Rotor for an axial flux machine, axial flux machine and vehicle

Abstract

The invention relates to a rotor (3) having the features of claim 1, an axial flux machine (2) having the features of claim 15, and a vehicle (1) having the features of claim 16.

Description

[0001] 202401348

[0002] 1

[0003] Description

[0004] Rotor for an axial flux machine, axial flux machine and vehicle

[0005] Technical field

[0006] The invention relates to a rotor for an axial flux machine, an axial flux machine and a vehicle.

[0007] State of the art

[0008] Rotors in electric machines containing permanent magnets are known from the prior art. However, at high rotational speeds, there is a risk that the permanent magnets will detach from the rotor due to the associated centrifugal forces.

[0009] Description of the invention, problem, solution, advantages

[0010] Therefore, the object of the present invention is to provide an alternative rotor which, in particular, overcomes at least some of the aforementioned disadvantages of the prior art. Furthermore, an object is to provide an axial flux machine with such a rotor, as well as a vehicle with such an axial flux machine or such a rotor.

[0011] The problem with regard to the rotor is solved by a device having the features of claim 1. The further problems are solved by a device having the features of claim 15 and a device having the features of claim 16, respectively.

[0012] One embodiment of the invention relates to a rotor for an axial flux machine, which has an axis of rotation about which the rotor can be rotated. 202401348

[0013] 2

[0014] is, wherein the rotor has permanent magnets on an end face of the rotor which extends transversely to the axis of rotation,

[0015] The permanent magnets are attached to the rotor's end face, preferably indirectly, by means of a fastening, in particular to a magnet yoke of the rotor. The fastening preferably comprises at least one positive fit, in particular at least one crimp. This creates a particularly reliable fastening of the permanent magnets to the rotor. Alternatively, the fastening can comprise a friction fit or a material fit. In other words, positive-locking, friction-locking, or material-locking fastenings are conceivable. Adhesive bonding, riveting, or screwing would be possible. The axial flux machine is preferably an electric motor.

[0016] It is particularly advantageous if the permanent magnets can be detached from the rotor without damage. This is preferably achieved by making the fastening or the at least one positive locking mechanism, preferably the at least one crimp, detachable either destructively or non-destructively.

[0017] A previous or preferred embodiment is characterized in that the fastening further comprises a magnet holder, in particular a cover plate, which holds and / or positions and / or centers the permanent magnets, in particular by positive locking and / or frictional locking, preferably directly, preferably by clamping the permanent magnets against the magnet yoke by the magnet holder, in particular the cover plate. In other words, the magnet holder is preferably attached directly to the magnet yoke by means of the fastening or the at least one positive locking, in particular the at least one crimp, while the permanent magnets are held by means of the magnet holder on the rotor or on the magnet yoke, in particular by means of a clamping, preferably a clamping between the rotor or magnet yoke on the one hand and the magnet holder on the other. In other words, it is preferred if the fastening only requires 202401348

[0018] 3

[0019] It serves for the indirect attachment of the permanent magnets to the rotor or the magnet yoke.

[0020] The magnetic holder allows the permanent magnets to be held preferably in a predetermined target position.

[0021] It is also preferable if the magnetic holder is pre-tensioned against the magnetic yoke. This increases the clamping force.

[0022] Preferably, the magnet holder is designed in such a way that the centrifugal forces acting on the permanent magnets due to a rotation of the rotor can be absorbed by means of the magnet holder.

[0023] One of the previous embodiments or a further preferred embodiment is characterized in that the magnet holder, in particular the cover plate, is attached by means of at least one positive locking mechanism, in particular to the rotor or the magnet yoke, preferably directly.

[0024] One of the preceding embodiments or a further preferred embodiment is characterized in that the at least one positive connection is formed by means of a radially outer edge of the magnet holder, in particular the cover plate, and / or a radially inner edge of the magnet holder, in particular the cover plate. The radially outer edge of the magnet holder is preferably located transversely to the direction of rotation of the axis of rotation and spaced apart from the radially inner edge of the magnet holder. The radially inner edge of the magnet holder is preferably located closer to the axis of rotation than the radially outer edge of the magnet holder. In particular, a direction extending radially outward is transverse or perpendicular to the axis of rotation and away from the axis of rotation.

[0025] One of the previous embodiments or a further preferred embodiment is characterized in that the radially inner edge 202401348

[0026] 4

[0027] and / or the radially outer edge engages behind the rotor or the magnetic yoke, especially when viewed from the front face, thereby forming at least one positive fit or the flanging.

[0028] One of the previous embodiments or a further preferred embodiment is characterized in that the radially inner edge is formed on a cylindrical section of the magnet holder, in particular the cover plate, and that the cylindrical section extends through an opening in the magnet yoke through the magnet yoke.

[0029] It is also preferable if the cylindrical section extends within the rotor shaft. Preferably, the cylindrical section can be fitted onto the rotor shaft. Alternatively or additionally, the cylindrical section can be pressed into the opening of the magnet yoke.

[0030] One of the previous embodiments or a further preferred embodiment is characterized in that the cylindrical section forms a centering of the magnet holder, in particular the cover plate, and / or permanent magnets to the rotor, in particular to the magnet yoke.

[0031] One of the previous embodiments or a further preferred embodiment is characterized in that the magnet holder, in particular the cover plate, positions the permanent magnets in a form-fitting manner, in particular in the radial direction and / or in the circumferential direction.

[0032] Furthermore, it is preferred if the magnet holder, in particular the cover plate, clamps the permanent magnets in the axial direction, especially against the magnet yoke.

[0033] It is also preferable if the permanent magnets are arranged at uniform intervals around the axis of rotation. 202401348

[0034] 5

[0035] Furthermore, it is advantageous if the permanent magnets are arranged uniformly in the circumferential direction, especially around the axis of rotation.

[0036] One of the previous embodiments or a further preferred embodiment is characterized in that the magnet holder, in particular the cover plate, has openings in the area of ​​the permanent magnets which extend from the permanent magnets, in particular parallel to the axis of rotation, through the magnet holder, in particular the cover plate, away from the magnet yoke.

[0037] It is also preferable if the openings are dimensioned in such a way that the permanent magnets are held only at their edge or only at their edge by the magnet holder.

[0038] One of the previous embodiments or a further preferred embodiment is characterized in that the magnet holder, in particular the cover plate, has pockets for receiving the permanent magnets in which the permanent magnets are received, and that the permanent magnets preferably have a retaining contour which interacts with a counter-retaining contour of the magnet holder, in particular the cover plate, to hold the permanent magnets.

[0039] It is also preferable if the holding contour is formed on the edge of the permanent magnets or on a peripheral area of ​​the permanent magnets.

[0040] Furthermore, it is advantageous if the holding contour is designed as a chamfer on the edges of the permanent magnets.

[0041] One of the previous embodiments or a further preferred embodiment is characterized in that the magnet holder, in particular the cover disk, and the rotor, in particular the magnet yoke, form an alignment positive fit with each other, which requires only a single 202401348

[0042] 6

[0043] and / or allows a specific, in particular predetermined, connection position between the magnet holder, in particular the cover plate, and the rotor, in particular the magnet yoke, which corresponds to a predetermined position, preferably a target position, of the permanent magnets in relation to the rotor, in particular the magnet yoke. This ensures the reproducibility of the rotor.

[0044] One of the previous embodiments or a further preferred embodiment is characterized in that the magnet holder, in particular the cover plate, is fastened to the rotor or magnet yoke by means of a fastening element designed separately from the magnet holder, in particular the cover plate, in particular by means of at least one positive locking.

[0045] One of the previous embodiments or a further preferred embodiment is characterized in that the fastening element is designed as a positive locking body, in particular a flange body, by means of which the at least one positive locking, in particular the flange, is formed.

[0046] It is also preferable if the form-fitting element, in particular the crimped element, is a cup which, starting from a further end face facing away from the first end face, engages a radially outer edge of the magnet holder and thereby fastens the magnet holder to the rotor or the magnet yoke by means of the at least one form-fitting element, in particular the crimp, preferably directly. It is further preferred that a base of the cup rests against the magnet yoke at the further end face.

[0047] Regardless of the design of the fastening element, it is preferred if the fastening element has a cylindrical section and that the cylindrical section extends through an opening in the magnet yoke. The opening in the magnet yoke preferably extends from the first end face to the second end face of the rotor or the 202401348

[0048] 7

[0049] Magnetic yokes. The cylindrical section of the fastening element preferably serves as a centering element for the fastening element to the magnetic yoke.

[0050] One of the preceding embodiments or a further preferred embodiment is characterized in that the magnet holder, in particular the cover plate, and / or the form-fitting element, in particular the crimped element, comprises metal and / or plastic. It can be made of high-temperature or austenitic steel. It can also be made of a plastically deformable plastic. Furthermore, it is preferred if the magnet holder in the area of ​​the permanent magnets, preferably the counter-holding contour, is made of plastic, while the radially inner edge and / or the radially outer edge is made of metal, preferably of a sheet. It is also conceivable that such an embodiment is formed by a sheet overmolded with plastic or a metal construction overmolded with plastic.

[0051] Another aspect of the invention relates to an axial flux machine with at least one rotor according to the invention. This is preferably an axial flux machine having a rotor-stator-rotor topology or a stator-rotor-stator topology. The stator preferably has a stator winding. Stator cooling is also conceivable. Rotor cooling is also conceivable. It is preferred if the axial flux machine is designed for a nominal electrical voltage of at least 600 volts.

[0052] Another aspect of the invention relates to a vehicle with an axial flux machine and / or a rotor according to the invention. The vehicle is preferably a hybrid vehicle in whose powertrain the axial flux machine according to the invention is integrated, preferably to support and / or replace an internal combustion engine in propelling the vehicle. Alternatively, it is an electric vehicle that has only an electric powertrain, wherein the axial flux machine according to the invention is part of the powertrain. 202401348

[0053] 8

[0054] It is also preferred if the electric vehicle is a battery-electric vehicle or a hydrogen vehicle. The vehicle can preferably be a passenger car or a truck.

[0055] Advantageous embodiments of the present invention are described in the dependent claims and in the following description of the figures.

[0056] Brief description of the drawings

[0057] The invention will now be explained in detail using exemplary embodiments and with reference to the drawings. The drawings show:

[0058] Fig. 1 is an exploded view of an embodiment of a rotor according to the invention,

[0059] Fig. 2a shows a schematic representation of a vehicle according to the invention with an embodiment of the axial flux machine according to the invention, and Fig. 2b shows a further embodiment of an axial flux machine according to the invention.

[0060] Preferred embodiment of the invention

[0061] Figure 1 shows an exploded view of an embodiment of a rotor according to the invention, without a rotor shaft being shown. Shown are permanent magnets 7, a magnet holder 4 for attaching the permanent magnets 7 to a magnet yoke 6, and a cup-shaped fastening element 10 for attaching the magnet holder 4 to the magnet yoke 6.

[0062] Figure 2a shows a schematic representation of a vehicle 1 according to the invention. The vehicle 1 is a battery-electric vehicle with an embodiment of an axial flux machine 2 according to the invention, which serves as the drive motor of the vehicle 1's drive train. The axial flux machine 2 comprises a rotor 3 according to 202401348

[0063] 9

[0064] Embodiment of Figure 1. The illustration of the rotor 3 is a sectional view, showing a section plane in which the axis of rotation 4 of the rotor 3 runs. For simplification, the rotor shaft is not shown here either, although a rotor shaft can be part of the rotor 3. The rotor 3 has a first end face A and a second end face B, which are spaced apart from each other in the axial direction 12a and face away from each other. On the first end face A, several permanent magnets 7 are spaced apart in the radial direction 12b from the axis of rotation 4 and are arranged uniformly, in particular at a uniform angular distance around the axis of rotation 4. The permanent magnets 7 are held in their position by a magnet holder 5. The magnet holder 5 is attached to a motor yoke 6 of the rotor 3 by means of a cup-shaped fastening element 10.The fastening is formed by a positive-locking crimp, whereby a radially outer edge of the fastening element 10 engages a radially outer edge 8 of the magnet holder 5 by means of the crimp. Furthermore, the fastening element 10 has a cylindrical section 11 that extends through an opening in the magnet yoke 6. The opening and the cylindrical section 11 extend from the first end face A to the second end face B. On the first end face A, the fastening element 10 engages a radially inner edge 9 of the magnet holder 5 to also secure the magnet holder 5 to the magnet yoke 6. The cylindrical section 11 preferably serves to center the fastening element 10.Alternatively, the magnet holder 5 may have a cylindrical section that projects into the opening of the magnet yoke 6, thereby centering the magnet holder 5 on the magnet yoke 6. Alternatively, the magnet holder 5 may interact with the cylindrical section 11 of the fastening element 10 in such a way that the magnet holder 5 is centered relative to the magnet yoke 6. Centering the magnet holder 5 primarily ensures the correct positioning of the permanent magnets 7 relative to the magnet yoke 6.

[0065] Figure 2b shows a schematic representation of another embodiment of an axial flux machine 2 according to the invention. This embodiment 202401348

[0066] 10

[0067] This embodiment differs from the axial flux machine shown in Figure 2a, particularly in the design of the rotor 3. It can be seen that, unlike the embodiment depicted in Figure 2a, the separately formed cup-shaped fastening element is absent. Instead, the crimps are formed directly on edges 8, 9 of the magnet holder 5 to attach the magnet holder to the magnet yoke 6 and thereby secure and align the permanent magnets 7 on the magnet yoke 6. The magnet holder 5 has a cylindrical section 11 that interacts with the opening of the magnet yoke 6 in such a way that the magnet holder 5 is centered relative to the magnet yoke 6. This ensures the correct position of the permanent magnets 7.In general, i.e., regardless of the embodiment of the rotor 3, the magnet holder 5 serves to position the permanent magnets 7 in the circumferential direction around the axis of rotation as well as in the radial direction 12b and to fasten the permanent magnets 7 to the magnet yoke 6, in that the magnet holder 5 is attached to the magnet yoke 6 and thereby secures the permanent magnets 7 in a form-fitting manner, in particular clamping them against the motor yoke 6.

[0068] The different features of the individual embodiments can also be combined with each other.

[0069] The embodiments shown in Figures 1 to 2b are not limiting in nature and serve to illustrate the

[0070] Inventive idea. 202401348

[0071] 11

[0072] Reference symbol list

[0073] 1 vehicle

[0074] 2 Axial flux machine

[0075] 3 Rotor

[0076] 4 Rotation axis

[0077] 5 magnetic holders

[0078] 6 magnetic yoke

[0079] 7 permanent magnet

[0080] 8 rand

[0081] 9 Rand

[0082] 10 Fastening element

[0083] 11 cylindrical section 12a radial direction

[0084] 12b Axial direction

Claims

202401348 12 Patent claims 1. Rotor (3) for an axial flux machine (2) having an axis of rotation (4) about which the rotor (3) is rotatable, wherein the rotor (3) has permanent magnets (7) on an end face (A) of the rotor (3) which extends transversely to the axis of rotation (4), wherein the permanent magnets (7) are attached to the end face (A) by means of a fastening to the rotor (3), in particular to a magnet yoke (6) of the rotor (3), preferably indirectly, wherein the fastening preferably comprises at least a positive locking, in particular at least a crimping.

2. Rotor (3) according to claim 1, characterized in that the fastening further comprises a magnet holder (5), in particular a cover plate, which holds and / or positions and / or centers the permanent magnets (7), in particular positively and / or force-fit, preferably directly, preferably by clamping the permanent magnets (7) against the magnet yoke (6) through the magnet holder (5), in particular the cover plate.

3. Rotor (3) according to claim 2, characterized in that the magnet holder (5), in particular the cover disk, is attached by means of at least one positive locking, in particular to the rotor (3) or the magnet yoke (6), preferably directly.

4. Rotor (3) according to one of the preceding claims, characterized in that the at least one positive locking is formed by means of a radially outer edge (8) of the magnet holder (5), in particular the cover disk, and / or a radially inner edge (9) of the magnet holder (5), in particular the cover disk.

5. Rotor (3) according to claim 4, characterized in that the radially inner edge and / or the radially outer edge (8, 9) define the rotor (3) or the 202401348 13 The magnetic yoke (6), especially when viewed from the front face (A), engages behind the magnetic yoke and thereby forms at least one positive locking connection.

6. Rotor (3) according to one of the preceding claims, characterized in that the radially inner edge (9) is formed on a cylindrical section of the magnet holder (5), in particular the cover disk, and that the cylindrical section (11) extends through an opening of the magnet yoke (6) through the magnet yoke (6).

7. Rotor (3) according to claim 6, characterized in that the cylindrical section (11) forms a centering of the magnet holder (5), in particular the cover disk, and / or permanent magnets (7) to the rotor (3), in particular to the magnet yoke (6).

8. Rotor (3) according to one of the preceding claims, characterized in that the magnet holder (5), in particular the cover disk, positions the permanent magnets (7) in a form-fitting manner, in particular in the radial direction (12b) and / or in the circumferential direction.

9. Rotor (3) according to one of the preceding claims, characterized in that the magnet holder (5), in particular the cover disk, has openings in the area of ​​the permanent magnets (7) which extend from the permanent magnets (7), in particular parallel to the axis of rotation (4), through the magnet holder (5), in particular the cover disk, away from the magnet yoke (6).

10. Rotor (3) according to one of the preceding claims, characterized in that the magnet holder (5), in particular the cover plate, has pockets for receiving the permanent magnets (7) in which the permanent magnets (7) are received, and that the permanent magnets (7) preferably have a retaining contour which interacts with a counter-retaining contour of the magnet holder (5), in particular the cover plate, to hold the permanent magnets (7). 202401348 14 11. Rotor (3) according to one of the preceding claims, characterized in that the magnet holder (5), in particular the cover disk, and the rotor (3), in particular the magnet yoke (6), form an alignment positive connection with each other, which allows only a single and / or specific connection position between the magnet holder (5), in particular the cover disk, and the rotor (3), in particular the magnet yoke (6), which corresponds to a predetermined position, preferably a target position, of the permanent magnets (7) in relation to the rotor (3), in particular the magnet yoke (6).

12. Rotor (3) according to one of the preceding claims, characterized in that the magnet holder (5), in particular the cover plate, is attached to the rotor (3) or magnet yoke (6) by means of a fastening element (10) formed separately from the magnet holder (5), in particular from the cover plate, in particular by means of at least one positive locking.

13. Rotor (3) according to claim 12, characterized in that the fastening element (10) is designed as a positive locking element, in particular a crimping element, by means of which at least one positive locking element, in particular the crimping element, is formed.

14. Rotor (3) according to one of the preceding claims, characterized in that the magnet holder (5), in particular the cover plate, and / or the form-locking body, in particular crimping body, comprises metal and / or plastic.

15. Axial flux machine (2) with at least one rotor (3) according to one of the preceding claims.

16. Vehicle (1) with an axial flux machine (2) according to claim 15 or at least one rotor (3) according to any one of claims 1 to 14.

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