Axial-flux motor and method for producing an axial-flux motor

Abstract

The invention relates to a method for producing an axial-flux motor (1), wherein a measurement result is generated in an axial run-out measurement on a rotor module (3) of a rotor assembly (2), wherein a first magnetic assembly (7) is positioned and held inside a first housing recess (6) of a first housing part (4) in a first position relative to a defined reference point of the first housing part (4) depending on the measurement result, wherein a first axial gap (10), formed inside the first housing recess (6) in the axial direction between the first magnetic assembly (7) and a wall of the first housing part (4), and / or a first radial gap (10'), formed in the radial direction between the first magnetic assembly (7) and a wall of the first housing part (4), is filled with a casting compound (11), wherein the casting compound (11) is cured such that the first magnetic assembly (7) is fixed to the first housing part (4) by the casting compound (11) in the axial direction and / or in the radial direction, and wherein the rotor assembly (2) is then mounted on the first housing part (4).

Description

[0001] AXIAL FLOW MOTOR AND METHOD FOR MANUFACTURING AN AXIAL FLOW MOTOR

[0002] The invention relates to a method for manufacturing an axial flux motor and an axial flux motor comprising a first housing part of a stator housing with at least one first housing recess, a first magnetic assembly arranged within the first housing recess, and a rotor assembly comprising a rotor module, in particular a disk-shaped one.

[0003] Axial flux motors offer several specific advantages over conventional radial flux motors. They are often more efficient, especially at low speeds, making them ideal for applications such as electric vehicles. Axial flux motors have a flatter and more compact design, resulting in smaller size and lighter weight. This compact structure is particularly beneficial for applications where space is limited. Axial flux motors can produce higher torque at lower speeds, making them especially useful for applications requiring strong starting torque. The design of axial flux motors can lead to reduced manufacturing costs, as they potentially require less material and are easier to assemble. Their design also allows for more efficient heat dissipation, increasing the motor's performance and lifespan.The design of axial flux motors allows them to be used in various configurations, opening up diverse application possibilities in different industries. These advantages make axial flux motors an attractive option for many modern technological applications, especially where efficiency, space savings, and performance are crucial.

[0004] The object of the present invention was to further simplify the construction of an axial flux motor in order to enable faster and more cost-effective manufacturing.

[0005] This task is solved by the aforementioned method by performing the following steps: providing a rotor assembly comprising a rotor module, in particular a disk-shaped one; performing a runout measurement on the rotor module, generating a measurement result; providing a first housing part of a stator housing comprising a first housing recess; providing a first magnetic assembly for arrangement within the first housing recess; positioning and holding the first magnetic assembly within the first housing recess in a first position relative to a defined reference point or a defined reference surface of the first housing part, depending on the measurement result.Filling a first axial space formed within the first housing recess in the axial direction with respect to an axis of rotation of the rotor assembly between the first magnetic assembly and a wall of the first housing part with a potting compound, and / or filling a first radial space formed within the first housing recess in the radial direction with respect to the axis of rotation of the rotor assembly between the first magnetic assembly and a wall of the first housing part with a potting compound, curing the potting compound in the first axial space so that the first magnetic assembly is fixed in the first position on the first housing part in the axial direction by the potting compound, preferably without further, in particular mechanical, fastening means, and / or curing the potting compound in the first radial space so that the first magnetic assembly is fixed in the radial direction by the potting compound, preferably without further,in particular mechanical fasteners, fixed in the first position on the first housing part, and mounting the rotor assembly on the first housing part.

[0006] Because the first magnetic assembly is fixed primarily using the potting compound, the air gap can be easily adjusted, eliminating the need for complex mechanical fasteners such as screws. Despite this simplicity, a very precise adjustment of the air gap between the first magnetic assembly and the rotor module is still possible. Generally, the air gap can range from 0.01 mm to 1 mm. The design of the first housing part and the magnetic assembly is therefore significantly simpler than in conventional motors. This allows for faster and more cost-effective manufacturing. In particular, the machining of the first housing part is simplified, as, for example, no threaded holes or similar features are required to secure the first magnetic assembly.Furthermore, the tolerances of the first housing recess and the surface roughness of the wall of the first housing recess can be significantly larger than in known motors, since the first magnetic assembly is not attached to the wall. In contrast, in known motors, precise manufacturing with tight tolerances and low surface roughness is essential to achieve accurate positioning of the first magnetic assembly relative to the rotor module.

[0007] A single-component or multi-component potting compound can be used, for example. Preferably, a potting compound based on a suitable epoxy resin is used. In its cured state, the potting compound has sufficient dimensional stability to permanently hold the first magnetic assembly in its initial position during operation. The potting compound should be selected so that, on the one hand, it cures slowly enough to allow the viscous compound to be poured as evenly as possible into the first cavity. On the other hand, it should cure as quickly as possible after filling.

[0008] Preferably, the following additional steps are performed: providing a second housing part of the stator housing, which includes a second housing recess, and providing a second magnetic assembly for arrangement within the second housing recess; positioning and holding the second magnetic assembly within the second housing recess in a second position relative to a defined reference point or a defined reference surface of the second housing part depending on the measurement result; filling a second axial space formed within the second housing recess in the axial direction between the second magnetic assembly and a wall of the second housing part with the potting compound; and / or filling a space formed within the second housing recess in the radial direction between the second magnetic assembly and a wall of the second housing part.second radial space with a potting compound, curing of the potting compound in the second axial space, so that the second magnetic assembly is fixed in the second position on the second housing part in the axial direction by the potting compound, preferably without further, in particular mechanical, fastening means, and / or curing of the potting compound in the second radial space, so that the second magnetic assembly is fixed in the second position on the second housing part in the radial direction by the potting compound, preferably without further, in particular mechanical, fastening means,and mounting the second housing part onto the first housing part. This allows the production of an axial flux motor with a double stator and correspondingly higher power or torque. The advantages mentioned above result. Preferably, at least some of the steps of claim 1 and at least some of the steps of claim 2 are performed simultaneously. This accelerates the manufacturing process. For example, the positioning of the first magnetic assembly on the first housing part and the filling with the potting compound can be performed simultaneously with the positioning of the second magnetic assembly on the second housing part and the filling with the potting compound. Two positioning tools can be used for this purpose.

[0009] Preferably, the step of positioning and holding the first magnetic assembly in the first position and / or the second magnetic assembly in the second position comprises fixing the respective magnetic assembly to the respective housing part, particularly at specific points, using an adhesive, wherein the adhesive preferably has a shorter curing time than the potting compound. The adhesive serves for temporary positioning or fixing. Alternatively or additionally, the step of positioning and holding the first magnetic assembly in the first position and / or the second magnetic assembly in the second position may include holding the respective magnetic assembly to the respective housing part using a positioning tool.When using adhesive, the positioning tool is preferably removed from the respective housing part after the adhesive has cured and before the potting compound is applied. This allows for better accessibility and consequently a simpler filling process. If no adhesive is used, the positioning tool is preferably removed from the respective housing part only after the potting compound has cured to prevent unwanted movement of the magnetic assembly.

[0010] Preferably, the measurement result of the runout measurement comprises a first axial distance between a first rotor end face of the rotor module, particularly in the region of a third magnetic assembly of the rotor module that interacts with the first magnetic assembly during operation, and a defined first reference point or a defined first reference surface of the rotor assembly, wherein the first axial distance is used to position the first magnetic assembly. Preferably, a maximum value for the first axial distance is used to ensure a sufficiently large air gap at every point in the radial direction.Alternatively or additionally, the measurement result of the runout measurement preferably includes a second axial distance between a second rotor tuning side of the rotor module, particularly in the area of ​​a fourth magnetic assembly of the rotor module that interacts with the second magnetic assembly during operation, and a defined second reference point or a defined second reference surface of the rotor assembly, wherein the second axial distance is used to position the second magnetic assembly. Again, a maximum value for the second axial distance is preferably used.

[0011] The first magnetic assembly can comprise a plurality of electrical coils or a plurality of permanent magnets. Similarly, the second magnetic assembly can comprise a plurality of electrical coils or a plurality of permanent magnets. The second magnetic assembly is preferably designed in the same way as the first magnetic assembly. The third magnetic assembly, interacting with the first magnetic assembly, preferably comprises a plurality of electrical coils or a plurality of permanent magnets. Similarly, the fourth magnetic assembly, interacting with the second magnetic assembly, preferably comprises a plurality of electrical coils or a plurality of permanent magnets. In particular, the fourth magnetic assembly can be designed in the same way as the third magnetic assembly. As mentioned above, (passive) permanent magnets are preferably used.According to a preferred embodiment, the first magnetic assembly comprises a plurality of electrical coils, the second magnetic assembly comprises a plurality of electrical coils, and the stator comprises permanent magnets that interact with the electrical coils. This results in a particularly simple and lightweight rotor module. Furthermore, no power supply is required for the rotor module. For example, one magnetic pole of a permanent magnet can form part of the third magnetic assembly, and the other magnetic pole of the respective permanent magnet can form part of the fourth magnetic assembly.

[0012] The first reference point or surface of the rotor assembly can, for example, be located on the first bearing face of a first rolling bearing of the rotor assembly, opposite the first rotor end face. Alternatively or additionally, the second reference point or surface of the rotor assembly can be located on the second bearing face of a second rolling bearing of the rotor assembly, opposite the second rotor end face. This generates a measurement result that can be easily used to position the first or second magnetic assembly.

[0013] Preferably, the first housing part has a first housing end face that includes the reference point or reference surface of the first housing part, and / or the second housing part has a second housing end face that includes the reference point or reference surface of the second housing part, wherein the first housing end face and the second housing end face face each other in the assembled state. Particularly advantageously, the first housing end face bounds the first housing part in the axial direction, and the second housing end face bounds the second housing part in the axial direction, and the first housing end face and the second housing end face are in contact with each other in the assembled state. This allows, advantageously, the use of surfaces as reference points that already exhibit relatively low manufacturing tolerances and relatively low surface roughness.Therefore, the provision of separate, high-quality finished areas can be dispensed with.

[0014] The first and / or second housing recesses can each comprise a single annular recess or multiple annular segment recesses. A single annular recess simplifies manufacturing and reduces costs. Multiple annular segment recesses offer the advantage of better retention of the magnetic assemblies by the potting compound and improved heat dissipation through the housing. A suitable variant can be selected depending on the application.

[0015] Preferably, the potting compound is introduced into at least one first (axial and / or radial) cavity through at least one first filling channel, wherein the first filling channel connects an outer surface of the first housing part with the first housing recess, and / or the potting compound is introduced into at least one second (axial and / or radial) cavity through at least one second filling channel, wherein the second filling channel connects an outer surface of the second housing part with the second housing recess. This prevents or reduces the formation of air inclusions in the potting compound during filling. The at least one first filling channel and / or the at least one second filling channel can also comprise multiple filling channels. Preferably, the filling channels are straight and extend axially between the end faces of the housing parts and the housing recesses.This allows the displaced air to escape, for example, through the open side of the housing from which the magnetic assemblies are inserted.

[0016] The problem is further solved with the aforementioned axial flux motor by positioning the first magnetic assembly within the first housing recess in a first position relative to a defined reference point or a defined reference surface of the first housing part, which is determined depending on a measurement result of a runout measurement carried out on the rotor module of the rotor assembly, and by fixing the first magnetic assembly in the first position in the axial direction and / or radial direction with respect to an axis of rotation of the rotor assembly, preferably without further, in particular mechanical, fastening means, by means of a potting compound.which is inserted in a first axial space formed within the first housing recess in the axial direction between the first magnetic assembly and a wall of the first housing part and / or in a first radial space formed within the first housing recess in the radial direction between the first magnetic assembly and a wall of the first housing part. Advantageous embodiments of the axial flux motor are specified in the dependent claims. The advantages mentioned above for the method result in each of these embodiments.

[0017] To better understand the invention, it is explained in more detail with reference to the following figures.

[0018] They each show, in a highly simplified, schematic representation:

[0019] Fig. 1 shows a longitudinal section through an axial flux motor of an exemplary embodiment of the invention;

[0020] Fig. 2 shows the axial flux motor in an exploded view; Fig. 3 shows a rotor assembly in a preferred embodiment in a top view;

[0021] Fig. 4 shows a longitudinal section through the rotor assembly;

[0022] Fig. 5 shows a runout measurement on a rotor assembly of the axial flux motor;

[0023] Fig. 6 Steps of an exemplary manufacturing process of the axial flux motor;

[0024] Fig. 7 further steps of the manufacturing process;

[0025] Fig. 8 shows further steps of the manufacturing process.

[0026] It should be noted at the outset that in the differently described embodiments, identical parts are provided with the same reference numerals or component designations, and the disclosures contained in the entire description can be applied analogously to identical parts with the same reference numerals or component designations. Furthermore, the positional designations chosen in the description, such as top, bottom, side, etc., refer to the figure directly described and illustrated, and these positional designations must be applied analogously to the new position if the position changes.

[0027] First, an axial flux motor 1 of an exemplary (non-limiting) embodiment of the invention is described with reference to Figs. 1 and 2. Fig. 1 shows the axial flux motor 1 in a longitudinal section, and Fig. 2 shows the axial flux motor 1 in an exploded view in longitudinal section.

[0028] The axial flux motor 1 of the illustrated embodiment has a stator housing 5 with a first housing part 4 and a second housing part 12. Furthermore, the axial flux motor 1 has a rotor assembly 2 with a rotor module 3, in particular a disk-shaped one.

[0029] The first housing part 4 has a first housing recess 6. This first housing recess 6 extends axially from a first end face of the first housing part 4 over a defined length towards the opposite second end face of the first housing part 4. Here, the first housing recess 6 is annular. Alternatively, however, several annular segment-shaped recesses would also be possible, each separated circumferentially by a housing section.

[0030] The axial flux motor 1 further comprises a first magnetic assembly 7, which is arranged within the first housing recess 6. The first magnetic assembly 7 is positioned within the first housing recess 6 in a first position relative to a defined reference surface 8 of the first housing part 4. The first position depends on a measurement result of a runout measurement performed on the rotor module 3 of the rotor assembly 2. The runout measurement is described separately below with reference to Fig. 5.

[0031] In the illustrated embodiment, the first magnetic assembly 7 is held in the first position axially exclusively, i.e., without any further fastening means, by means of a potting compound 11 to the first housing part 4. The potting compound 11 is introduced into a first axial space 10 formed within the first housing recess 6 axially between the first magnetic assembly 7 and a wall of the first housing part 4, as indicated in Fig. 1. The first axial space 10 is also visible in Fig. 2 (for better visibility, the potting compound 11 is not shown in Fig. 2).

[0032] The potting compound 11 serves, on the one hand, to fix the first magnetic assembly 7 in its first position on the first housing part 4. Preferably, the potting compound 11 also improves heat dissipation during operation, as the heat transfer between the first magnetic assembly 7 and the first housing part 4 in the axial direction is improved. The thermal conductivity of the potting compound 11 can be increased by suitable fillers. Preferably, the potting compound 11 is electrically insulating and exhibits high thermal conductivity. Such potting compounds 11 are known in the prior art.

[0033] In the illustrated embodiment, the first magnetic assembly 7 is held in the first position in the radial direction exclusively, i.e., without any further fastening means, by means of the potting compound 11 on the first housing part 4. The potting compound 11 is introduced into a first radial space 10' formed within the first housing recess 6 in the radial direction between the first magnetic assembly 7 and a wall of the first housing part 4, as indicated in Fig. 1. The first radial space 10' is also visible in Fig. 2 (for better visibility, the potting compound 11 is obscured in Fig. 2).

[0034] The potting compound 11 serves, on the one hand, to fix the first magnetic assembly 7 in the first position on the first housing part 4. Preferably, the potting compound 11 also improves heat dissipation during operation, since the heat transfer between the first magnetic assembly 7 and the first housing part 4 in the radial direction is improved.

[0035] The second housing part 12 has a second housing recess 13. This second housing recess 13 extends axially from a first end face of the second housing part 12 over a defined length towards the opposite second end face of the second housing part 12. In the assembled state of the axial flux motor 1, the first end face of the second housing part 12 faces the first end face of the first housing part 4. The second housing recess 13 is also annular in this case. Alternatively, several annular segment-shaped recesses, each separated circumferentially by a housing section, would also be possible.

[0036] The axial flux motor 1 further comprises a second magnetic assembly 14, which is arranged within the second housing recess 13. The second magnetic assembly 14 is positioned within the second housing recess 13 in a second position relative to a defined reference surface 15 of the second housing part 12. The second position also depends on a measurement result of the runout measurement performed on the rotor module 3 of the rotor assembly 2 (see Fig. 5).

[0037] Analogous to the first magnetic assembly 7, in the illustrated embodiment the second magnetic assembly 14 is also held in the second position exclusively, i.e., without any further fastening means, by means of the potting compound 11 on the second housing part 12. The potting compound 11 is introduced into a second axial space 16 formed within the second housing recess 13 in the axial direction between the second magnetic assembly 14 and a wall of the second housing part 12. Furthermore, the potting compound 11 is introduced into a second radial space 16' formed within the second housing recess 13 in the radial direction between the second magnetic assembly 14 and a wall of the second housing part 12, as indicated in Fig. 1. The second axial space 16 and the second radial space 16 1 are also visible in Fig. 2 (without potting compound 11).

[0038] In the example shown, the first magnetic assembly 7 comprises a plurality of electrical coils 17 arranged circumferentially within the first housing recess 6. The second magnetic assembly 14 is designed similarly to the first magnetic assembly 7 and also comprises a plurality of electrical coils 17 arranged circumferentially within the second housing recess 13. The coils 17 of the first magnetic assembly 7 can be arranged in the same positions circumferentially as the coils 17 of the second magnetic assembly 14. However, the coils 17 of the first magnetic assembly 7 can also be arranged circumferentially offset from the coils 17 of the second magnetic assembly 14. This offset arrangement reduces rotational non-uniformity.

[0039] A third magnetic assembly 20 is arranged on rotor module 3 of rotor assembly 2 and interacts magnetically with the first magnetic assembly 7. A fourth magnetic assembly 23 is provided on the opposite side of rotor module 3 from the third magnetic assembly 20 and interacts magnetically with the second magnetic assembly 14. Both the third magnetic assembly 20 and the fourth magnetic assembly 23 each comprise a plurality of permanent magnets 18.

[0040] In a known manner, a moving magnetic field can be generated by energizing the coils 17 of the first magnetic assembly 7. This field interacts with the permanent magnets 18 of the third magnetic assembly to generate a torque that sets the rotor module 3 in rotation. Similarly, a moving magnetic field can be generated by energizing the coils 17 of the second magnetic assembly 14. This field interacts with the permanent magnets 18 of the fourth magnetic assembly 23 to generate a torque that additionally (or alternatively) acts on the rotor module 3.

[0041] The permanent magnets 18 of the third magnetic assembly 20 can be arranged in the same positions circumferentially as the permanent magnets 18 of the fourth magnetic assembly 23. However, the permanent magnets 18 of the third magnetic assembly 7 can also be arranged circumferentially offset from the permanent magnets 18 of the fourth magnetic assembly 23. This offset arrangement reduces rotational non-uniformity. For example, one pole of the permanent magnets 18 can be part of the third magnetic assembly, and the other pole can be part of the fourth magnetic assembly 23.

[0042] In the illustrated example, the first housing part 4 includes a first filling channel 31 for introducing the potting compound 11 into the first housing recess 6. The first filling channel 31 connects an outer surface of the first housing part 4 with the first housing recess 6. The first filling channel 31 can comprise an axial filling channel section 31' and / or a radial filling channel section 31" as indicated in Fig. 2. Of course, several filling channel sections 31', 31" can also be provided, which can, for example, be arranged distributed circumferentially.

[0043] Similarly, the second housing part 12 includes at least one second filling channel 32 for introducing the potting compound 11 into the second housing recess 13. The second filling channel 32 connects an outer surface of the second housing part 12 to the second housing recess 13. Analogous to the first filling channel 31, the second filling channel 32 can also have one or more axial filling channel sections 32 1and / or include one or more radial filling channel sections 32".

[0044] With reference to Figures 3 and 4, a rotor assembly 2 of a preferred (non-limiting) embodiment is described below. Figure 3 shows the rotor assembly 2 in a top view (in the direction of an axis of rotation), and Figure 4 shows a longitudinal section along section line AA in Figure 3. The rotor assembly 2 can be used in the axial flux motor 1 described above.

[0045] The rotor assembly 2 comprises a rotor shaft 38 with a longitudinal axis L and a rotor module 3, which is attached to the rotor shaft 38. Several permanent magnets 18 are arranged on the rotor module 3, spaced apart from one another in the circumferential direction with respect to the longitudinal axis L. The permanent magnets 18 simultaneously form the third magnetic assembly 20 and the fourth magnetic assembly 23. The magnetic axes of the permanent magnets 18 are oriented essentially parallel to the longitudinal axis L, such that one magnetic pole (north pole N or south pole S) is located at each of the opposite end faces of the rotor module 3. The magnetic axis is generally understood to be an imaginary axis that passes through the magnetic north and south poles. Preferably, the permanent magnets 18 are arranged alternately with opposite poles in the circumferential direction.Thus, 18 permanent magnets of opposite polarity are arranged alternately in the circumferential direction.

[0046] The rotor shaft 38 has a mounting section 39 for attaching the rotor module 3, on the circumferential surface of which a mounting profile 40 is provided. The mounting section 39 is arranged between the two shaft ends of the rotor shaft 38 and can, for example, have a larger diameter than the rest of the rotor shaft 38. The mounting section 39 is preferably formed integrally with the rotor shaft 38. Alternatively, the mounting section 39 could also be a separate component and be connected to a shaft to form the rotor shaft 38. In this case, the mounting section 39 could, for example, be hollow cylindrical and pressed onto the shaft or connected to the shaft by another joining process, e.g., by welding or by means of a suitable shaft-hub connection.

[0047] The rotor module 3 has a rotor body 41 made of a potting compound. The potting compound preferably comprises a suitable epoxy resin. The rotor body 41 preferably consists of at least 90%, more preferably at least 95%, and in particular essentially entirely of the potting compound. Optionally, the potting compound could also contain additional components besides the epoxy resin that, for example, improve the strength and / or thermal conductivity.

[0048] The mounting section 39 of the rotor shaft 38 is encased in the potting compound in such a way that a positive-locking connection is established between the mounting profile 40 and the rotor body 41, at least in the circumferential direction. The mounting profile 40 is thus designed so that a torque can be transmitted from the rotor module 3 to the rotor shaft 38 (motor operation) or, if applicable, a torque from the rotor shaft 38 can be transmitted to the rotor module 3 (generator operation – if possible).

[0049] The permanent magnets 18 are also encased in the potting compound on their circumference in such a way that they are held on the rotor body 41 without any further fastening means. The permanent magnets 18 are encased in the potting compound in such a way that the effective surfaces facing away from each other in the direction of their magnetic axes (which, in the assembled state, interact with corresponding electrical coils of a stator via an air gap in the axial flux motor) are free, i.e., not covered by the potting compound. The effective surfaces are shown in Fig. 3.

[0050] In the example shown, the effective surfaces are essentially coplanar to the end faces of the rotor body 41, meaning that the permanent magnets 18 do not project beyond the end faces of the rotor body 41 in the axial direction. Alternatively, the permanent magnets 18 could project slightly beyond the end faces. In the example shown, the permanent magnets 18 are trapezoidal and have correspondingly trapezoidal effective surfaces. However, other shapes are also conceivable, for example, rectangular, particularly square, or round, particularly circular, with correspondingly shaped effective surfaces.

[0051] In the illustrated embodiment, the permanent magnets 18 are made in one piece (see also Fig. 4). Alternatively, however, it would also be conceivable for the permanent magnets 18 to be made in multiple parts. For example, segmented permanent magnets 18 could be used, which comprise several separate magnet segments that can be assembled to form a complete permanent magnet 18 (not shown). In the illustrated embodiment, the mounting profile 40 has a toothed section, as can be seen in Fig. 3. The teeth are encased in the potting compound, and the spaces between the teeth are filled with the potting compound. Here, the toothed section extends over the entire length of the mounting section 39. If the mounting section 5, as shown in Fig.3 shown, has a larger diameter than the rest of the rotor shaft 38, then the mounting profile 40 could also be spaced axially from opposite end faces of the mounting section 5.

[0052] Alternatively or additionally, the fastening profile 40 could also have other or further (not shown) profiles, preferably comprising at least one, in particular several, of the following profiles: a recess, in particular a groove or bore; a projection, in particular a rib or pin. The fastening profile 40 could optionally also have a back cut, so that an improved connection between the potting compound and the fastening section 39 is created.

[0053] In the illustrated embodiment, the rotor body 41 further comprises a reinforcing insert 42, preferably non-metallic, which is preferably completely encased in the potting compound, as shown in Fig. 4. The reinforcing insert 42 is preferably arranged in a plane of the rotor body 41 perpendicular to the longitudinal axis L, in particular a plane of symmetry.

[0054] The reinforcing insert 42 can, for example, comprise a mat or a mesh made of textile fibers, preferably of an aromatic polyamide. Alternatively or additionally, a mat or a mesh made of a glass fiber reinforced plastic and / or a mat or a mesh made of a carbon fiber reinforced plastic could also be provided. Fig. 3 shows a section of such a mesh.

[0055] In the illustrated example, a plurality of stiffening ribs 43 are provided on the axially opposite end faces of the rotor body 41, spaced apart from one another in the circumferential direction. Viewed radially, the stiffening ribs 43 are located in a region between the permanent magnets 18 and the mounting section 39 of the rotor shaft 38. The stiffening ribs 43 can, for example, have a substantially triangular cross-section, as can be seen in Fig. 4. The wider section of the triangle is located radially inward.

[0056] The rotor module 3 preferably comprises a closed stabilizing ring 44 located radially outside the permanent magnets 18. Similar to the permanent magnets 18, the stabilizing ring 44 is also held on the rotor body 41, preferably exclusively, by the potting compound. The stabilizing ring 44 is preferably encased in the potting compound at least radially outside the rotor body. In the example shown, the stabilizing ring 44 is in particular encased on all sides, as can be seen in Fig. 4.

[0057] The stabilizing ring 44 can be made of a metallic material, in particular comprising aluminum, or of a non-metallic material, in particular comprising carbon. Since the stabilizing ring 44 essentially only absorbs tensile forces, it could also be flexible, for example in the form of a rope or a band.

[0058] The stabilizing ring 44 can comprise several positioning projections 45 spaced apart from one another in the circumferential direction on an inner circumferential surface. In the example shown, each positioning projection 45 is located in the circumferential direction within the region of a permanent magnet 18, in particular without contacting an outer circumferential surface of the respective permanent magnet 18. According to an alternative embodiment (not shown), the stabilizing ring 44 could also be designed and arranged such that each positioning projection 45 projects radially between two circumferentially adjacent permanent magnets 18, in particular without contacting the permanent magnets 18. The positioning projections 45 serve in particular to position the permanent magnets 18 during manufacturing.

[0059] The permanent magnets 18 can each have a retaining profile on at least their circumferentially opposite outer surfaces, which is form-fittingly encased or cast in the potting compound (not shown). Additionally, the inner circumferential surface and / or the outer circumferential surface could each also include a retaining profile. The retaining profile can, for example, have an undercut and / or at least one, preferably several, of the following profiles: a recess, in particular a groove or bore; a projection, in particular a rib or pin.

[0060] With reference to Fig. 5, an exemplary runout measurement on rotor module 3 of rotor assembly 2 is described below. Rotor assembly 2 is shown here as a pre-assembled rotor group and thus differs from the embodiment shown in Figs. 3 and 4. The runout measurement can, for example, include one or more line measurements, e.g., with different radial distances to the axis of rotation, or an area measurement.

[0061] Fig. 5 shows the rotor assembly 2, comprising a rotor shaft 38 on which a first rolling bearing 26 and a second rolling bearing 28 are arranged. In the assembled state of the axial flux motor 1, the rotor shaft 38 of the rotor assembly 2 is rotatably mounted in the first housing part 4 by means of the first rolling bearing 26 and rotatably mounted in the second housing part 12 by means of the second rolling bearing 28 (see Fig. 1). The runout measurement can be carried out, for example, by clamping the rotor assembly 2 by means of the rolling bearings 26, 28 on a suitable measuring station 33 and rotating it at a defined speed, as schematically indicated in Fig. 5.

[0062] As part of the runout measurement, a first axial distance LI between a first rotor end face 19 of the rotor module 3 and a defined first reference surface 21 of the rotor assembly 2 is measured as an example. The first reference surface 21 of the rotor assembly 2 is located, for example, on the first bearing end face 25 of the first rolling bearing 26 of the rotor assembly 2, opposite the first rotor end face 19. The reference point on the rotor module 3 is preferably located in the area of ​​the third magnetic assembly 20, in particular the permanent magnets 18, which interact with the first magnetic assembly 7 of the first housing part 4 during operation. Of course, other suitable reference points or reference surfaces could also be used for the measurement.

[0063] The determined first axial distance LI can be used to position the first magnetic assembly 7 within the first housing recess 10. Preferably, a maximum value for the first axial distance LI is used to ensure a sufficiently large air gap between the rotor module 3 and the first magnetic assembly 7. The runout measurement is performed using a suitable measuring device. The measuring device can, for example, comprise one or more suitable distance sensors, e.g., laser sensors 34, as indicated in Fig. 5. Such measuring devices are known in the prior art, which is why no further description is given here.

[0064] Similarly, a second axial distance L2 can be determined between a second rotor end face.

[0065] The second axial distance L2 is measured between the rotor module 3 and a defined second reference point or a defined second reference surface 24 of the rotor assembly 2. The measured second axial distance L2, in particular a maximum value of the second axial distance L2, can in turn be used to position the second magnetic assembly 14 within the second housing recess.

[0066] The reference point on the rotor module 3 is preferably located in the area of ​​a fourth magnetic assembly that interacts with the second magnetic assembly 14.

[0067] 23 of the rotor module 3, in particular the permanent magnet 18. The second reference surface 24 of the rotor assembly 2 is located here on one of the second bearing faces 27 of the second rolling bearing 28 of the rotor assembly 2, which faces away from the second rotor end face 22. Of course, other references would again be possible.

[0068] The first housing part 4 can have a first housing end face 29 that includes the reference surface 8 of the first housing part 4. Similarly, the second housing part 12 can have a second housing end face 30 that includes the reference surface 15 of the second housing part 12 (see Fig. 2). In the assembled state of the axial flux motor 1, the first housing end face 29 and the second housing end face 30 are preferably facing each other. In the illustrated example, the first housing end face 29 defines the axial boundaries of the first housing part 4, and the second housing end face 30 defines the axial boundaries of the second housing part 12. In the assembled state, the first housing end face 29 and the second housing end face 30 are in contact with each other.

[0069] Since the first housing end face 29 and the second housing end face 30 are in contact with each other in the assembled state, they preferably exhibit a comparatively high machining quality, i.e., sufficiently low form and positional tolerances (e.g., flatness, parallelism) as well as sufficiently low roughness (e.g., mean roughness Ra value < 1.6). Thus, the first housing end face 29 and the second housing end face 30 are well suited as reference surfaces 8, 15, against which the magnet assemblies 7, 14 can be positioned.

[0070] The following section describes in more detail a method for manufacturing an axial flux motor 1 according to an advantageous embodiment, with reference to Figs. 6 to 8.

[0071] In a first step, S 1 provides a rotor assembly 2, which comprises a rotor module 3, in particular a disk-shaped one. Preferably, the two rolling bearings 26, 28 are already pre-mounted on the rotor shaft 38. The rotor assembly 2 can be configured, for example, according to Figs. 3 and 4. For details of the rotor assembly 2, reference is made to the embodiments described above.

[0072] In a further step S2, a runout measurement is performed on the rotor module 3, generating a measurement result. The measurement result preferably includes the first axial distance LI. If the axial flux motor 1 is designed as a double stator motor, then the measurement result preferably also includes the second axial distance L2. For details of the measurement, reference is made to the embodiments described above in Fig. 5.

[0073] In a further step S3, at least the first housing part 4 of the stator housing 5 of the axial flux motor 1, which includes at least a first housing recess 6, and a first magnetic assembly 7 are provided for arrangement within the first housing recess 6.

[0074] In a further step S4 (Fig. 7), the first magnetic assembly 7 is positioned within the first housing recess 6 in a first position relative to a defined reference point or a defined reference surface 8 of the first housing part 4, depending on the measurement result, in particular the first axial distance LI. The positioning is carried out such that, in the assembled state of the rotor assembly 2, a defined and preferably as constant as possible air gap exists between the rotor module 3 and an end face of the first magnetic assembly 7 facing the rotor module. The air gap is preferably located in the area of ​​the third magnetic assembly, in particular the permanent magnets 18. The first magnetic assembly 7 comprises, for example, a plurality of electrical coils 14, as already described. In general, the air gap in the assembled state can be, for example, 0.01 mm to 1 mm.

[0075] In a further step S5, the first magnetic assembly 7 is held in the first position. Preferably, the positioning and holding are carried out using the positioning tool 9. The positioning tool 9 is shown schematically in Fig. 7. The positioning tool 9 enables precise positioning of the first magnetic assembly 7 relative to the defined reference point or the defined reference surface 8. "Precise" can, for example, mean positioning in the range of tenths of a millimeter or hundredths of a millimeter.

[0076] Alternatively or additionally to the positioning tool 9, positioning and holding can also be achieved using a suitable adhesive (not shown). The adhesive can, for example, be applied in spots to the first magnetic assembly 7, in particular to an end face and / or one of the circumferential surfaces, before it is positioned in the first housing recess 6. Alternatively or additionally, the adhesive could, of course, also be applied, preferably in spots, to an inner end face and / or inner circumferential surface of the first housing part 4 before the first magnetic assembly 7 is positioned in the first housing recess 6. The adhesive serves to temporarily fix the first magnetic assembly 7.

[0077] In the illustrated example, the positioning tool 9 is configured, for instance, to position the first magnetic assembly 7 relative to the first housing end face 29 (see Fig. 2). The positioning tool 9 can, for example, include a centering section 35 to center the positioning tool 9 with respect to a rotational axis of the axial flux motor 1. Furthermore, the positioning tool 9 can include a suitable fastening device 36 for attachment to the first housing part 4. The centering section 35 can, for example, be configured for arrangement on a bearing bushing 37 of the first housing part 4, on which the first rolling bearing 26 is arranged in the assembled state (see Fig. 2). The fastening device 36 can include a number of screws or similar components. Preferably, the positioning tool 9 also includes a suitable fastening section for attaching the first magnetic assembly 7 to the positioning tool 9.Furthermore, the positioning tool 9 can have a suitable (not shown) adjustment device for adjusting the position of the first magnetic assembly 7 relative to the positioning tool 9 or for adjusting the position of the first magnetic assembly 7 within the first housing recess 10 relative to the first housing part 4. The adjustment device is preferably designed to adjust the position at least in the axial direction. Additionally, adjustability of the position in the radial direction and / or adjustability of an angle could be provided.

[0078] After positioning the first magnetic assembly 7, in a further step S6 at least one axial cavity 10 formed within the first housing recess 6 in the axial direction between the first magnetic assembly 7 and a wall of the first housing part 4 is filled with a potting compound 11. The filling can be done manually or, if necessary, automatically. The potting compound 11 can be introduced into the first cavity 10 from a container. Figure 7 shows tubes only as examples. However, the filling could also be done, for example, using one or more suitable syringes or similar devices.

[0079] Preferably, the potting compound 11 is introduced into the first axial space 10 through at least one first filling channel 31. The first filling channel 31 connects an outer surface of the first housing part 4 with the first housing recess 6 (see also Figs. 1 and 2) and can, for example, comprise one or more axial filling channel sections 31. 1and / or have one or more filling channel sections 31" (see Figs. 1 and 2 and the above descriptions). The amount of potting compound 11 is preferably selected such that substantially the entire first intermediate space 10 is filled. The amount of potting compound 11 can be determined beforehand, for example, based on the component geometries. An overflow bore (not shown) could also be provided in addition to the first filling channel 31, and the potting compound 11 could be filled until it overflows from the overflow bore. The overflow bore could be provided on the first housing part 4 or, if necessary, on the positioning tool 9 in an area that closes the open side of the first housing part 4. If necessary, a pressure gradient could also be created between the first filling channel 31 and the overflow bore to ensure rapid and uniform filling.

[0080] If the first housing recess 6 comprises an annular recess, then it would generally be sufficient to provide a single first filling channel 31. If the first housing recess 6 comprises several annular segment-shaped recesses, e.g., one annular segment-shaped recess per coil 14, then it is advantageous if each annular segment-shaped recess is assigned a separate first filling channel 31, possibly comprising first and / or second filling channel sections 31', 31

[0081] Alternatively or additionally, in step S6, after positioning the first magnetic assembly 7, a first radial space 10' formed within the first housing recess 6 in a radial direction between the first magnetic assembly 7 and a wall of the first housing part 4 can also be filled with the potting compound 11 in order to hold the first magnetic assembly 7 also in a radial direction, preferably exclusively, i.e. without further fastening means, on the first housing part 4 by means of the potting compound 11.

[0082] In a further step S7 (see Fig. 8), the potting compound 11 located in the first axial space 10 and / or the potting compound 11 located in the radial space 10' is cured. In the simplest case, this can be achieved by holding the first magnetic assembly 7 in place using the positioning tool 9 for a sufficiently long curing time. Additionally, the curing process could optionally be accelerated by the application of heat.

[0083] In a further step S8, the positioning tool 9 is removed from the first housing part 4. The first magnetic assembly 7 is now held in its initial position on the first housing part 4, at least axially (and possibly also radially), solely by the cured potting compound 11. If an adhesive is used in addition to the positioning tool 9 to (temporarily) hold the first magnetic assembly 7, then the positioning tool 9 could also be removed after the adhesive has cured and before the potting compound 11 is poured. Finally, in a further step S9, the rotor assembly 2 is mounted on the first housing part 4 to form the axial flux motor 1.If the axial flux motor 1 comprises only a stator (first housing part 4 with first magnetic assembly 7), then a cover (not shown) could also be mounted on the first housing part to shield the rotor module 3 from the environment. The cover could optionally include a bearing bushing for the second rolling bearing 28 and an opening for the rotor module 3. Alternatively, the cover could be closed, and the rotor shaft 38 could be fully supported within the first housing part 4. Furthermore, the rotor shaft 38 could extend outwards through a designated opening in the first housing part 4.

[0084] If the axial flux motor 1 is designed as a double stator motor, as shown in Fig. 1, then the second housing part 12 of the stator housing 5, including the second magnetic assembly 14 attached to it, can be manufactured in an analogous manner as described above with reference to the first housing part 4. For details, reference is made to the explanations for steps S3-S9.

[0085] In particular, analogous to step S3, the second housing part 12, which includes at least a second housing recess 13, and the second magnetic assembly 14 can first be provided for arrangement within the second housing recess 13. Analogous to step S4, the second magnetic assembly 14 can be positioned within the second housing recess 13 in a second position relative to a defined reference point or a defined reference surface 15 of the second housing part 12, depending on the measurement result, in particular the second axial distance L2.

[0086] Analogous to step S5, the second magnetic assembly 14 can be held in the second position using the positioning tool 9 (previously used on the first housing part 4), another positioning tool 9, and / or an adhesive. Analogous to step S6, a second axial gap 16 formed within the second housing recess 13 in the axial direction between the second magnetic assembly 14 and a wall of the second housing part 12 can be filled with the potting compound 11. Alternatively or additionally, a second radial gap 16' formed within the second housing recess 13 in the radial direction between the second magnetic assembly 14 and a wall of the second housing part 12 can also be filled with the potting compound 11.

[0087] Analogous to step S7, the potting compound 11 can be cured in the second axial space 16 (and, if applicable, the radial space 16'). Analogous to step S8, the respective positioning tool 9 can be removed from the second housing part 12 after the potting compound 11 has cured. However, if an adhesive is also used, the positioning tool 9 could be removed even before the potting compound 11 is poured in. Analogous to step S9, the second housing part 12 can be mounted on the first housing part 4 to form the axial flux motor 1.

[0088] The exemplary embodiments show possible embodiment variants, whereby it should be noted at this point that the invention is not limited to the specifically illustrated embodiment variants, but rather various combinations of the individual embodiment variants are also possible and this possibility of variation lies within the skill of the person skilled in this technical field due to the teaching on technical action by the present invention.

[0089] The scope of protection is defined by the claims. However, the description and drawings must be consulted for the interpretation of the claims. Individual features or combinations of features from the different embodiments shown and described can, in themselves, represent independent inventive solutions. The problem underlying these independent inventive solutions can be found in the description.

[0090] All references to value ranges in this description are to be understood as encompassing any and all sub-ranges thereof. For example, the reference 1 to 10 is to be understood as including all sub-ranges, starting with a lower limit of 1 and ending with an upper limit of 10. This means that all sub-ranges begin with a lower limit of 1 or greater and end with an upper limit of 10 or less, e.g., 1 to 1.7, or 3.2 to 8.1, or 5.5 to 10. Finally, for the sake of clarity, it should be noted that, for better understanding of the structure, some elements have been shown not to scale and / or enlarged and / or reduced.

[0091] Reference sign setup

[0092] Axial flux motor 28 Second rolling bearing

[0093] Rotor assembly 29 First housing tuning surface

[0094] Rotor module 30 Second housing tuning surface

[0095] First housing part 31 First filling channel

[0096] Stator housing 31 1 Axial filling channel section

[0097] First housing recess 31" Radial filling channel section

[0098] First magnetic assembly 32 Second filling channel Reference surface of the first housing 32 1 Axial filling channel section, partially 32" Radial filling channel section

[0099] Positioning of tool 33 measuring station

[0100] First axial gap 34 Distance sensor ' First radial gap 35 Centering section

[0101] Potting compound 36 Fastening device

[0102] Second housing part 37 bearing bushing

[0103] Second housing recess 38 Rotor shaft

[0104] Second magnetic assembly 39 Mounting section Reference surface of the second Ge40 Mounting profile Housing part 41 Rotor body

[0105] Second axial gap 42 Reinforcing insert' First radial gap 43 Stiffening rib

[0106] Electrical coil 44 stabilizing ring

[0107] Permanent magnet 45° positioning projection

[0108] First rotor end face LI First axial distance

[0109] Third magnetic assembly L2 Second axial spacing

[0110] First reference surface

[0111] Second rotor end face

[0112] Fourth magnetic assembly

[0113] Second reference surface

[0114] First camp voting page

[0115] First rolling bearing

[0116] Second camp voting page

Claims

Patent claims 1. Method for manufacturing an axial flux motor (1) comprising the following steps: - Providing a rotor assembly (2) comprising a rotor module (3), in particular a disk-shaped one, - Performing a runout measurement on the rotor module (3), generating a measurement result, - Providing a first housing part (4) of a stator housing (5) comprising a first housing recess (6) and providing a first magnetic assembly (7) for arrangement within the first housing recess (6), - Positioning and holding the first magnetic assembly (7) within the first housing recess (6) in a first position relative to a defined reference point or a defined reference surface (8) of the first housing part (4) depending on the measurement result, - Filling a first axial space (10) formed within the first housing recess (6) in the axial direction with respect to an axis of rotation of the rotor assembly (2) between the first magnetic assembly (7) and a wall of the first housing part (4) with a potting compound (11) and / or filling a first radial space (10') formed within the first housing recess (6) in the radial direction with respect to the axis of rotation of the rotor assembly (2) between the first magnetic assembly (7) and a wall of the first housing part (4) with a potting compound (11), - Curing of the potting compound (11) in the first axial space (10) so that the first magnetic assembly (7) is fixed in the first position on the first housing part (4) in the axial direction by the potting compound (11), preferably without further, in particular mechanical, fastening means, and / or curing of the potting compound (11) in the first radial space (10') so that the first magnetic assembly (7) is fixed in the first position on the first housing part (4) in the radial direction by the potting compound (11), preferably without further, in particular mechanical, fastening means, and - Mounting the rotor assembly (2) on the first housing part (4).

2. The method according to claim 1, characterized in that the following additional steps are carried out: - Providing a second housing part (12) of the stator housing (5) comprising a second housing recess (13) and providing a second magnetic assembly (14) for arrangement within the second housing recess (13), - Positioning and holding the second magnetic assembly (14) within the second housing recess (13) in a second position relative to a defined reference point or a defined reference surface (15) of the second housing part (12) depending on the measurement result, - Filling a second axial space (16) formed within the second housing recess (13) in the axial direction between the second magnetic assembly (14) and a wall of the second housing part (12) with the potting compound (11) and / or filling a second radial space (16') formed within the second housing recess (13) in the radial direction between the second magnetic assembly (14) and a wall of the second housing part (12) with a potting compound (11), - Curing of the potting compound (11) in the second axial space (16) so that the second magnetic assembly (14) is fixed in the second position on the second housing part (12) in the axial direction by the potting compound (11), preferably without further, in particular mechanical, fastening means, and / or curing of the potting compound (11) in the second radial space (16') so that the second magnetic assembly (14) is fixed in the second position on the second housing part (12) in the radial direction by the potting compound (11), preferably without further, in particular mechanical, fastening means, and - Mounting the second housing part (12) onto the first housing part (4).

3. Method according to claim 2, characterized in that at least some of the steps of claim 1 and at least some of the steps of claim 2 are carried out simultaneously.

4. Method according to one of claims 1 to 3, characterized in that the step of positioning and holding the first magnetic assembly (7) in the first position and / or the second magnetic assembly (14) in the second position comprises fixing, in particular at specific points, the respective magnetic assembly (7, 14) to the respective housing part (4, 12) by means of an adhesive, wherein the adhesive preferably has a shorter curing time than the potting compound (11) 5. Method according to any one of claims 1 to 4, characterized in that the step of positioning and holding the first magnetic assembly (7) in the first position and / or the second magnetic assembly (14) in the second position comprises holding the respective magnetic assembly (7, 14) on the respective housing part (4, 12) by means of a positioning tool (9, 9'), wherein, when using the adhesive, the positioning tool (9, 9') is preferably removed from the respective housing part (4, 12) after the adhesive has cured and before the step of filling with potting compound (11), and, without using the adhesive, is preferably removed from the respective housing part (4, 12) after the potting compound (11) has cured.

6. A method according to any one of claims 1 to 5, characterized in that the measurement result of the runout measurement comprises a first axial distance (LI) between a first rotor end face (19) of the rotor module (3), in particular in the region of a third magnetic assembly (20) of the rotor module (3) that interacts with the first magnetic assembly (7) during operation, and a defined first reference point or a defined first reference surface (21) of the rotor assembly (2), in particular a maximum value or minimum value of the first axial distance (LI), and wherein the first axial distance (LI) is used to position the first magnetic assembly (7) and / or that the method comprises the steps according to claim 2, wherein the measurement result of the runout measurement comprises a second axial distance (L2) between a second rotor end face (22) of the rotor module (3),in particular in the area of ​​a fourth magnetic assembly (23) of the rotor module (3) which interacts with the second magnetic assembly (14) during operation, and a defined second reference point or a defined second reference surface (24) of the rotor assembly (2), in particular a maximum value or minimum value of the second axial distance (L2), and wherein the second axial distance (L2) is used to position the second magnetic assembly (14).

7. A method according to any one of claims 1 to 6, characterized in that the first magnetic assembly (7) comprises a plurality of electrical coils (17) or a plurality of permanent magnets (18) and / or that the method comprises the steps according to claim 2, wherein the second magnetic assembly (14) is configured similarly to the first magnetic assembly (7) and / or that a third magnetic assembly (20) of the rotor module (3) interacting with the first magnetic assembly (7) a plurality of electrical coils (17) or a plurality of permanent magnets (18) and / or that a fourth magnetic assembly (23) of the rotor module (3) cooperating with the second magnetic assembly (14) comprises a plurality of electrical coils (17) or a plurality of permanent magnets (18), wherein the fourth magnetic assembly (23) is designed in the same way as the third magnetic assembly (20).

8. Method according to claim 6 or 7, characterized in that the first reference point or the first reference surface (21) of the rotor assembly (2) is located on a first bearing face (25) of a first rolling bearing (26) of the rotor assembly (2) facing away from the first rotor face (19) and / or that the method comprises the steps according to claim 2, wherein the second reference point or the second reference surface (24) of the rotor assembly (2) is located on a second bearing face (27) of a second rolling bearing (28) of the rotor assembly (2) facing away from the second rotor end face (22).

9. Method according to any one of claims 1 to 8, characterized in that the first housing part (4) has a first housing end face (29) which includes the reference point or reference surface (8) of the first housing part (4) and / or that the method comprises the steps according to claim 2 and the second housing part (12) has a second housing end face (30) which includes the reference point or reference surface (15) of the second housing part (12), wherein the first housing end face (29) and the second housing end face (30) face each other in the assembled state, wherein preferably the first housing end face (29) limits the first housing part in the axial direction, the second housing end face (30) limits the second housing part (12) in the axial direction and the first housing end face (29) and the second housing end face (30) are in contact with each other in the assembled state.

10. Method according to any one of claims 1 to 9, characterized in that the at least one first housing recess (6) comprises an annular recess or several annular segment-shaped recesses and / or that the method comprises the steps according to Annex 2, wherein the at least one second housing recess (13) comprises an annular recess or several annular segment-shaped recesses.

11. Method according to any one of claims 1 to 10, characterized in that the potting compound (11) is introduced through at least one first filling channel (31) into at least one first intermediate space (10, 10'), wherein the first filling channel (31) connects an outer surface of the first housing part (4) with the first housing recess (6) and / or that the method comprises the steps according to claim 2, wherein the potting compound (11) is introduced through at least one second filling channel (32) into at least one second intermediate space (16, 16'), wherein the second filling channel (32) connects an outer surface of the second housing part (12) with the second housing recess (13).

12. Axial flux motor (1) comprising: - a first housing part (4) of a stator housing (5), comprising a first housing recess (6), - a first magnetic assembly (7) arranged within the first housing recess (6), - a rotor assembly (2) comprising a rotor module (3), in particular a disk-shaped one, characterized in that: the first magnetic assembly (7) is positioned within the first housing recess (6) in a first position relative to a defined reference point or a defined reference surface (8) of the first housing part (4), which is determined depending on a measurement result of a runout measurement carried out on the rotor module (3) of the rotor assembly (2), and that the first magnetic assembly (7) is fixed in the first position in an axial direction and / or in a radial direction with respect to an axis of rotation of the rotor assembly (2), preferably without further, in particular mechanical, fastening means, by means of a potting compound (11),which is inserted in a first axial space (10) formed within the first housing recess (6) in the axial direction between the first magnetic assembly (7) and a wall of the first housing part (4) and / or in a first radial space (10') formed within the first housing recess (6) in the radial direction between the first magnetic assembly (7) and a wall of the first housing part (4).

13. Axial flux motor (1) according to claim 12, characterized in that the axial flux motor (1) additionally comprises the following: - a second housing part (12) of the stator housing (5), comprising a second Housing recess (13), - a second magnetic assembly (14) located within the second housing recess (13) is arranged, wherein the rotor module (3) of the rotor assembly (2) is located in the direction of an axis of rotation of the rotor assembly (2) between the first magnetic assembly (7) and the second magnetic assembly (14), wherein the second magnetic assembly (14) is positioned within the second housing recess (13) in a second position relative to a defined reference point or a defined reference surface (15) of the second housing part (12), which is determined depending on the measurement result of the runout measurement carried out on the rotor module (3) of the rotor assembly (2), and wherein the second magnetic assembly (14) is fixed in the second position in the axial direction and / or in the radial direction, preferably without further, in particular mechanical, fastening means, by means of a potting compound (11) on the second housing part (12),which is provided in a second axial space (16) formed within the second housing recess (13) in the axial direction between the second magnetic assembly (14) and a wall of the second housing part (12) and / or in a second radial space (10') formed within the second housing recess (6) in the radial direction between the second magnetic assembly (14) and a wall of the second housing part (12).

14. Axial flux motor (1) according to claim 12 or 13, characterized in that the measurement result of the runout measurement comprises a first axial distance (LI) between a first rotor end face (19) of the rotor module (3), in particular in the region of a third magnetic assembly (20) of the rotor module (3) interacting with the first magnetic assembly (7), and a defined first reference point or a defined first reference surface (21) of the rotor assembly (2), in particular a maximum value or minimum value of the first axial distance (LI), and wherein the first magnetic assembly (7) is positioned depending on the first axial distance (LI) and / or that, if the axial flux motor (1) is configured according to claim 13, the measurement result of the runout measurement comprises a second axial distance (L2) between a second rotor end face (22) of the rotor module (3),in particular in the area of ​​a fourth magnetic assembly (23) of the rotor module (3) interacting with the second magnetic assembly (14), and a defined second reference point or a defined second reference surface (24) of the rotor assembly (2), in particular a maximum value or minimum value of the second axial distance, (L2), and wherein the second magnetic assembly (14) is positioned depending on the second axial distance (L2).

15. Axial flux motor (1) according to one of claims 12 to 14, characterized in that the first magnetic assembly (7) comprises a plurality of electrical coils (17) or a plurality of permanent magnets (18) and / or that, if the axial flux motor (1) is configured according to claim 13, the second magnetic assembly (14) is configured similarly to the first magnetic assembly (7) and / or that a third magnetic assembly (20) of the rotor module (3) interacting with the first magnetic assembly (7) comprises a plurality of electrical coils (17) or a plurality of permanent magnets (18) and / or that a third magnetic assembly (20) of the rotor module (3) interacting with the first magnetic assembly (7) comprises a plurality of electrical coils (17) or a plurality of permanent magnets (18) and / or that a third magnetic assembly (20) interacting with the second magnetic assembly (14) The fourth magnetic assembly (23) of the rotor module (3) comprises a plurality of electrical coils (17) or a plurality of permanent magnets (18), wherein the fourth magnetic assembly (23) is designed in the same way as the third magnetic assembly (20).

16. Axial flux motor (1) according to claim 14 or 15, characterized in that the first reference point or the first reference surface (21) of the rotor assembly (2) is located at a first bearing contact side (25) of a first rolling bearing (26) of the rotor assembly (2) facing away from the first rotor end face (19) and / or that, if the axial flux motor (1) is configured according to claim 13, the second reference point or the second reference surface (24) of the rotor assembly (2) is located at a second bearing contact side (27) of a second rolling bearing (28) of the rotor assembly (2) facing away from the second rotor end face (22).

17. Axial flux motor (1) according to one of claims 12 to 16, characterized in that the first housing part (4) has a first housing end face (29) which includes the reference point or reference surface (8) of the first housing part (4) and / or that, if the axial flux motor (1) is designed according to claim 13, the second housing part (12) has a second housing end face (30) which includes the reference point or reference surface (15) of the second housing part (12), wherein the first housing tuning surface (29) and the second housing tuning surface (30) face each other in the assembled state, wherein preferably the first housing tuning surface (29) aligns the first housing part in an axial direction limited, the second housing end face (30) limits the second housing part (12) in the axial direction and the first housing end face (29) and the second housing end face (30) are in contact with each other.

18. Axial flux motor (1) according to one of claims 12 to 17, characterized in that the at least one first housing recess (6) comprises an annular recess or several annular segment-shaped recesses and / or that, if the axial flux motor (1) is designed according to claim 13, the at least one second housing recess (13) comprises an annular recess or several annular segment-shaped recesses.

19. Axial flux motor (1) according to one of claims 12 to 18, characterized in that the first housing part (4) comprises at least one first filling channel (31) for introducing the potting compound (11) into at least one first intermediate space (10, 10'), wherein the first filling channel (31) connects an outer surface of the first housing part (4) with the first housing recess (6) and / or that, if the axial flux motor (1) is configured according to claim 13, the second housing part (12) comprises at least one second filling channel (32) for introducing the potting compound (11) into at least one second intermediate space (16, 16'), wherein the second filling channel (32) connects an outer surface of the second housing part (12) with the second housing recess (13).

20. Axial flux motor (1) according to one of claims 12 to 19, characterized in that the rotor assembly (2) comprises a rotor shaft (38) with a longitudinal axis on which a mounting section (39) is provided, on the circumferential surface of which a mounting profile (40) is provided, that the rotor module (3) comprises a rotor body (41) made of a potting compound, preferably comprising epoxy resin, wherein the mounting section (39) of the rotor shaft (38) is encased by the potting compound in such a way that a positive connection is established between the mounting profile (40) and the rotor body (41) at least in the circumferential direction, and that a third magnetic assembly (20), preferably permanent magnets (18), which interacts with the first magnetic assembly (7), is circumferentially encased by the potting compound in such a way that it is held on the rotor body (41), in particular without further fastening means, and that when the axial flux motor (1) according to claim 13 is configured, preferably a fourth magnetic assembly (23) cooperating with the second magnetic assembly (14), preferably permanent magnets (18), are circumferentially encased by the potting compound in such a way that they are held on the rotor body (41), in particular without further fastening means.

Images