Electric motor

Abstract

Electric motor comprising a stator and a rotor (22), wherein the rotor (22) comprises rings (1) made of permanent magnet material, wherein these rings (1) have alternating magnetic poles in the circumferential direction, wherein in a first axial region of the rotor (22) the sequence of magnetic poles provided in the circumferential direction has an offset compared to the corresponding sequence in a second axial region, wherein the rings (1) are pushed axially onto the rotor (22) and are connected to the rotor (22) in a materially and positively locking manner, characterized in that the rings (1) each have a groove (2) on their inside or outside, which is in engagement with a guide element (20), wherein the guide elements (20) are designed as axially extended sliding blocks or keys, which are provided in corresponding axially extending grooves (2) of the rotor (22), wherein at least one first guide element (20) is provided in the first axial region and at least one second guide element (21) is provided in the second axial region, wherein the first and second guide elements (20, 21) are offset from one another in the circumferential direction, where the electric motor is a synchronous motor, wherein the rings (1) are glued to the rotor (22), i.e. are connected by a material bond, wherein the magnetic poles have a course with a non-vanishing helix angle in the axial direction, the offset being 180° / KGV (2p, N1), where KGV (2p, N1) is the smallest common multiple of the number of rotor poles 2p and the number of stator slots N1.

Description

[0001] The invention relates to an electric motor and a method for producing an electric motor.

[0002] Synchronous motors are known whose rotors contain permanent magnets.

[0003] From JP 2004-153 962 A a rotor is known which is manufactured as a stack of individual laminations.

[0004] From DE 10 2005 013 674 A1 an electric motor is known as the closest state of the art.

[0005] From DE 103 07 231 A1 a method for producing a rotor for such an electric motor is known.

[0006] The rotor of a synchronous motor is known from JP 2004- 343 907 A.

[0007] Radially anisotropic cylindrical ferrite magnets are known from US 5 506 557 A.

[0008] A rotor of a motor with permanent magnets is known from US 5 952 755 A.

[0009] A magnetizing device is known from JP S63 - 257 444 A.

[0010] The invention is therefore based on the object of developing a synchronous motor so that it can be manufactured simply and inexpensively.

[0011] According to the invention, the object is achieved in the electric motor according to the features specified in claim 1.

[0012] Important features of the invention in the electric motor are that it comprises a rotor which comprises at least one ring of permanent magnet material, and a stator, in particular a stand, where alternating magnetic poles are pronounced in the circumferential direction, wherein in a first axial region the sequence of magnetic poles provided in the circumferential direction has an offset compared to the corresponding sequence in a second axial region.

[0013] The advantages are that cogging torques are suppressed, torque fluctuations are reduced, and manufacturing is simple and inexpensive. Furthermore, the rotors can be made of any length, while still using the same magnetization device.

[0014] In an advantageous embodiment, the first and second axial regions are of equal size. This has the advantage of allowing torque ripple to be easily suppressed.

[0015] In an advantageous embodiment, the magnetic poles have a course in the axial direction with a vanishing or non-vanishing helix angle. This is advantageous in that a simple, straight course without a helix angle can be used to reduce cogging torque. However, an additional, somewhat more complex helix angle can also be used. However, this increases the complexity of the magnetization device, since different axial lengths require different magnetization coils.

[0016] In an advantageous embodiment, the electric motor is designed as an internal rotor or an external rotor. The advantage here is that the invention can be applied to both types of electric motors.

[0017] According to the invention, one or more rings are axially slid onto the rotor and connected to the rotor by a material fit and / or form-fitting connection. This is advantageous because both an adhesive connection and a form-fitting connection can be implemented. Thus, if one of the connections fails, the other is load-bearing. The form-fitting connection can also be used to maintain the offset, allowing the offset to be easily specified.

[0018] In an advantageous design, each of the rings is of the same type. This is advantageous because only one type of ring needs to be kept in stock. Rotors of any length can be manufactured from these by sliding the desired number of rings onto the rotor and connecting them.

[0019] According to the invention, the rings have a groove on their inner or outer side that engages with a guide element. This is advantageous because the positive connection can be implemented in a particularly simple manner.

[0020] According to the invention, at least one first guide element is provided in the first axial region and at least one second guide element is provided in the second axial region, The first and second guide elements are offset from each other in the circumferential direction. The advantage here is that parallel keys or T-nuts can be used as guide elements, allowing the offset to be specified.

[0021] In an advantageous embodiment, the rings are magnetized before being fitted and / or connected to the rotor. This has the advantage that the magnetic forces generated during fitting can be dissipated by the guide elements, thus enabling simple manufacturing and highly precise maintenance of the offset.

[0022] In an advantageous embodiment, the rings are magnetized after being fitted and / or connected to the rotor. This is advantageous because no magnetic forces are exerted during fitting, and furthermore, no guide elements are required to specify an offset. A simple adhesive connection is sufficient. The rings can be made with a constant thickness in the circumferential direction. Alternatively, if increased security against failure of the adhesive connection is desired, a positive fit can also be provided using the guide elements.

[0023] In an advantageous embodiment, the offset is 180° / KGV (2p, N1), where KGV (2p, N1) is the lowest common multiple of the number of rotor poles 2p and the number of stator slots N1. The advantage here is that with this offset, the cogging torque is particularly low, as is the torque ripple.

[0024] In a process for manufacturing an electric motor, one or more rings are placed on a rotor and connected, - in a first step, a first axial region is magnetized, whereby a sequence of poles magnetized alternately in the circumferential direction is generated - in a second step the rotor is rotated by an offset angle, - in a third step the first step is repeated for a second axial area.

[0025] The advantage here is that a simple, small magnetizing device is sufficient, which only needs to magnetize part of the axial length. The offset can be achieved by a simple rotation.

[0026] If the magnetization device is smaller in the axial direction than the first axial region, each sub-region of the first axial region is magnetized sequentially without rotating the rotor. Only before the corresponding sub-regions of the second axial region are magnetized is the rotor rotated by the offset angle value.

[0027] In an advantageous embodiment, a magnetizing device is used for magnetization, and after the third step, the rotor is installed in a motor. The advantage here is that no magnetic forces are exerted when the rings are attached, and the rotor is only magnetized after its manufacture.

[0028] In the final step, the rotor can then be inserted into the stator to form the synchronous motor.

[0029] Further advantages emerge from the dependent claims. The invention is not limited to the combination of features in the claims. Further possible combinations of claims and / or individual claim features and / or features of the description and / or the figures will become apparent to those skilled in the art, particularly from the problem and / or the problem posed by comparison with the prior art.

[0030] The invention will now be explained in more detail with the aid of illustrations: In the Fig. 1a shows a cross section through a ring 1 of an electric motor according to the invention. In Fig. 1b shows the corresponding top view. In Fig. 2a shows a top view of the rotor 22 with rotor shaft 23 from the radial direction. In Fig. Figure 2b shows a view looking in the axial direction.

[0031] The ring 1 has recesses on its inner surface, which are designed as grooves 2. The rotor 22 and the rotor shaft 23 are connected to each other. Guide elements 20 and 21 are attached to the rotor 22 and are provided for a positive connection with the recesses, in particular grooves 2, of the rings 1. The positive connection is pronounced in the circumferential direction and thus enables the transmission of torque.

[0032] The guide element 20 of a first ring is arranged offset in the circumferential direction to the guide element 21 of a second ring.

[0033] For example, the guide elements can be designed as axially extended sliding blocks or keys which are provided in corresponding axially extending grooves of the rotor 22.

[0034] The rings are thus arranged so that they can be plugged on axially.

[0035] The rings are each designed identically and have alternating magnetized regions in the circumferential direction, with the magnetization direction being essentially radial and having a rotor pole number of 2p, where p is an integer.

[0036] The rings are designed as permanent magnets and are magnetized in the final manufacturing step.

[0037] In the Fig. 2a and Fig. 2b, the rotor is an internal rotor, and thus the electric motor is a correspondingly designed synchronous motor. The stator winding is designed with a stator slot number N1.

[0038] The most advantageous dimensioning has been found with an offset of 180° / KGV (2p, N1). This involves determining the lowest common multiple of the number of rotor poles and the number of stator slots, and dividing 180° by this lowest common multiple.

[0039] The axial length of the first ring and the axial length of the second ring are the same.

[0040] In another embodiment of the invention, multiple rings are used instead of a single first ring. This allows longer rotors to be manufactured as needed. Furthermore, only one type of ring needs to be kept in stock, and the length is determined by the number of rings used. Since the axial length of the offset ring areas is the same, the total number of rings is an even number.

[0041] In another embodiment of the invention, the rings are glued to the rotor, thus forming a material bond. The guide elements serve only as an assembly aid to maintain the defined offset.

[0042] In a further embodiment of the invention, no guide elements are used, but at least one or more unmagnetized rings are glued onto the rotor. The number of rings is irrelevant here. The rings extend over an axial region. After the rotor has been manufactured, it is introduced into a magnetizing device which, in a first manufacturing step, magnetizes a first half of the axial region. The second half is then magnetized, but with an offset in the circumferential direction. For example, after the first step, the rotor is axially displaced by half the axial length and rotated by the offset. Then, in a final step, the first step is repeated.

[0043] Preferably, an isotropic magnetizable material is used as the material for the rings.

[0044] In a further embodiment of the invention, an external rotor is used instead of an internal rotor. The above description applies accordingly. Instead of the guide elements on the outside, they are then provided on the inside. The rings are then connected to the rotor on their outside instead of on the inside. The stator is then located inside the area surrounded by the rotor.

[0045] In all cases described, the axial alignment of the north and south poles is straight. Thus, there is no oblique angle to the alignment.

[0046] In a further embodiment of the invention, a helix angle is additionally provided. This enables further improved suppression of cogging torques. List of reference symbols 1 ring 2 grooves 20 guide element 21 Guide element 22 Rotor 23 Rotor shaft

Claims

[1] Electric motor comprising a stator and a rotor (22), wherein the rotor (22) comprises rings (1) made of permanent magnet material, wherein these rings (1) have alternating magnetic poles in the circumferential direction, wherein in a first axial region of the rotor (22) the sequence of magnetic poles provided in the circumferential direction has an offset compared to the corresponding sequence in a second axial region, wherein the rings (1) are pushed axially onto the rotor (22) and are connected to the rotor (22) in a materially and positively locking manner, characterized by , that the rings (1) each have a groove (2) on their inside or outside, which is in engagement with a guide element (20), wherein the guide elements (20) are designed as axially extended sliding blocks or keys, which are provided in corresponding axially extending grooves (2) of the rotor (22), wherein at least one first guide element (20) is provided in the first axial region and at least one second guide element (21) is provided in the second axial region, wherein the first and second guide elements (20, 21) are offset from one another in the circumferential direction, where the electric motor is a synchronous motor, wherein the rings (1) are glued to the rotor (22), i.e. are connected by a material bond, wherein the magnetic poles have a course with a non-vanishing helix angle in the axial direction, the offset being 180° / KGV (2p, N1), where KGV (2p, N1) is the smallest common multiple of the number of rotor poles 2p and the number of stator slots N1. [2] Electric motor according to claim 1, characterized by that the first and second axial areas are of equal size. [3] Electric motor according to at least one of the preceding claims, characterized bythat the electric motor is designed as an internal rotor or an external rotor. [4] Electric motor according to at least one of the preceding claims, characterized by that each of the rings (1) is of the same design. [5] Electric motor according to at least one of the preceding claims, characterized by that the rings (1) are magnetized before being fitted and / or connected to the rotor (22). [6] Electric motor according to one of claims 1 to 4, characterized by that the rings (1) are magnetized after being fitted and / or connected to the rotor (22).

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