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 loading station (20) for supplying a laminated core (12) and a rotor shaft (11), a heating station (30) for heating a laminated core (12), a pressing station (40) for pressing a rotor shaft (11) into a laminated core (12), and a transport unit (50) for transporting a laminated core (12) between the loading station (20), the heating station (30), and the pressing station (40). 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 loading station (20); transporting the laminated core (12) from the loading station (20) to the heating station (30); heating the laminated core (12) in the heating station (30); transporting the heated laminated core (12) from the heating station (30) to the loading station (20); supplying a rotor shaft (11) to the loading station (20); placing the rotor shaft (11) on the laminated core (12); transporting the laminated core (12) together with the rotor shaft (11) from the loading station (20) 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 the laminated core (12) and the rotor shaft (11) pressed into the laminated core, from the pressing station (40) to the loading station (20); and removing the produced rotor (10) from the loading station (20).

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 rotates around an axis relative to the stator. This requires that the laminated core and the rotor shaft be connected in a rotationally fixed manner.

[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 12.

[0008] A device according to the invention for manufacturing a rotor for an electric motor comprises a loading station for feeding a laminated core and a rotor shaft, a heating station for heating a laminated core, a pressing station for pressing a rotor shaft into a laminated core, and a transport unit for transporting a laminated core between the loading station, the heating station, and the pressing station.

[0009] Using the device according to the invention, a rotor shaft can be connected to a laminated core by shrinking. This creates a frictional and rotationally fixed connection between the laminated core and the rotor shaft. 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 pressing station ensures precise pressing of the rotor shaft into the laminated core.

[0010] According to an advantageous embodiment of the invention, the pressing station has a cooling device for cooling the hydraulic press.

[0011] According to an advantageous embodiment of the invention, the heating station comprises an induction furnace for heating a laminated core. The induction furnace ensures relatively rapid heating of the laminated core to the required temperature within a few minutes.

[0012] According to an advantageous embodiment of the invention, the induction furnace is designed to heat a laminated core to a temperature of at least 400°C. At this temperature, the laminated core expands sufficiently to accommodate the rotor shaft.

[0013] According to an advantageous embodiment of the invention, the loading station is located between the heating station and the pressing station. The feeding of the laminated core, the feeding of the rotor shaft, and the removal of the finished rotor can be carried out at the loading station, and the transport routes for the laminated core, the rotor shaft, and the rotor are relatively short.

[0014] According to an advantageous embodiment of the invention, the transport unit comprises a circulating conveying medium which is configured to transport a laminated core from the loading station to the heating station, to transport a heated laminated core from the heating station to the loading station, to transport a laminated core with a rotor shaft from the loading station to the pressing station and to transport a manufactured rotor, which comprises a laminated core and a rotor shaft pressed therein, from the pressing station to the loading station.

[0015] According to an advantageous embodiment of the invention, the conveying medium can be operated bidirectionally. If the loading station is located between the heating station and the pressing station, the laminated core, the rotor shaft, and the rotor can be transported between the loading station, the heating station, and the pressing station by means of the conveying medium.

[0016] According to an advantageous embodiment of the invention, the loading station has a first sensor for detecting a laminated core located on the conveying medium. The first sensor enables control of the transport unit. When the first sensor detects the laminated core, the conveying medium is driven, and the laminated core is transported to the heating station.

[0017] According to an advantageous embodiment of the invention, the loading station has a temperature sensor for detecting the temperature of a laminated core located on the conveying medium. If the temperature is too low, further processing of the laminated core is prevented. This advantageously reduces scrap during rotor production.

[0018] According to an advantageous embodiment of the invention, the loading station has a second sensor for detecting a rotor shaft placed on the laminated core. The second sensor enables control of the transport unit. When the second sensor detects the rotor shaft placed on the laminated core, the conveying medium is driven, and the laminated core with the rotor shaft is transported to the pressing station.

[0019] 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:

[0020] Feeding a sheet package into the charging station;

[0021] Transport of the sheet package from the charging station to the heating station;

[0022] Heating the sheet package in the heating station;

[0023] Transport of the heated sheet package from the heating station to the charging station;

[0024] Feeding a rotor shaft into the charging station;

[0025] Placing the rotor shaft on the laminated core;

[0026] Transporting the laminated core with the rotor shaft from the loading station to the pressing station; pressing the rotor shaft into the laminated core in the pressing station;

[0027] Transporting the finished rotor, which comprises the laminated core and the rotor shaft pressed into it, from the pressing station to the loading station; and removing the finished rotor from the loading station. Using the method according to the invention, a rotor shaft can be connected to a laminated core by shrinking. This results in a friction-locked and rotationally fixed connection between the laminated core and the rotor shaft. The method according to the invention allows for the almost continuous production of rotors. In particular, the heating station operates continuously, and cooling is largely avoided.

[0028] The invention is not limited to the combination of features in the claims. Further possible combinations of claims and / or individual claim features and / or features of the description and / or the figures will become apparent to those skilled in the art, particularly from the problem and / or the problem posed by comparison with the prior art.

[0029] 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:

[0030] Figure 1 : a rotor for an electric motor,

[0031] Figure 2: a front view of a device for manufacturing a rotor and

[0032] Figure 3: a perspective view of a device for manufacturing a rotor.

[0033] 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.

[0034] 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.

[0035] Figure 2 shows a front view of a device for manufacturing a rotor 10 for an electric motor. The device comprises a charging station 20, a heating station 30, a pressing station 40, and a transport unit 50. The charging station 20, the heating station 30, and the pressing station 40 are arranged side by side. The charging station 20 is located between the heating station 30 and the pressing station 40.

[0036] The loading station 20 is used to feed a laminated core 12, to feed a rotor shaft 11 and to remove a finished rotor 10. The heating station 30 is used to heat a laminated core 12. The pressing station 40 is used to press a rotor shaft 11 into a laminated core 12. The transport unit 50 is used to transport a laminated core 12 from the loading station 20 to the heating station 30, to transport a laminated core 12 from the heating station 30 to the loading station 20, to transport a laminated core 12 with a rotor shaft 11 from the loading station 20 to the pressing station 40 and to transport a finished rotor 10 from the pressing station 40 to the loading station 20. Figure 3 shows a perspective view of the device shown in Figure 2 for manufacturing a rotor 10 for an electric motor. As already mentioned, the device comprises the loading station 20, the heating station 30, the pressing station 40 and the transport unit 50.The charging station 20 is arranged between the heating station 30 and the pressing station 40.

[0037] The heating station 30 has an induction furnace 31 for heating a laminated core 12. The induction furnace 31 is configured to heat a laminated core 12 to a temperature of at least 400°C. The heating station 30 further has a power supply unit 32. The power supply unit 32 supplies the induction furnace 31 with electrical energy.

[0038] The pressing station 40 has a hydraulic press 41 for pressing a rotor shaft 11 into a laminated core 12. The pressing station 40 also has a cooling device 42 for cooling the hydraulic press 41. A cooling circuit connects the cooling device 42 to the hydraulic press 41. To cool the hydraulic press 41, water is pumped through the cooling circuit by the cooling device 42.

[0039] The transport unit 50 comprises a circulating conveying medium 51. The conveying medium 51 is, for example, a conveyor belt, a conveyor belt, or a conveyor chain. The conveying medium 51 is bidirectionally operable. The conveying medium 51 is configured to transport a laminated core 12 from the loading station 20 to the heating station 30, to transport a heated laminated core 12 from the heating station 30 to the loading station 20, to connect a laminated core 12 with a rotor shaft

[0040] 11 from the loading station 20 to the pressing station 40 and to transport a finished rotor 10 from the pressing station 40 to the loading station 20. The finished rotor 10 comprises a laminated core 12 and a rotor shaft 11 pressed into it.

[0041] The conveying medium 51 has receiving devices (not visible here) for receiving laminated cores 12. The receiving devices are each designed to receive a laminated core

[0042] 12 such that a central axis of the laminated core 12 runs perpendicular to a base on which the device for manufacturing a rotor 10 is located. The receiving devices are each also configured to receive a manufactured rotor 10 such that a central axis of the rotor 10 runs perpendicular to the base.

[0043] The charging station 20 has a first sensor (not shown here) for detecting a laminated core 12 located on the conveying medium 51. Furthermore, the charging station 20 has a temperature sensor (not shown here) for detecting the temperature of a laminated core 12 located on the conveying medium 51. The charging station 20 also has a second sensor (not shown here) for detecting a rotor shaft 11 placed on the laminated core 12.

[0044] To manufacture a rotor 10 for an electric motor using a device shown in Figure 2 and Figure 3, a laminated core 12 is first fed into the loading station 20. For this purpose, the laminated core 12 is inserted, for example manually, into a receiving device for the conveying medium 51.

[0045] The first sensor detects the laminated core 12 located on the conveying medium 51. The laminated core 12 is then transported from the loading station 20 to the heating station 30 by means of the conveying medium 51 of the transport unit 50.

[0046] In the heating station 30, the laminated core 12 is heated in the induction furnace 31 to a temperature of approximately 400°C. This causes the laminated core 12 to expand radially. In particular, the bore in the laminated core 12 is enlarged to accommodate the rotor shaft 11.

[0047] The heated laminated core 12 is then transported from the heating station 30 to the loading station 20 by means of the conveying medium 51. At the loading station 20, the first sensor again detects the laminated core 12 located on the conveying medium 51. Furthermore, the temperature sensor detects the temperature of the laminated core 12 located on the conveying medium 51.

[0048] A rotor shaft 11 is then fed into the loading station 20. For this purpose, the rotor shaft 11 is placed, for example manually, onto the laminated core 12.

[0049] The second sensor detects the rotor shaft 11 placed on the laminated core 12. The laminated core 12 with the rotor shaft 11 is then transported from the loading station 20 to the pressing station 40 by means of the conveying medium 51.

[0050] In the pressing station 40, the rotor shaft 11 is pressed into the laminated core 12 in the hydraulic press 41. After the laminated core 12 has cooled, the bore in the laminated core 12, in which the rotor shaft 11 is accommodated, is reduced in size. In this process, the laminated core 12 and the rotor shaft 11 are connected to each other in a force-fitting and rotationally fixed manner to form the rotor 10. The finished 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 loading station 20 by means of the conveying medium 51.

[0051] The finished rotor 10 is then removed from the loading station 20. For this purpose, the rotor 10 is removed, for example manually, from the receiving device for the conveying medium 51.

[0052] List of reference symbols

[0053] 10 Rotor 11 Rotor shaft

[0054] 12 sheet package

[0055] 20 charging stations

[0056] 30 heating stations

[0057] 31 Induction furnace 32 Power supply unit

[0058] 40 pressing station

[0059] 41 hydraulic press

[0060] 42 Cooling device

[0061] 50 Transport unit 51 Conveying medium

Claims

Patent claims:

1. Device for manufacturing a rotor (10) for an electric motor, comprising a loading station (20) for feeding a laminated core (12) and a rotor shaft (11), a heating station (30) for heating a laminated core (12), a pressing station (40) for pressing a rotor shaft (11) into a laminated core (12) and a transport unit (50) for transporting a laminated core (12) between the loading station (20), the heating station (30) and the pressing station (40).

2. Device according to claim 1, characterized in that the pressing station (40) has a hydraulic press (41) for pressing a rotor shaft (11) into a laminated core (12).

3. Device according to claim 2, characterized in that the pressing station (40) has a cooling device (42) for cooling the hydraulic press (41).

4. Device according to one of the preceding claims, characterized in that the heating station (30) has an induction furnace (31) for heating a laminated core (12).

5. Device according to claim 4, characterized in that the induction furnace (31) is designed to heat a laminated core (12) to a temperature of at least 400°C.

6. Device according to one of the preceding claims, characterized in that the charging station (20) is arranged between the heating station (30) and the pressing station (40).

7. Device according to one of the preceding claims, characterized in that the transport unit (50) comprises a circulating conveying medium (51) which is designed to transport a laminated core (12) from the loading station (20) to the heating station (30), to transport a heated laminated core (12) from the heating station (30) to the loading station (20), to transport a laminated core (12) with a rotor shaft (11) from the loading station (20) to the pressing station (40) and to transport a manufactured rotor (10), which comprises a laminated core (12) and a rotor shaft (11) pressed therein, from the pressing station (40) to the loading station (20).

8. Device according to claim 7, characterized in that the conveying medium (51) can be operated bidirectionally.

9. Device according to one of claims 7 to 8, characterized in that the loading station (20) has a first sensor for detecting a laminated core (12) located on the conveying medium (51).

10. Device according to one of claims 7 to 9, characterized in that the loading station (20) has a temperature sensor for detecting a temperature of a laminated core (12) located on the conveying medium (51).

11. Device according to one of the preceding claims, characterized in that the charging station (20) has a second sensor for detecting a rotor shaft (11) placed on the laminated core (12).

12. 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 loading station (20); Transporting the sheet stack (12) from the loading station (20) to the heating station (30); Heating the laminated core (12) in the heating station (30); Transporting the heated sheet stack (12) from the heating station (30) to the loading station (20); Feeding a rotor shaft (11) into the charging station (20); Placing the rotor shaft (11) on the laminated core (12); Transporting the laminated core (12) with the rotor shaft (11) from the loading station (20) to 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 loading station (20); and Removing the finished rotor (10) from the loading station (20).

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