Slip ring module, rotor for a separately excited electric machine and method for manufacturing a rotor

Abstract

The invention relates to a slip ring module (SRM) for arrangement on a shaft end section (WEA) of a rotor shaft (RW), with a slip ring carrier (SRT) comprising a receiving section (ANA) for receiving a distal end section (DEA) of a shaft end section (WEA) of the rotor shaft, and a locking element (VE) for axially fixing the slip ring carrier (SRT) on the distal end section (DEA).

Description

[0001] The invention relates to a slip ring module for arrangement on a shaft end section of a rotor shaft, wherein the slip ring module can be locked to the shaft end section for axial fixation thereon. The invention also relates to a rotor for a separately excited electrical machine with the slip ring module according to the invention. Furthermore, the invention relates to a method for producing a rotor.

[0002] Slip ring modules for electrical machines are generally known. For example, DE 10 2021 123 305 A1 shows a multi-part slip ring module that is plugged into a base part and secured in the base part via a screw connection. The slip ring module design shown not only has an increased component length, since the two slip rings must protrude at the ends, but also requires increased manufacturing effort due to the multi-part design of the slip ring module with the screw connection.

[0003] An object of the invention is to provide a slip ring module with which the axial installation space of a rotor can be reduced and which can be arranged easily and inexpensively on a shaft end section of the rotor.

[0004] The problem is solved by the subject matter of the independent patent claims. Preferred developments are the subject matter of the dependent patent claims, the following description, and the drawings. Each feature shown and / or described can represent an aspect of the invention, both individually and in combination, unless explicitly stated otherwise in the description.

[0005] In a first aspect, the invention relates to a slip ring module for arrangement on a shaft end section of a rotor shaft, with a slip ring carrier having a receiving section for receiving a distal end section of a shaft end section of the rotor shaft, and a locking element for axially fixing the slip ring carrier on the distal end section.

[0006] In other words, according to the first aspect of the invention, a slip ring module is provided. The slip ring module is designed and / or constructed to be arranged on a shaft end section of a rotor shaft. The slip ring module has at least one slip ring carrier. The slip ring carrier comprises a receiving section. The receiving section is designed and / or constructed to receive a distal end section of the shaft end section. In other words, the distal end section engages in the receiving section. For this purpose, the receiving section preferably has an opening. The opening can particularly preferably be designed as an edge-closed opening. Because the distal end section engages in the slip ring carrier, the axial installation space of the rotor can preferably be reduced.Furthermore, the slip ring module features a locking element for axially securing the slip ring carrier to the distal end section. This locking element allows the slip ring module to be easily and inexpensively secured to the shaft end section in the axial direction of the rotor.

[0007] The locking element is designed and constructed in such a way that it can lock positively with a corresponding counter contour of the shaft end section.

[0008] An advantageous development of the invention is that the locking element has at least one locking hook. In other words, at least one locking hook is formed on the slip ring carrier, which can lock with a corresponding mating contour on the shaft end section. By locking the locking hook with a corresponding mating contour on the shaft end section, the slip ring module can be easily fixed to the distal end section in the axial direction of the rotor.

[0009] It is conceivable that only one locking element is provided. It is particularly advantageous to provide a plurality of locking elements. The locking elements are particularly advantageously arranged at a distance from one another. The locking elements are particularly preferably spaced from one another at regular intervals. The plurality of locking elements allows for uniform pressing of the slip ring carrier against the shaft end section over the circumference of the slip ring module.

[0010] In a preferred embodiment of the invention, the locking element is arranged on an end face of the slip ring carrier and / or projects beyond an end face of the slip ring carrier. In other words, the slip ring carrier has an end face. The end face is preferably formed by a wall of the slip ring carrier surrounding the opening of the receiving section. The locking element is formed on the end face or projects beyond this end face. If the locking element projects beyond the end face, it can preferably be provided that the locking element is formed on an outer circumferential surface of the slip ring carrier.Because the locking element is located on the end face and / or extends beyond the end face, the slip ring module can easily lock into the mating contour when plugged onto the shaft end section and upon reaching a final position on the shaft end section. Furthermore, the arrangement of the locking element does not increase the installation space in the axial direction of the rotor.

[0011] It is conceivable that the locking element is formed separately from the slip ring carrier or is made of a different material than the slip ring carrier. This can be advantageous if different materials are to be used for the slip ring carrier and the locking element.

[0012] A preferred embodiment of the invention is that the locking element is formed integrally with the slip ring carrier. In other words, the locking element and the slip ring carrier are inseparably connected to one another in a single manufacturing process and also comprise the same material. It is conceivable that the slip ring carrier and the locking element are manufactured in a single injection molding process.

[0013] In a preferred embodiment of the invention, the slip ring carrier is formed from an electrically insulating material. It is conceivable that the electrically insulating material comprises a plastic material. The plastic material can preferably be a thermoplastic or a thermosetting plastic. In this way, the slip ring carrier can be manufactured simply and inexpensively, preferably by means of an injection molding process.

[0014] According to an advantageous development of the invention, the slip ring carrier has a conductor feedthrough opening adjacent to and connected to the receiving section. The conductor feedthrough opening is preferably arranged directly on the receiving section and has a smaller cross-section or diameter than the receiving section. The conductor feedthrough opening is preferably designed with a closed edge. In other words, if the slip ring carrier is plugged onto the shaft end section and the distal end section engages in the receiving section of the slip ring carrier, an electrically conductive connecting element extending through the shaft end section can be guided through the conductor feedthrough opening. Furthermore, the transition between the receiving section and the conductor feedthrough opening can function as a stop for the distal end section.

[0015] A preferred embodiment of the invention is that a rotation-locking contour is formed in the receiving section, preferably on an inner circumferential surface of the receiving section. The rotation-locking contour enables a positive fixation of the slip ring module on the shaft end section in one direction of rotation of the rotor or the slip ring module.

[0016] In an advantageous development of the invention, the slip ring carrier comprises a slip ring and a connecting wire connected to the slip ring, wherein the connecting wire is guided into a connecting region of the slip ring carrier in order to be electrically conductively connected in the connecting region to a connecting element guided through the conductor feedthrough opening. Preferably, the connecting region has an access opening on a side facing away from the receiving section, through which access opening a connecting device, in particular a welding device, can be guided towards the connecting wire in order to connect it to the connecting element in a materially bonded and electrically conductive manner. This enables an electrically conductive connection between the connecting wire and the connecting element in a simple and inexpensive manner.

[0017] The connecting element is usually electrically connected to a rotor winding on a side facing away from the connecting wire.

[0018] An advantageous embodiment of the invention is that a plurality of slip rings are arranged in the slip ring carrier, wherein a first slip ring is formed at the level of the receiving section and a second slip ring is formed at the level of the connecting region. In other words, two slip rings are provided. The first slip ring is arranged in the region of the receiving section with respect to an axial direction of the slip ring module or the shaft end section. With respect to a radial direction of the slip ring module, the first slip ring is arranged at a distance from the receiving section. This arrangement can reduce the axial installation space of the rotor because the first slip ring is arranged on the shaft end section and not adjacent to the shaft end section. The second slip ring is arranged at the level of the connecting region with respect to the axial direction of the slip ring module.

[0019] The first slip ring and the second slip ring preferably have the same outer diameter. This allows for even wear of the brushes, since both slip rings have the same peripheral speed on the outside of the slip ring when the rotor, and thus the slip ring module, rotates.

[0020] In a second aspect, the invention relates to a rotor with the slip ring module according to the invention, comprising a shaft end section, with an electrically conductive connecting element guided through the shaft end section, wherein the shaft end section has a distal end section which engages in the receiving section of the shaft end section, and a locking section is formed on the shaft end section, with which the locking element locks for axially fixing the slip ring module on the shaft end section.

[0021] In other words, according to the second aspect of the invention, a rotor is provided. The rotor is preferably designed to be arranged in a traction drive of an electric machine for a motor vehicle. Typically, the rotor has a rotor shaft on which a laminated core with a salient pole is arranged. A rotor winding is wound on the salient pole.

[0022] The rotor shaft comprises a shaft end section. An electrically conductive connecting element is guided through the shaft end section. The connecting element is preferably electrically conductively connected to the rotor winding at a first free end.

[0023] The slip ring module according to the invention is plugged onto a distal end section of the shaft end section. In other words, the distal end section engages the receiving section of the slip ring module. The slip ring module is preferably plugged onto the distal end section by a translational movement in the longitudinal direction of the rotor, with the receiving section first. A locking section is formed on the shaft end section, with which the locking element of the slip ring module locks to axially fix the slip ring module on the shaft end section. In this way, a rotor is provided which can have a reduced installation space in terms of axial length and can be easily fixed to the shaft end section in the axial direction of the rotor.

[0024] In principle, a merely positive axial fixation of the slip ring module on the shaft end section may be sufficient. It is conceivable, and not impossible, that in addition to the positive fixation via the locking element and the locking section, a material connection, in particular an adhesive connection, is provided to permanently and captively connect the slip ring module to the shaft end section.

[0025] It is conceivable that the locking section is formed only in some areas on an outer surface of the shaft end section.

[0026] Alternatively, a preferred embodiment of the invention provides for the locking section to be circumferential. In particular, the locking section is formed as a projection on the outer surface of the shaft end section or as an undercut, i.e., as a circumferential groove or channel, in the outer surface of the shaft end section. In this way, the locking section can be easily manufactured by a turning and / or milling process.

[0027] In an advantageous development of the invention, it is provided that the locking section is ramp-shaped on a side facing the distal end section and / or the slip ring module. In other words, a cross-section of the locking section increases in a direction in which the slip ring module is plugged onto the shaft end section. When the slip ring module is plugged onto the distal end section, the ramp-shaped contour deflects the locking element, preferably slightly in the radial direction of the slip ring module, in order to then engage behind the locking section in the final position on the shaft end section. This allows for simple locking of the locking element and the locking section.

[0028] In a preferred embodiment of the invention, the locking section is formed integrally with the shaft end section. In this way, the locking section can be manufactured simply and inexpensively, preferably by an additive or machining process.

[0029] An advantageous development of the invention is that an electrically conductive connecting element extends through the shaft end section, is guided through the conductor feedthrough opening into the connection area, and is electrically connected to the connecting wire of the slip ring module in the connection area. The first free end of the connecting element is preferably electrically conductively connected to a rotor winding. A second free end, spaced apart from the first free end, is electrically conductively connected to the connecting wire of the slip ring module.

[0030] The electrically conductive connection between the connecting element and the connecting wire is preferably a material connection, in particular a welded connection.

[0031] In a preferred embodiment of the invention, a counter-contour corresponding to the anti-rotation contour is formed on an outer surface of the distal end section, and when the slip ring module is plugged onto the shaft end section, the anti-rotation contour engages the counter-contour. This enables a rotation-proof arrangement of the slip ring module on the shaft end section.

[0032] The anti-rotation contour and the counter-contour are preferably designed as a tongue-and-groove connection. This allows for a cost-effective and simple anti-rotation contour and counter-contour.

[0033] In a third aspect, the invention relates to a method for producing the rotor according to the invention, comprising the steps: - Providing a rotor shaft having a shaft end section; - Providing a slip ring module having a slip ring carrier; - Attaching the slip ring module to a distal end portion of the shaft end portion, wherein the distal end portion engages in a receiving portion of the slip ring carrier; - Locking a locking element of the slip ring carrier with a locking section of the shaft end section for axially fixing the slip ring module on the shaft end section.

[0034] In this way, a method is provided with which a rotor can be manufactured which can have a reduced axial installation space and also enables an axial fixation of the slip ring module on the shaft end section in a simple manner.

[0035] An advantageous development of the invention provides for the slip ring module to be attached to the shaft end section by means of a translational and / or linear displacement or movement. In this way, the slip ring module can also be easily attached to the shaft end section by machine.

[0036] According to an advantageous development of the invention, an electrically conductive connecting element is guided through the shaft end section, and when the slip ring module is plugged onto the distal end section, the connecting element is guided through a conductor feedthrough opening in the slip ring carrier into a connection area. In this way, the connecting element can be easily guided into a region of the slip ring module when the slip ring module is plugged onto the shaft end section, in order to later be electrically connected to the slip rings via the connecting wire.

[0037] In this context, a preferred development of the invention provides that, after the slip ring module has been plugged into the final position on the shaft end section and fixed in the axial direction, the connecting element is materially connected to a connecting wire of the slip ring module.

[0038] Finally, an advantageous embodiment of the invention is that, for the integral connection, a welding diode of a welding device is guided into the connection area via an access opening formed in the slip ring carrier. This allows the electrically conductive connection to be implemented in a simple and cost-effective manner.

[0039] It should be noted that all features described above and below with respect to one aspect of the present invention equally apply to any other aspect of the present invention. In particular, all features of the slip ring module can equally apply to the rotor and / or the method for manufacturing the rotor. This also applies vice versa.

[0040] Further features and advantages of the present invention emerge from the dependent claims and the following exemplary embodiments. The exemplary embodiments are not restrictive, but rather to be understood as examples. They are intended to enable the skilled person to implement the invention. The applicant reserves the right to make individual and / or several of the features disclosed in the exemplary embodiments the subject of patent claims or to incorporate such features into existing patent claims. The exemplary embodiments are explained in more detail with reference to drawings.

[0041] In these show: Fig. 1 a longitudinal section through a shaft end section of a rotor with a slip ring module arranged thereon; Fig. 2 a method for manufacturing a rotor.

[0042] In Fig. Figure 1 shows a longitudinal section through a shaft end section WEA of a rotor RO with a slip ring module SRM arranged thereon. The rotor RO is designed and / or configured to be arranged in a traction drive of a motor vehicle, in particular an at least partially or fully electrically powered motor vehicle.

[0043] The slip ring module SRM has at least one slip ring carrier SRT. The slip ring carrier SRT comprises a receiving section ANA. The receiving section ANA is configured and / or designed to receive a distal end section DEA of the shaft end section WEA. In other words, the distal end section DEA engages in the receiving section ANA. For this purpose, the receiving section ANA has an opening OE. The opening OE is designed as a closed-edge opening OE. Because the distal end section DEA engages in the slip ring carrier SRT, the axial installation space of the rotor RO can be reduced.

[0044] Furthermore, the slip ring module SRM has a locking element VE for axially fixing the slip ring carrier SRT on the distal end section DEA. In the present exemplary embodiment, the locking element VE is arranged on an end face SS of the slip ring carrier SRT. The end face SS is formed by a wall WA of the slip ring carrier SRT surrounding the opening OE of the receiving section ANA and faces a laminated core BP arranged on the rotor shaft RW. A locking section VA corresponding to the locking element VE is formed on the distal end section DEA of the shaft end section WEA.The locking element VE locks and / or engages with the locking section VA as soon as the slip ring module SRM is plugged onto the distal end section DEA, preferably via a translational movement in the longitudinal direction of the rotor RO with the receiving section ANA first, and reaches an end position on the distal end section DEA.

[0045] The locking section VA has a ramp-shaped contour or is ramp-shaped on a side facing the distal end section DEA and / or the slip ring module SRM. In other words, a cross-section of the locking section VA increases in a plug-on direction of the slip ring module SRM onto the shaft end section WEA. When the slip ring module SRM is plugged onto the distal end section DEA, the locking element VE is preferably slightly deflected in the radial direction of the slip ring module SRM via the ramp-shaped contour in order to then engage behind the locking section AV in the final position on the shaft end section WEA. In this way, locking between the locking element VE and the locking section VA can be achieved in a simple manner.

[0046] It can also be seen that the slip ring carrier SRT has a conductor feed-through opening LDO adjacent to and connected to the receiving section ANA. The conductor feed-through opening LDO is arranged directly next to the receiving section ANA and has a smaller cross-section or diameter than the receiving section ANA. The conductor feed-through opening LDO is designed with a closed edge. A wall surrounding the conductor feed-through opening LDO is thus an intermediate wall ZW of the slip ring carrier SRT. Due to the reduced diameter and / or cross-section of the conductor feed-through opening LDO compared to the receiving section ANA, the intermediate wall ZW can serve as a stop for the distal end section DEA for the axial fixation of the slip ring module SRM on the shaft end section WEA.

[0047] The slip-ring carrier SRT has at least one slip ring SR and a connecting wire VD connected to the slip ring SR, wherein the connecting wire VD is guided into a connecting region VB of the slip-ring carrier SRT. The connecting region VB is arranged and / or formed adjacent to the conductor lead-through opening LDO. Preferably, the connecting wire VD extends at least partially through the intermediate wall ZW. In the connecting region VB, the connecting wire VD preferably runs parallel to a longitudinal axis LA of the rotor RO or the slip-ring module SRM.

[0048] A connecting element VBE is guided through the shaft end section WEA. The connecting element VBE is designed and / or configured to be electrically connected to a rotor winding of the rotor RO on the one hand and to the connecting wire VD on the other. Preferably, the connecting element VBE runs parallel to the longitudinal axis LA of the rotor RO.

[0049] The connecting element VBE is preferably arranged in the shaft end section WEA via a potting body VK. The connecting element VBE is further guided through the conductor feed-through opening LDO into the connecting area VB. In the connecting area VB, the connecting element VBE is electrically connected to the connecting wire VD. For this purpose, the connecting area VB has an access opening ZOE on a side facing away from the receiving section ANA, through which a connecting device, in particular a welding device, can be guided towards the connecting wire VD in order to connect it to the connecting element VBE in a materially bonded and electrically conductive manner. This enables an electrically conductive connection between the connecting wire VD and the connecting element VE to be made in a simple and inexpensive manner.

[0050] The slip ring module SRM has a plurality of slip rings SR arranged in the slip ring carrier SRT. A first slip ring SR is formed at the level of the receiving section ANA and a second slip ring SR is formed at the level of the connection area VB. In other words, two slip rings are provided. The first slip ring SR is arranged in the area of ​​the receiving section ANA with respect to an axial direction of the slip ring module SRM or the shaft end section WEA. With respect to a radial direction of the slip ring module SRM, the first slip ring SR is arranged at a distance from the receiving section ANA. This arrangement allows the axial installation space of the rotor RO to be reduced because the first slip ring SR is arranged on the shaft end section WEA and not adjacent to the shaft end section WEA in the axial direction of the rotor RO.The second slip ring SR is arranged at the level of the connection area VB with respect to the axial direction of the slip ring module SRM.

[0051] Fig. Figure 2 shows a method for manufacturing the rotor RO. The method provides that, in a first step 100, the rotor RO is provided with the rotor shaft RW, wherein the rotor shaft RW has the shaft end section WEA with the distal end section DEA in the axial direction. The locking section VA is formed on the shaft end section WEA of the rotor shaft RW.

[0052] In a second step 110, the slip ring module SRM is provided. The slip ring module SRM comprises the slip ring carrier SRT, at least the slip ring SR arranged in the slip ring carrier SRT, and the connecting wire VD connected to the slip ring SR. Furthermore, the slip ring carrier SRT comprises at least the receiving section ANA for receiving the distal end section DEA.

[0053] In a third step 120, the slip ring module SRM is plugged onto the distal end section DEA of the shaft end section WEA, preferably via a translational movement, so that the distal end section DEA engages the receiving section ANA. Due to the fact that the distal end section DEA engages the shaft end section WEA and a slip ring SR of the slip ring carrier SRT is preferably arranged at the level of the receiving section ANA with respect to the longitudinal direction of the shaft end section WEA, the axial installation space of the rotor RO can be reduced.

[0054] In a fourth step 130, the locking element VE of the slip ring carrier SRT engages with the locking section VA of the shaft end section WEA for axially fixing the slip ring module SRM on the shaft end section WEA. Furthermore, it can be provided that an axial end of the distal end section DEA also abuts against the intermediate wall ZW of the conductor lead-through opening LDO. 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] DE 10 2021 123 305 A1

[0002]

Claims

[1] Slip ring module (SRM) for arrangement on a shaft end section (WEA) of a rotor shaft (RW), with a slip ring carrier (SRT), which a receiving section (ANA) for receiving a distal end section (DEA) of a shaft end section (WEA) of the rotor shaft (RW), and a locking element (VE) for axially fixing the slip ring carrier (SRT) on the distal end section (DEA). [2] Slip ring module according to claim 1, characterized by that the locking element (VE) has at least one locking hook. [3] Slip ring module according to one of the preceding claims, characterized by that the locking element (VE) is arranged on an end face (SS) of the slip ring carrier (SRT) and / or projects beyond an end face (SRT) of the slip ring carrier (SRT). [4] Slip ring module according to one of the preceding claims, characterized by that the locking element (VE) is formed integrally with the slip ring carrier (SRT). [5] Slip ring module according to one of the preceding claims, characterized by that the slip ring carrier (SRT) is made of an electrically insulating material. [6] Slip ring module according to one of the preceding claims, characterized by that the slip ring carrier (SRT) has a conductor lead-through opening (LDO) adjacent to and connected to the receiving section (ANA). [7] Slip ring module according to one of the preceding claims, characterized by that a rotation-locking contour is formed in the receiving section (ANA), preferably on an inner circumferential surface of the receiving section (ANA). [8] Slip ring module according to one of the preceding claims, characterized bythat the slip ring carrier (SRT) has a slip ring (SR) and a connecting wire (VD) connected to the slip ring (SR), wherein the connecting wire (VD) is guided into a connecting region (VB) of the slip ring carrier (SRT) in order to be electrically conductively connected in the connecting region (VB) to a connecting element (VBE) guided through the conductor lead-through opening (LDO). [9] Slip ring module according to claim 8, characterized in that a plurality of slip rings (SR) are arranged in the slip ring carrier (SRT), wherein a first slip ring (SR) at the level of the receiving section (ANA) and a second slip ring (SR) is formed at the level of the connection area (VB). [10] Rotor (RO) with a slip ring module (SRM) according to one of the preceding claims, comprising a shaft end section (WEA), with an electrically conductive connecting element (VBE) guided through the shaft end section (WEA), wherein the shaft end section (WEA) has a distal end section (DEA) which engages in the receiving section (ANA) of the shaft end section (WEA), and a locking section (VA) is formed on the shaft end section (WEA), with which the locking element (VE) locks for axially fixing the slip ring module (SRM) on the shaft end section (WEA). [11] Rotor according to claim 10, characterized by that the locking section (VA) is designed to be circumferential. [12] Rotor according to claim 10 or 11, characterized by that the locking section (VA) is ramp-shaped on a side facing the distal end and / or the slip ring module (SRM). [13] Rotor according to one of claims 10 to 12, characterized bythat the locking section (VA) is formed integrally with the shaft end section (WEA). [14] Rotor according to one of claims 10 to 13, characterized by that an electrically conductive connecting element (VBE) runs through the shaft end section (WEA), which is guided through the conductor feed-through opening (LDO) into the connection area (VB) and is electrically conductively connected to the connecting wire (VD) of the slip ring module (SRM) in the connection area (VB). [15] Rotor according to one of claims 10 to 14, characterized by that a counter-contour corresponding to the anti-rotation contour is formed on an outer surface of the distal end section (DEA) and when the slip ring module (SRM) is plugged onto the shaft end section (WEA), the anti-rotation contour engages in the counter-contour. [16] A method for producing a rotor RO) according to any one of claims 10 to 15, comprising the steps: - Providing a rotor shaft (RW) having a shaft end section (WEA); - Providing a slip ring module (SRM) having a slip ring carrier (SRT); - Plugging the slip ring module (SRM) onto a distal end section (DEA) of the shaft end section (WEA), wherein the distal end section (DEA) engages in a receiving section (ANA) of the slip ring carrier (SRT); - Locking a locking element (VE) of the slip ring carrier (SRT) with a locking section (VA) of the shaft end section (WEA) for axially fixing the slip ring module (SRM) on the shaft end section (WEA). [17] Method according to claim 16, wherein the slip ring module (SRM) is attached to the shaft end section (WEA) by a translational and / or rectilinear displacement. [18] Method according to claim 16 or 17, characterized bythat an electrically conductive connecting element (VBE) is guided through the shaft end section (WEA), and when the slip ring module (SRM) is plugged onto the distal end section (DEA), the connecting element (VBE) is guided through a conductor feed-through opening (LDO) of the slip ring carrier (SRT) into a connection area (VB). [19] Method according to claim 18, characterized by that after the slip ring module (SRM) has been plugged into the final position on the shaft end section (WEA) and fixed in the axial direction, the connecting element (VBE) is materially connected to a connecting wire (VD) of the slip ring module (SRM). [20] Method according to claim 19, characterized by that for the material connection, a welding diode of a welding device is guided into the connection area (VB) via an access opening ZOE of the connection report VB formed in the slip ring carrier (SRT).

Images