Sensor device for an electromechanical rotor, electromechanical device, and method for manufacturing such a sensor device.

Abstract

The present invention provides a sensor device for an electromechanical rotor, an electromechanical device, and a method for manufacturing the sensor device. [Solution] A sensor device (1) for the rotor of an electromachine, an electromachine and a method for manufacturing the sensor device (1), wherein the sensor device (1) comprises a magnet (5), a cover member (2), and a sleeve (3), the sleeve (3) being coupled to the rotor, the cover member (2) being coupled to the sleeve (3), and the magnet (5) being held within the cover member (2) by shrinkage coupling, particularly by laser shrinkage coupling.

Description

Technical Field

[0001] The present invention relates to a sensor device for a rotor of an electric machine, an electric machine, and a method for manufacturing such a sensor device.

Background Art

[0002] Patent Document 1 discloses a rotor for an electric machine, an electric machine, and a method for manufacturing such a rotor.

[0003] Patent Document 2 shows an electric motor of a drive device in an automobile.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Patent Document 2

Summary of the Invention

[0005] In a sensor device for a rotor of an electric machine, the core of the present invention is that the sensor device has a magnet, a cover member, and a sleeve, the sleeve is coupled to the rotor, the cover member is coupled to the sleeve, and the magnet is held in the cover member by shrink fitting, particularly by laser shrink fitting.

[0006] The background of the present invention is that the magnet can be reliably coupled to the sensor device. At that time, the thermal load or force applied to the magnet can be reduced, and as a result, a vulnerable magnet with a large magnetic field strength can be used for the sensor device. At that time, in an advantageous aspect, a predetermined holding force can be adjusted.

[0007] In advantageous embodiments, this sensor device can be used as a rotor position sensor for electromachines, thereby reducing the required space.

[0008] Furthermore, a shrinkage joint is understood to be a pressure-welded joint achieved using a shrinkable material or by using a constriction.

[0009] Furthermore, laser shrinkage bonding is understood to be a pressure-welded joint achieved using laser-shrinkage sections welded by a laser, or by using necking. In this case, the material is not welded to other workpieces, but only 50% to 80% of the material thickness is welded, resulting in a welded seam that reduces the inner diameter of the cover member and / or sleeve.

[0010] Further advantageous embodiments of the present invention are subject to the dependent claims.

[0011] In the advantageous configuration, the cover member has a bottom portion and a projection, in which case the projection extends along the side of the magnet and holds the magnet. Thus, the magnet is surrounded by the cover member so as to form at least partially a housing.

[0012] In this case, it is advantageous if the projection is positioned radially between the magnet and the sleeve, and the sleeve has at least one laser-shrinkable portion that extends circumferentially, and as a result the projection is pressed against the magnet by the laser-shrinkable portion. In this way, a secure bond between the magnet and the cover member is possible, and the thermal load or force applied to the magnet is reduced.

[0013] Furthermore, it is advantageous if the inner diameter of the sleeve has a stepped portion, in which case the bottom portion of the cover member rests on the stepped portion, and as a result the bottom portion is positioned between the stepped portion and the magnet. This prevents the magnetic field sensor side surface of the magnet from being covered, and as a result the magnet can operate without being shielded.

[0014] Alternatively, it is advantageous if the inner diameter of the sleeve has a stepped portion, in which case the magnet is placed on the stepped portion, and as a result the magnet is positioned between the stepped portion and the bottom portion of the cover member. In this way, reliable coupling between the magnet and the sensor device is possible. At that time, the thickness of the bottom portion is selected so as to minimize the shielding of the magnetic field of the magnet from the magnetic field sensor.

[0015] In a further advantageous configuration, the cover member is made of glass, in which case the magnet is housed within the cover member. This ensures that the magnet is surrounded by the cover member, at least partially, forming a housing.

[0016] In this case, it is advantageous if the outer diameter of the sleeve increases in a stepped manner from the magnet towards the rotor, and the cover member is positioned on the sleeve and extends from the minimum outer diameter to the maximum outer diameter of the sleeve. In this way, the magnet can be pre-installed between the cover member and the sleeve.

[0017] Furthermore, it is advantageous if the cover member has an inner diameter reduction portion in the region of the sleeve's minimum outer diameter, particularly a constricted portion, and especially if the cover member has a laser shrinkage coupling portion in the region of the inner diameter reduction portion. The inner diameter reduction portion allows the cover member to be pressed against the sleeve, and as a result, the magnet can be positioned on the outer bottom portion of the sleeve.

[0018] In an advantageous embodiment, the cover member is materially bonded and / or frictionally bonded to the sleeve, particularly in the region of the sleeve's maximum outer diameter. This allows the magnet to be pre-installed between the cover member and the sleeve.

[0019] In a more advantageous configuration, the sleeve is frictionally and / or materially bonded to the rotor, and in this particular case, the outer diameter of the rotor is smaller than the outer diameter of the sleeve. The sleeve can be used between the rotor and the magnet as a tolerance compensating sleeve.

[0020] The core of the invention in the electrical machine lies in that the electrical machine has a rotor and, in particular, a sensor device as described above, or a sensor device according to any one of the claims related to the sensor device.

[0021] The background of the invention is that the sensor device can be implemented in a compact manner, and as a result, the required structural space inside the electrical machine can be reduced.

[0022] The core of the invention in a method for manufacturing a sensor device having a magnet, a sleeve, and a cover member, in particular a sensor device as described above, or a sensor device according to any one of the claims related to the sensor device, lies in inserting the magnet into the cover member, and in this case subsequently contracting the cover member and / or the sleeve by laser, so that the magnet is held by the cover member.

[0023] The background of the invention is to reliably couple the magnet with the sensor device. In this process, the thermal load or force applied to the magnet is reduced, and as a result, a vulnerable magnet with a large magnetic field strength can be used for the sensor device. In this case, in an advantageous aspect, a predetermined holding force can be adjusted.

[0024] According to an advantageous configuration, before laser contraction, the cover member is frictionally coupled and / or materially coupled with the sleeve. This enables the magnet to be pre-mounted between the cover member and the sleeve.

[0025] In this case, it is advantageous if, in the first method step, the sleeve is coupled with the rotor. In this way, the thermal load on the magnet can be reduced.

[0026] Alternatively, it is advantageous if, in the last method step, the sleeve is coupled with the rotor. This enables the sensor device to be manufactured as a pre-mounted unit.

[0027] The above configurations and developments can be arbitrarily combined with each other as long as they are meaningful. Further possible configurations, developments, and embodiments of the present invention also include combinations that do not explicitly mention the constituent elements of the invention described above with respect to the embodiments or the constituent elements of the invention described below. In that case, in particular, those skilled in the art will add individual viewpoints as improvements or supplements to each basic form of the present invention.

[0028] In the following paragraphs, the present invention will be described using embodiments (from which further inventive constituent elements can also be obtained, but the present invention is not limited to the embodiments within its scope of rights). These embodiments are illustrated in the drawings.

Brief Description of the Drawings

[0029] [Figure 1] It is a cross-sectional view of a sensor device 1 for a rotor according to a first embodiment of the present invention. [Figure 2] It is a cross-sectional view of a sensor device 100 for a rotor according to a second embodiment of the present invention. [Figure 3] It is a cross-sectional view of a sensor device 200 for a rotor according to a third embodiment of the present invention in a first method step 301. [Figure 4] It is a cross-sectional view of a sensor device 200 for a rotor according to a third embodiment of the present invention in a second method step 302. [Figure 5] It is a cross-sectional view of a sensor device 200 for a rotor according to a third embodiment of the present invention in a third method step 303. [Figure 6] It is a schematic flowchart of a first aspect of a method 300 according to the present invention for manufacturing a sensor device (1, 100, 200) for a rotor. [Figure 7] It is a schematic flowchart of a second aspect of a method 400 according to the present invention for manufacturing a sensor device (1, 100, 200) for a rotor.

Modes for Carrying Out the Invention

[0030] The first embodiment of the sensor device 1 according to the present invention, shown in Figure 1, includes a magnet 5, a cover member 2, and a sleeve 3.

[0031] The magnet 5 is preferably implemented as a permanent magnet, and more particularly as a neodymium magnet. The magnet 5 is substantially disc-shaped and has a circular cross-section. In this case, the height of the magnet 5 is smaller than the diameter of the magnet 5.

[0032] Sleeve 3 is positioned between the magnet 5 and a rotor (not shown in Figure 1). Sleeve 3 is made of special steel. The sleeve is hollow and cylindrical, and has a first inner diameter and a second inner diameter. The first inner diameter is positioned on the rotor side, and the second inner diameter is positioned on the magnet 5 side. The first inner diameter is smaller than the second inner diameter, and in this case, the inner diameter of sleeve 3 increases in a stepped manner from the rotor towards the magnet, i.e., the inner diameter of sleeve 3 has a stepped portion. In this case, sleeve 3 can be inserted onto the rotor and can be frictionally coupled and / or materially coupled to the rotor, for example, by welding and / or pressure welding.

[0033] The magnet 5 can be coupled to the sleeve 3 using the cover member 2. For this purpose, the cover member 2 has a circular bottom portion, with a plurality of protrusions 2a arranged around its circumference. Each protrusion 2a extends from the bottom portion along the side surface of the magnet 5. The protrusions 2a are integrally formed with the bottom portion and are positioned perpendicular to the bottom portion, particularly bent. In an advantageous embodiment, the protrusions 2a are evenly distributed in the circumferential direction of the bottom portion. The height of the protrusions 2a substantially corresponds to the height of the magnet 5.

[0034] According to the first embodiment, the cover member 2 is placed inside the sleeve 3 and rests on a stepped portion inside the sleeve 3 at its bottom. In this case, the projection 2a extends from the bottom portion toward the magnet 5. The projection 2a is located inside the sleeve 3, and in this case, the sleeve 3 radially surrounds the projection 2a in a region of a second diameter. The magnet 5 is placed on the bottom portion and held by the projection 2a. In this case, the magnet 5 is pressure-bonded to the cover member 2 and the sleeve 3. For this reason, the sleeve 3 is pressure-bonded to the projection 2a using a laser 4. In an advantageous embodiment, the sleeve 3 has two laser-shrinkable portions that extend circumferentially. The laser-shrinkable portions are portions in which the outer diameter of the sleeve 3 is shrunken by the laser 4 by laser welding the sleeve 3. In this case, no material bonding occurs between the sleeve 3 and each projection 2a. The sleeve 3 is not welded all the way through, but only 50% to 80% is welded. The resulting welded joint reduces the second inner diameter in the region of each laser-shrinked area, causing the sleeve 3 to press against the cover member 2 and the magnet 5 located within it. This joining technique is also called laser-induced interference fit.

[0035] In an advantageous embodiment, the cover member 2 is made of aluminum, which allows for good heat dissipation during laser welding. Thus, the magnet 5 is protected from thermal overload.

[0036] The embodiment of the sensor device shown in Figure 2 differs from the first embodiment in that the magnet 5 is positioned between the bottom portion of the cover member 102 and the stepped portion of the sleeve 3. In this case, the magnet 5 is placed on the stepped portion. The projection 102a of the cover member 102 extends from the bottom portion toward the sleeve 3. In this case, the magnet 5 is at least partially surrounded by the projection 102a in the circumferential direction.

[0037] In this case, the thickness of the bottom portion is selected to be sufficiently thin, and as a result, the magnetic field of magnet 5 is not shielded, or is only shielded very slightly.

[0038] The projection 102a extends into the internal region of the sleeve 3 in a region of the second diameter. That is, the projection 102a is positioned between the magnet 5 and the sleeve 3. Thus, the sleeve 3 radially surrounds the projection 102a in a region of the second diameter.

[0039] The magnet 5 is pressure-bonded to the cover member 102 and the sleeve 3. Therefore, the sleeve 3 is pressure-bonded to the projections 102a using a laser 4. In an advantageous embodiment, the sleeve 3 has two laser-shrinkable portions that extend circumferentially. One laser-shrinkable portion is a portion in which the outer diameter of the sleeve 3 is shrinked by the laser 4 by laser welding the sleeve 3. In this case, no material bonding occurs between the sleeve 3 and each projection 102a. The sleeve 3 is not welded all the way through, but only 50% to 80% is welded. The resulting weld seams reduce the second diameter in the region of each laser-shrinkable portion, and as a result the sleeve 3 is pressure-bonded to the cover member 102 and the magnet 5 placed therein.

[0040] Figures 3, 4, and 5 illustrate a third embodiment of the sensor device 200.

[0041] The sensor device 200 also includes a sleeve 203 for coupling with the rotor 206, a magnet 5, in particular a neodymium magnet, and a cover member 202.

[0042] The magnet 5 is preferably implemented as a permanent magnet, and more particularly as a neodymium magnet. The magnet 5 is substantially disc-shaped and has a circular cross-section. In this case, the height of the magnet 5 is smaller than the diameter of the magnet 5.

[0043] The cover member 202 is substantially made of glass. In this case, the inner diameter of the cover member 202 is somewhat larger than the diameter of the magnet 5, and as a result the magnet 5 can be inserted into the cover member 202. The cover member 202 is preferably made of special steel.

[0044] The sleeve 203 is substantially made of glass. In this case, the inner diameter of the sleeve 203 is large enough that the rotor 206 can be inserted into the sleeve 203 and that it can be materially bonded to the sleeve 203 by, for example, welding or pressure welding and / or friction bonding. The sleeve 203 is preferably made of special steel.

[0045] The outer diameter of the sleeve 203 has a stepped section, in which case the outer diameter of the sleeve 203 decreases from the opening of the sleeve 203 towards the bottom portion of the sleeve 203. In this case, the minimum outer diameter of the sleeve 203 is smaller than the diameter of the magnet 5. The maximum outer diameter of the sleeve 203 is substantially the same size as the diameter of the magnet 5.

[0046] The magnet 5 is placed on the outer bottom portion of the sleeve 203 by its first side and held by the inner bottom portion of the cover member 202 by its second side. In other words, the magnet 5 is positioned between the outer bottom portion of the sleeve 203 and the inner bottom portion of the cover member 202.

[0047] The cover member 202 completely covers the sleeve 203 in the region of the sleeve 203's minimum diameter. In the region of the sleeve 203's maximum diameter, the cover member 202 at least partially covers the sleeve 203. In this case, the cover member 202 and the sleeve 203 are bonded to each other by material and / or friction in the region of the sleeve 203's maximum diameter, for example, by welding or pressure welding.

[0048] To fix the magnet 5, the cover member 202 has an inner diameter reduction portion in the region of the sleeve 203's minimum diameter, and in particular has a constricted portion 204, preferably two constricted portions 204 positioned at intervals in the axial direction. Therefore, after the cover member 202 is coupled to the sleeve 203, the wall of the cover member 202 is contracted in the region of the diameter reduction portion, and in particular, contracted using a laser 4. At that time, the wall of the cover member 202 is deformed so that the magnet 5 is pressed against the sleeve 203.

[0049] The magnet 5 is pressure-bonded to the cover member 202 and the sleeve 203. In this case, no material bonding occurs between the sleeve 203 and the wall of the cover member 202 in the region where the diameter of the sleeve 203 is reduced. The cover member 202 is not welded all the way through, but only 50% to 80% is welded. The resulting welded seams reduce the inner diameter of the cover member 202 in the region of each constricted portion 204, and as a result the sleeve 203 is pressure-bonded to the cover member 202 and the magnet 5 placed inside it.

[0050] Figure 6 illustrates a first embodiment of the method 300 according to the present invention for manufacturing a rotor 206.

[0051] In the first method step 301, the magnet 5 is positioned or placed on the sleeve 203, particularly on the outer bottom portion of the sleeve 203.

[0052] In the second method step 302, the cover member 202 is guided via the magnet 5 and the sleeve 203, so that the magnet 5 is positioned between the cover member 202 and the sleeve 203, and in particular between the outer bottom portion of the sleeve 203 and the inner bottom portion of the cover member 202.

[0053] In the third method step 303, the cover member 202 is friction-bonded and / or material-bonded to the sleeve 203 in the region of the sleeve 203's maximum diameter, and in particular by welding and / or pressure bonding.

[0054] In the fourth method step 304, the cover member 202 is deformed, particularly contracted, in the region of the sleeve 203's minimum outer diameter, thereby reducing the inner diameter of the cover member 202. In an advantageous embodiment, the walls of the cover member 202 are laser-contracted using a laser 4. In this case, no material bonding occurs between the sleeve 203 and the walls of the cover member 202 in the region of the diameter reduction of the sleeve 203. The cover member 202 is not welded all the way through, but only 50% to 80% is welded. The resulting welded seams reduce the inner diameter of the cover member 202 in the region of each constricted portion 204, resulting in the sleeve 203 being pressed against the cover member 202 and the magnet 5 placed therein.

[0055] In the fifth method step 305, the sleeve 203 is material-bonded and / or friction-bonded to the rotor 206, and in particular, welded.

[0056] Figure 6 illustrates a second embodiment of the method 400 according to the present invention for manufacturing a rotor 206. In the first method step 401, the sleeve 203 is materially bonded and / or frictionally bonded to the rotor 206.

[0057] In the second method, step 402, the magnet 5 is placed on the sleeve 203, and in particular on the outer bottom portion of the sleeve 203.

[0058] In the third method step 403, the cover member 202 is guided through the magnet 5 and the sleeve 203, so that the magnet 5 is positioned between the cover member 202 and the sleeve 203, and in particular between the outer bottom portion of the sleeve 203 and the inner bottom portion of the cover member 202. The cover member 202 is then friction-coupled and / or material-coupled with the sleeve 203 over the area of ​​the sleeve 203's maximum diameter, in particular by welding and / or pressure bonding.

[0059] In the fourth method step 404, the cover member 202 is deformed, particularly contracted, in the region of the sleeve 203's minimum outer diameter, thereby reducing the inner diameter of the cover member 202. In an advantageous embodiment, the walls of the cover member 202 are laser-shrunk using a laser 4. In this case, no material bonding occurs between the sleeve 203 and the walls of the cover member 202 in the region of the sleeve 203's outer diameter reduction. The cover member 202 is not welded all the way through, but only 50% to 80% is welded. The resulting welded seams reduce the inner diameter of the cover member 202 in the region of each constricted portion 204, resulting in the sleeve 203 being pressed against the cover member 202 and the magnet 5 placed therein. [Explanation of symbols]

[0060] 1,100,200 Sensor device 2,102,202 Cover components 2a,102a protrusion 3,203 sleeves 4 Lasers 5 Magnets 204 Waist area 206 Rotor

Claims

1. In a sensor device (1,100,200) for a rotor (206) of an electric machine, The sensor device (1,100,200) includes a magnet (5), cover members (2,102,202), and a sleeve (3,203). The sleeve (3, 203) is coupled to the rotor (206), and the cover member (2, 102, 202) is coupled to the sleeve (3, 203), The magnet (5) is held within the cover member (2, 102, 202) by contraction coupling, particularly by laser contraction coupling. A sensor device characterized by (1,100,200).

2. The sensor device (1,100) according to claim 1, characterized in that the cover member (2, 102) has a bottom portion and protrusions (2a, 102a), and the protrusions (2a, 102a) extend along the side surface of the magnet (5) to hold the magnet (5).

3. The sensor device (1,100) according to claim 2, wherein the projections (2a, 102a) are positioned radially between the magnet (5) and the sleeve (3), and the sleeve (3) has at least one laser contraction portion that extends circumferentially, and in particular, the projections (2a, 102a) are pressed against the magnet (5) by the laser contraction portion.

4. The sensor device (1) according to claim 2 or 3, characterized in that the inner diameter of the sleeve (3) has a stepped portion, the bottom portion of the cover member (2) is placed on the stepped portion, and as a result the bottom portion is positioned between the stepped portion and the magnet (5).

5. The sensor device (100) according to claim 2 or 3, characterized in that the inner diameter of the sleeve (3) has a stepped portion, the magnet (5) is placed on the stepped portion, and as a result the magnet (5) is positioned between the stepped portion and the bottom portion of the cover member (102).

6. The sensor device (200) according to claim 1, characterized in that the cover member (202) is made in the shape of glass and the magnet (5) is received inside the cover member (202).

7. The sensor device (200) according to claim 6, characterized in that the outer diameter of the sleeve (203) increases in a stepped manner from the magnet (5) toward the rotor (206), and the cover member (202) is positioned on the sleeve (203) and extends from the minimum outer diameter of the sleeve (203) toward the maximum outer diameter of the sleeve (203).

8. The sensor device (200) according to claim 7, wherein the cover member (202) has an inner diameter reduction portion in the region of the minimum outer diameter of the sleeve (203), and in particular has a constricted portion (204), and in this case, the cover member has a laser shrinkage coupling portion in the region of the inner diameter reduction portion.

9. The sensor device (200) according to any one of claims 6 to 8, characterized in that the cover member (202) is materially bonded and / or frictionally bonded to the sleeve (203), particularly in the region of the sleeve (203)'s maximum outer diameter.

10. The sensor device (1,100,200) according to any one of claims 1 to 9, wherein the sleeve (3,203) is frictionally coupled and / or materially coupled to the rotor (206), and in particular, in this case, the outer diameter of the rotor (206) is smaller than the outer diameter of the sleeve (3,203).

11. An electromachine having a rotor (206) and a sensor device (100, 200, 300) according to any one of claims 1 to 10.

12. A method for manufacturing a sensor device (1,100,200) for a rotor (206) according to any one of claims 1 to 10, comprising a magnet (5), a sleeve (3,203), and a cover member (2,102,202), Insert the magnet (5) into the cover member (2, 102, 202), Next, the cover members (2, 102, 202) and / or the sleeve (3, 203) are shrunk by a laser (4), and as a result the magnet (5) is held by the cover members (2, 102, 202). method.

13. A method for manufacturing a sensor device (1,100,200) according to claim 12, characterized in that the cover member (202) is friction-bonded and / or material-bonded to the sleeve (203) before laser shrinkage.

14. A method for manufacturing a sensor device (1,100,200) according to claim 12 or 13, characterized in that the sleeve (3,203) is coupled with the rotor (206) in the first or last method step.

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