Method for manufacturing at least one stator for an electromechanical inertial drive

Abstract

The present invention relates to a method for manufacturing at least one stator (1) for an electromechanical inertial drive, wherein the stator (1) comprises at least one electromechanical actuator (2) and a stator frame (3) for receiving the actuator (2). To reduce the manufacturing costs for the stator, the stator frame (3) comprises several components (4, 5.1, 5.2, 6) which are manufactured from at least one planar semi-finished product in a separation process and are arranged in a stacked configuration to form the stator frame (3).

Description

[0001] The present invention relates to a method for producing at least one stator for an electromechanical inertial drive.

[0002] A method according to the preamble of claim 1 is known, for example, from US 2022 / 0 255 467 A1, WO 2021 / 190 953 A1 and WO 2022 / 135 905 A1. As the Fig. 1a to 1d show, the stator 1 known from the prior art has a stator frame 3 for accommodating two electromechanical actuators 2. Fig. 2 clearly shows that the known stator frame 3 comprises a stator base 5, which accommodates the electromechanical actuators 2 in a cavity 7. The stator base 5 of the known stator 1 is typically a one-piece component manufactured by CNC machining. The production of a stator comprising such a CNC-machined stator base 5 is complex and expensive.

[0003] Further prior art is disclosed in DE 10 2021 118 783 B3 and EP 3 503 139 B1.

[0004] Therefore, the object of the invention is to provide a method by which the manufacturing costs of a stator for an electromechanical inertial drive can be reduced.

[0005] To achieve this object, the present invention provides a method according to claim 1.

[0006] The object is achieved in that the stator frame comprises a plurality of components that are manufactured from at least one flat semi-finished product in a thermal or mechanical separation process and are arranged in a stack to form the stator frame. This means that the stator frame according to the invention is defined by a stack of several components, all of which are manufactured from at least one flat semi-finished product in a separation process.

[0007] Because the stator frame is formed from several individual components in a stacked assembly and each of these individual components is manufactured in a cost-effective separation process from a readily available and therefore inexpensive semi-finished product, the overall manufacturing costs for the stator can be significantly reduced.

[0008] Advantageous further training is the subject of the subclaims.

[0009] It may be advantageous if the stator frame comprises at least two spring plates and a stator base comprising at least two components, which is arranged between the two spring plates. While the stator base is provided to accommodate the at least one electromechanical actuator, the external spring plates can create a connection to a higher-level structure into which the stator is installed.

[0010] It can be helpful to install an additional flat spring on one of the spring plates. This flat spring can be used to apply a suitable preload force to the at least one electromechanical actuator.

[0011] It can be practical if the components of the stator frame are manufactured from at least two different plate-shaped semi-finished products with different thicknesses. This makes it possible to provide components that meet different requirements for rigidity or elasticity. In particular, it can be useful for the components of the stator base to be manufactured from a thicker semi-finished product in order to have sufficient rigidity to support the at least one electromechanical actuator. On the other hand, it can be useful for the spring plates to be manufactured from a thinner semi-finished product in order to have a certain degree of elasticity.

[0012] It can be advantageous to manufacture various components of the stator frame from a common plate-shaped semi-finished product. This allows components of the same thickness to be manufactured efficiently and cost-effectively.

[0013] It can be beneficial if the stator base has a cavity in which the at least one electromechanical actuator is inserted, and the components of the stator base are preferably made from semi-finished products of the same thickness, particularly preferably from the same semi-finished product. By making the components of the stator base from the same semi-finished product, i.e., having the same thickness, a rigid stator base can be provided that adequately supports the actuator.

[0014] It may be advantageous if the components of the stator base are formed by a support element on which the at least one electromechanical actuator is placed, and a housing element that at least partially surrounds the at least one electromechanical actuator. The support element is preferably rod-shaped and the housing element is preferably U-shaped. The support element and / or the housing element can be divided into further elements if necessary. Such shapes of the support element and housing element can be easily and quickly cut out of the semi-finished product.

[0015] It may prove helpful if the components of the stator frame are aligned to one another via reference means, preferably formed by through holes and / or threaded holes, and the stack assembly is preferably fixed by connecting means, preferably by screws or welded joints.

[0016] It may be practical if the cutting process is preferably a laser cutting process, a water jet cutting process or an electrical discharge machining process.

[0017] It can be useful to stack multiple component groups, each formed by a series connection of several components of the same type, to form multiple stator frames in a series connection. This allows multiple stator frames to be manufactured simultaneously, improving stator manufacturing efficiency.

[0018] It can be useful if the components in a series assembly are manufactured integrally from a semi-finished product.

[0019] It may be useful to separate the multiple stator frames in the series to provide individual stator frames. Terms and definitions

[0020] In the context of the present invention, a flat semi-finished product refers to a flat raw material, workpiece, or semi-finished product. The flat semi-finished product is, for example, plate-shaped, e.g., made of plastic, metal, or ceramic, and preferably extends in a single plane. The flat semi-finished product preferably has the same cross-section in its thickness direction, i.e., perpendicular to its plane of extension.

[0021] In the context of the present invention, a stacked assembly refers to a stacked arrangement of several components that are fixed to one another using a joining process.

[0022] In the context of the present invention, a series connection refers to an arrangement of several components next to one another, which are preferably connected to one another integrally, particularly preferably materially, by connecting sections.

[0023] In the context of the present invention, an electromechanical actuator refers to an element which changes its geometric dimensions due to the application of electrical energy. Short description of the characters Fig. 1a to 1d show a stator 1 according to the prior art in different views. Fig. 2 shows a stator base 5 of the stator 1 known from the prior art. Fig. 3a and Fig. 3b shows a first embodiment of the stator base 5 of a stator 1 having two components 5.1, 5.2, which is manufactured according to the method according to the invention. Fig. 4 to 10 show the production of several stator frames 3 or stators 1 in a series connection according to a first embodiment, wherein the respective stack connection of a stator frame 3 is produced by screw connections. Fig. 4a and Fig. 4b show a partially machined semi-finished product used to manufacture the stator base 5 comprising two components 5.1, 5.2 according to Fig. 3 is used, in a top view and a perspective view. Fig. 5a and Fig. 5b show the first embodiment of the semi-finished product made of Fig. 4 shows two components 5.1, 5.2 of the stator base 5, each manufactured in a series assembly G5.1, G5.2 by means of a separation process, in a plan view and a perspective view. Fig. 6a and Fig. 6b show a first embodiment of the spring sheet halves 4.1 3 manufactured from a semi-finished product by means of a separation process in a series assembly G4.1 in a plan view and a perspective view. Fig. 7 shows a series connection G4 of spring plates 4, which is formed from two series connections G4.1 of spring plate halves 4.1 of the first embodiment, connected by welded joints S. Fig. 8 shows the series connection G4 of spring plates 4 from Fig. 7, in which a friction element 9 is applied to each spring plate 4. Fig. 9 shows a stacked and pre-assembled arrangement of the series interconnections G4, G5.1 and G5.2 of the first embodiment. Fig. 10a and Fig. 10b show in various perspective views a stacked assembly of the series assemblies G4, G5.1, G5.2, G4 and G6, which forms a series assembly G3 of several stator frames 3 or, in conjunction with the electromechanical actuators 2 and the friction elements 9, a series assembly G1 of stators 1. Fig. 11 to 17 show the production of several stators 1 in series connection according to a second embodiment, wherein the respective stack connection of a stator frame 3 is produced by welded connections S. Fig. 11 shows a second embodiment of the spring sheet halves 4.1 manufactured from a semi-finished product by means of a separation process in a series assembly G4.1. Fig. 12a and Fig. 12b shows a second embodiment of the two components 5.1, 5.2 of the stator base 5, each manufactured from a semi-finished product by means of a separation process in a series connection G5.1, G5.2. Fig. 13 shows a series connection G4 of spring plates 4, which is formed from two series connections G4.1 of spring plate halves 4.1 of the second embodiment, connected by welded joints S. Fig. 14 shows the series connection G4 of spring plates 4 from Fig. 13, in which a friction element 9 is applied to each spring plate 4. Fig. 15a and Fig. 15b shows a stacked assembly of the series assemblies G5.1 and G5.2 of the second embodiment in various perspective views, wherein two components 5.1 and 5.2 are fixed to one another by welded joints S to form a series assembly G5 of stator bases 5. Fig. 16 shows a stacked arrangement of individual series interconnections G4, G5, G4 and G6 according to the second embodiment in an exploded view. Fig. 17a and Fig. 17b show in different views the welded joints S for producing a series connection G3 of several stator frames 3 or, in connection with the electromechanical actuators 2 and the friction elements 9, a series connection G1 of stators 1 from the Fig. 16 series connections G4, G5, G4 and G6 shown. Detailed description of the preferred embodiments

[0024] Preferred embodiments of the present invention will be described in detail below with reference to the attached figures.

[0025] Fig. 3a and Fig. 3b shows the two components 5.1, 5.2 that form a stator base 5 according to a first embodiment. In particular, Fig. 3b a support element 5.1 which is provided to support the electromechanical actuators 2, and Fig. Figure 3a shows a housing element 5.2, which is provided to surround the electromechanical actuators 2 at least in sections. The support element 5.1 is preferably rod-shaped and the housing element 5.2 is preferably U-shaped. When the two components 5.1, 5.2 are arranged in a stack, a cavity 7 is created (see Fig. 9), in which the electromechanical actuators 2 can be accommodated. The two components 5.1 and 5.2 of the stator base 5 are provided with through holes and threaded holes, respectively.

[0026] The following is based on Fig. 4 to 10 describe the manufacture of a plurality of stators 1 in a series arrangement according to a first embodiment. The first embodiment is essentially characterized in that the respective stacked assembly of a stator frame 3 is manufactured using connecting means, such as screws.

[0027] Fig. 4a and Fig. 4b show a flat semi-finished product already provided with through holes or threaded holes, which is used to manufacture the stator base 5 having two components 5.1, 5.2 according to Fig. 3 is used. The semi-finished product is in particular a plate-shaped element of constant thickness, which preferably extends in a plane and is made of metal.

[0028] As can be seen from the different views in Fig. 5a and Fig. 5b, a series assembly G5.1 of support elements 5.1 and a series assembly G5.2 of housing elements 5.2 are manufactured from the aforementioned semi-finished product using a separation process. The individual support elements 5.1 are arranged next to one another in the series assembly G5.1, with two support elements 5.1 being integrally connected via a common connecting section, which is designed, for example, as a material web. The individual housing elements 5.2 in the series assembly G5.2 are connected to one another in the same way. Because the series assembly G5.1 of support elements 5.1 and the series assembly G5.2 of housing elements 5.2 are manufactured from the same semi-finished product, the individual support elements 5.1 and housing elements 5.2 have the same thickness, which is preferred. Of course, the series assembly G5.1 and G5.1 can also be manufactured from different semi-finished products, possibly with different thicknesses.

[0029] Fig. 6a and Fig. 6b show various views of a series assembly G4.1 of spring sheet metal halves 4.1 according to the first embodiment. The series assembly G4.1 of spring sheet metal halves 4.1 is also manufactured from a flat semi-finished product, preferably a plate-shaped element made of metal or a sheet metal by means of a separation process. Analogous to the series assemblies G5.1 and G5.2, the individual spring sheet metal halves 4.1 in the series assembly G4.1 are arranged next to one another, with two spring sheet metal halves 4.1 being integrally connected via a common connecting section, which is designed, for example, as a material web. Each spring sheet metal half 4.1 is also provided with through-holes. Preferably, the spring sheet metal halves 4.1 are manufactured from a thinner semi-finished product than the components 5.1 and 5.2 of the stator base 5. As in Fig. As shown in Figure 7, to form a series assembly G4 of spring sheets 4, two series assemblies G4.1 of spring sheet halves 4.1 are welded together. The two series assemblies G4.1 are not stacked congruently to one another, but rather one series assembly G4.1 is rotated 180° around the longitudinal axis with respect to the other series assembly G4.1. The welded joints S are preferably placed at the connecting sections of the series assemblies G4.1, at which two spring sheet halves 4.1 are connected to one another. Fig. 8 shows the series connection G4 of spring plates 4 from Fig. 7, in which a friction element 9 is applied to each spring plate 4. The friction elements 9, which are hemispherical in the present embodiment, can be attached to the spring plates 4 using epoxy resin, whereby the position of the friction elements can be predetermined by a recess in the corresponding spring plate half 4.1.

[0030] Fig. Figure 9 shows a stacked arrangement of the series assemblies G4, G5.1, and G5.2. The individual series assemblies G4, G5.1, and G5.2 can be preassembled in a stacked assembly using screws that penetrate the through-holes of the spring plates 4 and the support elements 5.1 and are screwed into the threaded holes of the housing elements 5.2. The screws are not visible in this view because the screw heads are located on the side of the series assemblies G4 of the spring plates 4. The electromechanical actuators 2 are then inserted into the cavity 7 of each stator base 5 and secured to the respective support element 5.1 using epoxy resin.

[0031] As can be seen from the Fig. 10a and Fig. 10b, the stack assembly is finally completed using a further series assembly G4 of spring plates 4 and a series assembly G6 of flat springs 6 and further screws, so that a series assembly G3 of stator frames 3 or a series assembly G1 of stators 1 is produced. Since electromechanical actuators 2 have already been accommodated in the individual stator frames 3 and a friction element 9 is attached to each stator frame 3, this step not only creates a series assembly G3 of stator frames 3, but simultaneously a series assembly G1 of stators 1. Epoxy resin is also applied to the upper side of the electromechanical actuators 2 in order to create a firm connection to the spring plate 4 located above them. In the stack assembly of a stator frame 3, the stator base 5, which has two components 5.1, 5.2, is therefore arranged between two spring plates 4.The spring plates 4 essentially serve to connect the stator 1 to a higher-level structure. A flat spring 6 is preferably arranged on the spring plate 4 equipped with the friction element 9 and serves to apply a preload force to the electromechanical actuators 2. Analogous to the series connections G4, G5.1, and G5.2, the individual flat springs 6 in the series connection G6 are arranged next to one another, with two flat springs 6 being integrally connected via a common connecting section (see ). Fig. 16). The individual flat springs 6 are also provided with through holes. Finally, the series connection G1 of the stators 1 is separated at the respective connection points of the individual series connections G4, G5.1, G5.2, G4, and G6 by a separation process, i.e., the individual stators 1 are separated from each other.

[0032] Fig. 11 to 17 show the production of several stators 1 in series connection according to a second embodiment, wherein the second embodiment is essentially characterized in that the respective stack connection of a stator frame 3 is produced by welded connections S. Except for the difference that the stack connection in the method according to Fig. 11 to 17 is manufactured by welding S instead of screw connections, the manufacture of the stators 1 is basically identical to that described in the Fig. 4 to 10. Therefore, the differences will be discussed below.

[0033] Like the Fig. 11 and Fig. 12, the individual components 4.1, 5.1 and 5.2 in the series connections G4.1, G5.1 and G5.2 according to the second embodiment can have a slightly different shape than the components known from the first embodiment (cf. Fig. 5 and Fig. 6), but are also manufactured from a flat semi-finished product using a separation process. In particular, the components for the second embodiment do not require threaded holes. Instead, the individual components are provided with holes or recesses where they can be easily welded.

[0034] Fig. Figure 13 shows preferred positions of the welded joints S for producing a series assembly G4 of spring plates 4 from two series assemblies G4.1 of spring plate halves 4.1 according to the second embodiment. The preferred positions of the welded joints S are shown only on one spring plate 4 in the series assembly G4, but apply analogously to all spring plates 4 in the series assembly G4. Fig. 14 shows analogous to Fig. 8 the series assembly G4 of spring plates 4, in which a friction element 9 is applied to each spring plate 4.

[0035] Fig. 15a and Fig. 15b shows preferred positions of the welded joints S for producing a series assembly G5 of stator bases 5 from a series assembly G5.1 of support elements 5.1 and a series assembly G5.2 of housing elements 5.2 according to the second embodiment. The preferred positions of the welded joints S are shown only on one stator base 5 in the series assembly G5, but apply analogously to all stator bases 5 in the series assembly G5.

[0036] Fig. Figure 16 shows an exploded view of the series assemblies G4, G5, G4, and G6 in the arrangement as they will subsequently be welded to form a stacked assembly. The electromechanical actuators are already inserted into the cavities 7 of the stator bases 5.

[0037] Fig. 17a and Fig. 17b show preferred positions of the welded joints S for producing a series connection G3 of several stator frames 3 or a series connection G1 of several stators 1 from the Fig. 16 series connections G4, G5, G4 and G6 shown.

[0038] In the above description, the production of a stator 1 was described by producing a series connection G1 of several stators 1 and subsequently dissolving this series connection by separating the individual stators 1 from one another. However, the present invention is not limited to this type of production. In particular, a single stator 1 can also be produced independently of other stators 1 by forming a stator frame 3 from a stack of individual independent components 4, 5.1, 5.2, 4, 6 and equipping it with electromechanical actuators 2 and a friction element 9.

[0039] Furthermore, the series configurations disclosed in the above description are each formed, by way of example, by three components arranged side by side. It goes without saying that the respective series configurations can comprise any number of components, as long as the individual series configurations remain easy to handle for the production of the stators.

[0040] The separation process for producing the individual components from the flat semi-finished product can be any two-dimensional separation process. Preferably, it is a laser cutting process, a water jet cutting process, or an electrical discharge machining process. The same applies to the separation process used to separate the individual stators 1 from the series assembly G1. List of reference symbols 1 stator 2 electromechanical actuator 3 Stator frame 4 spring plate 4.1 Spring plate half 5 Stator base 5.1 Support element 5.2 Housing element 6 flat springs 7 Cavity 8 screw 9 Friction element G1 Series connection of stators G3 Series connection of stator frames G4 Series connection of spring sheets G4.1 Series connection of spring sheet halves G5 Series connection of stator bases G5.1 Series connection of support elements G5.2 Series connection of housing elements G6 Series combination of flat springs S welded joint

Claims

[1] Method for producing at least one stator (1) for an electromechanical inertial drive, wherein the stator (1) has at least one electromechanical actuator (2) and a stator frame (3) for receiving the actuator (2), characterized by that the stator frame (3) comprises a plurality of components (4, 5.1, 5.2, 6) which are produced in a separation process from at least one flat semi-finished product and are arranged in a stack to form the stator frame (3). [2] Method according to claim 1, characterized by that the stator frame (3) comprises at least two spring plates (4) and a stator base (5) having at least two components (5.1, 5.2) which is arranged between the two spring plates (4). [3] Method according to claim 2, characterized by that an additional flat spring (6) is arranged on one of the spring plates (4). [4] Method according to one of the preceding claims, characterized bythat the components (4, 5.1, 5.2, 6) of the stator frame (3) are made from at least two different plate-shaped semi-finished products with different thicknesses. [5] Method according to one of the preceding claims, characterized by that various components of the stator frame (3) are manufactured from a common plate-shaped semi-finished product. [6] Method according to one of the preceding claims, characterized by that the stator base (5) has a cavity (7) in which the at least one electromechanical actuator (2) is inserted, and the components (5.1, 5.2) of the stator base (5) are preferably made from semi-finished products of the same thickness, particularly preferably from the same semi-finished product. [7] Method according to claim 6, characterized bythat the components of the stator base (5) are formed by a support element (5.1), on which the at least one electromechanical actuator (2) is placed, and a housing element (5.2), which surrounds the at least one electromechanical actuator (2) at least in sections, wherein the support element (5.1) is preferably rod-shaped and the housing element (5.2) is preferably U-shaped. [8] Method according to one of the preceding claims, characterized by that the components (4, 5.1, 5.2, 6) of the stator frame (3) are aligned with one another via reference means, preferably formed by through-holes and / or threaded holes, and the stack assembly is preferably fixed by connecting means, preferably screws (8) or welded joints (S). [9] Method according to one of the preceding claims, characterized bythat the cutting process is preferably a laser cutting process, a water jet cutting process or a spark erosion process. [10] Method according to one of the preceding claims, characterized by that several component groups, each formed by a series connection (G4, G5.1, G5.2, G6) of several components (4, 5.1, 5.2, 6) of the same type, are arranged in a stack connection to form several stator frames (3) in the series connection (G3). [11] Method according to claim 10 characterized by that the components (4, 5.1, 5.2, 6) in a series assembly (G4, G5.1, G5.2, G6) are manufactured integrally from a semi-finished product. [12] Method according to claim 10 or 11, characterized by that the plurality of stator frames (3) in the series connection (G3) are separated from one another in order to provide individual stator frames (3).

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