Rotor of electric motor and method for manufacturing rotor

Abstract

The invention relates to a rotor of an electric motor, the rotor comprising a rotor stack arranged on a rotor shaft of the rotor, and the rotor stack comprising a rotor yoke and a plurality of rotor teeth, each carrying an excitation winding. The rotor further comprises at least two segments which at least divide the rotor stack in the circumferential direction of the rotor, each segment comprising at least one rotor tooth with the excitation winding thereof, and at least one part of the segments comprising a section of the rotor yoke which is embodied in one piece with the corresponding rotor tooth of the segment. In this case, the sections are joined to each other via a force-fitting and / or form-fitting connection. The connection is at least partially established in such a way that the segments are clamped against each other by a force acting on the rotor stack, the force being formed as a result of a shaft-hub connection present between the rotor stack and the rotor shaft. The invention further relates to a method for producing a rotor.

Description

The rotor of the electric motor and the method for manufacturing the rotor Technical Field

[0001] This invention relates to a rotor for an electric motor, wherein the rotor includes a rotor pad arranged on a rotor shaft, and the rotor pad includes a rotor yoke and a plurality of rotor teeth, each rotor tooth carrying an excitation winding. The rotor further has at least two segments that divide the rotor pad at least circumferentially, wherein each segment includes at least one rotor tooth along with its excitation winding, and at least a portion of one segment includes a section of the rotor yoke integrally formed with the corresponding rotor tooth of that segment. The segments are engaged with each other via force-fit and / or form-fit connections.

[0002] Furthermore, the present invention relates to a method for manufacturing a rotor. Background Technology

[0003] Separately excited synchronous motors are widely used in industrial fields due to their precise controllability and high efficiency. Compared with permanent magnet synchronous motors, separately excited synchronous motors do not rely on permanent magnets and / or the raw materials required for permanent magnets, especially rare earth metals. This allows separately excited synchronous motors to meet drive requirements, for example, in the automotive industry, even when these raw materials are scarce.

[0004] However, the manufacturing of rotors for separately excited synchronous motors is very complex. Typically, coil windings are wound onto rotor stacks consisting of single-piece rotor plates using pin winding technology. This process is significantly slower than methods such as fly-fork winding or linear winding, which prolongs the production time of separately excited synchronous motors. Due to the mechanical limitations of pin winding, especially the space required for the winding pins in the winding area, the winding density is generally lower than with other technologies. This results in a lower winding fill factor and / or conductor fill factor, and consequently, a reduced power capability.

[0005] To address these issues, solutions are already known from existing technologies.

[0006] For example, DE 10 2021 122 066 A1 discloses a rotor for a separately excited synchronous motor, wherein star disks are arranged at the ends of the rotor laminations, and at least one star disk has embedded conductive bars. These conductive bars electrically connect the pole shoes or slots of the star disks to the adjacent pole shoes or slots of the star disks, and each of the two ends of the star disks has a contact element for receiving winding wires, which protrudes from the surface of the star disk. Here, the contact element forms an interface between the coil wound on the rotor and the conductive bars. Here, the star disks avoid the need to guide the coil windings with a trapezoidal winding structure back to the yoke, and instead close the current loop through the conductive bars of the star disks. Thus, although the efficiency and power density of the synchronous motor can be improved, it is disadvantageous that, due to the one-piece design of the rotor laminations, the windings must still be attached to the rotor laminations by means of pin winding technology.

[0007] Furthermore, DE 10 2020 107 830 A1 describes a rotor for a separately excited synchronous motor, comprising a cylindrical base having multiple axially extending connecting slots. Multiple rotor teeth, made of magnetic material and arranged radially on the base, are inserted into the connecting slots, wherein these rotor teeth form an annular closed shape in the radial direction. Electrical windings are performed around the respective rotor teeth. The windings can be mounted onto the rotor teeth before they engage with the base. This allows for a larger copper fill factor in the rotor, as the winding area of ​​the respective rotor teeth can be completely filled since no space is needed for needles or tools. Furthermore, adjacent rotor teeth can be interconnected, particularly fully bonded, by means of paint. In the radial direction, sleeves are also arranged around the rotor teeth, these sleeves being composed of magnetic material, particularly carbon fiber reinforced plastic. The sleeves can be fitted onto the annular closed shape, thus holding the rotor teeth at the base and withstanding the centrifugal forces acting on the base and rotor teeth at high speeds.

[0008] Another rotor for separately excited synchronous motors is known through DE 10 2022 204 361 A1, in which the winding carrier is not composed of a single, one-piece formed sheet metal part, but rather of at least two sub-segments connected to each other via pin hinges. These sub-segments can also be manufactured as sheet metal stampings, wherein multiple such sheet metal stampings are stacked together in the axial direction to form the respective sub-segments. An advantage of these sub-segments is that the rotor windings wound around the respective sub-segments can be manufactured separately on individual sub-segments, thereby eliminating the need for pin winding techniques or hairpin techniques to manufacture the rotor windings. Here, the rotor windings are wound around the bridging portion of the respective sub-segment. Preferably, the individual sheet metal part of the sub-segment or the sub-segment itself is implemented as a universal part, so that the rotor windings can be manufactured using the same sheet metal stamping press and winding apparatus. Each sub-segment has two outer arms and one inner arm, and a bridging portion located between them. Two adjacent sub-segments are connected to each other via their outer arms and additionally via their inner arms via pin hinges. The bridging portion of the rotor has a constant width in the radial direction, which facilitates the winding of the rotor winding around the bridging portion. Furthermore, the rotor windings of two adjacent sub-segments can contact each other, so that the recesses accommodating the rotor windings, defined by the two adjacent bridging portions and two interconnected outer arms, can be completely filled by the rotor windings. This allows for a high copper fill factor and thus enables a high power capability in the synchronous motor equipped with this rotor.

[0009] However, using such additional connecting elements (such as the pins in the solution described above) has disadvantages in terms of the mechanical and magnetic properties of the rotor and / or the motor having the rotor. For example, the smoothness of rotor operation and / or the magnetic flux in the rotor (especially due to leakage flux at the connecting elements) may be negatively affected. Summary of the Invention

[0010] In this context, the objective of the present invention is to realize a rotor of the type described at the beginning without the need for additional connecting elements to connect the rotor segments. Furthermore, the objective of the present invention is to provide a method for manufacturing this rotor.

[0011] This task is solved by having a rotor according to the invention and a method according to the invention.

[0012] Therefore, according to the present invention, a rotor for an electric motor, particularly a separately excited synchronous motor, is provided, wherein the rotor includes a rotor stack arranged on a rotor shaft, and the rotor stack includes a rotor yoke and a plurality of rotor teeth, each of which carries an excitation winding. Here, the rotor teeth themselves have a tooth head or pole shoe and a tooth shank, and the excitation winding is mounted on the tooth shank.

[0013] Furthermore, the rotor has at least two, preferably more than two, particularly preferably multiple segments that divide the rotor stack in the circumferential direction of the rotor, wherein each segment includes at least one rotor tooth together with its excitation winding, and at least a portion of the segment includes a section of the rotor yoke integrally implemented with the corresponding rotor tooth of that segment. Here, the segments are engaged with each other via force-fit and / or form-fit connections.

[0014] Furthermore, according to the invention, the connection is established at least in part by means of forces acting radially on the rotor stack, particularly on the sections of the rotor stack. Here, the sections are engaged with each other, particularly at least radially and / or circumferentially. Therefore, the connection, or part of the connection between the sections, is designed in principle to be at least axially force-fitted. Radially (particularly radially outward and / or circumferentially), there is at least a form-fitting connection, or a form-fitting portion of the connection. According to the invention, the forces that engage or clamp the sections are formed here by the hub connection, particularly a compression connection and / or a clamping connection, existing between the rotor stack and the rotor shaft.

[0015] This provides a substantially self-supporting segmented rotor that requires no additional connecting elements to link rotor segments, thus essentially guaranteeing optimal mechanical and magnetic properties of the rotor and / or the motor having it. Furthermore, the multi-segment design ensures that the rotor can be manufactured with reduced manufacturing complexity, particularly shortened manufacturing time and minimized manufacturing costs, as the segments eliminate the need for complex and time-consuming pin-winding techniques. Moreover, this also achieves a high winding fill factor and / or conductor fill factor for the rotor, resulting in higher efficiency and / or power capability for the motor having the rotor according to the invention compared to a non-segmented, single-piece rotor.

[0016] While it is conceivable in principle that the corresponding sub-components of the rotor stack are part of a segment and consist of a single section comprising the rotor teeth and rotor yoke—that is, constituted by a single main body and therefore not by multiple interconnected or assembled individual components—it is preferred that the corresponding sub-components of the rotor stack be composed of individual components interconnected, particularly in a force-fitting, form-fitting, and / or material-fitting manner. Here, these individual components are, in particular, laminations and / or partial laminations, especially sheet metal laminations, arranged axially in sequence, particularly by stacking, for example, by stamping and / or bonding, into segments, especially sub-components.

[0017] The segments of the rotor (especially the sub-components of the rotor stack) can always have the same shape, especially the same cross-sectional shape. Here, each segment can have a connecting structure, which is shaped accordingly for each segment, and at least partially fits together to form a connection.

[0018] However, in a highly advantageous improvement of the invention, the segments, especially the sub-components of the rotor stack, belong to at least two, preferably exactly two different types of segments and / or sub-components, wherein, or in other words, the segments have at least partially different shapes, especially at least partially different cross-sectional shapes, depending on the type (that is, varying accordingly). Preferably, these different types of segments, especially sub-components, are arranged alternately to each other and / or alternately form at least the rotor teeth of the rotor stack. For example, the design scheme of segments, especially sub-components, having different shapes and / or forms allows the rotor and / or rotor stack to be better adapted to the mechanical loads during the operation of the motor having the rotor. In particular, this achieves that the connection and / or connection structure that adapts the segments and / or sub-components in this way is such that the load is applied evenly to the connection and / or connection structure, and therefore no localized excessive values ​​(e.g., stress peaks) are generated, which may lead to damage and / or failure of the connection and / or connection structure and thus the rotor.

[0019] When implementing a segment consisting of laminates and / or partial laminates, it is preferable that different types of segments have different laminate thicknesses. This advantageously avoids the laminates and / or partial laminates sliding against each other, especially radially and / or circumferentially, when different types of segments are arranged together (e.g., during assembly).

[0020] Furthermore, one embodiment of the invention proves advantageous, wherein the at least partially different shapes of different types of segments, particularly sub-components, are achieved at least partially by connection structures formed differently for each type of segment and / or sub-component, wherein the connection structures of the corresponding types of segments and / or sub-components are complementaryly formed to each other and at least partially fit together in shape, thereby establishing a connection at least partially between the segments. Implementing connection structures for each segment and / or sub-component (which are complementary to the connection structures of the corresponding other types, depending on the type of segment and / or sub-component) here represents an advantageous possibility for establishing and / or forming connections between segments. This ensures optimal fitting accuracy and more reliable shape-fit connections. In addition, the complementary connection structures provide the advantage of self-centering of the segments during rotor assembly. Here, the connection structures of segments within one type are uniformly and identically formed.

[0021] Furthermore, it is advantageous that in one embodiment of the invention, the corresponding connection structure has at least one concave and / or convex connecting element and / or sub-connecting element, wherein the connection structure of the segments and / or sub-components of the corresponding type of rotor stack is at least partially formed complementary to each other via at least one connecting element and / or sub-connecting element, and engages with each other in a form-fitting manner. Here, implementing the connection structure via the concave and / or convex connecting element advantageously provides an undercut connection structure, wherein, correspondingly, the connecting element itself is also preferably at least undercut to each other segment by segment. Furthermore, the embodiment via the concave and / or convex connecting element achieves a partial change in the direction of the force acting radially on the rotor stack and / or segments via the hub connection, and also allows it to act on the rotor stack and / or segments in the circumferential direction. This force can cause the segments and / or sub-components, especially the first type, to open accordingly in the circumferential direction via the portion acting in the circumferential direction, so that the segments and / or sub-components press against another type, especially the second type, not only radially but also circumferentially, and thus lock. In this way, additional locking and / or fixing elements can be omitted, as the connecting element itself acts as such locking and / or fixing elements. In the case of rounded concave and / or convex connecting elements, the force acting through the hub connection and the load acting on the rotor can be distributed substantially on the rotor stack and / or segments without generating stress peaks, thereby minimizing the probability of defects.

[0022] Furthermore, one design of the invention can be considered advantageous, wherein two sections and / or sub-components of a rotor stack, preferably of the first type, are formed into overlapping connecting elements, which are therefore particularly two connecting structures. Here, the overlapping connecting element works in conjunction with complementary connecting elements of another type, preferably of the second type, sections and / or sub-components, and is, for example, surrounded or at least abutted against by the complementary connecting element section by section. In this way, a highly stable connection between the connecting elements and / or sections and / or sub-components can be ensured.

[0023] Furthermore, an improved embodiment of the invention is also advantageous, wherein at least two, preferably exactly two types (particularly preferably the first and second types) of rotor stack segments and / or sub-components are abutted against the rotor shaft in a manner that at least partially forms the rotor yoke of the rotor stack, and particularly only on the sides, that is, by means of their circumferential sides, wherein their connecting structures are partially shape-fitted into each other. Thus, the forces acting through the hub connection and the load acting on the rotor are distributed substantially evenly to the segments and / or sub-components, particularly to the connecting structures of the segments and / or sub-components. Here, the shape-fitting, particularly radially outwardly shaped, and / or circumferentially shaped portions of the connection are equally established through the connecting structures of different types of segments, particularly in the direction of the shape-fitting portions of the connection.

[0024] Conversely, in another, but not disadvantageous, design of the invention, it is envisioned that only one type, particularly a first type, of rotor stack segments and / or sub-components abut against the rotor shaft in a manner that at least partially, preferably substantially forms the rotor yoke of the rotor stack, and abuts against each other in the mating region of these segments and / or sub-components. Furthermore, another type, particularly a second type, of segments and / or sub-components abuts against the first type of segments and / or sub-components, wherein the connecting structures of the segments and / or sub-components partially engage with each other in a shape-fitting manner, and the base of the corresponding segment and / or sub-component of the second type, particularly the second type, including the connecting structure, is surrounded by the adjacent segment and / or sub-component of the first type on its sides and base surface. Thus, although a large portion of the force acting through the hub connection and the load acting on the rotor is substantially applied to the connecting structure of the second type of segments and / or sub-components, the assembly of the different types of segments is simplified because the connecting structures of the different types of segments have smaller surfaces that guide each other. Here, the parts of the connection that fit together, especially those that fit together radially outward and / or fit together in the circumferential direction, are established by connection structures of different types of segments, especially in different directions of the parts of the connection that fit together.

[0025] In principle, it is possible to implement energy transfer to the excitation winding of the rotor in a motor with a rotor via contact and / or wireless means, particularly inductively. The first possibility is that electrical energy is inductively transferred through the stator winding (which serves as the primary coil) to the receiving coil of the rotor (which serves as the secondary coil), which is implemented separately from the excitation winding. The receiving coil can then supply power to the excitation winding, particularly via a rectifier electrically connected to it. Another possibility is that the rotor shaft is constructed as a hollow shaft, in which an inductive transmitter is arranged. Here, the inductive transmitter includes a secondary winding anti-rotationally connected to the hollow shaft and a primary winding fixedly positioned in the rotor shaft relative to it. Current can be supplied to the primary winding via an electrical energy source. Furthermore, the secondary winding is electrically connected to the excitation winding, and thus an induced excitation current can be supplied via the excitation winding.

[0026] Furthermore, one embodiment of the invention has proven advantageous, wherein at least a portion of the excitation winding is electrically connected and / or mounted, particularly at least at the axial end of the rotor, and preferably pushed onto the rotor shaft, and the contact ring is in electrical contact with at least one slip ring transmitter. Here, the contact provides reliable electrical contact for the excitation winding, and the slip ring transmitter provides reliable and continuous electrical contact to direct current to the rotor rotating during operation of the motor with the rotor. By connecting to the slip ring transmitter, electrical contact is maintained despite rotational motion, ensuring a stable supply of excitation winding. Mounting the contact ring, particularly at the axial end of the rotor, onto the rotor shaft ensures space-saving integration into the overall rotor structure. This contributes to a compact and slender form of the rotor and / or the motor with that rotor, which is particularly advantageous in confined installation spaces.

[0027] Another advantageous embodiment of the invention involves the provision of end caps at the ends of at least one axial and / or end face of a segment, preferably at the ends of two axial and / or end faces of the corresponding segment or all segments. In particular, one or more end caps are arranged at the sub-component of the rotor stack included by the segment, wherein the end caps terminate flush with the two sides of the rotor teeth, particularly the tooth shank, where the excitation winding rests against these sides and forms a rounded transition between the sides. For this purpose, the corresponding end cap has an elliptical or circular, particularly circular or semi-circular, cross-section or longitudinal section in its winding receiving area. This avoids contact between the excitation winding and the edges between the sides and end faces of the segment and / or sub-component, and thus prevents damage to the excitation winding during segment manufacturing.

[0028] Furthermore, one embodiment of the invention can be considered advantageous, wherein at least one support (also called a pusher) is arranged between the excitation windings, particularly between correspondingly adjacent rotor teeth, to support and / or push the excitation windings, thus being arranged in slots between adjacent rotor teeth. Here, one or a corresponding support advantageously ensures that the excitation windings remain in place under mechanical loads (which occur, for example, in the operation of a motor with a rotor). This results in higher mechanical stability of the excitation windings, which is particularly important under stronger mechanical loads (such as higher rotational speeds). Here, a support can be used that has a smaller volume, particularly compared to the support used in excitation windings mounted onto rotor teeth, for example, by means of pin winding technology. Since the proper positioning and support of the excitation windings via the support avoids unwanted movement that could lead to electromagnetic losses, the efficiency of the motor with a rotor, especially a separately excited synchronous motor, is also improved.

[0029] Furthermore, one advantageous design aspect of the invention involves a retaining element arranged radially outward between the rotor teeth, preferably between the tooth tips, particularly in particular, that at least radially restricts and / or covers the slots formed between the rotor teeth. Firstly, this advantageously prevents the excitation winding and / or portions thereof (such as the electrical conductors forming the excitation winding) from dislodging from the slots between the rotor teeth, for example, under higher rotor loads, and thus potentially reaching the air gap between the stator and rotor of the motor with the rotor. Furthermore, the retaining element can serve as a support between the rotor teeth, thereby improving the mechanical stability of the rotor. In particular, vibration of the rotor teeth can be minimized. Moreover, by covering the slots, the retaining element can also help dampen vibrations, and thus help reduce noise emissions during the operation of the motor with the rotor. Therefore, this vibration damping ensures quieter and more efficient operation of the motor.

[0030] The rotor may also be cast, either as an alternative to or in combination with the support and / or retaining elements.

[0031] Furthermore, an improvement of the invention is advantageous in which the excitation winding is composed of aluminum or an aluminum alloy. Compared to an excitation winding made of copper, using aluminum for the excitation winding maximizes the mass and / or weight of the excitation winding, and therefore the rotor. This results in a lower moment of inertia of the rotor, which in turn leads to improved efficiency, power, and / or dynamics of the motor having the rotor, and consequently also improves the acceleration and overall performance of motor vehicles using such a motor as a drive unit.

[0032] According to the invention, a method for manufacturing the rotor described above is also provided, wherein different types of segments are first provided sequentially via a pre-assembly method of the rotor. In the subsequent final assembly method of the rotor, sub-assemblies of segments, particularly star-shaped segments, are arranged by one type, particularly a first type of segment, and then a complete assembly of segments, particularly star-shaped segments, is produced by connecting another type, particularly a second type of segment, to the sub-assembly in a shape-fitting manner. Preferably, the segments, particularly the first type, that should form the sub-assembly are first assembled and held in the form of a sub-assembly via a holding device. Thereafter, another type, particularly the second type of segment, is axially mounted (here, particularly axially pushed up) onto the sub-assembly. Here, mounting, and particularly pushing up, is performed such that the corresponding connecting structure of the other type, particularly the second type of segment is inserted (here, particularly axially pushed in) into the complementary-shaped—and thus substantially-forming—negativistic—connecting structure of the segments of the sub-assembly. Due to the installation, especially the pushing, of another type of segment, the connecting structures engage with each other in a shape-fitting manner. In this complete assembly, a connection is at least partially established between the segments, particularly the shape-fitting parts of the connection. Thus, especially radially and / or circumferentially, a structural integrity of the complete assembly is formed, which is not present in the sub-assemblies. The segments can be separated from each other again simply by axially moving the segments of the complete assembly.

[0033] To establish connections between the segments of the complete assembly also in the axial direction, and thus to establish the structural integrity of the rotor, in a highly advantageous improvement of the invention, a hub connection is formed between the rotor shaft and the rotor stack in the final assembly sequence by force-fitting and / or form-fitting engagement of the rotor shaft with the complete assembly, particularly the star-shaped segments. Through the engagement of the rotor shaft and the resulting hub connection between the rotor shaft and the rotor stack (which is comprised of the complete assembly of segments), a force advantageously acts radially on the rotor stack, thereby advantageously locking the segments together, particularly via their connecting structures. This locking thus establishes a connection, particularly a force-fitting portion, between the segments also in the axial direction. In this way, a substantially self-supporting segmented rotor can be provided, which requires no additional connecting elements to connect the rotor segments, essentially guaranteeing optimal mechanical and magnetic properties of the rotor and / or the motor having it.

[0034] Furthermore, one design of the invention is advantageous, wherein the segments are sequentially provided via a pre-assembly method comprising: for each segment, winding, particularly linearly winding, the excitation winding onto a separate sub-piece of the rotor stack, comprising rotor teeth and rotor yoke. Winding the excitation winding, particularly linearly winding, onto a single sub-piece of the rotor stack allows for significantly more efficient and faster manufacturing compared to conventional winding techniques (such as pin winding) on ​​a monolithic rotor stack. Furthermore, winding onto smaller, individual sub-pieces simplifies the automation of the winding process, reducing manufacturing time and complexity. Because the excitation winding is wound onto a single sub-piece, higher winding density and / or higher winding fill factor and / or conductor fill factor, particularly copper or aluminum fill factor, can also be achieved, which in turn improves the electrical power capability of the rotor or the motor having that rotor. Moreover, the advantage of dividing the rotor stack into individual sub-pieces and forming segments from these sub-pieces is that each segment can be tested individually before being integrated into the rotor. This reduces waste during rotor manufacturing. Furthermore, it improves the sustainability and maintainability of the rotor and / or the motor with it, by enabling the replacement of individual defective sections.

[0035] Furthermore, one construction embodiment of the invention has proven advantageous, wherein the segments are sequentially provided via a pre-assembly method comprising: for each segment, particularly in an impregnation bath, impregnating the excitation winding wound onto the individual sub-piece. Impregnating the excitation winding, especially in an impregnation bath, ensures continuous and seamless coating of the excitation winding with an insulating medium (such as insulating resin or varnish). This improves the electrical insulation capability of the excitation winding, which enhances dielectric strength and prevents short circuits or electrical breakdowns. Consequently, the reliability and operational safety of the rotor are significantly improved. Furthermore, the excitation winding is additionally mechanically strengthened through impregnation. The impregnated layer stabilizes the excitation winding and prevents it from becoming at least partially loose, for example, during operation or under mechanical loads. This results in increased stability of the excitation winding and extended rotor life. The impregnation of the winding also provides effective protection against moisture, cooling lubricants, dust, contaminants, and other environmental influences. The sealing treatment of the winding minimizes the risk of corrosion or moisture damage, ensuring rotor functionality, especially when aluminum or aluminum alloys are used as the material for the excitation winding. Attached Figure Description

[0036] This invention allows for various embodiments. To further clarify its basic principles, some of these are shown in the accompanying drawings and described below. Specifically: Figure 1 shows a first embodiment of the rotor; Figures 2 to 7 show embodiments of rotors with different designs of segments and connection structures; Figures 8 to 13 show a portion of a method for manufacturing the rotor; Figures 14 and 15 show embodiments of rotors with different thicknesses of segment laminations; Figures 16 to 19 show one embodiment of the method; Figure 20 shows a detailed diagram of the method steps for winding the excitation winding; Figure 21 shows a detailed diagram of the method steps for impregnating the excitation winding. Detailed Implementation

[0037] Figure 1 illustrates one embodiment of a rotor 1 according to the invention, which, after being manufactured using a design scheme according to the method of the invention, is used in an electric motor (not shown in detail), particularly a separately excited synchronous motor. Here, the rotor 1 includes a rotor stack 3 arranged on a rotor shaft 2 of the rotor 1, wherein the rotor stack 3 itself has a rotor yoke 4 and a plurality of rotor teeth 5, each carrying an excitation winding 6. To reinforce the rotor 1, a reinforcing ring 37 is further engaged with the rotor stack 3.

[0038] Furthermore, Figures 2 to 7 show cross-sections of different embodiments of the rotor 1, wherein, as can be seen from Figures 2 to 7, the rotor 1 has a plurality of (specifically, six in this case) segments 7, 8 that divide the rotor 1 and / or the rotor stack 3 in the circumferential direction 19 of the rotor 1. The difference between these embodiments lies in the design of the segments 7, 8, which in this case belong to two different types of segments 7, 8. The segments 7, 8 have shapes that vary depending on their type, or are partially different. Furthermore, each segment 7, 8 includes a rotor tooth 5 together with its excitation winding 6 and a segment 30 of the rotor yoke 4 that is a single piece of the rotor tooth 5 of the corresponding segment 7, 8. Here, the rotor tooth 5 and the subordinate segment 30 form sub-components 29, 32 of the rotor stack 3, which are included by the corresponding segments 7, 8, except for the excitation winding 6 arranged on the tooth shank 31 of the rotor tooth 5 and / or abutting against the tooth head 40 of the rotor tooth 5. Furthermore, the rotor yoke 4 is schematically indicated by dashed lines in Figures 2 and 3, so that it can be seen more clearly that the rotor teeth 5 of the two types of segments 7 and 8 are basically the same in shape; however, the segments 30 of the two types of segments 7 and 8 are different in shape.

[0039] Furthermore, different types of segments 7,8 and / or the sub-components 29,32 of the rotor stack 3 included by segments 7,8 are joined together by force-fitting and / or form-fitting connections 11 to form the rotor stack 3 and / or the rotor 1.

[0040] Here, as can be seen particularly from Figures 2 and 3, the connection 11 is at least partially established via a connecting structure 21 of segments 7, 8, which is formed in section 30 of the rotor yoke 4. The at least partially different shapes of the two types of segments 7, 8 are primarily due to the connecting structures 21, which are formed differently according to the type of segments 7, 8. To establish the connection 11, the connecting structures 21 of the two types of segments 7, 8 are formed complementaryly to each other, and at least partially engage with each other in a shape-fitting manner. The respective connecting structures 21 have multiple concave and / or convex connecting elements 22 and / or sub-connecting elements 23, wherein the connecting structures 21 of the two types of segments 7, 8 are respectively formed complementaryly to each other via connecting elements 22 and / or sub-connecting elements 23.

[0041] Here, the sub-connecting element 23 is implemented in the first type of segment 7 of the embodiment of rotor 1 in Figures 2 to 6, wherein two corresponding contacting sub-connecting elements 23 of the first type of segment 7 that abut against each other in the corresponding mating area 24 form overlapping connecting elements 22.

[0042] Here, the corresponding overlapping connecting element 22, composed of two sub-connecting elements 23, works in conjunction with the complementary connecting element 22 of the second type of segment 8 and / or sub-piece 32 (which is arranged in the circumferential direction 19 between segments 7 having sub-connecting elements 23), and is segmentally surrounded by the complementary connecting element, or, as particularly in the embodiment of FIG. 6, at least abuts against the complementary connecting element. Thus, the connecting element 22 of the second type of segment 8 essentially forms a clamp-shaped member or a bridge member across the connecting element 22 composed of two sub-connecting elements 23 surrounding the two segments 7 of the first type.

[0043] Here, the forming of the sub-connecting element 23 in the embodiments of rotor 1 in Figures 2 to 6 is accompanied by this, that is, in these embodiments, only the first type of segment 7 abuts against the rotor shaft 2 and abuts against each other in the mating area 24 of the segments 7. In addition, the second type of segment 8 abuts against the first type of segment 7, wherein the base 25 of the corresponding second type segment 8, including the connecting structure 21, is surrounded by the corresponding adjacent first type segment 7 on the side and on the base surface.

[0044] Conversely, in the embodiment of rotor 1 in Figure 7, both types of segments 7, 8 abut against rotor shaft 2 and against each other on the sides, wherein the connecting structures 21 are respectively alternately and form-fittingly engaged with each other.

[0045] The connection structure 21 described above, which interlocks via a form-fitting mechanism, establishes a connection 11 between segments 7 and 8, providing a form-fitting portion of the connection 11 in both the radial and circumferential directions 19. Furthermore, the connection 11 is established at least partially by means that segments 7 and 8 are engaged with each other by a force F acting radially on the rotor stack 3 and thus on segments 7 and 8, wherein, particularly as shown in FIG. 2, the force F is formed by the hub connection 20, especially the clamping connection and / or locking connection, existing between the rotor stack 3 and the rotor shaft 2. Thus, in the axial direction of the rotor 1, there is also a force-fitting portion of the connection 11 between segments 7 and 8, thereby fully achieving the structural integrity of the rotor 1, and relative movement of the components of the rotor 1, especially segments 7 and 8, and the rotor shaft 2 is impossible.

[0046] Furthermore, in all embodiments of rotor 1 shown in Figures 2 to 7, retaining elements 15 are arranged between rotor teeth 5 (here, between the tooth tips 40 of rotor teeth 5), which radially restrict and / or cover the slots 35 formed between rotor teeth 5. In the embodiment of rotor 1 shown in Figure 2, supports 14 are also arranged between the excitation windings 6 of correspondingly adjacent rotor teeth 5 to support the excitation windings 6 in the slots 35 between adjacent rotor teeth 5.

[0047] Now, Figures 8 to 11 depict a portion of the method for manufacturing the rotor 1 known in Figures 1 to 7, wherein the method is again shown in Figures 16 to 19 with its multiple method sequences and method steps.

[0048] Here, as seen from Figures 8 to 10, the first type of segment 7 (which is provided sequentially via the method of pre-assembly 100 marked in Figure 16, in which the excitation winding 6 is also wound 203 onto the rotor teeth 5) is arranged 206 into sub-assemblies 9 of segment 7, in particular, in the method of final assembly 102 of rotor 1, which is indirectly thereafter.

[0049] Here, Figure 8 shows segment 7, which includes a sub-piece 29 of rotor stack 3, which is composed of rotor teeth 5 and rotor yoke 4, with segments 30 integrally formed with rotor teeth 5. Figure 9 shows two first-type segments 7, and Figure 10 shows three first-type segments 7, which are assembled and arranged 206 with each other, thereby obtaining the sub-assembly 9 shown in Figure 10. Here, the sub-assembly 9 is held in principle by a holding device not shown in detail. Then, the segments 7 of the first-type sub-assembly 9 are connected in a form-fitting manner with second-type segments 8, which are also provided sequentially via the method of pre-assembly 100 marked in Figure 16, thereby producing the complete assembly 10 of segments 7,8 shown in Figure 11.

[0050] For this purpose, the second type of segment 8 is axially mounted (pushed up) onto the sub-assembly 9. This mounting, and especially the pushing up, is carried out such that the corresponding connecting structure 21 of the second type of segment 8 is inserted (pushed in axially) into the negative-shaped connecting structure 21 of the complementary and thus substantially forming connecting structure 21 of the segment 7 of the first type of sub-assembly 9. Due to the mounting, and especially the pushing up, of the second type of segment 8, the connecting structures 21 form-fittingly engage with each other, wherein, in the complete assembly 10, a connection 11 is at least partially established between the two types of segments 7, 8, where the form-fitting portion of the connection 11 is formed. Thus, especially radially and / or in the circumferential direction 19, the structural integrity of the complete assembly 10 is also formed, which is not yet present in the sub-assembly 9. The segments can be separated from each other again simply by axially moving the segments 7, 8 of the complete assembly 10 relative to each other.

[0051] In order to establish a connection 11 (the force-fit portion of this connection 11) between the segments 7,8 of the complete assembly 10 in the axial direction, and thus also to establish the structural integrity of the rotor 1, in the method sequence of the final assembly 102 shown in FIG. 17, a hub connection 20 is formed between the rotor shaft 2 and the rotor stack 3 (the segments 7,8 or the sub-pieces 29,32 of the rotor stack 3) by force-fitting and / or form-fitting engagement 208 of the rotor shaft 2 with the star-shaped complete assembly 10 of the two types of segments 7,8. Through the engagement 208 of the rotor shaft 2 and the resulting hub connection 20 between the rotor shaft 2 and the rotor stack 3 (which is included in the complete assembly 10 of segments 7,8), as shown again in FIG. 13, a force F, particularly radial, is formed on the rotor stack 3, by which the segments 7,8 are clamped together via their connection structure 21. Through this clamping, a connection, the force-fit portion of this connection 11, is thus established between the segments 7,8 in the axial direction.

[0052] Here, Figures 12 and 13 further illustrate this clamping in detail. Figure 12 first shows the complete assembly 10 with the rotor shaft 2 not engaged and therefore without the force F acting on the rotor stack 3 and / or the two types of segments 7, 8. Here, as can be seen from the detailed view of Figure 12, since the segment 8 is mounted onto the segment 7 of the sub-assembly 9, the concave and convex connecting elements 22 of the connecting structure 21 of segments 7, 8 have gaps between each other in the complete assembly 10, so that in the detailed view of Figure 12, the connecting structures 21 of segments 7, 8 (here, the concave connecting element 22 of the first type of segment 7 and the convex connecting element 22 of the second type of segment 8) are externally abutting each other in the circumferential direction 19.

[0053] By engaging the rotor shaft 2 with the complete assembly 10 208, and thus acting on the segments 7, 8 of the rotor stack 2 or the complete assembly 10 due to the formed hub connection 20, the force F acting in the circumferential direction 19 causes the first type of segments 7 and / or sub-pieces 29 to open 33 in the circumferential direction 19, as shown in the detail view of FIG13. This causes the segments 7 and / or sub-pieces 29 to press against the second type of segments 8 and / or sub-pieces 32 in the circumferential direction 19, and thus be locked. Due to the opening 33, the connecting structures 21 of segments 7, 8 (here, the concave connecting element 22 of the first type of segment 7 and the convex connecting element 22 of the second type of segment 8) are internally abutted against each other in the circumferential direction 19. Thus, the opening 33 of the first type of segment 7 is achieved here by the convex connecting element 22 of the connecting structure 21 of segment 7 being implemented as an overlapping connecting element 22 composed of sub-connecting elements 23. Therefore, additional clamping and / or fixing elements can be omitted, since the connecting element 22 itself acts as such clamping and / or fixing elements.

[0054] To prevent the segments 7, 8 and / or sub-components 29, 32 of the rotor stack 3 formed by laminations 12, 13 from sliding radially and / or in the circumferential direction 19 into each other, for example, when producing the complete assembly 10, especially by mounting segment 8 onto segment 7, the laminations 12, 13 of segments 7, 8 have different lamination thicknesses D1, D2 depending on the type. Here, the lamination thickness D1 of the laminations 12 of the first type of segment 7 and / or sub-component 29 is greater than the lamination thickness D2 of the laminations 13 of the second type of segment 8 and / or sub-component 32. This can be seen from the cross-section AA shown in Figures 14 and 15.

[0055] Furthermore, Figures 16 to 19 illustrate a substantially complete process of one embodiment of the method according to the invention, which has a plurality of method sequences and method steps.

[0056] Here, the sequence of the pre-assembly 100 is first shown in Figure 16. In this sequence, prefabricated sub-pieces 29 and 32 of rotor stack 3 are first provided, and then end caps 16 are arranged 201 at the axial ends of sub-pieces 29 and 32. After this, the slot bottom 34 of slot 35, or the side of rotor teeth 5, especially the side of tooth shank 31 of sub-pieces 29 and 32, is insulated 202, and then the excitation winding 6 is wound 203 onto the corresponding sub-pieces 29 and 32.

[0057] Figure 20 shows the winding 203 again in detail, specifically the linear winding of the excitation winding 6 onto the sub-component 29 (in this case) by means of the winding tool 17. Thus, due to the winding of the excitation winding 6 onto the rotor teeth 5 by winding 203, a first type of section 7 exists. Here, it can also be seen from Figure 20 that the excitation winding 6 is wound 203 onto the end cover 16, thereby avoiding contact between the excitation winding 6 and the edges between the side and end faces of the section 7 and / or the sub-component 29, and thereby avoiding damage to the excitation winding 6.

[0058] The segments 7, 8 are provided sequentially via a pre-assembly 100 method, comprising, as can be seen in the details of Figures 16 and 21, excitation windings 6 wound onto individual sub-pieces 29, 32 and impregnated in an impregnation bath 18 by a method of 204. In particular, here as shown in Figure 21, the excitation windings of the first type of segment 7 are immersed in an impregnation medium 36 located in the impregnation bath 18.

[0059] In the sequence of testing 101 after pre-assembly 100, electrical tests 205 are performed on sections 7 and 8 (here, the excitation winding 6).

[0060] Furthermore, Figures 17 and 18 illustrate the final assembly sequence of the rotor 1. In addition to the steps already explained with respect to Figures 8 to 13—arranging the first-type segment 7 206 into sub-assemblies 9, generating 207 the complete assembly 10, and engaging the rotor shaft 2 with the complete assembly 10 208—a contact ring 26 is mounted 209 onto the rotor shaft 2 at the axial end of the rotor 1, and then the excitation winding 6 is electrically connected to the contact ring 26 210. Following this, the slip ring transmitter 27 is engaged 211 with the rotor shaft 2 and electrically contacts the contact ring 26 212.

[0061] Following this, in this embodiment of the method, the support 14 and retaining element 15, particularly shown in FIG. 2, are inserted 213 into the rotor 1, and the reinforcing ring 37, shown in more detail in FIG. 1, is engaged 214 with the rotor stack 2 for this purpose, after preheating them. Subsequently, the rotor 1 is laser-marked 215, and at the respective axial ends of the rotor 1, preheated balance discs 38, 39 are mounted 216, 217 onto the rotor shaft 2, and bearings 28 are machined 218.

[0062] The balancing sequence of rotor 1 following final assembly 102 also includes pre-balancing 219, dynamic balancing 220, and final balancing 221 of rotor 1. After this, the electrical testing 104 and final inspection 105 of rotor 1 are performed, in which electrical testing 222 and final inspection 223 are performed on rotor 1 respectively.

[0063] List of reference numerals: 1. Rotor; 2. Rotor shaft; 3. Rotor stack; 4. Rotor yoke; 5. Rotor tooth; 6. Excitation winding; 7. Section; 8. Section; 9. Sub-assembly; 10. Complete assembly; 11. Connection; 12. Lamination; 13. Lamination; 14. Support; 15. Holding element; 16. End cap; 17. Winding tool; 18. Impregnation tank; 19. Circumferential direction; 20. Shaft-hub connection; 21. Connection structure; 22. Connection element; 23. Sub-connection element; 24. Butt joint area; 25. Base; 26. Contact ring; 27. Slip ring transmitter; 28. Bearing; 29. ​​Sub-component; 30. Section; 31. Tooth shank; 32. Sub-component; 33. Opening; 34. Slot bottom; 35. Slot; 36. Impregnation medium; 37. Reinforcing ring; 38. Balance disc; 39. Balance disc; 40. Tooth head; 100. Pre-assembly; 101. Testing; 102. Final assembly; 103. Balancing; 104. Testing; 105. Final inspection; 200. Provision; 201. Arrangement 202 Insulation 203 Winding 204 Impregnation 205 Testing 206 Arrangement 207 Generation 208 Joining 209 Installation 210 Connection 211 Joining 212 Contact 213 Installation 214 Joining 215 Laser Marking 216 Installation 217 Installation 218 Processing 219 Pre-balancing 220 Dynamic balancing 221 Final balancing 222 Testing 223 Final inspection F Force D1 Lamination thickness D2 Lamination thickness.

Claims

1. A rotor (1) for an electric motor, wherein, The rotor (1) includes a rotor stack (3) arranged on a rotor shaft (2) of the rotor (1), and the rotor stack (3) includes a rotor yoke (4) and a plurality of rotor teeth (5), each of which carries an excitation winding (6). The rotor (1) also has at least two segments (7,8) that divide the rotor stack (3) at least in the circumferential direction (19) of the rotor (1), wherein each segment (7,8) includes at least one rotor tooth (5) together with its excitation winding (6), and in the segment (7,8) At least a portion of the rotor yoke (4) comprises a section (30) of the rotor yoke (4) and a corresponding rotor tooth (5) of the section (7,8) implemented in one piece, and the sections (7,8) are engaged with each other via a force-fitting and / or form-fitting connection (11), characterized in that the connection (11) is established at least in part by the sections (7,8) being engaged with each other by a force (F) acting on the rotor stack (3), wherein the force (F) is formed due to the hub connection (20) between the rotor stack (3) and the rotor shaft (2).

2. The rotor (1) according to claim 1, characterized in that, The segment belongs to at least two different types of segments (7,8), and the segment has at least partially different shapes depending on the type.

3. The rotor (1) according to claim 1 or 2, characterized in that, The at least partially different shapes of the different types of segments (7,8) are achieved at least partially by the connection structure (21) of each segment (7,8) which is formed differently for each type, wherein the connection structure (21) of the corresponding types of segments (7,8) is formed complementaryly to each other and at least partially fits together.

4. The rotor (1) according to at least one of the preceding claims, characterized in that, The corresponding connection structure (21) has at least one concave and / or convex connection element (22) and / or sub-connection element (23), wherein the connection structure (21) of the corresponding type of segment (7,8) is at least partially formed complementary to each other via at least one connection element (22) and / or sub-connection element (23).

5. The rotor (1) according to at least one of the preceding claims, characterized in that, Two sub-connecting elements (23) of two segments (7,8) that are abutting each other in the mating area (24) of one type are formed into overlapping connecting elements (22).

6. The rotor (1) according to at least one of the preceding claims, characterized in that, At least two types of segments (7,8) are abutted against the rotor shaft (2) in such a way that they at least partially form the rotor yoke (4) of the rotor stack (3) and abut against each other on the sides, wherein their connecting structures (21) are partially shaped to fit together.

7. The rotor (1) according to at least one of the preceding claims, characterized in that, Only one type of segment (7,8) abuts against the rotor shaft (2) in a manner that at least partially forms the rotor yoke (4) of the rotor stack (3), and abuts against each other in the mating area (24) of the segment (7,8). In addition, another type of segment (7,8) abuts against the segment (7,8), wherein the connecting structure (21) of the segment (7,8) partially engages with each other in a shape-fitting manner, and the base (25) of at least part of the connecting structure (21) of the other type of corresponding segment (7,8) is surrounded by the adjacent segment (7,8) on the side and on the base surface.

8. The rotor (1) according to at least one of the preceding claims, characterized in that, At least a portion of the excitation winding (6) is electrically connected and / or connected to a contact ring (26) mounted on the rotor shaft (2) at the axial end of the rotor (1), and the contact ring (26) is in electrical contact with at least one slip ring transmitter (27).

9. The rotor (1) according to at least one of the preceding claims, characterized in that, An end cap (16) is provided at at least one radial and / or end-side end of the segment (7,8).

10. The rotor (1) according to at least one of the preceding claims, characterized in that, At least one support (14) is arranged between the excitation windings (6) of adjacent rotor teeth (5) to support the excitation windings (6).

11. The rotor (1) according to at least one of the preceding claims, characterized in that, The excitation winding (6) is made of aluminum or aluminum alloy.

12. A method for manufacturing a rotor (1) according to at least one of the preceding claims, characterized in that, Different types of segments (7,8) are provided sequentially via a method of pre-assembly (100) of the rotor (1), and in particular, in a method of final assembly (102) of the rotor (1) which is subsequently indirectly thereafter, a sub-assembly (9) of the segments (7,8) is first arranged (206) by one type of segments (7,8), and then a complete assembly (10) of the segments (7,8) is produced (207) by connecting the segments (7,8) of the sub-assembly (9) in a shape-fitting manner with another type of segments (7,8).

13. The method according to at least one of the preceding claims, characterized in that, In the final assembly (102) sequence, a hub connection (20) is formed between the rotor shaft (2) and the rotor stack (3) by force-fitting and / or form-fitting engagement (208) of the rotor shaft (2) with the complete assembly (10) of the segment (7,8).

14. The method according to at least one of the preceding claims, characterized in that, The segments (7,8) are provided sequentially via a pre-assembly (100) method, comprising: for each segment (7,8), winding (203) the excitation winding (6) onto a sub-piece (29,32) of a separate section (30) of the rotor stack (3) that includes rotor teeth (5) and rotor yoke (4).

15. The method according to at least one of the preceding claims, characterized in that, The segments (7,8) are provided sequentially via a pre-assembly (100) method, comprising: for each segment (7,8), an excitation winding (6) impregnated (204) and wound onto the individual sub-component (29,32).

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