Method for manufacturing a rotor of a transverse flux machine

Abstract

Method for manufacturing a rotor of a transverse flux machine, in particular a disk rotor machine, which is formed from flux guide stones (10) and permanent magnets (20) arranged alternately on a circular circumference, comprising the steps: a) Providing a support plate (60); b) Providing a number of river guide stones (10), each of which has a first trapezoidal shape in plan view, and arranging the river guide stones (10) equidistantly on the support plate (60) along a predetermined first circular path (105), so that the spaces (120) formed between two adjacent river guide stones (10) have a second trapezoidal shape in plan view; c) Providing a number of permanent magnets (20) corresponding to the number of spaces (120), each of which has the second trapezoidal shape of the associated space (120) in plan view; d) uniformly inserting the permanent magnets (20) into the associated spaces (120) until air gaps between the respective adjacent side surfaces (13, 14, 23, 24) of the flux guide stones (10) and the permanent magnets (20) are minimized or eliminated, so that the flux guide stones (10) and the permanent magnets (20) come to rest side by side on the first circular path (105); and e) Fixing the flow guide stones (10) and the permanent magnets (20) by means of a potting material; characterized by the fact that In step c) the permanent magnets (20) are arranged on a second circular path (115) that is larger than the first circular path (105) such that they come to rest in a radial direction outside the associated spaces (120); and The arrangement of the permanent magnets (20) on the carrier plate (60) in step c) is carried out sequentially, wherein after the arrangement of a permanent magnet (20) on the carrier plate (60) a holding force (F1) acting perpendicular to the carrier plate (60) is applied to prevent the permanent magnets (20) from twisting due to the orientation of the poles of neighboring permanent magnets (20).

Description

[0001] The invention relates to a method for manufacturing a rotor of a transverse flux machine, in particular a disc rotor machine, which is formed alternately from flux guide stones and permanent magnets arranged on a circular circumference.

[0002] A disc rotor motor is an electric motor whose rotor is shaped like a disc. In English, it is also known as a "pancake motor," "disc motor," or "printed motor." One advantage of disc rotor motors is their high power density and compact design. When used in vehicles, such as electric or hybrid vehicles, disc rotor motors often eliminate the need for a gearbox for speed reduction or reduction. The rotors can be constructed from alternating permanent magnets and flux concentrators. Flux concentrators are components made of a highly magnetically permeable material (e.g., soft iron), which, due to this property, concentrates or directs the magnetic flux of a magnetic field acting upon it.

[0003] One challenge in manufacturing a disc rotor motor with a rotor featuring flux guides and permanent magnets arranged around a circumference is the need to assemble numerous individual parts, each with its own tolerances, into a single circular component. Due to the design, adjacent permanent magnets are oriented with the same polarity and therefore repel each other. This significantly complicates the manufacturing of the disc rotor motor. Furthermore, to achieve a disc rotor motor with excellent electromagnetic properties, there must be no air gap between the permanent magnets and flux guides. To ensure concentricity, the rotor's center of gravity must lie on its axis of rotation. Finally, the individual components must be joined in such a way as to guarantee the rotor's smooth rotation.It must also be ensured that, due to a small air gap to the stator halves arranged axially to the left and right of the rotor, all individual parts of the rotor are parallel to each other.

[0004] A transverse flux machine for use in a direct drive for vehicles, in particular a railway drive, is known, for example, from EP 0 749 877 B1. The transverse flux machine described therein uses a rotor which – viewed in a cross-sectional view perpendicular to the axis – is constructed of alternating magnets and soft iron elements (flux guides).

[0005] EP 0 998 010 B1 discloses a transverse flux machine with a plurality of permanent magnets arranged along the circumference of the rotor and flux guide pieces arranged between them, made of a material with high magnetic and low electrical conductivity, without describing in detail how the rotor is to be mounted.

[0006] DE 42 00 239 A1 discloses a method for manufacturing a rotor for an electric machine in which the adhesive-based intermediate layers have a consistently uniform thickness, are free of air inclusions, and are easy to apply. For this purpose, adhesive is poured into the recesses between the permanent magnets, then the permanent magnets are inserted into the recesses from top to bottom, displacing the liquid adhesive, which rises in the gaps and fills them.

[0007] EP 0 161 832 B1 discloses a segmented permanent ring magnet that is tunable to provide a preselected transverse magnetic field within the magnet's interior. The permanent magnet is constructed from a material that exhibits essentially linear behavior in the second quadrant of the BH curve. The magnets are particularly suitable for use as premagnets in NMR imaging systems.

[0008] US 2010 / 0187940A1 discloses a rotating electrical machine comprising a stator formed by winding a coil around a stator core of substantially cylindrical shape, and a rotor rotatably mounted in a radial direction of the stator, wherein at least one coil end section in an axial direction of the stator is a curved coil end section formed such that it is curved inwards in a radial direction of the stator core.

[0009] The object of the present invention is to provide a method for manufacturing a rotor of a disc rotor machine which makes it possible to connect the individual parts of the rotor in such a way that, on the one hand, a concentricity is given and, on the other hand, a planar parallelism of the rotor is ensured.

[0010] This problem is solved by a method according to the features of claim 1. Advantageous embodiments result from the dependent claims.

[0011] The invention provides a method for manufacturing a rotor of a disc rotor machine, which is formed from flux guide stones and permanent magnets arranged alternately on a circular circumference. The method comprises the following steps: a) Providing a carrier plate. The carrier plate is in particular circular and made of a non-magnetic material. b) Providing a number of river guide stones, each having a first trapezoidal shape in plan view, and arranging the river guide stones equidistantly on the support plate along a predetermined first circular path, such that the spaces formed between two adjacent river guide stones have a second trapezoidal shape in plan view. When this description refers to a plan view, it means a view in a section perpendicular to the axis. In particular, this step provides that the spaces formed between two adjacent river guide stones are approximately the same size. c) Providing a number of permanent magnets corresponding to the number of spaces, each having the second trapezoidal shape of the associated space when viewed from above. d) Uniformly inserting the permanent magnets into the assigned spaces until air gaps between the respective adjacent side surfaces of the flux guide stones and the permanent magnets are minimized or eliminated, so that the flux guide stones and the permanent magnets come to lie next to each other on the first circular path. e) Fixing the flow guide stones and the permanent magnets using a potting compound.

[0012] The invention is characterized in that the permanent magnets are arranged on a second circular path that is larger than the first circular path, such that they lie radially outside the associated spaces. Furthermore, the arrangement of the permanent magnets on the carrier plate in step c) is carried out sequentially, wherein, after a permanent magnet has been placed on the carrier plate, a holding force acting perpendicular to the carrier plate is applied to prevent the permanent magnets from rotating due to the orientation of the poles of adjacent permanent magnets.

[0013] In other words, the inventive method is based on first arranging flux guide blocks of a predetermined diameter on the first circular path of the carrier plate to establish a defined rotor center. Subsequently, the permanent magnets, pre-positioned outside the first circular path, are uniformly inserted into the spaces formed between adjacent flux guide blocks until the surfaces facing each other between the permanent magnets and the flux guide blocks are in complete contact. Uniform insertion of the permanent magnets is understood to mean a simultaneous radial movement of all permanent magnets towards the center of the first circular path, such that they maintain an approximately equal distance from the center of the first circular path at every point during the insertion movement.

[0014] This makes it possible to connect the individual parts of the rotor in such a way that the concentricity required for the operation of the disc rotor motor is achieved. In particular, it is possible to position the center of gravity of the rotor's mass on the subsequent axis of rotation. Furthermore, the method according to the invention allows the rotor to be manufactured with good plane parallelism, resulting in a small air gap to axially arranged stators. The method also has the advantage that, due to the precise manufacturing, good electromagnetic properties of the disc rotor machine can be achieved. Moreover, the repulsive magnetic forces can be effectively managed in this way.

[0015] In particular, the method is used to manufacture a rotor for a disc rotor machine. However, rotors for any transverse flux machine can be manufactured in general, where the rotor is formed by flux guide blocks and permanent magnets arranged alternately on a circular circumference.

[0016] According to a suitable embodiment, the arrangement of the flux guide blocks on the carrier plate in step b) includes applying a holding force to each flux guide block. This fixation ensures that the gaps corresponding to the shape of the permanent magnets cannot be altered, or can only be minimally altered, during the step of uniformly inserting the permanent magnets. This is advantageous in order to manufacture the rotor with the desired accuracy.

[0017] According to a further advantageous embodiment, the holding force is applied radially by pressing each guide stone against a stop using an associated spring tensioning mechanism. The stops, which are part of or attached to the support plate, are arranged in a circle around the center of the first circular path. The number of stops corresponds to the number of guide stones.

[0018] According to a further advantageous embodiment, in step c), the permanent magnets are arranged on the carrier plate such that, in any two adjacent permanent magnets, their like poles face each other. The permanent magnets are arranged on the carrier plate in step c) such that they are aligned with the same poles. "Like poles" here means that the north poles of adjacent permanent magnets lie next to each other, and vice versa. This results in adjacent permanent magnets repelling each other. The holding force acting perpendicular to the carrier plate ensures, during the arrangement of the permanent magnets on the carrier plate, that due to the repulsive forces, permanent magnets already in place cannot move or change their defined position.

[0019] In particular, the holding force is dimensioned such that it allows the permanent magnets to be inserted uniformly into the designated spaces in step d). The holding force and the insertion device used for this purpose must therefore be designed in such a way that, on the one hand, rotation of the permanent magnets due to the orientation of the poles of adjacent permanent magnets is prevented, and on the other hand, radial insertion of the permanent magnets into the spaces is enabled.

[0020] Advantageously, in step d), each permanent magnet is inserted into its designated space using an associated insertion device. Preferably, each insertion device has a spring mechanism which, during the insertion process, limits the force acting on the connection between the permanent magnet and the adjacent flux guide blocks at the end of the insertion movement. This means that when the side surfaces of a particular permanent magnet are in contact with the side surfaces of the two adjacent flux guide blocks, the insertion device must no longer exert an uncontrolled thrust force on the permanent magnet. Otherwise, damage to the side surfaces of the flux guide blocks and / or permanent magnets could result. The spring mechanism provided for each insertion device ensures that the force occurring at the end of the insertion movement is limited to an acceptable level.

[0021] It is further stipulated that a central clamping mechanism will be used to carry out step d), according to which the permanent magnets are inserted uniformly into the assigned spaces. For example, a so-called spiral disc can be used for this purpose, which enables uniform joining / shifting over the entire radial displacement path of the permanent magnets.

[0022] It is further stipulated that non-magnetic materials will be used for the carrier plate, the shearing elements, and the means that generate the holding force. This ensures that the insertion process of the permanent magnets can take place unaffected by any other magnetic force.

[0023] In a further advantageous embodiment, before step e), an expansion ring is placed on the arrangement of alternating adjacent flux guide blocks and permanent magnets from the side opposite the carrier plate to release the spring tensioning mechanism from the flux guide blocks. If the permanent magnets and flux guide blocks are arranged alternately around the circumference so that their respective side faces are in contact with each other, the holding force exerted by the spring tensioning mechanism is no longer required, as the arrangement possesses a certain degree of inherent stability. The placement of the expansion ring then initiates the permanent connection between the flux guide blocks and the permanent magnets. The expansion ring is necessary to release the holding force of the respective spring tensioning mechanisms and to enable further processing.

[0024] In a further advantageous embodiment, in step e), another magnetic support plate is placed onto the arrangement of alternating adjacent flux guide stones and the permanent magnet from the side opposite the support plate, in order to be inserted as a composite into a potting device containing magnetic material. The arrangement of flux guide stones and permanent magnets can, for example, be bonded together in the potting device. Suitable materials for potting are at the discretion of the person skilled in the art.

[0025] It is further stipulated that the additional magnetic support plate will be removed before potting in step e). This ensures that the arrangement of flow guide stones and permanent magnets can be completely enveloped by potting compound, in particular adhesive.

[0026] The additional magnetic carrier plate allows the assembly of flux guide stones and permanent magnets to be detached as a unit from the non-magnetic carrier plate and placed into the potting device. This additional magnetic carrier plate ensures that the relative arrangement of the flux guide stones and permanent magnets, which are alternately arranged along a circular path, is no longer adversely affected.

[0027] It is further provided that, in the potting device, at the points on a support plate where the permanent magnets will rest after the assembly is inserted, either projections are provided in the potting device or, before the assembly is placed in the potting device, shims, particularly made of wax, are inserted into these shims. This ensures the desired plane parallelism of the permanent magnets, thereby supporting the desired concentricity and plane parallelism.

[0028] It is further advantageous if, in step e), a retaining ring enclosing the circumference of the assembly, particularly made of CFRP, is cast into the assembly. The retaining ring serves to absorb centrifugal forces occurring during the operation of the rotor in the transverse flux machine, especially in the disc rotor motor, and to counteract any potential damage to the rotor caused by these centrifugal forces. To ensure a secure connection between the retaining ring and the assembly of flux guide blocks and permanent magnets, it is advantageous to cast or bond it to the assembly.

[0029] It is further planned that in step f) the main surfaces of the cast composite will be connected to rotor shells, in particular made of carbon fiber. If necessary, the rotor shells may also be bonded to the assembly comprising the retaining ring or otherwise mechanically connected to each other.

[0030] The invention is explained in more detail below with reference to an exemplary embodiment shown in the drawing. The drawing shows: Fig. 1 a perspective view of a rotor of a transverse flux machine, in particular a disc rotor machine, partially equipped with rotor shells, Fig. 2 a perspective view of a river guide stone as used in a rotor according to Fig. 1 is used, Fig. 3 a perspective view of a permanent magnet of the rotor in Fig. 1, Fig. 4 A schematic representation of the arrangement of flow guide stones and permanent magnets on a carrier plate in a top view before the permanent magnets are pushed into the spaces formed between adjacent flow guide stones, Fig. 5 to 9 schematic cross-sectional views of chronologically successive manufacturing steps for producing a rotor of a disc rotor machine, Fig. 10 a schematic representation of river guide stones arranged side by side on a support plate, and Fig. 11 an expanded perspective view of a rotor produced according to the invention and two rotor shells arranged on opposite sides.

[0031] Fig. Figure 1 shows a rotor 1 of a disc rotor machine. The rotor 1 is formed from flux guide blocks 10 and permanent magnets 20 arranged alternately around a circumference. In plan view, the flux guide blocks 10 and the permanent magnets 20 each have an approximately trapezoidal shape, with all flux guide blocks and all permanent magnets 20 having an identical shape. However, it is not necessary for the flux guide blocks 10 and the permanent magnets 20 to have the same size and shape. The flux guide blocks 10 are made of a magnetically conductive material, such as soft iron, and serve to guide the magnetic flux. Together with the adjacent permanent magnets, the flux guide blocks form a permanently excited magnetic circuit.

[0032] The rotor is attached to a rotor shaft (not shown) via a carrier disk 50 arranged within the arrangement of flux guide stones 10 and permanent magnets 20. For this purpose, the carrier disk has a central bore around which equidistant openings are provided for attaching the carrier disk 50 to the rotor shaft.

[0033] To absorb the centrifugal forces occurring during the operation of the rotor 1, a retaining ring 30 is provided around the outer circumference of the arrangement of flux guide stones 10 and permanent magnets 20. The retaining ring 30 is preferably made of carbon fiber reinforced plastic (CFRP). Also to provide mechanical protection, a rotor shell 40, shown only partially, preferably also made of a carbon fiber composite material, is attached to the arrangement of flux guide stones 10 and permanent magnets 20.

[0034] Such a rotor 1 is known in principle from the prior art. The following figures describe in more detail the manufacturing of the arrangement consisting of flux guide blocks 10 and permanent magnets 20. The inventive method enables the individual components of flux guide blocks 10 and permanent magnets 20 to be joined together in such a way that, on the one hand, concentricity is ensured despite the individual tolerances of the components, and on the other hand, the opposing cylindrical surfaces are parallel. This parallelism is necessary to allow for a small air gap to the stator halves arranged to the left and right of the cylindrical surfaces. Furthermore, the inventive manufacturing method makes it possible to position the center of mass in the center of the rotor 1.

[0035] The Fig. 2 and Fig. Figure 3 each shows a single river guide stone in a perspective view ( Fig. 2) and a single permanent magnet ( Fig. 3) The shape of the trapezoid as seen in plan view, i.e., in view of an axial section, is dimensioned such that preferably 48 flux guide stones 10 and 48 permanent magnets 20 fit the in Fig. 1 illustrated rotor 1 result.

[0036] The river guide stone 10 has a trapezoidal underside 11, a trapezoidal topside 12, a first side surface 13, an opposite side surface 14, an inner side surface 17, and an opposite outer side surface 18. In the figures described below, the underside 11 represents a bearing surface. The side surface 13 has a chamfer 15 on each of its opposite edges projecting towards the underside and top surfaces 11 and 12, such that the side surface 13 is recessed relative to the outer edges of the chamfers 15. Similarly, chamfers 16 are provided on the edges of the side surface 14 facing the underside and top surfaces 11 and 12. The chamfers 15 and 16 serve to guide the permanent magnets during an assembly process. Accordingly, the distance formed between the chamfers 15 and 16 is dimensioned such that it corresponds approximately to the height of the permanent magnets 20.

[0037] The permanent magnets 20 have a bottom surface 21, which serves as a contact surface, a top surface 22, two opposing side surfaces 23, 24, and two opposing inner and outer side surfaces 25, 26. The bottom and top surfaces 21, 22 have the trapezoidal shape already mentioned. The two poles (N, S) of the permanent magnet 20 are also shown schematically. The poles are arranged in the permanent magnet such that, for example, side surface 23 forms the south pole and side surface 24 forms the north pole of the permanent magnet 20.

[0038] Fig. Figure 4 shows a schematic representation of the initial situation preceding the joining process of flux guide stones 10 and permanent magnets 20. In a first step, the number of flux guide stones 10 are arranged along a predetermined first circular path 105 on a carrier plate made of a non-magnetic material (not shown in detail). This results in the inner side surfaces 17 resting on an inner circumferential line 100 of the subsequently completed rotor. Similarly, the outer side surfaces 18 rest on an outer circumferential line 110 of the subsequently completed rotor. The inner and outer circumferential lines 100 and 110 are indicated by solid lines. The first circular path 105 and a second circular path 115, on which the permanent magnets are initially arranged, are indicated by a dashed line. A gap 120 is created between each adjacent flux guide stone 10.Due to the equidistant arrangement of the flow guide stones 10, the shape of the gaps 120 is approximately identical. The dimensions of the gaps 120 correspond in size and shape to the trapezoidal shape of the permanent magnets to be inserted into the gaps 120.

[0039] The flux guide stones 10 are fixed in place on the carrier plate along the first circular path 105 in a manner described later, so that they can no longer be displaced from their position. In a further step, the permanent magnets 20 are arranged radially outside the assigned spaces 120 along the second circular path 115. The permanent magnets 20 are arranged so close together with respect to their poles that they repel each other. For this reason, after each permanent magnet has been sequentially arranged on the carrier plate, it is fixed in place to prevent rotation and lateral displacement. This is achieved schematically by the means described later with reference numerals 72, 73, and 74.

[0040] Once all permanent magnets are arranged on the carrier plate, i.e., each of the formed spaces 120 is assigned a permanent magnet 20, the permanent magnets 20 are then uniformly inserted into their respective spaces 120 until the corresponding distances or air gaps between the facing side surfaces 13, 14, 23, 24 are minimized or even eliminated. As a result, the permanent magnets 20 also come to rest along the first circular path. With ideal tolerances of all components, the inner side surfaces 25 would lie on the inner circumferential line 100 and the outer side surfaces 26 on the outer circumferential line 110. However, due to the tolerances that occur in practice, this is not always the case.

[0041] By uniformly inserting the permanent magnets, for example using a so-called central clamping mechanism, each permanent magnet is inserted into its assigned space 120 in such a way that any air gaps are minimized. This means that the respective side surfaces 13, 14, 23, 24 between the permanent magnets 20 and the flux guide stones 10 lie as close together as possible. It is possible that some permanent magnets are pushed further towards the center until the described condition is reached, while others end up further outwards with respect to their radial distance from the center. Finally, in a further step, the arrangement of the flux guide stones and permanent magnets is fixed in place by a potting compound, in particular an adhesive.

[0042] The Fig. Figures 5 to 9 illustrate this described procedure in detail in a cross-sectional view. First, the flow guide stones 10 are applied to a support plate 60 along the specified first circular path. The support plate 60 has grooves 61 adapted to the shape of the flow guide stones 10 in the area where they are positioned (see Figure 5). Fig. 10) The flux guide blocks 10 are inserted into the grooves 61 with their underside 11 facing down. The depth of the grooves 61 is dimensioned such that the surfaces receiving the permanent magnets 20 come to rest approximately at the level of the edges formed between the chamfers 15, 16 and the side surfaces 13, 14. The grooves in the carrier plate 60 ensure that the permanent magnets 20 are positioned in a controlled manner relative to the flux guide blocks 10. Furthermore, once the permanent magnets 20 have penetrated the space formed between two flux guide blocks 10, it is ensured that they cannot slip out of the space in the axial direction of the rotor. The chamfers 15, 16 thus ensure not only a controlled joining process but also axial stability until the potting process is complete.

[0043] In Fig. Figure 5 shows a cross-sectional view of a flow guide stone 10 arranged in a described groove 61 of the support plate 60. The flow guide stone 10 rests against an associated stop 65 on its inner side surface 17, e.g., a pin projecting from the plane of the support plate 60. Each flow guide stone 10 is associated with such a stop 65. To ensure that the flow guide stone 10 rests in a defined position against the stop 65, a spring tensioning mechanism 62 is provided, which presses a stop 63 against the outer side surface 18 of the respective flow guide stone 10. To prevent axial displacement of the flow guide stone 10, i.e., perpendicular to the plane of the support plate 10, a retaining lug 64 is formed on the stop 63, which engages the upper surface 12 of the flow guide stone 10.The force F0 applied by the spring tensioning mechanism 62 is dimensioned such that the flow guide stone 10 is clamped between the stop 65 and the stop 63 and slippage is also excluded.

[0044] A hold-down device 70 is also arranged on the spring tensioning mechanism 62. This includes a clamp 74, which is in Fig. 5 with its longitudinal side extending in the direction of thrust of the spring tensioning mechanism 62. The clamp 74 is attached to the spring tensioning mechanism by a fastening element 71, e.g., a screw. The clamp 74 is rotatable about a rotation axis 72 of the fastening element 71. The hold-down device 70 is required to apply a holding force F1 to one or more associated permanent magnets in order to prevent them from rotating due to their polarity and relative arrangement to one another. This is shown schematically in Fig. 6 recognizable.

[0045] In the Fig. For the sake of clarity, the spring tensioning mechanism 62, including the stop 63 and the retaining lug 64 actuated by it with a spring force, is not shown in Figures 6 to 9. This force F0 is nevertheless maintained until the completed assembly of all flux guide stones 10 and permanent magnets 20 is transferred to a potting device.

[0046] In Fig. 6 It is now assumed that all, preferably 48, flow guide stones 10 are arranged equidistantly to each other and fixed along the first circular path on the support plate 60. The permanent magnets 20 are then arranged sequentially in a radial direction outside the assigned spaces along the second circular path (see 115 in Fig. 4) Lateral guidance of the permanent magnet 20 is achieved, for example, by the spring tensioning mechanisms 62 arranged approximately on the second circular path. To prevent rotation or movement perpendicular to the plane of the support plate, the clamp 74 provided on the adjacent spring tensioning mechanism 62 is rotated about the axis of rotation 72, so that the clamp 74 extends transversely to the associated permanent magnet. Furthermore, a thrust element 73, for example, a spring tensioning mechanism, is applied to the outer side surface 26 of the permanent magnet. Initially, however, the permanent magnet 20 is not subjected to any thrust force F2 by the thrust element 73. This only occurs after all permanent magnets 20 are arranged radially outside the associated spaces on the second circular path.

[0047] As in the Fig. 7 and Fig. As can be seen in Figure 8, a permanent magnet 20 is inserted into the corresponding space between two flux guide stones 10 by means of the thrust device 73, which is connected to a central clamping mechanism. The central clamping mechanism ensures that all permanent magnets 20 are inserted into the spaces more or less simultaneously with a uniform movement. This is the only way to ensure that controlled insertion into the spaces 120 is guaranteed despite the repulsive forces acting on the permanent magnets.

[0048] The holding force generated by the hold-down device 70 on the associated permanent magnet 20 is dimensioned such that, on the one hand, rotation of the permanent magnet about its longitudinal axis and lifting it out perpendicular to the plane of the support plate 16 are prevented. On the other hand, the holding force must be dimensioned such that the push element 73, driven by the spring tensioning mechanism, allows insertion in a radial direction into the gap.

[0049] The permanent magnets 20 are inserted into the designated spaces in such a way that there is as little air gap as possible between the side surfaces 13, 14 of the flux guide blocks 10 and the side surfaces 23, 24 of the permanent magnets 20. To prevent damage to the side surfaces of the permanent magnets and / or the flux guide blocks 10, each pushing element 30 has a spring element that absorbs a force acting in the direction of F2 as soon as the permanent magnet inserted into the designated space, with its two side surfaces 23, 24, rests against the corresponding side surfaces 13, 14 of the adjacent flux guide blocks 10, even if the spring tensioning mechanism continues to be operated to insert other permanent magnets.

[0050] Are the permanent magnets, as described in Fig. As shown in Figure 9, in their final position, the river guide stones 10 are fixed in a perpendicular direction to the plane of the support plate 60 due to the chamfered side surfaces 13, 14. Further fixation results from the ideally gapless fit of the river guide stones 10 to their side surfaces.

[0051] All of the in the Fig. Components 5 to 9 shown for the relative arrangement of flux guide stones and permanent magnets next to each other on the carrier plate 60 are made of a non-magnetic material.

[0052] In a subsequent step, not shown in detail, the spring tensioning mechanism 62, which up to this point held the flow guide stones 10 in the Fig. The assembly is fixed to the stop 65 as shown in Figure 5. Release is achieved by an expansion ring, which is placed from above onto the assembly of flux guide stones 10 and permanent magnets 20 and pushes the spring tensioning mechanisms 62 radially outwards. Subsequently, another carrier plate 80, made of magnetic material, is placed onto the assembly from above. Solely by magnetic force and any additional mechanical fixation, the assembly of flux guide stones 10 and permanent magnets 20 can now be removed and transferred to a device for applying the potting compound. After the assembly, fixed by the additional magnetic plate, has been inserted, a so-called ejector crown can be placed to release the additional magnetic carrier plate 80 from the assembly. The assembly can then be potted with an adhesive or other potting compound.Preferably, a retaining ring 30, such as this one in . is used. Fig. 1 is shown, inserted into the potting system in order to absorb centrifugal forces on the outer circumference of the arrangement during rotor operation.

[0053] It is advantageous if at least some of the components of the potting device are magnetic in order to attract the permanent magnets 20 of the rotor assembly. It can also be advantageous if the potting device has a profiled bearing surface for the arrangement of flux guide stones 10 and permanent magnets 20 to promote planar parallelism of the rotor after potting. For this purpose, the bearing surface can be shaped as described in Fig. The 10 grooves shown above are for inserting the flow guide stones 10. Likewise, shims, particularly made of wax, can be placed in the spaces between the permanent magnets so that the magnets are aligned parallel to each other. The components are then potted or bonded together as previously mentioned.

[0054] In a further, optional step, the attachment of one or more rotor shells could be provided. This is shown schematically in Fig.Figure 11 illustrates a perspective view of a completed rotor. Reference numeral 1 denotes the arrangement of permanent magnets 20 and flux guide stones 10, removed from the casting device and surrounded by the retaining ring 30. For mechanical protection, the rotor shell, designated by reference numeral 40, can be connected to the rotor 1. Reference numeral 50 denotes the carrier disk, which is coupled to the arrangement from the other side on its inner circumference. Through the bores provided in both the rotor shell 40 and the carrier disk 50, the rotor shell and carrier disk 40, 50 can be screwed or otherwise mechanically fixed to each other and to a rotor shaft. The shape of the rotor shell and the carrier disk may, of course, differ from the embodiment shown in the figure. Reference symbol list 1 Rotor 10 River guide stone 11 Underside (contact surface) 12 Top 13 side surface 14 side surface 15th phase 16th phase 17 inner side surface 18 outer side surface 20 permanent magnets 21 Underside (contact surface) 22 Top 23 side surface 24 side surface 25 inner side surface 26 outer side surface 30 (outer) x retaining ring 40 rotor shell 50 carrier disc 60 carrier plate 61 Nut 62 Spring tensioning mechanism 63 attacks 64 Retaining nose 65 stop 70 hold-down devices 71 Fasteners (screws) 72 Rotary axis 73 Pushing device (spring tensioning mechanism) 74 bracket 80 more, magnetic plate 100 inner circumferential line of the later completed rotor 105 first circular track 110 outer circumferential line of the later completed rotor 115 second circular track 120 space

Claims

[1] Method for manufacturing a rotor of a transverse flux machine, in particular a disk rotor machine, which is formed from flux guide stones (10) and permanent magnets (20) arranged alternately on a circular circumference, comprising the steps: a) Providing a support plate (60); b) Providing a number of river guide stones (10), each of which has a first trapezoidal shape in plan view, and arranging the river guide stones (10) equidistantly on the support plate (60) along a predetermined first circular path (105), so that the spaces (120) formed between two adjacent river guide stones (10) have a second trapezoidal shape in plan view; c) Providing a number of permanent magnets (20) corresponding to the number of spaces (120), each of which has the second trapezoidal shape of the associated space (120) in plan view; d) uniformly inserting the permanent magnets (20) into the associated spaces (120) until air gaps between the respective adjacent side surfaces (13, 14, 23, 24) of the flux guide stones (10) and the permanent magnets (20) are minimized or eliminated, so that the flux guide stones (10) and the permanent magnets (20) come to rest side by side on the first circular path (105); and e) Fixing the flow guide stones (10) and the permanent magnets (20) by means of a potting material; characterized by , that In step c) the permanent magnets (20) are arranged on a second circular path (115) that is larger than the first circular path (105) such that they come to rest in a radial direction outside the associated spaces (120); and The arrangement of the permanent magnets (20) on the carrier plate (60) in step c) is carried out sequentially, wherein after the arrangement of a permanent magnet (20) on the carrier plate (60) a holding force (F1) acting perpendicular to the carrier plate (60) is applied to prevent the permanent magnets (20) from twisting due to the orientation of the poles of neighboring permanent magnets (20). [2] Method according to claim 1, wherein the arrangement of the river guide stones (10) on the support plate (60) in step b) comprises the application of a respective holding force to the river guide stones (10). [3] Method according to claim 2, wherein the holding force is applied in a radial direction by pressing each flow guide stone (10) against a stop by means of an associated spring tensioning mechanism. [4] Method according to one of the preceding claims, wherein in step c) the permanent magnets (20) are arranged on the carrier plate (60) such that in each pair of adjacent permanent magnets (20) the same poles are facing each other. [5] Method according to one of the preceding claims, wherein the holding force is dimensioned such that it allows the uniform insertion of the permanent magnets (20) into the associated spaces (120) in step d). [6] Method according to one of the preceding claims, wherein in step d) each permanent magnet (20) is inserted into the associated space (120) with an associated pusher. [7] Method according to claim 6, wherein each pushing means has a spring mechanism which limits the force acting on the connection between permanent magnet (20) and adjacent flux guide stones (10) during the insertion process. [8] Method according to one of the preceding claims, wherein a central clamping mechanism is used to carry out step d). [9] Method according to one of the preceding claims, wherein non-magnetic materials are used for the carrier plate (60), for the shear means, for a means generating the holding force. [10] Method according to one of the preceding claims, wherein, prior to step e), an expansion ring is placed on the arrangement of the alternating adjacent flux guide stones (10) and the permanent magnets (20) from the side opposite the carrier plate (60) in order to release the spring tensioning mechanism from the flux guide stones (10). [11] Method according to one of the preceding claims, wherein in step e) a further magnetic carrier plate (80) is placed on the arrangement of the alternating adjacent flux guide stones (10) and the permanent magnets (20) from the side opposite the carrier plate (60) in order to be inserted as a composite into a potting device comprising magnetic material. [12] Method according to claim 11, wherein the further magnetic support plate (80) is removed before potting in step e). [13] Method according to claim 11 or 12, wherein in the potting device projections are optionally provided in the potting device at the locations where the permanent magnets (20) come to rest after the composite is inserted, or, before the composite is inserted into the potting device, shims, in particular made of wax, are inserted therein. [14] Method according to one of the preceding claims, wherein in step e) a retaining ring enclosing the circumference of the arrangement, in particular made of CFRP, is cast into the arrangement. [15] Method according to one of the preceding claims, wherein in a step f) the main surfaces of the cast composite are joined with rotor shells, in particular made of carbon fiber.

Images