (2), the core partial stack (2) and the segment partial stack (3) are at least temporarily in contact in the connected state.

Description

Technical Field

[0001] The invention relates to a rotor for a permanently excited electric machine. The rotor has an embedded permanent magnet arrangement, which includes a plurality of permanent magnets for exciting the rotor flux and a rotor plate stack for holding and guiding the rotor flux of the permanent magnet arrangement. The rotor plate stack has a plurality of axial magnetic pockets distributed in the circumferential direction, in which the permanent magnets are arranged. The invention also relates to a permanently excited electric machine and a method for manufacturing a rotor. Background Art

[0002] Attention is now focused on permanently excited electric machines, which are used in particular as traction machines for electrified motor vehicles, such as electric or hybrid vehicles. Such permanently excited electric machines have a stator and a rotor rotatably supported relative to the stator. The rotor has a rotor lamination and a permanent magnet arrangement for the excitation magnetic flux. The permanent magnet arrangement can be an embedded or buried permanent magnet arrangement in which the permanent magnets are arranged in magnetic pockets extending axially in the rotor lamination. The rotor lamination is usually composed of a plurality of axially stacked stamped laminations. In order to form magnetic pockets for permanent magnets, gaps are punched out of the laminations, which are arranged aligned with each other in the axial stacking of the laminations and form tunnel-like chambers. In addition, other gaps can be punched out of the laminations, which form air-filled cavities in the sense of chambers by axial stacking and mechanical connection of the laminations, for example, by packing the laminations. These cavities act as electromagnetic insulators and form flux deflection sections in the rotor core which are designed for targeted deflection of the rotor flux in the rotor core and which are therefore intended to minimize, in the best case completely avoid, undesired magnetic leakage and thus losses in the rotor core.

[0003] In and adjacent to the cavities, web regions can be provided in the lamination stack, which have a very small cross section and act as so-called flux barriers. The minimum width of these webs is often limited by the material properties of the rotor lamination stack, such as strength, especially under loads due to centrifugal forces, and in connection with production, such as by punching tools and packaging processes, so that compromises must be made here with regard to their function as flux barriers. For this reason, in known rotor lamination stacks, material, for example in the form of webs, is often present at locations where it is to be avoided according to an optimized electromagnetic design because it adversely affects the power characteristics or performance of the electric machine. Summary of the invention

[0004] The object of the present invention is to provide a high-performance, mechanically stable and electromagnetically improved permanently excited electric machine.

[0005] This object is achieved according to the invention by a rotor, a permanently excited electric machine and a method having the features according to the respective independent claims. Advantageous embodiments of the invention are the subject matter of the dependent claims, the description and the drawings.

[0006] The rotor of the permanent excitation motor according to the invention has: an embedded permanent magnet arrangement structure, which includes a plurality of permanent magnets for exciting the rotor flux. In addition, the rotor has a rotor plate stack for holding and guiding the rotor flux of the permanent magnet arrangement structure, the rotor plate stack including a plurality of axial magnetic pockets arranged in a distributed manner in the circumferential direction, the permanent magnets being arranged in the magnetic pockets. The rotor plate stack is constructed in a multi-piece manner. For this purpose, the rotor plate stack has a core plate stack, which has a plurality of first receiving areas for permanent magnets arranged in a distributed manner in the circumferential direction on the outer side. In addition, the rotor plate stack has a plurality of segment plate stacks arranged in a distributed manner in the circumferential direction on the outer side of the core plate stack, the segment plate stacks each having at least one second receiving area for permanent magnets on the inner side. Here, each first and second receiving area constitutes a magnetic pocket. In addition, the rotor has a hoop ring surrounding the multi-piece rotor plate stack, the hoop ring being used for the force-locking connection of the segment plate stack with the core plate stack. In this case, the core partial laminated core and the segment partial laminated core are in contact at least temporarily in the connected state.

[0007] The invention also relates to a permanently excited electric machine for a motor vehicle, comprising a stator and a rotor according to the invention which is rotatably mounted relative to the stator. The electric machine functions in particular as a drive machine for a motor vehicle, so that the motor vehicle is designed as an electrified motor vehicle. The permanently excited electric machine is an internal rotor machine, in which the rotor is rotatably mounted in the stator. The stator can have a stator laminated core and a stator winding held by the stator laminated core and which can be energized for exciting the stator flux.

[0008] The rotor has a plurality of rotor poles arranged adjacent to each other in the circumferential direction. Here, each rotor pole is equipped with a sector of a particularly cylindrical rotor lamination. The rotor lamination is constructed in a multi-piece manner and has a core lamination and a segment lamination, and the segment lamination, that is, the core lamination and the segment lamination are connected to form a rotor lamination in a manner that can be detached again. For example, the rotor lamination can have a segment lamination per rotor pole. The segment lamination is a lamination separated from each other, and the lamination has a plurality of axially stacked laminations. The segment lamination is joined to form a rotor lamination in this manner, and the segment lamination is arranged radially outside the core lamination in the circumferential direction. That is, in the joined state of the segment lamination, the core lamination is arranged radially internally with respect to the rotation axis of the rotor and the segment lamination is arranged radially externally distributed in the circumferential direction. The core lamination has an axial passage opening in this, and the rotor shaft extending along the rotation axis is guided through the passage opening and is connected to the core lamination in a rotationally fixed manner.

[0009] The core laminate and the segment laminate have receiving areas on radially mutually facing surfaces or sides, which are arranged at least partially radially spaced apart from each other in the joined state of the segment laminate and thus form magnetic pockets in the form of axial, tunnel-shaped chambers. At least one magnetic pocket is formed in the rotor laminate for each rotor pole. The first receiving area is formed by the contour of the outer side or by the outer contour of the core laminate and the second receiving area by the contour of the inner side or by the inner contour of the segment laminate. The receiving area, in particular the first receiving area of ​​the core laminate, can have, for example, a groove-shaped, axially extending recess, which is arranged in the outer side of the core laminate and in which the permanent magnet is partially arranged. The recess can be formed, for example, by punching out a recess or notch in the laminate and by axial stacking of the laminate. The receiving area, in particular the second receiving area of ​​the segment laminate can also have a contact surface or a contact surface, which is arranged in contact with the permanent magnet and forms a cover for the groove-shaped recess. The receiving region surrounds the permanent magnet in such a way that the permanent magnet is embedded or integrated into the rotor core. As a result, the rotor core has a full-pole geometry.

[0010] In order to equip the rotor lamination with permanent magnets, a sleeve-shaped assembly aid can be provided. The sleeve-shaped assembly aid and the core lamination can be axially joined, for example, in that the assembly aid is pushed or pulled axially onto the core lamination. Subsequently, the permanent magnets and the segment lamination are arranged or positioned on the core lamination with the aid of the assembly aid. For example, the permanent magnets and the segment lamination are pushed axially into an intermediate space, which is formed between the outer side of the core lamination and the inner side of the assembly aid. The permanent magnets are not yet magnetized here, in particular. In order to position the segment lamination in the assembly aid and thereby correctly position the permanent magnets and the segment lamination on the core lamination, the outer side of the segment lamination and the inner side of the assembly aid can have positioning elements that correspond to each other and act together.

[0011] The positioning elements of the segment laminate stack are in particular axial chamfers on the outer side of the segment laminate stack and the positioning elements of the assembly aid are in particular axial projections on which the chamfers are supported in the circumferential direction. For example, the segment laminate stack can be arranged between two projections of the assembly aid, so that chamfers of the segment laminate stack adjacent in the circumferential direction are supported in the circumferential direction on two projections of the assembly aid adjacent in the circumferential direction. Once all permanent magnets and the segment laminate stack are arranged on the core laminate stack, the assembly aid is removed again, for example pulled out axially or peeled off, wherein the permanent magnets and the segment laminate stack remain on the core laminate stack.

[0012] For the mechanical connection of the segment part lamination and the core part lamination in the case of containing permanent magnets, a hoop is provided. The hoop is in particular an elastic element, which forms an extrusion bond in the already set state on the rotor lamination, by which the segment part lamination is directly or indirectly pressed onto the core part lamination by the permanent magnet. Thus, the segment lamination is connected in a force-locking manner. By means of the force-locking connection made by means of the hoop, the core part lamination and the segment part lamination are in contact at least temporarily, that is, for example, when the motor is stopped and / or in operation. The hoop is cylindrical and can be formed in one piece or in multiple pieces. In particular, the hoop has a fiber-reinforced, for example, carbon fiber-reinforced plastic. The hoop can therefore be a CFK hoop with a particularly low weight. However, the hoop can also be formed by another material. The hoop can, for example, be axially engaged in the form of a hoop covering, pushing or pulling the hoop onto the rotor lamination. In particular, the removal of the assembly aid and the installation of the hoop are carried out in a temporarily overlapping manner. In other words, both the assembly aid and the collar are temporarily arranged on the rotor lamination stack in order to prevent the rotor lamination stack from falling apart again. That is, while the assembly aid is being pulled out or peeled off through the first end side of the rotor lamination stack, the collar is already pulled onto the axially opposite second end side of the rotor lamination stack. During the joining process of the rotor, two support and balancing disks can additionally be arranged on the axially opposite end sides of the rotor lamination stack. These support and balancing disks can also be joined by means of the assembly aid.

[0013] In contrast to a one-piece rotor lamination stack, in which magnetic pockets or chambers are surrounded by lamination material in the form of webs on all sides by punching out, the chambers are formed here by radially joining partial laminations provided with receiving regions. As a result, the dimensions of the webs or webs that are determined by stability and / or related to manufacturing can be at least reduced in the rotor lamination stack at electromagnetically unfavorable locations. This is also accompanied by a reduction in the weight of the rotor, so that the performance of the motor can be improved in an advantageous manner. In addition, the rotor can be disassembled again particularly simply by removing the hoop. As a result, in particular the permanent magnets can be removed from the rotor lamination stack and recycled, so that the motor is also designed to be particularly sustainable.

[0014] In one embodiment of the rotor, it is provided that the core laminate has a first receiving region with two V-shaped groove-shaped recesses per rotor pole, which are covered by one segment laminate respectively when forming a V-shaped magnetic pocket. For example, each segment laminate can have a second receiving region with two V-shaped contact surfaces or cover surfaces, which cover the groove-shaped recesses when forming a V-shaped magnetic pocket. Due to the V-shaped contact surfaces, the segment laminate has, for example, a triangular contour segment.

[0015] The V-shaped magnetic pocket is here in particular formed as a chamber, in which the area between the two permanent magnets is formed without a web in order to provide a cavity for reducing the leakage flux. That is, no plate stack material is arranged between the two V-shaped permanent magnets of the rotor pole. The area or free space between the permanent magnets is used to reduce the leakage flux, which can appear at the edges or ends of the permanent magnets. The rotor plate stack can have additional cavities, which act as flux barriers or flux deflection elements. These flux barriers or flux deflection elements can be arranged in the core part plate stack and / or the segment part plate stack and are formed by hole-shaped stampings in the axially stacked and mechanically connected plate stacks of the corresponding partial plate stack.

[0016] It can be provided that the core laminate is star-shaped or radially configured. For this purpose, the core laminate has radially outwardly protruding core teeth or core spokes, which define a first receiving area in the circumferential direction, and the segment laminate arranged in the circumferential direction is at least partially and / or at least temporarily supported on the core teeth or core spokes. The core teeth define the corresponding rotor pole on the pole edge side and therefore have the q axis of the corresponding rotor pole. The d axis extends in the center of the rotor pole, for example between two V-shaped permanent magnets. In particular, the core tooth side of the core tooth has a first receiving area. For example, the core tooth side can extend obliquely and have groove-shaped recesses respectively. That is, two permanent magnets are arranged in the core tooth sides of the core teeth facing each other on the pole edge side of each rotor pole. The core teeth also act as a supporting element for the segment laminate. For example, the segment laminate is at least temporarily supported and fixed to two core teeth adjacent to each other in the circumferential direction by means of a hoop.

[0017] For example, it can be provided that the segmental laminations have radially inwardly protruding segment sections on the edge side, which are arranged on the head surface of the core part tooth and are radially supported on the core part tooth. The radially inwardly protruding segment sections form radial webs, which are arranged on both sides on the triangular profile segment sections, for example, by tangential segment sections in the form of tangential webs. The ends of the radial webs are arranged in contact with the head surface of the core part tooth. In this case, two adjacent segmental laminations share a core part tooth in that the mutually adjacent radial webs of the two segmental laminations are arranged side by side on the head surface of the core part tooth. The head surface is in particular flat or not arched. Preferably, the radially inwardly protruding segment sections of two adjacent segmental laminations are arranged side by side on the head surface of the core part tooth while forming a tangential gap, wherein the outer side of the rotor lamination is formed by the outer side of the segmental laminations and the tangential gap forms a cavity that reduces the leakage flux. The outer side of the segment partial laminated core is in particular designed to be curved, so that the outer side of the rotor laminated core is designed to be cylindrical.

[0018] It can also be provided that the core part tooth has elastic tangential webs extending in the circumferential direction on both sides and the segment part laminated core has protrusions extending tangentially on the edge side. The protrusions are arranged radially overlapping with the elastic tangential webs in the connected state of the core part laminated core and the segment part laminated core, while forming corresponding radial gaps. The elastic tangential webs are arranged against the protrusions by radial deflection caused by centrifugal force when forming flexible flux webs and thus at least temporarily and at least partially close the radial gaps. In particular, the outer side of the rotor laminated core is formed by the outer side of the segment part laminated core and by the head surface of the core part tooth. The tangential webs of the core part tooth can extend from the core part tooth side in the direction of the corresponding pole center and together with the protrusions form flexible flux webs. In the undeflected state of the tangential webs, radial gaps are at least partially formed between the tangential webs and the corresponding overlapping protrusions. For example, the segment laminated core can be supported only on the permanent magnets in the undeflected state and thus connected to the core laminated core by means of the collar via the permanent magnets in a force-locking manner. Thus, the segment laminated core and the core laminated core do not touch in the undeflected state.

[0019] The radial gap can be closed at least partially and temporarily by the deflection of the tangential webs due to centrifugal forces. As a result, the magnetic flux can flow through the formed leakage flux webs and reduce the magnetic flux of the rotor. The centrifugal forces can increase the proportion of the abutting sheet metal parts and thereby form a larger leakage flux web. This design leads to a weakening of the excitation of the rotor and requires less field weakening of the stator. As a result, the power loss of the electric machine can be reduced at high speeds.

[0020] The embodiments and advantages with regard to the rotor configuration according to the invention apply correspondingly to the permanently excited electric machine according to the invention and to the method according to the invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Further features of the invention are apparent from the claims, the drawings and the description of the drawings. The features and feature combinations mentioned above in the description and the features and feature combinations mentioned below in the description of the drawings and / or shown individually in the drawings can be used not only in the respectively indicated combination but also in other combinations or individually.

[0022] The invention will now be further explained with the aid of preferred embodiments and with reference to the accompanying drawings.

[0023] Figure 1 A schematic perspective view showing a rotor for a permanently excited electric machine;

[0024] Figure 2 A perspective view showing a first configuration of a rotor core lamination stack;

[0025] Figure 3 A perspective view showing a first configuration of a segment partial laminated core of a rotor;

[0026] Figure 4 a perspective view showing a rotor shaft of the rotor;

[0027] Figure 5 A perspective view showing the permanent magnets of the rotor;

[0028] Figure 6 a perspective view showing a hoop of a rotor;

[0029] Figure 7 A perspective view showing the support and balancing disc of the rotor;

[0030] Figures 8a-8f Showing the assembly steps when assembling the rotor;

[0031] Fig. 9 shows a cross section through the rotor when it is assembled;

[0032] Fig.10 Shown in accordance with Fig. 9 An enlarged portion of a cross section;

[0033] Fig.11 shows a front view of the rotor when it is assembled;

[0034] Fig.12 Shown in accordance with Fig.11 An enlarged portion of a front view of ;

[0035] Fig.13a perspective view showing a second configuration of a rotor laminated core including a core laminated core and a segment laminated core; and

[0036] Fig.14 Shown by including Fig.13 Cross section of a rotor with a rotor plate stack.

[0037] In the figures, identical elements or elements having the same function are provided with the same reference symbols. DETAILED DESCRIPTION

[0038] Figure 1 The rotor 1 for a permanently excited electric machine, which is used, for example, as a motor for an electrified motor vehicle, is shown. The rotor 1 has a multi-part rotor plate stack 27 (see Figure 8d ), the rotor plate stack is assembled from a core plate stack 2 and a segment plate stack 3. Figure 2 A first configuration of the core laminate 2 is shown in FIG. Figure 3 A first embodiment of a segment laminate core 3 is shown in FIG. The core laminate core 2 has a guide passage 4, Figure 4 The rotor shaft 5 shown in FIG. 1 is guided through the guide passage and is connected to the core laminated core 2 in a rotationally fixed manner. The core laminated core 2 also has a first receiving region 6 on the outer side 7 per rotor pole, which is arranged distributed in the circumferential direction. The first receiving region 6 has two V-shaped, groove-like recesses 8 per rotor pole, which extend axially in the outer side 7 of the core laminated core 2. The segment laminated core 3 has a second receiving region 10 on its inner side 9, which has two V-shaped contact surfaces 11 per rotor pole and thus per segment laminated core 3. The segment laminated core 3 thus has a segment section with a triangular profile.

[0039] The first receiving region 6 and the second receiving region 10 form a magnet pocket 28 for the permanent magnets 12 in the assembled state of the core partial laminate core 2 and the segment partial laminate core 3 (see Figure 8d ), for example in Figure 5 1 , one of the permanent magnets 12 is shown. That is, the permanent magnets 12 are each enclosed in an axial magnetic pocket 28 formed by the recess 8 and the contact surface 11 and are thus embedded in the rotor core 27. For the deflection of the magnetic flux and / or for the purpose of preventing the leakage flux share of the magnetic flux of the permanent magnets 12, the core core 2 can have a further cavity 13, which extends axially through the rotor core 27. In addition, the cavity 13 can be used to improve the elastic properties in the core core 2 of the joined rotor core 27.

[0040] For the mechanical connection of the segment laminated core 3 to the core laminated core 2 , the rotor 1 has a collar 14 , which is provided, for example, at Figure 6 . The hoop ring 14 is in particular a CFK hoop ring and is cylindrically configured so that the hoop ring 14 can radially surround the cylindrical rotor plate stack 27. The hoop ring 14 and the segment plate stack 3 arranged on the core plate stack 2 have an excess to each other, so that the segment plate stack 3 is pressed directly or indirectly onto the core plate stack 2 via the permanent magnets 12 arranged in the magnetic pockets 28. Therefore, a force-locking connection or a compression connection between the core plate stack 2 and the segment plate stack 3 can be provided by means of the hoop ring 14. In addition, the rotor 1 has two support and balancing disks 15, which are arranged on axially opposite end sides of the assembled rotor plate stack 27. Figure 7 The support and balancing disk 15 shown in the figure has, for example, a peripheral recess 16 in the form of an annular groove, which acts as a positioning aid for a drill for inserting a balancing hole. In addition, the support and balancing disk 15 has a passage 17 for the rotor shaft 5, which is connected to the support and balancing disk 15.

[0041] Figures 8a to 8f The assembly steps in the assembly of the rotor 1 are shown. First, the core laminate 2 and the rotor shaft 5 are joined and then one of the support and balancing disks 15 is joined, so that Figure 8a The structural assembly 18 shown in FIG. Figure 8b 19 is a sleeve-shaped assembly aid 19 shown in FIG. The assembly aid has a positioning element 21 in the form of axial projections 22 arranged at intervals from each other in the circumferential direction on the inner side 20. The assembly aid 19 engages with the structural assembly 18 in the axial direction, so that the assembly aid 19 is arranged as in FIG. Figure 8c As shown in FIG. 1 , the structural assembly 18 is radially surrounded.

[0042] The permanent magnets 12 and the segment laminated core 3 are then arranged on the core laminated core 2 by means of an assembly aid 19. For this purpose, the segment laminated core 3 also has positioning elements 23 (see Figure 3), the positioning element is designed here as a chamfer 24 on the outer side 25 of the segment laminate core 3. The permanent magnets 12 and the segment laminate core 3 are here particularly continuously pushed into the intermediate space 26 between the assembly aid 19 and the core laminate core 2, the structural assembly 18 together with the assembly aid 19 being twistable in the circumferential direction during the assembly process. For example, first, the permanent magnet 12 can be pushed axially into the recess 8 of the rotor pole of the core laminate core 2 which is at the apex. Subsequently, the segment laminate core 3 is pushed in axially so that the chamfer 24 of the segment laminate core 3 is supported in the circumferential direction on two adjacent projections 22 of the assembly aid 19 and the segment laminate core 3 is thus guided between the projections 22 during the insertion. Subsequently, the assembly aid 19 can be twisted with the structural assembly 18 so that the rotor pole of the core laminate core 2 which has not yet been assembled is at the apex and can subsequently be assembled. By arranging all the permanent magnets 12 and the segment laminate core 3 on the core laminate core 2, a rotation of the structural assembly 18 is produced. Figure 8d , a rotor laminated core 27 is shown having axial magnet pockets 28 which are formed by the receiving regions 6 , 10 of the partial laminated cores 2 , 3 and which surround the permanent magnets 12 .

[0043] Then, as in Figure 8e As shown in FIG. 1 , the second support and balancing disk 15 is pushed axially into the assembly aid 19 and arranged on the end side on the rotor plate stack 27 . Figure 8f As shown in FIG. 1 , the assembly aid 19 is pulled out of the rotor plate pack 27 in a pull-out direction 29, while the hoop 14 is simultaneously pulled onto the rotor plate pack 27 in a joining direction 30. The pull-out direction 29 and the joining direction 30 are oriented identically here. After the assembly aid 19 has been completely pulled out and the hoop 14 has been completely pulled on, a Figure 1 The rotor 1 is shown in FIG.

[0044] Fig. 9 A cross section through a rotor laminated core 27 which is equipped with permanent magnets 12 and surrounded by an assembly aid 19 is shown. Fig.10 Shown in accordance with Fig. 9 The core laminate 2 and the segment laminate 3 are shown in the enlarged cross-sectional detail A. Figure 2 and Figure 3The first embodiment shown in FIG. 2 is formed in a star-shaped or radial shape and has a plurality of core teeth 31 spaced apart in the circumferential direction. The core tooth sides 32 of the core teeth 31 have one recess of each of the groove-shaped recesses 8. The core tooth sides 32 extend obliquely here, so that two recesses 8 are arranged in a V-shaped manner per rotor pole. The contact surface 11 of the segment plate stack 3 is also arranged in a V-shaped manner, so that the magnetic pockets 28 are formed in a V-shaped manner and the permanent magnets 12 have a V-arrangement structure in the rotor plate stack 27. The regions 33 of the magnetic pockets 28 between the permanent magnets 12 are formed without webs, so that the regions 33 constitute air-filled cavities for reducing leakage flux, in particular for preventing leakage flux.

[0045] Furthermore, the core tooth 31 has a flat, axially and tangentially extending head surface 34, on which radially inwardly protruding segment sections 35 of the segment laminated core 3 are arranged. In this case, two radial segment sections 35 in the form of radial webs of two adjacent segment laminated cores 3 are arranged on the head surface 34 of the core tooth 31, so that the outer side of the rotor laminated core 27 is formed by the curved outer side of the segment laminated core 3. The head surface 34 forms the contact area between the core laminated core 2 and the segment laminated core 3. The overhang and centering between the segment laminated core 3 and the subsequently joined hoop 14 and the resulting load path from the segment laminated core 3 to the core laminated core 3 can be damped by the cavity 13 and thus by the elastic properties of the core laminated core 2.

[0046] A chamfer 24 is provided on the outer edge of the segment section 35, which interacts with the projection 22 of the assembly aid 19. A radial gap 36 is formed between the segment sections 35 of the segment partial laminated core 3 for tolerance compensation during assembly of the rotor 1, which radial gap also acts as an electromagnetic insulator or flux barrier. A tangential segment section 37 in the form of a tangential web is also provided between the radial web 35 and the contact surface 11 of the segment partial laminated core 3, which serves for targeted flux guidance.

[0047] Fig.11 A front view of a rotor laminated core 27 provided with balancing and support disks 15 is shown, which is surrounded by an assembly aid 19 . Fig.12An enlarged detail B of the front view is shown. There is a clearance fit between the outer side 25 of the segment laminated core 3 and the inner side 20 of the mounting aid 19. Furthermore, the inner diameter of the mounting aid 19 in the region of the positioning elements 21 is larger than the outer diameter of the support and balancing disk 15. As a result, the mounting aid 19 can be pulled out past the support and balancing disk 15 and its outer diameter after the support and balancing disk 15 has been joined. The inner diameter of the subsequently joined collar 14 is larger than the outer diameters of the two support and balancing disks 15. As a result, the collar 14 can be joined to the segment laminated core 3 of the rotor laminated core 2 without collision and simultaneously joined past the support and balancing disk 15.

[0048] Fig.13 A second embodiment of a rotor core 27 comprising a core partial core 2 and a segment partial core 3 is shown in a perspective view. Fig.14 Shown by including Fig.13 1 is a partial cross-section of a rotor 1 with a rotor lamination 27. The core lamination 2 is also star-shaped and has core teeth 31, which have elastic tangential webs 38 extending in the circumferential direction on both sides. The tangential webs 38 can be deflected radially outward when the rotor 1 rotates under the influence of centrifugal force. For this purpose, the tangential webs 38 have a head area 38a with increased weight on the end side. The tangential webs 38 are offset radially inward relative to the head surface 34 of the core teeth 31 and are arranged on the corresponding core tooth side 32. The segment lamination 3 has a tangential protrusion 39, which is arranged radially overlapping with the tangential web 38 while forming a radial gap 40. The tangential protrusion 39 is connected to the triangular contour segment on both sides. The radial gap 40 can be closed at least partially by the deflection of the corresponding tangential web 38 in the direction of the overlapping protrusion 39 caused by the centrifugal force, thereby forming a flexible flux web. The overhang of the laminated core 2, 3 relative to the collar 14 and the radial gap 40 between the tangential webs 38 and the projections 39 can be adjusted in such a way that in the armature adjustment region of the electric machine there is sufficient gap 40 for as little leakage flux as possible to flow through the tangential webs 38 and the projections 39. The outer side 25 of the segment laminated core 3 and in particular the arched head surface 34 form the outer side of the rotor laminated core 27, which is radially surrounded by the collar 14.

Claims

1. A rotor (1) for a permanently excited electric machine, the rotor comprising: - an embedded permanent magnet arrangement comprising a plurality of permanent magnets (12) for exciting the rotor flux, and - a rotor plate stack (27) for holding and guiding the rotor magnetic flux of the permanent magnet arrangement, the rotor plate stack comprising a plurality of axial magnetic pockets (28) distributed in the circumferential direction, the permanent magnets (12) being arranged in the magnetic pockets, characterized in that - the rotor laminate (27) is constructed in multiple parts, comprising a core laminate (2) and a plurality of segment laminates (3) arranged distributed in the circumferential direction on the outer side 7 of the core laminate (2), the core laminate having a plurality of first receiving areas (6) for the permanent magnets (12) arranged distributed in the circumferential direction on the outer side (7), the segment laminate having at least one second receiving area (10) for the permanent magnets (12) on the inner side (9), each of the first and second receiving areas (6, 10) forming a magnet pocket (28), and The rotor (1) has a collar (14) surrounding the multi-part rotor laminate core (27), the collar being used for a friction-locking connection of the segment laminate core (3) to the core laminate core (2), the core laminate core (2) and the segment laminate core (3) being in at least temporary contact in the connected state.

2. The rotor (1) according to claim 1, characterized in that The bracket (14) comprises a fiber-reinforced, in particular carbon fiber-reinforced, plastic.

3. The rotor (1) according to claim 1 or 2, characterized in that The core laminated core (2) has a first receiving region (6) per rotor pole with two V-shaped, groove-shaped recesses (8) which are arranged in a V-shaped manner and which are covered by one segment laminated core (3) per rotor pole, forming a V-shaped magnet pocket (28).

4. The rotor (1) according to claim 3, characterized in that The V-shaped magnet pocket (28) is designed as a chamber in which the region (33) between two permanent magnets (12) is designed without webs in order to provide a cavity that reduces leakage flux.

5. The rotor (1) according to any one of the preceding claims, characterized in that The core laminated core (2) is of star-shaped design and the first receiving region (6) has core teeth (31) defined in the circumferential direction and projecting radially outward, on which the segment laminated core (3) is at least temporarily supported.

6. The rotor (1) according to claim 5, characterized in that The segment part laminated core (3) has, on the edge side, a segment section (35) protruding radially inwards, which is arranged on a head surface (34) of the core part tooth (31) and is radially supported on the core part tooth (31).

7. The rotor according to claim 6, characterized in that Radially inwardly projecting segment sections (35) of two adjacent segment laminated cores (3) are arranged side by side on a head surface (34) of a core tooth (31) while forming tangential gaps (36), the outer side of the rotor laminated core (27) being formed by the outer sides (25) of the segment laminated cores (3) and the tangential gaps (36) forming cavities that reduce leakage flux.

8. The rotor (1) according to claim 5, characterized in that The core part tooth (31) has elastic tangential webs (38) extending in the circumferential direction on both sides, and the segment part laminated core (3) has projections (39) extending tangentially on the edge side, wherein the projections (39) are arranged radially overlapping with the elastic tangential webs (39) while forming a radial gap (40) in the connected state of the core part laminated core (2) and the segment part laminated core (3), and the elastic tangential webs (38) are arranged to abut against the projections (39) by radial deflection caused by centrifugal force while forming flexible flux webs and thus at least temporarily and at least partially close the radial gap (40).

9. The rotor (1) according to claim 8, characterized in that The outer side of the rotor laminated core (27) is formed by the outer side (25) of the segment laminated core (3) and by the head surfaces (34) of the core teeth (31).

10. The rotor according to any one of the preceding claims, characterized in that The segment partial laminated core (3) has a positioning element (23), in particular an axially extending chamfer (24), for positioning the segment partial laminated core (3) in a sleeve-like assembly aid (19). 11 . A permanently excited electric machine for a motor vehicle, comprising a stator and a rotor ( 1 ) as claimed in one of the preceding claims, which is mounted rotatably relative to the stator.

12. Method for producing a rotor (1) according to any one of claims 1 to 10, comprising the steps of: - providing the core stack (2), - providing a sleeve-shaped assembly aid (19), - axially joining the assembly aid (19) and the core laminate core (2), wherein: The sleeve-shaped assembly aid (19) radially surrounds the core laminate (2) in the joined state. - positioning the permanent magnet (12) and the segment laminated core (3) on the core laminated core by axially introducing the permanent magnet (12) and the segment laminated core (3) into the assembly aid (19), - engaging the support and balancing disk (15) on the opposite end side of the rotor plate stack (27), - removing the assembly aid (19), - Mounting the hoop ring (14) on the rotor plate stack (27).

13. The method according to claim 12, characterized in that The removal of the assembly aid (19) from the rotor laminated core (27) and the installation of the bracket (14) on the rotor laminated core (27) are temporarily performed in an overlapping manner.

Images