Steering feedback actuator, steering system and steer-by-wire device

Abstract

The invention relates to a steering feedback actuator, a steering system, and a steer-by-wire device. The steering feedback actuator comprises a transverse flux machine connected to a control unit via sensor data exchange. The transverse flux machine has a rotor and a stator arranged coaxially to the rotor, the stator comprising at least one stator ring with at least one ring coil, the at least one ring coil being arranged in a cavity formed by a press fit of a first half-shell and a second half-shell, wherein the first claws of the first half-shell and the second claws of the second half-shell of a press fit of the first half-shell and the second half-shell are oriented towards each other and spaced apart from each other, and a circumferential zigzag groove is formed on the at least one stator ring.

Description

[0001] The invention relates to a steering feedback actuator, a steering system and a steer-by-wire device.

[0002] The steering of vehicles, such as cars, aircraft, or floating systems, can be implemented using a so-called steer-by-wire system. In this system, a steering command is detected, primarily by sensors, and sent electrically via a signal from one or more control units to an electromechanical actuator. This actuator then executes the corresponding steering command to steer the vehicle, such as a car, motorcycle, aircraft, and / or ship. Essentially, there is no mechanical connection between the steering device, such as a steering wheel, and the steering system, particularly the steered wheels and the steering actuator.

[0003] The driver of the vehicle uses the steering system to input steering commands. For safety and driver ergonomic reasons, it is essential to provide the driver with steering feedback at the steering system, representing the current steering behavior, such as resistance at a steered wheel, and to synchronize the steering system position with the wheel position, such as ensuring the wheels are straight when exiting a curve, particularly in at least partially automated driving situations.

[0004] To implement steering feedback, a steering feedback device can be used which either causes a rotational movement of the steering wheel and / or acts on a rotational movement of the steering wheel induced by the driver.

[0005] The steering feedback device can be configured to influence the driver-induced rotational movement of the steering wheel by providing an adjustable force transmission to the steering shaft or steering wheel. This adjustable force transmission allows the ease of steering wheel rotation to be set and thus adapted to a specific driving situation.

[0006] To achieve a rotational movement of the steering wheel, the steering feedback device can include an actuator, in particular an electric motor.

[0007] Steering feedback devices are known which include a motor and / or a gearbox and / or a brake and act on a steering shaft that is rigidly connected to the steering system. These known steering feedback devices thus achieve both the initiation of a rotational movement of the steering wheel and the influencing of a rotational movement of the steering wheel.

[0008] JP 2004 182061 A discloses a vehicle steering device acting on a steering device with an axial flux electric motor which generates a steering reaction force and has a rotatable rotor and a stator, wherein the rotor is arranged on the steering device and the stator is arranged inside the rotor.

[0009] DE 10 2018 101 528 A1 discloses a steering column for a steer-by-wire steering system of a motor vehicle, comprising a steering shaft connectable to a steering wheel. This steering shaft is rotatably mounted in an inner sleeve tube about a longitudinal axis, the inner sleeve tube having an outer diameter. Furthermore, an outer sleeve tube is described in which the inner sleeve tube is displaceable along the longitudinal axis and which is connectable to the vehicle chassis. The steering column also includes a feedback actuator with an electric motor that drives the steering shaft via a drive component having a recess with a diameter larger than that of the inner sleeve tube.

[0010] DE 10 2017 105 361 A1 discloses a claw-pole stator for a transverse flux motor, consisting of a plurality of segments arranged side by side along a circumferential direction to form an annular claw-pole stator. Each segment extends from an inner circumferential surface along a radial direction to an outer circumferential surface and is bounded circumferentially by a first and a second side surface and axially by a first and a second end surface. The segments are connected to each other via the side surfaces, with adjacent segments forming a positive-locking connection in the circumferential direction via contact surfaces. This arrangement enables a stable and efficient claw-pole stator structure for use in transverse flux motors.

[0011] DE 10 2019 106 322 B3 discloses a method for manufacturing claw pole laminations for stators of electric claw pole generators. The method comprises providing a strip of ferromagnetic material, punching the strip to create a continuous web and tabs for forming claw poles, and bending the tabs about at least one bending axis. Furthermore, the strip is divided into individual strips, the webs of the punched and bent strips are bent into ring segments with different diameters, and the resulting claw pole laminations are assembled into claw pole cages.

[0012] A steering system for a vehicle, comprising a steering wheel hub connected or connectable to a steering wheel, wherein the steering wheel hub is rotatable about an axis of rotation, a steering system support column having an off-axis section with a first longitudinal axis offset from the axis of rotation and preferably extending parallel thereto, wherein the steering system support column has an aligned section with a second longitudinal axis corresponding to the axis of rotation, wherein the steering wheel hub is rotatably mounted on the aligned section, while the off-axis section is axially spaced from the steering wheel hub, and wherein the steering system comprises a torque feedback device comprising an electric machine with a rotor and a stator, wherein the rotor is attached to the steering wheel hub such that it is rotatable with the steering wheel hub about the axis of rotation, and the stator is non-rotatably attached to the aligned section of the steering system support column.where the rotor is an external rotor and the stator is an internal stator, is disclosed in EP 3 960 583 B1.

[0013] The realization of an axial flux machine as part of a feedback actuator with planetary gears is disclosed in JP 2023 - 92 017 A.

[0014] In WO 2019 / 185 712 A1, the use of a reluctance machine as a steering feedback device is shown.

[0015] To achieve the desired effect of the steering feedback system on the steering wheel shaft and / or the steering wheel itself, the steering feedback system must be positioned in close proximity to the steering wheel and / or the steering shaft, which is rigidly connected to the steering wheel. The installation space near the steering wheel is very limited, and only a small volume is available for accommodating the steering feedback system, as the passenger compartment, control units, safety devices, and storage compartments are also located in this area. Furthermore, the weight of the steering feedback system should be as low as possible to minimize the vehicle's overall mass. The steering feedback system should also feature a high degree of redundancy. Finally, the steering feedback system should be manufactured as efficiently as possible. Therefore, the goal is to provide steering feedback systems that are as compact and cost-effective as possible.

[0016] The known steering feedback devices have the disadvantage of being complex to manufacture and incurring high material costs. For example, in classic radial flux machines, a stator with teeth is manufactured, and the teeth or poles are wound with multiphase wire. In axial flux machines or conventional transverse flux machines, sintering is used to achieve a 3D stator geometry. The materials are iron-powder-containing composites, which are formed by pressing and then sintered.

[0017] Another disadvantage of known steering feedback systems is their high torque ripple. Torque ripple, also known as torque waveform, is an effect characterized by a periodic rise and / or fall in the output torque of an electric motor during one rotation of the motor shaft. Torque ripple is thus defined as the difference between a minimum and a maximum torque over exactly one revolution of the electric motor.

[0018] The purpose of the invention is to improve the state of the art.

[0019] The problem is solved by a steering feedback actuator with the features of claim 1, a steering system with the features of claim 7, and a steer-by-wire device with the features of claim 9. Advantageous embodiments are described in the dependent claims. Advantageously, the steering feedback actuator according to the invention achieves a high torque at a low rotational speed, particularly below 200 rpm, which is expected to occur during steering wheel rotation. The torque of the steering feedback actuator can be 3 to 10 Nm. Furthermore, the steering feedback actuator according to the invention advantageously achieves low torque ripple, particularly due to the shape and arrangement of the first and second claws.Furthermore, the steering feedback actuator is advantageously inexpensive to produce, since the stator, while maintaining at least the same technical functionality as a known electric motor, can be realized as a solid sheet metal component and essentially does not contain any SMC material. Finally, the steering feedback actuator according to the invention is very compact and thus has small dimensions.

[0020] A key idea is based in particular on the use of a transverse flow machine with a control unit as a steering feedback actuator, thus providing a cost-effective and compact steering feedback actuator.

[0021] The following terms will be explained: A "transverse flux machine" is an electric motor with a circumferential winding arranged concentrically to a central axis. The magnetic flux, generated by the circumferential winding and an applied current, thus runs transversely and perpendicular to a plane of rotation. The axis of rotation features a magnetic ring with areas of varying magnetization, enabling the rotation of a shaft located on the axis of rotation through the interaction of the magnetic flux and the magnetic ring. Advantageously, a transverse flux machine can achieve high continuous torque. Furthermore, it requires less installation space than an axial flux machine. Finally, a transverse flux machine can operate continuously without cooling.

[0022] The transverse flux machine comprises, in particular, a rotor and a stator. The stator is arranged, in particular, coaxially to the rotor.

[0023] The stator is formed by means of at least one stator ring. Additionally or alternatively, the stator can have a second stator ring and / or a plurality of stator rings. The plurality and / or multiple stator rings are arranged, in particular along a longitudinal extension of the stator that is oriented in the same direction as a longitudinal extension of the steering feedback actuator, adjacent to one another and / or in contact with each other.

[0024] Especially for use with three-phase current, the stator has three stator rings, each carrying one phase, which can be arranged slightly rotated relative to each other. In other words, the three phases together form the first winding system of a multi-phase stator. The stator rings can be rotated around 14 until 16 The claws are arranged in a twisted manner according to a claw repetition angle. The angular distance between the first flank of a first claw and the first flank of a second claw adjacent to the first claw is called the claw repetition angle.

[0025] Additionally or alternatively, the overall stator can have a second winding system with three further stator rings arranged side by side along the longitudinal axis of the stator. The multiple sets of three stator rings can also be arranged slightly rotated relative to each other, especially around 14 to 16 The claw repeat angle is rotated. In other words, such a complete stator comprises a first stator with the first three-phase winding system and a second stator with the second three-phase winding system. This advantageously increases the redundancy of the complete stator. To reduce torque ripple, the second and / or subsequent winding systems can be arranged with a minimal rotational offset relative to the first winding system.

[0026] The rotor can have aluminum (e.g. as a support ring) and additionally or alternatively an iron ring.

[0027] The rotor can be a hollow shaft and / or a shaft. Additionally or alternatively, the rotor can have a stepped outer contour. In particular, to generate the holding and / or rotational force between the stator and the rotor, the rotor has a magnetic ring, preferably a hollow cylindrical one. The hollow cylindrical magnetic ring is arranged, in particular, on a surface of the rotor facing the stator and covers at least a width of the stator, especially of the stator ring and / or stator rings.

[0028] The hollow cylindrical magnet ring is rigidly connected to the rotor. Additionally or alternatively, the rotor encompasses the hollow cylindrical magnet ring. The hollow cylindrical magnet ring consists primarily of plastic containing magnetizable particles and / or iron.

[0029] The hollow cylindrical magnet ring has at least one first permanently magnetized segment and one second permanently magnetized segment along its surface facing the stator. The first segment is imprinted with a first magnetization direction, and the second segment with a second magnetization direction oriented 90° relative to the first magnetization direction in the direction of the longitudinal axis of the steering feedback actuator. By imprinting the first and second magnetizations, a Halbach arrangement is advantageously implemented. Due to more harmonic field distributions, a lower torque ripple advantageously occurs when implemented as a Halbach arrangement.

[0030] To create the permanent magnet, the hollow cylindrical magnet ring incorporates, in particular, plastic-bonded metal particles. Furthermore, a magnet ring with low material costs is advantageously achieved, especially since no NdFeB permanent magnet is used. The plastic can be, in particular, a thermoplastic and / or a thermoset.

[0031] In one embodiment, a shear gap exists between the hollow cylindrical magnet ring and the stator. This shear gap also essentially has a hollow cylindrical shape. The height of the shear gap can be 0.2 mm to 1 mm, particularly 0.3 mm to 0.6 mm. Advantageously, the accuracy of the shear gap is predefined by arranging a bearing seat for the rotor on a stator housing. This bearing seat can be located at least partially within a region of the stator, resulting in a very compact design for the steering feedback actuator.

[0032] The stator ring has a thickness of 8 mm to 15 mm and comprises at least one ring coil, a first half-shell and a second half-shell.

[0033] The ring coil is arranged in particular in a cavity which is formed by a first half-shell and a second half-shell.

[0034] One form of the first half-shell and / or the second half-shell is essentially U-shaped. The first half-shell and the second half-shell are designed to form a press fit. To create the press fit, the first half-shell and the second half-shell are essentially inserted into each other with the open side of the U-shape.

[0035] A press fit is understood in particular to be a fixed arrangement of the first half-shell relative to the second half-shell, in which the first half-shell is inserted into the second half-shell and pressed against it with a predefined force, wherein the outer dimension of the first half-shell and the inner dimension of the second half-shell correspond to each other in such a way that a surface pressure is realized at a contact surface of the first half-shell and the second half-shell.

[0036] The first half-shell has, in particular, a first end face, a first lateral surface projecting from the first end face on one side, and a second lateral surface arranged parallel to the first lateral surface on the first end face. The first end face corresponds to a U-shaped connecting element between a first leg (the first lateral surface) and a second leg (the second lateral surface) of the U-shape.

[0037] At least two first connector elements are arranged on the first lateral surface. These at least two connector elements can, in particular, be implemented as protrusions. The protrusions are open, in particular, on an open side of the first lateral surface, which is arranged opposite the end face, and have a predefined depth in the direction of the first end face.

[0038] On the second surface of the mantle, the first claws are arranged essentially equidistant from each other.

[0039] A cable gland can be arranged on the first end face. By means of this cable gland, an electrical conductor of the ring coil can be led out of the cavity formed by the first and second half-shells in the press fit, specifically from exactly one end face of the stator ring. Additionally or alternatively, the first end face can be designed as a closed surface.

[0040] The first claws are tapered, particularly from a foot located on the first end face. The claw angle can be, in particular, 20° to 30°. The first claws have a height of, in particular, 5 mm to 15 mm, and in particular, 10 mm. Furthermore, the foot width of the first claws is, in particular, 3 mm to 15 mm, and in particular, 5 mm. A gap, also called a space, can exist between a first claw of the first set of claws and an adjacent second claw of the first set of claws. Alternatively, the first claw of the first set of claws and the second claw of the second set of claws can touch each other. The gap between the first claw of the first set of claws and the second claw of the first set of claws can be 0.5 mm to 2 mm, and in particular, 1 mm to 1.5 mm. A recess can be present in the space between the first claw of the first set of claws and the second claw of the first set of claws.The material recess can additionally or alternatively extend at least partially over the first end face. A chamfer can be arranged on the first jaws and / or on the material adjacent to the gap, which advantageously reduces material stresses. This advantageously enables simple production of the first jaws of the first half-shell. The design of the first jaws described above advantageously achieves optimized functionality of the transverse flow machine.

[0041] In one embodiment, the first claws and / or the claws are not distributed absolutely equidistantly around the circumference, but exhibit a twist of 0.1 mm to 0.5 mm, particularly 0.2 mm. This advantageously reduces the torque ripple.

[0042] The second half-shell has a second end face, a third lateral surface projecting from one side of the second end face, and a fourth lateral surface arranged parallel to the third lateral surface on the second end face.

[0043] On the third surface of the casing, second connector elements corresponding to the first connector elements are arranged.

[0044] On the fourth surface of the shell, second claws are arranged essentially equidistant from one another. The arrangement of the second claws corresponds in particular to the arrangement of the first claws on the first half-shell. The other design features of the second claws correspond to those of the first claws. Both the first and second half-shells each have exactly one end face.

[0045] The features of the second end face can, in particular, correspond to the features of the first end face.

[0046] The first and second end faces are oriented in opposite directions within the clamping assembly, and the first claw of the first claw and the first claw of the second claw are spaced apart from each other. In other words, the first and second claws do not touch each other in the clamping assembly. The first and second claws form a zigzag-shaped groove between them.

[0047] In a transverse projection of the first and second claws of the press fit, an overlap between the first and second claws is evident. The resulting amount of material in the first and second claws is therefore essentially constant across the inner diameter of the stator and is initially comprised of the first claw of the first claw and the first claw of the second claw.

[0048] The first half-shell and / or the second half-shell contains, in particular, metal. The metal can, in particular, be a soft magnetic and malleable, especially ductile, metal.

[0049] A first ring coil and / or a second ring coil can be arranged in the cavity formed by the first and second half-shells of a stator ring. Arranging multiple ring coils in a stator ring can advantageously increase the redundancy of the functionality of the ring coil and thus of the stator ring and / or the transverse flux machine.

[0050] The ring coil contains copper, which advantageously has good electrical conductivity.

[0051] The toroidal coil can have at least one first winding zone and one second winding zone along its circumference and / or along its cross-section. In this way, the functionality of the toroidal coil and / or the transverse flux machine can be advantageously adjusted by means of the first and second winding zones, and / or redundancy is advantageously increased.

[0052] In one embodiment, the rotor is an internal rotor. The second surface of the first half-shell is an inner surface of the first half-shell. Additionally or alternatively, the fourth surface of the second half-shell is an inner surface of the second half-shell. Thus, in this embodiment, the first and second claws, respectively, located on the second and fourth surfaces, are arranged on an inner surface of the stator ring. A rotatable shaft, acting as a rotor, located within the stator ring can advantageously be rotated and / or its rotation controlled by the transverse flux machine. Alternatively, the stator ring of this embodiment can be used for separately excited rotors.

[0053] In an alternative embodiment, the rotor is an external rotor. In this embodiment, the second surface of the first half-shell is an outer surface. Additionally or alternatively, the fourth surface of the second half-shell is also an outer surface. Thus, the first and second claws, located on the second and fourth surfaces, are positioned on the outer surface of the stator ring. This allows the transverse flux machine to rotate an annular rotor located outside the outer surface and / or to control its rotation.

[0054] In one embodiment, the first and second connector elements are each arranged such that the second half-shell can only be inserted into the first half-shell in a predefined orientation. This advantageously ensures high manufacturing quality of the stator.

[0055] In one embodiment, the transverse flux machine has, in particular, 25 to 40, and in particular 36, pairs of claws. Each pair of claws comprises, in particular, a first claw of the first claws and an adjacent first claw of the second claws.

[0056] The first claws of a stator ring exhibit a first polarity when a current is applied to the ring coil. Additionally or alternatively, the second claws of the stator ring exhibit a second polarity when a current is applied to the ring coil. The first polarity is, in particular, opposite to the second polarity. In this way, the transversely acting magnetic flux is realized.

[0057] In one embodiment, the first half-shell is manufactured from a single sheet of metal. Additionally or alternatively, the second half-shell is manufactured from a second single sheet of metal. The first sheet and / or the second sheet has a thickness of 1 mm to 3 mm. The first half-shell and / or the second half-shell is manufactured, in particular, by means of a stamping process. The stamping process can be multi-stage. This ensures simple manufacturability of the first half-shell and the second half-shell.

[0058] In one embodiment, the stator comprises a first stator ring, a second stator ring, and / or a third stator ring. The first stator ring, the second stator ring, and / or the third stator ring are arranged, in particular, alongside one another and / or in at least partial contact with each other along a longitudinal axis of the stator. The first stator ring, the second stator ring, and / or the third stator ring, in particular, constitute a first three-phase winding system.

[0059] A first winding system can be arranged offset from a second winding system in one direction of rotation. Additionally or alternatively, a third winding system can be arranged offset from the first winding system in the same direction of rotation. The offset angle between the winding systems can be 120°. Additionally or alternatively, the three winding systems can be arranged in a star configuration and / or a delta configuration.

[0060] The respective electrical connections of the ring coils, also called conductors, wires, and / or cables, which are arranged on the first, second, third, and / or subsequent stator rings of a stator, are led out of the respective stator ring, particularly at the respective end faces. Additionally or alternatively, the respective electrical connections are guided along a surface of an adjacent stator ring and / or penetrate an adjacent stator ring. To guide the respective electrical connections along the surface of the adjacent stator ring, the stator ring and / or the housing may have a groove in which at least one electrical connection can be at least partially inserted. An electrical connection of a stator ring is located, in particular, on the surface of the stator ring opposite the clamps.In this way, all electrical connections of the ring coils of all stator rings of the stator can advantageously be led to exactly one connection point on the stator, which is in particular arranged on an end face of the stator and / or a housing of the stator.

[0061] The stator can be arranged in a housing. In other words, the housing can be designed to accommodate the individual stator rings. The housing thus at least partially encloses a cavity in which the stator is located. The housing can contact the stator, which is particularly well-designed as an internal rotor. Additionally or alternatively, the housing has recesses from which the electrical connections of the respective ring coils of the stator rings can be routed. In this way, the stator can advantageously be connected to the control unit of the steering feedback actuator using these electrical connections.

[0062] The control unit is specifically designed to regulate a function of the transverse flux machine via a signal-based approach. This is achieved by the control unit determining a current and transmitting a corresponding current to the transverse flux machine. One function of the transverse flux machine is, in particular, the active movement of the rotor relative to the stator and / or the magnitude of a force transmission from the stator to the rotor.

[0063] In another aspect, the problem is solved by a steering system according to claim 7.

[0064] In one embodiment, the steering system has a housing that is associated with the transverse flux machine in a contacting manner. The first and second connector elements, which are implemented as interlocking protrusions, correspond to the housing in such a way that the transverse flux machine is arranged in a predefined position within the housing and / or can be locked in a predefined position within the housing by means of the first and / or the second connector elements.

[0065] In a further embodiment, the steering system additionally features a controllable braking device. The braking device is arranged, in particular, coaxially with the steering feedback actuator. In this way, both the steering feedback actuator and the braking device act on the rotor. The braking device can have a torque of 100% to 300% of the torque of the transverse flux machine. The torque of the braking device is, in particular, 5 Nm to 30 Nm.

[0066] The braking device can influence the rotation of the rotor, in particular by means of adjustable friction. The braking device can be a powder brake. The powder brake specifically comprises a brake rotor, which can correspond to the rotor of the transverse flux machine and / or is directly and / or indirectly coupled to the rotor of the transverse flux machine, and a brake stator. The brake stator can additionally or alternatively be attached to the housing by means of a press fit and / or positive locking mechanism and / or contains an excitation coil.

[0067] A gap containing a magnetizable powder exists between the brake stator and the brake rotor. The degree of magnetization of the powder allows for adjustment of the rotor's resistance. Thus, the brake device and the steering feedback actuator share a common rotor shaft. This advantageously enables a positive-locking arrangement of both the brake device and the steering feedback actuator within a single housing.

[0068] A surface of the rotor and / or a surface of the stator may be coated and / or treated. Additionally or alternatively, the surface of the rotor and / or the surface of the stator may have textures, in particular grooves and / or roughening. The textures and / or surface finishes may, in particular, influence the power transmission properties and / or the sliding properties of the stator relative to the rotor and / or of the stator relative to the housing.

[0069] The braking device can additionally or alternatively be a controllable band brake. A band brake, in particular, comprises a steel brake band. The brake band can be slotted and / or coated and / or laminated. The brake band and / or a stator of the braking device can be coated and / or laminated with a thin, tribologically effective material, such as Teflon, DLC, chromium, friction paper, or similar. An appropriate coating advantageously achieves optimized friction behavior. Due to the large effective diameter and the cylindrical friction surface of the brake band, the band brake advantageously exhibits a high frictional torque.

[0070] The braking system, in conjunction with the steering feedback actuator, advantageously supports a quality of steering feedback that is perceptible to the driver of the vehicle at the steering mechanism. A particularly advantageous feature is that the braking system and the steering feedback actuator share common support components, such as stator carriers, and that a high degree of coaxiality is ensured by their common arrangement on a shaft and / or in a housing.

[0071] Finally, the braking device can be an electromagnetic brake; a control device of the braking device can correspond to a control device of the steering feedback actuator.

[0072] The steering system may additionally or alternatively include a steering end stop. The steering end stop limits the angle of rotation. It can be implemented using radial protrusions on the rotor. Alternatively, it can be implemented via software. Alternatively, it can be implemented using multi-turn angle limiters, such as those with rotatable intermediate rings.

[0073] Extending from a steering device, such as a steering wheel, a steering shaft can be arranged on the steering wheel in a steering-wheel-remote embodiment of the steering system. This steering shaft is rigidly connected to the steering wheel. In particular, the steering shaft corresponds to a rotor that, as an internal rotor, interacts with a steering feedback actuator and / or the braking system. The steering shaft can be designed in two parts, allowing the steering wheel to be extended relative to a fixed part of the steering shaft located within the steering feedback actuator. Additionally or alternatively, the steering shaft can be height-adjustable. Both length and height adjustment of the steering wheel advantageously improve the ergonomics for the driver of the vehicle.

[0074] In the steering system's remote configuration, the transverse flux machine is arranged closer to the steering wheel than a braking device. Additionally or alternatively, the braking device can also be arranged closer to the steering wheel. Finally, a gearbox can be arranged on the steering shaft.

[0075] In an alternative embodiment, the steering system can be implemented as a steering wheel-mounted design, wherein the steering feedback actuator, in particular as an external rotor, is arranged directly on the steering wheel and interacts with a rotationally fixed steering column, which serves as the stator of the steering feedback actuator and / or the braking device. In other words, the steering feedback actuator is cup-shaped.

[0076] The braking system can be located between the steering feedback actuator and the steering wheel. Additionally or alternatively, the braking system can be located on the steering feedback actuator, opposite the steering wheel. The rotationally fixed steering column can also be length-adjustable and / or height-adjustable. Adjustability can be achieved manually and / or electrically. Advantageously, the adjustable steering column improves the ergonomics of the vehicle.

[0077] The steering wheel may incorporate a storage compartment. Additionally or alternatively, a crash energy absorption device may be located in close proximity to the steering shaft.

[0078] The control unit is connected to the transverse flux machine and / or the braking system via current and / or sensor data exchange. Based on sensor signals such as the steering angle, control information for the steering feedback actuator and / or control information for the braking system and / or vehicle information such as wheel position, and / or environmental information such as distance traveled or speed, the control unit determines a corresponding control signal and transmits it to a current transmitter, which sends a current corresponding to the control signal to the steering feedback actuator and / or the braking system. Alternatively, the control unit sends a current corresponding to the control signal to the steering feedback actuator and / or the braking system.The steering feedback actuator and / or the braking device react to the applied current, so that a rotational force and / or a braking force acts on the steering shaft and / or the steering column, thus realizing steering feedback.

[0079] In another aspect, the problem is solved by a steer-by-wire device according to claim 9.

[0080] The features, combinations of features and the advantages arising from them of the second to fourth aspects correspond to those mentioned with the first-mentioned aspect of the invention.

[0081] The invention will now be explained in more detail using exemplary embodiments. These will show... Fig. 1 a schematic representation of a first steering system, Fig. 2 a schematic representation of a second steering system, Fig. 3 a schematic representation of a first stator, Fig. 4 a schematic representation of a third stator in a housing, Fig. 5 a schematic representation of a housing, Fig. 6 a schematic representation of a steering wheel-remote steering feedback actuator, Fig. 7 a schematic representation of a stator ring, Fig. 8 a schematic representation of a transverse flux machine as an external rotor, as well as Fig. 9 a schematic representation of the second steering system.

[0082] A first steering system 141a has a steering wheel 143, which is arranged on a steering shaft as a rotor 107a, which is at least partially arranged in an extension carrier 151, as well as a control unit as a control unit 103 and a steering wheel-remote steering feedback actuator 101a with a transverse flux machine 105a, which is designed as an internal rotor, and a braking device 147, which is designed as a magnetic powder brake 147a.

[0083] The steering shaft, as rotor 107a, has a fixed section 107a1 and a length-variable section 107a2. The steering wheel 143 and the steering shaft, as rotor 107a, are rotationally movable with respect to an axis of rotation A.

[0084] The steering shaft, as rotor 107a, is adjustable in length and lockable along the axis of rotation A. An angle between the extension carrier 151 and the axis of rotation A is adjustable and lockable by means of an adjustment device (not shown). Thus, length and height variability of the steering wheel 143 are achieved.

[0085] The control unit 103 is arranged on the extension carrier 151 and is connected by means of a cable 137 to the transverse flux machine as an internal rotor 105a and the braking device 147 designed as a magnetic powder brake 147a and controls the transverse flux machine as an internal rotor 105a and the braking device 147 designed as a magnetic powder brake 147a by means of electrical energy.

[0086] The steering feedback actuator 101a, located away from the steering wheel, is arranged at an end of the extension carrier 151 facing away from the steering wheel 143. The steering shaft is the rotor of the steering feedback actuator 101a, with a magnetic ring 135 arranged as rotor 107a on an outer surface of the steering shaft for power transmission. This magnetic ring extends beyond the transverse flux machine as an inner rotor 105a and partially beyond the magnetic powder brake 147a.

[0087] The braking device 147, designed as a magnetic powder brake 147a, and the transverse flux machine as an internal rotor 105a act on the steering shaft as a rotor 107a, which projects at least partially through the steering feedback actuator 101a located away from the steering wheel. A rotational movement applied to the steering shaft as a rotor 107a by means of the transverse flux machine as an internal rotor 105a is thus perceptible to a driver at the steering wheel 143, as is an influence on a rotational movement applied to the steering wheel 143 by the driver.

[0088] A second steering system 141b also has a steering wheel 143, which is rotatable about a pivot axis A and movable about an extension sleeve 153, which is arranged on an extension carrier 151, as well as a transverse flux machine arranged in a steering wheel pot as a rotor 107b as an external rotor 105b with a steering wheel-adjacent steering feedback actuator 101b and a braking device 147 designed as a band brake 147b.

[0089] A control unit 103 is arranged on the steering wheel hub as rotor 107b, which forms the housing of the transverse flux machine as external rotor 105b, which is connected by means of a cable 137 to the transverse flux machine as external rotor 105b and the braking device 147 designed as a band brake 147b and controls the transverse flux machine as external rotor 105b and the braking device 147 designed as a band brake 147b depending on the driving situation by means of electrical energy.

[0090] The extension shell 153 with the transverse flux machine as external rotor 105b and the braking device 147 designed as a band brake 147b form the stator in a transverse flux machine as external rotor 105b and the steering wheel pot as rotor 107b is designed as a rotor, wherein a magnet ring 135 is arranged on an inner surface of the steering wheel pot as rotor 107b to realize a power transmission.

[0091] The extension sleeve 153 projects largely into the steering feedback actuator 101b located near the steering wheel from a side facing away from the steering wheel 143. The extension sleeve 153 is fixedly connected to the extension carrier 151. The extension carrier 151 enables height adjustment of the steering wheel 143. Furthermore, the sliding motion of the extension sleeve 153 relative to the extension carrier 151 enables length displacement of the steering wheel 143 along the axis of rotation A, thus allowing length adjustment of the steering wheel 143.

[0092] The transverse flux machine as an internal rotor 105a and the transverse flux machine as an external rotor 105b each have a stator with at least one stator ring 111.

[0093] A stator ring 111 comprises a first half-shell 115 and a second half-shell 125, as well as a ring coil 113. The first half-shell 115 has a first end face 117, from which a first inner surface projects as a second surface 121, formed by first claws 123. The number of claws of the first claws 123 is 27. Opposite the first inner surface 121, a first outer surface 119 projects from the first end face 117. On the first outer surface 119, 12 protrusions are arranged as first connector elements 120, distributed equidistantly around the circumference.

[0094] The second half-shell 125 has a second end face 127, from which a second inner surface projects as the fourth surface 131, formed by second claws 133. The number of claws of the second claws 133 is 27. On a second outer surface 129 opposite the second end face 127, forming the third surface 129, 12 notches are arranged as two plug-in connection elements 130, which are equidistantly distributed around the circumference of the second outer surface 129 and correspond to the shape of the first plug-in connection elements 120 on the first half-shell 115, which are designed as bulges, so that the first plug-in connection elements 120 on the first half-shell 115 can be inserted into the second plug-in connection elements 130 on the second half-shell 125, which are designed as notches.

[0095] By inserting the first plug-in connection elements 120, designed as bulges, into the second plug-in connection elements 130, designed as notches, a rotationally secured press fit between the first half-shell 115 and the second half-shell 125 can be achieved. The first claws 123 and the second claws 133 are spaced 1.2 mm apart. The claw angle of the first claws 123 and the second claws 133 is approximately 25°.

[0096] A first stator 109a has a first half-shell 115, a second half-shell 125 and a stator ring 111, which is arranged in a cavity between the first half-shell 115 and the second half-shell 125.

[0097] A second stator 109b has a first half-shell 115, a second half-shell 125, and three stator rings 111, which are arranged in a cavity between the first half-shell 115 and the second half-shell 125, wherein a first of the stator rings 111 is assigned to a first electrical phase U, a second of the stator rings 111 to a second electrical phase V, and a third of the stator rings 111 to a third electrical phase W. The first electrical phase U, the second electrical phase V, and the third electrical phase W form a first winding system UVW1.

[0098] A third stator 109c has a first half-shell 115, a second half-shell 125 and six stator rings 111, which are arranged in a cavity between the first half-shell 115 and the second half-shell 125, wherein a first and a fourth of the stator rings 111 are assigned to a first electrical phase U, a second and a fifth of the stator rings 111 to a second electrical phase V and a third and a sixth of the stator rings 111 to a third electrical phase W. The first electrical phase U of the first stator ring 111, the second electrical phase V of the second stator ring 111 and the third electrical phase W of the third stator ring 111 form the first winding system UVW1 and the first electrical phase U of the fourth stator ring 111, the second electrical phase V of the fifth stator ring 111 and the third electrical phase W of the sixth stator ring 111 form a second winding system UVW2, which realizes a redundancy of the first winding system UVW1.

[0099] In Fig. Figure 6 shows a steering feedback actuator 101a located away from the steering wheel, comprising a third stator 109c and a braking device 147 designed as a magnetic powder brake 147a. These act on a steering shaft as a rotor 107a and are at least partially enclosed by a housing 145. Each electrical connection of the six ring coils 113 protrudes from an end face of the housing 145 and is connected to the control unit 103, which is designed as a control device. Recesses 149 are arranged on an inner side of the housing 145. These recesses correspond to the second connector elements 130, designed as notches, in particular to an outer contour of the second connector elements 130, such that the ring coils 113 are securely held in the housing 145 by the recesses 149.

[0100] In Fig. 8 and Fig.Figure 9 shows a steering feedback actuator 101b located near the steering wheel, comprising a transverse flux machine as an external rotor 105b with a second stator 109b and a braking device in the form of a magnetic powder brake 147a, which are arranged within a steering wheel housing as a rotor 107b that is rigidly connected to a steering wheel (not shown here). A magnetic ring 135 and a control unit 103 are also arranged on the steering wheel housing as rotor 107b, the control unit 103 being configured for driving situation-dependent control of the steering feedback actuator 101b and the braking device as a magnetic powder brake 147a. On the side facing a stationary extension sleeve (not shown here), the steering wheel housing as rotor 107b has two rotation angle limiters 155 for limiting the rotation of the steering wheel housing as rotor 107b around the extension sleeve 153. Reference symbol list 101a Steering wheel remote feedback actuator 101b steering wheel feedback actuator 103 Control unit 105a Transverse flux machine as an internal rotor 105b Transverse flux machine as an external rotor 107a Steering shaft as rotor 107a1 fixed area of ​​the steering shaft 107a2 variable length range of the steering shaft 107b Steering wheel hub as rotor 109a first stator 109b second stator 109c third stator 111 Stator ring 113 Ring coil 115 first half-shell 117 first front face 119 first lateral surface 120 first plug connector elements 121 second lateral surface 123 first claws 125 second half-shell 127 second front face 129 third lateral surface 130 second plug connector elements 131 fourth lateral surface 133 second claws 135 Magnetic ring 137 cables 141a first steering system 141b second steering system 143 Steering wheel 145 cases 147 Braking system 147a Braking device as magnetic powder brake 147b Braking device as a band brake 149 exceptions 151 extract carriers 153 Extraction coat 155 Rotation angle limiter A axis of rotation U first electrical phase V second electrical phase W third electrical phase UVW1 first winding system UVW2 second winding system

Claims

[1] Steering feedback actuator (101a, 101b) comprising a transverse flux machine (105a, 105b) connected to a control unit (103) for sensor data exchange, the stator having a rotor (107a, 107b) and a stator arranged coaxially to the rotor, the stator (109a, 109b, 109c) comprising at least one stator ring (111) with at least one ring coil (113), the at least one ring coil (113) being arranged in a cavity formed in a press fit of a first half-shell (115) and a second half-shell (125), the first half-shell (115) comprising a first end face (117), a first outer surface (119) projecting from one side of the first end face (117) with at least two first connector elements (120), and a first outer surface (119) parallel to the first outer surface (119) on the first The front surface (117) has a second lateral surface (121) arranged with first claws (123) arranged equidistantly to each other,and wherein the second half-shell (125) has a second end face, a third lateral surface (129) projecting from one side of the second end face with at least two second connecting elements (130) corresponding to the first connecting elements (120), and a fourth lateral surface (131) arranged parallel to the third lateral surface (129) on the second end face with second claws (133) arranged equidistantly to each other, wherein the first connecting elements (120) and the second connecting elements (130) are designed to interlock at a predefined depth, wherein the first claws (123) and the second claws (133) of the press fit are oriented towards each other and spaced apart from each other, and a circumferential zigzag groove is formed on the at least one stator ring (111) in this way. characterized by, that the first half-shell (115) is made from a single first sheet and / or the second half-shell (125) is made from a single second sheet by means of a stamping and / or forming process. [2] Steering feedback actuator (101a, 101b) according to the preceding claim, wherein the rotor is an internal rotor (107a) in which the second lateral surface (121) of the first half-shell (115) corresponds to an inner lateral surface of the first half-shell (115) and the fourth lateral surface (131) of the second half-shell (125) corresponds to an inner lateral surface of the second half-shell (125) or wherein the rotor is an external rotor (107b) in which the second lateral surface (121) of the first half-shell (115) corresponds to an outer lateral surface of the first half-shell (115) and the fourth lateral surface (131) of the second half-shell (125) corresponds to an outer lateral surface of the second half-shell (125). [3] Steering feedback actuator (101a, 101b) according to one of the preceding claims, wherein the transverse flow machine (105a, 105b) has 25 to 40 pairs of claws, wherein each pair of claws comprises one of the first claws (123) of a first polarity and one adjacent to it of the second claws (133) of a second polarity. [4] Steering feedback actuator (101a, 101b) according to one of the preceding claims, wherein the stator (109b) has three stator rings (111) arranged side by side along a longitudinal axis of the stator (109b) and / or a plurality of three stator rings (111) arranged side by side along a longitudinal axis of the stator (109b). [5] Steering feedback actuator (101a, 101b) according to the preceding claim, wherein the three stator rings (111) and / or the plurality of three stator rings (111) are arranged relative to each other, in particular by 14 to 16 a claw repetition angle, are arranged in a twisted manner. [6] Steering feedback actuator (101a, 101b) according to one of the preceding claims, wherein the rotor (107a, 107b) has a hollow cylindrical magnet ring (135) facing the stator, which has at least a first segment and a second segment of a permanent magnet, wherein the first segment has a first magnetization direction and the second segment has a second magnetization direction oriented rotated by 90° in the direction of the longitudinal axis relative to the first magnetization direction, wherein a shear gap is in particular present between the hollow cylindrical magnet ring (135) and the stator (109, 109b, 109c), wherein the shear gap has a substantially hollow cylindrical shape and a height of 0.2 mm to 1 mm. [7] Steering system (141a, 141b) comprising a steering wheel (143) rotatable about an axis of rotation (A) and a steering feedback actuator (101a, 101b) acting on the axis of rotation (A) according to one of the preceding claims, further comprising a braking device (147) acting on the steering feedback actuator (101a, 101b), characterized by , that the braking device (147) is arranged coaxially to the steering feedback actuator (101a, 101b). [8] Steering system (141a, 141b) according to claim 7, wherein the steering feedback actuator (101a, 101b) comprises at least one transverse flux machine (105a, 105b) with a first half-shell (115) having first plug-in connection elements (120) and a second half-shell (125) having second plug-in connection elements (130), wherein the first plug-in connection elements (120) and the second plug-in connection elements (130) are realized as interlocking protrusions (120, 130) and an arrangement of the first plug-in connection elements (120) and an arrangement of the second plug-in connection elements (130) correspond to each other such that the second half-shell (125) can be plugged into the first half-shell (115) in at least one predefined orientation and wherein the steering system additionally comprises a contacting transverse flux machine (105a, 105b). associated housing (145)wherein the first plug-in connectors (120) and the second plug-in connectors (130) of the transverse flux machine (105a, 105b) correspond to recesses (149) arranged on the housing (145) such that the transverse flux machine (105a, 105b) is arranged in a predefined position in the housing (145) and can be locked in a predefined position by means of the first plug-in connectors (120) and / or second plug-in connectors (130). [9] Steer-by-wire device comprising a steering system (140a, 140b) according to claim 7 or 8.

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