Rotor arrangement, separating body and method for manufacturing a separating body

Abstract

Rotor arrangement (1) comprising a rotor body (2) which forms several slots (3) in the axial direction for receiving a winding (4), rotor poles (5) which are formed in the radial direction between each pair of slots (3), windings (4) which run in the slots (3) and enclose the rotor poles (5), slot closure elements (6) which close the slots (3) in the radial direction, at least one separating body (7) which is arranged in one of the slots (3) in the circumferential direction between two of the windings (4), wherein the separating body (7) comprises at least one continuous cooling channel (8) extending in the axial direction through which a cooling medium can flow, characterized in that the separating body (7) has a housing (9) with a first outer half-shell (10) and a second outer half-shell (11), wherein inside the housing (9) a first inner half-shell (12) is sectionally attached to the first outer half-shell (10) is locatedthat a first cooling channel section (13) of the cooling channel (8) is defined between the first inner half-shell (12) and the first outer half-shell (10), and that within the housing (9) a second inner half-shell (14) abuts the second outer half-shell (11) section by section such that a second cooling channel section (15) of the cooling channel (8) is defined between the second inner half-shell (14) and the second outer half-shell (11).

Description

The present invention relates to a rotor arrangement comprising a rotor body which forms a plurality of slots in the axial direction for receiving a winding; rotor poles which are formed in the radial direction between in each case two of the slots; windings which run in the slots and surround the rotor poles; slot closure elements which close the slots in the radial direction; at least one separating body which is arranged in one of the slots in the circumferential direction between two of the windings, wherein the separating body comprises at least one continuous cooling duct which extends in the axial direction and through which a cooling medium can flow. The invention further relates to a separating body and a method for producing a separating body.In motor vehicles, electric machines are increasingly used for the drive in order to create alternatives to internal combustion engines that require fossil fuels. In order to improve the suitability of electric drives for all days and in addition to be able to offer users the usual riding comfort, considerable efforts have already been made.In the development of electric machines, which are provided in particular for E-axles or hybrid modules, there is a continuing need to increase their power densities and efficiency and at the same time to reduce the production costs. In this context, it is also known to design the electric machines as a separately excited synchronous machine (FSM). A separately excited synchronous machine is a special form of the synchronous machine in which the magnetic field in the rotor is not generated by permanent magnets but by energizable coils. The coils are frequently also referred to as field coils or excitation coils. To energize the coils in the rotating rotor, the current must be supplied via suitable transformer devices.Gaps can arise between each two exciter windings of a rotor on account of the production method. In particular, supporting or separating bodies are joined into these gaps, which fill the gaps completely or to large portions. Particularly for applications with high rotational speed, the separating bodies secure the windings of the excitation coils against unintentional movement in the centrifugal field. EP 1 494 335 B1 discloses corresponding separating bodies between adjacent excitation coils.In particular with regard to increased power densities and efficiency, there is the need to cool the rotor during operation, in particular even in the case of externally excited synchronous machines, and to dissipate thermal energy. Air-cooled rotors or fluid-cooled hollow shafts are known from the prior art, for example. DE102018220810A1 discloses a fluid-cooled rotor for an electric machine and a separately excited synchronous machine with a directly or near-loss cooled rotor winding. A fluid cooled hollow shaft with a conical wall is disclosed in EP3618241A1.The object of the present invention is now to provide a rotor arrangement for the dissipation of thermal energy from a rotor for a separately excited synchronous machine, which has a compact structure, favorable manufacturing costs and high operating reliability. It is also the object of the invention to realize an optimized separating body and an optimized method for producing a separating body.This object is achieved by a rotor arrangement comprising a rotor body which forms a plurality of slots in the axial direction for receiving a winding, rotor poles which are formed in the radial direction between in each case two of the slots, windings which run in the slots and surround the rotor poles, slot closure elements which close the slots in the radial direction, at least one separating body which is arranged in one of the slots in the circumferential direction between two of the windings, wherein the separating body comprises at least one continuous cooling channel which extends in the axial direction and through which a cooling medium can flow, wherein the separating body has a housing having a first outer half shell and a second outer half shell, wherein within the housing a first inner half shell bears in sections against the first outer half shell in this way, a first cooling channel section of the cooling channel is defined between the first inner half shell and the first outer half shell, and a second inner half shell abuts the second outer half shell in sections inside the housing in such a way that a second cooling channel section of the cooling channel is defined between the second inner half shell and the second outer half shell.This achieves the advantage of effective cooling of the heat generated during operation of an externally excited synchronous machine. Furthermore, the rotor arrangement according to the invention can not only meet the stringent requirements for tightness, but can also structurally withstand the pressures of up to 100 bar induced by the rotational speed. This combination of strength and tightness is critical to ensure long term performance and reliability of the rotor assembly. By using half shells, extruded profiles with plastic inserts for the cooling bodies can be dispensed with, which meet their strength limits under the above-mentioned high pressure loads.The double-walled embodiment of the rotor arrangement according to the invention represents a significant improvement in this connection, since not only the strength of the system under high operating pressures is optimized, but at the same time the tightness requirements can also be complied with. This construction also makes possible an improved connection to the cooling medium supply and discharge, wherein, for example, the need for glued-in plastic elements can be dispensed with. The double-walled configuration with the inner and outer half shells offers a robust solution which overcomes the structural limitations of conventional cooling body constructions and contributes to an increased power density of the externally excited synchronous machine due to the optimized heat dissipation.In the sense of this patent application, an outer half shell is a component of the housing which serves to form the outer contour of the separating body within the rotor arrangement and to enclose a part of the cooling duct system together with the inner half shell. The outer half shell is one of two complementary halves that together form the outer housing of the separator, each half shell being specifically designed to allow efficient cooling and protection of the inner components.The function of the outer half shell can also include the protection of the inner components from external influences such as mechanical loads, environmental influences and electromagnetic interference. In addition, the outer half shell plays a central role in the thermal management strategy of the separating body in that it forms the outer boundary of the cooling duct system and thus contributes directly to the heat dissipation from the windings.The structure of the outer half shell is designed in such a way that it ensures optimum fit and function within the rotor arrangement. This involves precisely matching its geometry with the inner half shell to form effective cooling channel sections. The outer half shell may include features such as guides for placement and fixation within the rotor body, connection points for integration into the overall system, and structures for improving heat transfer.With regard to the embodiments of the outer half shell, different materials and construction techniques are conceivable. Robust materials such as metals, for example aluminum or steel, are preferred because of their good thermal conductivity, mechanical strength and durability. In this context, the use of nonferromagnetic steel sheet is particularly preferred. For applications in which a weight reduction or an electrical insulation is required, however, high-performance plastics or composite materials can also be used.The construction of the outer half shell can furthermore be adapted to specific requirements, for example by integrating cooling ribs or ducts to improve the heat dissipation, the use of special surface treatments to reduce friction or the incorporation of sealing systems to prevent leaks in the cooling circuit. The outer half shells can be produced by various methods such as deep drawing, casting or CNC machining, depending on the requirements with respect to precision, piece count and cost. Advantageously, the outer half shells are designed such that they can form a cohesive connection, preferably by welding, soldering or adhesive bonding, with the corresponding counterparts, in order to ensure high structural integrity and tightness of the entire separating body.For the purposes of this patent application, an inner half shell is a component of the separating body which is connected to an outer half shell in order to form a part of the cooling duct system within the rotor arrangement. The inner half shell is constructed to abut directly against the inner surface of the outer half shell and define, together with it, specific cooling channel portions through which a cooling medium can flow to efficiently assist in heat dissipation from the surrounding windings.The function of the inner half shell is to define the shape and boundary of the cooling channels and thereby to ensure an optimized flow guidance of the cooling medium. Due to its specific arrangement and configuration, the inner half shell contributes significantly to efficient heat dissipation by maximizing the thermal contact between the windings resting on the outer half shell and the cooling medium. Moreover, it serves as a structural reinforcement which contributes to the mechanical stability of the entire separating body.The structure of the inner half shell is precisely matched to the outer half shell in order to ensure effective and efficient cooling. This includes a special design of the surfaces which are in contact with the cooling medium in order to optimize the heat transfer. In addition, features can be integrated into the inner half shell, which promote a uniform distribution of the cooling medium over the entire cooling channel length and thus help avoid hotspots within the rotor arrangement.With regard to the embodiments of the inner half shell, different materials and construction techniques are conceivable in order to meet the different requirements. Preferred are materials having a high thermal conductivity, such as metals, to allow efficient heat transfer. In this context, the use of nonferromagnetic steel sheet is particularly preferred. For applications in which light construction or electrical insulation is important, however, advanced plastics or composite materials could also be used.The construction of the inner half shell may additionally include specific adaptations, such as for example the integration of structures for enhancing the mechanical strength or for improving the flow dynamics of the cooling medium. Methods such as deep drawing, casting or CNC machining are advantageously used for producing the inner half shells, depending on the required tolerances, the complexity of the design and the production costs. The choice of the production method depends on the specific properties of the material chosen and the requirements of the particular application. The inner half shell can also be designed such that it enables simple assembly and a reliable connection to the outer half shell, for example by means of fit or snap connections, in order to ensure high overall stability and tightness of the cooling duct system.For the purposes of this patent application, a spacer element is a structural component which is used within the separating body of the rotor arrangement in order to create a defined distance between the inner and outer half shells. By this specific arrangement, spacers contribute significantly to the formation and maintenance of the structure of cooling channel sections by precisely defining the space between the half shells. This enables optimized guidance of the cooling medium through the separating body, which significantly increases the efficiency of the heat dissipation from the windings.The function of a spacer element also extends to improving the mechanical stability of the entire separating body. By ensuring a fixed distance between the half shells, they contribute to the strength of the construction and protect the internal components from mechanical influences and deformations which could be caused by operating pressures or temperature fluctuations.The construction of a spacer element is preferably designed such that it offers high precision in the spacing, but at the same time also has the necessary flexibility in order to be able to compensate for assembly and production tolerances. Spacer elements can be designed as individual inserts, integrated structures within a half shell or as separate components which are arranged between the half shells.It is particularly preferred that the spacer elements are formed integrally, in particular monolithically, with an inner and / or outer half shell, for example by means of deep-drawing a steel sheet. In this context, the use of nonferromagnetic steel sheet is particularly preferred.With regard to the embodiments of the spacer element, different materials and constructions are conceivable in order to meet the diverse requirements. Preferred materials are materials which have good thermal resistance and mechanical properties, such as high-performance plastics, metals, in particular nonferromagnetic steel sheets, or composite materials. The choice of material depends on the specific operating conditions and requirements for the thermal conductivity, strength and compatibility with the cooling medium.The construction of the spacer element can vary from simple geometric shapes such as cylinders, dome-like half shells (knobs) or blocks to complex structures with specific surface profiles in order to optimize the flow of the cooling medium and to avoid hotspots. Advantageously, the spacer elements can be designed in such a way that they allow simple assembly, for example by snap-fit or plug-in connections, in order to increase production and maintenance efficiency. In addition, it is possible to design the spacer elements such that they fulfill multiple functionality by contributing not only to the spacing but also to the guidance of the cooling medium or to the reinforcement of the structure.The rotor arrangement, by means of the inner and outer half shells, thus preferably has a construction of a double-walled cooler which is advantageously realized using nonferromagnetic steel sheet. In this context, the introduction of a deep-drawn structure into one of the half shells is preferred, which can preferably be configured either in the form of dome-like half shells (knobs) or alternatively as channels. The height of the dome-like half shells (knobs) is preferably between 0.2 mm and 1 mm and thus makes it possible to precisely determine the throughflow cross section for the cooling medium and to ensure a small but effective throughflow cross section. This structuring contributes at the same time to preventing local plugging of the cooling channels by ensuring consistent flow through the preferably uniform spacing of the knobs.In principle, it is of course also possible for the first outer half shell to have a plurality of spaced-apart first spacer elements which bear against the first inner half shell and / or for the second outer half shell to have a plurality of spaced-apart second spacer elements which bear against the second inner half shell. In this context, it is further preferred that the first spacer elements are formed integrally, in particular monolithically, with the first outer half shell and / or the second spacer elements are formed integrally, in particular monolithically, with the second outer half shell.Finally, it is also conceivable that the first outer half shell and the first inner half shell each have a plurality of spaced-apart first spacer elements which abut the respective opposite half shell and / or the second outer half shell and the second inner half shell each have a plurality of spaced-apart second spacer elements which abut the respective opposite half shell. In this context, it is further preferred that the first spacer elements are formed integrally, in particular monolithically, with the first outer and the first inner half shell and / or the second spacer elements are formed integrally, in particular monolithically, with the second outer half shell and the second inner half shell.For absorbing the forces arising from operating pressures, it is advantageous that both halves of the cooler, i.e. an inner and an outer half shell, enter into a fixed connection. This connection can preferably be produced in the region of the studs, in particular by methods such as resistance spot welding or laser welding, wherein alternatively a soldering process can also be used in the region of the studs.In order to simplify assembly and at the same time to ensure high strength of the separating body, the separating body is produced in two half shells. In a first step, an outer half shell is preferably welded to the preferably structured sheet metal of a corresponding inner half shell at the knobs and at the outer diameter. The welding of both half shells is then carried out along their center line.The stability of the entire cooling system can additionally be ensured by welding end caps on both sides of the separating body. This measure makes it possible to withstand the high internal pressure loads without transmitting pressure forces to the surrounding structure. This enables the rotor to be operated at high speeds without compromising the integrity of the cooling system.According to a preferred embodiment, a cavity is formed in the groove, which cavity is bounded by one of the windings and the separating body, wherein the cavity comprises a potting material. In other words, it is preferred that a potting material fills these cavities in possibly present cavities between the separating body and one of the windings. The advantageous effect of the embodiment is that the potting material in the cavity improves the thermal connection of the windings to the separating body. The cavity results from component tolerances of windings and separating bodies due to the production process.According to one configuration, the cooling medium is a cooling liquid. The advantageous effect of the embodiment is that cooling fluids have a higher heat capacity and a higher thermal conductivity in comparison with gases and thus make possible a better heat dissipation or dissipation of the power loss. In particular, the cooling liquid contains oil and / or water.According to one embodiment, the rotor body is designed as a laminated core. The advantageous effect of the embodiment is that eddy current losses in the rotor body are thus minimized.The separating body is preferably made of a non-ferromagnetic material so that the electromagnetic function of the rotor or of the electric machine is not disturbed. The separating body is preferably made at least partially from a material with good thermal conductivity in order to realize a good thermal connection between the rotor windings and the cooling medium. The separating body thus essentially provides two functions. On the one hand, the separating body can contribute to fixing the windings in the slots also under the influence of centrifugal force and, on the other hand, to providing fluid-based cooling within the slots by means of the cooling duct. Thus, the rotor windings are supported fixed against rotational speed by means of this separating body and are simultaneously cooled.According to a further preferred development of the invention, it can also be provided that a fluid inlet element is coupled at a first axial end of the cooling duct and a fluid outlet element is coupled at a second axial end of the cooling duct, such that the cooling medium can flow into the cooling duct via the fluid inlet element and can flow out of the cooling duct via the fluid outlet element.This makes it possible to achieve a particularly favorable connection of the separating element to a cooling circuit. It can be preferred that the fluid inlet element and the fluid outlet element are substantially identical.The separating body is formed in the region of at least one of its axial ends on its inner wall such that a smooth inner contour is produced over an axial length, preferably of up to 15 mm. This region can in particular also have been post-machined by means of machining production methods. An inlet element or an outlet element for the cooling medium is then inserted into this region. The inlet element and / or the outlet element can be glued, welded, joined by means of a press fit and / or form fit to the separating body. In a preferred embodiment, the inlet element or the outlet element is sealed with a seal, for example an O-ring seal, toward the separating body. Thus, closed assemblies are produced which are tight with respect to the cooling medium and are each joined between two rotor coils, but do not substantially project beyond the axial extent of the rotor coils, so that the axial length of the rotor is not significantly increased by the assemblies mentioned.The inlet element and / or the outlet element preferably contain / contain openings and / or channels in their / their interior for guiding the cooling medium in the axial and / or radial direction, so that the shape of the opening in the interior of the separating body is transferred to a shape which is suitable for guiding the cooling medium into adjacent components.Furthermore, the invention can also be further developed to the effect that the fluid inlet element and / or the fluid outlet element engage at least in sections in the separating body and bear / abut the inner wall of the separating body. As a result, a high degree of tightness can be achieved between the fluid inlet element and / or the fluid outlet element and the separating body. This embodiment has also proven to be particularly favorable with regard to the absorption and support of centrifugal forces during operation of the rotor arrangement.In a likewise preferred embodiment variant of the invention, it can also be provided that the fluid inlet element and / or the fluid outlet element each have / have a hydraulic path for guiding the cooling medium in the radial direction. It can also be advantageous to further develop the invention to the effect that the fluid inlet element and / or the fluid outlet element each have / have a hydraulic path for guiding the cooling medium in the axial direction. As a result, a channel system can be formed, by means of which the cooling medium can be directed into the cooling channel of the separating body and / or out of the separating body in a targeted manner. A hydraulic path can comprise an open or closed channel, an inflow surface, a centrifugal section and / or a free fall section.In a further preferred embodiment, an inlet element and / or an outlet element can each have an axial opening. As a result, the cooling medium can be guided through the respective axial opening into components axially adjoining the inlet element and / or the outlet element.In a likewise preferred embodiment, an outlet element can have an axial opening via which the cooling medium is ejected from the rotor during operation and onto stator components located radially further outward, such that cooling of the stator components can additionally be achieved.According to one configuration, the rotor arrangement comprises a rotor shaft which is designed as a hollow shaft and has an opening in the radial direction for guiding the cooling medium.According to a further preferred embodiment of the subject matter of the invention, it can be provided that the fluid inlet element and / or the fluid outlet element are / is each coupled to a rotor shaft configured as a hollow shaft, so that the cooling medium can flow from the rotor shaft into the fluid inlet element and / or from the fluid outlet element into the rotor shaft.Preferably, the fluid inlet element and / or the fluid outlet element can each contain a radial opening which is connected to a corresponding radial opening in the rotor shaft. Most preferably, the radial opening of the fluid inlet element and / or of the fluid outlet element is sealed with respect to the radial opening of the rotor shaft by means of a seal. Thus, the cooling medium can be guided from the rotor shaft into the separating body or from the separating body into the rotor shaft without the guiding of the cooling medium having to be integrated into axial rotor housing parts, so that these can be designed to be particularly space-saving axially.The radial opening of the rotor shaft is thus connected via the fluid inlet element and / or the fluid outlet element to the cooling channel of the separating element for guiding the cooling medium and accordingly forms a channel system. Thus, in a preferred embodiment of the invention, the cooling channel can be connected to a cooling system via the channel system. Particularly advantageously, the cooling channel is connected to the cooling system on both end sides via a respective further component, preferably the fluid inlet element and / or the fluid outlet element, so that a closed cooling circuit is formed.In a further preferred development of the invention, it can also be provided that the separating body has an electrical insulation on its outer wall at least in sections. The electrical insulation can be embodied, for example, as an electrically insulating coating. It is also conceivable for the electrical insulation to be designed as a separate component which is connected detachably or firmly to the separating body. The separating body can thereby be electrically insulated with respect to current-carrying parts in order in particular to avoid electrical contact between excitation coils or between excitation coil and vehicle and thus to meet the requirements of high-voltage safety. A coating can be realized, for example, by painting, overmolding or an adhesively bonded layer. For electrical insulation with limited requirements, the aluminum separating body can also be anodized, for example. In the case of high requirements, it can be injection-molded with plastic, coated with an alternative material or coated with a film at the contact surfaces toward the rotor coils. It can thus be ensured that no electrical short circuit is produced between excitation coils or between an excitation coil and the vehicle.The separating body is preferably connected to a groove closure element which radially closes the groove and supports the supporting body in a rotationally fixed manner. The groove closure element is preferably made of a non-ferromagnetic and non-electrically conductive material, e.g. plastic, so that the electromagnetic behavior of the machine is not impaired and no additional eddy current losses arise in this component. The groove closure element can be produced by plastic injection molding or by extrusion and joined to the separating body in a form-fitting or adhesive-bonding manner. Alternatively, the groove closure element can be sprayed directly onto the separating body. In this case, it can be integrally connected to a plastic injection molding of the separating body.The invention can also be advantageously embodied to the effect that the groove closure element and the separating body are integrally connected. The advantageous effect of the embodiment is that the integral connection allows the groove closure element and the separating body to be produced as a single component. Thus, the complexity of the rotor assembly is reduced. A further advantage is that a more stable component is provided by an integral connection. Particularly preferably, the groove closure element and the separating body are formed monolithically, for example from aluminum or plastic.In a likewise preferred embodiment variant of the invention, it can also be provided that the separating body is formed from an aluminum. The material properties of aluminum make it possible to achieve good mechanical properties and good thermal conductivity within the separating body. Since aluminum is not ferromagnetic, the electromagnetic function of the machine is not impaired.The outer cross-sectional contour of the separating body can have a contour deviating from the rectangular shape. The cross-sectional contour of the separating body is preferably shaped in such a way that the smallest possible distance is formed between the winding and the separating body. It would be conceivable, for example, for the separating body to have a trapezoidal section at its radially outer end, a rectangular section adjoining the short side of said trapezoidal section radially inward. As a result, the heat transfer from the winding to the separating body can be further optimized, since the thermal conductivity of the potting compound, which usually fills the cavity between the winding and the separating body, is generally poorer than the thermal conductivity of the separating body.According to a further preferred development of the invention, it can also be provided that the separating body comprises a plurality of cooling channels which are spaced apart from one another radially and / or in the circumferential direction. The advantageous effect of the embodiment is that in this way a better heat dissipation or dissipation of the power loss takes place. A further advantage is that a more uniform heat dissipation or dissipation of the power loss takes place through a plurality of cooling channels spaced apart.According to an advantageous embodiment of the invention, it can be provided that the first inner half shell has a plurality of spaced-apart first spacer elements which abut the first outer half shell and / or the second inner half shell has a plurality of spaced-apart second spacer elements which abut the second outer half shell. This arrangement ensures a uniform distribution of the cooling medium and thus optimizes the heat exchange between the half shells and the cooling medium. The improved cooling contributes to a further reduction in the operating temperatures, which increases the efficiency of the motor and reduces the thermal load on the components. The selective arrangement of the spacer elements also enables a reduction of pressure losses in the cooling circuit, which leads to a lower energy requirement for the cooling.According to a further preferred development of the invention, it can also be provided that the first spacer elements are formed integrally, in particular monolithically, with the first inner half shell and / or the second spacer elements are formed integrally, in particular monolithically, with the second inner half shell. The one-piece, in particular monolithic, shaping of the spacer elements with the inner half shells offers the technical advantage of increased mechanical stability and reliability of the cooling channel structure. This integrated construction avoids weak spots that could arise from assembly or joining processes and provides for durable performance and resistance of the cooling channels. In addition, this construction simplifies production since fewer individual parts have to be produced and joined together, which reduces production costs and facilitates quality assurance.Furthermore, according to a likewise advantageous embodiment of the invention, it can be provided that the first spacer elements are substantially identically designed and / or the second spacer elements are substantially identically designed. Standardization of the spacer elements, by being substantially identical, leads to considerable economic and production-related advantages. The uniformity of the parts simplifies storage and logistics, since fewer different parts have to be kept in stock, as long as the spacer elements are not already configured monolithically with an inner half shell. This reduces the complexity of the production process and enables cost-effective mass production.According to a further particularly preferred embodiment of the invention, it can be provided that the first spacer elements are arranged on the first inner half shell in a grid-like manner and / or the second spacer elements are arranged on the second inner half shell in a grid-like manner. The grid-like arrangement of the spacer elements on the inner half shells optimizes the flow dynamics of the cooling medium within the cooling channels. This arrangement allows maximum penetration of the cooling medium through the cooling channels, resulting in more efficient heat dissipation. The increased cooling capacity makes it possible to further reduce the operating temperatures, thereby increasing the efficiency and performance of the engine. In addition, the improved cooling leads to a lower thermal load on the components, which lengthens their service life and increases the reliability of the rotor arrangement.Furthermore, the invention can also be further developed to the effect that the first inner half shell covers 75-95% of the surface of the first outer half shell and / or the second inner half shell covers 75-95% of the surface of the second outer half shell. The specified overlap ensures efficient use of the available space for the cooling channels. This overlap rate allows an optimum configuration of the cooling duct sections in order to achieve maximum heat dissipation with a minimum space requirement. The precise coordination between the overlap and the cooling power leads to a compact construction of the rotor arrangement, which nevertheless provides excellent cooling. This is particularly advantageous for applications where available space is limited without sacrificing performance or reliability.In a likewise preferred embodiment variant of the invention, it can also be provided that the first outer half shell and the second outer half shell are connected, preferably welded, in a materially bonded manner. The material-to-material connection, preferably by welding, of the outer half shells ensures a permanent and robust construction of the separating bodies. This type of connection ensures high mechanical strength and tightness of the cooling channel structure, which improves the reliability and durability of the rotor arrangement under different operating conditions. The choice of welding as a connecting technique also allows hermetic sealing of the cooling channels, thereby minimizing the risk of leaks and maximizing the efficiency of the cooling system.It can also be advantageous to further develop the invention to the effect that the first outer half shell and the second outer half shell are substantially identically shaped and / or the first inner half shell and the second inner half shell are substantially identically shaped. The identical formation of the outer and inner half shells simplifies the production and assembly of the separating bodies considerably. By using identical molds for the half shells, manufacturing costs can be reduced and the assembly process can be accelerated, since fewer different parts have to be manufactured and handled. This standardization contributes to a reduction in production cost while enhancing the quality and accuracy of the components. The uniform design also supports flexible production and facilitates storage and logistics.It is furthermore particularly preferred that the first outer half shell and the second outer half shell are produced by means of at least one forming process and / or the first inner half shell and the second inner half shell are produced by means of at least one forming process. Forming methods enable high precision in the production of the half shells. This accuracy is decisive for the correct fit of the half shells with respect to one another, which in turn ensures optimum functioning of the cooling duct system. By precisely manufacturing the components, gap dimensions can be minimized and the efficiency of the heat transfer between the windings and the cooling medium can be maximized. The production of the half shells by forming methods is often more cost-effective compared to other production methods, in particular in the production of large numbers. The flexibility of the forming processes also allows to realize complex shapes and structures which could be difficult or uneconomical to produce using other methods. This also opens up possibilities for innovative designs of the cooling channel structures, which make possible a more effective heat dissipation. Finally, half shells with uniform material properties can also be produced by using forming methods, which leads to increased strength and reliability of the components. The homogeneous material structure, which is achieved by forming processes, can improve the mechanical load-bearing capacity of the half shells and thus contribute to the durability of the rotor arrangement.The object of the invention can also be achieved by a separating body for a rotor arrangement, in particular for a rotor arrangement according to claim 1, comprising at least one continuous cooling channel which extends through the separating body in the axial direction and through which a cooling medium can flow, wherein the separating body has a housing having a first outer half shell and a second outer half shell, wherein within the housing a first inner half shell abuts in sections against the first outer half shell in such a way that a first cooling channel section of the cooling channel is defined between the first inner half shell and the first outer half shell, and within the housing a second inner half shell abuts in sections against the second outer half shell in such a way that a second cooling channel section of the cooling channel is defined between the second inner half shell and the second outer half shell.Finally, the object of the invention can also be achieved by a method for producing a separating body for arrangement in a rotor arrangement, in particular a rotor arrangement according to claim 1, comprising the following steps:• Providing a first sheet and forming the first sheet into a first outer half shell and a second outer half shell;• Providing a second metal sheet and forming the second metal sheet into a first inner half shell and a second inner half shell;• Formation of the separating body with a housing made of the first outer half shell and the second outer half shell, wherein within the housing the first inner half shell abuts in sections against the first outer half shell in such a way that a first cooling channel section of the cooling channel is defined between the first inner half shell and the first outer half shell, and within the housing the second inner half shell abuts in sections against the second outer half shell in such a way that a second cooling channel section of the cooling channel is defined between the second inner half shell and the second outer half shell.The described method for producing a separating body enables efficient and cost-effective production of high-precision and efficient cooling structures for rotor arrangements. The steps of the method are optimized in such a way that a high quality and accuracy of fit of the components is ensured, which simplifies the assembly and improves the reliability of the finished separating bodies. The use of metal sheets for the production of the half shells makes it possible to adapt flexibly to different design requirements and contributes to a reduction in the production costs. This method helps mass produce separators with integrated cooling channels and thus promotes the spread of efficient and powerful rotor assemblies in various applications.In a preferred embodiment variant of the method, first of all an outer and the inner half shell are respectively connected to one another in the region of the contact points, preferably by welding or soldering. The contact points are preferably formed by the spacer elements. The outer and inner half shells which are then firmly connected are then joined together to form the separating body, which can likewise preferably be carried out by means of welding or soldering. The secure connection of the contact points prevents the entire cooling structure of the separating body, similar to an air balloon, from being inflated by the pressure acting on it during operation.The invention will be explained in more detail below with reference to figures without limiting the general concept of the invention.It shows: FIG. 1 shows a detail view of a groove of a separately excited rotor in a cross-sectional view, FIG. 2 shows a perspective view of an exposed separating body, FIG. 3 shows a cross-sectional illustration of the separating body, FIG. 4 shows a perspective view of an exposed separating body with separating caps placed on or inserted, FIG. 5 shows an inner half shell with knob-like, grid-like arranged spacer elements in two perspective views, FIG. 6 shows an outer half shell in a perspective view, FIG. 7 shows an inner half shell fixed to the outer half shell in two perspective views.FIG. 1 shows a rotor arrangement 1, comprising a rotor body 2 which forms a plurality of slots 3 in the axial direction for receiving a winding 4. One of these grooves 3 is shown in FIG. 1. It is understood that the rotor body 2 has a plurality of these grooves 3, as shown in FIG. 1, distributed circumferentially.The rotor arrangement further has rotor poles 5, which are formed in the radial direction between two of the slots 3 in each case, and windings 4, which run in the slots 3 and enclose the rotor poles 5. Furthermore, the rotor arrangement 1 has slot closure elements 6, which close the slots 3 in the radial direction, and a separating body 7 per slot 3, which is arranged in the slot 3 in the circumferential direction between two of the windings 4. In the embodiment shown, the groove closure elements 6 are integrally connected to the separating bodies 7 or are embodied therewith.the separating body 7 comprises two continuous cooling channels 8 a, 8 bextending in the axial direction, through which a cooling medium can flow, which is explained in more detail below with reference to FIG. 3.As can be clearly seen from FIG. 2, the separating body 7 has a housing 9 with a first outer half shell 10 and a second outer half shell 11, wherein within the housing 9 a first inner half shell 12 abuts in sections against the first outer half shell 10 in such a way that a first cooling channel section 13 of the cooling channel 8 ais defined between the first inner half shell 12 and the first outer half shell 10, and within the housing 9 a second inner half shell 14 abuts in sections against the second outer half shell 11 in such a way that a second cooling channel section 15 of the cooling channel 8 bis defined between the second inner half shell 14 and the second outer half shell 11. This can be easily understood from FIG. 3. The first outer half shell 10 and the second outer half shell 11 are connected in a materially integral manner via the weld seam 28.In the embodiment shown, the separating body 7 has a radially outer trapezoidal contour, which is adjoined by a radially inner rectangular contour, so that an overall contour which narrows towards a key blank is obtained. As can be clearly seen from FIG. 1, the outer contour of the separating body 7 thus nestles against the winding located in the groove 3. In addition to an optimized heat dissipation, this also ensures a radial fixing of the winding 4 under the influence of centrifugal force in the slot 3.It can also be seen that the end-face ends of the housing 9 are slightly offset inwardly, which can also be seen from the combination with FIG. 6. In this case, the surface sections 27 a, 27 bon a first end side form the inwardly directed first step of the housing 9 and the surface sections 26 a, 26 bform the inwardly directed second step of the housing 9 formed on the second end side. In or on these steps, an end cap 29 is then placed in or on each case, as can be seen in FIG. 4, in order to complete the production process of the separating body 7.It can also be seen from FIG. 5 that the first inner half shell 12 has a plurality of spaced-apart first spacer elements 16 which abut against the first outer half shell 10 and the second inner half shell 14 has a plurality of spaced-apart second spacer elements 17 which abut against the second outer half shell 11. The first spacer elements 16 are monolithically formed with the first inner half shell 10 and the second spacer elements 17 are monolithically formed with the second inner half shell 14. The first spacer elements 16 and the second spacer elements 17 are here substantially identical, which can be seen easily from FIG. 5. The first spacer elements 16 are arranged in a grid-like manner on the first inner half shell 10 and the second spacer elements 17 are arranged in a grid-like manner on the second inner half shell 14. In the embodiment shown, the inner half shells 12, 14 have stamped spacing knobs as spacer elements 16, 17.The inner half shells 12, 14 show a substantially parallel contour profile to the outer half shells 10, 11, so that in each case cooling ducts 8 a, 8 bhaving a constant duct height are produced. Accordingly, the inner half shells 12, 14 have two surface sections 18, 19 which are arranged at an angle to one another on a common edge, as can also be seen from FIG. 5. At the end-face ends of the inner half shells 12, 14, an end face 20, 21 is formed in each case, via which the end-face closure of the assembled inner half shells 12, 14 takes place. This results in a cavity in the interior of the assembled inner half shells 12, 14.To absorb the compressive forces during operation of the rotor arrangement 1, it is advantageous if the half shells 10, 11, 12, 14 are connected to one another. In the embodiment shown, this is done in the region of the stud-like spacer elements 16, 17 by welding (e.g. resistance spot welding or laser welding) or optionally also soldering in the region of the studs.In order to ensure the high strength of the complete separating body 7, a connection of the end-face ends with high strength is also advantageous. This is achieved by welding an end cap 29 with a hydraulic connection 30 to an end face of the housing 9. This achieves a design which can support the high pressure in itself and no compressive forces are introduced into the surrounding structure of the rotor arrangement. High rotational speeds can thereby be achieved with the rotor.FIG. 7 shows an outer half shell 10, 11, The surface sections 22, 23 arranged at an angle to one another are clearly visible. At the radially outer end of the surface section 23, the surface section 24 is formed from the surface section 23 and forms a top surface of the housing 9. Analogously to this, at the radially inner end of the surface section 22, a surface section 25 is formed from the surface section 22, which forms a bottom surface of the housing 9. The inwardly recessed surface sections 26, 27 at the front ends of the outer half shell 10, 11 are also clearly visible, which serve for the support or fixing of the end caps 29.As can be seen from FIG. 7, the inner half shell 12, 14 covers 75-95% of the surface of the outer half shell 10, 11, which enables cooling performance that is as uniform as possible over the outer lateral surface of the housing 9.As can also be seen from the overview of FIGS. 5-7, the first outer half shell 10 and the second outer half shell 11 are substantially identically shaped. Likewise, the first inner half shell 12 and the second inner half shell 14 are substantially identically shaped. In this case, the first outer half shell 10 and the second outer half shell 11 are produced from a sheet metal by means of at least one forming method. The first inner half shell 12 and the second inner half shell 14 have also been produced by means of at least one forming process.To produce a separating body 7 for arrangement in a rotor arrangement 1, as is known from FIGS. 1-7, the following steps can be carried out:First, a first sheet metal is provided and the first sheet metal is transformed into a first outer half shell 10 and a second outer half shell 11, as can be seen, for example, in FIG. 6.A second sheet metal is also provided and the second sheet metal is transformed into a first inner half shell 12 and a second inner half shell 14, as shown in FIG. 5.The separating body 7 is now formed with a housing 9 made of the first outer half shell 10 and the second outer half shell 11, wherein within the housing 9 the first inner half shell 12 abuts in sections against the first outer half shell 10 in such a way that a first cooling channel section 13 of the cooling channel 8 is defined between the first inner half shell 12 and the first outer half shell 10, and within the housing 9 the second inner half shell 14 abuts in sections against the second outer half shell 11 in such a way that a second cooling channel section 15 of the cooling channel 8 is defined between the second inner half shell 14 and the second outer half shell 11.Overall, therefore, the two outer half shells 10, 11, the two inner half shells 12, 14 and two structurally identical end caps 29 are required for producing a separating body 7.FIG. 7 shows how the inner half shells 12, 14 are inserted into the outer half shells 10, 11. In order to make simple assembly possible, it is advantageous to produce the separating body 7 in the following steps. First, the first inner half shell is welded to the knob-like spacer elements 16, 17 and to the outer diameter on the first outer half shell 10. The same is done with the second outer half shell 11 and the second inner half shell 14. Alternatively, it would also be possible first to weld the two inner half shells 12, 14 and then to arrange the two outer half shells 10, 11 around the inner half shells 12, 14 and then also to weld them.The housing 9 of the separating body 7 is thus finished with the corresponding cooler structure for heat dissipation from the winding 4. In order to be able to pump the cooling fluid through the cooling channels 8 a, 8 b, the hydraulic connection 30 is provided on the end caps 29. The end caps 29 are welded to the housing 9. A closed fluid space is thus created. The cooling fluid is supplied via the hydraulic connection 30, which are connected via suitable pipe connections to an oil pump, which provides the necessary oil volume flow. The connection to the hydraulic connections 30 can be established via lines or through holes in adjacent structural components.The invention is not limited to the embodiments shown in the figures. The foregoing description is, therefore, not to be considered as limiting, but illustrative. The following claims should be understood to mean that a said feature is present in at least one embodiment of the invention. This does not exclude the presence of further features. If the patent claims and the above description define "first" and "second" features, this designation serves to distinguish two features of the same type without specifying a ranking.List of reference characters1 Rotor arrangement 2 Rotor body 3 Slots 4 Winding 5 Rotor poles 6 Slot closure elements 7 Separating body 8 Cooling channel 9 Housing 10 Outer half shell 11 Outer half shell 12 Inner half shell 13 Cooling channel section 14 Inner half shell 15 Cooling channel section 16 Spacer elements 17 Spacer elements 18 Surface section 19 Surface section 20 End surface 21 End surface 22 Surface section 23 Surface section 24 Surface section 25 Surface section 26 Surface section 27 Surface section 28 Weld seam 29 End cap 30 Hydraulic connectionReferences included in the specificationThis list of documents cited by the applicant has been produced in an automated manner and is only included for the better information of the reader. The list is not part of the German patent application or utility model application. The DPMA does not take any adhesion for any faults or omissions.Patent Literature citedEP 1 494 335 B1

[0004] DE 102018220810A1

[0005] EP 3618241A1

[0005]

Claims

Rotor arrangement (1) comprising a rotor body (2) which forms a plurality of slots (3) in the axial direction for receiving a winding (4), rotor poles (5) which are formed in the radial direction between in each case two of the slots (3), windings (4) which run in the slots (3) and enclose the rotor poles (5), slot closure elements (6) which close the slots (3) in the radial direction, at least one separating body (7) which is arranged in one of the slots (3) in the circumferential direction between two of the windings (4), wherein the separating body (7) comprises at least one continuous cooling duct (8) which extends in the axial direction and through which a cooling medium can flow, characterized in that the separating body (7) has a housing (9) having a first outer half shell (10) and a second outer half shell (11), wherein within the housing (9) a first inner half shell (12) abuts in sections against the first outer half shell (10) such that between the first inner half shell (12) and the first outer half shell (10) a first cooling channel section (13) of the cooling channel (8) is defined and within the housing (9) a second inner half shell (14) abuts in sections against the second outer half shell (11) such that between the second inner half shell (14) and the second outer half shell (11) a second cooling channel section (15) of the cooling channel (8) is defined.Rotor arrangement (1) according to claim 1, characterised in that the first inner half shell (10) has a plurality of spaced-apart first spacer elements (16), which abut against the first outer half shell (10), and / or the second inner half shell (14) has a plurality of spaced-apart second spacer elements (17), which abut against the second outer half shell (11).Rotor arrangement (1) according to Claim 2, characterized in that the first spacer elements (16) are formed integrally, in particular monolithically, with the first inner half shell (10) and / or the second spacer elements (17) are formed integrally, in particular monolithically, with the second inner half shell (14).Rotor arrangement (1) according to Claim 2 or 3, characterized in that the first spacer elements (16) are of substantially identical design and / or the second spacer elements (17) are of substantially identical design.Rotor arrangement (1) according to one of Claims 2 to 4, characterized in that the first spacer elements (16) are arranged on the first inner half shell (10) in a grid-like manner and / or the second spacer elements (17) are arranged on the second inner half shell (14) in a grid-like manner.Rotor arrangement (1) according to one of the preceding claims, characterized in that the first inner half shell (12) covers 75-95% of the surface of the first outer half shell (10) and / or the second inner half shell (14) covers 75-95% of the surface of the second outer half shell (11).Rotor arrangement (1) according to one of the preceding claims, characterized in that the first outer half shell (10) and the second outer half shell (11) are connected, preferably welded, in a materially bonded mannerRotor arrangement (1) according to one of the preceding claims, characterized in that the first outer half shell (10) and the second outer half shell (11) are substantially identically shaped and / or the first inner half shell (12) and the second inner half shell (14) are substantially identically shaped.Separating body (7) for a rotor arrangement (1), in particular for a rotor arrangement (1) according to Claim 1, comprising at least one continuous cooling duct (8) which extends through the separating body (7) in the axial direction and through which a cooling medium can flow, characterized in that the separating body (7) has a housing (9) having a first outer half shell (10) and a second outer half shell (11), wherein within the housing (9) a first inner half shell (12) bears in sections against the first outer half shell (10) in such a way that between the first inner half shell (12) and the first outer half shell (10) a first cooling duct section (13) of the cooling duct (8) is defined and within the housing (9) a second inner half shell (14) bears in sections against the second outer half shell (11), a second cooling channel section (15) of the cooling channel (8) is defined between the second inner half shell (14) and the second outer half shell (11).Method for producing a separating body (7) for arrangement in a rotor arrangement (1), in particular a rotor arrangement (1) according to claim 1, comprising the following steps: • providing a first metal sheet and forming the first metal sheet into a first outer half shell (10) and a second outer half shell (11); • providing a second metal sheet and forming the second metal sheet into a first inner half shell (12) and a second inner half shell (14); • Formation of the separating body (7) with a housing (9) made of the first outer half shell (10) and the second outer half shell (11), wherein within the housing (9) the first inner half shell (12) abuts in sections against the first outer half shell (10) in such a way that a first cooling channel section (13) of the cooling channel (8) is defined between the first inner half shell (12) and the first outer half shell (10), and within the housing (9) the second inner half shell (14) abuts in sections against the second outer half shell (11) in such a way that a second cooling channel section (15) of the cooling channel (8) is defined between the second inner half shell (14) and the second outer half shell (11).

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