Axial flux machine for a motor vehicle and method for assembling such an axial flux machine

Abstract

The invention relates to an axial flux machine (10) for a motor vehicle, comprising at least one stator (12b), at least two rotors (14b, c) which are rotationally fixed to a rotor shaft (16) common to the rotors (14b, c) of the axial flux machine (10), and a housing device (22) which forms at least one axial contact surface (42c) against which the stator (12b) rests in the axial direction of the axial flux machine (10), wherein the housing device (22) has two separately formed and interconnected housing half-shells (44, 46) whose separating surfaces (48, 50), via which the housing half-shells (44, 46) are at least indirectly assembled and at least indirectly supported against each other, extend in a respective separating plane which runs in the axial direction of the axial flux machine (10).

Description

[0001] The invention relates to an axial flux machine for a motor vehicle. Furthermore, the invention relates to a method for assembling such an axial flux machine.

[0002] DE 10 2020 122 249 A1 discloses an electrical machine arrangement, comprising an electric machine for driving an electrically powered motor vehicle.

[0003] The object of the present invention is to provide an axial flux machine for a motor vehicle and a method for assembling such an axial flux machine, so that a particularly advantageous design of the axial flux machine can be realized.

[0004] This problem is solved by an axial flux machine with the features of claim 1 and by a method with the features of claim 8. Advantageous embodiments with expedient further developments of the invention are specified in the remaining claims.

[0005] A first aspect of the invention relates to an axial flux machine for a motor vehicle, also referred to simply as a vehicle. This means that the motor vehicle, preferably designed as a motor vehicle, in particular as a passenger car, in its fully manufactured state, has the axial flux machine and can be driven electrically by means of the axial flux machine, in particular purely electrically. The axial flux machine is also referred to as an electric axial flux machine and is an electrical machine. The axial flux machine is also referred to as an axial flux motor (AFM). Preferably, the axial flux machine is a high-voltage component whose electrical voltage, in particular its operating or rated voltage, is preferably greater than 50 volts, in particular greater than 60 volts, and most preferably several hundred volts.The axial flux machine comprises a stator and two rotors, also referred to as rotor elements, which are non-rotatably connected to a common rotor shaft of the axial flux machine, particularly via a radial shaft connection. Each rotor is thus designed separately from the rotor shaft and non-rotatably connected to it. The rotors are therefore designed separately from one another, with the rotors being non-rotatably connected to each other, particularly exclusively, via the rotor shaft. The rotors form, in particular, a complete rotor, which also includes the rotor shaft. The complete rotor can be driven by means of the stator and is thus rotatable about a machine axis of rotation relative to the stator. Thus, the rotors and the rotor shaft are rotatable about the machine axis of rotation relative to the stator of the axial flux machine, the axial direction of which coincides with the machine axis of rotation.The axial flux machine, whose radial direction is perpendicular to the axial direction of the axial flux machine and thus perpendicular to the machine's axis of rotation, also has a housing assembly, wherein the rotors and the rotor shaft, in particular the complete rotor, are rotatable about the machine's axis of rotation relative to the housing assembly. In particular, the respective rotor is at least partially arranged in the housing assembly. For example, the rotor shaft is at least partially arranged in the housing assembly. For example, the stator is at least partially arranged in the housing assembly. In particular, it is provided that the stator is designed separately from the housing assembly and is rotationally fixed to the housing assembly. In particular, the stator is connected to the housing assembly in such a way that translational relative movements between the stator and the housing assembly in the axial direction of the axial flux machine are prevented.Preferably, the respective rotor is connected to the rotor shaft in such a way that translational relative movements between the respective rotor and the rotor shaft (also simply referred to as the shaft) in the axial direction of the rotor shaft, and thus in the axial direction of the axial flux machine, are prevented. For example, the axial flux machine can provide drive torques via the rotor shaft for, in particular, purely electric propulsion of the motor vehicle. For example, the respective rotor is designed in a disk shape, at least in a respective partial area, so that the respective rotor is designed, for example, as a respective rotor disk.

[0006] It is most preferably provided that the stator is arranged at least partially between the rotors in the axial direction of the axial flux machine, whereby at least a part of the stator is arranged between the rotors in the axial direction of the axial flux machine in such a way that a first of the rotors, viewed in a first viewing direction parallel to the axial direction of the axial flux machine and extending from the first rotor to a second of the rotors, is at least partially overlapped, i.e. covered, by the part of the stator, and that the second rotor, viewed in a second viewing direction parallel to the axial direction of the axial flux machine and extending from the second rotor to the first rotor and opposite to the first viewing direction, is at least partially overlapped, i.e. covered, by the part of the stator.The axial direction of the axial flux machine, whose circumferential direction runs around the axial direction of the axial flux machine and thus around the machine's axis of rotation, is perpendicular to the radial direction of the axial flux machine. When the radial direction is mentioned before and after, this refers, unless otherwise specified, to the radial direction of the axial flux machine. Furthermore, "axial" means the axial direction, and "radial" means the radial direction.

[0007] For example, the stator has a through-hole, particularly a central one, into which, viewed in a plane perpendicular to the axial direction, the rotor is arranged at least substantially circularly and / or coaxially with the machine's axis of rotation. The through-hole is, for example, penetrated by the length of the entire rotor, particularly in the axial direction and / or completely. For example, the length is partially formed by the first rotor and partially by the second rotor. Furthermore, the length is, for example, penetrated by the rotor shaft, particularly in the axial direction and / or completely. For example, the rotor shaft is designed as a hollow shaft at least over a length of its length, particularly along its entire axial length.

[0008] For example, the housing assembly, in particular an inner circumferential surface of the housing assembly, defines a receiving space, in particular directly, wherein, for example, the respective rotor and / or the rotor shaft and / or the stator is arranged, in particular at least partially, in the receiving space and thus in the housing assembly. The housing assembly forms at least one axial contact surface against which the stator rests in the axial direction, in particular directly, whereby, for example, the stator is positioned axially relative to the housing assembly, which is also simply referred to as the housing. The aforementioned axial contact surface is also referred to as the first axial contact surface. When the contact surface is mentioned above and below, unless otherwise specified, this refers to the first axial contact surface.For example, the housing assembly has several axial contact surfaces, namely the first contact surface and at least or exactly one further, second contact surface, wherein, for example, the stator rests against the contact surfaces in the axial direction, in particular directly. Thus, the housing assembly forms the axial contact surfaces.

[0009] The housing assembly comprises, in particular, at least or exactly, two separately formed and interconnected housing half-shells, also referred to as half-shell housing parts, whose separating surfaces, via which the housing half-shells are at least indirectly joined and at least indirectly supported against each other, extend in a respective separating plane running in the axial direction. In particular, when the separating surfaces are in direct contact with each other, i.e., directly supported against each other, so that the housing half-shells are then directly joined and directly supported against each other via the separating surfaces, the separating planes coincide.If, for example, the separating surfaces are supported against each other by means of at least one element formed separately from the housing halves and arranged between the separating surfaces, such that the housing halves are indirectly joined and supported against each other via the element, then the interfaces and thus the separating planes are spaced apart from each other, with the separating planes running parallel to each other. The element can, for example, be a sealing element, which is formed, for example, from an elastomer, so that, for example, the housing halves are sealed against each other by means of the sealing element. In particular, when the separating surfaces are in direct contact with each other, the separating planes coincide, and preferably the separating planes coincide with the machine's axis of rotation, which thus runs in the respective separating plane.For example, if the separating surfaces are indirectly supported against each other, for instance via the element, the separating planes are spaced apart from one another, in particular such that the respective separating plane is spaced away from the machine's axis of rotation and runs parallel to it. Furthermore, it would be conceivable for the separating surfaces to be in direct contact with each other, in which case the respective separating plane is spaced away from the machine's axis of rotation and runs parallel to it. Since the housing assembly comprises the housing half-shells, each housing half-shell partially, and in particular partially, delimits the receiving space, so that the receiving space is partially, and in particular directly, delimited by the respective housing half-shell. In particular, each housing half-shell thus forms a respective part, in particular a respective half, of the aforementioned inner circumferential surface.The invention enables a particularly advantageous design for the axial flux machine, allowing for particularly simple and therefore time- and cost-effective assembly and manufacturing. Furthermore, a modular design of the axial flux machine is possible, enabling, for example, the easy implementation of different performance levels. Additionally, the axial flux machine can be manufactured with a significantly reduced number of parts.

[0010] Since the housing assembly, which is also referred to as the housing, comprises at least or exactly two housing halves, the housing assembly is multi-part, in particular two-part. The different power levels can be achieved, in particular, by stacking several stators and several rotors, especially in the axial direction, i.e., arranging them sequentially. In particular, the invention allows for the advantageous creation of a modular system, enabling the different power levels to be represented with a particularly small number of components. Furthermore, a large number of identical components can be implemented, making the different power levels simple and cost-effective to represent.

[0011] One of the housing halves is, for example, an upper shell, while the other housing half is, for example, a lower shell. In particular, it is conceivable that, in the installed position of the axial flux machine, which assumes its installed position in the fully manufactured state of the motor vehicle containing the axial flux machine, the housing halves are arranged successively in the vehicle's vertical direction, especially such that the upper shell is positioned higher than the lower shell in the vehicle's vertical direction, and thus the lower shell is positioned lower than the upper shell in the vehicle's vertical direction. The contact surface is also referred to as the housing contact surface and enables simple and precise positioning of the housing, particularly relative to the housing assembly. Furthermore, the multi-part, especially two-part, housing assembly is suitable for advantageous overall integration.

[0012] In an advantageous embodiment of the invention, the contact surface is machined by machining, in particular by milling. This allows the stator to be positioned and thus aligned particularly precisely and easily relative to the housing.

[0013] To achieve a particularly advantageous design of the axial flux machine, a further embodiment of the invention provides that the stator, which is formed separately from the housing assembly, is screwed to the housing assembly by means of at least one screw element, which is formed separately from both the housing assembly and the stator, and is thereby connected to the housing assembly, in particular such that the stator is rotationally fixed to the housing assembly and preferably such that translational relative movements in the axial direction between the stator and the housing assembly are prevented. This allows the axial flux machine to be assembled and thus manufactured in a particularly time- and cost-effective manner. Furthermore, this enables a particularly advantageous modular design of the axial flux machine.

[0014] It has proven particularly advantageous if the screw element is screwed to the corresponding housing assembly from the outside. This allows the stator to be connected to the housing assembly particularly easily, especially by arranging the stator within the housing assembly. For this purpose, for example, a screwing tool is brought into torque-transmitting interaction with the screwing element in the vicinity of the housing assembly, so that the screwing element is screwed in by means of the screwing tool, thereby connecting the stator to the housing.

[0015] To enable a particularly simple and rotationally rigid connection of the respective rotor to the rotor shaft, a further embodiment of the invention provides that a respective first length section of the rotor shaft is arranged within a respective second length section of the respective rotor, such that the respective second length section is arranged on the respective first length section. Each length section has a non-circular shape when viewed in a plane perpendicular to the axial direction, specifically such that the respective first length section has a non-circular shape on its outer circumference when viewed in the respective plane, and the respective second length section has a non-circular shape on its inner circumference when viewed in the respective plane. This ensures that the respective rotor is rotationally rigidly connected to the rotor shaft.

[0016] Preferably, the respective shape, viewed in the respective plane, is a polygon or polygonal profile. Thus, the aforementioned radial shaft connection, also simply referred to as a shaft connection, which is, for example, a shaft-hub connection, comprises the described non-circular shapes, such as those formed as polygons. Alternatively or additionally, it is conceivable that the respective rotor is rotationally fixed to the rotor shaft via a splined connection, so that, for example, the radial shaft connection also features the splined connection.

[0017] To enable particularly time- and cost-effective assembly, i.e., manufacturing, of the axial flux machine, a further embodiment of the invention provides that at least one spacer element, designed separately from the rotors, the stator, and the housing, and for example also referred to as an adjusting disk, is arranged in the axial direction of the axial flux machine between the rotors. This spacer element holds at least the respective sections of the rotors at an axially extending distance from one another. For this purpose, the spacer element can be supported at least indirectly, and in particular directly, on the respective rotor in the axial direction. It is particularly conceivable that a set of adjusting disks is provided to allow the rotors to be adjusted, i.e., positioned, axially relative to one another as required.

[0018] In comparison to an axial connection, which, for example, has axial teeth arranged on mutually facing sides and interlocking, and optionally an axial screw connection, the radial shaft connection in the invention has the advantage that such an axial connection or axial toothing does not require further machining or fine-machining for final assembly and the axial final adjustment of the rotors relative to each other; only the contact surface of the housing needs to be machined. This allows for time- and cost-effective assembly and manufacturing of the axial flux machine.

[0019] A second aspect of the invention relates to a method for assembling an axial flux machine according to the first aspect of the invention. Advantages and advantageous embodiments of the first aspect of the invention are to be regarded as advantages and advantageous embodiments of the second aspect of the invention, and vice versa.

[0020] To achieve a particularly advantageous design and thus a particularly simple, time-saving, and cost-effective assembly of the axial flux machine, one embodiment of the second aspect of the invention provides that, in the first step of the process, the rotors, including any axial adjusting disks between the rotors, are arranged on the rotor shaft and thus pre-assembled by sliding the rotors onto the rotor shaft in the axial direction. In a second step of the process, following the first, the rotor assembly is balanced. In a third step of the process, following the second, the rotor assembly is disassembled by pulling the rotors off the rotor shaft and removing them.In a fourth step of the process, which follows the third step, the rotors are magnetized while removed from the rotor shaft, i.e., without the rotor shaft. In other words, in the fourth step of the process, the rotors are magnetized while completely removed from the rotor shaft and thus not mounted on it. Therefore, it is preferably provided that the rotors are not magnetized in the second step, the first step, and the third step of the process.In a fifth step of the process, following the fourth step, the magnetized rotors are arranged on the rotor shaft and thus mounted on it, forming a rotor-stator assembly. This is achieved, in particular, by sliding the magnetized rotors onto the rotor shaft in the axial direction of the rotor shaft and thus of the axial flux machine, for example, while the stator is also moved in the axial direction of the rotor shaft and thus of the axial flux machine relative to the rotor shaft, thereby positioning the stator between the rotors in the axial direction of the axial flux machine. Furthermore, in a fifth step of the process, for example, the stator is arranged on the rotor shaft, in particular such that the stator is spaced, especially completely, away from the rotor shaft in the radial direction of the rotor shaft and thus of the axial flux machine.In other words, for example, in a fifth step of the process, an inner area of ​​the rotor shaft is arranged in the stator, in particular such that the stator, in particular the entire stator, is spaced away from the rotor shaft in the radial direction of the rotor shaft.

[0021] In a sixth step of the process, which follows the fifth step, the housing assembly is mounted by at least indirectly assembling and screwing the housing halves together and thereby connecting them, with the rotor-stator assembly arranged in the housing assembly, i.e., in the receiving space.

[0022] To enable particularly time- and cost-effective assembly of the axial flux machine, a further embodiment of the second aspect of the invention provides that, in the fifth step of the method, the rotors and the stator are held at a distance from each other in the axial direction of the axial flux machine by means of a holding device. Alternatively or additionally, in the fifth step of the method, the rotor shaft is held in a fixed position in the axial direction of the axial flux machine by means of a clamping device. Alternatively or additionally, in the fifth step of the method, the stator is arranged between the rotors. Alternatively or additionally, in the fifth step of the method, the stator is arranged on the rotor shaft at a distance from the rotor shaft in the radial direction of the axial flux machine.Alternatively or additionally, in the fifth step of the process, the stator is held in a fixed position in the axial direction of the axial flux machine by means of a fixing device. Alternatively or additionally, in a further step of the process following the fifth step and preceding the sixth step, the housing assembly is measured and / or calculated, wherein in the sixth step of the process the housing assembly is mounted depending on the result of the measurement and / or calculation.

[0023] Further advantages, features, and details of the invention will become apparent from the following description of a preferred embodiment and from the drawing. The features and combinations of features mentioned above in the description, as well as those mentioned below in the figure description and / or shown in the figures alone, can be used not only in the combinations specified, but also in other combinations or individually, without departing from the scope of the invention.

[0024] The drawing shows in: Fig. 1 a schematic perspective view of an axial flux machine for a motor vehicle; Fig. 2. Partially a schematic longitudinal section view of the axial flux machine; Fig. 3 a schematic and perspective longitudinal section view of the axial flux machine; and Fig. 4 A schematic perspective view of a rotor shaft of the axial flux machine.

[0025] In the figures, identical or functionally equivalent elements are provided with the same reference symbols.

[0026] Fig. Figure 1 shows a schematic perspective view of an axial flux machine 10 for a motor vehicle, also simply referred to as a vehicle. Fig. Figure 2 shows a section of the axial flux machine 10 in a schematic longitudinal section view, and Fig. Figure 3 shows the axial flux machine 10 in a schematic and perspective longitudinal section view. From Fig. 1, Fig. 2 to Fig. Figure 3 shows that the axial flux machine 10 has several, in this case at least or exactly three, stators 12a-c. For example, the stators 12a-c are designed separately from one another and, in particular, are connected to one another indirectly. Furthermore, the axial flux machine 10 has several, in this case at least or exactly four, rotors 14a-d, which are also referred to as rotor elements. The rotor elements are designed separately from one another and separately from the stators 12a-c. The separately designed rotor elements are connected to one another indirectly in a rotationally fixed manner, in particular exclusively. In the embodiment shown in the figures, the rotor elements are connected to one another in a rotationally fixed manner, in particular exclusively, via a rotor shaft 16 of the axial flux machine 10, which is also simply referred to as a shaft and is designed separately from the stators 12a-c and separately from the rotor elements.The rotor elements and the rotor shaft 16 thus form a complete rotor 18, which is rotatable about a machine axis of rotation 20 relative to the stators 12a-c and relative to a housing 22 of the axial flux machine 10. The axial flux machine 10, whose axial direction coincides with the machine axis of rotation 20, thus comprises the housing 22, which, in particular directly, delimits a receiving space 24. The stators 12a-c and the rotors 14a-d are each arranged at least partially, in particular at least predominantly and thus to more than half or completely, in the receiving space 24 and thus in the housing 22. It is evident that the rotor shaft 16 is arranged partly in the receiving space 24 and partly protrudes from the receiving space 24 and thus from the housing 22. It is also evident that the rotor shaft 16 is a shaft common to the rotors 14a-d.Each rotor element is connected to the rotor shaft 16 in a rotationally fixed manner, in particular via a radial shaft connection, and the rotor elements are connected to each other in a rotationally fixed manner, in particular exclusively via the radial shaft connections. In particular, a direct rotationally fixed connection between the rotor elements themselves is not provided.

[0027] The complete rotor 18 is rotatably mounted on the housing assembly 22 via at least or exactly two bearings 26 and 28 of the axial flux machine 10, the radial direction of which is perpendicular to the axial direction of the axial flux machine 10 and thus perpendicular to the machine's axis of rotation 20. Each bearing 26, 28 is a rolling bearing, in particular a ball bearing. Each bearing 26, 28 has an inner ring 30, 32 and an outer ring 34, 36. The inner rings 30, 32 and the outer rings 34, 36 are also referred to as bearing rings. Each bearing ring has a raceway. Each bearing 26, 28 also has rolling elements 38, 40. The rolling elements 38, 40 are designed as balls. For example, the respective inner bearing ring 30, 32 is connected to the rotor shaft 16 in a rotationally fixed manner.In particular, the respective outer bearing rings 34 and 36 are non-rotatably connected to the housing assembly 22. Thus, the inner bearing rings 30 and 32 rotate with the rotor shaft 16 about the machine axis of rotation 20 relative to the housing and relative to the outer bearing rings 34 and 36. As the rotor shaft 16 and therefore the inner bearing rings 30 and 32 rotate about the machine axis of rotation 20 relative to the outer bearing rings 34 and 36, the rolling elements 38 roll directly on the raceways of the bearing rings of bearing 26, and the rolling elements 40 roll directly on the raceways of the bearing rings of bearing 28. It is also evident that the stator 12a is arranged in the axial direction of the axial flux machine 10 between the rotors 14a and 14b, the stator 12b is arranged in the axial direction of the axial flux machine 10 between the rotors 14b and 14c, and the stator 12c is arranged in the axial direction of the axial flux machine 10 between the rotors 14c and 14d.

[0028] The housing assembly 22 forms axial contact surfaces 42a-f against which the stators 12a-c bear, in particular directly and in the axial direction of the axial flux machine 10. Stator 12a bears directly against the contact surfaces 42a and 42b, which face each other in the axial direction of the axial flux machine 10. Where the axial direction is mentioned above and below, this refers, unless otherwise specified, to the axial direction of the axial flux machine 10. Stator 12b bears in the axial direction, in particular directly, against the contact surfaces 42c and 42d, which face each other in the axial direction. Stator 12c bears in the axial direction, in particular directly, against the contact surfaces 42e and 42f, which face each other in the axial direction. This positions the stators 12a-c in the axial direction relative to each other and relative to the housing assembly 22.In particular, the respective mounting surface 42a-f is machined, especially by milling, and especially post-processed in order to be able to position the stators 12a-c in the axial direction of the axial flux machine 10 relative to each other and relative to the housing device 22.

[0029] For example, bearing 26 is a fixed bearing. For example, bearing 28 is an elastically positioned bearing.

[0030] For example, rotors 14a and 14b form a first rotor pair. For example, rotors 14b and 14c form a second rotor pair. For example, rotors 14c and 14d form a third rotor pair. It is conceivable that at least one or exactly one spacer element, also referred to as a distance element, is arranged axially between rotors 14a and 14b of the first rotor pair and / or between rotors 14b and 14c of the second rotor pair and / or between rotors 14c and 14d of the third rotor pair, by means of which, for example, the respective rotors 14a-d of the respective rotor pair are held at an axial distance from each other.In the axial direction, an air gap is arranged between each rotor 14a-d and each stator 12a-c, which is limited in the axial direction on one side, particularly directly, by the respective rotor 14a-d and on the other side, particularly directly, by the respective stator 12a-c. The respective air gap can be adjusted, for example, by means of the spacer element. Alternatively or additionally, an air gap between the respective rotors 14a-d of the respective rotor pair can be adjusted, for example, by means of the spacer element.

[0031] Out of Fig. Figure 4 clearly shows that the respective radial shaft connection is a polygon connection. In this case, the rotor shaft 16, over a total length GL, has a non-circular shape on its outer circumference and in a plane perpendicular to the axially extending plane. This shape is a polygon, such as a square or a hexagon. The respective parts of the total length GL are also referred to as the respective first length sections of the rotor shaft 16, so that the rotor shaft 16 exhibits the aforementioned polygon in these first length sections. The respective first length section of the rotor shaft 16 is arranged within a respective second length section of the respective rotor 14a-d, so that the respective second length section of the respective rotor 14a-d is arranged on the respective first length section of the rotor shaft 16.The respective second length section, viewed in the aforementioned plane, also exhibits the non-circular shape on its inner circumference, in this case in the form of a polygon. The rotor shaft 16 is inserted into the rotors 14a-d. In other words, the rotors 14a-d are mounted onto the total length section GL and thus onto the rotor shaft 16, so that the respective first length section of the rotor shaft 16, in the circumferential direction of the axial flux machine 10 running around the machine's axis of rotation 20, positively engages with the respective second length section of the respective rotor 14a-d. This connects the respective rotor 14a-d to the rotor shaft 16 in a rotationally fixed manner, with the rotors 14a-d being connected to each other, for example, exclusively via the rotor shaft 16 and thus via the respective radial shaft connection, in a rotationally fixed manner.In particular, it is provided that a rotationally fixed connection of the respective rotors 14a-d of the respective rotor pair is arranged via axially facing end faces of the respective rotors 14a-d of the respective rotor pair; interlocking gears are not provided, i.e., they are omitted. This allows the axial flux machine 10 to be assembled, i.e., manufactured, in a particularly time- and cost-effective manner.

[0032] Out of Fig. 1, Fig. 2 to Fig. 3 It can be seen that the housing assembly 22 has two separately formed and interconnected housing half-shells 44 and 46, which are in Fig. Figure 3 shows a schematic, sectioned, and perspective exploded view. The housing halves 44 and 46 are joined at least indirectly via their parting surfaces 48 and 50 and supported at least indirectly against each other, with the respective parting surface 48, 50 extending in a respective parting plane that runs in the axial direction of the axial flux machine 10. This means that the respective parting plane coincides with the machine's axis of rotation 20, or the respective parting plane is spaced from the machine's axis of rotation 20 and runs parallel to the machine's axis of rotation 20. The respective first length section is in Fig. 3 labelled L1, and the respective second length range are in Fig. 3 labeled L2.

[0033] The following describes a method, also referred to as an assembly method, for assembling, that is, for manufacturing, the axial flux machine 10. The axial flux machine 10 is characterized by its two-part housing assembly 22 and a positive-locking shaft-hub connection, via which the respective rotor 14a-d is positively and rotationally fixedly connected to the rotor shaft 16. The housing (housing assembly 22) is composed of the housing half-shells 44 and 46. For example, the respective housing half-shell 44, 46 is manufactured by a casting process and is thus designed as a single cast component. The respective contact surfaces 42a-f, facing each other in the axial direction, form or define, for example, a respective receptacle for the respective, at least partial, receiving and guiding of the respective stator 12a-c.In particular, the axial distances between the stators 12a-c are determined by the described machining or post-processing of the respective contact surfaces 42a-f. After the stators 12a-c have been arranged in the housing, for example, they are connected to the housing assembly 22 from the outside by screws. The rotors 14a-d are aligned with the stators 12a-c, resulting, for example, in air gaps between the rotors 14a-d and the stators 12a-c.

[0034] Out of Fig.It is evident from Figure 3 that, for example, each stator 12a-c is assigned at least or exactly one screw opening 52 of the housing assembly 22, which is designed, in particular, as a through-opening. The screw opening 52 assigned to each stator 12a-c, which is designed, for example, as a through-opening, is penetrated, for example, by a screw element assigned to each stator 12a-c, which is designed, in particular, as a screw. The stator 12a-c is connected to the housing assembly 22 by means of the screw element assigned to it, in particular by being screwed to the housing assembly 22 and thus connected to the housing assembly 22. The shaft-hub connection between the rotor shaft 16 and the rotor 14a-d is positively engaged by the polygon.The polygon profile, also known as a polygon profile, is, for example, a P4C polygon profile. This profile is characterized by high torque transmission and longitudinal displacement of the rotor shaft 16 relative to the respective rotor 14a-d, which acts as a hub, particularly under torque and centric load application. Furthermore, the polygon-designed rotor shaft 16 can be machined economically in a single setup. For example, the bearings 26 and 28 are designed as identical deep groove ball bearings. In this process, the rotors 14a-d are, for example, unbalanced and unmagnetized before the process begins. The rotors 14a-d are slid onto the polygon-designed rotor shaft 16 one after the other, for example, starting with rotor 14a.Axially, that is, axially oriented distances between the rotors 14a-d are optimally adjusted using the aforementioned spacer elements, since, for example, the positioning of the stators 12a-c is predetermined by the mounting surfaces 42a-f of the housing, which act as guide surfaces. After the rotors 14a-d are mounted, a sleeve is inserted, for example, as a placeholder for a spacer element between the rotor 14d and the bearing 28, as well as for the bearing 28 itself, and is clamped with a shaft nut, which is screwed, for example, onto the rotor shaft 16. Subsequently, the assembly formed in this way can be balanced and magnetized. Since the shape of the polygonal shaft is rotationally symmetrical four times, each rotor 14a-d can be subsequently rotated. Such rotation should be prevented by a suitable marking.Furthermore, the rotors 14a-d must not be interchanged when viewed axially. A dowel pin is not required for positioning them relative to each other. For mounting the magnetized rotors 14a-d, the polygon shaft is clamped, for example. A mounting fixture is provided for all rotors 14a-d and all stators 12a-c. The rotors 14a-d should be held radially from the outside. The four rotors 14a-d and the three stators 12a-c are guided together to the rotor shaft 16 at relative speeds, ensuring that the air gaps between the stators 12a-c and the rotors 14a-d are always symmetrical. This common feeding reduces the load on rotors 14b and 14c, for example, because an attractive force acts on both sides. The stators 12a-c are held in place after reaching their respective end positions, allowing both bearings 26 and 28 to be mounted.First, the spacer element for bearing 28 is slid onto the rotor shaft 16, allowing bearing 28b to then be pressed onto the rotor shaft 16. After tightening the inner bearing ring 32 with the shaft nut, the rotor mounting fixtures can be removed. Bearing 26a is then installed. Preferably, no spacer element for adjusting the rotor shaft 16 relative to the housing is provided or required between bearing 26a and rotor shaft 16. In particular, bearing 26a is pressed onto rotor shaft 16. Then, for example, the inner bearing ring 30 is tightened using another shaft nut, which is screwed onto rotor shaft 16. To mount the two housing halves 44 and 46, they are attached to the stators 12a-c so that all stators 12a-c rest against their respective contact surfaces 42a-f.From this point on, the mounting fixtures for the stators 12a-c can be disassembled, and the housing halves 44 and 46 are assembled. After the housing halves 44 and 46 are bolted together, the stators 12a-c are connected to the housing assembly 22 by bolts. Subsequently, for example, a bearing cap 54 can be mounted for the bearing 26. And after inserting a spring, for example, a bearing cap 56 can also be mounted for the bearing 28. Reference symbol list 10 Axial flux machine 12a-c Stator 14a-d Rotor 16 Rotor shaft 18 Total rotor 20 Machine rotary axis 22 Housing setup 24 Recording Room 26 warehouses 28 warehouses 30 inner bearing ring 32 inner bearing ring 34 Outer bearing ring 36 Bearing outer ring 38 rolling elements 40 rolling elements 42a-f Plant area 44 Housing half shell 46 Housing half shell 48 Separation surface 50 Separation area 52 Screw opening 54 bearing caps 56 bearing caps GL Total Length Range L1 first length range L2 second length range QUOTES INCLUDED IN THE DESCRIPTION

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

[0000] DE 10 2020 122 249 A1

[0002]

Claims

[1] Axial flux machine (10) for a motor vehicle, comprising at least one stator (12b), at least two rotors (14b, c) which are rotationally fixed to a rotor shaft (16) common to the rotors (14b, c) of the axial flux machine (10), and a housing assembly (22) which forms at least one axial contact surface (42c) against which the stator (12b) rests in the axial direction of the axial flux machine (10), wherein the housing assembly (22) has two separately formed and interconnected housing half-shells (44, 46) whose separating surfaces (48, 50), via which the housing half-shells (44, 46) are at least indirectly joined and at least indirectly supported against each other, extend in a respective separating plane which runs in the axial direction of the axial flux machine (10). [2] Axial flux machine (10) according to claim 1, characterized by , that the mounting surface (42c) is machined. [3] Axial flux machine (10) according to claim 1 or 2, characterized by , that the stator (12b), which is formed separately from the housing assembly (22), is screwed to the housing assembly (222) by means of at least one screw element formed separately from the housing assembly (22) and separately from the stator (12b), and is thereby connected to the housing assembly (22). [4] Axial flux machine (10) according to claim 3, characterized by , that the screw element is screwed in from outside the housing assembly (22). [5] Axial flux machine (10) according to any one of the preceding claims, characterized by, that a respective first length section (L1) of the rotor shaft (16) is arranged in a respective second length section (L2) of the respective rotor (14b, c), wherein the respective length section (L1, L2) has a non-circular shape when viewed in a plane perpendicular to the axial direction of the axial flux machine (10), whereby the respective rotor (14b, c) is connected to the rotor shaft (16) in a rotationally fixed manner. [6] Axial flux machine (10) according to claim 5, characterized by , that the respective shape, when viewed in the respective plane, is a respective polygon. [7] Axial flux machine (10) according to any one of the preceding claims, characterized by, that in the axial direction of the axial flux machine (10) between the rotors (14b, c) at least one spacer element is arranged, which is separate from the rotors (14b, c), separate from the stator (12b) and separate from the housing assembly (22), by means of which at least respective partial areas of the rotors (14b, c) are held at a distance from each other in the axial direction of the axial flux machine (10). [8] Method for assembling an axial flux machine (10) according to one of the preceding claims. [9] Method according to claim 8, characterized by , that: - in a first step of the process, forming a rotor assembly (18), the rotors (14b, c) are arranged on the rotor shaft (16) and thereby pre-assembled on the rotor shaft (16) by sliding the rotors (14b, c) onto the rotor shaft (16) in the axial direction of the rotor shaft (16); - in a second step of the process following the first step, the rotor assembly (18) is balanced; - in a third step of the procedure following the second step, the rotor assembly (18) is disassembled by pulling the rotors (14b, c) off the rotor shaft (16) and removing them; - in a fourth step of the process following the third step, the rotors (14b, c) located away from the rotor shaft (16) are magnetized; - in a fifth step of the process following the fourth step, forming a rotor-stator assembly: ◯ the magnetized rotors (14b, c) are arranged on the rotor shaft (16) and are thereby mounted on the rotor shaft (16); and ◯ the rotor shaft (16) arranged in the stator (12b); and - in a sixth step of the procedure following the fifth step, the housing assembly (22) is assembled by at least indirectly assembling and screwing the housing halves (44, 46) together and connecting them by arranging the rotor-stator assembly in the housing assembly (22). [10] Method according to claim 9, characterized by , that: - in the fifth step of the process, the rotors (14b, c) and the stator (12b) are held at a distance from each other in the axial direction of the axial flux machine (10) by means of a holding device; and / or - in the fifth step of the process, the rotor shaft (16) is held stationary in the axial direction of the axial flux machine (10) by means of a clamping device; and / or - in the fifth step of the process, the stator is arranged between the rotors (!4b, c); and / or - in the fifth step of the process, the stator (12b) is arranged on the rotor shaft (16) at a distance from the rotor shaft (16) extending in the radial direction of the axial flux machine (10); and / or - in the fifth step of the process, the stator (12b) is held in a fixed position in the axial direction of the axial flux machine (10) by means of a fixing device; and / or - in a further step of the procedure following the fifth step and preceding the sixth step, the housing device (22) is measured and / or calculated, wherein in the sixth step of the procedure the housing device (22) is mounted depending on a result of the measurement and / or calculation.

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