Rotor having a laminated core and a magnet caulked on one side, traction drive having a rotor, and method for producing a rotor

Abstract

The invention relates to a rotor (RO) for an electric machine of an at least partially electrically driven motor vehicle, having a laminated core (BP) that has a plurality of successively arranged individual laminations, wherein the laminated core (BP) has a first end face (ES) and a second end face (ZS) that is located at a distance in the axial direction of the laminated core (BP), a magnetic pole (MP) being formed in the laminated core (BP), wherein the magnetic pole (MP) comprises a first magnet pocket (MT1) that has a first magnet-receiving opening (MA01) in the first end face (ES), and a first magnet (MA1) is arranged in the first magnet pocket (MT1), wherein the first magnet (MA1) is form-fittingly held in the first magnet pocket (MT1) by a caulking point (VP) in the laminated core (BP), and the caulking point (VP) is formed on the first end face (ES), and the second end face (ZS) is designed to be free from caulking points in the region of the first magnet pocket (MT1).

Description

[0001] 202401228

[0002] 1

[0003] Description

[0004] Rotor with laminated core and magnet riveted on one side, traction drive with rotor and method for manufacturing a rotor

[0005] The invention relates to a rotor for an electric machine of a motor vehicle that is at least partially electrically powered, wherein the rotor comprises a laminated core consisting of several laminated sheets arranged one behind the other. A magnet pocket is formed in the laminated core, and a magnet is arranged in the magnet pocket. The magnet is fixed in the magnet pocket by crimping the laminated core on one side. The invention also relates to a traction drive with the rotor according to the invention. Furthermore, the invention relates to a method for manufacturing the rotor according to the invention.

[0006] Rotors for electric machines are generally known. It is also known that magnets are fixed in the magnet pocket by crimping. The magnets are fixed in the magnet pockets by crimping both end faces, which are spaced apart from each other in the axial direction of the laminated core, so that the electrical contact resistance is reduced in the contact areas between the magnet and the laminated core. Since the magnetic flux through the pole pulsates due to harmonics and overtones of the air gap field, eddy currents are formed, which close axially through the magnet and transversely through the laminate. It has been shown that crimping on both sides forms lower-resistance eddy current paths, which can lead to increased rotor heating.Increased rotor heating can, on the one hand, necessitate the use of magnets with higher temperature stability, which can negatively impact rotor costs. On the other hand, increased rotor heating causes the thermal continuous power limit to be reached sooner. This can negatively affect the performance and / or efficiency of the electric machine. 202401228.

[0007] 2

[0008] A primary objective of the invention is to provide a rotor for a motor vehicle that is at least partially electrically powered and can be manufactured inexpensively and exhibit reduced eddy currents.

[0009] A second object of the invention is to provide a traction drive for an electrically powered motor vehicle that can be manufactured inexpensively and can have improved efficiency and lower rotor heating.

[0010] A third object of the invention is to provide a method for manufacturing a rotor that is inexpensive to produce and can exhibit reduced eddy currents.

[0011] The first problem is solved by the subject matter of claim 1. The second problem is solved by the subject matter of claim 10. The third problem is solved by the subject matter of claim 11. Preferred embodiments of the invention are the subject matter of the dependent claims, the following description, and the drawings, wherein each feature, individually or in combination, can represent an aspect of the invention, unless explicitly stated otherwise in the description.

[0012] According to a first aspect, the invention relates to a rotor for an electric machine of an at least partially electrically powered motor vehicle, comprising a laminated core consisting of a plurality of individual laminations arranged one behind the other, wherein the laminated core has a first end face and a second end face spaced apart axially from the laminated core, wherein a magnetic pole is formed in the laminated core, the magnetic pole comprising a first magnetic pocket having a first magnet receiving opening in the first end face, and wherein a first magnet is arranged in the first magnetic pocket, the first magnet being positively locked in the first magnetic pocket by a riveting point in the laminated core, the riveting point being formed on the first end face, and the second end face being free of riveting points in the region of the first magnetic pocket. 202401228

[0013] 3

[0014] In other words, according to the first aspect of the invention, a rotor is provided for an electric machine of a motor vehicle that is at least partially electrically powered. The electric machine is preferably a radial flux machine. The rotor can be designed as an external rotor. Preferably, the rotor is designed as an internal rotor.

[0015] The rotor comprises a laminated core. The laminated core consists of a plurality of individual laminations arranged one behind the other and preferably connected to each other. The respective end laminations of a laminated core are preferably identical. It is particularly advantageous that all laminations of a laminated core are identical. This reduces the number of parts, which can have a beneficial effect on costs. The laminated core is preferably annular in shape. According to the invention, the laminated core has a first end face that is aligned and / or formed in an axial direction of the laminated core. The laminated core has a second end face located axially to and spaced apart from the first end face. Furthermore, the laminated core includes a magnetic pole. The magnetic pole has a first magnetic pocket for receiving a magnet.In the first end face of the laminated core, the first magnet pocket has a first magnet receiving opening, so that the first magnet can be inserted into the first magnet pocket via the first magnet receiving opening and is preferably inserted there. The first magnet arranged in the first magnet pocket is held in the first magnet pocket by a stapling, in particular by a stapling point. It is provided that the first magnet is held in the first magnet pocket by a stapling of the first end face, wherein the stapling point in the first end face is preferably formed by a stapling tool. The second end face is free of stapling points in the area of ​​the first magnet pocket. In other words, the first magnet is fixed in the first magnet pocket by a stapling of the laminated core on one side, here the first end face of the laminated core, in or spaced apart from an edge region of the first magnet receiving opening. By means of the 202401228.

[0016] 4

[0017] When the first end face is riveted, one or more sheets in the edge region of the first magnet pocket are plastically deformed, causing the material of the laminated core to shift into the first magnet pocket and clamp the first magnet in place. "Ram-point-free" means that the laminated core or the second end face in the area of ​​the first magnet pocket is not plastically deformed by riveting in such a way as to fix or hold the first magnet in the first magnet pocket.

[0018] By crimping the laminated core on one side, the axial distance between the contact points between the core and the first magnet can be reduced. At these contact points, the contact resistance is lowest, so that an eddy current to a second magnet at the magnetic pole is conducted axially along the laminated core only through a few laminations in the area of ​​the contact point. The contact resistance of the first magnet to the laminated core outside the contact points is greater and negligible.However, if the first magnet in the laminated core is fixed in place by riveting the core to both the first and second end faces, as is known in the prior art, the contact resistances of the magnet are lowest at the respective ends of the magnet with respect to the axial direction of the laminated core. This allows the eddy currents to extend along the entire axial length of the magnet and transversely through the laminated core to its longitudinal direction. In other words, the invention provides that the contact resistance between the first magnet and the first end face is lower than the contact resistance between the first magnet and the second end face of the laminated core.

[0019] The invention described above therefore provides a rotor in which eddy currents within the laminated core or the rotor can be reduced in a simple and cost-effective manner, namely by crimping the laminated core on one side. 202401228

[0020] 5

[0021] An advantageous embodiment of the invention comprises a second magnet pocket, which has a second magnet receiving opening in its first end face, and in which a second magnet is arranged. The second magnet is positively locked in the second magnet pocket by a riveting point in the laminated core, and the riveting point is formed on the first end face, while the second end face is free of riveting points in the region of the second magnet pocket. In other words, the second magnet, like the first magnet, is positively locked and / or force-locked in the magnet pocket solely by riveting from the first end face. The second end face is free of riveting points. Consequently, an eddy current in the magnet pole in the axial direction of the laminated core BP is reduced to the depth of the riveting point VP.A further advantage is that the crimps, in particular all crimps, for fixing the magnets in the magnet pockets are formed exclusively on the first end face. Rotating the laminated core for crimping is therefore unnecessary, which can have a beneficial effect on the manufacturing costs of the laminated core or the rotor.

[0022] Alternatively, a preferred embodiment provides that the magnetic pole comprises a second magnetic pocket which has a second magnet receiving opening in the second end face, and a second magnet is arranged in the second magnetic pocket, wherein the second magnet is positively locked in the second magnetic pocket by a riveting point in the laminated core, and the riveting point is formed on the second end face, and the first end face is free of riveting points in the area of ​​the second magnetic pocket.In other words, two magnets are provided, wherein the first magnet is fixed in the first magnet pocket by crimping the first end face in the first magnet pocket, wherein the second end face is formed without crimping points in the area of ​​the first magnet pocket, and the second magnet is fixed in the second magnet pocket by crimping the second end face in the second magnet pocket, wherein the first end face is formed without crimping points in the area of ​​the second magnet pocket. This can advantageously reduce the formation of eddy currents between the two magnets of a magnetic pole 202401228.

[0023] 6. This is because the contact resistance of the two magnets is reduced only on one side and on opposite sides.

[0024] Advantageously, the riveting point is positioned at a distance from the perimeter of the respective magnet receptacle, so that the material of the sheet metal of the first end face, and preferably of the directly and / or indirectly adjacent sheets, is plastically deformed in such a way that it can fix the first magnet in the first magnet pocket in a form-fit and / or force-fit manner. The same applies accordingly to the second magnet in the second magnet pocket.

[0025] The riveting point preferably has a center point. The center point of the riveting point is particularly preferably located between 1 mm and 2 mm, preferably between 1.2 mm and 1.8 mm, and particularly preferably between 1.4 mm and 1.6 mm from the edge or rim of the first magnet receiving opening in the undeformed state of the sheet metal.

[0026] The distance between the center of the riveting point and the edge of the magnetic pocket can be selected depending on the riveting tool chosen. The riveting tool preferably has a riveting tip. The riveting tip has a round or oval cross-section, preferably perpendicular to a longitudinal direction of the riveting tip. The section of the riveting tip that penetrates at least partially into the sheet metal and / or the laminated core has a maximum cross-sectional outer dimension of between 1.1 mm and 1.7 mm, preferably between 1.2 mm and 1.6 mm, and most preferably between 1.3 mm and 1.5 mm.

[0027] It goes without saying that the larger the cross-section of the caulking tip, the greater the distance between the center of the caulking point and the edge of the magnet receiving opening. If the cross-section of the caulking tip is smaller, the distance between the 202401228

[0028] 7

[0029] The center point of the crimping point and the rim of the magnet receiving opening are reduced.

[0030] It is advantageously provided that the cross-section of the riveting tool and the distance between the center of the riveting point and the perimeter are selected before the deformation of the sheet metal such that the smallest distance between the riveting point and the perimeter of the magnetic pocket is between 0.6 mm and 1 mm, preferably between 0.7 mm and 0.9 mm, and preferably 0.8 mm.

[0031] Before caulking, the first magnet surrounding the first magnet pocket preferably has a minimum gap and / or space of between 0.07 mm and 0.18 mm, preferably between 0.07 mm and 0.13 mm, and most preferably between 0.07 mm and 0.10 mm, including the limits. In other words, this minimum gap is present before caulking between the edge of the first magnet pocket and the first magnet, particularly in the area that is plastically deformed by the caulking process. After caulking, there is a zero gap in this local area between the first magnet and the edge of the first magnet receiving opening or the first magnet pocket of the deformed sheet.

[0032] The same procedure applies analogously to the second magnet.

[0033] It is conceivable, and not excluded, that the first magnet is additionally fixed in the first magnetic pocket using a material-bonded material. A similar arrangement could be made for the second magnet in the second magnetic pocket.

[0034] Advantageously, it is provided that for a number of sheets XBL of a lamination stack, the following applies: 25 < XBL 125, preferably 50 < XBL 100, particularly preferably 60 < XBL 90. This means that the lamination stack has a plurality of sheets, the number of sheets preferably depending on the 202401228

[0035] 8. The power of the rotor or electric machine or traction drive is selected or defined.

[0036] It is conceivable that for a sheet thickness dßL in the axial direction of the laminated core, the following applies: 0.1 mm < dßL 1 mm, preferably 0.1 mm < dßL 0.7 mm, particularly preferably 0.1 mm < dßL < 0.4 mm. The thinner the sheets and the shallower the riveting depth, the lower the eddy current losses. However, thin sheets can be somewhat more expensive. Therefore, with cost savings in mind, slightly thicker sheets can also be used, reducing the number of sheets joined together by single-sided riveting to thus reduce the formation of eddy currents in a magnetic pole.

[0037] In an advantageous embodiment of the invention, the riveting depth of the riveting point extends in the axial direction of the laminated core over a maximum of 7 sheets, preferably over a maximum of 5 sheets, and particularly preferably over a maximum of 3 sheets. The fewer sheets that are plastically deformed, and the smaller the thickness of the sheets, the shorter the length of the contact point to the first magnet and / or second magnet in the axial direction of the laminated core, resulting in reduced contact resistance, which can ultimately have a beneficial effect on reducing eddy currents.

[0038] A preferred embodiment of the invention is characterized in that the first magnet and / or the second magnet has an electrically insulating coating. The coating can increase the contact resistance at the contact point between the laminated core and the first magnet and / or the second magnet, thereby reducing eddy currents. However, the coating may adversely affect the cost.

[0039] The coating is preferably a plastic coating.

[0040] Alternatively, a preferred embodiment of the invention provides that the first magnet and / or the second magnet is uncoated. (202401228)

[0041] In other words, the first magnet and / or the second magnet has no electrically insulating coating on its outer surface. This reduces the cost of the magnet(s) and consequently the cost of the rotor. Furthermore, in conjunction with the one-sided crimping of the magnet(s), this also reduces eddy currents within the rotor.

[0042] According to an advantageous embodiment of the invention, the individual sheets of the laminated core are connected to each other by a positive fit and / or a material bond. A positive fit preferably refers to a stamping process to assemble the sheets into a laminated core. The material bond is preferably an adhesive bond. In this way, the sheets can preferably be arranged and connected to each other in an electrically insulating manner in the axial direction of the laminated core. The material bond can increase the electrical resistance of the sheets relative to each other, which can advantageously reduce eddy currents.

[0043] The bonding can be applied at specific points or across the entire surface. A bonded connection at specific points can save material and therefore costs. A bonded connection across the entire surface can have a beneficial effect on the noise, vibration, and harshness (NVH) behavior of the rotor, reducing the risk of individual laminations within a laminated core flaking. Furthermore, the electrical resistance between the laminations can be increased, which can have a positive effect on the formation of eddy currents.

[0044] In this context, a preferred embodiment of the invention provides that the individual sheets are bonded together by means of a baking varnish. The baking varnish can preferably be sprayed or laminated onto the sheet blank before the sheets are punched out. Punching out the sheets thus preferably enables a complete coating with the baking varnish in a simple manner. By pressing the sheets together, the bond is achieved.

[0045] Ten stacked sheets of metal are bonded together, and through the application of heat, the baking lacquer connects the respective adjacent sheets to each other, creating a sheet metal package in which the sheets are materially bonded, electrically insulating and permanently connected.

[0046] An advantageous embodiment of the invention provides that the rotor has a plurality of laminated cores, wherein the first end face of one laminated core abuts the second end face of an immediately adjacent laminated core. In other words, it is provided that the first end faces of two adjacent laminated cores do not abut each other in order to avoid an increased eddy current concentration of adjacent laminated cores.

[0047] An advantageous further development of the invention lies in the fact that the rotor has a plurality of laminated stacks which are preferably arranged offset from each other in the circumferential direction.

[0048] In a second aspect, the invention relates to a traction drive for a motor vehicle that is at least partially electrically powered, with the rotor according to the invention.

[0049] The traction drive is preferably designed and configured to power the motor vehicle at least partially, and preferably completely, electrically. The rotor is preferably part of an electric machine of the traction drive, wherein the electric machine comprises the rotor and a stator spaced apart from the rotor by an air gap. The reduced eddy current losses of the rotor minimize additional eddy current-induced heating of the rotor, thereby increasing the efficiency of the traction drive.

[0050] In a third aspect, the invention relates to a method for manufacturing the rotor according to the invention, wherein the laminated core comprising a plurality of laminations is provided, wherein a first magnet pocket is formed in the laminated core, and the first magnet is inserted into the first magnet pocket, 202401228

[0051] 11 wherein the first magnet is fixed in the first magnet pocket by riveting the first end face of the lamination stack, and the second end face in the area of ​​the first magnet pocket is not riveted.

[0052] According to the third aspect of the invention, the first magnet is fixed in the first magnet pocket by crimping the laminated core on one side, specifically the first end face, so that the contact resistance between the first magnet and the first end face is lower than the contact resistance between the second end face and the first magnet. This reduces the eddy currents of the rotor in its axial direction, which can have a beneficial effect on the performance of the electric machine or traction drive.

[0053] It is conceivable that, prior to the placement of the first magnet in the first magnet pocket, the laminations of the laminated core are joined together to form a single core using a stamping process and / or an interlocking mechanism. Joining the laminations into a single core can offer manufacturing advantages and simplify handling. This can have a positive impact on production costs. Furthermore, it can reduce the tendency of the individual laminations to fan out under centrifugal force, which can have a beneficial effect on rotor noise.

[0054] Alternatively or additionally, a preferred embodiment of the invention provides that, prior to the placement of the first magnet in the first magnet pocket, the laminations of the laminated core are bonded together by a bonding process. This allows the laminated core to be manufactured independently of the magnet insertion process, thereby optimizing process sequences. A further advantage is that, during the pressing and bonding of the laminations to form a laminated core, a small amount of the bonding lacquer or an adhesive material penetrates the first magnet pocket. This excess material acts as an insulating gap when the first magnet is inserted, thus reducing the contact resistance.

[0055] 12 can be increased between the first magnet and the laminated core, thereby reducing or minimizing eddy currents.

[0056] Preferably, the magnet is held in the magnetic pocket exclusively by a form-fitting connection.

[0057] Alternatively, a preferred embodiment of the invention provides that, after the first magnet is positioned in the first magnet pocket and before the first end face is crimped, the laminations of the laminated core are bonded together by a bonding process. This allows excess adhesive material, preferably a bonding lacquer, which flows into the first magnet pocket during the crimping and bonding process, to further bond the magnet within the pocket. This additional bond can increase the contact resistance between the laminated core and the first magnet, thereby reducing or minimizing eddy currents.

[0058] Finally, a preferred embodiment of the invention provides that the magnetic pole has a second magnetic pocket, wherein the second magnet is arranged in the second magnetic pocket and the second magnet is fixed in the second magnetic pocket by means of a one-sided riveting of the lamination stack, wherein either the first end face in the area of ​​the second magnetic pocket or the second end face in the area of ​​the second magnetic pocket is riveted by means of a riveting tool.

[0059] It should be noted that all features described above and below with respect to one aspect of the present invention apply equally to every other aspect of the present invention. In particular, all features of the rotor can apply equally to the traction drive and / or to the method for manufacturing the rotor. The reverse is also true. 202401228

[0060] 13

[0061] Further features and advantages of the present invention will become apparent from the dependent claims and the following exemplary embodiments. These exemplary embodiments are not intended to be limiting, but rather to be understood as illustrative. They are meant to enable a person skilled in the art to carry out the invention. The applicant reserves the right to make one or more of the features disclosed in the exemplary embodiments the subject of patent claims, or to include such features in existing patent claims. The exemplary embodiments are explained in more detail with reference to the drawings.

[0062] These show:

[0063] Fig. 1 shows a section of a three-dimensional view of a laminated core for a rotor, as known from the prior art.

[0064] Fig. 2 shows a section of a three-dimensional view of a laminated core for a rotor according to the invention.

[0065] Figure 1 shows a section of a three-dimensional view of a laminated core BP for a rotor RO, as known from the prior art. The laminated core BP comprises a plurality of laminations arranged one behind the other. A magnetic pole MP is formed in the laminated core BP, comprising a first magnetic pocket MT1 and a second magnetic pocket MT2. The first magnetic pocket MT1 and the second magnetic pocket MT2 each extend through the entire laminated core BP in an axial direction between a first end face ES and a second end face ZS of the laminated core BP, which is spaced axially apart. The first magnetic pocket MT1 and the second magnetic pocket MT2 have corresponding magnet receiving openings MAO in the first end face ES and the second end face ZS.

[0066] Each of the first magnetic pocket MT1 and the second magnetic pocket MT2 contains a magnet MA. The magnet MA in the first magnetic pocket MT1 is secured by crimping, or by forming a 202401228

[0067] 14

[0068] The first magnet pocket MT1 is positively and force-fit held by a riveting point VP, connecting the first end face ES and the second end face ZS at the edge of the magnet receiving opening MAO. Similarly, the magnet MA, located in the second magnet pocket MT2, is positively and force-fit held by a riveting point VP, connecting the first end face ES and the second end face ZS at the edge of the magnet receiving opening MAO. This riveting of the first end face ES and the second end face ZS plastically deforms the respective outer sheet, as well as the adjacent sheets of the laminated core BP, pressing them against the magnet MA. The contact resistance is reduced in the contact areas KB between the sheets and the magnet MA.This results in a closed magnetic flux in the magnetic pole MP between the magnet MA of the first magnet pocket MT1 and the magnet MA of the second magnet pocket MT2, extending over the entire depth of the magnets MA in the axial direction of the laminated core BP and through the outer laminations in the transverse direction of the laminated core BP. Such eddy currents WS can further heat the rotor, thus negatively impacting the performance of the rotor RO and / or the traction drive.

[0069] Figure 2 shows a section of a three-dimensional view of the laminated core BP for the rotor RO according to the preferred embodiment of the invention. The laminated core BP comprises a plurality of individual laminations arranged one behind the other. The present laminated core preferably comprises 75 individual laminations, each with a thickness of 0.3 mm. However, a higher or lower number of laminations is also conceivable. Likewise, the lamination thickness can be different, such as preferably—but not limited to—0.2 mm or even more preferably 0.4 mm.

[0070] The laminated core BP is annular in shape, with only a section shown in Fig. 2. According to the preferred embodiment, the laminated core BP has a first end face ES which is aligned and / or formed in an axial direction of the laminated core BP. In the axial direction of the 202401228

[0071] 15

[0072] The laminated core BP has a second end face ZS, spaced apart from the first end face ES. Furthermore, the laminated core BP includes a magnetic pole MP. The magnetic pole MP has a first magnetic pocket MT1 for receiving a first magnet MA1. In the first end face ES of the laminated core BP, the first magnetic pocket MT1 has a first magnet receiving opening MA01, so that the first magnet MA1 can be inserted and / or is inserted into the first magnetic pocket MT1 via the first magnet receiving opening MA01.

[0073] The first magnet MA1, located in the first magnetic pocket MT1, is held in place by a rivet, specifically by a rivet point VP. The first magnet MT1 is held in place by riveting the first end face ES, where the rivet point VP is formed by a riveting tool. The second end face ZS is free of rivet points in the area of ​​the first magnetic pocket MT1. In other words, the first magnet MA1 is positively and / or force-fitted in the first magnetic pocket MT1 by riveting the laminated core BP, specifically the first end face ES of the laminated core BP, either within or at a distance from an edge region of the first magnet receiving opening MA01.By caulking the first end face ES, one or more sheets in the edge region of the first magnet receptacle MA01 are plastically deformed, causing the sheet material to shift into the first magnet pocket MT1 and clamp the first magnet MA1. "Casting point-free" means that the sheet stack BP or the second end face ZS in the area of ​​the first magnet pocket MT1 is not plastically deformed by caulking in such a way as to fix or hold the first magnet MA1 in the first magnet pocket MT1.

[0074] By riveting the laminated core BP on one side, the axial distance between the contact points KP of the laminated core BP and the first magnet MA1 can be reduced. At these contact points KP, the contact resistance is lowest, so that an eddy current WS to a second magnet MA2 of the magnetic pole MP in 202401228

[0075] The axial direction of the laminated core BP is guided only over a few sheets in the region of the contact point KP. The contact resistance of the first magnet MA1 to the laminated core BP outside the contact points KP is greater and therefore negligible, since there is no positive or frictional connection between the first magnet MA1 and the laminated core BP outside the contact point KP. In other words, according to the invention, the contact resistance between the first magnet MA1 and the first end face ES is lower than the contact resistance between the first magnet MA1 and the second end face ZS of the laminated core BP.

[0076] As mentioned in the preceding paragraph, the magnetic pole MP has a second magnet MA2 in a second magnet pocket MT2 extending through the laminated core BP. Like the first magnet MA1, the second magnet MA2 is fixed in the second magnet pocket MT2 by a positive-locking and / or force-locking connection solely through a riveting point VP on the first end face ES of the laminated core BP. The second end face ZS is free of riveting points in the area of ​​the first magnet pocket MA1. Consequently, an eddy current WS in the magnetic pole MP in the axial direction of the laminated core BP is reduced to the depth of the riveting point VP.

[0077] The described embodiment provides a laminated core BP for a rotor RO, in which the eddy currents WS within the rotor RO can be reduced in a simple and cost-effective manner, namely by crimping the laminated core BP on one side to fix the magnets MA1 and MA2. The reduced eddy currents WS minimize additional heating of the rotor. Reduced heating of the rotor RO can have a beneficial effect on the performance of the electric machine or the traction drive.

Claims

202401228 17 Patent claims 1. Rotor (RO) for an electric machine of an at least partially electrically powered motor vehicle, comprising a laminated core (BP) having a plurality of individual laminations arranged one behind the other, wherein the laminated core (BP) has a first end face (ES) and a second end face (ZS) spaced apart in the axial direction of the laminated core (BP), wherein a magnetic pole (MP) is formed in the laminated core (BP), wherein the magnetic pole (MP) comprises a first magnet pocket (MT1) having a first magnet receiving opening (MAO1) in the first end face (ES), and wherein a first magnet (MA1) is arranged in the first magnet pocket (MT1), wherein the first magnet (MA1) is positively locked in the first magnet pocket (MT1) by a riveting point (VP) in the laminated core (BP), and the riveting point (VP) is formed on the first end face (ES), and the second end face (ZS) is formed without riveting points in the region of the first magnet pocket (MT1). is.

2. Rotor according to claim 1, characterized in that the magnetic pole (MP) comprises a second magnetic pocket (MT2) which has a second magnet receiving opening (MA02) in the first end face (ES), and a second magnet (MA2) is arranged in the second magnetic pocket (MT2), wherein the second magnet (MA2) is positively locked in the second magnetic pocket (MT2) by a riveting point (VP) in the laminated core (BP), and the riveting point (VP) is formed on the first end face (ES), and the second end face (ZS) is formed without riveting points in the area of ​​the second magnetic pocket (MT2).

3. Rotor according to claim 1, characterized in that the magnetic pole (MP) comprises a second magnetic pocket (MT2) which has a second magnetic receiving opening (MA02) in the second end face (ZS), and a second magnet (MA2) is arranged in the second magnetic pocket (MT2), wherein the second magnet (MA2) is positively locked in the second magnetic pocket (MT2) by a riveting point (VP) in the laminated core (BP), and the riveting point (VP) is formed on the second end face (ZS), and the first end face (ES) in the area of ​​the second magnetic pocket (MT2) is formed without riveting points. 202401228 18 4. Rotor according to one of the preceding claims, characterized in that a riveting depth of the riveting point (VP) extends in the axial direction of the laminated core (BP) over a maximum of 7 sheets.

5. Rotor according to one of the preceding claims, characterized in that the first magnet (MA1 ) is designed without coating.

6. Rotor according to one of the preceding claims, characterized in that the individual laminations of the laminated core (BP) are positively connected and / or materially connected to one another.

7. Rotor according to one of the preceding claims, characterized in that the rotor (RO) has a plurality of laminated cores (BP), wherein the first end face (ES) of a laminated core (BP) adjoins the second end face (ZS) of an immediately adjacent laminated core (BP).

8. Rotor according to one of the preceding claims, characterized in that the first magnet (MA1 ) for surrounding the first magnet pocket (MT1 ) preferably has a minimum distance and / or gap which has a size between 0.07 mm and 0.18 mm, preferably between 0.07 mm and 0.13 mm and most preferably between 0.07 mm and 0.10 mm, the limits being included.

9. Rotor according to one of the preceding claims, characterized in that the riveting point (VP) has a center point, wherein the center point of the riveting point (VP) is particularly preferably a distance between 1 mm and 2 mm, preferably between 1.2 mm and 1.8 mm, and particularly preferably between 1.4 mm and 1.6 mm from the edge and / or perimeter of the first magnet receiving opening (MA01) in the undeformed state of the sheet.

10. Rotor according to one of the preceding claims, characterized in that a minimum distance between the riveting point (VP) and the 202401228 19 The perimeter of the first magnet receiving opening (MAO1) is between 0.6 mm and 1 mm, preferably between 0.7 mm and 0.9 mm, and particularly preferably 0.8 mm, including the limits.

11. Traction drive for a motor vehicle that is at least partially electrically powered, comprising a rotor (RO) according to one of the preceding claims.

12. Method for manufacturing a rotor (RO) according to any one of claims 1 to 10, wherein the laminated core (BP) comprising a plurality of laminations is provided with the first magnet pocket (MT1), the first magnet (MA1) is inserted into the first magnet pocket (MT1), and subsequently the first magnet (MA1) is fixed in the first magnet pocket (MT1) by riveting the first end face (ES) of the laminated core (BP), and the second end face (ZS) in the area of ​​the first magnet pocket (MT1) is not riveted.

13. Method according to claim 12, characterized in that, prior to the arrangement of the first magnet (MA1 ) in the first magnet pocket (MT1), the sheets of the laminated core (BP) are bonded together by a material bonding process.

14. Method according to claim 13, characterized in that after arranging the first magnet (MA1) in the first magnet pocket (MT1) and before caulking the first end face (ES), the sheets of the laminated core (BP) are bonded together by a bonding process.

15. Method according to one of claims 12 to 14, characterized in that the magnetic pole (MP) has a second magnetic pocket (MT2), wherein the second magnet (MA2) is arranged in the second magnetic pocket (MT2) and the second magnet (MA2) is fixed in the second magnetic pocket (MT2) by staking the laminated core (BP) on one side, wherein either the first end face (ES) in the area of ​​the second magnetic pocket (MT2) or the second end face (ZS) in the area of ​​the second magnetic pocket (MT2) is staking by means of a staking tool.

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