Rotor assembly, separating body and method for producing a separating body

Abstract

The invention relates to a rotor assembly (1), comprising a rotor body (2) which forms a plurality of slots (3) in the axial direction for receiving a winding (4), rotor poles (5) which are each formed between two of the slots (3) in the radial direction, windings (4) which run in the slots (3) and surround the rotor poles (5), slot closure elements (6) which close the slots (3) in the radial direction, and at least one separating body (7) which is arranged in one of the slots (3) in the circumferential direction between two of the windings (4), wherein the separating body (7) comprises at least one continuous cooling channel (8) which extends in the axial direction and through which a cooling medium can flow, wherein the separating body (7) has a housing (9) with a first outer half-shell (10) and a second outer half-shell (11), wherein, within the housing (9), a first inner half-shell (12) bears in sections against the first outer half-shell (10) in such a way that a first cooling channel section (13) of the cooling channel (8) is defined between the first inner half-shell (12) and the first outer half-shell (10), and, within the housing (9), a second inner half-shell (14) bears in sections against the second outer half-shell (11) in such a way that a second cooling channel section (15) of the cooling channel (8) is defined between the second inner half-shell (14) and the second outer half-shell (11).

Description

[0001] Rotor arrangement, separating body and method for producing a separating body

[0002] The present invention relates to a rotor arrangement comprising a rotor body which forms a plurality of slots in the axial direction for receiving a winding; rotor poles which are formed in the radial direction between each two of the slots; windings which run in the slots and enclose the rotor poles; slot closure elements which close the slots in the radial direction; at least one separating body which is arranged in one of the slots in the circumferential direction between two of the windings, wherein the separating body comprises at least one continuous cooling channel extending in the axial direction through which a cooling medium can flow. The invention further relates to a separating body and a method for producing a separating body.

[0003] Electric motors are increasingly being used for propulsion in motor vehicles to create alternatives to combustion engines that require fossil fuels. Considerable efforts have already been made to improve the everyday suitability of electric drives and also to offer users the same driving comfort they are accustomed to.

[0004] In the development of electrical machines, particularly those intended for electric axles or hybrid modules, there is a continuing need to increase their power density and efficiency while simultaneously reducing manufacturing costs. In this context, it is also known to design electrical machines as separately excited synchronous machines (FSM). A separately excited synchronous machine is a special type of synchronous machine in which the magnetic field in the rotor is generated not by permanent magnets, but by energizable coils. The coils are often also referred to as field or excitation coils. To energize the coils in the rotating rotor, the current must be supplied via suitable transformer devices. Gaps can occur between any two excitation windings of a rotor due to the manufacturing process.In particular, support or separating elements are inserted into these gaps, filling them completely or largely. Particularly for high-speed applications, these separating elements protect the windings of the excitation coils in the centrifugal force field against unintentional movement. EP 1 494 335 B1 discloses corresponding separating elements between adjacent excitation coils.

[0005] Particularly with regard to increased power density and efficiency, there is a need to increase the rotor, especially in separately excited

[0006] To cool synchronous machines during operation and to dissipate thermal energy. State-of-the-art solutions include air-cooled rotors or fluid-cooled

[0007] Hollow shafts are known. DE102018220810A1 discloses a fluid-cooled rotor for an electrical machine and a separately excited synchronous machine with a directly or near-loss cooled rotor winding. A fluid-cooled hollow shaft with a conical wall is disclosed in EP3618241A1.

[0008] The object of the present invention is to provide a rotor arrangement for dissipating thermal energy from a rotor of a separately excited synchronous machine, which has a compact design, low manufacturing costs, and high operational reliability. Furthermore, the object of the invention is to realize an optimized separator and an optimized method for producing a separator.

[0009] This object is achieved by a rotor arrangement comprising a rotor body which forms a plurality of slots in the axial direction for receiving a winding, rotor poles which are formed in the radial direction between two of the slots, windings which run in the slots and enclose the rotor poles, slot closure elements which close the slots in the radial direction, at least one separating body which is arranged in one of the slots in the circumferential direction between two of the windings, wherein the separating body comprises at least one continuous cooling channel extending in the axial direction through which a cooling medium can flow, wherein the separating body has a housing with a first outer half-shell and a second outer half-shell, wherein within the housing a first inner half-shell rests in sections against the first outer half-shell,that a first cooling channel section of the cooling channel is defined between the first inner half-shell and the first outer half-shell, and within the housing a second inner half-shell rests partially against the second outer half-shell such that a second cooling channel section of the cooling channel is defined between the second inner half-shell and the second outer half-shell.

[0010] This provides the advantage of effective cooling of the heat generated during operation of a separately excited synchronous machine. Furthermore, the rotor assembly according to the invention not only meets the stringent sealing requirements but also structurally withstands the speed-induced pressures of up to 100 bar. This combination of strength and sealing is critical to ensuring the long-term performance and reliability of the rotor assembly. The use of half shells eliminates the need for extruded profiles with plastic inserts for the heat sinks, which reach their strength limits under the aforementioned high pressure loads.

[0011] The inventive double-walled design of the rotor assembly represents a significant improvement in this context, as it not only optimizes the system's strength under high operating pressures, but also simultaneously meets the tightness requirements. This design also enables improved connection to the cooling media supply and discharge, eliminating, for example, the need for glued-in plastic elements. The double-walled design with the inner and outer half-shells offers a robust solution that overcomes the structural limitations of conventional heat sink designs and, through optimized heat dissipation, contributes to increased power density of the separately excited synchronous machine.

[0012] For the purposes of this patent application, an outer half-shell is a component of the housing that serves to form the outer contour of the separator within the rotor assembly and, together with the inner half-shell, encloses part of the cooling channel system. The outer half-shell is one of two complementary halves that together form the outer housing of the separator, with each half-shell being specifically designed to enable efficient cooling and protection of the internal components.

[0013] The outer half-shell's function can also include protecting the internal components from external influences such as mechanical stress, environmental influences, and electromagnetic interference. Furthermore, the outer half-shell plays a central role in the thermal management strategy of the separator by forming the outer boundary of the cooling channel system and thus directly contributing to heat dissipation from the windings.

[0014] The outer half-shell structure is designed to ensure optimal fit and function within the rotor assembly. This includes precise coordination of its geometry with the inner half-shell to form effective cooling channel sections. The outer half-shell can include features such as guides for placement and fixation within the rotor body, connection points for integration into the overall system, and structures to improve heat transfer.

[0015] Regarding the design of the outer half-shell, various materials and construction techniques are conceivable. Robust materials such as metals, such as aluminum or steel, are preferred due to their good thermal conductivity, mechanical strength, and durability. The use of non-ferromagnetic sheet steel is particularly preferred in this context. However, for applications where weight reduction or electrical insulation is required, high-performance plastics or composite materials can also be used.

[0016] The design of the outer half-shell can be further adapted to specific requirements, for example, by integrating cooling fins or channels to improve heat dissipation, applying special surface treatments to reduce friction, or incorporating sealing systems to prevent leaks in the cooling circuit. The outer half-shells can be manufactured using various processes such as deep drawing, casting, or CNC machining, depending on the requirements regarding precision, quantity, and cost. Advantageously, the outer half-shells are designed to form a material-to-material connection, preferably by welding, soldering, or bonding, with the corresponding counterparts to ensure high structural integrity and tightness of the entire separator.

[0017] For the purposes of this patent application, an inner half-shell is a component of the separator body that connects with an outer half-shell to form part of the cooling channel system within the rotor assembly. The inner half-shell is designed to directly abut the inner surface of the outer half-shell and, together with it, define specific cooling channel sections through which a cooling medium can flow to efficiently support heat dissipation from the surrounding windings.

[0018] The function of the inner half-shell is to define the shape and boundaries of the cooling channels, ensuring optimized flow of the cooling medium. Due to its specific arrangement and design, the inner half-shell contributes significantly to efficient heat dissipation by maximizing thermal contact between the windings adjacent to the outer half-shell and the cooling medium. Furthermore, it serves as structural reinforcement, contributing to the mechanical stability of the entire separator.

[0019] The structure of the inner half-shell is precisely matched to the outer half-shell to ensure effective and efficient cooling. This includes a special design of the surfaces in contact with the cooling medium to optimize heat transfer. Furthermore, features can be integrated into the inner half-shell to promote even distribution of the cooling medium across the entire cooling channel length, thus helping to avoid hot spots within the rotor assembly. Various materials and construction techniques are conceivable for the inner half-shell designs to meet different requirements. Materials with high thermal conductivity, such as metals, are preferred to enable efficient heat transfer. In this context, the use of non-ferromagnetic sheet steel is particularly preferred.However, for applications where lightweight construction or electrical insulation is important, advanced plastics or composite materials could also be used.

[0020] The design of the inner half-shell can also include specific adaptations, such as the integration of structures to increase mechanical strength or improve the flow dynamics of the cooling medium. Methods such as deep drawing, casting, or CNC machining are advantageously used to manufacture the inner half-shells, depending on the required tolerances, design complexity, and production costs. The choice of manufacturing process depends on the specific properties of the selected material and the requirements of the specific application. The inner half-shell can also be designed to allow easy assembly and a reliable connection to the outer half-shell, for example, through fittings or snap-in connections, to ensure high overall stability and tightness of the cooling channel system.

[0021] For the purposes of this patent application, a spacer element is a structural component used within the separator body of the rotor assembly to create a defined distance between the inner and outer half-shells. Due to this specific arrangement, spacer elements contribute significantly to the formation and maintenance of the structure of cooling channel sections by precisely defining the space between the half-shells. This enables optimized guidance of the cooling medium through the separator body, which significantly increases the efficiency of heat dissipation from the windings. The function of a spacer element also extends to improving the mechanical stability of the entire separator body.By ensuring a fixed distance between the half-shells, they contribute to the strength of the structure and protect the internal components from mechanical influences and deformations that could be caused by operating pressures or temperature fluctuations.

[0022] The design of a spacer element is preferably designed to provide high spacing precision while also maintaining the necessary flexibility to compensate for assembly and manufacturing tolerances. Spacer elements can be designed as individual inserts, integrated structures within a half-shell, or as separate components arranged between the half-shells.

[0023] It is particularly preferred for the spacer elements to be formed integrally, in particular monolithically, with an inner and / or outer half-shell, for example by deep-drawing a steel sheet. The use of non-ferromagnetic steel sheet is particularly preferred in this context.

[0024] Regarding the design of the spacer element, various materials and constructions are conceivable to meet the diverse requirements. Materials with good thermal resistance and mechanical properties are preferred, such as high-performance plastics, metals, especially non-ferromagnetic steel sheets, or composite materials. The choice of material depends on the specific operating conditions and requirements regarding thermal conductivity, strength, and compatibility with the cooling medium.

[0025] The design of the spacer element can vary from simple geometric shapes such as cylinders, dome-like half-shells (nubs), or blocks to complex structures with specific surface profiles to optimize the flow of the cooling medium and avoid hot spots. Advantageously, the spacers can be designed to allow easy assembly, for example, through snap-on or plug-in connections, to increase production and maintenance efficiency. Furthermore, it is possible to design the spacers to fulfill multiple functions, by contributing to the guidance of the cooling medium or to strengthen the structure in addition to maintaining spacing.

[0026] The rotor arrangement thus preferably has a double-walled cooler design with its inner and outer half-shells, which is advantageously realized using non-ferromagnetic sheet steel. In this context, it is preferred to incorporate a deep-drawn structure into one of the half-shells, which can preferably be designed either in the form of dome-like half-shells (nubs) or alternatively as channels. The height of the dome-like half-shells (nubs) is preferably between 0.2 mm and 1 mm, thus enabling the flow cross-section for the cooling medium to be precisely determined and ensuring a small but effective flow cross-section. This structuring also helps prevent local clogging of the cooling channels by ensuring consistent flow through the preferably uniform spacing of the nubs.

[0027] In principle, it is of course also possible for the first outer half-shell to have a plurality of spaced-apart first spacer elements that abut the first inner half-shell, and / or for the second outer half-shell to have a plurality of spaced-apart second spacer elements that abut the second inner half-shell. In this context, it is further preferred for the first spacer elements to be formed integrally, in particular monolithically, with the first outer half-shell, and / or for the second spacer elements to be formed integrally, in particular monolithically, with the second outer half-shell.

[0028] Finally, it is also conceivable for the first outer half-shell and the first inner half-shell to each have a plurality of spaced-apart first spacer elements that abut the respective opposite half-shell, and / or for the second outer half-shell and the second inner half-shell to each have a plurality of spaced-apart second spacer elements that abut the respective opposite half-shell. In this context, it is further preferred for the first spacer elements to be formed integrally, in particular monolithically, with the first outer and the first inner half-shell, and / or for the second spacer elements to be formed integrally, in particular monolithically, with the second outer half-shell and the second inner half-shell.

[0029] To absorb the forces generated by operating pressures, it is advantageous for both halves of the cooler, i.e., an inner and an outer half-shell, to form a solid connection. This connection can preferably be created in the area of ​​the studs, particularly using processes such as resistance spot welding or laser welding, although a soldering process can also be used in the area of ​​the studs.

[0030] To simplify assembly and ensure high strength of the separator, the separator is manufactured in two half-shells. In a first step, an outer half-shell is welded to the preferably structured sheet metal of a corresponding inner half-shell at the studs and outer diameter. Subsequently, both half-shells are welded along their centerline.

[0031] The stability of the entire cooling system can be further ensured by welding end caps to both sides of the separator. This measure allows the high internal pressure loads to be withstood without transferring compressive forces to the surrounding structure. This allows the rotor to operate at high speeds without compromising the integrity of the cooling system.

[0032] According to a preferred embodiment, a cavity is formed in the slot, which is delimited by one of the windings and the separating body, wherein the cavity comprises a potting material. In other words, it is preferred that a potting material fills any cavities that may be present between the separating body and one of the windings. The advantageous effect of this embodiment is that the potting material in the cavity improves the thermal connection between the windings and the separating body. The cavity results from component tolerances of the windings and the separating body due to manufacturing constraints.

[0033] According to one embodiment, the cooling medium is a cooling liquid. The advantageous effect of this embodiment is that cooling liquids have a higher heat capacity and higher thermal conductivity than gases, thus enabling better heat dissipation and dissipation of power losses. In particular, the cooling liquid contains oil and / or water.

[0034] According to one embodiment, the rotor body is designed as a laminated core. The advantageous effect of this design is that eddy current losses in the rotor body are minimized.

[0035] The separator is preferably made of a non-ferromagnetic material to prevent interference with the electromagnetic function of the rotor or the electric machine. The separator is preferably made at least partially of a material with good thermal conductivity to ensure good thermal conductivity between the rotor windings and the cooling medium. The separator thus essentially serves two functions. Firstly, the separator can help secure the windings in the slots, even under the influence of centrifugal force, and secondly, it can provide fluid-based cooling within the slots through the cooling channel. Thus, the rotor windings are supported at a constant speed via this separator and simultaneously cooled.

[0036] According to a further preferred development of the invention, it can also be provided that a fluid inlet element is coupled to a first axial end of the cooling channel and a fluid outlet element is coupled to a second axial end of the cooling channel, so that the cooling medium can flow into the cooling channel via the fluid inlet element and out of the cooling channel via the fluid outlet element. This allows for a particularly favorable connection of the separating element to a cooling circuit. It can be preferred that the fluid inlet element and the fluid outlet element are designed essentially identically.

[0037] The separating body is formed on its inner wall in the region of at least one of its axial ends such that a smooth inner contour is created over an axial length of preferably up to 15 mm. This region can also be remachined using machining processes. An inlet element or an outlet element for the cooling medium is then inserted into this area. The inlet element and / or the outlet element can be glued, welded, joined by a press fit and / or form-fitting to the separating body. In a preferred embodiment, the inlet element or the outlet element is sealed off from the separating body with a seal, for example an O-ring seal.In this way, closed assemblies are produced that are sealed against the cooling medium and are each joined between two rotor coils, but essentially do not protrude beyond the axial extent of the rotor coils, so that the axial length of the rotor is not significantly increased by the aforementioned assemblies.

[0038] Preferably, the inlet element and / or the outlet element contain / contains in their interior openings and / or channels for guiding the cooling medium in the axial and / or radial direction, so that the shape of the opening in the interior of the separating body is converted to a shape that is suitable for guiding the cooling medium into adjacent components.

[0039] Furthermore, the invention can also be further developed such that the fluid inlet element and / or the fluid outlet element engage at least partially in the separating body and bear against the inner wall of the separating body. This makes it possible to achieve a high level of tightness between the fluid inlet element and / or fluid outlet element and the separating body. This design has also proven particularly advantageous with regard to absorbing and supporting centrifugal forces during operation of the rotor arrangement. In a likewise preferred embodiment variant of the invention, it can also be provided that the fluid inlet element and / or the fluid outlet element each have a hydraulic path for guiding the cooling medium in the radial direction.It may also be advantageous to further develop the invention such that the fluid inlet element and / or the fluid outlet element each have a hydraulic path for guiding the cooling medium in the axial direction. This allows a channel system to be formed by means of which the cooling medium can be guided in a targeted manner into the cooling channel of the separating body and / or out of the separating body. A hydraulic path can comprise an open or closed channel, an inflow surface, a centrifugal section, and / or a free-fall section.

[0040] In a further preferred embodiment, an inlet element and / or an outlet element can each have an axial opening. This allows the cooling medium to be guided through the respective axial opening into components axially adjacent to the inlet element and / or the outlet element.

[0041] In a likewise preferred embodiment, an outlet element can have an axial opening through which the cooling medium is thrown out of the rotor during operation and onto stator components located radially further outwards, so that additional cooling of the stator components can be achieved.

[0042] According to one embodiment, the rotor arrangement comprises a rotor shaft which is designed as a hollow shaft and has an opening in the radial direction for guiding the cooling medium.

[0043] According to a further preferred embodiment of the subject matter of the invention, it can be provided that the fluid inlet element and / or the fluid outlet element are / is each coupled to a rotor shaft configured as a hollow shaft, so that the cooling medium can flow from the rotor shaft into the fluid inlet element and / or from the fluid outlet element into the rotor shaft. Preferably, the fluid inlet element and / or the fluid outlet element can each contain a radial opening which is connected to a corresponding radial opening in the rotor shaft. Most preferably, the radial opening of the fluid inlet element and / or the fluid outlet element is sealed off from the radial opening of the rotor shaft by means of a seal. In this way, the cooling medium can flow from the rotor shaft into the separating body orfrom separating bodies into the rotor shaft without the need to integrate the cooling medium guide into axial rotor housing parts, so that these can be designed to be particularly space-saving in axial terms.

[0044] The radial opening of the rotor shaft is thus connected via the fluid inlet element and / or the fluid outlet element to the cooling channel of the separating element for guiding the cooling medium, thus forming a channel system. Thus, in a preferred embodiment of the invention, the cooling channel can be connected to a cooling system via the channel system. Particularly advantageously, the cooling channel is connected to the cooling system at both end faces via a respective additional component, preferably the fluid inlet element and / or the fluid outlet element, so that a closed cooling circuit is formed.

[0045] In a further preferred development of the invention, it can also be provided that the separating body has electrical insulation on its outer wall, at least in sections. The electrical insulation can be designed, for example, as an electrically insulating coating. It is also conceivable for the electrical insulation to be designed as a separate component that is detachably or permanently connected to the separating body. The separating body can thus be electrically insulated from live parts, in particular to avoid electrical contact between excitation coils or between the excitation coil and the vehicle and thus to meet the requirements of high-voltage safety. A coating can be realized, for example, by painting, overmolding, or an adhesively bonded layer. For electrical insulation with limited requirements, the aluminum separating body can also be anodized, for example.For demanding applications, it can be overmolded with plastic, coated with an alternative material, or covered with a film on the contact surfaces facing the rotor coils. This ensures that no electrical short circuit occurs between excitation coils or between an excitation coil and the vehicle.

[0046] The separating body is preferably connected to a slot closure element that radially closes the slot and supports the support body at a fixed speed. The slot closure element is preferably made of a non-ferromagnetic and non-electrically conductive material, e.g., plastic, so that the electromagnetic behavior of the machine is not impaired and no additional eddy current losses occur in this component. The slot closure element can be manufactured using plastic injection molding or extrusion and joined to the separating body by form-fitting or adhesive bonding. Alternatively, the slot closure element can be injection-molded directly onto the separating body. In this case, it can be integrally connected to a plastic overmolding of the separating body.

[0047] The invention can also be advantageously designed such that the slot closure element and the separating body are integrally connected.

[0048] The advantageous effect of this design is that the integral connection allows the slot closure element and the separating body to be manufactured as a single component. This reduces the complexity of the rotor assembly. A further advantage is that the integral connection provides a more stable component. Particularly preferably, the slot closure element and the separating body are formed monolithically, for example, from aluminum or plastic.

[0049] In a likewise preferred embodiment of the invention, it can also be provided that the separating body is formed from aluminum. The material properties of aluminum make it possible to achieve good mechanical properties and good thermal conductivity within the separating body. Since aluminum is not ferromagnetic, the electromagnetic function of the machine is not impaired. The outer cross-sectional contour of the separating body can have a contour deviating from a rectangular shape. Preferably, the cross-sectional contour of the separating body is shaped such that the distance between the winding and the separating body is as small as possible. For example, it would be conceivable for the separating body to have a trapezoidal section at its radially outer end, to the short side of which a rectangular section adjoins radially inward.This allows the heat transfer from the winding to the separator to be further optimized, since the thermal conductivity of the potting compound, which usually fills the cavity between the winding and the separator, is generally worse than the thermal conductivity of the separator.

[0050] According to a further preferred development of the invention, the separating body can also comprise a plurality of cooling channels that are spaced apart radially and / or circumferentially. The advantageous effect of this design is that this improves heat dissipation and dissipation of power losses. A further advantage is that the multiple spaced cooling channels allow for more uniform heat dissipation and dissipation of power losses.

[0051] According to an advantageous embodiment of the invention, it can be provided that the first inner half-shell has a plurality of spaced-apart first spacer elements which abut against the first outer half-shell and / or the second inner half-shell has a plurality of spaced-apart second spacer elements which abut against the second outer half-shell. This arrangement ensures an even distribution of the cooling medium and thus optimizes the heat exchange between the half-shells and the cooling medium. The improved cooling contributes to a further reduction in operating temperatures, which increases the efficiency of the engine and reduces the thermal load on the components. The targeted arrangement of the spacer elements also enables a reduction in pressure losses in the cooling circuit, which leads to lower energy requirements for cooling.According to a further preferred development of the invention, it can also be provided that the first spacer elements are formed integrally, in particular monolithically, with the first inner half-shell and / or the second spacer elements are formed integrally, in particular monolithically, with the second inner half-shell. The integral, in particular monolithic, formation of the spacer elements with the inner half-shells offers the technical advantage of increased mechanical stability and reliability of the cooling channel structure. This integrated construction avoids weak points that could arise during assembly or joining processes and ensures long-term performance and durability of the cooling channels. In addition, this design simplifies production, as fewer individual parts have to be manufactured and assembled, which reduces production costs and facilitates quality assurance.

[0052] Furthermore, according to a likewise advantageous embodiment of the invention, it can be provided that the first spacer elements are designed essentially identically and / or the second spacer elements are designed essentially identically. The standardization of the spacer elements by having them designed essentially identically leads to significant economic and production-related advantages. The uniformity of the parts simplifies warehousing and logistics, since fewer different parts need to be kept in stock, unless the spacer elements are already designed monolithically with an inner half-shell. This reduces the complexity of the production process and enables cost-effective mass production.

[0053] According to another particularly preferred embodiment of the invention, the first spacer elements can be arranged in a grid-like manner on the first inner half-shell and / or the second spacer elements can be arranged in a grid-like manner on the second inner half-shell. The grid-like arrangement of the spacer elements on the inner half-shells optimizes the flow dynamics of the cooling medium within the cooling channels. This arrangement enables maximum penetration of the cooling medium through the cooling channels, which leads to more efficient heat dissipation. The increased cooling capacity makes it possible to further reduce operating temperatures, thereby increasing the efficiency and performance of the motor. In addition, the improved cooling leads to lower thermal stress on the components, which extends their service life and increases the reliability of the rotor assembly.

[0054] Furthermore, the invention can also be further developed such that the first inner half-shell covers 75-95% of the area of ​​the first outer half-shell and / or the second inner half-shell covers 75-95% of the area of ​​the second outer half-shell. The specified coverage ensures efficient use of the available space for the cooling channels. This coverage ratio enables optimal design of the cooling channel sections to achieve maximum heat dissipation with minimal space requirements. The precise coordination between coverage and cooling performance results in a compact design of the rotor assembly that still offers excellent cooling. This is particularly advantageous for applications where available space is limited without compromising performance or reliability.

[0055] In a likewise preferred embodiment of the invention, it can also be provided that the first outer half-shell and the second outer half-shell are integrally connected, preferably by welding. The integral connection, preferably by welding, of the outer half-shells ensures a durable and robust construction of the separating bodies. This type of connection ensures high mechanical strength and tightness of the cooling channel structure, which improves the reliability and longevity of the rotor arrangement under various operating conditions. The choice of welding as the connection technique also enables a hermetic seal of the cooling channels, thereby minimizing the risk of leaks and maximizing the efficiency of the cooling system.

[0056] It may also be advantageous to further develop the invention such that the first outer half-shell and the second outer half-shell are shaped essentially identically and / or the first inner half-shell and the second inner half-shell are shaped essentially identically. The identical shape of the outer and inner half-shells considerably simplifies the manufacture and assembly of the separating bodies. By using identical shapes for the half-shells, manufacturing costs can be reduced and the assembly process can be accelerated, as fewer different parts have to be manufactured and handled. This standardization contributes to a reduction in production costs, while at the same time increasing the quality and accuracy of fit of the components. The uniform design also supports flexible production and facilitates warehousing and logistics.

[0057] It is further particularly preferred that the first outer half-shell and the second outer half-shell are produced by means of at least one forming process and / or that the first inner half-shell and the second inner half-shell are produced by means of at least one forming process. Forming processes enable a high level of precision in the manufacture of the half-shells. This accuracy is crucial for the correct fit of the half-shells to one another, which in turn ensures optimal function of the cooling channel system. The precise manufacture of the components allows gaps to be minimized and the efficiency of heat transfer between the windings and the cooling medium to be maximized. The production of the half-shells by forming processes is often more cost-effective than other manufacturing methods, particularly when producing large quantities.The flexibility of forming processes also allows for the realization of complex shapes and structures that might be difficult or uneconomical to manufacture using other methods. This also opens up opportunities for innovative designs of cooling channel structures that enable more effective heat dissipation. Finally, the use of forming processes also allows for the production of half-shells with uniform material properties, leading to increased strength and reliability of the components. The homogeneous material structure achieved through forming processes can improve the mechanical strength of the half-shells and thus contribute to the longevity of the rotor assembly.

[0058] The object of the invention can also be achieved by a separating body for a rotor arrangement, in particular for a rotor arrangement according to claim 1, comprising at least one continuous cooling channel which extends in the axial direction through the separating body and through which a cooling medium can flow, wherein the separating body has a housing with a first outer half-shell and a second outer half-shell, wherein within the housing a first inner half-shell rests in sections on the first outer half-shell such that a first cooling channel section of the cooling channel is defined between the first inner half-shell and the first outer half-shell, and within the housing a second inner half-shell rests in sections on the second outer half-shell such that a second cooling channel section of the cooling channel is defined between the second inner half-shell and the second outer half-shell.

[0059] Finally, the object of the invention can also be achieved by a method for producing a separating body for arrangement in a rotor arrangement, in particular a rotor arrangement according to claim 1, comprising the following steps:

[0060] • Providing a first sheet and forming the first sheet into a first outer half-shell and a second outer half-shell;

[0061] • Providing a second sheet and forming the second sheet into a first inner half-shell and a second inner half-shell;

[0062] • Formation of the separating body with a housing made of the first outer half-shell and the second outer half-shell, wherein within the housing the first inner half-shell rests in sections on the first outer half-shell such that a first cooling channel section of the cooling channel is defined between the first inner half-shell and the first outer half-shell, and within the housing the second inner half-shell rests in sections on the second outer half-shell such that a second cooling channel section of the cooling channel is defined between the second inner half-shell and the second outer half-shell.

[0063] The described process for manufacturing a separator enables the efficient and cost-effective production of high-precision and high-performance cooling structures for rotor assemblies. The process steps are optimized to ensure high quality and precision fit of the components, which simplifies assembly and improves the reliability of the finished separators. The use of sheet metal for the production of the half-shells enables flexible adaptation to different design requirements and contributes to a reduction in manufacturing costs. This process supports the mass production of separators with integrated cooling channels, thus promoting the widespread use of efficient and high-performance rotor assemblies in various application areas.

[0064] In a preferred embodiment of the method, an outer and inner half-shell are first connected to each other in the area of ​​the contact points, preferably by welding or soldering. The contact points are preferably formed by the spacer elements. The then firmly connected outer and inner half-shells are then assembled to form the separating body, which can also preferably be done by welding or soldering. The firm connection of the contact points prevents the entire cooling structure of the separating body from being inflated, similar to a balloon, by the pressure acting on it during operation.

[0065] The invention will be explained in more detail below with reference to figures without limiting the general inventive concept.

[0066] It shows:

[0067] Figure 1 shows a detailed view of a groove of a separately excited rotor in a cross-sectional view,

[0068] Figure 2 is a perspective view of a cut-out separating body,

[0069] Figure 3 shows a cross-sectional view of the separating body,

[0070] Figure 4 is a perspective view of a free-standing separating body with separating caps fitted or inserted, Figure 5 is an inner half-shell with knob-like, grid-shaped spacer elements in two perspective views,

[0071] Figure 6 shows an outer half-shell in a perspective view,

[0072] Figure 7 shows an inner half-shell fixed to the outer half-shell in two perspective views.

[0073] Figure 1 shows a rotor assembly 1 comprising a rotor body 2, which forms a plurality of slots 3 in the axial direction for receiving a winding 4. One of these slots 3 is shown in Figure 1. It is understood that the rotor body 2 has a plurality of these slots 3, as shown in Figure 1, distributed circumferentially.

[0074] The rotor arrangement further comprises rotor poles 5, which are formed in the radial direction between each two of the slots 3, as well as windings 4, which run in the slots 3 and enclose the rotor poles 5. Furthermore, the rotor arrangement 1 comprises slot closure elements 6, which close the slots 3 in the radial direction, and a separating body 7 for each slot 3, which is arranged in the slot 3 in the circumferential direction between two of the windings 4. In the embodiment shown, the slot closure elements 6 are integrally connected to the separating bodies 7 or are designed with them. The separating body 7 comprises two continuous cooling channels 8a, 8b extending in the axial direction, through which a cooling medium can flow, which will be explained in more detail below with reference to Figure 3.

[0075] The separating body 7 has, as can be clearly seen from Figure 2, a housing 9 with a first outer half-shell 10 and a second outer half-shell 11, wherein within the housing 9 a first inner half-shell 12 partially abuts the first outer half-shell 10 such that a first cooling channel section 13 of the cooling channel 8a is defined between the first inner half-shell 12 and the first outer half-shell 10, and within the housing 9 a second inner half-shell 14 partially abuts the second outer half-shell 11 such that a second cooling channel section 15 of the cooling channel 8b is defined between the second inner half-shell 14 and the second outer half-shell 11. This can be clearly seen from Figure 3. The first outer half-shell 10 and the second outer half-shell 11 are integrally connected via the weld seam 28.

[0076] In the embodiment shown, the separating body 7 has a radially outer trapezoidal contour, which is adjoined by a radially inner rectangular contour, resulting in an overall contour reminiscent of a key blank. As can be clearly seen in Figure 1, the outer contour of the separating body 7 thus conforms to the winding located in the slot 3. This ensures not only optimized heat dissipation but also radially fixates the winding 4 in the slot 3 under the influence of centrifugal force.

[0077] It can also be seen that the front ends of the housing 9 are slightly offset inwards, which is also evident when viewed together with Figure 6. In this case, the surface sections 27a, 27b on a first front side form the inwardly directed first step of the housing 9 and the surface sections 26a, 26b form the inwardly directed second step of the housing 9 formed on the second front side. In or on these steps, an end cap 29 is then inserted or placed on each of these steps at the end of the manufacturing process of the separating body 7, as can be seen in Figure 4.

[0078] It can also be seen from Figure 5 that the first inner half-shell 12 has a plurality of spaced-apart first spacer elements 16 which abut against the first outer half-shell 10, and the second inner half-shell 14 has a plurality of spaced-apart second spacer elements 17 which abut against the second outer half-shell 11. The first spacer elements 16 are formed monolithically with the first inner half-shell 10, and the second spacer elements 17 are formed monolithically with the second inner half-shell 14. The first spacer elements 16 and the second spacer elements 17 are essentially identical, which can be clearly seen from Figure 5. The first spacer elements 16 are arranged in a grid-like manner on the first inner half-shell 10, and the second spacer elements 17 are arranged in a grid-like manner on the second inner half-shell 14.In the embodiment shown, the inner half-shells 12, 14 have embossed spacer studs as spacer elements 16, 17. The grid-like spacer studs serve to precisely adjust the flow cross-section for the cooling fluid.

[0079] The inner half-shells 12, 14 have a contour that is essentially parallel to the outer half-shells 10, 11, resulting in cooling channels 8a, 8b with a constant channel height. Accordingly, the inner half-shells 12, 14 have two surface sections 18, 19 that are arranged at an angle to one another on a common edge, as can also be seen in Figure 5. At the front ends of the inner half-shells 12, 14, a front surface 20, 21 is formed, via which the front closure of the assembled inner half-shells 12, 14 takes place. This creates a cavity inside the assembled inner half-shells 12, 14.

[0080] To absorb the compressive forces during operation of the rotor assembly 1, it is advantageous if the half-shells 10, 11, 12, 14 are connected to one another. In the illustrated embodiment, this is achieved in the area of ​​the stud-like spacers 16, 17 by welding (e.g., resistance spot welding or laser welding) or, optionally, by soldering in the area of ​​the studs.

[0081] To ensure the high strength of the entire separating body 7, a high-strength connection of the front ends is also advantageous. This is achieved by welding an end cap 29 with a hydraulic connection 30 to each front end of the housing 9. This results in a design that can support the high pressure and prevents compressive forces from being introduced into the surrounding structure of the rotor assembly. This allows high rotor speeds to be achieved.

[0082] Figure 7 shows an outer half-shell 10, 11. The surface sections 22, 23, which are arranged at an angle to one another, can be clearly seen. At the radially outer end of the surface section 23, the surface section 24 is formed from the surface section 23 and forms a head surface of the housing 9. Analogously, at the radially inner end of the surface section 22, a surface section 25 is formed from the surface section 22, which forms a bottom surface of the housing 9. The inwardly recessed surface sections 26, 27 at the front ends of the outer half-shell 10, 11, which serve to support or fix the end caps 29, can also be clearly seen.

[0083] As can be seen from Figure 7, the inner half-shell 12,14 covers 75-95% of the surface of the outer half-shell 10,11, which enables the most uniform cooling performance possible over the outer surface of the housing 9.

[0084] As can be seen from the combined view of Figures 5-7, the first outer half-shell 10 and the second outer half-shell 11 are essentially identical in shape. Likewise, the first inner half-shell 12 and the second inner half-shell 14 are essentially identical in shape.

[0085] Here, the first outer half-shell 10 and the second outer half-shell 11 are manufactured from sheet metal by at least one forming process. The first inner half-shell 12 and the second inner half-shell 14 are also manufactured by at least one forming process.

[0086] To produce a separating body 7 for arrangement in a rotor arrangement 1 as known from Figures 1-7, the following steps can be carried out:

[0087] First, a first sheet is provided and the first sheet is formed into a first outer half-shell 10 and a second outer half-shell 11, as can be seen, for example, in Figure 6.

[0088] A second sheet is also provided and the second sheet is formed into a first inner half-shell 12 and a second inner half-shell 14, as shown in Figure 5.

[0089] The separating body 7 is now formed with a housing 9 made up of the first outer half-shell 10 and the second outer half-shell 11, wherein within the housing 9 the first inner half-shell 12 rests in sections against the first outer half-shell 10 such that a first cooling channel section 13 of the cooling channel 8 is defined between the first inner half-shell 12 and the first outer half-shell 10, and within the housing 9 the second inner half-shell 14 rests in sections against the second outer half-shell 11 such that a second cooling channel section 15 of the cooling channel 8 is defined between the second inner half-shell 14 and the second outer half-shell 11.

[0090] In total, the two outer half-shells 10, 11, the two inner half-shells 12, 14 and two identical end caps 29 are required to produce a separating body 7.

[0091] Figure 7 shows how the inner half-shells 12, 14 fit into the outer half-shells 10, 11. To enable simple assembly, it is advantageous to manufacture the separating body 7 in the following steps. First, the first inner half-shell is welded to the knob-like spacer elements 16, 17 on the first outer half-shell 10, as well as to the outer diameter. The same is done with the second outer half-shell 11 and the second inner half-shell 14. Subsequently, both prefabricated halves of the housing 9 are welded along their abutting edge to create the weld seam 28. Alternatively, it would also be possible to first weld the two inner half-shells 12, 14 and then arrange the two outer half-shells 10, 11 around the inner half-shells 12, 14 and then weld these as well.

[0092] The housing 9 of the separator 7 is thus completed, with the corresponding cooler structure for heat dissipation from the winding 4. To pump the cooling fluid through the cooling channels 8a, 8b, the hydraulic connection 30 is provided on the end caps 29. The end caps 29 are welded to the housing 9. This creates a closed fluid chamber. The cooling fluid is supplied via the hydraulic connection 30. These are connected via suitable pipe connections to an oil pump, which provides the necessary oil flow. The connection to the hydraulic connections 30 can be established via lines or through holes in adjacent structural components. The invention is not limited to the embodiments illustrated in the figures. The above description is therefore not to be regarded as limiting, but rather as explanatory.The following claims are to be understood as meaning that a named feature is present in at least one embodiment of the invention. This does not exclude the presence of further features. Where the claims and the above description define 'first' and 'second' features, this designation serves to distinguish between two similar features without establishing a priority.

[0093] List of reference symbols

[0094] 1 Rotor arrangement

[0095] 2 rotor bodies

[0096] 3 grooves

[0097] 4 windings

[0098] 5 rotor poles

[0099] 6 slot closure elements

[0100] 7 separating bodies

[0101] 8 cooling channel

[0102] 9 housings

[0103] 10 outer half shell

[0104] 11 outer half shell

[0105] 12 inner half shell

[0106] 13 Cooling channel section

[0107] 1 inner half shell

[0108] 15 Cooling channel section

[0109] 16 spacer elements

[0110] 17 spacer elements

[0111] 18 Area section

[0112] 19 Area section

[0113] 20 frontal area

[0114] 21 Frontal surface

[0115] 22 Area section

[0116] 23 Area section

[0117] 24 area section

[0118] 25 Area section

[0119] 26 Area section

[0120] 27 Area section

[0121] 28 Weld seam

[0122] 29 End cap

[0123] 30 Hydraulic connection

Claims

Claims 1. Rotor arrangement (1 ), comprising a rotor body (2) which forms a plurality of slots (3) in the axial direction for receiving a winding (4), Rotor poles (5), which are arranged in the radial direction between two of the slots (3) are trained, Windings (4) which run in the slots (3) and enclose the rotor poles (5), Slot closure elements (6) which close the slots (3) in the radial direction, at least one separating body (7) which is arranged in one of the slots (3) in the circumferential direction between two of the windings (4), wherein the separating body (7) comprises at least one continuous cooling channel (8) extending in the axial direction, through which a cooling medium can flow, characterized in that the separating body (7) has a housing (9) with a first outer half-shell (10) and a second outer half-shell (11), wherein within the housing (9) a first inner half-shell (12) rests in sections against the first outer half-shell (10) such that between the first inner half-shell (12) and the first outer half-shell (10) a first cooling channel section (13) of the cooling channel (8) is defined, and within the housing (9) a second inner half-shell (14) rests in sections against the second outer half-shell (11) such that between the second inner half-shell (14) and the second outer half-shell (11), a second cooling channel section (15) of the cooling channel (8) is defined.

2. Rotor arrangement (1) according to claim 1, characterized in that the first inner half-shell (10) has a plurality of spaced-apart first spacer elements (16) which abut against the first outer half-shell (10) and / or the second inner half-shell (14) has a plurality of spaced-apart second spacer elements (17) which abut against the second outer half-shell (11).

3. Rotor arrangement (1) according to claim 2, characterized in that the first spacer elements (16) are formed in one piece, in particular monolithically, with the first inner half-shell (10) and / or the second spacer elements (17) are formed in one piece, in particular monolithically, with the second inner half-shell (14).

4. Rotor arrangement (1) according to claim 2 or 3, characterized in that the first spacer elements (16) are designed substantially identically and / or the second spacer elements (17) are designed substantially identically.

5. Rotor arrangement (1) according to one of claims 2 to 4, characterized in that the first spacer elements (16) are arranged in a grid-like manner on the first inner half-shell (10) and / or the second spacer elements (17) are arranged in a grid-like manner on the second inner half-shell (14).

6. Rotor arrangement (1) according to one of the preceding claims, characterized in that the first inner half-shell (12) covers 75-95% of the area of ​​the first outer half-shell (10) and / or the second inner half-shell (14) covers 75-95% of the area of ​​the second outer half-shell (11).

7. Rotor arrangement (1) according to one of the preceding claims, characterized in that the first outer half-shell (10) and the second outer half-shell (11) are integrally connected, preferably welded 8. Rotor arrangement (1) according to one of the preceding claims, characterized in that the first outer half-shell (10) and the second outer half-shell (11) are shaped substantially identically and / or the first inner half-shell (12) and the second inner half-shell (14) are shaped substantially identically.

9. Separating body (7) for a rotor arrangement (1), in particular for a rotor arrangement (1) according to claim 1, comprising at least one continuous cooling channel (8) extending in the axial direction through the separating body (7), through which a cooling medium can flow, characterized in that the separating body (7) has a housing (9) with a first outer half-shell (10) and a second outer half-shell (11), wherein within the housing (9) a first inner half-shell (12) partially abuts the first outer half-shell (10) such that a first cooling channel section (13) of the cooling channel (8) is defined between the first inner half-shell (12) and the first outer half-shell (10), and within the housing (9) a second inner half-shell (14) partially abuts the second outer half-shell (11) such that a second Cooling channel section (15) of the cooling channel (8) is defined.

10. A method for producing a separating body (7) for arrangement in a rotor arrangement (1), in particular a rotor arrangement (1) according to claim 1, comprising the following steps: • Providing a first sheet and forming the first sheet into a first outer half-shell (10) and a second outer half-shell (11); • Providing a second sheet and forming the second sheet into a first inner half-shell (12) and a second inner half-shell (14); • Formation of the separating body (7) with a housing (9) from the first outer half-shell (10) and the second outer half-shell (11), wherein within the housing (9) the first inner half-shell (12) rests in sections on the first outer half-shell (10) such that a first cooling channel section (13) of the cooling channel (8) is defined between the first inner half-shell (12) and the first outer half-shell (10), and within the housing (9) the second inner half-shell (14) rests in sections on the second outer half-shell (11) such that a second cooling channel section (15) of the cooling channel (8) is defined between the second inner half-shell (14) and the second outer half-shell (11).

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