Device and method for producing a laminated core equipped with magnets of a rotor of an electrical machine

Abstract

Device for producing a rotor core (10) of a rotor of an electrical machine comprising magnets, wherein the magnets are accommodated in magnet pockets (11, 12) of the rotor core (10), with an insertion mask (13) for the magnets, which can be positioned on a first axial side of a rotor laminated core (10) and has recesses (14), wherein the recesses (14) of the insertion mask (13) can be aligned with the magnet pockets (11, 12) of the rotor laminated core (10) in order to insert the magnets into the magnet pockets (11, 12) of the rotor laminated core (10) via the recesses (14) of the insertion mask (13), with a body positionable on an opposite second axial side of the rotor core (10) to limit the movement of the magnets when they are inserted into the magnet pockets (11, 12) of the rotor core (10), characterized in that the body positionable on the opposite second axial side of the rotor core (10) is a damping body (15) for the magnets in order to additionally dampen the movement of the magnets when they are introduced into the to dampen the magnetic pockets (11, 12) of the rotor core (10), the recesses (14) of the insertion mask (13) have insertion bevels (18) for the magnets.

Description

[0001] The invention relates to a device for producing a rotor core having magnets of a rotor of an electrical machine and a method for producing the rotor core having magnets using such a device.

[0002] An electrical machine has a rotor and a stator. The rotor of an electrical machine is also called the rotor, and the stator of an electrical machine is also called the stator. The rotor of an electrical machine has a rotor core and magnets held in magnetic pockets by the rotor core. The rotor core, with the magnet held by the rotor core, can be mounted on a rotor shaft.

[0003] Rotors of electrical machines are known in practice in which the magnets are housed radially inward by the rotor core. Such radially inwardly housed magnets are also referred to as buried magnets, which are arranged in corresponding magnetic pockets of the rotor core. Buried magnets are inserted into the magnetic pockets of the rotor core, viewed in the axial direction of the rotor core, to accommodate the magnets in the rotor core. Such axial mounting of the magnets can damage both the magnets and the rotor core.

[0004] Furthermore, rotors of electrical machines are known in practice in which, in addition to or as an alternative to buried magnets, magnets are positioned radially outside adjacent to the rotor core. Such magnets, which are radially outside adjacent to the rotor core, are also referred to as surface magnets. The surface magnets are attached to the rotor core via an enveloping body, also known as a bandage.

[0005] US 2007 / 0 205 682 A1, US 2011 / 0 101 814 A1 and EP 0 013 157 B1 disclose different rotors of electrical machines.

[0006] US 2019 / 0 089 229 A1 and US 2019 / 0 190 330 A1 disclose rotors of electrical machines with buried magnets, wherein US 2019 / 0 089 229 A1 discloses a device for producing a rotor core of a rotor of an electrical machine equipped with magnets.

[0007] DE 10 2011 077 215 A1 discloses a device according to the preamble of claim 1.

[0008] The object of the invention is to provide a novel device for producing a rotor core having magnets of a rotor of an electrical machine and a method for producing a rotor core having magnets of a rotor of an electrical machine using such a device.

[0009] This object is achieved by a device according to claim 1.

[0010] The device according to the invention has an insertion mask for the magnets, wherein the insertion mask can be positioned on a first axial side of a rotor laminated core and has recesses, and wherein the recesses of the insertion mask can be aligned with the magnet pockets of the rotor laminated core in order to insert the magnets into the magnet pockets of the rotor laminated core via the recesses of the insertion mask.

[0011] The device according to the invention further comprises a damping body for the magnets, wherein the damping body can be positioned on an opposite second axial side of the rotor core in order to limit and dampen the movement of the magnets when they are inserted into the magnet pockets of the rotor core.

[0012] The invention can prevent damage to the magnets and the rotor core during assembly or manufacture of the rotor core equipped with magnets.

[0013] Damage to the magnets, particularly to their magnetic coating, which can occur as a result of the magnetic attraction between the magnets and the rotor core according to the prior art, can be avoided with the device according to the invention. Furthermore, it can prevent magnets inserted into the magnetic pockets of the rotor core from striking a solid surface due to the strong attractive force and thus becoming damaged.

[0014] The recesses of the insertion mask feature chamfered edges for the magnets. These chamfers prevent the magnets from jamming. They can be inserted into the magnetic pockets without damage.

[0015] According to an advantageous development, the device according to the invention comprises a skirt, which can be positioned radially around a circumferential side of the rotor core. The skirt can also be used to shield the rotor core radially on the outside during magnet assembly, thereby further reducing the risk of damage to the rotor core due to attractive forces and magnetic fragments.

[0016] According to an advantageous development, the device according to the invention has at least one positioning aid for aligning the insertion mask relative to the rotor core, wherein a first positioning aid serves to radially align the insertion mask relative to the rotor core and / or a second positioning aid serves to circumferentially align the insertion mask relative to the rotor core. Using the at least one positioning aid, the insertion mask of the device according to the invention can be precisely aligned with the magnetic pockets of the rotor core to enable precise and damage-free positioning of the magnets in the magnetic pockets of the rotor core.

[0017] The method is defined in claim 9 and comprises at least the following steps: Providing a rotor core with magnetic pockets. Providing magnets. Providing a device according to the invention. Arranging the rotor core between the damping body and the insertion mask, aligning the recesses of the insertion mask with the magnetic pockets of the rotor core. Inserting the magnets into the magnetic pockets of the rotor core via the recesses of the insertion mask.

[0018] Preferred developments of the invention will become apparent from the dependent claims and the following description. Exemplary embodiments of the invention are explained in more detail, without being limited thereto, with reference to the drawings. Herein: Fig. 1 a perspective view of a rotor core of a rotor of an electrical machine without magnets, Fig. 2 a perspective view of a rotor core together with a device according to the invention for producing a rotor core comprising magnets of a rotor of an electrical machine, Fig. 3 a plan view of the arrangement of the Fig. 1, and Fig. 4 a cross section through the arrangement of the Fig. 1.

[0019] The invention relates to a device for producing a rotor core comprising magnets for a rotor of an electrical machine, namely a device for damage-free installation of the magnets in magnet pockets of the rotor core. Furthermore, the invention relates to a method for producing such a rotor core using the device according to the invention.

[0020] Fig. 1 shows a perspective view of a rotor core 10 of a rotor of an electrical machine.

[0021] The rotor core 10 has several magnet pockets 11, 12 of different sizes to accommodate magnets of different sizes. In the illustrated embodiment, the magnets can be inserted into the magnet pockets 11, 12 of the rotor core 10 in the axial direction of the core. The magnets arranged in the magnet pockets 11, 12 are then accommodated radially inward in the rotor core 10 and are thus designed as buried magnets.

[0022] The present invention is now about arranging the magnets in the magnet pockets 11, 12 of the rotor laminated core 10 without causing damage, and without any risk of damage to the magnets and the rotor laminated core.

[0023] The device according to the invention for mounting the magnets in the magnet pockets 11, 12 of the rotor laminated core 10 has an insertion mask 13 that can be positioned on a first axial side of the laminated core 10. The insertion mask 13 has recesses 14 for the magnets to be inserted into the magnet pockets 11, 12. The recesses 14 of the insertion mask 13 can be aligned with the magnet pockets 11, 12 of the rotor laminated core 10 in order to overlap them and thus insert the magnets into the magnet pockets 11, 12 of the rotor laminated core 10 via the recesses 14 of the insertion mask 13.

[0024] The device according to the invention further comprises a damping body 15, which can be positioned on a second axial side of the laminated core 10 opposite the first axial side, wherein the damping body 15 limits and dampens the movement of the magnets to be inserted into the magnet pockets 11, 12 during the insertion of the same into the magnet pockets 11, 12 of the rotor laminated core 10. The damping body 15 is in the illustrated embodiment (see in particular Fig. 1) taken from a base 16.

[0025] When mounting the magnets in the magnet pockets 11, 12 of the rotor laminated core 10, the rotor laminated core 10 is arranged in a sandwich-like manner between the insertion mask 13 and the damping body 15, wherein the magnets can be inserted via the recesses 14 of the insertion mask 13 into the recesses 11, 12 of the rotor laminated core 10 in the axial direction of the rotor laminated core 10, wherein the damping body 15 located at the front in the direction of this insertion movement of the magnets into the magnet pockets 11, 12 limits and dampens the insertion movement of the magnets into the magnet pockets 11, 12 of the rotor laminated core 10. During assembly or arrangement of the magnets in the magnet pockets 11, 12 of the rotor lamination stack 10 and thus during production of a rotor lamination stack 10 having magnets or a rotor lamination stack 10 equipped with magnets, there is no risk of damage to the magnets to be arranged in the magnet pockets 11, 12 of the rotor lamination stack 10 or to the rotor lamination stack 10.

[0026] In the illustrated embodiment, the device further comprises a skirt 17 positioned radially around a circumferential surface of the rotor core 10. The insertion mask 13, skirt 17, and damping body 15 with base plate 16 thus form a housing for the rotor core 10 when the magnets are arranged in the magnet pockets 11, 12 of the rotor core 10. This further reduces the risk of damage to the rotor core 10 during assembly. There is no risk of damage to the rotor core 10 on its circumferential surface from magnetic splinters or the like.

[0027] The insertion mask 13 as well as the apron 17 and the base body 16 are preferably made of a paramagnetic material.

[0028] The damping body 15 is preferably made of an elastic material which absorbs a kinetic energy of the magnets to be arranged in the magnetic pockets 11, 12 and dampens their movement.

[0029] The damping body 15 is preferably designed such that a horizontal alignment of the rotor core 10 and the magnets is not influenced and a flush connection can be provided between the rotor core 10 and the magnets to be arranged in the magnet pockets 11, 12 of the rotor core 10.

[0030] The recesses 14 of the insertion mask 13 preferably have insertion bevels 18 for inserting the magnets into the magnetic pockets 11, 12 via the recesses 14. There is no risk of the magnets becoming jammed and thus damaged when they are inserted into the magnetic pockets 11, 12.

[0031] The device according to the invention further comprises at least one positioning aid for aligning the insertion mask 13 relative to the rotor core 10, specifically for aligning the recesses 14 of the insertion mask 13 relative to the magnetic pockets 11, 12 of the rotor core 10.

[0032] Thus, the device according to the invention preferably has a first positioning aid for the radial alignment of the insertion mask 13 relative to the rotor laminated core 10 and a second positioning aid for the circumferential alignment of the insertion mask 13 relative to the rotor laminated core 10.

[0033] In the illustrated embodiment, the first positioning aid for radially aligning the insertion mask 13 relative to the rotor core 10 is provided by a multi-part locating mandrel 19. The multi-part locating mandrel 19 has a first part 19a, which extends from the second side of the rotor core 10 through a central recess 20 thereof. This central recess 20 serves to position the rotor core 10 on a rotor shaft after the magnets have been mounted in the magnet pockets 11, 12 of the rotor core 10.

[0034] This first part 19a of the receiving mandrel 19 is preferably an integral part of the base body 16, which in the embodiment shown also carries the damping body 15.

[0035] From the opposite first side of the rotor core 10, the second part 19b of the receiving mandrel 19 can be positioned on the first part 19a of the receiving mandrel 19, whereby these two parts 19a, 19b of the receiving mandrel 19 can be fastened to one another via a union nut 21. The second part 19b of the receiving mandrel 19 can be inserted into a central recess in the insertion mask 13, whereby a circumferential collar 24 of the part 19b comes into contact with the insertion mask 13.

[0036] By tightening the union nut 21, the arrangement of the rotor laminated core 10, which is arranged between the base body 16 with the damping body 15 and the insertion mask 13, can be clamped.

[0037] The second positioning aid for determining a relative position in the circumferential direction between the insertion mask 13 and the rotor core 10 is provided in the embodiment shown by gauges 22 which are arranged according to Fig.2 for determining the relative circumferential position between the insertion mask 13 and the rotor laminated core 10, on the one hand, into the recesses 14 of the insertion mask 13 and, on the other hand, into the magnetic pockets 11 of the rotor laminated core 10. With the union nut 21 still loose, the insertion mask 13 can thus be rotated in the circumferential direction relative to the rotor laminated core 11 in order to then insert the gauges 22 into the magnetic pockets 11 of the rotor laminated core 10 via the recesses 14 of the insertion mask 13 in the desired relative circumferential position and then to clamp the arrangement of the rotor laminated core 10 and insertion mask 13 by tightening the union nut 21. The gauges 22 can then be removed again in order to make all magnetic pockets 11, 12 of the rotor laminated core 10 accessible for inserting the magnets via the recesses 14 of the insertion mask 13.

[0038] Instead of the gauges 22 or in addition to them, projections (not shown) can also be used as second positioning aids, which are formed on a side of the insertion mask 13 facing the rotor laminated core 10 and can be inserted into flux barriers (not shown) and / or into a contour in the region of the central recess 20 of the rotor laminated core 10 in order to thus carry out the circumferential alignment of the insertion mask 13 relative to the rotor laminated core 10.

[0039] In the preferred embodiment shown, an orientation device 23 is formed on the insertion mask 13 of the device according to the invention. This orientation device 23 is a device that has at least one optical and / or tactile orientation feature 25, which can be used by a robot or other automatic handling device to automatically determine the position of the insertion mask 13 and thus insert the magnets to be positioned in the magnetic pockets 11, 12 into the correct magnetic pockets 11, 12. This allows for fully automatic loading of the magnetic pockets 11, 12 of the rotor core 10 with magnets, eliminating manual processing steps and reducing production costs.

[0040] The invention proposes a device comprising at least the insertion mask 13 and the damping body 15, which can be arranged on two opposite axial sides or axial ends of the rotor core 10.

[0041] When the skirt 17 is additionally present, these assemblies provide a nearly complete enclosure of the rotor core 10, protecting it during the insertion of the magnets into the magnet pockets 11, 12 of the rotor core 10. In this case, the rotor core 10 is optimally protected from damage.

[0042] The alignment of the insertion mask 13 relative to the rotor core 10, namely the alignment of the recesses 14 of the insertion mask 13 to the magnetic pockets 11, 12 to be equipped with the magnets, is carried out using at least one positioning aid.

[0043] In order to prevent the magnets from tilting when inserted into the magnetic pockets 11, 12 via the recesses 14 of the insertion mask 13, the recesses 14 of the insertion mask have the insertion bevels 18.

[0044] The damping body 15, which is arranged on the opposite axial side of the rotor core 10 to be equipped with magnets as the insertion mask 13, consists of an elastic material in order to dampen the movement of the magnets into the magnet pockets 11, 12 at the end of the movement.

[0045] The device according to the invention can be used for semi-automatic as well as fully automatic loading of the magnetic pockets 11, 12 with the magnets. For fully automatic loading, the orientation device 23 is advantageous, providing at least one automatically evaluable, optical or tactile orientation feature 25, based on which a robot can automatically determine the position of the insertion mask 13.

[0046] The invention further relates to a method for producing a rotor core 10 having magnets, namely a method for equipping the magnet pockets 11, 12 of the rotor core 10 with magnets using the device described above.

[0047] In order to produce or provide a rotor core 10 equipped with magnets, on the one hand the rotor core 10 with the magnet pockets 11, 12 is provided, on the other hand magnets are provided and the device described above.

[0048] The rotor core 10 to be equipped with the magnets is positioned between the damping body 15 and the insertion mask 13, aligning the recesses 14 of the insertion mask 13 with the magnet pockets 11, 12 of the rotor core 10.

[0049] The magnets are then inserted into the magnet pockets 10, 11 of the rotor laminated core 12 via the recesses 14 of the insertion mask 13, whereby after the magnet pockets 11, 12 of the rotor laminated core 10 have been completely equipped with magnets, the rotor laminated core 10 can be removed from the device, namely by loosening the union nut 21 and removing the insertion mask 13 and the equipped rotor laminated core 10 from the holding mandrel 19a, 19b.

[0050] The heart-setting rotor of an electrical machine is in particular a rotor of a permanent magnet excited synchronous machine, in which the magnets to be arranged in the magnet pockets 11, 12 of the rotor laminated core 10 are permanent magnets. List of reference symbols 10 rotor lamination stack 11 magnetic pocket 12 magnetic pockets 13 Insertion mask 14 Recess 15 damping bodies 16 Base 17 Apron 18 insertion bevel 19 first positioning aid / mandrel 19a first part of the mandrel 19b second part of the mandrel 20 central recess 21 Union nut 22 second positioning aid / gauge 23 Orientation facility 24 bundles 25 Orientation feature

Claims

[1] Device for producing a rotor core (10) of a rotor of an electrical machine comprising magnets, wherein the magnets are accommodated in magnet pockets (11, 12) of the rotor core (10), with an insertion mask (13) for the magnets, which can be positioned on a first axial side of a rotor laminated core (10) and has recesses (14), wherein the recesses (14) of the insertion mask (13) can be aligned with the magnet pockets (11, 12) of the rotor laminated core (10) in order to insert the magnets into the magnet pockets (11, 12) of the rotor laminated core (10) via the recesses (14) of the insertion mask (13), with a body positionable on an opposite second axial side of the rotor core (10) to limit the movement of the magnets when they are inserted into the magnet pockets (11, 12) of the rotor core (10), characterized by , that the body positionable on the opposite second axial side of the rotor core (10) is a damping body (15) for the magnets in order to additionally dampen the movement of the magnets when they are introduced into the to dampen the magnetic pockets (11, 12) of the rotor core (10), the recesses (14) of the insertion mask (13) have insertion bevels (18) for the magnets. [2] Device according to claim 1, characterized by an apron (17) which can be positioned radially around a circumferential side of the rotor core (10). [3] Device according to claim 1 or 2, characterized by that the insertion mask (13) and, if applicable, the apron (17) are made of a paramagnetic material. [4] Device according to one of claims 1 to 3, characterized by at least one positioning aid (19, 22) for aligning the insertion mask (13) relative to the rotor laminated core (10). [5] Device according to claim 4, characterized bythat a first positioning aid (19) serves for the radial alignment of the insertion mask (13) relative to the rotor laminated core (10). [6] Device according to claim 5, characterized by that the first positioning aid (19) is a receiving mandrel (19a, 19b) which can be inserted into a central recess (20) of the rotor laminated core (10) and into a central recess of the insertion mask (13). [7] Device according to one of claims 5 to 6, characterized by that a second positioning aid (22) serves for the circumferential alignment of the insertion mask (13) relative to the rotor laminated core (10). [8] Device according to claim 7, characterized by that the second positioning aid (22) is at least one gauge which can be inserted into a recess (14) of the insertion mask (13) and into a magnetic pocket (11, 12) of the rotor laminated core (10), and / or is at least one projection which can be inserted into a flux barrier of the rotor laminated core (10). [9] Method for producing a rotor core (10) of a rotor of an electrical machine comprising magnets, wherein the magnets are accommodated in magnet pockets (11, 12) of the rotor core (10), comprising at least the following steps: a) providing a rotor core (10) with magnetic pockets (11, 12), b) Providing magnets, c) providing a device according to one of claims 1 to 8, d) arranging the rotor core (10) between the damping body (15) and the insertion mask (13) while aligning the recesses (14) of the insertion mask (13) with the magnetic pockets (11, 12) of the rotor core (10), e) Inserting the magnets into the magnet pockets (11, 12) of the rotor core (10).

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