Method for producing at least one stator for an electromechanical inertia drive

Abstract

The present invention relates to a method for producing at least one stator (1) for an electromechanical inertia drive, wherein the stator (1) has at least one electromechanical actuator (2) and a stator frame (3) for receiving the actuator (2). To lower the production costs for the stator, the stator frame (3) comprises a plurality of components (4, 5.1, 5.2, 6) which are produced in a cutting process from at least one planar semifinished product and which are stacked to form the stator frame (3).

Description

[0001] METHOD FOR PRODUCING AT LEAST ONE STATOR FOR AN ELECTROMECHANICAL INERTIAL DRIVE

[0002] The present invention relates to a method for producing at least one stator for an electromechanical inertial drive.

[0003] A method according to the preamble of claim 1 is known, for example, from US 2022 / 0255467 A1, WO 2021 / 190953 A1, and WO 2022 / 135905 A1. As shown in Figs. 1a to 1d, the stator 1 known from the prior art has a stator frame 3 for accommodating two electromechanical actuators 2. Fig. 2 clearly shows that the known stator frame 3 comprises a stator base 5, which accommodates the electromechanical actuators 2 in a cavity 7. The stator base 5 of the known stator 1 is typically a one-piece component manufactured by CNC machining. The production of a stator comprising such a CNC-manufactured stator base 5 is complex and expensive.

[0004] Therefore, the object of the invention is to provide a method by which the manufacturing costs of a stator for an electromechanical inertial drive can be reduced.

[0005] To achieve this object, the present invention provides a method according to claim 1.

[0006] The object is achieved in that the stator frame comprises a plurality of components that are manufactured from at least one flat semi-finished product in a thermal or mechanical separation process and are arranged in a stack to form the stator frame. This means that the stator frame according to the invention is defined by a stack of several components, all of which are manufactured from at least one flat semi-finished product in a separation process.

[0007] Because the stator frame is formed from several individual components in a stacked assembly and each of these individual components is manufactured in a cost-effective separation process from a readily available and therefore inexpensive semi-finished product, the overall manufacturing costs for the stator can be significantly reduced.

[0008] Advantageous further training is the subject of the subclaims.

[0009] It may be advantageous if the stator frame comprises at least two spring plates and a stator base comprising at least two components, which is arranged between the two spring plates. While the stator base is provided to accommodate the at least one electromechanical actuator, the external spring plates can create a connection to a higher-level structure into which the stator is installed.

[0010] It can be helpful to install an additional flat spring on one of the spring plates. This flat spring can be used to apply a suitable preload force to the at least one electromechanical actuator.

[0011] It can be practical if the components of the stator frame are manufactured from at least two different plate-shaped semi-finished products with different thicknesses. This makes it possible to provide components that meet different requirements for rigidity or elasticity. In particular, it can be useful for the components of the stator base to be manufactured from a thicker semi-finished product in order to have sufficient rigidity to support the at least one electromechanical actuator. On the other hand, it can be useful for the spring plates to be manufactured from a thinner semi-finished product in order to have a certain degree of elasticity.

[0012] It can be advantageous to manufacture various components of the stator frame from a common plate-shaped semi-finished product. This allows components of the same thickness to be manufactured efficiently and cost-effectively.

[0013] It can be beneficial if the stator base has a cavity in which the at least one electromechanical actuator is inserted, and the components of the stator base are preferably made from semi-finished products of the same thickness, particularly preferably from the same semi-finished product. By making the components of the stator base from the same semi-finished product, i.e., having the same thickness, a rigid stator base can be provided that adequately supports the actuator.

[0014] It can be advantageous if the components of the stator base are formed by a support element on which the at least one electromechanical actuator is placed, and a housing element which at least partially surrounds the at least one electromechanical actuator, wherein the support element is preferably rod-shaped and the housing element is preferably U-shaped. The support element and / or the housing element can, if necessary, be divided into further elements. Such shapes of the support element and housing element can be cut out of the semi-finished product quickly and easily. It can prove helpful if the components of the stator frame are aligned to one another via reference means, preferably formed by through-holes and / or threaded holes, and if the stack assembly is preferably fixed by connecting means, preferably by screws or welds.

[0015] It may be practical if the cutting process is preferably a laser cutting process, a water jet cutting process or an electrical discharge machining process.

[0016] It can be useful to stack multiple component groups, each formed by a series connection of several components of the same type, to form multiple stator frames in series. This allows multiple stator frames to be manufactured simultaneously, improving stator manufacturing efficiency.

[0017] It can be useful if the components in a series assembly are manufactured integrally from a semi-finished product.

[0018] It may be useful to separate the multiple stator frames in the series to provide individual stator frames.

[0019] Terms and definitions

[0020] In the context of the present invention, a flat semi-finished product refers to a flat raw material, workpiece, or semi-finished product. The flat semi-finished product is, for example, plate-shaped, e.g., made of plastic, metal II, or ceramic, and preferably extends in a single plane. The flat semi-finished product preferably has the same cross-section in its thickness direction, i.e., perpendicular to its plane of extension.

[0021] In the context of the present invention, a stacked assembly refers to a stacked arrangement of several components that are fixed to one another using a joining process.

[0022] In the context of the present invention, a series connection refers to an arrangement of several components next to one another, which are preferably connected to one another integrally, particularly preferably materially, by connecting sections.

[0023] In the context of the present invention, an electromechanical actuator refers to an element that changes its geometric dimensions due to the application of electrical energy. Brief description of the figures

[0024] Fig. 1a to 1d show a stator 1 according to the prior art in different views.

[0025] Fig. 2 shows a stator base 5 of the stator 1 known from the prior art.

[0026] Fig. 3a and 3b show a first embodiment of the stator base 5 of a stator 1 having two components 5.1, 5.2, which is manufactured according to the method according to the invention.

[0027] Fig. 4 to 10 show the production of several stator frames 3 or stators 1 in a series connection according to a first embodiment, wherein the respective stack connection of a stator frame 3 is produced by screw connections.

[0028] Fig. 4a and 4b show a partially machined semi-finished product used to manufacture the stator base 5 according to Fig. 3, comprising two components 5.1, 5.2, in a plan view and a perspective view.

[0029] Fig. 5a and 5b show the first embodiment of the two components 5.1, 5.2 of the stator base 5, each manufactured from the semi-finished product from Fig. 4 by means of a separation process in a series connection G5.1, G5.2, in a plan view and a perspective view.

[0030] Fig. 6a and 6b show a first embodiment of the spring sheet halves 4.1 3 manufactured from a semi-finished product by means of a separating process in a series assembly G4.1 in a plan view and a perspective view.

[0031] Fig. 7 shows a series connection G4 of spring plates 4, which is formed from two series connections G4.1 of spring plate halves 4.1 of the first embodiment, connected by welded joints S.

[0032] Fig. 8 shows the series assembly G4 of spring plates 4 from Fig. 7, in which a friction element 9 is applied to each spring plate 4.

[0033] Fig. 9 shows a stacked and pre-assembled arrangement of the series interconnections G4, G5.1 and G5.2 of the first embodiment.

[0034] Fig. 10a and 10b show, in various perspective views, a stacked assembly of the series assemblies G4, G5.1, G5.2, G4 and G6, which forms a series assembly G3 of several stator frames 3 or, in conjunction with the electromechanical actuators 2 and the friction elements 9, a series assembly G1 of stators 1. Fig. 11 to 17 show the production of several stators 1 in a series assembly according to a second embodiment, wherein the respective stacked assembly of a stator frame 3 is produced by welded joints S.

[0035] Fig. 11 shows a second embodiment of the spring sheet halves 4.1 manufactured from a semi-finished product by means of a separation process in a series assembly G4.1.

[0036] Fig. 12a and 12b show a second embodiment of the two components 5.1, 5.2 of the stator base 5, each manufactured from a semi-finished product by means of a separation process in a series connection G5.1, G5.2.

[0037] Fig. 13 shows a series connection G4 of spring plates 4, which is formed from two series connections G4.1 of spring plate halves 4.1 of the second embodiment, connected by welded joints S.

[0038] Fig. 14 shows the series assembly G4 of spring plates 4 from Fig. 13, in which a friction element 9 is applied to each spring plate 4.

[0039] Fig. 15a and 15b show a stacked assembly of the series assemblies G5.1 and G5.2 of the second embodiment in different perspective views, wherein two components 5.1 and 5.2 are fixed to each other by welded joints S to form a series assembly G5 of stator bases 5.

[0040] Fig. 16 shows a stacked arrangement of individual series interconnections G4, G5, G4 and G6 according to the second embodiment in an exploded view.

[0041] Fig. 17a and 17b show in different views the welded joints S for producing a series connection G3 of several stator frames 3 or, in connection with the electromechanical actuators 2 and the friction elements 9, a series connection G1 of stators 1 from the series connections G4, G5, G4 and G6 shown in Fig. 16.

[0042] Detailed description of the preferred embodiments

[0043] Preferred embodiments of the present invention will be described in detail below with reference to the attached figures.

[0044] 3a and 3b show the two components 5.1, 5.2 that form a stator base 5 according to a first embodiment. In particular, Fig. 3b shows a support element 5.1 that is provided to support the electromechanical actuators 2, and Fig. 3a shows a housing element 5.2 that is provided to at least partially surround the electromechanical actuators 2. The support element 5.1 is preferably rod-shaped and the housing element 5.2 is preferably U-shaped. When the two components 5.1, 5.2 are arranged in the stack, a cavity 7 is created (see Fig. 9), in which the electromechanical actuators 2 can be accommodated. The two components 5.1 and 5.2 of the stator base 5 are provided with through holes or threaded holes.

[0045] The following describes the manufacture of a plurality of stators 1 in a series arrangement according to a first embodiment with reference to Figs. 4 to 10. The first embodiment is essentially characterized in that the respective stacked assembly of a stator frame 3 is manufactured using connecting means, such as screws.

[0046] Fig. 4a and 4b show a flat semi-finished product already provided with through holes or threaded holes, which is used to manufacture the stator base 5 according to Fig. 3, which has two components 5.1, 5.2. The semi-finished product is in particular a plate-shaped element of constant thickness, which preferably extends in a plane and is made of metal.

[0047] As can be seen from the various views in Fig. 5a and 5b, a series assembly G5.1 of support elements 5.1 and a series assembly G5.2 of housing elements 5.2 are manufactured from the aforementioned semi-finished product using a separation process. The individual support elements 5.1 are arranged next to one another in the series assembly G5.1, with two support elements 5.1 being integrally connected via a common connecting section, which is designed, for example, as a material web. The individual housing elements 5.2 in the series assembly G5.2 are connected to one another in the same way. Because the series assembly G5.1 of support elements 5.1 and the series assembly G5.2 of housing elements 5.2 are manufactured from the same semi-finished product, the individual support elements 5.1 and housing elements 5.2 have the same thickness, which is preferred. Of course, the series assembly G5.1 and G5.1 can also be manufactured from different semi-finished products, possibly with different thicknesses.

[0048] Fig. 6a and 6b show different views of a series assembly G4.1 of spring sheet metal halves 4.1 according to the first embodiment. The series assembly G4.1 of spring sheet metal halves 4.1 is also manufactured from a flat semi-finished product, preferably a plate-shaped element made of metal or sheet metal, by means of a separating process. Analogous to the series assemblies G5.1 and G5.2, the individual spring sheet metal halves 4.1 in the series assembly G4.1 are arranged next to one another, with two spring sheet metal halves 4.1 being integrally connected via a common connecting section, which is designed, for example, as a material web. Each spring sheet metal half 4.1 is also provided with through-holes. The spring sheet metal halves 4.1 are preferably manufactured from a thinner semi-finished product than the components 5.1 and 5.2 of the stator base 5. As shown in Fig. 7, two series assemblies G4.1 of spring sheet metal halves 4.1 are welded together, wherein the two series assemblies G4.1 are not stacked congruently to one another, but rather one series assemblies G4.1 is rotated by 180° around the longitudinal axis with respect to the other series assemblies G4.1. The welded connections S are preferably made at the connecting sections of the series assemblies G4.1 at which two spring plate halves 4.1 are connected to one another. Fig. 8 shows the series assemblies G4 of spring plates 4 from Fig. 7, in which a friction element 9 is applied to each spring plate 4. The friction elements 9, which are hemispherical in the present embodiment, can be fastened to the spring plates 4 using epoxy resin, wherein the position of the friction elements can be predetermined by a recess in the corresponding spring plate half 4.1.

[0049] Fig. 9 shows a stacked arrangement of the series assemblies G4, G5.1, and G5.2. The individual series assemblies G4, G5.1, and G5.2 can be preassembled in a stacked assembly using screws that penetrate the through-holes of the spring plates 4 and the support elements 5.1 and are screwed into the threaded holes of the housing elements 5.2. The screws are not visible in this view because the screw heads are located on the side of the series assembly G4 of the spring plates 4. The electromechanical actuators 2 are then inserted into the cavity 7 of each stator base 5 and secured to the respective support element 5.1 using epoxy resin.

[0050] 10a and 10b, the stack assembly is finally completed using a further series assembly G4 of spring plates 4 and a series assembly G6 of flat springs 6 and further screws, so that a series assembly G3 of stator frames 3 and a series assembly G1 of stators 1 is produced. Since electromechanical actuators 2 have already been accommodated in the individual stator frames 3 and a friction element 9 has been attached to each stator frame 3, this step not only creates a series assembly G3 of stator frames 3, but simultaneously a series assembly G1 of stators 1. Epoxy resin is also applied to the upper side of the electromechanical actuators 2 in order to create a firm connection to the spring plate 4 located above them. In the stack assembly of a stator frame 3, the stator base 5 comprising two components 5.1, 5.2 is therefore arranged between two spring plates 4.The spring plates 4 essentially serve to connect the stator 1 to a higher-level structure. A flat spring 6 is preferably arranged on the spring plate 4 equipped with the friction element 9 and serves to apply a preload force to the electromechanical actuators 2. Analogous to the series connections G4, G5.1 and G5.2, the individual flat springs 6 in the series connection G6 are arranged next to one another, with two flat springs 6 being integrally connected via a common connecting section (see Fig. 16). The individual flat springs 6 are also provided with through-bores. Finally, the series connection G1 of the stators 1 is dissolved at the respective connection points of the individual series connections G4, G5.1, G5.2, G4 and G6 by a separation process, i.e. the individual stators 1 are separated from one another.

[0051] Figs. 11 to 17 show the production of a plurality of stators 1 in a series connection according to a second embodiment, wherein the second embodiment is essentially characterized in that the respective stack assembly of a stator frame 3 is produced by welded connections S. Except for the difference that the stack assembly in the method according to Figs. 11 to 17 is produced by welded connections S instead of screw connections, the production of the stators 1 is basically identical to the production process shown in Figs. 4 to 10. The differences will therefore be discussed in detail below.

[0052] As can be seen from Figs. 11 and 12, the individual components 4.1, 5.1 and 5.2 in the series connections G4.1, G5.1 and G5.2 according to the second embodiment can have a slightly different shape than the components known from the first embodiment (cf. Figs. 5 and 6), but are also manufactured from a flat semi-finished product by means of a separation process. In particular, there is no need for threaded holes in the components for the second embodiment. Instead, the individual components are provided with holes or recesses to which the components can be easily welded.

[0053] Fig. 13 shows preferred positions of the welded joints S for producing a series assembly G4 of spring plates 4 from two series assemblies G4.1 of spring plate halves 4.1 according to the second embodiment. The preferred positions of the welded joints S are shown only on one spring plate 4 in the series assembly G4, but apply analogously to all spring plates 4 in the series assembly G4. Fig. 14 shows, analogously to Fig. 8, the series assembly G4 of spring plates 4, in which a friction element 9 is applied to each spring plate 4.

[0054] Figs. 15a and 15b show preferred positions of the welded joints S for producing a series assembly G5 of stator bases 5 from a series assembly G5.1 of support elements 5.1 and a series assembly G5.2 of housing elements 5.2 according to the second embodiment. The preferred positions of the welded joints S are shown only on one stator base 5 in the series assembly G5, but apply analogously to all stator bases 5 in the series assembly G5.

[0055] Fig. 16 shows an exploded view of the series assemblies G4, G5, G4, and G6 in the arrangement as they will subsequently be welded to form a stacked assembly. The electromechanical actuators are already inserted into the cavities 7 of the stator bases 5.

[0056] Fig. 17a and 17b show preferred positions of the welded joints S for producing a series connection G3 of several stator frames 3 or a series connection G1 of several stators 1 from the series connections G4, G5, G4 and G6 shown in Fig. 16.

[0057] In the above description, the production of a stator 1 was described by producing a series connection G1 of several stators 1 and subsequently dissolving this series connection by separating the individual stators 1 from one another. However, the present invention is not limited to this type of production. In particular, a single stator 1 can also be produced independently of other stators 1 by forming a stator frame 3 from a stack of individual independent components 4, 5.1, 5.2, 4, 6 and equipping it with electromechanical actuators 2 and a friction element 9.

[0058] Furthermore, the series connections disclosed in the above description are each formed, by way of example, by three components arranged side by side. It goes without saying that the respective series connections can comprise any number of components, as long as the individual series connections remain easy to handle for the production of the stators.

[0059] The separation process for producing the individual components from the flat semi-finished product can be any two-dimensional separation process. Preferably, it is a laser cutting process, a water jet cutting process, or a spark erosion process. The same applies to the separation process used to separate the individual stators 1 from the series assembly G1. List of reference symbols

[0060] 1 stator

[0061] 2 electromechanical actuator

[0062] 3 stator frames

[0063] 4 spring plate

[0064] 4.1 Spring plate half

[0065] 5 Stator base

[0066] 5.1 Support element

[0067] 5.2 Housing element

[0068] 6 flat springs

[0069] 7 Cavity

[0070] 8 screw

[0071] 9 Friction element

[0072] G1 Series connection of stators

[0073] G3 Series connection of stator frames

[0074] G4 Series connection of spring sheets

[0075] G4.1 Series connection of spring sheet halves

[0076] G5 Series connection of stator bases

[0077] G5.1 Series connection of support elements

[0078] G5.2 Series connection of housing elements

[0079] G6 Series combination of flat springs

[0080] S welded joint

Claims

Claims 1 . Method for producing at least one stator (1) for an electromechanical inertial drive, wherein the stator (1) has at least one electromechanical actuator (2) and a stator frame (3) for receiving the actuator (2), characterized in that the stator frame (3) comprises a plurality of components (4, 5.1, 5.2, 6) which are produced in a separation process from at least one flat semi-finished product and are arranged in a stack to form the stator frame (3).

2. Method according to claim 1, characterized in that the stator frame (3) comprises at least two spring plates (4) and a stator base (5) having at least two components (5.1, 5.2) which is arranged between the two spring plates (4).

3. Method according to claim 2, characterized in that an additional flat spring (6) is arranged on one of the spring plates (4).

4. Method according to one of the preceding claims, characterized in that the components (4, 5.1, 5.2, 6) of the stator frame (3) are produced from at least two different plate-shaped semi-finished products with different thicknesses.

5. Method according to one of the preceding claims, characterized in that various components of the stator frame (3) are produced from a common plate-shaped semi-finished product.

6. Method according to one of the preceding claims, characterized in that the stator base (5) has a cavity (7) in which the at least one electromechanical actuator (2) is inserted, and the components (5.1, 5.2) of the stator base (5) are preferably produced from semi-finished products of the same thickness, particularly preferably from the same semi-finished product.

7. The method according to claim 6, characterized in that the components of the stator base (5) are formed by a support element (5.1), on which the at least one electromechanical actuator (2) is placed, and a housing element (5.2), which surrounds the at least one electromechanical actuator (2) at least in sections, wherein the support element (5.1) is preferably rod-shaped and the housing element (5.2) is preferably U-shaped.

8. Method according to one of the preceding claims, characterized in that the components (4, 5.1, 5.2, 6) of the stator frame (3) are aligned with each other via reference means, preferably formed by through holes and / or threaded holes, and the The stacked assembly is preferably fixed by means of connecting means, preferably screws (8) or welded joints (S).

9. Method according to one of the preceding claims, characterized in that the separating method is preferably a laser cutting method, a water jet cutting method or a spark erosion method.

10. Method according to one of the preceding claims, characterized in that a plurality of component groups, each formed by a series connection (G4, G5.1, G5.2, G6) of a plurality of components (4, 5.1, 5.2, 6) of the same type, are arranged in a stack connection to form a plurality of stator frames (3) in a series connection (G3).

11. Method according to claim 10, characterized in that the components (4, 5.1, 5.2, 6) in a series assembly (G4, G5.1, G5.2, G6) are manufactured integrally from a semi-finished product.

12. Method according to claim 10 or 11, characterized in that the plurality of stator frames (3) in the series connection (G3) are separated from one another in order to provide individual stator frames (3).

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