Rotor lamination package for an electric machine

Abstract

Rotor lamination stack (1) for an electric machine (2), the rotor lamination stack (1) comprising a first end lamination (3), a second end lamination (4), a first intermediate lamination (5), a second intermediate lamination (6) and a permanent magnet (7), wherein - the intermediate sheets (5, 6) between the end sheets (3, 4) are arranged in a stacking direction (L), - the first end plate (3) has a sprue bore (8) and a vent bore (9), - the first intermediate plate (5) has a first opening (10) and a first distribution bore (11), wherein the first opening (10) comprises two partial openings (10.1, 10.2) which are separated from each other by a central web (22), - the second intermediate plate (6) has a second opening (12), a second distribution bore (13) and a filling channel (14), - the permanent magnet (7) is received within the first opening (10) in such a way that a first gap (17) is created between the permanent magnet (7) and the first opening (10), - the permanent magnet (7) is received within the second opening (12) in such a way that a second space (18) is created between the permanent magnet (7) and the second opening (12), the second space (18) being larger than the first space (17), - the sprue bore (8), the first distributor bore (11) and the second distributor bore (13) are connected to each other in such a way that a first distributor channel (15) extending in the axial direction (L) through the rotor lamination stack (1) is formed, - the vent hole (9), the first space (17) and the second space (18) are connected to each other in such a way that a second distribution channel (19) extending in the axial direction (L) through the rotor lamination stack (1) is formed, - the filling channel (14) connects the first distribution channel (13) with the second distribution channel (19), - the second end plate (4) closes the second distributor bore (13), the filling channel (14) and the second opening (12) at the front, and - the first space (17) and the second space (18) are filled with a potting compound (20) so that the permanent magnet (7) is bonded to the first intermediate sheet (5) and the second intermediate sheet (6) by means of the potting compound (20).

Description

[0001] The invention relates to a rotor core stack for an electrical machine, in particular a dynamoelectric machine. Further claims are directed to an electrical machine with the rotor core stack and to a method for producing the rotor core stack.

[0002] To easily and reliably insert permanent magnets into recesses or openings in a rotor core, the openings are typically slightly larger than the permanent magnets, as viewed orthogonally to the stacking direction of the rotor core. The permanent magnets must therefore be secured in the rotor core. This can be achieved by pouring a potting compound into the spaces between the rotor cores or their openings on the one hand and the permanent magnets on the other. Potting is usually done manually using a commercially available syringe. However, this manual potting of the rotor is very time-consuming.

[0003] The following procedure is commonly used to pour the potting compound into the gaps: the rotor lamination stack is positioned vertically so that the individual rotor laminations are horizontal. The potting compound is then poured from above into the (usually very small) gaps between the openings in the rotor laminations and the permanent magnets. The potting compound then chemically cures into a solid. This secures the permanent magnets in the recesses.

[0004] However, this type of casting is very time-consuming. The casting compound is poured into only one of the gaps at a time. A separate cycle is therefore required for each stack of permanent magnets arranged one above the other. Furthermore, the casting compound must flow from top to bottom in the (small) gap, while the air in the gap must rise to the top in equilibrium. Filling the gap can therefore only occur in a balance between venting on the one hand and the inflow of casting compound on the other.

[0005] A rotor for an electric machine is known from DE 10 2009 054 584 A1. The rotor comprises laminations arranged one above the other to form a lamination stack, wherein pockets are formed in the lamination stack for accommodating permanent magnets. The permanent magnets arranged in the pockets are firmly bonded to the lamination stack with a bonding material, wherein the lamination stack is provided with at least one recess for introducing the bonding material.

[0006] JP 2015-82 854 A describes a rotor and a manufacturing method for a rotor, wherein end plates are arranged on the end of the rotor, and openings are formed in these end plates for introducing a potting material for fastening magnets arranged in the magnet pockets.

[0007] US 2011 / 0 000 079 A1 describes a rotor manufacturing process in which a space between a magnet and a magnet pocket is filled with a resin.

[0008] DE 10 2005 041 352 A1, DE 10 2008 018 724 A1 and DE 10 2010 032 864 A1 each show a permanent magnet synchronous machine in which two adjacently arranged magnetic pockets are connected to each other via a web.

[0009] It is an object of the present invention to provide a rotor lamination stack, an electrical machine and a method of the type mentioned above, which enable a simpler and more secure fastening of permanent magnets within the rotor lamination stack and thus a more cost-effective production of a rotor lamination stack or an electrical machine, and in addition the rotor can have an increased torsional strength.

[0010] The problem is solved by the subject matter of the independent patent claims. Advantageous embodiments are the subject matter of the dependent claims, the following description, and the figures.

[0011] According to a first aspect of the invention, a rotor lamination stack for an electrical machine is provided. The rotor lamination stack comprises a first end lamination, a second end lamination, a first intermediate lamination, a second intermediate lamination, and at least one permanent magnet, wherein the intermediate laminations are arranged between the end laminations in a stacking direction. Depending on the intended length of the rotor lamination stack, a plurality of first intermediate laminations and a plurality of second intermediate laminations are arranged between the end laminations.

[0012] The first end plate has at least one sprue bore and at least one vent bore, the first intermediate plate has at least one first opening and at least one first distributor bore, and the second intermediate plate has at least one second opening, at least one second distributor bore and a filling channel.

[0013] The permanent magnet is accommodated within the first opening in such a way that a first gap is created between the permanent magnet and the first opening, and the permanent magnet is further accommodated within the second opening in such a way that a second gap is created between the permanent magnet and the second opening.

[0014] The sprue bore, the first distributor bore, and the second distributor bore are connected to one another in such a way that a first distributor channel is formed, extending axially through the rotor core. The vent bore, the first intermediate space, and the second intermediate space are connected to one another in such a way that a second distributor channel is formed, extending axially through the rotor core. The fill channel connects the first distributor channel to the second distributor channel.

[0015] The second end plate closes the second distributor bore, the filling channel and the second opening at the front, and the first intermediate space and the second intermediate space are filled with a potting compound, so that the permanent magnet is connected to the first intermediate plate and the second intermediate plate in a material-locking and form-fitting manner by means of the potting compound.

[0016] A key aspect of the invention is that the potting compound for securing permanent magnets within the rotor core does not need to be filled into each individual magnet pocket or each individual aperture of a lamination of the rotor core, but is distributed via an end plate with a sprue hole and a vent hole, as well as via a distribution channel and a filling channel in the spaces between the apertures and the permanent magnets. Such potting of the potting compound can be automated, thereby reducing manufacturing costs. The sprue hole, the distribution channel, the filling channel, the interconnected apertures, and the vent hole form a cavity within the rotor core.

[0017] This makes it possible to supply the potting compound under pressure through the rotor laminations via the sprue hole in an upper end plate, via the axial distribution channel from top to bottom, via the filling channel laterally or radially outwards, and via the interconnected openings axially from bottom to top towards the vent hole. This procedure allows air trapped within the cavity to be vented upwards via the vent hole. In particular, it is also possible to use a highly viscous potting compound. Furthermore, it is possible to fill the spaces between the rotor laminations and the permanent magnets simultaneously and quickly with the potting compound. Lateral leakage from the rotor laminations and the formation of bubbles can be almost completely avoided.

[0018] The rotor lamination stack can have an end plate in a first axial end region. It is advantageous for the at least one sprue hole to be arranged within the end plate. Alternatively, the at least one sprue hole can be arranged in a first group of rotor laminations, and the distribution channel and the filling channel can be arranged in an adjacent second group of rotor laminations. The sprue holes are preferably accessible in the axial direction of the rotor lamination stack. The number of sprue holes can vary as needed and can, in particular, be greater than two.

[0019] According to one embodiment, the filling channel is filled with the potting compound, so that the first intermediate plate is connected to the second intermediate plate by means of the potting compound in a materially and positively locking manner. This can strengthen the cohesion, particularly between the intermediate plates, in the axial direction.

[0020] According to the invention, the second intermediate space is larger than the first intermediate space. For example, the first opening can be smaller than the second opening, so that with a permanent magnet of constant width and height arranged within the openings, the first intermediate space is also smaller than the second intermediate space. Due to the different sizes of the intermediate spaces or openings, undercuts or incisions (in the area of ​​the first openings) and bulges (in the area of ​​the second openings) are created in the stacking direction in the area of ​​the openings. These undercuts or incisions (in the area of ​​the first openings) and bulges (in the area of ​​the second openings) result in a positive fit between the stacked intermediate sheets when filled with the potting compound after it has hardened.

[0021] In particular, the first gap can be so small that the potting compound filling the first gap creates a structural adhesive bond between the permanent magnet and the first opening in the rotor core. Such a structural adhesive bond enables very high rigidity and very high strength in the joint or in the material-to-material connection. To make optimal use of this advantage, the first gap is preferably selected to be relatively small, for example, with a gap of 0.2 mm to 0.3 mm between the permanent magnet and the first opening. Compared to other joining methods, this adhesive bond allows the load to be applied without reducing the inherent strength of the joining partners. In view of high moduli, it is particularly important to avoid brittle material behavior in the adhesion promoter, as otherwise it is unable to absorb impact loads.

[0022] Furthermore, the second gap, in particular, can be so large that the potting compound filling the second gap creates an elastic adhesive bond between the permanent magnet and the second opening in the rotor core. Such an elastic adhesive bond exhibits a high ability to absorb movement. The elastic behavior of the potting compound within the second gap allows stresses to be distributed over larger areas, thus avoiding localized overloading of the substrate and adhesive. The required strength and rigidity of the structure can be achieved through the dimensioning of the bond or the gap between the permanent magnet and the second opening, as well as the selection of the adhesion promoter material.To accommodate movement, a minimum gap is preferably provided between the permanent magnet and the second aperture, with the gap particularly preferably being more than 0.3 mm. Another strength of the elastic adhesive bond is its ability to dampen vibrations. This, in particular, enables a significant reduction in sound transmission.

[0023] Polyurethanes, acrylics, silicones, polymers and epoxies are particularly suitable as casting compounds for creating elastic adhesive bonds and structural adhesive bonds.

[0024] According to the invention, the first opening or first gap has two partial openings or two partial gaps separated from each other by a central web. Such a geometry of the first opening can increase the rotor strength at high speeds and the associated high centrifugal forces.

[0025] According to a further embodiment, the first intermediate plate has the first distributor bore, the second distributor bore, the first opening, the second opening, and the filling channel, the first distributor bore and the second distributor bore are arranged offset from one another by 90° in the circumferential direction, the first opening and the second opening are each arranged offset from one another by 90° in the circumferential direction, the first intermediate plate and the second intermediate plate are identical, and the second intermediate plate is arranged rotated by 90° in the circumferential direction relative to the first intermediate plate. Thus, the rotor laminated core according to this embodiment comprises first and second intermediate plates with a single symmetrical sheet blank having two different opening geometries. The distributor channels and filling channels are produced by rotating the same individual sheets during stacking.For example, symmetrically arranged recesses or openings are made in each individual sheet to accommodate permanent magnets of various sizes. When stacked, the individual sheets are then placed on top of each other in a twisted manner, with the openings of different sizes aligned with each other. Alternatively, the overlapping openings can differ from each other not in size, but in their shape.

[0026] According to a further embodiment, it can be provided that the first intermediate plate has eight first openings, each spaced 45° apart from one another in the circumferential direction, the second intermediate plate has eight second openings, each spaced 45° apart from one another in the circumferential direction, the first intermediate plate and the second intermediate plate each have four distributor bores, each spaced 90° apart from one another in the circumferential direction, and two adjacent second openings are each connected to one of the distributor bores via a section of the filling channel. According to this embodiment, two types of intermediate plates are thus produced, the recesses of which essentially overlap one another but differ from one another in their contour, wherein the two types of intermediate plates can be stacked alternately on top of one another or can be stacked alternately on top of one another in small stacks of similar individual plates.Because two second openings are connected to a distribution hole, the number of distribution holes and thus the number of necessary supply points for casting compound can be kept particularly small.

[0027] Furthermore, it is advantageously provided that the first intermediate plate has a further first opening offset by 45° in the circumferential direction from the first opening, the second intermediate plate has a further second opening offset by 45° in the circumferential direction from the second opening, the second opening is connected to the second distributor bore via a first section of the filling channel, and the further second opening is connected to the second distributor bore via a second section of the filling channel.

[0028] According to a second aspect of the invention, an electrical machine is provided, in particular a dynamoelectric machine, wherein the electrical machine comprises a rotor core according to the first aspect of the invention.

[0029] According to a third aspect of the invention, a method for producing a rotor lamination stack according to the first aspect of the invention is provided. The method comprises the following method steps: - Providing a first end plate, a second end plate, a first intermediate plate, a second intermediate plate and a permanent magnet, - Arranging the intermediate plates on the second end plate in a stacking direction so that the first distribution channel and the second distribution channel are formed, - Inserting the permanent magnet into the openings of the intermediate plates, - Arranging the first end plate on the first intermediate plate, - sealing compression of the end plates and the intermediate plates arranged between the end plates in the axial direction, e.g. in a device designed for this purpose, - Filling the casting compound into the sprue hole so that the casting compound flows through the first distribution channel and the filling channel into the spaces between the intermediate plates and the permanent magnet, and - Curing of the casting compound.

[0030] The potting compound can be introduced into the distribution channels and filling channels in a thin to viscous form. The distribution of the introduced material or potting compound can be assisted by gravity, vibration, or mechanical impact. However, the filling material is preferably pressed into the distribution channels and filling channels. Sufficient filling is easily achieved by pressing.

[0031] According to one embodiment of the method according to the invention, the potting compound is a volume-expanding filler foam, a thermoplastic, or a self-curing resin system, in particular a two-component system. A thermoplastic can advantageously be introduced into the distribution channels and the filling channels by extrusion. The filler material can then harden by cooling. Alternatively, the distribution channels and the filling channels can be partially filled with a filler foam. During its curing, the filler foam expands, wets the openings, and thus ensures a material-to-material bond after curing, particularly between the openings and the permanent magnet.

[0032] In the following, embodiments of the invention are explained in more detail with reference to the schematic drawing, wherein identical or similar elements are provided with the same reference numerals. Fig. 1 a longitudinal section of a rotor core with first distribution channel, filling channel and second distribution channel, Fig. 2 a plan view of a first intermediate plate for the rotor core according to Fig. 1, Fig. 3 a plan view of a second intermediate plate for the rotor core according to Fig. 1, Fig. 4 a plan view of a first end plate for the rotor core according to Fig. 1, Fig. 5 a perspective view of a hardened filler body with a first distribution channel, filling channel and second distribution channel, which are formed by stacking sheets according to Fig. 2 to 4 arise, Fig. 6 a plan view of a further first or second intermediate plate for the rotor core according to Fig. 1, Fig. 7 a plan view of several stacked intermediate sheets according to Fig. 6, Fig. 8 a perspective view of a rotor lamination stack made of stacked intermediate laminations according to Fig. 7, Fig. 9 a perspective view of a hardened filler body with a first distribution channel, filling channel and second distribution channel, which are formed by the intermediate plates according to Fig. 6 to 8 arise, and Fig. 10 an enlarged section of the intermediate plates according to Fig. 7.

[0033] Fig. Figure 1 shows the right half of a rotor core 1, symmetrical about a longitudinal axis L, for an electrical machine 2 (not shown in detail), e.g., a dynamoelectric machine. The rotor core 1 comprises a first end plate 3, a second end plate 4, a total of four first intermediate plates 5, a total of four second intermediate plates 6, and a permanent magnet 7.

[0034] The end plates 3 and 4 and the intermediate plates 5 and 6 are circular disk-shaped and have the same outer diameter. The first end plate 3, the second end plate 4, the first intermediate plates 5, and the second intermediate plates 6 are stacked congruently one above the other in a stacking direction L, with the first intermediate plates 5 and the second intermediate plates 6 being arranged alternately within the end plates 3 and 4.

[0035] In this context, “congruent” can be understood as meaning that the outer circumferences of the end plates 3 and 4 as well as the intermediate plates 5 and 6 form a common cylindrical outer surface in the stacking direction L. In the Fig. In the example shown in Figure 1, the second end plate 4 is arranged at the bottom. A second intermediate plate 6 and a first intermediate plate 5 are stacked four times, alternating on the second end plate 4, with the first end plate 3 being stacked on the topmost first intermediate plate 5.

[0036] The first end plate 3 has a sprue hole 8 and a vent hole 9, which pass vertically through the first end plate 3 in the stacking direction L, which corresponds to an axial direction of the rotor laminated core 1, ie connect opposite end faces of the first end plate 3 to one another.

[0037] The first intermediate plates 5 are all identical and each have a first opening 10 and a first distribution bore 11, which pass vertically through the first intermediate plates 5 in the stacking direction L, i.e., connect opposite end faces of the first intermediate plates 5. For reasons of clarity, Fig. 1 only a first opening 10 and a first distributor bore 11 are provided with a reference symbol.

[0038] The second intermediate plates 6 are also all identical and each have a second opening 12 and a second distribution bore 13, which pass vertically through the second intermediate plates 6 in the stacking direction L, ie connect opposite end faces of the second intermediate plates 6. Furthermore, the second intermediate plates 6 each have a filling channel 14, which connects one of the second openings 12 with one of the second distribution bores 13. For reasons of clarity, Fig. 1 only a second opening 12, a second distributor bore 13 and a filling channel 14 are provided with a reference symbol.

[0039] The sprue bore 8, the first distributor bores 11 and the second distributor bores 13 lie one above the other on a common imaginary inner circular ring of the rotor laminated core 1 in the stacking direction L, so that they are aligned with one another and together form a first distributor channel 15 running in the axial direction L through the rotor laminated core 1.

[0040] The shape and size of the first openings 10 and the second openings 12 can be different. In particular, the second openings 12 can be larger than the first openings 10. A correspondingly possible smaller size of the first openings 10 is shown in Fig. 1 each indicated by dashed lines 16. The first openings 10 and the second openings 12 lie on a common imaginary outer circular ring of the rotor laminated core 1 in the stacking direction L, so that together they form a receiving space for the permanent magnet 7 running in the axial direction L through the rotor laminated core 1. The vent hole 9 of the first end plate 3 also lies on the imaginary outer circular ring of the rotor laminated core 1 and is connected to the first opening 10 of the Fig. 1 top first intermediate plate 5.

[0041] The permanent magnet 7 is accommodated within the receiving space or within the first openings 10 and within the second openings 12 in such a way that a first intermediate space 17 is created between the permanent magnet 7 and the first openings 10, and that a second intermediate space 18 is created between the permanent magnet 7 and the second openings 12. In other words, the permanent magnet 7 does not lie against the openings 10 and 12 of the rotor core 1, but is arranged at a (different) distance from the openings 10 and 12. For reasons of clarity, Fig. 1, only one of the first spaces 17 and one of the second spaces 18 is provided with a reference symbol. The permanent magnet 7 is in the Fig. 1, a bar magnet with a constant width and a constant height. Because the second openings 12 can be larger than the first openings 10, the constant width and height of the permanent magnet 7 also allows the second spaces 18 to be larger than the first spaces 17.

[0042] The vent hole 9, the first intermediate spaces 17 and the second intermediate spaces 18 are connected to one another in such a way that a second distribution channel 19 is formed, which runs in the axial direction L through the rotor core 1. The first distribution channel 15 and the second distribution channel 19 are connected to one another via the total of four filling channels 14. The second end plate 4 is designed to be at least partially closed, ie it has in particular no openings, perforations or the like in the region of the first distribution channel 15, the second distribution channel 19 and the filling channel 14 of the Fig. 1 of the lowest second intermediate plate 6. Thus, the second end plate 4 closes the distribution channels 15 and 19 as well as the filling channel 14 of the lowest intermediate plate 6 on one side.

[0043] Since the permanent magnet 7 is held neither force-fitting nor form-fitting by the openings 10 and 12 of the rotor laminated core 1 alone, the permanent magnet 7 is firmly fixed within the openings 10 and 12 by means of a potting compound 20, which acts as an adhesive between the rotor laminated core 1 and the permanent magnet 7. For this purpose, the potting compound, e.g. a thermoplastic, a filling foam or a self-curing resin system, is introduced in liquid form under pressure into the sprue 8. The pressure causes the potting compound to move through the first distribution channel 15 and through the four filling channels 14 into the first spaces 17 and the second spaces 18, whereby at the same time air displaced by the potting compound 20 can escape via the vent hole 9.

[0044] The first gaps 17 and the second gaps 18 are completely filled with the potting compound 20. In this way, the potting compound 20 wets both the permanent magnet 7 and the openings 10 and 12 of the rotor core 1. If a filling foam is used, the gaps 17 and 18 are not completely filled with the filling foam, as this subsequently expands. After the potting compound 20 has cured, it firmly bonds the permanent magnet 7 to the first intermediate sheets 5 and the second intermediate sheets 6 of the rotor core 1.

[0045] If the second intermediate space 18 is larger than the first intermediate space 17, the permanent magnet 17 is connected to the first intermediate sheets 5 of the rotor laminated core 1 in the region of the first intermediate spaces 17 by the potting compound 20 in the sense of a structural adhesive connection and is connected to the second intermediate sheets 6 of the rotor laminated core 1 in the region of the second intermediate spaces 18 by the potting compound 20 in the sense of an elastic adhesive connection.

[0046] The distance between the permanent magnet 7 and the first openings 10 can be, in particular, 0.2 mm to 0.3 mm. Such a distance is particularly suitable for creating a structural adhesive bond. Furthermore, the distance between the permanent magnet 7 and the second openings 12 can be, in particular, more than 0.3 mm. Such a distance is particularly suitable for creating an elastic adhesive bond.

[0047] If the first intermediate space 17 and the second intermediate space 18 have a different size or a different shape, and the intermediate spaces 17 and 18 are at least partially filled with the casting compound 20, the intermediate sheets 5 and 6 are positively connected to one another by the casting compound 20 after the casting compound 20 has hardened. In particular, the smaller size of the first openings 10 compared to the second openings 12 allows undercuts 23 or depressions (cf. Fig. 5 and Fig. 9) are created, which are filled by the casting compound 20. Complementary to this, bulges 24 (cf. Fig. 5 and Fig. 9) arise.

[0048] If the potting compound 20 also wets the first end plate 3 and / or the second end plate 4, the end plates 3 and / or 4 are integrally bonded to one another via the potting compound 20, so that the cohesion of the rotor core 1 in the axial direction L is further strengthened. If the potting compound 20 also completely or almost completely fills the first distribution channel 15 and the four filling channels 14, after curing of the potting compound 20, a materially bonded connection is also created between the intermediate plates 5 and 6 and between the end plates 3, 4 and the intermediate plates 5, 6.

[0049] Fig. 1 further shows that the end plates 3 and 4 as well as the intermediate plates 5 and 6 are each punched out centrally in a circular manner, whereby a central bore 21 is formed which runs in the axial direction L through the rotor laminated core 1 and by means of which the rotor laminated core 1 can be mounted in a rotationally fixed manner on a rotor shaft (not shown) of the electrical machine 2.

[0050] Fig. 2 shows a first intermediate plate 5 for the rotor core 1 according to Fig. 1, Fig. 3 a second intermediate plate 6 for the rotor core 1 according to Fig. 1 and Fig. 4 a first end plate 3 for the rotor core according to Fig. 1.

[0051] The first intermediate plate 5 after Fig. 2 comprises four first distribution bores 11.1 to 11.4, which are arranged on an imaginary inner circular ring (which corresponds to the imaginary inner circular ring according to Fig. 1) are arranged offset by 90° relative to one another in the circumferential direction. Furthermore, the first intermediate plate 5 comprises a total of eight first openings 10.1 to 10.8, which are arranged on an imaginary outer circular ring (which corresponds to the imaginary outer circular ring according to Fig. 1) are arranged offset by 45° in the circumferential direction and are designed for structural bonding of permanent magnets 7. As can be seen from Fig. As can be seen in Figure 2, the first openings 10.1 to 10.4 are divided into two parts. The division into two parts is achieved by the first intermediate plate 5 forming a central web 22 in the middle of each of the first openings 10.1 to 10.4, which divides the first openings 10.1 to 10.4 into a first partial opening 10.A and a second partial opening 10.B. A permanent magnet 7 can be accommodated within each of the partial openings 10.A and 10.B.

[0052] The second intermediate plate 6 after Fig. 3 has the same outer diameter as the first intermediate plate 5 according to Fig. 2. Furthermore, the second intermediate plate 6 comprises Fig. 3 four second distribution bores 13.1 to 13.4, which, like the first distribution bores 11.1 to 11.4, Fig. 2 are arranged on the imaginary inner circular ring offset by 90° to each other in the circumferential direction. Furthermore, the second intermediate plate 6 comprises a total of eight second openings 12.1 to 12.8, which, like the first openings 10.1 to 10.8, are arranged according to Fig. 2 are arranged on the imaginary outer circular ring, offset by 45° from each other in the circumferential direction, and are designed for elastic bonding of permanent magnets 7. The second openings 12 are larger than the first openings 10.

[0053] The second distribution holes 13 are in accordance with the Fig. 3, each of the second openings 12 is connected via a first filling channel section 14.1 of the filling channel 14 and each of the second openings 12 is connected via a second filling channel section 14.2 of the filling channel 14. The filling channel sections 14.1 and 14.2 extend in an arc between the respective second distributor bore 13 and the respective second openings 12. Thus, each of the second distributor bores 13 is connected to two second openings 12.

[0054] The first end plate 3 after Fig. 4 has the same outer diameter as the first intermediate plate 5 after Fig. 2 and the second intermediate plate 6 after Fig. 3. Furthermore, the first end plate 3 comprises Fig. 4 four sprue holes 8.1 to 8.4, which, like the first distributor holes 11.1 to 11.4, Fig. 2 and the second distribution holes 13.1 to 13.4 according to Fig. 3 are arranged on the imaginary inner circular ring offset by 90° to each other in the circumferential direction. Furthermore, the first end plate 3 comprises a total of eight vent holes 9.1 to 9.8, which, like the first openings 10.1 to 10.8, are arranged Fig. 2 and the second breakthroughs 12.1 to 12.8 after Fig. 3 are arranged on the imaginary outer circular ring offset by 45° to each other in the circumferential direction. A second end plate 4 for the rotor core 1 according to Fig. 1 can be constructed similarly to the end plate 3 according to Fig. 4, wherein the sprue holes 8 and the vent holes 9 are not present and the second end plate is designed to be closed at least in these areas.

[0055] The first end plate 3 after Fig. 4, the first intermediate plate 5 after Fig. 2, the second intermediate plate 6 after Fig. 3 and a second end plate 4 described in the previous paragraph can be stacked one above the other in a stacking direction L in such a way that four first distribution channels 15, a number of filling channels 14 (or filling channel sections 14.1 and 14.2) corresponding to the number of second intermediate plates 6 and four second distribution channels 19 are formed, as shown by Fig. 5. Permanent magnets 7 can be arranged within the second distribution channels 19, whereby the spaces 17 and 18 are formed between the permanent magnet 7 and the openings 10 and 12. The spaces 17, 18 as well as the first distribution channel 15 and the filling channel sections 14.1, 14.2 can be arranged as in connection with Fig. 1 described are filled with a casting compound in order to connect the permanent magnets 7 within the openings 10, 12 of the rotor laminated core 1 and the laminations 3 to 6 with each other.

[0056] The first intermediate plates 5 and the second intermediate plates 6 are according to Fig. 2 and Fig. 3 are not identical. The sheets 3 to 6 can be stacked on top of each other in such a way that they form a common cylindrical outer surface and the first distribution holes 11 and the second distribution holes 13 as shown by Fig. 1 are aligned with each other, so that four first distribution channels 15 are formed, extending axially through the rotor core 1. In this rotational position of the intermediate plates 5 and 6 relative to each other, the first openings 10.1 to 10.8 and the second openings 12.1 to 12.8 are also aligned with each other, so that eight distribution channels 19 are formed, extending axially through the rotor core 1.

[0057] As from Fig. 5, are - deviating from the rotor core 1 according to Fig. 1 - stacks of two first intermediate sheets 5 and stacks of two second intermediate sheets 6 are stacked alternately one above the other, so that the filling channel sections 14.1, 14.2 in particular are particularly wide, and the filling channel 14 thus has a particularly large cross-section. This can be particularly useful if the individual intermediate sheets 5 and 6 are very thin.

[0058] Fig. 6 shows a first intermediate plate 5, which is simultaneously used as a second intermediate plate 6. In other words, the first intermediate plate 5 and the second intermediate plate 6 are identical components.

[0059] The first intermediate plate 5 comprises four first distribution holes 11.1 to 11.4, which are arranged on an imaginary inner circular ring (which corresponds to the imaginary inner circular ring Fig. 1) are arranged offset from one another by 90° in the circumferential direction. The first distributor bores 11.1 to 11.4 simultaneously represent second distributor bores 13.1 to 13.4. Furthermore, the first intermediate plate 5 comprises a total of four first openings 10.1 to 10.4, which, as in connection with Fig. 2 are each divided into partial openings 10.A and 10.B. Furthermore, the first intermediate plate 5 comprises a total of four second openings 12.1 to 12.4, which, as described in connection with Fig. 3 are each connected to one of the distributor bores 11.1 to 11.4 via a filling channel section 14.1 or 14.2.

[0060] A first of the first openings 10.1 and a second of the first openings 10.2 are on an imaginary outer circular ring (which corresponds to the imaginary outer circular ring Fig. 1) are arranged offset by 45° to one another in the circumferential direction and are designed for structural bonding of permanent magnets 7. A third of the first openings 10.3 is arranged on the imaginary outer circular ring, offset by 180° in the circumferential direction from the first of the first openings 10.1. A fourth of the first openings 10.4 is arranged on the imaginary outer circular ring, offset by 180° in the circumferential direction from the second of the first openings 10.2. The third of the first openings 10.3 and the fourth of the first openings 10.4 are also designed for structural bonding of permanent magnets 7.

[0061] A first of the second openings 12.1 and a second of the second openings 12.2 are arranged on the imaginary outer circular ring, offset by 45° in the circumferential direction, and are designed for elastic bonding of permanent magnets 7. The first of the second openings 12.1 is arranged clockwise in the circumferential direction, offset by 90° from the third of the first openings 10.3, and the second of the second openings 12.2 is arranged clockwise in the circumferential direction, offset by 90° from the fourth of the first openings 10.4.

[0062] A third of the second openings 12.3 and a fourth of the second openings 12.4 are arranged on the imaginary outer circular ring, also offset by 45° in the circumferential direction, and are designed for elastic bonding of permanent magnets. The third of the second openings 12.3 is arranged clockwise in the circumferential direction at a 90° offset from the first of the first openings 10.1, and the fourth of the second openings 12.4 is arranged clockwise in the circumferential direction at a 90° offset from the second of the first openings 10.2.

[0063] Several of the intermediate sheets 5 / 6 can be stacked on top of each other in a stacking direction L such that a rotor sheet stack 1 is Fig. 7 to 10. Furthermore, end plates 3 and 4 (not Fig. 7 to 10; cf. Fig. 1 and Fig. 4) be applied, as is the case, for example, Fig. 1. The intermediate plates 5 can be stacked one above the other, rotated by 90° in the circumferential direction, in particular, so that they form a common cylindrical outer surface and the first distributor bores 11 and the second distributor bores 13 as shown by Fig. 1 are aligned with each other, so that four first distribution channels 15 are formed, extending axially through the rotor core 1. In this rotational position of the intermediate plates 5 / 6 relative to each other, the first openings 10.1 to 10.4 and the second openings 12.1 to 12.4 are also aligned with each other, so that eight second distribution channels 19 are formed, extending axially through the rotor core 1.

[0064] As from Fig. 9, are - deviating from the rotor core 1 according to Fig.1 - stacks of two first intermediate sheets 5 arranged not offset from one another in the circumferential direction and stacks of two second intermediate sheets 6 arranged offset from one another by 90° in the circumferential direction are alternately stacked one above the other, so that the filling channel sections 14.1, 14.2 in particular are particularly wide and the filling channel 14 thus has a particularly large cross-section. This can be particularly useful if the individual intermediate sheets 5 and 6 are very thin.

Claims

[1] Rotor lamination stack (1) for an electrical machine (2), the rotor lamination stack (1) comprising a first end plate (3), a second end plate (4), a first intermediate plate (5), a second intermediate plate (6) and a permanent magnet (7), wherein - the intermediate sheets (5, 6) are arranged between the end sheets (3, 4) in a stacking direction (L), - the first end plate (3) has a sprue hole (8) and a vent hole (9), - the first intermediate plate (5) has a first opening (10) and a first distributor bore (11), wherein the first opening (10) comprises two partial openings (10.1, 10.2) which are separated from one another by a central web (22), - the second intermediate plate (6) has a second opening (12), a second distributor bore (13) and a filling channel (14), - the permanent magnet (7) is accommodated within the first opening (10) in such a way that a first intermediate space (17) is created between the permanent magnet (7) and the first opening (10), - the permanent magnet (7) is accommodated within the second opening (12) in such a way that a second intermediate space (18) is created between the permanent magnet (7) and the second opening (12), the second intermediate space (18) being larger than the first intermediate space (17), - the sprue bore (8), the first distributor bore (11) and the second distributor bore (13) are connected to one another in such a way that a first distributor channel (15) is formed running in the axial direction (L) through the rotor core (1), - the vent hole (9), the first intermediate space (17) and the second intermediate space (18) are connected to one another in such a way that a second distribution channel (19) is formed running in the axial direction (L) through the rotor core (1), - the filling channel (14) connects the first distribution channel (13) with the second distribution channel (19), - the second end plate (4) closes the second distributor bore (13), the filling channel (14) and the second opening (12) at the front, and - the first intermediate space (17) and the second intermediate space (18) are filled with a casting compound (20), so that the permanent magnet (7) is integrally connected to the first intermediate plate (5) and the second intermediate plate (6) by means of the casting compound (20). [2] Rotor laminated core (1) according to claim 1, wherein the filling channel (14) is filled with the potting compound (20) so that the first intermediate plate (5) is integrally connected to the second intermediate plate (6) by means of the potting compound (20). [3] Rotor core (1) according to one of the preceding claims, wherein - the first intermediate plate (5) has the first distributor bore (11.1 to 11.4), the second distributor bore (13.1 to 13.4), the first opening (10.1 to 10.4), the second opening (12.1 to 12.4) and the filling channel (14), - the first distributor bore (11.1) and the second distributor bore (13.2) are arranged offset by 90° to each other in the circumferential direction, - the first opening (10.1) and the second opening (12.1) are arranged offset by 90° to each other in the circumferential direction, - the first intermediate plate (5) and the second intermediate plate (6) are identical, and - the second intermediate plate (6) is arranged rotated by 90° in the circumferential direction relative to the first intermediate plate (5). [4] Rotor laminated core (1) according to one of claims 1 to 2, wherein - the first intermediate plate has eight first openings spaced 45° apart from each other in the circumferential direction, - the second intermediate plate has eight second openings spaced 45° apart from each other in the circumferential direction, - the first intermediate plate and the second intermediate plate each have 4 distribution holes spaced 90° apart in the circumferential direction, and - two adjacent second openings are each connected to one of the distribution bores via a section of the filling channel. [5] Rotor laminated core (1) according to claim 3 or 4, wherein - the first intermediate plate (5) has a further first opening (10.2) offset by 45° in the circumferential direction from the first opening (10.1), - the second intermediate plate (6) has a further second opening (12.2) offset by 45° in the circumferential direction from the second opening (12.1), - the second opening (12.1) is connected to the second distributor bore (13.1) via a first section (14.1) of the filling channel (14), and - the further second opening (12.2) is connected to the second distributor bore (13.2) via a second section (14.2) of the filling channel (14). [6] Electrical machine (2) comprising a rotor core (1) according to one of the preceding claims. [7] Method for producing a rotor core (1) according to one of claims 1 to 5, the method comprising the steps: - Providing a first end plate (3), a second end plate (4), a first intermediate plate (5), a second intermediate plate (6) and a permanent magnet (7), - arranging the intermediate plates (5, 6) on the second end plate (4) in a stacking direction (L) so that the first distribution channel (15) and the second distribution channel (19) are formed, - Inserting the permanent magnet (7) into the openings (10, 12) of the intermediate plates (5, 6), - Arranging the first end plate (3) on the first intermediate plate (5), - filling the casting compound (20) into the sprue hole so that the casting compound (20) flows via the first distribution channel (15) and the filling channel (14) into the spaces (17, 19) between the intermediate plates (5, 6) and the permanent magnet (7), - sealingly pressing together the end plates (3, 4) and the intermediate plates (5, 6) arranged between the end plates (3, 4) in the axial direction (L), - Curing of the casting compound (20). [8] Method according to claim 7, wherein the potting compound (20) - a filling foam that hardens under volume expansion - a thermoplastic or - is a self-curing resin system, in particular a two-component system.

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