Method for manufacturing a rotor of a permanently excited electric motor by means of an embedded distribution disc

Abstract

The invention relates to a method for producing a rotor (5) with embedded permanent magnets (9), in particular a rotor of a permanently excited electric motor (1), comprising the following steps: - stacking of laminations (8), in particular punching stacking, to a lamination core (47) of the rotor (5), the lamination core having a recess (18) extending substantially in the axial direction and being closed in the circumferential direction, the recess serving to accommodate the permanent magnets (9) in the axial direction, wherein the recess (18) has a pocket (10) and a flux barrier (13), - axial insertion of the permanent magnets (9) into the pocket (10), - positioning of a distribution disc (16) on an end face of the lamination core (47) of the rotor (5) by means of a positioning element (40) of the distribution disc (16), the positioning element (40) being clamped in an axial recess (41) and / or in an axial recess (18) of the lamination core (47), wherein the distribution disc (16) has a distribution channel (17) facing the end face of the lamination core (47) and at least one delivery portion (15) leading to the distribution channel (17), - delivery of a thixotropic potting compound (20) to the spaces of the recess (18) of the pole (48) not occupied by the permanent magnets (9) in the recess (18) by means of the delivery portion (15) and the distribution channel (17) of the distribution disc (16) at a predefinable pressure until at least all axially extending gaps (12) are filled or the recess (18) is filled up.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a rotor for a permanently excited motor, a rotor manufactured by the method, a permanently excited motor having such a rotor, and applications of the permanently excited motor. Background Technology

[0002] Industrial low-voltage motors (<1000 V rated voltage), especially those with an efficiency class of IE4 and above, are typically manufactured using rotors equipped with permanent magnets. These permanent magnets are housed within pockets (so-called embedded permanent magnets) within the laminated iron core of the rotor. The geometry of these pockets has a positive margin relative to the permanent magnets to allow for axial insertion.

[0003] After the permanent magnets are installed in the pocket section, they must be mechanically secured to the laminated iron core of the rotor. This is to prevent backlash in the permanent magnets within the pocket section, which could cause positional changes in the permanent magnets due to vibrations, centrifugal forces, or mechanical forces such as those experienced during the operation of a permanently excited motor.

[0004] Typically, this is done by using reactive plastic adhesives to bond the permanent magnet to the inside of the pocket. There are several commonly used methods for this.

[0005] One method involves pre-filling the pocket with a paste-like adhesive, then inserting the permanent magnet and pressing it against the adhesive to make it adhere tightly around the magnet. However, inserting the magnet into the paste can lead to some inaccuracy in placement, as the squeezed-out paste doesn't adhere evenly around the magnet, resulting in only dotted adhesion. Furthermore, handling the magnetized magnet is not easy, and due to the magnetic force, the handling cannot be performed ideally. Additionally, after each magnet insertion, the pre-applied adhesive paste on the auxiliary device must be removed.

[0006] Another method for securing the permanent magnet within the pocket is to subsequently encapsulate the pocket containing the permanent magnet with reactive resin, which must then be cured by heat (using an oven, for example, at 140 °C for 2 hours). Heating and cooling the entire rotor is a time-consuming and costly process.

[0007] Furthermore, such temperatures during the operating time may cause partial demagnetization of the permanent magnets, thereby continuously impairing the performance of the permanently excited motor.

[0008] In addition, the components need to be properly sealed beforehand to prevent the liquid reactive resin from overflowing from the designated areas. This is necessary on the end faces of the rotor laminations and also on the outer cylindrical surface of the rotor, because in the thin-walled areas (<1 mm) required for optimal magnetic flux, the resin can penetrate the individual laminations, resulting in contamination and dripping on the outer cylindrical surface.

[0009] To prevent time-consuming cleaning and subsequent processing of these surfaces in later steps, the outer cylindrical surface of the rotor must be sealed beforehand through a coating process. Here, a high-temperature curing paint is also used, resulting in an additional processing step and another heating and cooling cycle.

[0010] When using adhesives to integrally pot the rotor core, pressure plates are installed on the rotor end faces. These pressure plates are made of aluminum and are heat-fitted onto the shaft with an interference fit when the rotor core is axially clamped. By installing these heated pressure plates under axial clamping, the rotor core is axially reinforced. Therefore, the force for clamping is transmitted and supported on the shaft. For this purpose, a precise fitting system is required, including the fit between the pressure plates and the shaft. Summary of the Invention

[0011] Therefore, the purpose of this invention is to provide a rotor for a permanently excited motor, particularly a rotor for a permanently excited synchronous motor, which is relatively simple to manufacture and requires fewer cumbersome process steps. The rotor thus manufactured must meet the required efficiency level when used in a permanently excited motor, particularly a permanently excited synchronous motor, thereby providing relatively favorable energy consumption data for the application scenarios of such a permanently excited motor.

[0012] The above objective is achieved through a combination of features in the independent claims.

[0013] Advantageous designs of the invention are given in the dependent claims.

[0014] According to the present invention, the above-mentioned technical objective is achieved by a method of manufacturing a rotor, particularly a method of manufacturing a rotor for a permanently excited synchronous motor, wherein permanent magnets are fixed and positioned in the laminated iron core of the rotor by means of a distribution plate and by using a thixotropic potting compound.

[0015] The distribution disk, which forms the basis of the potting process of this invention, is installed on at least one end face of the rotor lamination core and fixed to the rotor lamination core by the positioning elements of the distribution disk. This avoids axial support of the distribution disk on the shaft, thereby further simplifying the rotor manufacturing process.

[0016] The distribution plate is mounted on the laminated iron core in a form-fit manner at the end face and can also be used for rotor balancing in subsequent processes after the potting process.

[0017] The distribution disk has at least one annular distribution channel on the side facing the rotor lamination core that is open to the lamination core (especially the magnetic poles facing the rotor).

[0018] At least one injection port (i.e., conveying section) is provided on the side of the distribution plate away from the laminated iron core for supplying potting material to the distribution channel.

[0019] Optionally, when viewed circumferentially, the distribution channel has an extension in the flux barrier region of the rotor poles to provide sufficient potting compound to the corresponding poles.

[0020] The dispensing channel and its optional extensions mate with and seal against the end face shape of the laminated iron core, enabling the establishment of appropriate pressure within the potting compound during the potting process to generate the required shear force. This annular dispensing channel is used to supply potting compound or adhesive to the axial cavities of the magnetic poles.

[0021] The distribution disc is fixed on the end face by a positioning element, which is designed, for example, in the shape of a pin or dowel, and is integrally formed with the distribution disc.

[0022] Before the potting process, the distribution plate with the positioning element is axially fixed to the end face of the rotor lamination core by anchoring it in the existing grooves of the lamination core (such as inertia slots, magnetic flux barriers, etc.) using positioning elements, especially by force-fitting.

[0023] Because the permanent magnets inserted axially into the pocket tend to partially eject from the pocket under the influence of mutual magnetic repulsion, the assembled distribution disc must be able to withstand this force. In other words, the pressed-in distribution disc must not detach from the end face of the laminated iron core due to the axial thrust of the permanent magnets until potting compound or adhesive is filled into the cavities and gaps provided for this purpose.

[0024] Therefore, the “resistance” of the positioning element, i.e., the length of the pin or dowel and its clamping function, should be designed to be at least equal to, but preferably greater than, the axial repulsive force of these permanent magnets.

[0025] In addition, force compensation must be provided for the forces generated by the potting process, which are formed by the pressure generated during the filling process, so that the distribution plate does not fall off the end face of the laminated core during the potting process and continues to maintain its axial shape fit.

[0026] Therefore, according to the present invention, the integrally injection-molded pin is designed with a slight interference fit relative to the corresponding opening of the laminated iron core, ideally having a cross-shaped profile.

[0027] As an alternative, an expanded shape similar to a pin could also be envisioned.

[0028] These positioning elements enable the distribution disc to be coaxially clamped or fastened to the end face of the laminated iron core.

[0029] The distributor plate may optionally have fasteners positioned radially outward. These fasteners ensure that the distributor plate is secured to the end face of the rotor lamination core even during operation of the permanently excited motor, due to adhesion within the flux barrier section provided for this purpose. The positioning elements are not surrounded by potting compound, while the fasteners are surrounded by potting compound, which reliably secures the distributor plate at that location after curing.

[0030] Therefore, the positioning element of the distribution disc is pressed into the end face of the laminated iron core and is important for manufacturing, while the optional fixing element extends into the flux barrier during manufacturing and is surrounded or encapsulated there by adhesive. After the adhesive cures, this specifically secures the distribution disc to the end face.

[0031] The distribution channel can be designed to be circular along its circumferential direction. Alternatively, it can be designed with radially and / or axially extending extensions and / or corrugated shapes to achieve sufficient filling within the cavity as quickly as possible. The orientation of the distribution channel essentially "follows" the magnetic pole arrangement. This applies to both the coverage area of ​​the distribution disk on the end face of the laminated core and the coverage area of ​​the distribution channel.

[0032] The coverage area of ​​the distribution disk is always larger than the coverage area of ​​the distribution channel.

[0033] Based on the design of the distribution channel, the distribution disk is suitable for all arrangements of permanent magnets in the poles of the rotor lamination core, such as radial, tangential, linear, V-shaped or multi-row arrangements.

[0034] Optionally, the distribution plate may be additionally equipped with fan blades on the side of the distribution plate away from the distribution channel, so as to generate airflow in the motor cavity, especially in the winding end space, during the operation of the permanently excited synchronous motor, thereby improving the heat dissipation of the rotor and / or winding end space.

[0035] The distribution disc can be made as an injection molded part, a deep-drawn part, or manufactured using a 3D printing process. Preferably, the distribution disc is made of plastic or a non-magnetic metal. Positioning elements, such as pins or dowels, or optional fan blades, are also integrated with the distribution disc.

[0036] During the injection process into the cavity via the distribution discs, tools are used to axially clamp the rotor lamination core through these distribution discs to ensure a seal between the distribution discs and the lamination core, as well as between the laminations, under any circumstances.

[0037] The distribution disc is axially fixed and positioned on the rotor lamination core, eliminating the need for a shaft to perform this operation.

[0038] The tensioning tool is protected from contamination by using a distribution disc and its seal on the distribution channel opening toward the end face, so it can then be used directly for subsequent operations.

[0039] The tensioning tool is also used to stack rotor laminations, particularly during the injection molding process. This stacking (i.e., applying axial force to the laminations) is achieved via a distribution disc and / or via a "radial gap" between the distribution disc and the shaft.

[0040] The side of the distribution disc facing the rotor lamination core may have a flexible geometry, or alternatively, a sealing material to improve axial sealing when clamped during potting processes using potting compound or adhesive.

[0041] Optionally, distribution discs are arranged on both sides of the rotor laminar core, i.e., at the end faces of the laminar core, to improve the stacking of the laminar parts. At least one distribution disc has a conveying section, i.e., an adhesive supply opening. To ensure the two components are identical, a supply hole is typically provided, which is sealed by a cast skin. If necessary, this cast skin can be knocked off the distribution disc before potting. Therefore, fewer components need to be stocked.

[0042] This manufacturing method is also applicable to (axially viewed) stepped rotor sub-laminated cores. The cavities of each pole have sufficient overlap in their axial extension direction to allow potting compound to be delivered to the other axial end of the pole lamination core. The flux barriers of the axially successive poles or cavities of the sub-laminated cores have sufficient overlap in area. However, as mentioned above, the entire lamination core has a distribution disc on at least one end face.

[0043] In the case of only one distribution plate, the cavity on the other end face of the laminated core is closed, for example by an end plate, so that the potting compound cannot overflow and the potting compound can produce a thixotropic effect.

[0044] In a method for manufacturing a rotor having embedded permanent magnets, particularly for rotors used in permanently excited synchronous motors, the following steps are performed: - The laminations are stacked, particularly the lamination core of the rotor is stamped and stacked, the lamination core having a substantially axially extended, circumferentially closed cavity for accommodating permanent magnets along the axial direction, wherein the cavity has a pocket portion and a flux barrier portion.

[0045] -Then the permanent magnet is inserted into the pocket along the axial direction.

[0046] - The distribution disc is positioned on the end face of the rotor lamination core by means of the positioning member of the distribution disc, wherein the positioning member extends into and / or clamps in the axial cavity and / or axial groove of the lamination core, wherein the distribution disc has a distribution channel open toward the end face of the lamination core and at least one conveying part leading to the distribution channel.

[0047] - Now, under a preset pressure, the thixotropic potting compound is conveyed through the conveying section to the space of the cavity of the magnetic pole that is not occupied by the permanent magnet in the cavity through the dispensing plate and dispensing channel, and this process continues until at least all axially extending gaps are filled or until the cavity is filled.

[0048] In the manufacturing method of a stepped rotor with embedded permanent magnets, particularly for rotors used in permanently excited synchronous motors, the following steps are performed: - The laminations are axially stacked, particularly stamped and stacked into sub-laminated cores, wherein the sub-laminated cores have cavities that extend substantially axially to accommodate permanent magnets, wherein the cavities have pocket portions and flux barriers.

[0049] -Then the permanent magnet is inserted axially into the pocket of the sub-laminated iron core.

[0050] - Subsequently, the individual sub-laminated iron cores are stacked in a circumferentially staggered manner to form the laminated iron core of the rotor, that is, the sub-laminated iron cores are sequentially staggered at a predetermined angle along the circumference and arranged on the shaft in a torsion-resistant manner, so that when viewed along the axial direction, the magnetic pole pockets with permanent magnets extend in stages.

[0051] - The distribution disc is positioned on the end face of the rotor lamination core by means of the positioning member of the distribution disc, wherein the positioning member extends into and / or clamps in the axial cavity and / or axial groove of the lamination core, wherein the distribution disc has a distribution channel open toward the end face of the lamination core and at least one conveying part leading to the distribution channel.

[0052] - Now, under a preset pressure, the thixotropic potting compound is conveyed through the conveying section to the space of the cavity of the magnetic pole that is not occupied by the permanent magnet in the cavity through the dispensing plate and dispensing channel, and this process continues until at least all axially extending gaps are filled or until the cavity is filled.

[0053] A "gap filler," preferably a thixotropic two-component epoxy resin, is used as the potting compound or adhesive in this method to bond the permanent magnets into their respective pockets.

[0054] The stacking of laminations, especially the stacking of sub-laminated cores, can be performed on an auxiliary shaft. Laminations can also be bonded together. Alternatively, laminations can be stamped and stacked to obtain a laminated core composed of single laminations or sub-laminated cores. Permanent magnets can be inserted into the laminated core or sub-laminated core.

[0055] When the laminated iron core is located on the actual shaft, additional stacking can be performed if necessary. This involves pressing the laminated iron core together using two discs. At least one of the two discs can be a distribution disc.

[0056] The stacking of laminated iron cores can also be achieved through tie rod connections.

[0057] The rotor's laminated iron core or sub-laminated iron core is preferably fitted with an anti-torsional geothermal assembly or cold-pressed onto the shaft.

[0058] The laminated iron core of the rotor can also be cold-jointed to obtain the required torsional and axial strength of the laminated iron core on the shaft. This reduces the axial joint force.

[0059] The distribution plate can therefore perform one or more of the following functions: stacking rotor laminations onto the shaft, distributing potting compound, promoting heat dissipation of the rotating motor, and balancing the rotor.

[0060] The cavity in the rotor laminated core is the punched portion of the laminated core, and the laminated cores are stacked sequentially in the axial direction to form a laminated core or a sub-laminated core. The cavity has both a pocket portion and a flux barrier portion. The pocket portion is used to accommodate one or more permanent magnets.

[0061] A retaining element, such as a retaining flange, may optionally extend into the space of the cavity to provide supplementary fixation and retention of the permanent magnet, at least during the manufacture and / or operation of the rotating motor, especially when subjected to centrifugal loads.

[0062] The torsional strength of the laminated core on the shaft is achieved by lamination tongues, which are arranged in slots at the inner diameter of at least some individual laminations and extend into the shaft bore. Ideally, these lamination tongues extend into the shaft bore by about 0.2 to 0.3 mm. Depending on the shaft height of the rotating electric machine, these values ​​may be greater or less.

[0063] The overlapping tongues in these insert slots are made together when punching individual overlapping pieces, so no additional processing work is required.

[0064] In one embodiment, the insertion slots and the resulting lamination tongues and spacer cavities are positioned 180° offset at the inner diameter of the laminations via a punching process. Therefore, when the laminations are arranged sequentially with a preset 90° torsion angle between the insertion slots and spacer cavities, the lamination tongues extend into the gaps of the spacer cavities, forming a lamination core with axial gaps equal to the thickness of a lamination before and after each lamination tongue. Thus, there is a possibility of slight elastic axial deformation of the lamination tongues. When the lamination core composed of the laminations is assembled onto a shaft, the lamination tongues of the laminations deflect axially into the spacer cavities of adjacent laminations.

[0065] However, in the direction of rotation, the lamination tongues now possess higher stiffness. During axial assembly of the rotor lamination core, these lamination tongues rub against the machined surface along the shaft. Thus, during assembly, a slight form fit is formed between the lamination tongues and the shaft in the width direction. Compared to the primary cylindrical fit, the axial assembly force component of the lamination tongues is relatively small because these lamination tongues are easily bent. However, the sum of the form fits gives the entire lamination core relatively high torsional resistance on the shaft.

[0066] The elasticity achieved by the stacked tongue reliably compensates for the expansion of the shaft hole caused by temperature rise or centrifugal load during operation, without losing positioning, and in particular without losing torsional performance.

[0067] Therefore, the axial hooking of the lamination tongues also provides axial safety to prevent the lamination core from slipping on the shaft. This manufacturing and assembly method can be used for typically angled rotor lamination cores without additional machining.

[0068] To achieve sufficient torsional strength, the rotor laminations are fitted with the shaft in an additional slight shape fit.

[0069] Similarly, there are other methods to transfer torque from the laminated core to the shaft, such as keyed connections.

[0070] The potting compound can be injected into the rotor lamination core at all possible angular positions along the rotor axis.

[0071] Advantageously, under increased potting pressure, the potting compound is injected into the rotor equipped with permanent magnets using a lift-type potting method. At this point, the rotor's axis is essentially vertical. In particular, lift-type potting allows for simple, bubble-free injection.

[0072] In another possible process step, the potting compound is poured into the rotor equipped with permanent magnets from above. In this case, existing air in the cavities is forced out between the laminations. Therefore, there is no risk of shrinkage cavities. Due to the thixotropic properties of the potting compound, the adhesive will not leak from the laminations of the laminated core or between the laminations.

[0073] The filling process does not depend on whether the rotor's magnetic poles extend axially parallel, obliquely, or are staggered. The key is always that the potting compound can penetrate axially through the magnetic flux barriers and / or the aforementioned gaps of the magnetic poles and fill the cavities of the magnetic poles.

[0074] In the potting process, a static / dynamic mixing tube is used to mix the reactive mixture in situ, and then the mixture is applied directly to the rotor through a distribution plate on one end face of the rotor. Alternatively, distribution plates can be provided on both end faces of the rotor to fill the rotor from both sides. Preferably, the rotor axis is horizontally aligned.

[0075] Here, the distribution discs are either identical or configured such that each distribution disc is used to fill only half of the rotor's magnetic poles with potting compound.

[0076] Double-sided potting compound filling may be particularly advantageous for rotors with long axial lengths.

[0077] Pressures of up to 10 bar, preferably 4.5 bar, can be applied through one or more suitable injection ports on the dispensing disc, thereby making the preferably freshly mixed, thixotropic potting compound flowable and axially, particularly axially upward, into the remaining geometric space of the rotor cavity.

[0078] Therefore, the thixotropic potting compound is mixed in situ in a static or dynamic mixing tube, wherein the potting compound is conveyed at a temperature of up to 60°C, particularly up to 30°C, and distributed at a flow rate of up to 10 mm / s, wherein the pressure is up to 10 bar, particularly 4.5 to 5 bar, i.e., essentially at ambient temperature.

[0079] Therefore, the potting process can be carried out at almost ambient temperature, which simplifies the process and allows the rotor to be further processed immediately with almost no time interval.

[0080] The gap should be understood as the gap between the magnetic flux barrier, the permanent magnet and the corresponding lamination, but not or almost not the slit between the laminations.

[0081] In other words, the radial planes between the laminations should not and must not contain potting compound. This can be ensured, in particular, by axially stacking with thixotropic potting compound. Potting compound should be avoided in these radial planes. The potting compound should only fill the cavities containing permanent magnets, i.e., flux barriers, and the gaps between the laminations and the permanent magnets, i.e., channels, and should not fill the radial gaps between the laminations, i.e., the planes perpendicular to the axis.

[0082] Similarly, the rotor's inertia bore is also not filled with potting compound. Additionally, the bores used to accommodate the pins / pins of the distribution disc are typically also left unfilled. In other words, the pins / pins are not surrounded by potting compound.

[0083] However, in one implementation, the pins / pins of the dispensing disc are surrounded by potting compound, provided that they are positioned in the flux barrier and anchored there.

[0084] After the cavity is completely filled, the pressure is released. Detection of whether the critical gaps in the laminated core are filled is performed by comparing static and dynamic pressure (e.g., by establishing the pressure of dynamic and static pressure).

[0085] Once all channels are completely filled, the flow of the potting compound will stop, and this can be detected by the change in total pressure according to Bernoulli's principle. Bernoulli's pressure equation (total pressure = dynamic pressure + static pressure).

[0086] Similarly, the potting process can be visually inspected to detect any unwanted overflow on the outer cylindrical surface of the cylindrical laminated iron core. This is preferably observed at narrow ribs, which act as the boundary between the magnetic flux barrier and the outer cylindrical surface. Viewed radially, these ribs may be only a few millimeters, or even just a fraction of a millimeter.

[0087] Subsequently, the potting compound in the rotor lamination core gelled without pressure at room temperature and completely cured within 24 hours.

[0088] After approximately one hour, further processing can continue on the rotor or together with the rotor without mechanical load. By applying a thixotropic treatment to the potting compound, the material (i.e., the potting compound) is prevented from penetrating through individual laminations, thus eliminating the need for a pre-painting process on the outer cylindrical surfaces.

[0089] According to the present invention, a rotor with permanent magnets is now encapsulated by a thixotropic potting compound using a distribution disc of the present invention, the potting compound gelling and fully curing at room temperature.

[0090] By using high fill density and thixotropic additives, the pocket can be filled from bottom to top using a pressurized process, and the reactive material will not leak out through small slits (such as the slits between individual stacks).

[0091] As a potting compound or adhesive, a "gap filler," preferably a thixotropic two-component epoxy resin, is used to bond permanent magnets into their respective pockets, with a maximum operating temperature of approximately 160 °C. Conventional bonding systems are only suitable up to a maximum of 120 °C.

[0092] In the method for which protection is sought, the potting compound advantageously exhibits thixotropy, wherein the viscosity decreases due to externally controlled influences (e.g., pressure) and recovers to its initial viscosity after loading is completed.

[0093] By using thixotropic potting compound, the tensioning tool can be released immediately after injection potting. The potting compound will not flow away. The stacking of the rotor laminations remains unchanged.

[0094] Under constant shear (pressure), the viscosity of the potting compound decreases over time, and increases again over time after the shear load ends. By first applying static pressure and then applying dynamic pressure as the potting compound moves, viscous flow of the potting compound is first generated, thus producing shear force.

[0095] Thixotropy of potting compound is achieved by adding and dispersing fumed silica in the range of 0.1 to 0.5% by volume.

[0096] Before the potting compound is delivered to the rotor via a distribution disc through a pipe or hose, at least two of its components, which are separate from each other, are repositioned by relative motion, so that the components to be mixed present a uniform and well-defined distribution.

[0097] As a potting compound used to fix permanent magnets in the rotor lamination core of a permanently excited synchronous motor, a two-component reactive resin is set as the base resin material, which contains a preset amount of thermally conductive additives and / or additives that affect the gel time of the potting compound.

[0098] Preferably, a reactive resin based on epoxy / amine or, for example, polyurethane / isocyanate is used as the two-component base resin material. Here, gelation at room temperature can be adjusted to occur from minutes to hours, thus eliminating the need for additional heating (and the resulting further liquefaction of the resin mixture), and the potting compound cures substantially. In other words, it can therefore be fully cured at room temperature without subsequent temperature control.

[0099] Polysiloxanes and silicones are also suitable as other base materials.

[0100] In this process, the mixing of at least two components can be carried out using a dynamic mixer, such as a high-speed mixer.

[0101] A simpler and more cost-effective method is to statically mix the components.

[0102] Therefore, at lower shear forces (approximately 10 Pa), approximately 10 Pa can be obtained. 5 -10 7 The shear viscosity is measured in mPa. At higher shear forces (approximately 200 Pa), a viscosity of approximately 10 mPa can be obtained. 2 -10 4 The shear viscosity is measured in mPa. These shear forces are introduced into the potting compound through pressure.

[0103] After the shear force is reduced (pressure is reduced), the material viscosity recovers within minutes, thereby allowing the potting compound to self-cure in the predetermined gaps and / or flux barriers, no longer forming a flow path through small gaps, especially through the gaps formed between individual laminations of the rotor lamination core.

[0104] The potting compound is cured without axial tension, so the potting compound / adhesive is not pre-tightened along the flux barrier or gap and will not crack later.

[0105] The volume shrinkage rate of this type of filled rotor is less than 1%. This avoids, for example, the formation of shrinkage cavities, which can impair the positioning of the permanent magnet as well as its electromagnetic and thermal conductivity.

[0106] Preferred potting compounds that cure at room temperature, in addition to exhibiting strong thixotropic rheological properties, can be adjusted to be thermally conductive (>0.5 W / mK) through suitable additives. These additives are incorporated into the potting compound before injection into the rotor, particularly into the potting compound in the distribution plate. This improves heat dissipation of the permanent magnets during the operation of the rotating motor, as the permanent magnets are heated by eddy currents and / or air gap harmonics. Consequently, the permanent magnets are coupled to the rotor lamination core with relatively better thermal conductivity.

[0107] The thermal conductivity of potting compounds can be achieved by adding or mixing in various fillers. The available additives include quartz powder, fused silica, boron nitride (BN), alumina, and chalk. These components can be mixed together or separately, and therefore can comprise up to 40% of the total volume of the potting compound.

[0108] The method for manufacturing a permanently excited synchronous motor rotor according to the present invention provides the following advantages: This method is simpler and more cost-effective than methods known to date, in which the distribution disc is made of aluminum and fixed to the shaft with an interference fit.

[0109] By means of manufacturing a permanently excited synchronous motor rotor according to the present invention, a reliable axial sealing method for the distribution disc relative to the end face of the laminated iron core is achieved, because the axial tension required for this during the injection process can be adjusted by means of a closing force using appropriate tools.

[0110] Therefore, injection filling can be performed by dispensing disc at a relatively high working pressure of the potting compound, ranging from 2 to 10 bar, preferably 4 bar, which can particularly suppress the formation of pinholes.

[0111] By eliminating unnecessary preparation time (such as cleaning and tightening tools) at each process step (especially when carried out at ambient temperature), the manufacturing process time for rotors can be kept short, which in turn ensures that the manufacturing process time for rotating electric machines is also kept short.

[0112] Synchronous motors equipped with this type of rotor have a high efficiency rating, making them particularly suitable for driving continuous operation, especially compressors, air compressors, conveyor belts, fans, etc. Attached Figure Description

[0113] The present invention and other advantageous technical solutions of the present invention will be further described below with reference to the embodiments shown in the principle diagram, wherein: Figure 1 This shows a schematic longitudinal cross-sectional view of a rotary electric machine. Figure 2 A schematic longitudinal cross-sectional view of a rotor with embedded permanent magnets is shown. Figure 3 Showing the distribution disk, Figure 4 A three-dimensional view of the dispensing disk is shown. Figure 5 A partial perspective view of the distribution disk on the rotor lamination core is shown. Figure 6 The end face of the rotor is shown. Figure 7 Showing according to Figure 6 Cross-sectional view, Figure 8 A partial perspective view of the distribution disc on the rotor is shown. Figure 9 The end face of the rotor with the distribution disc is shown. Figure 10 A rotor with two distribution discs is shown. Figure 11 A perspective view of the distribution disc on the rotor is shown. Figure 12 The diagram shows a longitudinal cross-sectional view of a rotor consisting of sub-laminated iron cores arranged in a staggered manner along the circumference. Figure 13 , Figure 14 A partial 3D view of the dispensing disk is shown. Figure 15 The cross-section of the rotor is shown. Figure 16 A partial perspective view of the rotor end face with a distribution disc is shown. Figure 17 A schematic diagram of the magnetic poles is shown. Figure 18 A flowchart illustrating a feasible method is provided. Detailed Implementation

[0114] It should be noted that terms such as "axial," "radial," and "tangential" refer to the axis 7 used in the corresponding figures or described embodiments. In other words, the axial, radial, and tangential directions are always referenced to the axis 7 of the rotor 5, and thus also to the corresponding axis of symmetry of the stator 2. "Axial" describes a direction parallel to axis 7, "radial" describes a direction orthogonal to axis 7, toward axis 7, or away from axis 7, and "tangential" refers to a circular direction about axis 7 when the radial distance from axis 7 is constant and the axial position is constant. The expression "circumferentially" is equivalent to "tangential."

[0115] The terms “axial,” “radial,” “tangential,” etc., describe the orientation of the normal vector (i.e., the vector perpendicular to the relevant surface) of a surface, such as a cross-section.

[0116] Here, the expression "coaxial components" (e.g., coaxial assemblies such as rotor 5 and stator 2) should be understood as components having the same normal vector, that is, the planes defined by these coaxial components are parallel to each other. Furthermore, this expression should include the fact that the midpoints of the coaxial components lie on the same axis of rotation or axis of symmetry. However, these midpoints may be located at different axial positions on this axis 7, and the distance between the planes is greater than 0. This expression does not necessarily require that the coaxial components have the same radius.

[0117] In the context of two complementary components, the term "complementary" means that their shapes are designed such that one component can preferably be fully arranged within its complementary component, so that the inner surface of one component and the outer surface of the other component ideally make full or seamless contact. Therefore, in the case of two complementary objects, the shape of one object is determined by the shape of the other. The term "complementary" can be replaced by the term "inverse."

[0118] For clarity, in the accompanying drawings, where a component appears multiple times, not all of the components shown are usually labeled with reference numerals.

[0119] The embodiments described in the general description and the detailed drawings can be combined arbitrarily. Similarly, individual features of the corresponding embodiments can also be combined with each other without departing from the essence of the invention.

[0120] Figure 1 A schematic longitudinal view shows a rotary motor 1, in this case a permanently excited synchronous motor. This permanently excited synchronous motor has a stator 2 with a winding system 3 in slots not shown in detail, the winding system forming winding ends 4 at the end faces of the stator 2. The energized winding system 3 causes a rotor 5 to rotate about an axis 7 via electromagnetic interaction through an air gap 11. The rotor 5, coaxially arranged with the stator 2, has permanent magnets 9 arranged in axially extending cavities 18, also referred to as embedded permanent magnets 9. The laminations 8 of the rotor 5 are stacked to form a laminated core 47 and are torsionally connected to a shaft 6.

[0121] Figure 2 A rotor 5 is shown, its laminated iron core 47 being stacked by two end plates, wherein at least one end plate is configured as a distribution plate 16. The distribution plate 16 has at least one distribution channel 17 on the side facing the end face of the laminated iron core 47, which can be filled by a conveying section 15. In the potting process, a potting compound 20, particularly a thixotropic material, is applied to the distribution channel 17 by the conveying section 15 at a preset pressure.

[0122] The distribution plate 16 may also have multiple conveying sections 15 to increase the amount of potting compound 20 that can be conveyed.

[0123] The punched portions of each lamination 8 are stacked in the lamination core 47 to form a cavity 18 that extends substantially along the axial direction. The cavity 18 of the lamination core 47 extends either parallel to the axis, obliquely, or in a staggered manner.

[0124] In an axially parallel arrangement, the cavities 18 are aligned with each other. In an oblique arrangement, each lamination 8 is offset circumferentially relative to the lamination immediately following it in the axial direction at a preset angle.

[0125] Sub-laminated iron cores 42, arranged circumferentially and axially, form a stepped laminated iron core 47.

[0126] Regardless of the design of the laminated core 47 (straight, oblique, stepped), it is always required that the potting compound 20 can pass axially from the distribution plate 16 through the magnetic flux barrier portion 13 of the magnetic pole 48 and / or the gap 12 of the aforementioned cavity 18, and be able to fill the cavity of the magnetic pole 48.

[0127] The cavity 18 has both a pocket portion 10 and a magnetic flux barrier portion 13. The pocket portion 10 is configured to accommodate one or more permanent magnets 9. Retaining flanges 49 and retaining elements 46 extend into the space of the cavity 18, especially for supplementary fixation and retention of the permanent magnets 9 under centrifugal loads during the manufacture and operation of the rotating electric machine.

[0128] Ideally, the permanent magnet 9 would be placed seamlessly with the lamination 8 within the cavity 18, forming a seamless and full-surface fit. However, due to manufacturing limitations, such a complementary arrangement is not possible. Due to manufacturing constraints, axially extending gaps 12 are created between the permanent magnet 9 and the lamination 8, and these gaps must be closed.

[0129] The stacking of laminations 8 or sub-laminated cores 42 can be performed on an auxiliary shaft. Alternatively, laminations 8 can be bonded together. Similarly, laminations 8 can be stamped and stacked to obtain lamination cores 47 or sub-laminated cores 42 into which permanent magnets 9 can be inserted.

[0130] Alternatively, additional stacking is performed only when the laminated core 47 is located on the actual shaft 6. In this case, the laminated core 47 is pressed together by means of two disks, particularly at least one distribution disk 16.

[0131] The laminated iron core 47, rather than the distribution plate 16, is preferably assembled onto the shaft 6 by hot fitting or cold pressing to transmit torque.

[0132] Similarly, there are other methods for transmitting torque from the laminated core 47 to the shaft 6, such as a keyed connection. The lamination of the laminated core 47 can also be implemented by an axially parallel tie rod connection, which is preferably arranged radially inside the distribution plate 16.

[0133] The distribution disk 16 has at least one circumferential distribution channel 17 on its side facing the laminated iron core 47 of the rotor 5, which opens toward the laminated iron core 47 and is slot-shaped in cross-section. The distribution channel 17 fits the end face shape of the laminated iron core 47 and closes in a sealing manner.

[0134] The distribution channel 17 has a coverage area 44 and each cavity 18 of the magnetic pole 48 has at least a segmented supply area, which allows the potting compound 20 to reach the cavity 18 via the magnetic flux barrier 13 and / or the gap 12 between the permanent magnet 9 and the inner side of the lamination.

[0135] At least one injection port for potting compound 20, namely a conveying section 15, is provided on the side of the distribution plate 16 away from the laminated iron core 47 for supplying to the distribution channel 17 and thereby to the gap 12 and / or the magnetic flux barrier section 13 of the cavity 18 of the magnetic pole 48.

[0136] The distribution channel 17 is fitted with the end face shape of the laminated iron core 47 and is sealed closed so as to establish the corresponding pressure, thereby generating the required shear force in the potting compound 20.

[0137] The pre-mixed, especially in-situ mixed, potting compound 20 is pressed into the laminated iron core 47 of the rotor 5 at a preset pressure via the conveying section 15.

[0138] In this thixotropic potting compound 20, the relatively low viscosity due to increased shear force allows the potting compound 20 to penetrate into the gaps and cavities in the laminated iron core not occupied by the permanent magnet 9. During the potting process, the potting compound 20 is now pressed in under a predetermined pressure, and due to its low viscosity, it is distributed in the flux barrier portion 13 or in the gap 12 between the permanent magnet 9 and the inner side of the pocket portion 10 of the laminated iron core 47 of the rotor 5.

[0139] Pressure monitoring can terminate the process, thereby increasing the viscosity of the potting compound 20 at the moment when the shear force decreases (pressure decreases), and thus interrupting or potentially halting the potting process. Once the potting compound 20 has been distributed in the gaps 12 and flux barriers 13 around the permanent magnet 9, and is about to further extend into the spacers of the laminations 8, the required pressure increases, which can then be used as a criterion for interrupting the potting process. This prevents the potting compound 20 from, for example, radially penetrating between the laminations 8 of the rotor 5, and particularly from overflowing from the surface 19 of the rotor 5 via the ribs 14.

[0140] Therefore, the thixotropic potting compound 20 is mixed in situ in a static or dynamic mixing tube, wherein the potting compound 20 has a temperature of up to 60°C, particularly up to 30°C, during delivery, and is delivered to the distribution plate 16 and / or cavity 18 at a flow rate of up to 10 mm / s, wherein the pressure is up to 10 bar, particularly 4.5 to 5 bar.

[0141] Therefore, the potting process of the permanent magnet 9 in the cavity 18 can be carried out at almost room temperature, which simplifies the process and allows the rotor 5 to continue processing almost seamlessly in time.

[0142] Figure 3 A view of the distribution plate 16 is shown, in which an annular distribution channel 17 is provided, which then supplies potting compound 20 from the end face of the laminated iron core 47 to the magnetic poles 48 of the rotor 5.

[0143] Figure 4 A perspective view of the distribution disc 16 is shown, in which the pin 40 of the distribution disc 16 is visible, which is subsequently engaged in the axially extending cavity 18 and / or grooves 41, 45 of the laminated iron core 47 of the rotor 5.

[0144] Figure 5 A partial perspective view of the distribution disk 16 on the lamination core of the rotor 5 is shown with the distribution disk 16 positioned on the end face of the lamination core.

[0145] Figure 6 The end face of the laminated iron core 47 of the rotor 5 with the distribution disk 16 is shown. The coverage area 43 of the distribution disk 16 is radially smaller than the coverage area 44 of the distribution channel 17. The coverage area 44 covers at least part of the cavity 18 of the magnetic pole 48. The inertial opening 45 is not filled with potting compound 20.

[0146] Figure 6 The partially covered magnetic poles 48 of the rotor 5 are also shown. In this case, the magnetic poles 48 are formed by two permanent magnets 9 arranged in a V-shape. Similarly, the magnetic poles 48 of the rotor 5 can also be formed by multiple permanent magnets 9, for example, by a double V-shape arrangement, a U-shape arrangement, or a W-shape arrangement, or by only tangentially arranged permanent magnets 9. Depending on the axial length of the laminated core 47 of the rotor 5, multiple permanent magnets 9 are also provided in each cavity in the axial direction. This is especially necessary when the laminated core 47 is constructed by sub-laminated cores 42.

[0147] The permanent magnet 9 is arranged in the cavity 18, which consists of a magnetic flux barrier 13, a retaining element 46 (optional if necessary), and a pocket 10. The pocket 10 is used to accommodate the permanent magnet 9, and the magnetic flux barrier 13 and the retaining element 46 (optional) are used for fixation and magnetic flux optimization in the laminated iron core 47 of the rotor 5.

[0148] The gap 12 between the laminate 8 and the permanent magnet 9 may optionally have at least segmented protrusions 55 (according to...) Figure 17 This facilitates the axial filling process of the potting compound 20.

[0149] Figure 18 The basic principle steps of a method for manufacturing rotor 5, particularly the rotor of a permanent magnet rotary electric motor 1, are shown. These steps can be extended if necessary. - Step "30": Stacking, particularly stamped stacking, with laminated iron cores 47 or sub-laminated iron cores 42 having a cavity 18 extending substantially axially to accommodate the permanent magnet 9, wherein the cavity 18 has a pocket portion 10 and a magnetic flux barrier portion 13. - Step "31": The permanent magnet 9 is axially inserted into the pocket portion 10 of the cavity 18 of the laminated iron core 47 or the sub-laminated iron core 42. - Optional step "32" for the sub-laminated iron core 42: The sub-laminated iron core 42, which is provided with permanent magnets 9, is stacked in a circumferentially staggered manner to form the laminated iron core 47 of the rotor 5. That is, the sub-laminated iron cores 42 are sequentially staggered circumferentially at a preset angle and arranged on the shaft 6 in a torsion-resistant manner, so that the pocket portion 10 with permanent magnets 9 extends in stages when viewed from the axial direction. - Step "33": By means of the clamping of the positioning member 40 in the groove 41, at least one distribution disc 16 is mounted on the end face of the laminated iron core 47, wherein the distribution disc 16 has at least one conveying part 15 on the side opposite to the laminated iron core 47 and at least one distribution channel 17 on the side facing the laminated iron core 47. - Step “34”: Under preset pressure (up to 10 bar, especially 4.5 to 5 bar), maximum temperature 60°C (especially 30°C), and maximum flow rate 10 mm / s, the thixotropic potting compound 20 mixed in situ in the static or dynamic mixing tube is conveyed through the conveying part 15 of the dispensing disc 16 and via the dispensing channel 17 to the space in the cavity 18 not occupied by the permanent magnet 9, and this process continues until at least all axially extending gaps 12 and magnetic flux barriers 13 are filled, or until the cavity 18 is filled, and / or a pressure rise significantly higher than the processing pressure (especially 10 bar) is detected (detecting the dynamic and static pressures of the potting compound 20).

[0150] Thixotropic potting compound 20 is mixed in situ in a static or dynamic mixing tube.

[0151] The rotor 5 can be positioned in an auxiliary device such that, in particular, the axial gap 12 is filled axially parallel by means of the rising potting compound 20.

[0152] During the filling process with potting compound 20, the filling of the lamination core 47 of rotor 5 is monitored by detecting the dynamic pressure and static pressure of the potting compound 20.

[0153] When the pressure of the potting compound 20 differs from the ambient pressure, i.e., is lower or higher than the ambient pressure, it is advantageous to ensure that the distribution disc 16, especially the distribution channel 17, is sealed in accordance with the shape of the end face of the rotor 5 to ensure that the potting compound 20 is injected into the cavity 18 of the rotor 5 without loss, and to monitor the pressure to interrupt the filling process.

[0154] A two-component reactive resin is used as the base resin material for potting compound 20, wherein it contains or can be added in a preset amount of thermally conductive and / or additives that affect the gelation time of the potting compound.

[0155] The two-component reactive resin can be based on epoxy / amine or polyurethane / isocyanate.

[0156] In addition, thermally conductive additives, such as quartz powder and / or quartz sand and / or BN and / or alumina and / or chalk, may be added, with their total amount or individual content accounting for up to 40% of the volume of the potting compound 20. This achieves a better thermal connection between the permanent magnet 9 and the laminated iron core 47.

[0157] Figure 7 It shows according to Figure 6 The longitudinal section of rotor 5 shows both the covered area 44 and the axial engagement between pin 40 and the axially extending groove. After the potting process, the distribution disc 16 remains on the laminated core 47, thus forming a "residue". These axially extending holes or grooves 41 can be configured to be through or only have a predetermined depth (viewed from the corresponding end face). These holes or grooves 41, as particularly as Figure 6 and Figure 9 As shown, they are arranged in different configurations along the circumference at different radii.

[0158] Figure 8 It shows according to Figure 7 A partial perspective view of the distribution disk 16 on the rotor 5.

[0159] Figure 9 The end face of the rotor 5 with the distribution disk 16 is shown. The distribution disk 16 is configured in a “wavy” shape on its circumferential extension so as to align with the configuration of the magnetic poles 48, which is V-shaped in this example.

[0160] Figure 10 A rotor 5 with two distribution discs 16 is shown, wherein the laminated iron core 47 is formed axially by sub-laminated iron cores 42.

[0161] Figure 11 It shows according to Figure 10A perspective view of the distribution disc 16 on the rotor 5. In particular, the conveying section 15 for conveying the potting compound 20 to the distribution channel 17 can be seen.

[0162] Through the conveying section 15, the potting compound 20 is axially pressed into the cavity 18 via its adjacent flux barrier section 13. The potting compound 20 seeks a further flow path between the permanent magnet 9 and the laminations 8 to also penetrate and fill the radially outer flux barrier section 13. By monitoring the pressure and the resulting shear force, the process can be interrupted once the cavity 18 is full. This prevents the potting compound 20 from seeping, particularly through the narrow ribs 14 at the radial outer edge of the rotor 5, onto the surface 19 of the rotor 5 lamination core.

[0163] Figure 12 A longitudinal section of a rotor 5 consisting of sub-laminated cores 42 arranged in a staggered manner along the circumference is shown. This ensures axial supply to the cavities 18 of the sub-laminated cores 42. The circumferential stagger of the sub-laminated cores 42 should not unnecessarily impede the axial supply of potting compound 20 to the cavities 18 of the individual poles 48, and despite the stepped arrangement of the sub-laminated cores 42, axial filling from one end face of the laminated cores 47 must still be ensured by means of a distribution disc 16.

[0164] Figure 13 , Figure 14 Partial perspective views of the distribution plate 16 are shown, in which pins 40 are arranged not only in the radially inner region, but also fasteners 50 are arranged in the radially outer region.

[0165] In principle, the pins 40 hold the dispensing disc 16 on the end face of the laminated core 47 by clamping until adhesive is injected. These pins 40 are pressed into holes or grooves 41. The axial length of these pins 40—depending on the laminate thickness and the required holding force—is several laminate thicknesses, preferably 4 to 40 laminate thicknesses. Additionally, during adhesive filling, the dispensing disc 16 is pressed by an axial tensioning tool.

[0166] Optional fasteners 50 hold the dispensing disc 16 in place, particularly after the adhesive has cured. These fasteners 50 are not anchored in the flux barrier 13 with an interference fit, but rather have an adhesive gap within the flux barrier 13. Therefore, these fasteners 50 can only provide additional axial secure fixation to the dispensing disc 16 after the adhesive has cured.

[0167] In other words, while the positioning element, particularly the pin 40 of the distribution disc 16, is pressed into the end face of the laminated iron core and is important for manufacturing, the optional fastener 50 (which may also be configured as a pin) extends into the flux barrier portion 13 during manufacturing and is surrounded or covered there by the adhesive 20. After the adhesive 20 has cured, this, in particular, secures the distribution disc 16 to the end face.

[0168] Figure 15 A cross-section of the rotor 5 equipped with permanent magnets 9 is shown, wherein the permanent magnets 9 of the magnetic poles 48 are arranged in a V-shape. The inertia slots 45 and recesses 41 are not filled with potting compound 20. However, the flux barrier section 13 and the gaps 12 in the cavity 18 are filled with potting compound 20.

[0169] Figure 17 A detailed view of the magnetic pole 48 is shown, in which a mounting groove 51 is shown at the shaft hole of the laminated iron core, serving as a possible anti-torsion connection between the laminated iron core 47 and the shaft 6. Furthermore, an exaggeratedly shown gap 12 between the permanent magnet 9 and the inside of the pocket portion 10 is also shown here. Additionally, the retaining flange 49 and retaining element 46 in the cavity 18 are shown in more detail.

[0170] Figure 16 The end face of the rotor 5 with the distribution disc 16 is shown.

[0171] A permanently excited synchronous motor (with a rotor 5 according to the invention, the permanent magnets 9 of which are embedded and have a distribution disc 17 according to the invention and are fixed by such a thixotropic potting compound) is now relatively simple to manufacture and achieves relatively high efficiency. Therefore, it is particularly suitable for many types of machinery, especially continuously operating machines. These machines are used, for example, as drives for compressors, boosters, fans, and as drives in the food industry and marine applications.

[0172] Since the surface 19 of rotor 5 does not contain any residue of potting compound 20 or adhesive, the radial thickness of the air gap 11 between stator 2 and rotor 5 can be reduced, thereby further improving the efficiency of the permanently excited synchronous motor.

[0173] Therefore, the power density of the drive unit is relatively higher within the same volume. Consequently, permanently excited synchronous motors can be arranged relatively close to the working machinery, and thus can also be integrated as direct drive units into the housing of one of the aforementioned working machines.

[0174] List of reference numerals

[0175] 1 Rotary electric motor

[0176] 2. Stator

[0177] 3 Winding System

[0178] 4. Winding ends

[0179] 5 rotors

[0180] 6-axis

[0181] 7. Axis

[0182] 8 rotor laminations

[0183] 9 permanent magnets

[0184] 10 Pocket Section

[0185] 11 Air gap

[0186] 12. Gap between the laminate and the permanent magnet

[0187] 13. Flux Barrier Section

[0188] 14 ribs

[0189] 15. Conveyor section leading to the distribution tray

[0190] 16 Distribution Disk

[0191] 17. Allocation Channel

[0192] 18. Cavity

[0193] 19 Rotor surface

[0194] 20 potting compound

[0195] 30-Laminated Iron Core

[0196] 31. Insert permanent magnet

[0197] 32 Installation and Distribution Disks

[0198] 33 Fill with potting compound

[0199] 40 sales

[0200] 41 holes / grooves

[0201] 42-layer laminated iron core

[0202] 43 Distribution disk coverage area

[0203] 44. Coverage area of ​​the distribution channel

[0204] 45. Inertia groove

[0205] 46 Holding elements

[0206] 47 Laminated Iron Core

[0207] 48 magnetic poles

[0208] 49. Maintain the flange

[0209] 50 Fasteners

[0210] 51 Clothing Slots

[0211] 55. Protrusion.

Claims

1. A method for manufacturing a rotor (5) having embedded permanent magnets (9), the rotor being particularly a rotor of a permanently excited electric motor (1), the method comprising the steps of: - Stacking laminations (8), particularly stamping and stacking them into a lamination core (47) of the rotor (5), the lamination core having a circumferentially closed cavity (18) extending substantially axially for accommodating a permanent magnet (9) along the axial direction, wherein the cavity (18) has a pocket portion (10) and a magnetic flux barrier portion (13). - The permanent magnet (9) is inserted axially into the pocket portion (10). - The distribution disk (16) is positioned on the end face of the laminated iron core (47) of the rotor (5) by the positioning member (40) and the optional fixing member (50), such that the positioning member (40) is engaged in the axial groove (41) and / or axial cavity (18) of the laminated iron core (47), and the optional fixing member (50) extends into the magnetic flux barrier (13), wherein the distribution disk (16) has a distribution channel (17) facing the end face of the laminated iron core (47) and at least one conveying part (15) leading to the distribution channel (17). - Under a preset pressure, thixotropic potting compound (20) is delivered through the delivery section (15) and the distribution channel (17) of the distribution disc (16) to the space of the cavity (18) of the magnetic pole (48) that is not occupied by the permanent magnet (9) in the cavity (18) until at least all axially extending gaps (12) are filled or the cavity (18) is filled, wherein the positioning member (40) is not surrounded by the potting compound (20) and the optional fixing member (50) is surrounded by the potting compound (20).

2. A method for manufacturing a rotor (5) having embedded permanent magnets (9), the rotor being particularly a rotor of a permanently excited motor (1), the method comprising the steps of: - Stack the laminations (8) axially, particularly by stamping them into sub-laminated cores (42), wherein the sub-laminated cores (42) have cavities (18) extending substantially axially for accommodating permanent magnets (9), wherein the cavities have pocket portions (10) and flux barriers (13). - The permanent magnet (9) is inserted axially into the pocket portion (10) of the sub-laminated iron core (42). - The sub-laminated iron cores (42) are stacked in a staggered manner along the circumference to form the laminated iron core (47) of the rotor (5). The sub-laminated iron cores are cold-pressed onto the shaft (6) respectively, so that when viewed along the axial direction, the pocket portion (10) equipped with the permanent magnet (9) that generates the magnetic poles (48) has a hierarchical distribution. The distribution disk (16) is positioned on the end face of the laminated core (47) of the rotor (5) by means of the positioning element (40) and optional fixing element (50), such that the positioning element (40) is engaged in the axial cavity (18) and / or axial groove (41) of the laminated core (47), and the optional fixing element (50) extends into the magnetic flux barrier (13), wherein the distribution disk (16) has a distribution channel (17) facing the end face of the laminated core (47) and at least one conveying part (15) leading to the distribution channel (17). - Under a preset pressure, thixotropic potting compound (20) is delivered through the delivery section (15) and the distribution channel (17) of the distribution plate (16) to the space not occupied by the permanent magnet (9) in the cavity (18) of the magnetic pole (47) until at least all axially extending gaps (12) are filled or the cavity (18) is filled, wherein the positioning member (40) is not surrounded by the potting compound (20) and the optional fixing member (50) is surrounded by the potting compound (20).

3. The method for manufacturing a rotor (5) according to claim 1 or 2, characterized in that, The thixotropic potting compound (20) is mixed in situ in a static or dynamic mixing tube, wherein during the conveying process, the temperature is at most 60 °C, particularly at most 30 °C, the flow rate is at most 10 mm / s, and the pressure is at most 10 bar, particularly 5 bar.

4. The method for manufacturing a rotor (5) according to any one of the preceding claims, characterized in that, The positioning element (40) of the distribution disc (16) is configured as a stud and / or a pin-like structure.

5. The method for manufacturing a rotor (5) according to any one of the preceding claims, characterized in that, The filling of the rotor (5) is monitored by detecting the dynamic and static pressure of the potting compound (20).

6. The method for manufacturing a rotor (5) according to any one of the preceding claims, characterized in that, The distribution disc (16), and in particular the distribution channel (17), is segmentally sealed to fit the end face shape of the lamination core (47) of the rotor (5) to ensure that the potting compound (20) is injected into the cavity (18) of the lamination core (47) without loss.

7. The method for manufacturing a rotor (5) according to any one of the preceding claims, characterized in that, The tensioning tool applies an axial force to the laminated core (47) having the distribution disc (16) at least during the injection process.

8. A rotor (5) of a permanently excited synchronous motor, said rotor being made by means of the method according to any one or more of claims 1 to 7, characterized in that, The surface (19) of the laminated core (47) of the rotor (5) is not coated or potted (20), and the axially extending cavity (18) is filled with permanent magnet (9) or potting (20) and has at least one distribution disc (16), the positioning element (40) and optional fixing element (50) of the distribution disc are at least segmentally engaged in the cavity (18) and / or axial groove (41) of the laminated core (47), wherein the distribution disc (16) is not supported on the shaft (6).

9. The rotor (5) of the permanently excited synchronous motor (1) according to claim 8, characterized in that, By means of installing additional weight balancers on the end face of the laminated iron core (47) facing away from the rotor (15) of the distribution disk or by means of removing material from the distribution disk (16), at least the distribution disk (16) can be used in sections as a weight disk.

10. The rotor (5) of the permanently excited synchronous motor (1) according to claim 8 or 9, characterized in that, The distribution plate (16) has fan blades.

11. The rotor (5) of the permanently excited synchronous motor (1) according to any one of claims 8 to 10, characterized in that, Viewed along the axial direction, the laminated iron core (47) of the rotor (5) is constructed in a graded manner.

12. A permanently excited motor (1), particularly a permanently excited synchronous motor (1), the permanently excited motor having a rotor (5) according to any one of claims 8 to 11.

13. An application of the permanently excited synchronous motor (1) according to claim 12, the permanently excited synchronous motor being used in electric drive devices for compressor drives, air compressor drives, and fan drives, and as a drive device, particularly an integrated direct drive device, in the food industry and marine applications.

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