Rotor having insert segments fixed directly to the two end plates, and method for assembling the rotor

Abstract

A rotor (1) for an electric machine is proposed, having: a rotor shaft (12) which defines a rotor axis of rotation (100); a plurality of rotor poles (2) which are distributed in the circumferential direction and each have at least one magnet unit (3a), (3b); at least one lamination stack (4), which has a laminated core (5) and at least one insert segment (6) per rotor pole (2), wherein the laminated core (5) has a central shaft receptacle (11) for receiving the rotor shaft (12) for conjoint rotation and, for each rotor pole (2), a segment receptacle (7) which is open radially to the outside, wherein, in a preassembly state, the respective magnet unit (3a), (3b) and the respective insert segment (6) are received in the segment receptacle (7); a bandage (19) which surrounds the lamination stack (4) and via which, in a finally assembled state, the magnet units (3a), (3b) and the insert segments (6) are held in the respective segment receptacle (9); a first and a second end disc (10a), (10b) which are arranged at the end side on in each case one axial end face of the lamination stack (4) on the rotor shaft (12); wherein, in the pre-assembled state, the insert segments (10a), (10b) are fixed captively directly to the two end plates (10a), (10b) at least in the radial direction with respect to the rotor axis of rotation (100).

Description

[0001] Rotor with inserts fixed directly to the two end plates and method for assembling the rotor

[0002] The invention relates to a rotor for an electrical machine having the features of the preamble of claim 1. Furthermore, the invention relates to a method for assembling the rotor.

[0003] Rotors for electrical machines are known which typically have a rotor core formed from several individual laminations stacked one above the other, with the rotor core having several magnetic pockets distributed in the circumferential direction for accommodating permanent magnets. For rotors of permanently excited synchronous machines (PSM), so-called buried permanent magnets are generally used, which are embedded within the rotor core. Furthermore, it is known to supplement the buried permanent magnets with surface magnets to improve efficiency. These surface magnets are arranged on the outside of the rotor core and fixed by bandaging the rotor core. By bandaging the rotor core, particularly high mechanical strength and speed stability is achieved.

[0004] Document WO 2021 225 902 A1 describes an electric motor comprising a stator configured to generate a magnetic field and receive a rotor in a central opening; and a rotor configured to fit into the central opening, wherein the rotor comprises a plurality of magnets and is wrapped with a wound thread bandage on its outer periphery, wherein the magnets are not completely enclosed by the rotor. The rotor has a plurality of pole pieces connected via fixing dowels to a balancing ring adjacent to the first end of the shaft.

[0005] The object of the invention is to create a rotor of the type mentioned at the beginning, which is characterized by particularly simple assembly.

[0006] This object is achieved by a rotor having the features of claim 1 and a method having the features of claim 11. Further features, advantages, and effects of the invention are described in the subclaims and the description with the accompanying figures.

[0007] The subject matter of the invention is a rotor which is designed and / or suitable for an electrical machine. In particular, the electrical machine is designed and / or suitable for an electric axle drive and / or for driving a motor vehicle. The electrical machine is preferably designed as an internal rotor, wherein the rotor is arranged radially inside a stator. For example, the electrical machine can be designed as a traction machine, also known as a separate motor generator (SMG). The electrical machine is particularly preferably designed as a permanent magnet synchronous machine, PSM for short. An optional subject matter of the invention relates to an electrical machine with the rotor.

[0008] The rotor has a rotor shaft which defines a rotor axis of rotation. The rotor shaft can be designed in one or more parts. In particular, the rotor shaft essentially has a support section for receiving a laminated core and a shaft section for receiving a rotor bearing. In principle, the shaft section and the support section can be designed as separate components which are connected to one another in a form-fitting and / or force-fitting and / or material-fitting manner at least in the circumferential direction. Alternatively, however, the shaft section and the support section can also be made from a common section of material, in particular in one piece. In particular, the rotor shaft with its axis of rotation defines the rotor axis of rotation.

[0009] The rotor has a plurality of rotor poles distributed in the circumferential direction, each of which comprises at least or exactly one magnet unit. Preferably, the magnet units each comprise one or more pole-generating magnets, in particular permanent magnets. Preferably, the rotor has more than four, preferably more than six, in particular more than eight rotor poles, which are evenly distributed in the circumferential direction. In particular, the rotor has 1n, 2n, 3n, 4n or 5n magnet units, where n corresponds to the number of rotor poles. The rotor has at least or exactly one laminated core. In principle, the rotor can have exactly one laminated core. Alternatively, however, the rotor can also be constructed from at least two partial laminated cores, which are arranged together on the rotor shaft in the axial direction with respect to the rotor axis of rotation in a successive and / or rotationally fixed manner.For example, the rotor can comprise more than two, preferably more than four, and especially more than six of the partial laminated cores. In particular, it is provided that the laminated core is manufactured in one production process, e.g., by means of stamping and stacking.

[0010] The laminated core has a laminated core and at least one or exactly one insert segment for each rotor pole. Particularly preferably, the laminated core is formed by a plurality of individual laminates stacked in the axial direction with respect to the rotor rotation axis, and the insert segments are formed by a plurality of individual laminated segments stacked in the axial direction with respect to the rotor rotation axis. The individual laminates and the individual laminated segments are preferably each made of a magnetized and / or magnetizable material, preferably a steel alloy. Individual laminates and the individual laminated segments are preferably connected to one another, for example by means of baked enamel, gluing, punched stacking, welding, or the like. In particular, the individual laminates and the individual laminated segments are designed as so-called electrical laminates. The laminated core is preferably closed all around, in particular essentially annular. Alternatively, however, the laminated core can also be designed with circumferential segments.For example, the segmentation can occur in the circumferential direction in the area of ​​the pole edges or at the pole edges. The insert segments are preferably formed separately from the laminated core or as separate components. Preferably, exactly one insert segment is assigned to each rotor pole.

[0011] The laminated core has a central shaft receptacle, which is designed and / or suitable for the rotationally fixed reception of the rotor shaft. In particular, the central shaft receptacle extends continuously and / or linearly through the laminated core in the axial direction. Preferably, the central shaft receptacle is formed as a central through-opening or a central opening through which the rotor shaft is guided coaxially with respect to the rotor rotation axis. In particular, the shaft receptacles of all partial laminated cores are congruent in the circumferential direction or aligned with one another in the axial direction.

[0012] Furthermore, the laminated core has a radially outwardly open segment receptacle for each rotor pole, which is designed and / or suitable in particular for receiving at least or exactly one of the magnet units and at least or exactly one of the insert segments. In a pre-assembled state, the respective magnet unit and the respective insert segment are received in the segment receptacle. In particular, the segment receptacles have a contour that is complementary to and / or geometrically similar to the insert segments. Preferably, the insert segments are supported on the magnet units within the segment receptacles in a form-fitting manner in the circumferential direction and / or in the radial direction with respect to the rotor axis of rotation. Preferably, the insert segments are supported on the magnet units with a precise fit and / or without play.In particular, the insert segments are accommodated in the segment receptacles in such a way that their radial outer side defines an outer circumference of the rotor and / or is arranged on a common pitch circle around the rotor axis.

[0013] The rotor has a bandage enclosing the laminated core, by means of which the magnet units and the insert segments are held in the respective segment receptacle in a final assembly state. In particular, the pre-assembly state is understood to mean a state of the rotor before assembly of the bandage or without a bandage. Preferably, a lateral surface of the laminated core is completely covered with the bandage and / or completely enclosed by the bandage. The bandage can be designed as a thread bandage, which is formed by a thread wound in a strand around the rotor. Preferably, the thread is band-shaped and / or has an elliptical or rectangular cross-section. The thread can preferably be made of carbon fiber or other fiber materials, such as metal fibers or a fiber composite material, for example fiber-reinforced plastic. In particular, the thread can be embedded in a matrix.The rotor has a first and a second end plate, which are arranged at each end on an axial end face of the laminated core. The two end plates are designed, in particular, separately from the laminated core and the rotor shaft. Preferably, the two end plates each have a shaft mount complementary to the rotor shaft, in particular the support section. In particular, the end plates are each arranged in a rotationally fixed manner on the shaft section and / or one of the bearing sections via the shaft mount. In particular, the end plates are designed as so-called balancing discs.

[0014] Within the scope of the invention, it is proposed that the insert segments are captively secured directly to the two end plates in the pre-assembled state, at least in the radial direction with respect to the rotor rotation axis. In other words, the insert segments are connected to the two end plates in such a way that the insert segments are secured in the pre-assembled state, i.e. without a bandage, against falling out of the segment receptacles. Thus, before the bandage is installed, the magnet units are held captively in the respective segment receptacle by the insert segments. In particular, “directly” is to be understood as meaning that the insert segments are connected directly to the two end plates without additional securing means or assembly tools. Optionally, at least the insert segments are fixed directly to the two end plates in the axial direction and / or in the circumferential direction in the pre-assembled state.

[0015] The invention is based on the knowledge that in bandaged rotors the poles (magnet units and insert segments) are inserted radially from the outside into the sheet metal core. Threaded rods are then usually pushed through both end plates and the insert segments in between and secured with nuts on both sides. The insert segments fixed in this way hold the magnet units located further radially inwards in their position. The rotor is then wound with the bandage. After the bandage has been wound, fixing with the threaded rods and nuts is superfluous because the individual rotor components are held by the bandage. The threaded rods and nuts must therefore be removed again. By directly fixing the insert segments to the end plates, assembly can be made much easier because the nuts and threaded rods do not need to be removed after bandaging.This allows for a significant reduction in cycle time. Furthermore, the use of additional securing elements is eliminated, which reduces the overall weight and the number of individual parts, as well as the associated assembly effort. A further advantage is that no additional holes are required in the end plates, making them significantly simpler and more cost-effective to manufacture.

[0016] In a specific implementation, it is provided that the insert segments are each fixed to the two end plates in the pre-assembled state via a form-fitting and / or friction-fitting and / or material-fit connection. The insert segments can be detachably connected to the end plates via the form-fitting and / or friction-fitting connection and non-detachably connected to the end plates via the material-fit connection. The form-fitting connection is preferably created by an axial interlocking of the insert segments and the two end plates. The friction-fit connection is preferably created by axially clamping or pressing the insert segments between the two end plates. The material-fit connection is preferably created by gluing the insert segments between the two end plates. A rotor is thus proposed which is characterized by a particularly simple and cost-effective fixing of the insert segments to the two end plates.

[0017] In a further specific implementation, it is provided that the insert segments and the end plates each form a connection partner of the form-fitting and / or friction-fitting and / or material-fit connection. In particular, a first connection is established directly between the first end plate and the adjacent insert segments, and a second connection is established directly between the second end plate and the adjacent insert segments. In other words, the insert segments are directly operatively connected to the two end plates in a form-fitting and / or friction-fitting and / or material-fit connection. Thus, a fixation of the insert segments in the pre-assembled state is proposed which does not require the use of additional securing elements, such as screws, bolts, or the like.

[0018] In one specific embodiment, it is provided that the first and / or the second end plates have a form-fitting contour and the insert segments each have a form-fitting counter-contour corresponding to the form-fitting contour, via which counter-contour the insert segments are in form-fitting engagement with the two end plates to form the form-fitting connection, at least in the radial direction. In particular, the form-fitting contour can be designed as a recess and the form-fitting counter-contour as an elevation. Alternatively, however, the form-fitting contour can also be designed as the elevation and the form-fitting counter-contour as the recess. Preferably, the form-fitting contour and / or the form-fitting counter-contour is produced by forming, e.g. by punching and / or bending. The recess can be formed, for example, as an impression, cutout or the like.The raised portion can be formed, for example, by a stamping, punching, or the like. In principle, the form-fitting contour can be formed on only one side or on one of the two end plates. Alternatively, the form-fitting contours can be formed on both sides or on both end plates. This proposes a particularly simple and cost-effective connection between the insert segments and the two end plates.

[0019] In a specific embodiment, the positive locking contour is formed by an annular groove surrounding the rotor rotation axis, and the positive locking counter contour is formed by at least one spring tab formed on the end face of the insert segments, which is positioned opposite to the radial direction. In particular, a snap connection is realized by the spring tab. Preferably, the spring tabs are resiliently deformable during radial assembly of the insert segments. During assembly, the insert segments slide with the spring tabs on the axial inner sides of the end plates and are elastically deformed in the process. When an end position is reached, the spring tabs engage in the corresponding annular groove, thereby establishing the positive connection in the radial direction. A particularly simple assembly of the insert segments is thus proposed, in which the insert segments are inserted or engaged one after the other into the respective segment holder.

[0020] In an alternative or optionally additional embodiment, the form-fitting contour is formed by an annular shoulder running around the rotor rotation axis, and the form-fitting counter-contour is formed by a circumferential recess into which the annular shoulder engages. In particular, a plug-in connection is realized by the annular shoulder. The recess can in principle be formed by a diameter reduction on the outer diameter of the insert segments, into which the annular shoulder engages, preferably without offset. Alternatively, the recess can be formed by a circumferential annular groove on the end face of the insert segments, into which the annular shoulder is inserted in sections. The annular shoulder is designed, for example, as a cylindrical projection, collar, or the like projecting in the axial direction. During assembly, the insert segment is pushed or inserted into or onto the end plate in the axial direction.When an end position is reached, the annular shoulder is inserted into or onto the corresponding recess, thereby establishing a positive connection in the radial direction. Specifically, the positive connection can be designed as a plug-in connection on one side and a snap-in connection on the other. This enables simple and, preferably, play-free fixation of the insert segments in the segment receptacles.

[0021] Alternatively or optionally in addition, it is provided that the two end plates and the insert segments are subjected to a clamping force in the axial direction to form the frictional connection. The rotor shaft preferably has an axial end stop on the outer circumference for axially supporting the first end plate, which stop is designed to run circumferentially to the rotor axis of rotation. Furthermore, the rotor can have a securing means designed to apply the axial clamping force to the second end plate and thus to the laminated core. For this purpose, the rotor shaft can have an external thread via which the securing means, e.g. designed as a shaft nut, can be mounted or screwed on. Alternatively, however, the securing means can also be pressed directly onto the rotor shaft, e.g. designed as a press ring.Preferably, the end faces of the first and / or second end plate are inclined relative to the end faces of the insert segments, so that the end plate(s) are axially supported on the insert segments, at least with their outer diameter in the axial direction. Specifically, at least the second end plate can be designed in the form of a disc spring. The axial clamping force enables axial compression of the components, which secures them against loss and ensures that they are arranged with no play relative to one another.

[0022] Alternatively or optionally in addition, it is provided that the insert segments are each connected to the two end plates via an adhesive layer to form the material connection. The adhesive layer can be applied partially, preferably at specific points, or over the entire surface, preferably over the entire surface, in the contact area between the first and / or second end plate and the respectively facing insert segments. The end faces of the insert segments and the corresponding end plate are preferably parallel and / or flat. In particular, the adhesive layer can be activated and cured under the influence of heat and / or heat or via an activator. For example, the adhesive layer can be non-adhesive in its initial state. The insert segments can therefore be arranged in the segment receptacles without being directly bonded to one another. For this purpose, the adhesive layer can be formed, for example, by a "baking varnish".The adhesive layer allows the insert segments to be easily inserted into the segment holders and bonded to the end plates.

[0023] In a further development, it is provided that the first and second end plates have an axial bandage stop for the bandage. In particular, the axial bandage stop serves to prevent the thread from slipping off the end plates. The bandage stop preferably extends circumferentially in a radial plane of the rotor rotation axis. The bandage stops can have a smaller outer diameter than the bandage. In particular, the outer diameter of the bandage stops is at least one end-side, reduced outer diameter of the bandage. For example, the first and second bandage stops are formed by a circumferential rim, flange or the like. The bandage stops ensure axial securing of the thread bandage and prevent the thread from slipping off the end.

[0024] In a further specific embodiment, it is provided that the bandage at least partially covers the first and second end plates in the axial direction with respect to the rotor rotation axis. In other words, the bandage extends in the axial direction beyond the axial length of the laminated core. Preferably, the bandage has a constant and / or consistent winding thickness over the entire axial length of the laminated core. Optionally, the bandage has a winding thickness that decreases and / or falls axially outwards in the region of the two end plates. In particular, the thread start and / or the thread end are arranged outside the axial end of the laminated core.Due to the axial extension of the winding section beyond the laminated core to the two end plates, a particularly uniform force distribution can be achieved, since the winding thickness which decreases at the end is preferably arranged exclusively in the area of ​​the end plate and thus does not contribute to prestressing of the laminated core.

[0025] A further subject matter of the invention relates to a method for assembling the rotor, preferably as described above, in which the rotor shaft is provided; the laminated core and the two end plates are positively connected to the rotor shaft; the magnet units and the insert segments are inserted into the segment receptacles and are secured captively, at least in the radial direction with respect to the rotor rotation axis, directly to the two end plates; and the laminated core is finally wrapped with the bandage. The description of the method steps is not intended to specify a sequence for their execution. Rather, individual steps can be interchanged, repeated, or omitted. In concrete terms, this means that the magnet units and / or the insert segments can also be inserted into the segment receptacles of the laminated core before the first and / or second end plate is assembled, and the end plate(s) are then assembled.Preferably, however, at least the insert segments are inserted into the segment holders after assembly of the two end plates. In particular, when bandaging the rotor, a beginning of the thread is tied within a connecting groove of one of the end plates. The connecting groove can first be filled by repeatedly winding the beginning of the thread with the thread and then the laminated core can be wrapped with the thread to form the bandage. Preferably, the magnet units and the insert segments are inserted pole by pole into the respective segment holder. In particular, the insert segments can be inserted one after the other into the respective segment holder by hand or automatically.

[0026] In a specific embodiment, the insert segments are inserted radially into the segment receptacles, with the insert segments snapping positively into a circumferential annular groove of at least one or both end plates via at least one spring tab for captive securing. In principle, the insert segments can also be formed on only one side, whereby the insert segment on the opposite side can also be fixed with a force fit or a material fit.

[0027] In an alternative or optionally additional specification, it is provided that the insert segments are inserted into the segment receptacles in the axial direction, wherein the insert segments are each brought into engagement with a circumferential annular shoulder of at least one or both end plates for captive fastening. The annular shoulder can be brought into engagement with a recess formed in sections on the insert segments by inserting the insert segments in the axial direction onto or under the annular shoulder with the first end plate installed and the second end plate removed. Alternatively, the annular shoulder can be formed on only one side of the insert segments, whereby the insert segment can also be fixed on the opposite side by means of a force-fitting or material-fitting connection.In particular, the insert segments can have the spring tab on one side and the recess on the other side, whereby the insert segments can be inserted into the segment receptacles using a tilting and inserting movement. In an alternative or optionally additional specification, it is provided that the insert segments are inserted into the segment receptacles in the axial or radial direction, whereby the insert segments are each materially connected to one of the end plates via an adhesive layer for captive fastening. The adhesive layer can be applied or applied to the end face of the insert segments and / or the end plate(s). For example, the adhesive layer can be formed in each case by an adhesive dot. The insert segments are then inserted into the segment receptacles and the adhesive is cured under the influence of heat and / or heat or using an activator.For example, the bonding may be destroyed in its load-bearing capacity when bandaging the rotor.

[0028] In an alternative or optionally additional specification, it is provided that the insert segments are inserted into the segment receptacles in an axial or radial direction, whereby the insert segments are non-positively connected to the end plates via an axial clamping force for captive fixation. For example, after all magnet units and all insert segments have been inserted, the securing device can be subjected to the axial clamping force in order to clamp the sheet metal core, the magnet units and the insert segments between the two end plates or to fix them without play. In principle, the insert segments must be held by an assembly device during insertion. For tool-free assembly, the non-positive connection can therefore preferably be combined with the form-fit and / or material-fit connection, whereby the axial clamping force achieves a play-free fixation of the insert segments.

[0029] Further features, advantages, and effects of the invention will become apparent from the following description of preferred embodiments of the invention. In the following:

[0030] Fig. 1 is a perspective sectional view of a rotor in a final assembly state as a first embodiment of the invention; Fig. 2 is a perspective view of the rotor in a pre-assembly state.

[0031] Fig. 3 is a perspective sectional view of the rotor of Fig. 2;

[0032] Fig. 4 is a three-dimensional representation of a single sheet segment of an insert segment of the rotor from Fig. 3;

[0033] Fig. 5 is a perspective sectional view of an alternative embodiment of the rotor in the pre-assembled state-

[0034] Fig. 6 is a perspective view of the rotor of Fig. 5;

[0035] Fig. 7 is a schematic sectional view of another alternative embodiment of the rotor in the pre-assembled state;

[0036] Fig. 8 is a further schematic sectional view of another alternative embodiment of the rotor in the pre-assembled state.

[0037] Figure 1 shows a rotor 1 in a perspective sectional view with respect to a rotor rotation axis 100. The rotor 1 is designed or suitable for an electric machine of an electric vehicle (not shown). The electric machine can be a permanent magnet synchronous machine.

[0038] The rotor 1 comprises a plurality of rotor poles 2 evenly distributed in the circumferential direction around the rotor rotation axis 100, wherein each rotor pole 2 has two magnet units 3a, 3b, as also shown in Figure 2. The magnet units 3a, 3b are each formed by at least one pole-generating magnet, which is designed, for example, as a rod-shaped permanent magnet.

[0039] The rotor 1 comprises at least one laminated core 4, which is essentially formed from a star-shaped laminated core 5 and from one insert segment 6 for each rotor pole 2, wherein the insert segments 6 of each rotor pole 2 are each received in a segment receptacle 7 formed on the laminated core 5. The laminated core 5 is formed by a plurality of individual laminated sheets 8 stacked one above the other in the axial direction with respect to the rotor rotation axis 100, and the insert segments 6 are formed by a plurality of individual laminated sheet segments 9 stacked one above the other in the axial direction with respect to the rotor rotation axis 100. For example, the individual laminated sheets 8 and the individual laminated sheet segments 9 can each be manufactured by stamping and connected to one another.

[0040] The laminated core 5 has a central shaft receptacle 11, via which the laminated core 4 is arranged in a rotationally fixed manner on a rotor shaft 12. For this purpose, the rotor shaft 12 is guided coaxially with respect to the rotor rotation axis 100 through the shaft receptacle 11, wherein the shaft receptacles 11 penetrate the laminated core 5 in the axial direction with respect to the rotor rotation axis 100. For example, the laminated core 5 and the rotor shaft 12 are connected to one another via the shaft receptacle 11 in a form-fitting and / or force-fitting manner in the circumferential direction around the rotor rotation axis 100.

[0041] The rotor shaft 12 has a hollow shaft section 13, which is connected to a support section 14 via a flange connection. The shaft section 13 and the support section 14 are formed as separate components. The shaft section 13 essentially serves to rotatably support the rotor shaft 12 in a housing of the electric machine. For this purpose, a rotor bearing, e.g., a roller bearing, can be mounted on the shaft section 13.

[0042] The rotor 1 has a first and a second end plate 10a, 10b, which are arranged on the support section 14 at each end of an axial end face of the laminated core 4, coaxial with the rotor rotation axis 100. The two end plates 10a, 10b are designed as balancing plates formed separately from the laminated core 4 and the support section 14, respectively.

[0043] The support section 14 has an axial end stop 16 on its outer circumference, which is formed circumferentially around the rotor rotation axis 100. For example, the end stop 16 is formed by a flange circumferentially surrounding the rotor rotation axis 100. The end stop 16 serves to axially support the first end plate 10a on the support section. Furthermore, the support section 14 has an external thread 17, via which a securing means 18 can be mounted or screwed on. For example, the securing means 18 is formed by a shaft nut. The securing means 18 serves to axially secure the second end plate 10b and thus the laminated core 2 and the first end plate 10a to the support section 14.

[0044] The rotor 1 also has a bandage 19 that surrounds the laminated core 4 on its outer circumference. The bandage 19 serves to hold the individual components of the rotor 1 together, to apply a preload, and to shield the rotor 1 from heat. The magnet units 3a, 3b and the insert segments 6 are each clamped between the laminated core 5 and the bandage 19 in the segment receptacles 7. For example, the bandage 19 can be formed by a carbon fiber wrapping.

[0045] To prevent axial slippage of the bandage 19 at the axial ends, the first and second end plates 10a, 10b each have an axial bandage stop 15a, 15b. The bandage stops 15a, 15b are each designed as a rim surrounding the rotor rotation axis 100, each extending in a radial plane of the rotor rotation axis 100. The bandage stops 15a, 15b are arranged offset in the axial direction such that the bandage 19 at least partially covers the first and second end plates 10a, 10b in the axial direction with respect to the rotor rotation axis 100. In order to secure the insert segments 6 and thus the magnet units 3a, 3b against loss during bandaging, the insert segments 6 are fixed in a pre-assembled state directly to the two end plates 10a, 10b in a captive manner.

[0046] Figure 2 shows the rotor 2 in its pre-assembled state. For this purpose, the magnet units 3a, 3b and the insert segments 6 are inserted pole by pole from the radial outside into the corresponding segment holder 7 and are directly connected to the two end plates 10a, 10b in a form-fitting and / or material-fitting and / or force-fitting manner. Thus, the insert segments 6 and the two end plates 10a, 10b each form a connection partner. The laminated core 4 can then be wrapped with the bandage 19 during final assembly.

[0047] As shown in Figure 3, the insert segments 6 are each connected to the first and second end plates 10a, 10b via a positive-locking connection 20. For this purpose, the two end plates 10a, 10b each have a positive-locking contour 21, and the insert segments 6 each have a positive-locking counter-contour 22 on both sides that corresponds to the positive-locking contour 21. The insert segments 6, via which counter-contour, form the positive-locking connection 20 and engage the end plates 10a, 10b in a form-fitting manner in the radial direction relative to the rotor rotation axis 100, in order to secure the insert segments 6 in the segment holder 7 against loss.

[0048] In the exemplary embodiment shown, the positive-locking contour 21 is formed by an annular groove 23 which runs around the rotor rotation axis 100 and is provided in a front side of the end plates 10a, 10b facing the insert segments 6. The annular groove 23 can be continuous or uninterrupted in the circumferential direction. In the exemplary embodiment shown, the positive-locking counter-contour 22 is formed by a spring tab 24 which is formed on the front side of the insert segments 6 and which is positioned opposite to the radial direction and is thus positively supported in the radial direction within the annular groove 23. The spring tabs 24 of the insert segments 6 spring in during radial assembly, slide inwards on the front side of the end plates 10a, 10b and then engage in the corresponding annular groove 23 of the respective end plate 10a, 10b.The locking between the insert segment 24 and the end plates 10a, 10b also fixes the magnet units 3a, 3b located below the insert segments 24.

[0049] Figure 4 shows a front-side single sheet segment 9 of one of the insert segments 6 as described in Figure 3. The front-side single sheet segment 9 has the spring tab 24, which is introduced into the single sheet segment 9, for example, by punching and bending. Alternatively, embossing, elevations, etc. are also conceivable instead of the spring tabs 24. The front-side single sheet segments 9 are stacked and connected to the other single sheet segments 9 using known joining technologies, such as baked varnish, gluing, dotted glue, punching and stacking, welding, etc.

[0050] Figure 5 shows an alternative embodiment of the positive connection 20 between the insert segments 6 and at least one of the two end plates 10a, 10b. In the exemplary embodiment shown, the positive connection contour 21 is formed by an annular shoulder 25 which surrounds the rotor rotation axis 100 and extends in the axial direction on an outer diameter of the end plate 10a, 10b. In the exemplary embodiment shown, the positive connection counter contour 22 is formed by a recess 26 formed on the outer diameter of the insert segments 6, which is formed by a diameter reduction of the outer diameter of one or more individual sheet segments 9. To form the positive connection 20, the annular shoulder 25 engages over the individual sheet segments 6 without offset.

[0051] As shown in Figure 6, the recess 26 is formed in sections on the axial end face of the insert segments 6 and the sheet metal core 5. During assembly, the insert segments 6 are pushed under the corresponding annular shoulder 25 in the axial direction with respect to the rotor rotation axis 100. If the annular shoulder 25 is formed on both sides, the second end plate 10b must be removed to install the insert segments 6. If the annular shoulder 25 is formed on one side, the insert segments 6 can be installed in the assembled state of the two end plates 10a, 10b by a tilting and inserting movement into the segment receptacles 7. In this case, the insert segments 6 can have, for example, the spring tabs 24 on the opposite side.

[0052] As shown in Figure 7, the insert segments 6 can also be connected to the first and / or second end plate 10a, 10b via a material connection 27 instead of the form-fitting connection 20 in order to secure the insert segments 6 in the segment receptacle 7 against loss. For this purpose, an adhesive layer 28 is arranged axially between the insert segments 6 and the respective end plate 10a, 10b, via which adhesive layer 28 the insert segments 6 are materially connected on one or both sides to the respective end plate 10a, 10b. For example, the adhesive layer 28 can be formed by a respective adhesive point which is applied to an end face of the insert segments 6 before assembly. The insert segments 6 can be inserted either radially or axially into the segment receptacle 7, wherein the adhesive layer 28 cures, for example, under the influence of heat. The material connection 27 can also be combined with the form-fitting connection 20.

[0053] As shown in Figure 8, the insert segments 6 can be connected to the first and / or second end plate 10a, 10b instead of the form-fitting connection 20 or the material connection 27 or optionally additionally via a frictional connection 29 in order to secure the insert segments 6 in the segment holder 7 against loss. For this purpose, the two end plates 10a, 10b and the insert segments 6 are subjected to an axial clamping force 101 in the axial direction with respect to the rotor rotation axis 100. The axial clamping force F can be applied to the second end plate 10b by the securing means 18 in order to create a press fit for the insert segments 6 between the two end plates 10a, 10b. For this purpose, the securing means 18 can be designed as a shaft nut, as described in Figure 1, wherein the clamping force 101 can be adjusted by a tightening torque.Alternatively, the securing means 18 can also be designed as a press ring, which is pressed onto the support section 14 in the axial direction. Furthermore, at least the second end plate 10b can be designed in the form of a wave spring, which is supported with its peripheral circle on the axial end face of the insert segments 6.

[0054] When assembling the rotor 1, the insert segments 6 are first mounted pole by pole into the respective segment holder 7 and are connected directly to the end plates 10a, 10b via the form-fit connection 20 and / or the material connection 27 and / or the frictional connection 29, thus securing them securely. The rotor 1 is then wound with the bandage 19 without the individual parts having to be secured by a separate assembly aid. This provides a particularly simple assembly of the rotor 1. Reference numerals

[0055] 1 rotor

[0056] 2 poles

[0057] 3a, b magnetic units

[0058] 4 sheet package

[0059] 5 sheet core

[0060] 6 insert segments

[0061] 7 segment recordings

[0062] 8 individual sheets

[0063] 9 individual sheet segments

[0064] 10a, b end plates

[0065] 11 Wave recording

[0066] 12 Rotor shaft

[0067] 13 wave section

[0068] 14 supporting section

[0069] 15a, b Bandage stops

[0070] 16 End stop

[0071] 17 external threads

[0072] 18 securing devices

[0073] 19 Bandage

[0074] 20 Form-lock connection

[0075] 21 Form-fitting contour

[0076] 22 Form-fitting counter contour

[0077] 23 Ring groove

[0078] 24 pencil cases

[0079] 25 ring shoulder

[0080] 26 Deepening

[0081] 27 Material connection

[0082] 28 Frictional connection

[0083] 100 Rotor rotation axis

[0084] 101 Tension

Claims

Patent claims 1. Rotor (1 ) for an electrical machine, - with a rotor shaft (12) which defines a rotor rotation axis (100), - with several rotor poles (2) distributed in the circumferential direction, each having at least one magnet unit (3a, 3b), - with at least one laminated core (4) which has a laminated core (5) and at least one insert segment (6) for each rotor pole (2), wherein the laminated core (5) has a central shaft receptacle (11) for the rotationally fixed reception of the rotor shaft (12) and a radially outwardly open segment receptacle (7) for each rotor pole (2), wherein in a pre-assembled state the respective magnet unit (3a, 3b) and the respective insert segment (6) are received in the segment receptacle (7), - with a bandage (19) surrounding the laminated core (4), by means of which the magnet units (3a, 3b) and the insert segments (6) are held in the respective segment holder (9) in a final assembly state, - with a first and a second end plate (10a, 10b), which are arranged at the end on each of an axial end face of the laminated core (4) on the rotor shaft (12), characterized in that the insert segments (10a, 10b) are fixed in a captive manner in the pre-assembled state at least in the radial direction with respect to the rotor rotation axis (100) directly on the two end plates (10a, 10b).

2. Rotor (1) according to claim 1, characterized in that the insert segments (6) are each fixed to the two end plates (10a, 10b) in the pre-assembled state via a form-fitting connection (20) and / or a force-fitting connection (29) and / or a material connection (27).

3. Rotor (1) according to claim 2, characterized in that the insert segments (6) and the end plates (10a, 10b) each form a connection partner of the form-locking connection (20) and / or force-locking connection (29) and / or material-locking connection (27).

4. Rotor (1) according to claim 2 or 3, characterized in that the first and / or the second end plate (10a, 10b) have a positive-locking contour (21) and the insert segments (6) each have a positive-locking counter-contour (22) corresponding to the positive-locking contour (21), via which the insert segments (6) are in positive engagement with at least one of the end plates (10a, 10b) to form the positive-locking connection (20), at least in the radial direction.

5. Rotor (1) according to claim 4, characterized in that the form-fitting contour (21) is formed by an annular groove (23) surrounding the rotor rotation axis (100) and the form-fitting counter-contour (22) is formed by at least one spring tab (24) formed on the end face of the insert segments (6).

6. Rotor (1) according to claim 4 or 5, characterized in that the form-fitting contour (21) is formed by an annular shoulder (25) surrounding the rotor rotation axis (100) and the form-fitting counter-contour (22) is formed by a recess (26) formed in sections on the insert segments (6).

7. Rotor (1) according to claim 2 to 6, characterized in that the two end discs (10a, 10b) and the insert segments (6) are subjected to a clamping force (101) in the axial direction with respect to the rotor rotation axis (100) in order to form the frictional connection (29).

8. Rotor (1) according to claims 2 to 7, characterized in that the insert segments (6) are connected to at least one of the two end plates (10a, 10b) via an adhesive layer (28) in each case to form the material connection (27).

9. Rotor (1) according to one of the preceding claims, characterized in that the first and the second end plate (10a, 10b) have an axial bandage stop (15a, 15b) for the bandage (19).

10. Rotor (1) according to one of the preceding claims, characterized in that the bandage (19) at least partially covers the first and the second end plate (10a, 10b) in the axial direction with respect to the rotor axis of rotation (100).

11. A method for assembling the rotor according to any one of the preceding claims, wherein: - the rotor shaft (12) is provided; - the sheet metal core (5) and the two end plates (15a, 15b) are positively connected to the rotor shaft (12); - the magnet units (3a, 3b) and the insert segments (6) are inserted into the segment receptacles (7) and are secured in a captive manner directly to the two end plates (15a, 15b) at least in the radial direction with respect to the rotor rotation axis (100); - the sheet package (4) is then wrapped with the bandage (19).

12. Method according to claim 11, characterized in that the insert segments (6) are inserted in the radial direction into the segment receptacles (7), wherein the insert segments (6) are positively engaged in a circumferential annular groove (23) of at least one of the end plates (10a, 10b) for secure fixing via at least one spring pocket (24).

13. Method according to claim 11 or 12, characterized in that the insert segments (6) are inserted in the axial direction into the segment receptacles (7), wherein the insert segments (6) are brought into engagement with at least one of the end plates (10a, 10b) for captive fixing with a respective circumferential annular shoulder (26).

14. Method according to one of claims 11 to 13, characterized in that the insert segments (6) are inserted in the axial or radial direction into the segment receptacles (7), wherein the insert segments (6) are bonded to at least one of the end plates (10a, 10b) via an adhesive layer (28) for secure fastening.

15. Method according to one of claims 11 to 14, characterized in that the insert segments (6) are inserted in the axial or radial direction into the segment receptacles (7), wherein the insert segments (6) are non-positively connected to the end plates (10a, 10b) via an axial clamping force (101) for captive fixing.

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