Brake assembly, method for producing same, and electric motor having a brake assembly

Abstract

A brake assembly, a method for producing same, and an electric motor having a brake assembly, said brake assembly comprising: a magnet body (71) which has an annular recess; a coil former (1); a coil winding (72) which is composed of winding wire and is arranged on the coil former; and potting compound; wherein the coil former together with the coil winding is held in the annular recess, and wherein the recess is at least partially filled with potting compound which surrounds the coil former and the coil winding.

Description

[0001] Method for manufacturing a brake assembly, brake assembly and electric motor with brake assembly

[0002] Description:

[0003] The invention relates to a method for manufacturing a brake assembly, a brake assembly and an electric motor with a brake assembly.

[0004] It is generally known to accommodate a winding in a coil carrier.

[0005] From JP H05 - 256 330 A, an electromagnetically actuated brake is known as the closest state of the art.

[0006] An electric motor is known from DE 102010045447 A1.

[0007] The invention is therefore based on the objective of manufacturing a coil cost-effectively and operating it with a high energy density.

[0008] According to the invention, the problem is solved in the method for manufacturing a brake arrangement according to claim 1, in the brake arrangement according to claim 14 and in the electric motor with brake arrangement according to the features specified in claim 15.

[0009] Important features of the invention in the method are that the method is provided for manufacturing a brake assembly, wherein the brake assembly comprises a magnetic body having an annular recess, a coil carrier, a coil winding made of winding wire arranged on the coil carrier, and potting compound, wherein in a first process step the coil carrier is wound with the winding wire to produce a coil winding arranged on the coil carrier, and the

[0010] ISI \ EIDOPAT 28.07.2025 The coil carrier dissipates a tensile stress of the winding wire, in particular via a post area, and / or the coil carrier dissipates the force required to deflect the winding wire, in particular via a deflection area of ​​the coil carrier, wherein in a second process step, following the first process step, the coil carrier with the coil winding is inserted into the annular recess and received in the annular recess, wherein in a third process step, following the second process step, the recess is completely or at least partially filled with potting compound, so that the potting compound surrounds the coil carrier and the coil winding, wherein in a fourth process step, following the third process step, the potting compound is hardened, wherein in a fifth,In a subsequent process step following the fourth process step, and in particular after the curing of the potting compound, the winding wire is subjected to a current, especially for venting the brake assembly, such that the material of the coil carrier, especially at the operating temperature of the brake assembly established at the maximum permissible ambient temperature of the brake assembly, is heated and / or thermoelastically deformed, but in particular does not yet become thermoplastic, so that the potting compound dissipates the tensile stress of the winding wire and / or the potting compound dissipates the force required to deflect the winding wire, in particular where the temperature of the coil carrier material is lower than the melting temperature of the coil carrier material.

[0011] The advantage here is that while the coil has a cost-effectively manufactured coil carrier onto which the winding wire is wound during production, the current acting on the winding wire is so high that, at the operating temperature reached in this way, the coil carrier loses its ability to shape the winding and the winding wire, and the hardened potting compound takes over this function. This is because the hardened potting compound, unlike the coil carrier, is not elastically deformable and is not thermoelastic. For example, without potting compound, the tensile stress of the winding wire during winding is dissipated by the coil carrier, perhaps through a deflection area within the coil carrier.

[0012] After the potting compound poured into the recess has hardened, which then surrounds the coil carrier and the winding, and after reaching the operating temperature, which brings the coil carrier into a thermoelastic state, the tensile stress is no longer transferred through the coil carrier, but through the hardened potting compound.

[0013] The cost-effective production of the coil carrier is achieved through the use of readily available thermoplastic.

[0014] In an advantageous embodiment, a rotor shaft projects through the magnet body. It is advantageous that the rotor shaft can be braked by the braking arrangement and / or that the braking arrangement acts as a holding brake for the rotor shaft.

[0015] In an advantageous embodiment, the winding wire of the coil winding is shaped by the hardened potting compound. It is advantageous that the coil support acts as a lost mold when the operating temperature becomes so high that the material of the coil support becomes thermoelastic or even thermoplastic.

[0016] In an advantageous embodiment, the winding wire is wound around a post area formed on the coil carrier. The advantage here is that the winding wire is attached to the post area, thus transferring the tensile stress of the winding wire to the coil carrier, particularly via the post area.

[0017] In an advantageous embodiment, the winding wire rests against a deflection area and is deflected by it; in particular, the direction of the winding wire is changed by the deflection area. It is advantageous that the winding wire rests on the deflection area, thus transferring the force necessary for deflecting the tensile stress of the winding wire to the deflection area.

[0018] In an advantageous embodiment, the coil carrier, particularly including the post area and / or deflection area, functions as a lost mold for the winding wire and / or for the coil winding. It is advantageous that the potting compound gives the winding wire its shape. In an advantageous embodiment, the winding wire is held in place by the cured potting compound, particularly at least partially. It is advantageous that the potting compound surrounds the coil carrier including the post area and deflection area and also holds in place the areas of the winding wire that are not in contact with the coil carrier or other areas of the winding wire. Therefore, the tensile stress of the winding wire is maintained even after the coil carrier material transitions to thermoelastic behavior, particularly at least in the area of ​​the winding wire wetted by the potting compound.

[0019] In a preferred embodiment, the coil carrier material is a thermoplastic and the cured potting compound is a thermoset. The advantage here is that the thermoplastic loses its strength at operating temperature, while the thermoset retains its strength.

[0020] In an advantageous embodiment, the operating temperature at the maximum permissible ambient temperature is lower than the lowest temperature at which the coil carrier material is thermoplastic. This is advantageous because, after cooling, the coil carrier returns to its original shape, thus allowing the post and deflection areas to retain their function. If the operating temperature were to cause the material to become thermoplastic, the post and deflection areas would no longer retain their original function, even after cooling. In this case, the potting compound alone would permanently define the shape of the winding wire.

[0021] In an advantageous embodiment, the maximum permissible ambient temperature is between 35°C and 90°C, in particular 40°C, 70°C, or 80°C. The advantage here is that the ambient temperature can be selected appropriately, thus protecting the components of the brake assembly.

[0022] In an advantageous embodiment, the melting temperature, sublimation temperature, or glass transition temperature of the potting compound is higher than the melting temperature of the coil carrier material. It is advantageous that the cured potting compound retains its shape-giving function for the winding wire even at high, but permissible, operating temperatures. In another advantageous embodiment, the melting temperature, sublimation temperature, or glass transition temperature of the potting compound is higher than the operating temperature. It is advantageous that, during the intended and permissible continuous operation, the potting compound retains its shape-giving function, and the coil carrier is able to resume its shape-giving function after cooling.

[0023] In an advantageous embodiment, the current is suitable for providing continuous ventilation of the brake assembly, particularly without causing impermissible heating of the brake assembly. It is advantageous that the ohmic losses caused by the current keep the operating temperature below the temperature level of the thermoplastic layer of the coil carrier material.

[0024] Key features of the brake assembly for carrying out the aforementioned method are that the brake assembly comprises a magnetic body having an annular recess, a coil carrier, a coil winding made of winding wire arranged on the coil carrier, and potting compound, wherein the coil carrier with the coil winding is received in the annular recess, wherein the recess is at least partially filled with potting compound that surrounds the coil carrier and the coil winding, wherein the material of the coil carrier is a thermoplastic and the potting compound is a thermoset, particularly at the operating temperature, and especially the maximum permissible temperature, of the brake assembly. It is advantageous that the shape-giving function is transferred from the coil carrier to the potting compound at operating temperature.

[0025] In an advantageous embodiment, the axis of rotation of a rotatably mounted rotor shaft of the brake assembly is aligned coaxially with the annular axis of the annular recess, wherein an annular driver is mounted on the rotor shaft and non-rotatably connected to the rotor shaft, in particular by means of a keyway connection, wherein the driver has external teeth onto which the internal teeth of a perforated disc-shaped brake pad carrier are mounted, in particular wherein the internal teeth are non-rotatably connected to the external teeth, wherein the brake pad carrier is axially displaceable relative to the rotor shaft, in particular in the axial direction, in particular in the direction parallel to the direction of the axis of rotation of the rotor shaft, wherein a ferromagnetic armature disk is arranged axially between the brake pad carrier and the magnet body, wherein the armature is supported on the magnet body and spaced apart from each other, in particular in the circumferential direction.Spring elements press against the armature disc, the armature disc being rotationally fixed to the magnet body and axially displaceable, with the brake pad carrier being axially arranged between the armature disc and a braking surface, in particular formed on a housing part, especially functioning as a bearing shield, which is connected to the magnet body. An advantage of this is that in the event of a power failure, the brake engages automatically, thus increasing safety. When the coil winding is energized, the armature disc is pulled towards the magnet body against the spring force generated by the spring elements, and when the coil winding is de-energized, the spring elements, supported on the magnet body, press the armature disc onto the brake pad carrier.which is thus pressed onto the braking surface. The brake pads, which are attached to both sides of the brake pad carrier, thereby come into frictional contact with the anchor disc on one side and with the braking surface on the other, which is formed on a housing part, in particular where the housing can be designed as a bearing shield.

[0026] Important features of the electric motor with the aforementioned brake arrangement are that the rotor shaft in the electric motor is rotatably mounted via the bearing in the housing part designed as a bearing shield and a second bearing in a bearing flange of the electric motor.

[0027] An advantage of this is that the rotor shaft of the electric motor can be braked by means of the braking arrangement of the electric motor designed as a brake motor.

[0028] Further advantages arise from the dependent claims. The invention is not limited to the combination of features of the claims. For those skilled in the art, further meaningful combinations of claims and / or individual claim features and / or features of the description and / or the figures will become apparent, in particular from the problem statement and / or the problem arising from a comparison with the prior art.

[0029] The invention will now be explained in more detail with reference to schematic illustrations:

[0030] Figure 1 shows the coil carrier 1 of an electromagnetically actuated brake arrangement according to the invention in an oblique view in a first viewing direction.

[0031] Figure 2 shows the coil carrier 1 in an oblique view from a second viewing direction.

[0032] Figure 3 shows a top view of the coil carrier 1.

[0033] Figure 4 shows an enlarged view of an area of ​​the coil carrier 1.

[0034] Figure 5 shows an enlarged view of a second area of ​​the coil carrier 1.

[0035] Figure 6 shows an enlarged view of a second area of ​​the coil carrier 1.

[0036] Figure 7 shows a longitudinal section through the brake assembly. As shown in the figures, the brake assembly has a rotor shaft 70 which is rotatably mounted via a bearing 76 received in a housing part 78.

[0037] A ring-shaped driver 79, mounted on the rotor shaft 70, is connected to the rotor shaft 70 in a rotationally fixed manner by means of a keyway connection.

[0038] The driver 79 has an external toothing which is fitted onto the external toothing with an internal toothing of a disc-shaped brake pad carrier 75 and is thus connected in a rotationally fixed manner.

[0039] To suppress play acting in the circumferential direction, a clamping spring 73 is arranged between the external toothing and the internal toothing.

[0040] The brake pad carrier 75 is thus rotationally fixed to the rotor shaft 70 and axially movable relative to the rotor shaft 70.

[0041] The axial direction is aligned parallel to the axis of rotation of the rotor shaft 70. The radial direction is also relative to the axis of rotation of the rotor shaft 70, as is the circumferential direction.

[0042] The brake pad carrier 75 has at least one brake pad 77 on each axial side.

[0043] The housing part 78 is connected to a magnetic body 71, which is made of ferromagnetic material, in particular of GGG cast iron or spheroidal graphite cast iron.

[0044] The magnet body has a ring-shaped depression whose ring axis is aligned parallel, in particular coaxially, to the axis of rotation of the rotor shaft 70.

[0045] A coil winding 72 made of winding wire 21, which is arranged in the coil carrier 1, is received in the ring winding. The ends of the winding wire 21 are each led to a respective connecting plate 5 and are clamped and / or welded to it. A respective strand 4 is also led to this connecting plate 5 and is likewise clamped and / or welded to it. The connecting plate 5 is inserted into a recess in the coil carrier 1 and thus secured. An armature disk 74 is arranged axially between the brake pad carrier 75 and the magnet body 71. The armature disk 74 is rotationally connected to the magnet body 71 and is axially displaceable relative to the magnet body 71. This is preferably achieved by attaching axially oriented bolts to the magnet body 71, which pass through recesses in the armature disk.

[0046] 74 protrude through.

[0047] Spring elements supported on the magnet body 71 press on the armature disk, which is made of ferromagnetic material, in particular steel.

[0048] Thus, when the coil winding 72 is energized, the armature disk 74 is pulled towards the magnet body 71 in the opposite direction to the spring force generated by the spring elements.

[0049] When the coil winding 72 is not energized, the spring elements push the armature disk 71 away from the magnet body 71 towards the brake pad carrier 75, so that this brake pad carrier

[0050] 75 is pressed onto a braking surface, which is formed either on the housing part 78 or on a ring part, in particular a brake disc part, arranged between the housing part 78 and the brake pad carrier 75. In particular, a surface section is machined by fine machining, such as grinding.

[0051] In the case of using the ring part 80, the aforementioned bolts are attached to the ring part with their end area facing away from the magnetic body 71.

[0052] In any case, the ring part 80 is detachably connected to both the magnetic body 71 and the housing part 78.

[0053] In further embodiments according to the invention, the housing part 78 is designed as a bearing shield of an electric motor which drives the rotor shaft 70, which is rotatably mounted by a further bearing received in a bearing flange of the electric motor.

[0054] A stator housing of the electric motor, connected to the bearing shield and the bearing flange, is positioned between the bearing flange and the bearing shield, which is designed as housing part 78. As shown particularly in Figures 3 and 6, the winding wire is guided over a deflection area 3 formed on the coil carrier 1 and wound around a post area 2 formed on the coil carrier 1.

[0055] The ring-shaped depression in the magnet body 71 is filled with potting compound, so that the coil carrier 1 together with the winding wire is surrounded by the hardened potting compound.

[0056] Thus, the winding wire, together with the coil carrier 1, is surrounded and held by the potting compound.

[0057] The coil carrier 1 is preferably made of a thermoplastic which has a low melting temperature.

[0058] To release the brake assembly, the winding wire is subjected to a current which causes such a large force, attractive towards the armature disk and the magnet body 71, that the spring force generated by the spring elements is overcome.

[0059] However, this current flow through the winding wire causes ohmic losses, and therefore the coil carrier 1, the potting compound, and the magnet body 71 also heat up to an operating temperature above the ambient temperature.

[0060] The maximum permissible ambient temperature is, for example, 40°C.

[0061] The melting point of the potting compound is far above the operating temperature, so the potting compound remains in its hardened state. However, the coil carrier 1, made of thermoplastic, is thermoelastic at the operating temperature and thus elastically deformable, but not yet thermoplastic and therefore not yet plastically deformable.

[0062] In this way, at operating temperature, the winding wire is held by the potting compound within the space designated for the winding wire, but not by the coil carrier 1, onto which the winding wire was initially wound during manufacturing, i.e., before the potting compound was poured in liquid form and subsequently hardened. At operating temperature, the coil carrier 1 thus functions as a lost mold for the winding wire.

[0063] In further embodiments according to the invention, the operating temperature exceeds the thermoelastic range of the coil carrier 1, which is made of thermoplastic material, and reaches the thermoplastic range.

[0064] Thus, the winding wire is now only surrounded by the hardened potting compound, which gives it its shape. The coil carrier 1, on the other hand, loses its shape-giving function.

[0065] The post area 2, which is wrapped by the winding wire, is therefore no longer held by the post area 2 of the coil carrier 1. However, the winding wire is coated with potting compound along its length and held by it. Thus, the holding function for the winding wire changes from the post area 2 of the coil carrier 1, which initially performs the holding function, particularly before the potting compound has hardened, to the potting compound, which later performs the holding function, particularly after the potting compound has hardened.

[0066] In further embodiments according to the invention, the operating temperature exceeds not only the thermoelastic range but also the thermoplastic range. Thus, at the operating temperature, the material of the coil carrier 1 reaches its melting temperature.

[0067] Reference symbol list

[0068] 1 coil carrier

[0069] 2 Post area of ​​the coil carrier 1

[0070] 3 Deflection area of ​​the coil carrier 1

[0071] 4 strands

[0072] 5 Connecting plate

[0073] 21 winding wire

[0074] 70 Rotor shaft

[0075] 71 magnetic bodies

[0076] 72 Coil winding made of winding wire

[0077] 73 Clamp spring

[0078] 74 Anchor disc

[0079] 75 brake pad carriers

[0080] 76 warehouses

[0081] 77 Brake pad

[0082] 78 Housing part

[0083] 79 drivers

[0084] 80 ring part

Claims

Patent claims:

1. A method for manufacturing a brake assembly comprising a magnetic body having an annular recess, a coil carrier, a coil winding made of winding wire arranged on the coil carrier, and potting compound, wherein in a first process step the coil carrier is wound with the winding wire to produce a coil winding arranged on the coil carrier and the coil carrier conducts a tensile stress of the winding wire, in particular via a post area, and / or the coil carrier conducts the force required to deflect the winding wire, in particular via a deflection area of ​​the coil carrier, wherein in a second process step, following the first process step, the coil carrier with the coil winding is inserted into the annular recess and received in the annular recess, wherein in a third,In a process step following the second process step, the recess is completely or at least partially filled with potting compound so that the potting compound surrounds the coil carrier and the coil winding, wherein in a fourth process step following the third process step the hardening of the potting compound is effected, characterized in that in a fifth process step following the fourth process step, in particular after the hardening of the potting compound, the winding wire is subjected to a current, in particular for releasing the brake arrangement, such that the, The material of the coil carrier, in particular at the operating temperature of the brake assembly which is reached at the maximum permissible ambient temperature of the brake assembly, is heated and / or thermoelastically deformed, but in particular does not yet become thermoplastic, such that the potting compound dissipates the tensile stress of the winding wire and / or the potting compound dissipates the force required to deflect the winding wire, in particular where the temperature of the material of the coil carrier is lower than the melting temperature of the material of the coil carrier. - 15 - 2. Method according to claim 1, characterized in that a rotor shaft projects through the magnet body.

3. Method according to one of the preceding claims, characterized in that the winding wire of the coil winding is shaped by the hardened potting compound.

4. Method according to one of the preceding claims, characterized in that the winding wire is wound around a post area formed on the coil carrier and / or that the winding wire rests against a deflection area and is deflected by the deflection area, in particular the wire direction of the winding wire is changed by the deflection area.

5. Method according to one of the preceding claims, characterized in that the coil carrier, in particular including post area and / or deflection area, functions as a lost mold for the winding wire and / or for the coil winding.

6. Method according to one of the preceding claims, characterized in that the winding wire is held in a materially bonded manner by the hardened potting compound, in particular at least partially held in a materially bonded manner.

7. Method according to one of the preceding claims, characterized in that the material of the coil carrier is a thermoplastic and the cured potting compound is a thermoset. - 16 - 8. Method according to one of the preceding claims, characterized in that the operating temperature at the maximum permissible ambient temperature is lower than the lowest temperature at which the material of the coil carrier is thermoplastic.

9. Method according to one of the preceding claims, characterized in that the maximum permissible ambient temperature has a value between 35°C and 90°C, in particular the maximum permissible ambient temperature is 40°C, 70°C or 80°C.

10. Method according to one of the preceding claims, characterized in that the melting temperature of the potting compound, the sublimation temperature of the potting compound and / or the glass transition temperature of the potting compound is / are greater than the melting temperature of the material of the coil carrier.

11. Method according to one of the preceding claims, characterized in that the melting temperature of the potting compound or the sublimation temperature of the potting compound or the glass transition temperature of the potting compound is greater than the operating temperature.

12. Method according to one of the preceding claims, characterized in that the current is suitable to effect a permanent ventilation of the brake arrangement, in particular without impermissible heating of the brake arrangement. - 17 - 13. Brake arrangement, in particular for carrying out a method according to one of the preceding claims, wherein the brake arrangement comprises a magnetic body having an annular recess, a coil carrier, a coil winding made of winding wire arranged on the coil carrier, and potting compound, wherein the coil carrier with the coil winding is received in the annular recess, wherein the recess is at least partially filled with potting compound surrounding the coil carrier and the coil winding, characterized in that the material of the coil carrier is a thermoplastic and the potting compound is a thermoset, particularly at the, in particular maximum, permissible operating temperature of the brake arrangement. - 18 - 14. Brake arrangement according to claim 13, characterized in that the axis of rotation of a rotatably mounted rotor shaft of the brake arrangement is aligned coaxially with the annular axis of the annular recess, wherein an annular driver is mounted on the rotor shaft and connected to the rotor shaft in a rotationally fixed manner, in particular by means of a keyway connection, wherein the driver has an external toothing onto which the internal toothing of a perforated disc-shaped brake pad carrier is mounted, in particular wherein the internal toothing is connected to the external toothing in a rotationally fixed manner, wherein the brake pad carrier is axially displaceable relative to the rotor shaft, in particular in the axial direction, in particular in the direction parallel to the direction of the axis of rotation of the rotor shaft, wherein a ferromagnetically formed armature disk is arranged axially between the brake pad carrier and the magnet body, wherein the armature disk is supported on the magnet body and spaced apart from each other in the circumferential direction.Spring elements press onto the armature disc, wherein the armature disc is rotationally fixed to the magnet body and is arranged to be displaceable in the axial direction, wherein the brake pad carrier is arranged axially between the armature disc and a braking surface, in particular which is formed on a housing part, in particular functioning as a bearing shield, which is connected to the magnet body. - 19 - 15. Electric motor with brake arrangement according to claim 13 or 14, characterized in that the rotor shaft is rotatably mounted in the electric motor via the bearing received in the housing part designed as a bearing shield and a second bearing received in a bearing flange of the electric motor.

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