Rotor arrangement for an axial flux machine for a motor vehicle that is at least partially electrically powered, axial flux machine and method

Abstract

The invention relates to a rotor arrangement (10) for an axial flux machine (12) for an at least partially electrically powered motor vehicle, comprising at least one carrier plate (14) and a magnet arrangement (16) on the carrier plate (14), wherein the magnet arrangement (16) is connected to the carrier plate (14) at a first side (22) of the magnet arrangement (16), and wherein a non-magnetic plate (26) is arranged on a second side (24) opposite the first side (22), which faces a stator (28) of the axial flux machine (12). The invention further relates to an axial flux machine (12) and a method for manufacturing a rotor arrangement (10).

Description

[0001] The invention relates to a rotor arrangement for an axial flux machine for an at least partially electrically operated motor vehicle according to the applicable patent claim 1. Furthermore, the invention relates to an axial flux machine and a method for producing a rotor arrangement.

[0002] When developing an electric motor, especially an axial flux motor, one of the main goals is to achieve high power and torque density while maintaining excellent efficiency and low resource consumption. The required power levels entail speeds that represent physical limits for previous concepts.

[0003] Existing designs for axial flux machines utilize surface magnets that are attached by a material or force fit. This results in the disadvantages of low connection force and time-consuming processes. Alternatively, bandages made of ZFK or GRP can be used to support the centrifugal forces, which allows for increased speed but also results in increased material costs.

[0004] EP 3 602 740 A1 describes a motor or an electromagnetic generator having a rotor with magnetic structures with unit magnets and a stator with concentric windings.

[0005] EP 3 602 742 A1 describes a magnetic structure with a plurality of individual magnets integrated in a network structure.

[0006] The object of the present invention is to provide a rotor arrangement, an axial flow machine and a method for producing a rotor arrangement, by means of which an improved operation of an axial flow machine can be realized.

[0007] This object is achieved by a rotor assembly, an axial flux machine, and a method for producing a rotor assembly according to the independent patent claims. Advantageous embodiments are specified in the subclaims.

[0008] One aspect of the invention relates to a rotor arrangement for an axial flux machine for an at least partially electrically operated motor vehicle, having at least one carrier plate and having a magnet arrangement on the carrier plate, wherein the magnet arrangement is connected to the carrier plate by a first side of the magnet arrangement.

[0009] It is provided that a non-magnetic plate is arranged on a second side opposite the first side, which faces a stator of the axial flux machine.

[0010] In particular, additional support for the magnets can be provided by bonding an additional plate, particularly in the air gap between the stator and rotor, thus increasing the adhesive surface. This increases the rotor's maximum speed. Furthermore, if a magnet becomes loose, it is absorbed. This provides greater safety, especially during assembly processes. For example, if a carbon ring is not used during assembly, the deflection of the rotor relative to the air gap can be significantly reduced.

[0011] According to an advantageous embodiment, the rotor arrangement surrounds a carbon ring.

[0012] It is also advantageous if the non-magnetic plate has the same circumference as the magnet arrangement.

[0013] A further advantageous embodiment provides that the non-magnetic plate is designed as a carbon plate.

[0014] A further aspect of the invention relates to an axial flux machine for an at least partially electrically operated motor vehicle with at least one stator and a rotor arrangement according to the preceding aspect.

[0015] An advantageous embodiment provides an axial flux machine with a first rotor arrangement according to the preceding aspect, a stator, and a second rotor arrangement according to the preceding aspect. In other words, the axial flux machine is designed in particular as an H-axial flux machine.

[0016] Yet another aspect of the invention relates to a method for manufacturing a rotor assembly for an axial flux machine according to the preceding aspect. The carrier plate is provided and the magnet assembly is arranged on the carrier plate. The non-magnetic plate is then arranged on the magnet assembly.

[0017] Furthermore, the invention also relates to an at least partially electrically operated motor vehicle with at least one axial flux machine according to the preceding aspect.

[0018] Advantageous embodiments of the rotor arrangement are to be regarded as advantageous embodiments of the axial flux machine of the method, as well as of the motor vehicle.

[0019] Further advantages, features, and details of the invention will become apparent from the following description of a preferred embodiment and from the drawings. The features and combinations of features mentioned above in the description, as well as the features and combinations of features mentioned below in the description of the figures and / or shown alone in the single figure, can be used not only in the respective combinations specified, but also in other combinations or on their own, without departing from the scope of the invention.

[0020] The only figure shows a schematic flow diagram for producing a rotor arrangement of an axial flux machine with an embodiment of a rotor arrangement.

[0021] In the figures, identical or functionally identical elements are provided with the same reference numerals.

[0022] The only Fig. Figure 1 shows a schematic flow diagram according to an embodiment for producing a rotor assembly 10 for an axial flux machine 12 of an at least partially electrically powered motor vehicle, which is not shown here, however. The rotor assembly 10 has at least one carrier plate 14 and a magnet assembly 16.

[0023] In the present exemplary embodiment, it is shown in particular that, in a first step S1, the carrier plate 14 can be assembled from a disk-shaped rotor carrier 14a and an electrical steel strip 14b, which is spirally wound into an annular disk. In this way, the carrier plate 14, in particular, can be prepared for the next steps. Alternatively, the carrier plate 14 can also be manufactured differently and, for example, consist only of a rotor carrier 14a or only of a spirally wound electrical steel strip 14b.

[0024] In a second step S2, the magnet assembly 16 is arranged on the carrier plate 14. The magnet assembly 16 comprises a plurality of different magnet elements 18, which are arranged axially around a rotor axis (not shown). In particular, a plastic overmolding or at least an SMC is formed between the corresponding magnet elements 18.

[0025] In a potential third step S3, the magnet arrangement 16 arranged on the carrier plate 14 can then be arranged with a carbon ring 20. In particular, the Fig. 1, in the second and third steps S2, S3, the magnet assembly 16 is arranged on the carrier plate 14 with a first side 22. Then, as already mentioned, the carbon ring 20 can optionally be arranged. In a fourth step S4, it is then provided that a non-magnetic plate 26 is arranged on a side 24 opposite the first side 22. The non-magnetic plate 26 then faces a stator 28 of the axial flux machine 12.

[0026] In a fifth step S5, the axial flux machine 12 is then assembled again, in particular as a double-rotor axial flux machine. In other words, the axial flux machine 12 has a second rotor assembly 30, which in turn rests against the stator 28. The second rotor assembly 30 can also be formed, like the first rotor assembly 10, from a carrier plate, a magnet assembly, and the non-magnetic plate 26. In other words, viewed from left to right, the axial flux machine can have a carrier plate, a magnet assembly, a non-magnetic plate, the stator 28, the non-magnetic plate 26, the magnet assembly 16, and the carrier plate 14.

[0027] In particular, it is provided that the non-magnetic plate 26 has the same circumference as the magnet arrangement 16. Furthermore, it can be provided in particular that the non-magnetic plate 26 is designed as a carbon plate.

[0028] In particular, the Fig. 1, that in an existing concept for a double rotor arrangement in the axial flux machine 12. The surface magnets which are attached in a material and force-fitting manner. The arrangement according to the invention enables additional support of the magnet arrangement 16, for example by gluing on the additional non-magnetic plate 26, thus increasing the adhesive surface. This leads to an increase in the maximum speed of the rotor arrangement 10. Furthermore, if a magnet becomes loose, it is intercepted. This provides greater safety, particularly during the corresponding assembly processes. If, for example, the carbon ring 20 is not used during assembly, the deflection of the rotor arrangement 10 towards the air gap can be greatly reduced.

[0029] In particular, for better and simpler fixing of the magnet assembly 16 to the rotor assembly 10 of, for example, an H-type axial flux machine, the invention proposes arranging a non-magnetic plate 26 over the magnet assembly 16 toward the air gap, thereby fixing the magnet assembly 16 or at least supporting it. Such non-magnetic plates 26 are

[0030] As a result, the rotor assembly 16 can be manufactured better and more easily, since the non-magnetic plate 26 also fixes and supports the magnets to the magnetic elements 18 during manufacture and thus the outer ring, in particular the carbon ring 20 as a radial support, is only optional.

[0031] In particular, for example, the carbon ring 20 can either be added to the non-magnetic plate 26 and then both are attached to the rotor assembly 10, or the non-magnetic plate 26 already has a type of minimal pot shape or a collar in its basic form, similar to the radial ring, constituting the basic shape of the non-magnetic plate 26, so that the essentially flat / level non-magnetic plate 26 axially covers the magnetic elements 18 in the radial outer region and can thus simultaneously also represent a corresponding outer ring. This is particularly advantageous if, for example, the non-magnetic plate 26 and the potential ring are or should be made of the same material, such as carbon, so that they can also be manufactured in one piece. List of reference symbols 10 Rotor arrangement 12 axial flux machine 14 Carrier plate 14a Rotor carrier 14b Electrical steel strip 16 Magnet arrangement 18 Magnetic element 20 carbon rings 22 first page 24 second page 26 non-magnetic plate 28 Stator 30 second rotor arrangement S1-S5 steps of the procedure QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] EP 3 602 740 A1

[0004] EP 3 602 742 A1

[0005]

Claims

[1] Rotor arrangement (10) for an axial flux machine (12) for an at least partially electrically operated motor vehicle, with at least one carrier plate (14) and with a magnet arrangement (16) on the carrier plate (14), wherein the magnet arrangement (16) is connected to the carrier plate (14) by a first side (22) of the magnet arrangement (16), characterized by that a non-magnetic plate (26) is arranged on a second side (24) opposite the first side (22), which faces a stator (28) of the axial flux machine (12). [2] Rotor arrangement (10) according to claim 1, characterized by that the rotor arrangement (10) is surrounded by a carbon ring (20). [3] Rotor arrangement (10) according to claim 1 or 2, characterized by that the non-magnetic plate (26) has the same circumference as the magnet arrangement (16). [4] Rotor arrangement (10) according to one of the preceding claims, characterized bythat the non-magnetic plate (26) is designed as a carbon plate. [5] Axial flux machine (12) for an at least partially electrically operated motor vehicle with at least one stator (28) and a rotor arrangement (10) according to one of claims 1 to 4. [6] Axial flow machine (12) according to claim 5, characterized by that the axial flux machine (12) has a first rotor arrangement (10) according to one of claims 1 to 4, the stator (28) and a second rotor arrangement (30) according to one of claims 1 to 4. [7] Method for producing a rotor arrangement (10) for an axial flow machine (12) according to one of claims 1 to 4, comprising the steps: - Providing the carrier plate (14); - arranging the magnet arrangement (16) on the carrier plate (14); and - Arranging the non-magnetic plate (26) on the magnet arrangement (16).

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