Rotor device and stator device for a flat brushless electric motor and flat brushless electric motor for a roof system of an automobile

Description

[0001] The invention relates to a rotor device and a stator device for a flat brushless electric motor, in particular for a roof system of an automobile, and a flat brushless electric motor for a roof system of an automobile.

[0002] A flat, brushless electric motor is usually designed as a so-called external rotor or as a so-called internal rotor.

[0003] This means that - in the case of an external rotor - a rotor device has magnets of different polarity that rotate outside a stator device when the stator device is supplied with electrical energy.

[0004] In contrast, in the case of an internal rotor, the magnets of the rotor device are surrounded by the stator device.

[0005] In summary and in other words, in an external rotor the rotor device rotates outside around the stator device, whereas in an internal rotor the rotor device is surrounded by the stator device and rotates inside it.

[0006] These conventional brushless electric motors must be manufactured with high precision, making mass production costly.

[0007] Such motors can also only produce a low torque, which, however, does not adequately meet the increasing safety requirements of, for example, a folding or retractable roof system on a car. This is because, along with the increasing safety requirements, the mass of the roof elements that need to be moved in such a roof system also increases.

[0008] From the publication WO 2017 / 173188 A1, a double rotor motor is known in which an inner and outer rotor are formed concentrically to each other and are each provided with an arrangement of permanent magnets.

[0009] From the publication DE 11 2006 000 009 T5, a double rotor for a washing machine drive with an inner and outer rotor, each of which is provided with magnets, is known.

[0010] From the document JP 2010-284035 A, an electric rotary motor using permanent magnets is known, in which the rotor has an inner and an outer, each concentrically formed cylinder on which the permanent magnets are arranged.

[0011] It is known from document EP 2 722 971 A2 that an already assembled rotor can be inserted into a magnetization device for magnetization.

[0012] Therefore, it is an object of the present invention to provide a rotor device and preferably a stator device for a flat brushless electric motor, in particular for a roof system of an automobile, but also a flat, brushless electric motor, which can be produced cost-effectively and with reduced material consumption and preferably provides increased torque and advantageously competes with known devices and motors in terms of its dimensions.

[0013] These objects are achieved according to the invention by the features of the independent patent claims. Further advantageous developments are the subject of the dependent claims.

[0014] According to a first aspect of the present invention, a flat brushless electric motor for a roof system of an automobile comprises a rotor device comprising: a rotor housing element with a first and a second cylinder element, wherein the rotor housing element comprises an annular disc element which has an inner side and an outer side in the radial direction, wherein the first cylinder element is arranged on the inside, wherein the second cylinder element is arranged on the outside, wherein the first cylinder element has a first magnet assembly and the second cylinder element has a second magnet assembly, wherein the first cylinder element has an inner and an outer shell surface;wherein the first magnet assembly is arranged on the outer surface of the first cylinder element, wherein a rolling bearing is arranged on the inside of the first cylinder element, on the inner surface of which a rolling bearing is arranged, wherein the cylinder elements are hollow cylindrical, have different inner and outer diameters so that a stator device can be arranged between the cylinder elements, and are aligned concentrically to one another, wherein the inner diameter of the second cylinder element is larger than the outer diameter of the first cylinder element, and wherein at least one magnet assembly is arranged on each cylinder element. ;

[0015] Furthermore, the flat brushless electric motor has a stator device. This includes: a stator housing element with a base and a wall element, which are arranged relative to one another in such a way that the stator housing element is pot-shaped, and an axle element for the external arrangement of the rolling bearing for the rotor device, wherein the rotor device is connected to the axis element of the stator device via the rolling bearing, so that the rotor device and the stator device are rotatable relative to each other.

[0016] At least one magnet assembly is arranged on each cylinder element. In this way, at least two magnet assemblies are preferably available, compared to prior art solutions, making it possible to generate a torque that also meets the increasing safety requirements of a foldable or retractable roof system and the associated increased mass. With a sufficiently high torque, it is possible to move even relatively heavy roof elements of a foldable or retractable roof system safely and with sufficient speed.

[0017] The first cylinder element has a first magnet assembly, wherein the first magnet assembly is preferably hollow-cylindrical in shape.

[0018] The first cylinder element has an inner and an outer surface, wherein the first magnet assembly is arranged on the outer surface of the first cylinder element.

[0019] It can also be provided that the first magnet assembly comprises a magnetizable material, preferably to form different magnetic poles. Such a material allows, for example, the formation of magnetic poles after mounting the magnet assembly on the cylinder element.

[0020] Advantageously, the second cylinder element has a second magnet assembly, wherein the second magnet assembly is preferably hollow-cylindrical in shape.

[0021] Furthermore, it is advantageous if the second cylinder element has an inner and an outer surface, wherein the second magnet assembly is preferably arranged on the inner surface of the second cylinder element.

[0022] Furthermore, it is advantageous if the second magnet assembly comprises a magnetizable material to form different magnetic poles. For example, the aforementioned magnetizable material allows magnetic poles to be formed after the magnet assembly has been mounted on the cylinder element.

[0023] In particular, it is advantageous if the first and second magnet assemblies of the corresponding cylinder elements match in the radial direction with regard to pole pairs and the number of pole pairs. This allows for the realization of an efficient electric motor.

[0024] Advantageously, the rotor housing element has an annular disc element, in particular as the base of the rotor housing element, which has an inner side and an outer side in the radial direction.

[0025] It is also advantageous if the first cylinder element is arranged on the inside, in particular on the inner, circular recess of the disc element or on its edge.

[0026] The second cylinder element is preferably arranged on the outside, in particular on the outer edge of the disc element.

[0027] Furthermore, it can be provided that the inner side of the disc element and the inner surface of the first cylinder element merge into one another.

[0028] Preferably, the outer side of the disc element and the outer surface of the second cylinder element merge into one another.

[0029] In other words, it is advantageous if the rotor housing element is formed in one piece with the cylinder elements and the disc element.

[0030] It is possible that the rotor housing element is manufactured using a deep-drawing process or a pressing process.

[0031] A second aspect of the present invention comprises a method for magnetizing a rotor device of the flat brushless electric motor or for forming magnetic poles in such a rotor device.

[0032] According to the invention, the method uses a rotor device of the flat brushless electric motor according to the first aspect.

[0033] The method utilizes a magnetization device for magnetizing magnetizable material, which can be arranged in the space between the cylinder elements of the rotor housing element of the rotor device of the flat brushless electric motor. The magnetization device has at least one coil element for generating a magnetic field and preferably at least one core element, in particular an iron core, for amplifying the magnetic field that can be generated by at least one coil element.

[0034] The method according to the invention comprises the following steps. One step of the method comprises positioning the rotor device and the magnetization device. In other words, in a first step, the rotor device and the magnetization device must be positioned relative to one another.

[0035] One step of the method includes inserting the magnetization device into the space between the cylinder elements of the rotor housing element of the rotor device. The magnetization device is thus ready for magnetizing the rotor device.

[0036] Furthermore, it is advantageous that one step of the method includes a joint magnetization of the first and second magnet assemblies so that the cylinder elements match in terms of pole pairs and number of pole pairs. This step thus ensures that not only the exact number of pole pairs and the associated magnetic orientation (north pole, south pole) but also the position of the generated poles in the cylinder elements can be precisely predetermined.

[0037] It is also advantageous if one step of the method includes removing the magnetization device from the intermediate space. Thus, the magnetization device can be positioned relative to another rotor device, and the method can be repeated.

[0038] Further embodiments of the present invention specify the features of the stator device of the flat brushless electric motor.

[0039] Preferably, the axle element is designed as a protruding pin or the like, in particular made of a solid material.

[0040] Furthermore, it is preferred that the axis element is arranged in the center of the stator housing element and such that, viewed in cross section, the axis element and the wall element extend away from the base element in the same direction.

[0041] Advantageously, the stator housing element and the axle element are formed in one piece or integrally with each other.

[0042] It is also advantageous if the axle element comprises a securing device for securing a rolling bearing, in particular a snap ring with a corresponding recess on the axle element.

[0043] Advantageously, the stator device comprises a housing part for mounting a plurality of tooth elements.

[0044] Furthermore, it is advantageous if the housing part is designed as a disc-shaped plate.

[0045] Furthermore, it is advantageous if a plurality of tooth elements are firmly connected to the housing part, in particular cast, preferably cast by means of a plastic.

[0046] Preferably, the stator device has at least one tooth element for winding with a coil arrangement, wherein preferably the at least one tooth element has an inner and an outer end and a receptacle for a wound coil arrangement arranged therebetween.

[0047] It is also preferred that the stator device comprises a coil arrangement with a wire element wound around the receptacle of the toothed element. Preferably, the coil arrangement is encapsulated with the toothed element, in particular using a plastic.

[0048] Furthermore, it is possible for the at least one tooth element to have a surface portion of an inner peripheral surface and a surface portion of an outer peripheral surface at the inner and outer ends in order to form an inner peripheral surface and an outer peripheral surface.

[0049] Preferably, the inner circumferential surface is adapted to an outer circumferential surface of a first cylinder element, in particular to an outer circumferential surface of a first magnet assembly of a first cylinder element, of a rotor device, so that the inner circumferential surface and the outer circumferential surface can be separated from one another via an air gap.

[0050] Furthermore, it is preferred that the outer peripheral surface is adapted to an inner surface of a second cylinder element, in particular to an inner surface of a second magnet assembly of a second cylinder element, of a rotor device, so that the outer peripheral surface and the inner surface can be separated from one another via an air gap.

[0051] The rolling bearing is arranged on the outside of the axle element of the stator device and on the inside of the first cylinder element of the rotor device.

[0052] In this context, it is advantageous if the rolling bearing is pre-mounted either on the rotor device or on the stator device.

[0053] Furthermore, it is advantageous if the motor has a motor housing element for closing the motor and for fastening it to the stator housing element.

[0054] Using the rotor device and the stator device, it is possible to construct a motor with improved total effective torque compared to state-of-the-art solutions of the same size.

[0055] The motor according to the invention and the method according to the invention (see the second aspect of the present invention) can also simplify the manufacturing and assembly process. As a result, an improvement in the overall (manufacturing) cycle time can even be achieved.

[0056] Furthermore, it has been noticed as a surprising effect that the described construction of the motor according to the invention causes a considerable reduction in the noise generated precisely by the formation of the axle element on the stator housing element or on the stator device and the positioning of the rolling bearing.

[0057] The invention is explained in more detail below using exemplary embodiments in conjunction with the accompanying drawings. The drawings schematically show: Fig. 1 a schematic plan view of a rotor device according to the invention and a spatial view of the rotor device according to the invention; Fig. 2 a sectional view of the rotor device according to the invention Fig. 1 ; Fig. 3 a sectional view of a stator device according to the invention; Fig. 4 a spatial view of a tooth element of the stator device according to the invention; Fig. 5 a spatial view and a plan view of a housing part of the stator device according to the invention with a plurality of tooth elements; Fig. 6 a sectional view of a flat, brushless electric motor according to the invention; and Fig. 7 a top view of the rotor device Figure 1 with a magnetization device.

[0058] In the following description, the same reference symbols are used for the same items.

[0059] Figure 1 shows a schematic plan view of a rotor device 1 of a flat brushless electric motor according to an embodiment of the present invention as well as a spatial view of the rotor device 1 according to the invention, wherein Figure 2 a sectional view of the rotor device Fig. 1 represents.

[0060] For the sake of simplicity and brevity, the Figures 1 and 2 described together.

[0061] Shown in more detail Figures 1 and 2 a rotor device 1 for the flat brushless electric motor 30, in particular for a roof system of an automobile.

[0062] The rotor device 1 has a rotor housing element 2 with a first 3 and a second cylinder element 4, wherein a rolling bearing 31 can be arranged on the inside of the first cylinder element 3 on its inner lateral surface 3-IM.

[0063] The cylinder elements 3, 4 are hollow cylindrical, have different inner and outer diameters so that a stator device 10 can be arranged between the cylinder elements 3, 4, and are concentrically aligned with each other.

[0064] The inner diameter of the second cylinder element 4 is larger than the outer diameter of the first cylinder element 3.

[0065] Furthermore, Figures 1 and 2 that a magnet assembly 5, 6 is arranged on each cylinder element 3, 4.

[0066] Thus, the first cylinder element 3 has a first magnet assembly 5 which is hollow cylindrical in shape.

[0067] The first cylinder element 3 has an inner 3-IM and an outer surface 3-AM, wherein the first magnet assembly 5 is arranged on the outer surface 3-AM of the first cylinder element 3.

[0068] Furthermore, the second cylinder element 4 has a second magnet assembly 6 which is hollow-cylindrical in shape, wherein the second cylinder element 4 has an inner 4-IM and an outer lateral surface 4-AM.

[0069] The second magnet assembly 6 is arranged on the inner surface 4-IM of the second cylinder element 4.

[0070] Both the second magnet assembly 6 and the first magnet assembly 5 comprise a magnetizable material to form different magnetic poles.

[0071] So agree, as Figure 1in its schematic representation, the first and second magnet assemblies 5, 6 of the corresponding cylinder elements 3, 4 correspond in the radial direction with regard to pole pairs and number of pole pairs.

[0072] In particular Figure 2 shows that the rotor housing element 2 comprises an annular disc element 7, in particular as the base of the rotor housing element 2, which has an inner side IS and an outer side AS in the radial direction R.

[0073] Here, the first cylinder element 3 is arranged on the inside, in particular on the inner, circular recess of the disc element or on its edge, and the second cylinder element 4 is arranged on the outside, in particular on the outer edge of the disc element 7.

[0074] Shown in more detail, the inner side IS of the disc element 7 and the inner circumferential surface 3-IM of the first cylinder element 3 merge into one another, whereby the outer side AS of the disc element 7 and the outer circumferential surface 4-AM of the second cylinder element 4 also merge into one another.

[0075] The rotor housing element 2 is formed in one piece with the cylinder elements 3, 4 and the disc element 7 and is manufactured in a deep-drawing process or in a pressing process.

[0076] Figure 3 shows a sectional view of a stator device 10 according to the invention for the flat brushless electric motor 30 according to the embodiment, for a roof system of an automobile.

[0077] The stator device 10 has a stator housing element 11 with a base element 12 and a wall element 13, which are arranged relative to one another in such a way that the stator housing element 11 is pot-shaped.

[0078] Furthermore, the stator device 10 has an axle element 14 for the external arrangement of a rolling bearing 31 for a rotor device 1, wherein the axle element 14 is arranged in the center of the stator housing element 11 and such that, viewed in cross section, the axle element 14 and the wall element 13 extend away from the base element 12 in the same direction.

[0079] Also shows Figure 3 that the stator housing element 11 and the axle element 14 are formed in one piece or integrally with each other, wherein the axle element 14 has a securing device 15 for securing a rolling bearing, in particular a snap ring with a corresponding recess on the axle element 14.

[0080] Figure 4 shows a spatial view of a tooth element 17 of the stator device 10, wherein Figure 5 a spatial view and a plan view of a housing part 16 of the stator device 10 with a plurality of tooth elements 17.

[0081] As already indicated, the stator device 10 has a housing part 16 for attaching a plurality of tooth elements 17, wherein the housing part 16 is designed as a disc-shaped plate.

[0082] Here, the plurality of tooth elements 17 is firmly connected to the housing part 16, in particular cast (cf. in particular Figure 5 ).

[0083] In Figures 4 and 5 it is shown that the stator device 10 has various tooth elements 17 for winding with a coil arrangement 21.

[0084] Each tooth element 17 has an inner and an outer end 18, 19 and a receptacle 20 arranged therebetween for a wound coil assembly 21 comprising a wire element wound around the receptacle 20 of the tooth element 17.

[0085] The coil arrangement is cast with the tooth element 17.

[0086] How Figure 4shows, a tooth element 17 has at the inner and outer ends 18, 19 a surface portion 22 of an inner peripheral surface and a surface portion 23 of an outer peripheral surface to form an inner peripheral surface and an outer peripheral surface.

[0087] The inner circumferential surface is adapted to an outer circumferential surface 3-AM of the first cylinder element 3, in particular to an outer circumferential surface of the first magnet assembly 5 of the first cylinder element 3, of the rotor device 1, so that the inner circumferential surface and the outer circumferential surface can be separated from one another via an air gap.

[0088] The outer peripheral surface is adapted to an inner circumferential surface 4-IM of the second cylinder element 4, in particular to an inner circumferential surface of the second magnet assembly 6 of the second cylinder element 4, of the rotor device 1, so that the outer peripheral surface and the inner circumferential surface can be separated from one another via an air gap.

[0089] The above-mentioned facts are discussed with regard to Figure 6 clarified.

[0090] Because Figure 6 shows a sectional view of the flat, brushless electric motor 30 according to the invention for a roof system of an automobile.

[0091] The engine 30 has according Figure 6 a rotor device 1, as in Figures 1 to 3 shown, and a stator device 10, as shown in Figures 4 and 5 shown.

[0092] The rotor device 1 is connected to the axle element 14 of the stator device 10 via a rolling bearing 31, so that the rotor device 1 and the stator device 10 are rotatable relative to each other.

[0093] The motor further has a motor housing member 32 for closing the motor 30 and for fastening to the stator housing member 11.

[0094] Of course, the motor 30 also has connections for supplying electrical energy so that the rotor device can generate a torque relative to the stator device.

[0095] The double design of a magnet assembly 5, 6 on the rotor device 1 creates a motor that can generate higher torque compared to a conventional motor with only one magnet assembly.

[0096] Figure 7 shows a plan view of the rotor device 1 from Figure 1 with a magnetization device 8 for magnetizing magnetizable material of the cylinder elements 3, 4.

[0097] Shown in more detail Figure 7 a snapshot of a method for magnetizing the rotor device 1.

[0098] The method uses the described rotor device 1 and a magnetization device 8, which is arranged in the space between the cylinder elements 3, 4 of the rotor housing element 2 of the rotor device 1.

[0099] The magnetization device 8 has various coil elements 9 for generating a magnetic field and accordingly also various core elements, in particular iron cores, for amplifying the magnetic field that can be generated by the coil elements 9.

[0100] Basically, the method for magnetizing the rotor device 1 comprises the following steps: Positioning the rotor device 1 and the magnetization device 8, introducing the magnetization device 8 into the space between the cylinder elements 3, 4 of the rotor housing element 2 of the rotor device 1, jointly magnetizing the first and second magnet assemblies 5, 6 so that the cylinder elements 3, 4 match in terms of pole pairs and number of pole pairs, and then removing the magnetization device 8 from the space.

[0101] Here, the magnetization of the first and second magnet assemblies 5, 6 naturally includes that the magnetization device 8 is supplied with electrical energy for a certain period of time to generate magnetic fields. List of reference symbols

[0102] 1 Rotor device 20 Recording 2 Rotor housing element 21 Coil arrangement 3 first cylinder element 22 Part of the area 4 second cylinder element 23 Part of the area 5 first magnet assembly 6 second magnet assembly 30 Motor 7 Disc element 31 Rolling bearings 8 Magnetization device 32 Motor housing element 9 Coil element 10 Stator device 3-IM inner surface 11 Stator housing element 3 AM outer surface 12 Floor element 13 Wall element 4-IM inner surface 14 Axis element 4 AM outer surface 15 Safety device 16 Housing part IS inside 17 Tooth element AS outside 18 inner end 19 outer end R radial direction

Claims

1. Flat, brushless electric motor (30) for a roof system of an automobile a rotor device (1), comprising: - a rotor housing element (2) having a first (3) and a second cylinder element (4), - wherein the rotor housing element (2) comprises an annular disc element (7) which has an inner side (IS) and an outer side (AS) in the radial direction (R), - whereby the first cylinder element (3) is arranged on an inner side, - whereby the second cylinder element (4) is arranged on an outer side, - wherein the first cylinder element (3) has a first magnet assembly (5) and the second cylinder element (4) has a second magnet assembly (6), - wherein the first cylinder element (3) has an inner (3-IM) and an outer shell face (3-AM), - wherein the first magnet assembly (5) is arranged on the outer shell face (3-AM) of the first cylinder element (3), - wherein a roller bearing (31) can be arranged on the inner side of the first cylinder element (3) on its inner shell face (3-IM), - wherein the cylinder elements (3, 4) are formed to be hollow cylindrical, have different inner and outer diameters, so that a stator device (10) can be arranged between the cylinder elements (3, 4), and are aligned concentrically to one another, - wherein at least one magnet assembly (5, 6) is arranged on each cylinder element (3, 4); and a stator device (10), comprising: - a stator housing element (11) having a base element (12) and a wall element (13), which are mutually disposed in such a manner that the stator housing element (11) is configured in the shape of a pot, and - an axle element (14) for externally disposing the roller bearing (31) for the rotor device (1), wherein the rotor device (1) is connected to the axle element (14) of the stator device (10) via the roller bearing (31), so that the rotor device (1) and the stator device (10) are rotatable relative to one another.

2. Brushless electric motor (30) according to claim 1, wherein the first magnet assembly (5) is hollow cylindrical in shape.

3. Brushless electric motor (30) according to claim 1 or 2, wherein the second magnet assembly (6) is hollow cylindrical in shape.

4. Brushless electric motor (30) according to claim 3, - wherein the second cylinder element (4) has an inner (4-IM) and an outer shell face (4-AM), and - wherein the second magnet assembly (6) is arranged on the inner shell face (4-IM) of the second cylinder element (4).

5. Brushless electric motor (30) according to one of the preceding claims - wherein the inner side (IS) of the disc element (7) and the inner shell face (3-IM) of the first cylinder element (3) merge evenly into one another, and / or - wherein the outer side (AS) of the disc element (7) and the outer lateral surface (4-AM) of the second cylinder element (4) transition into one another in a planar manner, and / or - wherein the rotor housing element (2) is formed in one piece with the cylinder elements (3, 4) and the disc element (7), and / or - wherein the rotor housing element (2) is manufactured in a deep-drawing process or in a pressing process.

6. Brushless electric motor (30) according to one of the preceding claims, - wherein the axle element (14) comprises a securing installation (15) for securing a roller bearing, in particular a snap ring with a corresponding recess on the axle element.

7. Brushless electric motor (30) according to one of the preceding claims, - wherein the axle element (14) is arranged in the centre of the stator housing element (11) and in such a way that, when viewed in cross-section, the axle element (14) and the wall element (13) extend away from the base element (12) in the same direction, and / or - wherein the stator housing element (11) and the axle element (14) are formed integrally with one another.

8. Brushless electric motor (30) according to claim 6 or 7, - wherein the stator device (10) comprises a housing part (16) for attaching a plurality of tooth elements (17), - wherein the housing part (16) is designed as a disc-shaped plate, and / or - wherein a plurality of tooth elements (17) is firmly connected, in particular moulded, to the housing part (16).

9. Brushless electric motor (30) according to any one of claims 6 to 8, - wherein the stator device (10) has at least one tooth element (17) for winding with a coil assembly (21), - wherein the at least one tooth element (17) has an inner and an outer end (18, 19) and a receptacle (20) disposed therebetween for a wound coil arrangement (21), and / or - wherein the stator device (10) comprises a coil assembly (21) having a wire element which is wound around the receptacle (20) of the tooth element (17).

10. Brushless electric motor (30) according to claim 9, - wherein the at least one tooth element (17) has a surface portion (22) of an inner circumferential surface and a surface portion (23) of an outer circumferential surface at the inner and outer ends (18, 19) to form an inner circumferential surface and an outer circumferential surface, respectively.

11. Brushless electric motor (30) according to claim 10, - wherein the inner circumferential surface is adapted to an outer shell face (3-AM) of a first cylinder element (3) of the rotor device (1), so that the inner circumferential surface and the outer shell face are configured to be separated from one another via an air gap, and / or - wherein the outer circumferential surface is adapted to an inner shell face (4-IM) of a second cylinder element (4) of the rotor device (1), so that the outer circumferential surface and the inner shell face are configured to be separated from one another via an air gap.

12. Method for magnetising a rotor device having: - a rotor device (1) of the flat brushless electric motor (30) according to any one of claims 1 to 5, - a magnetising installation (8) which can be arranged in the space between the cylinder elements (3, 4) of the rotor housing element (2) of the rotor device (1), - wherein the magnetising installation (8) has at least one coil element (9) for generating a magnetic field and preferably at least one core element, in particular an iron core, for amplifying the magnetic field which can be generated by at least one coil element (9), - wherein the method comprises the following steps: - positioning the rotor device (1) and the magnetising installation (8), - inserting of the magnetising installation (8) into an intermediate space between the cylinder elements (3, 4) of the rotor housing element (2) of the rotor device (1), - jointly magnetising the first and second magnet assemblies (5, 6) so that the cylinder elements (3, 4) match in terms of pole pairs and number of pole pairs, - extracting the magnetising device (8) from the intermediate space.