Apparatus and method for manufacturing rotor of electric machine

Abstract

The invention relates to a device for producing a rotor of an electric machine, comprising a loading station for feeding a lamination stack and a rotor shaft, a heating station for heating the lamination stack, a press-fitting station for pressing the rotor shaft into the lamination stack, and a transport unit for transporting the lamination stack among the loading station, the heating station and the press-fitting station. The invention relates to a method for producing a rotor for an electric machine, comprising the following steps: feeding a stack of laminations in a loading station, transporting the stack of laminations from the loading station to a heating station, heating the stack of laminations in the heating station, transporting the heated stack of laminations from the heating station to the loading station, feeding a rotor shaft in the loading station, placing the rotor shaft on the stack of laminations, the lamination stack together with the rotor shaft is transported from the loading station to a press-fitting station, the rotor shaft is pressed into the lamination stack in the press-fitting station, a produced rotor comprising the lamination stack and the rotor shaft pressed therein is transported from the press-fitting station to the loading station, and the produced rotor is removed from the loading station.

Description

Field of the Invention

[0001] The present invention relates to an apparatus and a method for manufacturing a rotor of an electric machine by pressing a rotor shaft into a stack of laminations. Background Art

[0002] An electric machine having a rotor is known from document DE 10 2022 001 424 A1. The rotor includes a stack of laminations and a rotor shaft that is inserted into the stack of laminations. The rotor shaft is constructed approximately rotationally symmetrically. The stack of laminations consists of individual sheets arranged stacked in the axial direction. Each individual sheet has a central hole for receiving the rotor shaft.

[0003] The rotor is installed in the electric machine, which also includes a stator. Here, the rotor can rotate relative to the stator about a rotational axis. In this case, it is necessary for the stack of laminations and the rotor shaft to be connected to each other in a non-rotatable manner. Summary of the Invention

[0004] The object of the present invention is to provide an apparatus and a method for manufacturing a rotor of an electric machine.

[0005] This object is achieved by an apparatus for manufacturing a rotor of an electric machine having the features given in claim 1. Advantageous designs and improvements are the subject of the dependent claims. This object is also achieved by a method for manufacturing a rotor of an electric machine having the features given in claim 12.

[0006] The apparatus according to the present invention for manufacturing a rotor of an electric machine includes a loading station / workstation for supplying the stack of laminations and the rotor shaft, a heating station / workstation for heating the stack of laminations, a press-fitting station / workstation for pressing the rotor shaft into the stack of laminations, and a transport unit for transporting the stack of laminations between the loading station, the heating station, and the press-fitting station.

[0007] With the aid of the apparatus according to the present invention, the rotor shaft can be connected to the stack of laminations by thermal shrink fitting (Aufschrumpfen). Thereby, the stack of laminations and the rotor shaft are connected to each other in a force-locking and non-rotatable manner.

[0008] According to an advantageous design of the present invention, the press-fitting station has a hydraulic press for pressing the rotor shaft into the stack of laminations. The hydraulic press-fitting station ensures that the rotor shaft is precisely pressed into the stack of laminations.

[0009] According to an advantageous design of the present invention, the press-fitting station has a cooling device for cooling the hydraulic press.

[0010] According to an advantageous design of the present invention, the heating station has an induction furnace for heating the stack of laminations. The induction furnace ensures that the stack of laminations is relatively quickly heated to the required temperature within a few minutes.

[0011] According to an advantageous embodiment of the invention, the induction furnace is configured to heat the stack of laminations to a temperature of at least 400 °C. At this temperature, the stack of laminations expands sufficiently to receive the rotor shaft.

[0012] According to an advantageous embodiment of the invention, the loading station is arranged between the heating station and the press-fitting station. The feeding of the stack of laminations, the feeding of the rotor shaft, and the removal of the finished rotor can be carried out at the loading station, and the transport paths for the stack of laminations, the rotor shaft, and the rotor are relatively short.

[0013] According to an advantageous embodiment of the invention, the transport unit includes a circulating conveying medium, and the transport means is configured to transport the stack of laminations from the loading station to the heating station, transport the heated stack of laminations from the heating station to the loading station, transport the stack of laminations and the rotor shaft from the loading station to the press-fitting station, and transport the finished rotor including the stack of laminations and the rotor shaft pressed into the stack of laminations from the press-fitting station to the loading station.

[0014] According to an advantageous embodiment of the invention, the conveying medium can run bidirectionally. When the loading station is arranged between the heating station and the press-fitting station, the stack of laminations, the rotor shaft, and the rotor can be transported between the loading station, the heating station, and the press-fitting station by means of the conveying medium.

[0015] According to an advantageous embodiment of the invention, the loading station has a first sensor for detecting the stack of laminations located on the conveying medium. The first sensor enables the control of the transport unit. If the first sensor detects the stack of laminations, the conveying medium is driven, and the stack of laminations is transported to the heating station.

[0016] According to an advantageous embodiment of the invention, the loading station has a temperature sensor for detecting the temperature of the stack of laminations located on the conveying medium. If the temperature is too low, the further processing of the stack of laminations will be hindered. Thereby, the defective products in the rotor manufacturing are advantageously reduced.

[0017] According to an advantageous embodiment of the invention, the loading station has a second sensor for detecting the rotor shaft placed on the stack of laminations. The second sensor enables the control of the transport unit. If the second sensor detects the rotor shaft placed on the stack of laminations, the conveying medium is driven, and the stack of laminations and the rotor shaft are transported to the press-fitting station.

[0018] The method according to the invention for manufacturing a rotor of an electric machine by means of the device according to the invention includes the following steps:

[0019] Feeding the stack of laminations in the loading station;

[0020] Transporting the stack of laminations from the loading station to the heating station;

[0021] Heating the stack of laminations in the heating station;

[0022] Transport the heated stack of laminations from the heating station to the loading station;

[0023] Supply the rotor shaft at the loading station;

[0024] Place the rotor shaft onto the stack of laminations;

[0025] Transport the stack of laminations together with the rotor shaft from the loading station to the press-fitting station;

[0026] Press the rotor shaft into the stack of laminations at the press-fitting station;

[0027] Transport the manufactured rotor, which includes the stack of laminations and the rotor shaft pressed into the stack of laminations, from the press-fitting station to the loading station; and

[0028] Remove the manufactured rotor from the loading station.

[0029] By means of the method according to the invention, the rotor shaft can be connected to the stack of laminations by a thermal press fit. Thereby, the stack of laminations and the rotor shaft are connected to each other in a force-locking and non-rotatable manner. The method according to the invention enables the almost continuous manufacture of rotors. The heating station especially operates continuously and cooling is avoided as much as possible.

[0030] Further advantages are given by the dependent claims. The invention is not limited to the combination of features of the claims. For a person skilled in the art, especially from the object set and / or by comparison with the prior art, other reasonable combination possibilities of the claims and / or single claim features and / or features of the description and / or features of the drawings can be obtained. Description of the Drawings

[0031] The invention will now be further explained with the aid of the drawings. The invention is not limited to the embodiments shown in the drawings. The drawings only schematically show the subject matter of the invention. Among them:

[0032] Figure 1 A rotor for an electric machine is shown,

[0033] Figure 2 A front view of a device for manufacturing a rotor is shown, and

[0034] Figure 3 A perspective view of a device for manufacturing a rotor is shown.

[0035] List of Reference Signs:

[0036] 10 Rotor

[0037] 11 Rotor Shaft

[0038] 12 Stack of Laminations

[0039] 20 Loading Station

[0040] 30 Heating station

[0041] 31 Induction furnace

[0042] 32 Energy supply unit

[0043] 40 Pressing station

[0044] 41 Hydraulic press

[0045] 42 Cooling device

[0046] 50 Transport unit

[0047] 51 Transport medium Detailed implementation manner

[0048] Figure 1 The rotor 10 for an electric machine is shown. Here, an exploded view of the rotor 10 is shown in the left - hand part of the picture, while the assembled rotor 10 is shown in the right - hand part of the picture. The rotor 10 includes a lamination stack 12 and a rotor shaft 11. The rotor shaft 11 is inserted into the lamination stack 12.

[0049] The rotor shaft 11 is constructed approximately rotation - symmetrically. The lamination stack 12 is also constructed approximately rotation - symmetrically. Thus, the rotor 10 is also constructed approximately rotation - symmetrically. The lamination stack 12 has a central hole for receiving the rotor shaft 11.

[0050] Figure 2 A front view of the device for manufacturing the rotor 10 of an electric machine is shown. The device includes a loading station 20, a heating station 30, a pressing station 40, and a transport unit 50. The loading station 20, the heating station 30, and the pressing station 40 are arranged adjacent to each other. Here, the loading station 20 is arranged between the heating station 30 and the pressing station 40.

[0051] The loading station 20 is used for supplying the lamination stack 12, for supplying the rotor shaft 11, and for removing the finished rotor 10. The heating station 30 is used for heating the lamination stack 12. The pressing station 40 is used for pressing the rotor shaft 11 into the lamination stack 12. The transport unit 50 is used for: transporting the lamination stack 12 from the loading station 20 to the heating station 30; transporting the lamination stack 12 from the heating station 30 to the loading station 20; transporting the lamination stack 12 together with the rotor shaft 11 from the loading station 20 to the pressing station 40; and transporting the finished rotor 10 from the pressing station 40 to the loading station 20.

[0052] Figure 3 Shown in Figure 2 A perspective view of the device for manufacturing the rotor 10 of an electric machine shown above is shown. As already mentioned, the device includes a loading station 20, a heating station 30, a pressing station 40, and a transport unit 50. Here, the loading station 20 is arranged between the heating station 30 and the pressing station 40.

[0053] The heating station 30 has an induction furnace 31 for heating the stack of laminations 12. The induction furnace 31 is configured to heat the stack of laminations 12 to a temperature of at least 400 °C. The heating station 30 also has an energy supply unit 32. The energy supply unit 32 supplies electrical energy to the induction furnace 31.

[0054] The press-fitting station 40 has a hydraulic press 41 for pressing the rotor shaft 11 into the stack of laminations 12. The press-fitting station 40 also has a cooling device 42 for cooling the hydraulic press 41. A cooling circuit connects the cooling device 42 to the hydraulic press 41. To cool the hydraulic press 41, water is pumped by the cooling device 42 through the cooling circuit.

[0055] The transport unit 50 includes a circulating transport medium 51. The transport medium 51 is, for example, a conveyor belt, a conveyor belt, or a conveyor chain. The transport medium 51 can run bidirectionally. The transport medium 51 is configured to: transport the stack of laminations 12 from the loading station 20 to the heating station 30; transport the heated stack of laminations 12 from the heating station 30 to the loading station 20; transport the stack of laminations 12 together with the rotor shaft 11 from the loading station 20 to the press-fitting station 4; and transport the finished rotor 10 from the press-fitting station 40 to the loading station 20. Here, the finished rotor 10 includes the stack of laminations 12 and the rotor shaft 11 pressed into the stack of laminations.

[0056] The transport medium 51 has receiving means, not visible here, for receiving the stack of laminations 12. The receiving means are correspondingly configured to receive the stack of laminations 12 such that the central axis of the stack of laminations 12 extends perpendicular to the ground on which the equipment for manufacturing the rotor 10 is located. The receiving means are correspondingly also configured to receive the finished rotor 10 such that the central axis of the rotor 10 extends perpendicular to the ground.

[0057] The loading station 20 has a first sensor, not shown here, for detecting the stack of laminations 12 located on the transport medium 51. The loading station 20 also has a temperature sensor, not shown here, for detecting the temperature of the stack of laminations 12 located on the transport medium 51. The loading station 20 also has a second sensor, not shown here, for detecting the rotor shaft 11 placed on the stack of laminations 12.

[0058] In order to manufacture the rotor 10 for an electric motor by means of the equipment shown in Figure 2 and Figure 3 First, the stack of laminations 12 is supplied in the loading station 20. For this purpose, the stack of laminations 12 is, for example, manually loaded into the receiving means of the transport medium 51.

[0059] The first sensor detects the stack of laminations 12 located on the transport medium 51. Then, the stack of laminations 12 is transported from the loading station 20 to the heating station 30 by means of the transport medium 51 of the transport unit 50.

[0060] In the heating station 30, the stack 12 is heated to a temperature of approximately 400 °C in the induction furnace 31. As a result, the stack 12 expands in the radial direction. In particular, the holes in the stack 12 for receiving the rotor shaft 11 become larger.

[0061] Subsequently, the heated stack 12 is transported from the heating station 30 to the loading station 20 by means of the conveying medium 51. At the loading station 20, the first sensor again detects the stack 12 located on the conveying medium 51. The temperature sensor also detects the temperature of the stack 12 located on the conveying medium 51.

[0062] At this time, the rotor shaft 11 is supplied in the loading station 20. For this purpose, the rotor shaft 11 is placed on the stack 12 manually, for example.

[0063] The second sensor detects the rotor shaft 11 placed on the stack 12. Subsequently, the stack 12 together with the rotor shaft 11 is transported from the loading station 20 to the press-fitting station 40 by means of the conveying medium 51.

[0064] In the press-fitting station 40, the rotor shaft 11 is pressed into the stack 12 in the hydraulic press 41. After the stack 12 has cooled down, the holes in the stack 12 for receiving the rotor shaft 11 become smaller. Here, the stack 12 and the rotor shaft 11 are connected to each other in a force-locking and non-rotatable manner to form the rotor 10.

[0065] Subsequently, the completed rotor 10 comprising the stack 12 and the rotor shaft 11 pressed into the stack is transported from the press-fitting station 40 to the loading station 20 by means of the conveying medium 51.

[0066] Then, the completed rotor 10 is removed from the loading station 20. For this purpose, the rotor 10 is removed from the receiving device of the conveying medium 51 manually, for example.

Claims

1. An apparatus for manufacturing a rotor (10) of an electric machine, the apparatus comprising a loading station (20) for supplying a stack of laminations (12) and a rotor shaft (11), a heating station (30) for heating the stack of laminations (12), a press-fitting station (40) for press-fitting the rotor shaft (11) into the stack of laminations (12), and a transport unit (50) for transporting the stack of laminations (12) between the loading station (20), the heating station (30) and the press-fitting station (40).

2. The device according to claim 1, wherein, The press-fitting station (40) has a hydraulic press (41) for press-fitting the rotor shaft (11) into the stack of laminations (12).

3. The device according to claim 2, characterized in that, The press-fitting station (40) has a cooling device (42) for cooling the hydraulic press (41).

4. The device according to any one of the preceding claims, characterized in that, The heating station (30) has an induction furnace (31) for heating the stack of laminations (12).

5. The device according to claim 4, characterized in that, The induction furnace (31) is arranged to heat the stack of laminations (12) to a temperature of at least 400 °C.

6. The device according to any one of the above claims, characterized in that, The loading station (20) is arranged between the heating station (30) and the press-fitting station (40).

7. The device according to any one of the preceding claims, characterized in that, The transport unit (50) includes a circulating conveying medium (51) which is arranged to: transport the stack of laminations (12) from the loading station (20) to the heating station (30), transport the heated stack of laminations (12) from the heating station (30) to the loading station (20), transport the stack of laminations (12) and the rotor shaft (11) from the loading station (20) to the press-fitting station (40), and transport the manufactured rotor (10) including the stack of laminations (12) and the rotor shaft press-fitted into the stack of laminations from the press-fitting station (40) to the loading station (20).

8. The device according to claim 7, characterized in that, The conveying medium (51) can operate bidirectionally.

9. The device according to claim 7 or 8, characterized in that, The loading station (20) has a first sensor for detecting the stack of laminations (12) located on the conveying medium (51).

10. The device according to any one of claims 7 to 9, characterized in that, The loading station (20) has a temperature sensor for detecting the temperature of the stack of laminations (12) located on the conveying medium (51).

11. The device according to any one of the preceding claims, characterized in that, The loading station (20) has a second sensor for detecting the rotor shaft (11) placed on the stack of laminations (12).

12. A method for manufacturing a rotor (10) of an electric machine by means of the apparatus according to any one of the preceding claims, comprising the steps of: supplying a stack of laminations (12) in the loading station (20); transporting the stack of laminations (12) from the loading station (20) to the heating station (30); heating the stack of laminations (12) in the heating station (30); transporting the heated stack of laminations (12) from the heating station (30) to the loading station (20); supplying a rotor shaft (11) in the loading station (20); placing the rotor shaft (11) on the stack of laminations (12); transporting the stack of laminations (12) together with the rotor shaft (11) from the loading station (20) to the press-fitting station (40); press-fitting the rotor shaft (11) into the stack of laminations (12) in the press-fitting station (40); transporting the manufactured rotor (10) including the stack of laminations (12) and the rotor shaft press-fitted into the stack of laminations from the press-fitting station (40) to the loading station (20); and removing the manufactured rotor (10) from the loading station (20).

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