Device and method for producing a rotor for an electric motor

Abstract

A device according to the invention for producing a rotor (10) for an electric motor comprises a pressing station (40) for pressing a rotor shaft (11) into a laminated core (12), an aligning station (60) for aligning a rotor (10) which comprises a laminated core (12) and a rotor shaft (11) pressed into the laminated core, and a transport unit (50) for transporting a rotor (10) from the pressing station (40) to the aligning station (60). A method according to the invention for producing a rotor (10) for an electric motor has the following steps: supplying a laminated core (12) to the pressing station (40); supplying a rotor shaft (11) to the pressing station (40); pressing the rotor shaft (11) into the laminated core (12) in the pressing station (40); transporting the produced rotor (10), which comprises a laminated core (12) and the rotor shaft (11) pressed into the laminated core, from the pressing station (40) to the aligning station (60); aligning the produced rotor (10) in the aligning station (60); and removing the produced rotor (10) from the aligning station (60).

Description

[0001] Device and method for manufacturing a rotor for an electric motor

[0002] Description:

[0003] The invention relates to a device and a method for manufacturing a rotor for an electric motor by pressing a rotor shaft into a laminated core.

[0004] DE 102022 001 424 A1 discloses an electric motor with a rotor. The rotor comprises a laminated core and a rotor shaft inserted into the laminated core. The rotor shaft is designed to be approximately rotationally symmetrical. The laminated core consists of individual laminations stacked in an axial direction. Each individual lamination has a central bore for accommodating the rotor shaft.

[0005] The rotor is installed in an electric motor, which also includes a stator. The rotor can rotate relative to the stator about a rotational axis. This requires that the laminated core and the rotor shaft are connected in a rotationally fixed manner, and that the rotational axis runs centrally through the rotor.

[0006] The invention is based on the object of specifying a device and a method for manufacturing a rotor for an electric motor.

[0007] The object is achieved by a device for manufacturing a rotor for an electric motor having the features specified in claim 1. Advantageous embodiments and further developments are the subject of the subclaims. The object is also achieved by a method for manufacturing a rotor for an electric motor having the features specified in claim 10.

[0008] A device according to the invention for manufacturing a rotor for an electric motor comprises a pressing station for pressing a rotor shaft into a laminated core, a straightening station for straightening a rotor comprising a laminated core and a rotor shaft pressed into it, and a transport unit for transporting a rotor from the pressing station to the straightening station. By means of the device according to the invention, a rotor shaft and a laminated core can be connected to one another in a force-fitting and rotationally fixed manner to form a rotor. Furthermore, straightening of the rotor, in particular to remove eccentricity, is possible.

[0009] According to an advantageous embodiment of the invention, the transport unit has a gripper arm. The gripper arm is configured to pick up a rotor at the pressing station and place it on a holding device of the straightening station. The rotor can thus be automatically transported to the straightening station.

[0010] According to an advantageous embodiment of the invention, the pressing station comprises a hydraulic press for pressing a rotor shaft into a laminated core. The hydraulic press ensures precise pressing of the rotor shaft into the laminated core.

[0011] According to an advantageous embodiment of the invention, the pressing station comprises a receiving sleeve for receiving a rotor shaft and a receiving device for receiving a laminated core. The receiving sleeve can be moved by the hydraulic press toward the receiving device. This allows the rotor shaft to be pressed into the laminated core.

[0012] According to an advantageous embodiment of the invention, the pressing station has a first sensor for detecting a rotor shaft received in the receiving sleeve and a second sensor for detecting a laminated core received in the receiving device. The sensors enable control of the pressing station. When the sensors detect the laminated core and the rotor shaft, the receiving sleeve is moved by the hydraulic press toward the receiving device. This presses the rotor shaft into the laminated core.

[0013] According to an advantageous embodiment of the invention, the straightening station has a holding device for receiving a rotor. The holding device comprises two bearing points which are arranged such that the rotor shaft of a received rotor rests on the bearing points, and such that the laminated core of a received rotor is arranged between the bearing points. A received rotor can be rotated about an axis of rotation relative to the bearing points. According to an advantageous embodiment of the invention, the straightening station has a device for measuring the eccentricity of a received rotor. The device for measuring the eccentricity comprises a distance meter for detecting a distance to the laminated core of the received rotor and an angle meter for detecting an angular position of the received rotor relative to the bearing points. This makes it possible to determine whether and at which angular position the rotor has eccentricity.If the rotational axis runs centrically through the rotor, the distance of the distance sensor to the rotor's laminated core is the same at any angular position. The rotor exhibits eccentricity if the rotational axis runs eccentrically through the rotor, meaning the distance of the distance sensor to the rotor's laminated core varies depending on the angular position.

[0014] According to an advantageous embodiment of the invention, the straightening station has a drive device for the rotational drive of a rotor received on the holding device about the axis of rotation relative to the bearing points.

[0015] According to an advantageous embodiment of the invention, the straightening station comprises a straightening element. The straightening element is configured to exert a force in the radial direction on the laminated core of a mounted rotor. By exerting a force on the laminated core in the radial direction at an angular position at which the rotor exhibits an eccentricity, the rotor can be straightened, in particular, an eccentricity can be removed.

[0016] A method according to the invention for manufacturing a rotor for an electric motor with a device according to the invention comprises the following steps:

[0017] Feeding a sheet package into the pressing station;

[0018] Feeding a rotor shaft into the pressing station;

[0019] Pressing the rotor shaft into the laminated core in the pressing station;

[0020] Transport of the finished rotor, which includes the laminated core and the rotor shaft pressed into it, from the pressing station to the straightening station;

[0021] Straightening the finished rotor in the straightening station; and removing the finished rotor from the straightening station.

[0022] By means of the method according to the invention, a rotor shaft and a laminated core are non-positively and rotationally fixedly connected to form a rotor. The method according to the invention also allows for the rotor to be straightened, in particular to remove a detected eccentricity. The invention is not limited to the combination of features of the claims. Those skilled in the art will recognize further possible combinations of claims and / or individual claim features and / or features of the description and / or the figures, in particular from the task and / or the task arising from comparison with the prior art.

[0023] The invention will now be explained in more detail with reference to the accompanying drawings. The invention is not limited to the exemplary embodiments shown in the drawings. The drawings only represent the subject matter of the invention schematically. They show:

[0024] Figure 1 : a rotor for an electric motor,

[0025] Figure 2: a perspective front view of a device for manufacturing a rotor,

[0026] Figure 3: a sectional view of a device for manufacturing a rotor and

[0027] Figure 4: a perspective rear view of a device for manufacturing a rotor.

[0028] Figure 1 shows a rotor 10 for an electric motor. The left-hand part of the image shows an exploded view of the rotor 10, and the right-hand part shows the assembled rotor 10. The rotor 10 comprises a laminated core 12 and a rotor shaft 11. The rotor shaft 11 is inserted into the laminated core 12. The rotor shaft 11 and the laminated core 12 are non-positively and non-rotatably connected to form the rotor 10.

[0029] The rotor shaft 11 is approximately rotationally symmetrical. The laminated core 12 is also approximately rotationally symmetrical. Thus, the rotor 10 is also approximately rotationally symmetrical. The laminated core 12 has a central bore for accommodating the rotor shaft 11.

[0030] Figure 2 shows a perspective front view of an apparatus for manufacturing a rotor 10 for an electric motor. The apparatus comprises a pressing station 40 and a straightening station 60. The pressing station 40 serves to press a rotor shaft 11 into a laminated core 12. The straightening station 60 serves to straighten a rotor 10, which comprises a laminated core 12 and a rotor shaft 11 pressed into it.

[0031] The pressing station 40 has a receiving sleeve for receiving a rotor shaft 11. The pressing station 40 also has a receiving device for receiving a laminated core 12. The pressing station 40 further has a hydraulic press for pressing a rotor shaft 11 into a laminated core 12. The receiving sleeve can be moved by the hydraulic press toward the receiving device. The pressing station 40 has a first sensor for detecting a rotor shaft 11 received in the receiving sleeve. The pressing station 40 also has a second sensor for detecting a laminated core 12 received in the receiving device. The sensors serve to control the hydraulic press of the pressing station 40.

[0032] Figure 3 shows a sectional view of a device for manufacturing a rotor 10 for an electric motor. The device comprises a transport unit 50. The transport unit 50 serves to transport a rotor 10 from the pressing station 40 to the straightening station 60.

[0033] The transport unit 50 has a gripper arm 52. The gripper arm 52 is configured to pick up a rotor 10 at the pressing station 40 and place it on a holding device of the straightening station 60.

[0034] Figure 4 shows a perspective rear view of an apparatus for manufacturing a rotor 10 for an electric motor. The straightening station 60 has a holding device for receiving a rotor 10. The holding device comprises two bearing points. The bearing points are arranged such that the rotor shaft 11 of a received rotor 10 rests on the bearing points, and the laminated core 12 of a received rotor 10 is arranged between the bearing points.

[0035] The bearing points are designed such that a mounted rotor 10 can rotate about a rotational axis relative to the bearing points. The straightening station 60 also has a drive device for rotating a rotor 10 mounted on the holding device about the rotational axis relative to the bearing points.

[0036] The straightening station 60 has a device for measuring the eccentricity of a mounted rotor 10. The device for measuring the eccentricity comprises a distance meter for detecting a distance to the laminated core 12 of the mounted rotor 10 and an angle meter for detecting an angular position of the mounted rotor 10 relative to the bearing points.

[0037] The straightening station 60 also has a straightening element. The straightening element is designed to exert a force in the radial direction on the laminated core 12 of a received rotor 10 in order to remove any eccentricity. To manufacture a rotor 10 for an electric motor using a device shown in Figures 2, 3, and 4, a laminated core 12 is first fed into the receiving device of the pressing station 40. For this purpose, the laminated core 12 is inserted, for example manually, into the receiving device of the pressing station 40. Likewise, a rotor shaft 11 is fed into the receiving sleeve of the pressing station 40. For this purpose, the rotor shaft 11 is inserted, for example manually, into the receiving sleeve of the pressing station 40.

[0038] The first sensor of the pressing station 40 detects the rotor shaft 11 received in the receiving sleeve. The second sensor of the pressing station 40 detects the laminated core 12 received in the receiving device. The rotor shaft 11 is then pressed into the laminated core 12 in the pressing station 40. The receiving sleeve with the received rotor shaft 11 is moved by the hydraulic press in the direction of the receiving device with the received laminated core 12.

[0039] The manufactured rotor 10, which comprises the laminated core 12 and the rotor shaft 11 pressed into it, is then transported from the pressing station 40 to the straightening station 60. For this purpose, the rotor 10 is picked up by the gripper arm 52 of the transport unit 50 at the pressing station 40 and placed on the holding device of the straightening station 60.

[0040] In the straightening station 60, the manufactured rotor 10 is straightened. The rotor 10 is held on the holding device of the straightening station 60 in such a way that the rotor shaft 11 of the rotor 10 rests on the bearing points of the holding device, and that the laminated core 12 of the rotor 10 is arranged between the bearing points.

[0041] First, it is determined whether and at which angular position the rotor 10 exhibits eccentricity. For this purpose, the rotor 10, mounted on the holding device, is driven in rotation by the drive device of the straightening station 60 and thus rotates about a rotational axis relative to the bearing points of the holding device.

[0042] The distance meter of the eccentricity measuring device detects a distance from the distance meter to the laminated core 12 of the rotating rotor 10. The angle meter of the eccentricity measuring device simultaneously detects an angular position of the rotating rotor 10 relative to the bearing points. If the distance of the distance meter to the laminated core 12 of the rotor 10 is the same for every angular position, the axis of rotation of the rotor 10 runs centrally through the rotor 10. If the distance of the distance meter to the laminated core 12 of the rotor 10 varies depending on the angular position, the axis of rotation of the rotor 10 runs eccentrically through the rotor 10. If the axis of rotation runs eccentrically through the rotor 10, the rotor 10 exhibits eccentricity.

[0043] If the rotor 10 exhibits an eccentricity, the determined eccentricity is removed from the straightening element. To do this, the rotor 10 is aligned on the holding device such that the angular position at which the distance of the distance meter from the laminated core 12 of the rotor 10 is minimal faces the straightening element of the straightening station.

[0044] The straightening element is then moved toward the rotor 10. The straightening element exerts a force on the laminated core 12 of the mounted rotor 10 in the radial direction at the angular position where the rotor 10 exhibits the eccentricity. The rotor 10 thereby undergoes plastic deformation. The rotor 10 is plastically deformed by the straightening element in such a way that the determined eccentricity is removed.

[0045] If the rotational axis runs centrally through the rotor 10, the rotor 10 exhibits no eccentricity. The finished rotor 10 is then removed from the straightening station 60. For this purpose, the rotor 10 is removed, for example, manually, from the holding device of the straightening station 60.

[0046] List of reference symbols

[0047] 10 Rotor

[0048] 11 Rotor shaft

[0049] 12 sheet package

[0050] 40 pressing station

[0051] 50 transport units

[0052] 52 gripper arm

[0053] 60 alignment station

Claims

Patent claims:

1. Apparatus for manufacturing a rotor (10) for an electric motor, comprising a pressing station (40) for pressing a rotor shaft (11) into a laminated core (12), a straightening station (60) for straightening a rotor (10) which comprises a laminated core (12) and a rotor shaft (11) pressed therein, and a transport unit (50) for transporting a rotor (10) from the pressing station (40) to the straightening station (60).

2. Device according to claim 1, characterized in that the transport unit (50) has a gripping arm (52) which is designed to pick up a rotor (10) at the pressing station (40) and to place it on a holding device of the straightening station (60).

3. Device according to one of the preceding claims, characterized in that the pressing station (40) has a hydraulic press for pressing a rotor shaft (11) into a laminated core (12).

4. Device according to claim 3, characterized in that the pressing station (40) has a receiving sleeve for receiving a rotor shaft (11) and a receiving device for receiving a laminated core (12), and that the receiving sleeve can be moved by the hydraulic press in the direction of the receiving device.

5. Device according to claim 4, characterized in that the pressing station (40) has a first sensor for detecting a rotor shaft (11) received in the receiving sleeve and a second sensor for detecting a laminated core (12) received in the receiving device.

6. Device according to one of the preceding claims, characterized in that the straightening station (60) has a holding device for receiving a rotor (10), which comprises two bearing points which are arranged such that the rotor shaft (11) of a received rotor (10) rests on the bearing points, and that the laminated core (12) of a received rotor (10) is arranged between the bearing points, and that a received rotor (10) is rotatable about an axis of rotation relative to the bearing points.

7. Device according to claim 6, characterized in that the straightening station (60) has a device for measuring the eccentricity of a received rotor (10), which device comprises a distance meter for detecting a distance to the laminated core (12) of the received rotor (10) and an angle meter for detecting an angular position of the received rotor (10) relative to the bearing points.

8. Device according to claim 7, characterized in that the straightening station (60) has a drive device for the rotational drive of a rotor (10) received on the holding device about the axis of rotation relative to the bearing points.

9. Device according to one of the preceding claims, characterized in that the straightening station (60) has a straightening element which is designed to exert a force in the radial direction on the laminated core (12) of a received rotor (10).

10. A method for manufacturing a rotor (10) for an electric motor with a device according to one of the preceding claims, comprising the following steps: Feeding a sheet stack (12) into the pressing station (40); Feeding a rotor shaft (11) into the pressing station (40); Pressing the rotor shaft (11) into the laminated core (12) in the pressing station (40); Transporting the finished rotor (10), which comprises the laminated core (12) and the rotor shaft (11) pressed therein, from the pressing station (40) to the straightening station (60); Straightening the finished rotor (10) in the straightening station (60); and removing the finished rotor (10) from the straightening station (60).

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