Rotor with filling sprue for an electric machine
The rotor design simplifies manufacturing and reduces weight by integrating a filling sprue body to fix magnets and shaft stubs, enhancing torque transmission and cooling efficiency.
Patent Information
- Application Number
- DE102018216108
- Authority / Receiving Office
- DE · DE
- Patent Type
- Patents
- Current Assignee / Owner
- Filing Date
- 2018-09-21
- Publication Date
- 2024-12-19
- Estimated Expiration
- 2038-09-21
AI Technical Summary
Existing rotors for electrical machines require multiple process steps and are heavy due to magnetically inactive material, leading to increased manufacturing complexity and weight.
A rotor design featuring an annular laminated core with integrated channels and a filling sprue body that fixes permanent magnets and shaft stubs, allowing for simplified manufacturing and reduced weight through the use of a lightweight filling sprue material.
The design reduces manufacturing steps, weight, and mass moment of inertia, while enabling efficient torque transmission and cooling, resulting in cost savings and improved machine dynamics.
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Abstract
Description
[0001] The invention relates to a rotor for an electrical machine, such as a dynamoelectric machine, an electric motor and / or a synchronous machine.
[0002] Rotors for electrical machines typically comprise a laminated core with embedded magnets and / or permanent magnets. To manufacture such a rotor, magnetically inactive areas within the rotor are often punched out of the core to reduce weight. The rotor is then positioned vertically, the permanent magnets are inserted into designated recesses and / or pockets in the core, and these are then encapsulated with a potting compound. The potting compound chemically crosslinks to form a solid, securing the permanent magnets in the recesses. Therefore, the manufacture of a rotor requires several process steps, which, in particular, involve rotating the rotor.
[0003] DE 10 2016 225 180 A1 describes an electrical machine with a rotor, comprising a laminated core with a plurality of permanent magnets arranged within the laminated core, wherein a filling sprue is cast onto the laminated core, and the permanent magnets are fixed in the laminated core via the filling sprue.
[0004] The object of the present invention is to provide a rotor for an electrical machine which has a simplified structure and can convey a cooling fluid.
[0005] This object is achieved by the subject matter of the independent patent claim. Advantageous embodiments are specified in the dependent claims, the following description, and the figures.
[0006] One aspect of the invention relates to a rotor for an electric machine. The rotor comprises an annular laminated core configured to rotate about a rotor axis, with an inner surface facing inward in the radial direction of the rotor, and at least one pocket formed in the laminated core for accommodating at least one permanent magnet. The pocket and the inner surface are connected to one another via at least one channel. Furthermore, the rotor comprises at least one permanent magnet arranged in the pocket.Furthermore, the rotor has a filler sprue body cast at least onto the inner circumferential surface, which is arranged and / or designed such that it fixes the at least one permanent magnet arranged in the at least one pocket at least via the at least one channel and forms at least one receptacle for fastening at least one shaft stub and / or shaft journal that can be arranged on the end face of the laminated core.
[0007] The rotor has an annular laminated core that is designed to be rotatable about a rotor axis. The laminated core can comprise magnetically active electrical steel material. The annular laminated core has an inner surface that is directed inwards and / or faces the rotor axis of the rotor. Furthermore, the laminated core has at least one pocket that is designed to accommodate one or more permanent magnets. The at least one pocket can, as it were, designate a recess made in the laminated core, in which one or more permanent magnets can be accommodated. The inner surface and the at least one pocket are connected to one another via at least one channel. The channel can be designed as a slot that extends at least partially through the laminated core parallel to an axial direction of the rotor or in the axial direction of the rotor and / or the laminated core.In the axial direction (and / or parallel thereto), the at least one channel can extend completely through the laminated core. Alternatively, the at least one channel can have one or more interruptions in the axial direction, e.g., in the form of webs. Furthermore, the at least one channel can extend from the inner circumferential surface in the radial direction of the rotor and / or the laminated core to the at least one pocket.
[0008] The rotor has at least one permanent magnet arranged in the pocket. The permanent magnet can be a metal body that is only magnetized at the end of the manufacturing process.
[0009] The rotor further comprises a filler sprue body which is arranged and / or configured such that it fixes the at least one permanent magnet arranged in the at least one pocket at least via the at least one channel. In other words, the filler sprue body can extend from the inner circumferential surface via the at least one channel in the radial direction of the rotor and / laminated core to the at least one pocket, such that the filler sprue body and / or material of the filler sprue body fixes the at least one permanent magnet in the at least one pocket. The filler sprue body can be cast onto the laminated core using a casting process. The casting process can be an injection molding process, a die casting process, e.g. an aluminum die casting process, or another casting process, depending on the material used for the filler sprue body.During the casting of the filler sprue body onto the laminated core, the channel and the at least one pocket can be at least partially filled with a material of the filler sprue body, so that the permanent magnet arranged in the pocket is fixed when the material of the filler sprue body hardens. The at least one channel and / or a gap between the permanent magnet and the laminated core can be completely filled with the filler sprue body and / or with a material of the filler sprue body.
[0010] The filler sprue body can further form at least one receptacle on at least one end face of the rotor and / or the laminated core. The receptacle can serve to at least partially accommodate a shaft stub and / or a shaft journal, wherein the shaft stub can be at least partially centered with respect to the rotor axis and / or relative to the rotor axis by the receptacle. The at least one receptacle can also serve as a centering shoulder for centering the shaft stub.
[0011] The rotor according to the invention can be manufactured in a significantly simpler manner than conventional rotors, particularly since fewer manufacturing steps can be required. This can also lead to a reduction in manufacturing costs. Specifically, during the sprue of the filler sprue body, the at least one permanent magnet can be fixed and the receptacle for the at least one shaft stub can be formed in a single step, for example, without the rotor having to be rotated and / or repositioned during production.
[0012] Furthermore, the rotor according to the invention can be characterized by a lower weight and thus a low mass moment of inertia. This results, for example, from the fact that the magnetically inactive filler material of the sheet metal blank between the rotor shaft and the magnetically active electrical sheet material can be dispensed with in the rotor according to the invention, since this area of the rotor or sheet stack can be provided by the filler sprue body. Furthermore, e.g. due to the high stability of the filler sprue body, an inner diameter of the inwardly directed inner shell surface can be selected to be very large in relation to the outer diameter of the annular sheet stack. This not only brings about a (static) weight reduction of the entire electrical machine, but also further advantages in the dynamics of the machine, because the moving part of the machine (the rotor) is lighter and therefore has a lower mass moment of inertia.
[0013] In one embodiment, a material of the filler sprue body has a low specific gravity. This can lead to a further weight reduction of the rotor and / or the entire electric machine.
[0014] In one embodiment, the filling sprue body comprises aluminum and / or thermosetting plastic.
[0015] In one embodiment, the rotor has at least one shaft stub. The at least one shaft stub is fixed to the laminated core and / or the filler sprue body in a force-fitting, form-fitting, and / or material-fitting manner. The at least one shaft stub can, for example, be arranged and / or fixed to an end face of the laminated core and / or the filler sprue body.
[0016] The use of the filler sprue body opens up a number of possibilities for securing the shaft stub to the filler sprue body, e.g., by shrinking, clamping, gluing, screwing, and / or other fastening methods. Furthermore, the rotor described can be configured with both a detachable and a permanent connection between the shaft stub and the laminated core and / or filler sprue body.
[0017] According to the invention, the rotor has two shaft stubs, each of which is attached to a respective end face of the laminated core. The two shaft stubs can be arranged concentrically to the rotor axis and / or opposite each other in the axial direction of the rotor, which runs parallel to the rotor axis. The two shaft stubs can also be spaced apart from each other in the axial direction. This can lead to a further weight reduction, for example, compared to a continuous shaft.
[0018] According to the invention, the filler sprue body forms and / or has a receptacle on each end face of the laminated core. In this case, one of the shaft stubs is at least partially arranged in one of the receptacles in such a way that each of the shaft stubs is centered with respect to the rotor axis. In this case, “on each end face” can mean adjacent to each end face and / or to an end-face region of the laminated core. The part of the shaft stub that is arranged in one of the receptacles can be regarded as a centering seat. For example, the shaft stubs can each have an end plate that can be at least partially inserted into one of the receptacles. An outer contour and / or geometry of the end plates can correspond to a contour and / or geometry of the receptacles, such that the end plates can be held at least partially in the receptacles with a precise fit and / or a form-fitting fit.
[0019] According to the invention, each of the receptacles of the filler sprue body has a larger inner diameter than a central region of the filler sprue body, wherein the central region of the filler sprue body is arranged in the axial direction of the rotor between the two receptacles of the filler sprue body. The axial direction of the rotor is oriented along and / or parallel to the rotor axis. A transition between each of the receptacles and the central region of the filler sprue body can, for example, be stepped and / or have a step. The step can, for example, form a stop for the shaft stubs, so that a region of each shaft stub can at least partially bear against one of the steps in the axial direction. The shape of the step can also correspond to a shape of the centering seat, the end plate and / or the shaft stub, so that the shaft stub can be fitted into the receptacle.In general, the fit between the shaft stub and the filler sprue body can be designed to ensure the most efficient transmission of torque and to minimize torsional stresses.
[0020] In one embodiment, the filler sprue body has at least one opening in the central region for securing the shaft stub using a shaft journal screw. This at least one opening extends parallel to the rotor axis. The at least one opening can be configured as a blind hole and / or a through-hole.
[0021] In one embodiment, each of the shaft stubs is fixed by at least one shaft journal screw. The shaft journal screw engages at least partially in the at least one opening on the filler sprue body. In some embodiments, the opening can be designed as a through-hole, so that one shaft journal screw can be arranged on each side of the opening or each end face of the rotor. One of the shaft journal screws can also have an internal thread that corresponds to an external thread of the other shaft journal screw, so that the two shaft journal screws can be screwed together.
[0022] According to the invention, the filler sprue body has a plurality of openings in the central region, which are spaced apart from one another in the circumferential direction of the rotor and / or the laminated core. The plurality of openings allows for the use of multiple shaft journal bolts. This results in better transmission of the motor's torque and can increase mechanical stability.
[0023] According to the invention, the filler sprue body has at least one through-channel, which extends at least partially coaxially to and / or along the rotor axis through the filler sprue body and which is designed to conduct a cooling medium, such as a cooling fluid, for cooling the rotor. The through-channel can be aligned with another through-channel in the at least one shaft stub, thereby forming a common channel through which the cooling medium can be conducted.
[0024] According to the invention, the through-channel is connected to each of the openings of the filler sprue body via a plurality of spoke-like and / or spoke-shaped connecting webs. In other words, regions of the filler sprue body in which the openings are formed can be connected via the spoke-like connecting webs to a region of the filler sprue body in which the through-channel is formed.
[0025] In one embodiment, the filler sprue body forms an undercut and / or an undercut on each of the end faces of the laminated core, so that the laminated core is fixed in an axial direction of the rotor. To form the undercut, the filler sprue body can protrude at least partially beyond the laminated core in the axial direction and / or be formed in a region of each end face. This can further increase mechanical stability.
[0026] In one embodiment, the at least one channel and the at least one pocket together have a T-shaped cross-section. The T-shaped cross-section can lie in a cross-sectional plane through the rotor and / or the laminated core. By forming a T-shaped cross-section, the mechanical stability of the rotor can be further increased.
[0027] In one embodiment, the at least one channel extends parallel to the rotor axis completely through the laminated core. Depending on the material of the filler gate, this can lead to an improvement in the flow properties of the gate and / or contribute to further weight savings of the rotor. It can also simplify a manufacturing process, for example, the insertion of the channel into the laminated core.
[0028] In one embodiment, the laminated core has a plurality of pockets spaced apart from one another in the circumferential direction of the laminated core and / or in the circumferential direction of the rotor, with each of the pockets being connected to the outer surface of the laminated core via a channel. This allows the rotor to be designed symmetrically to the rotor's center axis in an electrically and mechanically advantageous manner. This counteracts, for example, the occurrence of mechanical imbalance and / or the generation of eddy currents. This can also increase the performance of an electrical machine equipped with the rotor according to the invention.
[0029] In one embodiment, the shaft end and the filler sprue are designed as a single piece. This further simplifies the rotor manufacturing process. In this embodiment, the power transmission takes place virtually monolithically via the filler sprue.
[0030] In one embodiment, the inner diameter of the inner lateral surface is at least 40%, in particular at least 60%, for example at least 80%, of the outer diameter of the laminated core. This design makes the rotor particularly lightweight. Such ratios of the inner diameter to the outer diameter of the laminated core can be achieved, in particular, due to the design of the filler sprue body.
[0031] In one embodiment, the permanent magnets comprise ferromagnetic materials such as iron, nickel, cobalt, neodymium, ferrite, alloys of these materials and / or magnetizable plastic.
[0032] In one embodiment, the rotor is designed as an internal rotor. In other words, the rotor can be configured to be at least partially accommodated in a stator of an electrical machine.
[0033] Another aspect of the present disclosure relates to an electric machine having a stator and a rotor, as described above and below. The rotor can be at least partially housed in the stator. The electric machine can be, for example, a dynamoelectric machine and / or a synchronous machine.
[0034] It should be noted that all features described above and below with respect to one aspect of the present disclosure equally apply to any other aspect of the present disclosure. In particular, all features of the rotor may also be features of the electric machine, and vice versa.
[0035] A further aspect of the present disclosure relates to a use of a rotor as described above and below for an electric machine, a dynamoelectric machine, an electric motor, and / or a synchronous machine, for example as part of a drive motor in a vehicle.
[0036] For further clarification, the invention is described using exemplary embodiments shown in the figures.
[0037] It shows: Fig. 1a: schematically shows a longitudinal section through a rotor according to an embodiment; Fig. 1b: schematically shows a further longitudinal section through a rotor according to an embodiment; Fig. 2a: schematically shows a longitudinal section through a rotor according to an embodiment; Fig. 2b: schematically shows a perspective view of a rotor with a filler sprue body according to an embodiment; Fig. 2c: schematically shows a perspective view of a rotor with a filler sprue body and a shaft according to an embodiment; Fig. 3a: schematically a longitudinal section through a rotor according to an embodiment; Fig. 3b: schematically shows a further perspective view of a rotor with a through-channel according to an embodiment.
[0038] Fig. Figure 1a schematically shows a section and / or longitudinal section (so-called 3 / 4 section) through a rotor 10. The rotor axis 11 of the rotor 10, around which the rotor 10 can rotate, is shown as a dashed line. The rotor 10 has a laminated core 17 with an inner surface 16.
[0039] The laminated core 17 has one or more pockets 32 in a region of an outer circumference of the rotor 10 and / or the laminated core. A plurality of permanent magnets 30 are arranged in each of the pockets 32. For example, a plurality of pockets 32 can be formed in the laminated core 17, which can be spaced apart from one another in the circumferential direction of the laminated core 17.
[0040] Each of the pockets 32 is connected to the inner surface 16 of the laminated core 17 via at least one channel 35.
[0041] A filler sprue 40 is cast onto the inner surface 16. The filler sprue 40 can cover the inner surface 16 of the laminated core 17; the filler sprue 40 can also completely fill an interior of the laminated core 17 or, as shown here, form a cavity 45 in the region of a rotor axis 11. The filler sprue 40 further extends over the channels 35 in the radial direction of the rotor 10 up to the pockets 32, so that the permanent magnets 30 are fixed. Furthermore, the filler sprue 40 forms a receptacle 18 and / or a centering shoulder 18 at each axial end of the filler sprue 40, the laminated core 17, and / or the rotor 10.
[0042] A stub shaft 22 is arranged or inserted into the receptacles 18, for example by means of a centering ring 24, on the end face of the laminated core 17. The centering ring 24 shown here consists of a section 24a, which is enclosed by the centering projection 18, and a further section 24b, which protrudes from the respective end face of the filler sprue body 40. The fit of section 24a can be selected, e.g. by shrinking, so that a positive connection is created between the filler sprue body 40 and the stub shaft 22. Furthermore, section 24b has bores and / or through holes for shaft journal screws 19, which engage in the filler sprue body 40 and can fix the stub shaft 22 to the filler sprue body 40 additionally or exclusively in this way.
[0043] The shaft stubs 22 can be connected to the laminated core 17 via the filler sprue body 40 in such a way that a torque can be transmitted from the rotor 10.
[0044] The filling sprue body 40 partially encompasses the laminated core 17 in the form of an undercut 42. The undercut 42 allows the laminated core 17 to be fixed and / or held together in the axial direction.
[0045] Fig. 1b shows schematically a further section through the rotor 10 of the Fig. 1a. The laminated core 17 is again clearly visible, in which, in an outer region of the laminated core 17, pockets 32 with permanent magnets 30 are arranged. Furthermore, the filler sprue body 40 can be seen, which holds the laminated core 17 together in a kind of clamping function via the end-face undercuts 42, approximately in the shape of an H.
[0046] Shaft stubs 22 are arranged on the front side of the filling sprue body 40 in such a way that the centering rings 24 with the sections 24a are arranged in the centering projection 18 and are additionally guided through bores through the sections 24b by means of shaft journal screws 19 which engage in the filling sprue body 40.
[0047] Fig. Figure 2a shows a schematic longitudinal section through a further embodiment of a rotor 10 according to the present invention. Unless otherwise described, the rotor of the Fig. 2a the same elements and features as the rotor of the Fig. 1a and Fig. 1b.
[0048] The laminated core 17 and the permanent magnets 30 are arranged in a similar manner as in Fig. 1a and Fig. 1b. The shaft stubs or shaft journals 22 show a variation in which the centering ring 24 is designed somewhat differently. The shaft stubs 22 are arranged at the end face in a centering shoulder 18 or the receptacle 18 of the filler sprue body 40 in such a way that they are partially countersunk into the filler sprue body 40.
[0049] The shaft stubs 22 are each secured in the filler sprue body 40 by means of shaft journal screws 19, each in an opening 47 formed as a blind hole 47. The cavity 45 can thus be designed somewhat larger than in another embodiment, thus contributing to a further weight reduction. The filler sprue body 40 has inwardly directed elevations 46, in each of which one of the openings 47 and / or blind holes 47 for the shaft journal screws 19 is arranged and / or formed.
[0050] Fig. Figure 2b shows schematically a perspective view of the rotor 10 of Fig. 2a without the shaft journal 22. The channels 35 of the filler sprue 40, which lead to the permanent magnets 30 and / or the pockets 32, are particularly clearly visible. These channels are filled with the filler sprue 40, thus securing the permanent magnets 30. As can be seen, the individual channels 35, together with the associated pockets 32, have a T-shaped cross-section.
[0051] In the presentation of the Fig. Figure 2b also clearly shows the receptacle 18 and / or the centering shoulder 18, which is arranged and / or formed in a front-end region of the filler sprue body 40 and serves to receive at least a portion of one of the shaft stubs 22, such as a centering ring 24 of a shaft stub 22. The filler sprue body 40 has a larger inner diameter in the region of the receptacles 18 than a central region 41 of the filler sprue body 40. This creates a step 43 between the receptacles 18 and the central region 41, against which the shaft stubs 22 can rest in the axial direction.
[0052] Furthermore, the elevations 46 of the filler sprue body pointing and / or oriented in the direction of the rotor axis 11 are visible, each of which has a blind hole 47 and / or an opening 47 formed therein. The elevations 46 can thus indicate regions 46 of the filler sprue body 40 in each of which at least one of the openings 47 is formed. The elevations 46 can extend in the direction of the rotor axis 11 and / or in the radial direction.
[0053] Fig. Figure 2c shows schematically a perspective view of the rotor 10 of the Fig. 2a and Fig. 2b. The shaft journal 22 is arranged at least partially in the filler sprue body 40. The channels 35 are again visible, which lead to the permanent magnets 30 and are filled with the filler sprue body 40. The shaft journal 22 is arranged in the centering shoulder 18 and / or the receptacle 18 and is fastened by means of the shaft journal screws 19 in a blind hole 47 or an opening 47 (see Fig. 2b) .
[0054] Fig. Figure 3a shows a schematic longitudinal section through a rotor 10 of a further embodiment of the invention. Unless otherwise described, the rotor 10 of the Fig. 3a the same elements and features as the rotor 10 of the Fig. 1a to 2c.
[0055] The rotor 10 of the Fig. 3a has a through-channel 15 in the area of the rotor axis 11, which is designed to guide a cooling fluid. The fastening of the shaft journals 22 is similar to that of Fig. 2a to 2c. The through-channel 15 is aligned with a channel 25 arranged in the shaft journal 22, thus creating a continuous fluid passage, for example for cooling liquid. The further features of the rotor 10 of the Fig. 3a correspond to those of the previous figures, so that in this regard the Fig. 1a to 2c.
[0056] Fig. Figure 3b shows schematically another perspective view of the rotor 10 of Fig.3a, without the shaft journals 22. It is clearly shown that the through-channel 15 is connected to each of the openings of the filler sprue body 14 via several spoke-like and / or spoke-shaped connecting webs 12 or spokes 12. The spokes 12 connect, as it were, a region of the filler sprue body 40, in which the through-channel 15 is formed, with one of the regions 46, in which one of the openings 47 and / or blind holes 47 for receiving the shaft journal screws 19 is formed.
[0057] Additionally, it should be noted that "comprising" and "having" do not exclude other elements, and "a" or "an" does not exclude a plurality. Furthermore, it should be noted that features described with reference to one of the above embodiments can also be used in combination with other features of other embodiments described above. Reference signs in the claims are not to be considered as limitations.
Claims
[1] Rotor (10) for an electrical machine, the rotor (10) comprising: an annular laminated core (17) rotatable about a rotor axis (11) having an inner circumferential surface (16) directed inwards in the radial direction of the rotor and at least one pocket (32) formed in the laminated core (17) for receiving at least one permanent magnet (30), wherein the pocket (32) and the inner circumferential surface (16) are connected to one another via at least one channel (35); at least one permanent magnet (30) arranged in the pocket (32); a filler sprue body (40) cast at least onto the inner circumferential surface (16), which is arranged and / or designed such that it fixes the at least one permanent magnet (30) arranged in the at least one pocket (32) at least via the at least one channel (35) and forms at least one receptacle (18) for fastening at least one shaft stub (22) which can be arranged on the end face of the laminated core (17); the rotor (10) has two shaft stubs (22), wherein in each case one shaft stub (22) is fastened to a respective end face of the laminated core (17), wherein the filler sprue body (40) forms and / or has a receptacle (18) on each end face of the laminated core (17); in each case one of the shaft stubs (22) is arranged and / or received at least partially in one of the receptacles (18) in such a way that each of the shaft stubs (22) is centered with respect to the rotor axis (11); each of the receptacles (18) of the filling sprue body (40) has a larger inner diameter than a central region (41) of the filling sprue body (40), wherein the central region (41) of the filling sprue body (40) is arranged in the axial direction of the rotor (10) between the two receptacles (18) of the filling sprue body (40); the filling sprue body (40) has a plurality of openings (47) in the central region (41) which are spaced apart from one another in the circumferential direction of the rotor (10) and / or the laminated core (17); the filler sprue body (40) has at least one through-channel (15) which extends at least partially coaxially to and / or along the rotor axis (11) through the filler sprue body (40) and which is designed to conduct a cooling medium for cooling the rotor (10); and the through-channel (15) is connected to the openings (47) of the filling sprue body (40) via a plurality of spoke-like and / or spoke-shaped connecting webs (12). [2] Rotor (10) according to claim 1, further comprising: at least one shaft stub (22); wherein the at least one shaft stub (22) is fixed to the laminated core (17) and / or the filler sprue body (40) in a force-fitting, form-fitting and / or material-fitting manner. [3] Rotor (10) according to one of the preceding claims, wherein the filling sprue body (40) has at least one opening (47) in the central region (41) for fastening the shaft stub (22) by means of a shaft journal screw (19), wherein the at least one opening (47) extends parallel to the rotor axis (11). [4] Rotor (10) according to one of the preceding claims, wherein each of the shaft stubs (22) is fixed to the filler sprue body (40) via at least one shaft journal screw (19) which at least partially engages in the at least one opening (47). [5] Rotor (10) according to one of the preceding claims, wherein the filler sprue body (40) forms an undercut (42) on each of the end faces of the laminated core (17) so that the laminated core (17) is fixed in an axial direction of the rotor (10). [6] Rotor (10) according to one of the preceding claims, wherein the at least one channel (35) and the at least one pocket (32) together have a T-shaped cross-section. [7] Rotor (10) according to one of the preceding claims, wherein the at least one channel (35) extends parallel to the rotor axis (11) completely through the laminated core (17). [8] Rotor (10) according to one of the preceding claims, wherein the laminated core (17) has a plurality of pockets (32) which are spaced apart from one another in the circumferential direction of the laminated core (17) and / or the rotor (10); and wherein each of the pockets (32) is connected to the outer surface of the laminated core (17) via a channel (35).
Citation Information
Patent Citations
electric machine
DE102016225180A1
