Rotor having a closure cover, closure cover for a rotor, electric drive machine having a rotor, and motor vehicle having an electric drive machine
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- Filing Date
- 2026-01-16
- Publication Date
- 2026-08-13
Smart Images
Figure DE2026100039_13082026_PF_FP_ABST
Abstract
Description
[0001] 24-1714 PIF
[0002] Rotor with a cover, cover for a rotor, electric drive motor with a rotor, and motor vehicle with an electric drive motor
[0003] The invention relates to a rotor for an electric drive motor, with an end cap having an inner surface. Further aspects of the invention relate to an end cap for such a rotor, an electric drive motor with such a rotor, and a motor vehicle.
[0004] Such an end cap serves, for example, to prevent unwanted leakage of potting compound, especially resin, during the potting of the rotor, and to dissipate heat during the intended use of the rotor as a component of an electric drive machine. The rotor can have two end caps arranged opposite each other in the axial direction of the rotor, which seal the rotor against unwanted leakage of potting compound and thus close it off.
[0005] The object of the present invention is to provide a rotor of the type mentioned above in which the respective rotor components are joined together in an improved manner. It is further an object of the invention to provide an end cap for such a rotor, an electric drive motor with such a rotor, and a motor vehicle.
[0006] This problem is solved by a rotor with the features of claim 1, by an end cover with the features of claim 8, by an electric drive motor with the features of claim 9, and by a motor vehicle according to claim 10. Advantageous embodiments with expedient further developments of the invention are specified in the dependent claims.
[0007] A first aspect of the invention relates to a rotor for an electric drive machine, with an end cover having an inner surface of the end cover facing a laminated core of the rotor, on which at least one recess is arranged, which is designed as an undercut for receiving potting compound during the manufacture of the rotor and on which the end cover is secured by at least one
[0008] The recess, as well as the hardened potting compound within it, fixes the rotor components against displacement in at least one spatial direction relative to the lamination stack. This is advantageous because the recess, designed as an undercut, allows for improved joining of the rotor components, which include the end cap and the lamination stack. The potting compound used in manufacturing, as a solidified body, engages in the recess, thereby ensuring a secure and captive fixation of the rotor components. This type of joining using the potting compound eliminates the need for additional components such as screws or a complex bayonet fitting to connect the end cap to the other rotor components.In other words, the end cover can be fixed without screws and / or bayonet connections relative to the offset to the lamination stack by means of at least one recess designed as an undercut and the potting compound that has solidified in the recess, so that the rotor components are joined together in an improved manner overall.
[0009] The invention is based on the understanding that, without securing the end cap, it can migrate, particularly in the axial direction of the rotor, over the service life of the electric drive motor. Furthermore, it is based on the understanding that conventional securing of the end cap via screw elements (bolts) or a bayonet fitting creates potential leakage points for the unwanted escape of cooling medium, especially oil. Sealing these leakage-prone areas requires increased assembly effort and additional components, resulting in high costs. Moreover, the preload required for the screw connection necessitates a more robust rotor design, thus requiring thicker walls and greater material usage than is the case with the invention.
[0010] In an advantageous embodiment of the invention, the end cap is connected to a star disk of the rotor and to rotor windings of the rotor via the at least one recess and through the potting compound that has solidified therein. This is advantageous because the star disk represents a particularly stable rotor component that can be arranged between the lamination stack (rotor lamination stack) and the end cap and thus be directly joined to the end cap via the solidified potting compound and the at least one recess. In other words, this provides a direct connection between the rotor component "star disk" and the rotor component "end cap". 24-1714 PIF
[0011] In a further advantageous embodiment of the invention, the at least one recess prevents offset in the axial direction of extension, i.e., the at least one spatial direction of the rotor. This is advantageous because it eliminates the need for bores—which are potential leakage points—in the end cover for its fastening by means of screw elements.
[0012] In a further advantageous embodiment of the invention, the at least one recess prevents misalignment in the circumferential direction as in the at least one spatial direction of the rotor. This advantageously prevents relative rotation between the end cap and the laminated core without the need for a screw connection. In other words, relative rotation between the end cap and the laminated core can be prevented.
[0013] In a further advantageous embodiment of the invention, the end cap has, in addition to the at least one recess, at least one additional recess designed as an undercut on its inner surface, which prevents displacement in the circumferential and / or axial direction of the rotor. Thus, the end cap as a whole can be prevented from displacement in various directions by means of several recesses in which the solidified potting compound is arranged.
[0014] In a further advantageous embodiment of the invention, the at least one recess and the at least one additional recess are arranged offset from one another in the radial direction of the rotor on the inner surface of the end cap. This advantageously enables the end cap to be secured at several radially offset points, resulting in a particularly stable positive fit between the hardened potting compound and the end cap.
[0015] In a further advantageous embodiment of the invention, the at least one recess and the at least one additional recess are shaped differently. This makes it possible to secure the end cap against unwanted relative movement in several different spatial directions in a simple manner.
[0016] A second aspect of the invention relates to an end cap for a rotor according to the first aspect of the invention. Such an end cap can be made without screws. 24-1714 PIF
[0017] The undercut allows the rotor components to be fixed in place, enabling them to be joined together in an improved manner.
[0018] A third aspect of the invention relates to a drive machine with a rotor according to the first aspect of the invention. Such a drive machine is assembled with an overall reduction in the number of components.
[0019] A fourth aspect of the invention relates to a motor vehicle with a drive motor according to the third aspect of the invention. In such a motor vehicle, the drive motor is particularly durable with regard to damage resulting from an undesired migration of the end cover.
[0020] The preferred embodiments and their advantages presented with respect to one of the aspects apply accordingly to the other aspects of the invention and vice versa.
[0021] The features and combinations of features mentioned above in the description, as well as the features and combinations of features mentioned below in the figure description and / or shown in the figures alone, can be used not only in the combination specified in each case, but also in other combinations or on their own, without leaving the scope of the invention.
[0022] Further advantages, features and details of the invention will become apparent from the claims, the following description of preferred embodiments and the drawings.
[0023] The invention is explained below again using a specific embodiment. This is illustrated by:
[0024] Fig. 1 is an abstract representation of a motor vehicle with an electric drive motor, the rotor of which has a cover, which is shown in a schematic perspective view;
[0025] Fig. 2 shows a detailed view of an area X outlined with a dashed line in Fig. 1.
[0026] End cap; 24-1714 PIF
[0027] Fig. 3 shows a sectional view of area X, in which a recess is visible which is designed as an undercut, wherein a section plane underlying the sectional view extends in the radial extension direction of the rotor in the installed position of the end cover between two adjacent poles of the rotor and through a rotation axis of the end cover and the rotor; and
[0028] Fig. 4 shows a further sectional view of a partial area of the end cover in which an additional recess is arranged, which is designed as an additional undercut, wherein a section plane underlying the further sectional view extends in the installation position of the end cover between two adjacent poles of the rotor and extends through the axis of rotation of the end cover and the rotor.
[0029] Fig. 1 shows a schematic perspective view of an end cover 20 for a rotor 10 of an electric drive motor 100, which serves as a traction motor for a motor vehicle K. The rotor 10, the drive motor 100 and the motor vehicle K are represented in abstract form in Fig. 1.
[0030] The end cap 20 has an inner surface 22 which, in the installed position of the end cap 20, faces a lamination stack of the rotor 10 (not shown here) as a rotor component. The lamination stack, as well as a star disk of the rotor 10 (also not shown here), each constitute a further rotor component.
[0031] On the inner surface of the end cap 22, several recesses 30 are arranged, each designed as an undercut for receiving potting compound 80 during the manufacture of the rotor 10. The potting compound 80, also called potting material, can be made of or comprise resin. During the manufacture of the rotor 10, the potting compound 80 is initially in a liquid state, allowing it to flow during a potting process into gaps and spaces that may be located between the end cap 20 and adjacent rotor components, particularly those directly adjacent in the axial direction, such as the star disk or rotor windings. The potting compound 80 eventually solidifies in these gaps and spaces and is present in the finished rotor 10 as solidified potting compound 80. 24-1714 PIF
[0032] On the inner surface 22 of the end cover, the end cover 20 is fixed in various spatial directions A, R, U—namely, in the axial direction A, in the radial direction R, and in the circumferential direction U—relative to the lamination stack by the recesses 30 and by the cast iron compound 80 solidified therein, with respect to a respective offset. The spatial directions A, R, U are indicated by double arrows in Figures 1 to 4. A rotation axis 12 of the rotor 10, around which the rotor 10 rotates during operation in the drive machine 100, runs coaxially to the axial direction A. The rotation axis 12 passes centrally through a rotor shaft receiving opening 21 of the end cover 20. When the rotor 10 is fully assembled, a rotor shaft of the rotor 10 (not shown here) can extend through the rotor shaft receiving opening 21 in the axial direction A.
[0033] Preferably and generally applicable, the end cap 20 can have a recess 30 on its inner surface 22 for each pole of the rotor 10, as shown in Fig. 1. In total, the end cap 20 can thus have six recesses 30, as shown here, each of which is designed as an undercut and of which each of the recesses 30 can be assigned to one of the six poles of the rotor 10. The recesses 30 can be spaced regularly apart from each other in the circumferential direction U, such that an internal angle α with a magnitude of 60° can extend between two adjacent recesses 30. The legs defining the internal angle α extend to the center of each adjacent recess 30, as shown in Fig. 1. In other words, the internal angle α is referenced to the respective centers of the adjacent recesses 30.
[0034] The end cap 20 has, on its inner surface 22, in addition to the recesses 30, at least one additional recess 40 designed as an additional undercut. The additional recess 40 can also be referred to as an additional undercut. The end cap 20 can generally be fixed to the star disk of the rotor 10 via the at least one recess 30 and by the potting compound 80 solidified therein, and additionally or alternatively via the at least one additional recess 40 and by the potting compound 80 solidified therein.
[0035] Each of the recesses 30, as well as each of the additional recesses 40, can be convex outwards in the radial direction R and partially in a trough-like or channel-like shape. The casting compound 80 solidifies in the recesses 30 and additionally or alternatively in the additional recesses 40, as shown in example 24-1714 PIF.
[0036] As shown section by section in Fig. 3 and Fig. 4, the potting compound 80 in the recesses 30 or the additional recesses 40 secures the end cover 20 against an undesired sliding or displacement in the axial direction A.
[0037] In the present case, the end cover 20 has a total of six additional recesses 40, which can prevent the offset in the circumferential direction U and additionally or alternatively in the axial extension direction A of the rotor 10 and additionally or alternatively in the radial extension direction.
[0038] Each pair of adjacent additional recesses 40 of the total six additional recesses 40 also encloses an interior angle α with a magnitude of 60° with respect to the respective centers of the adjacent additional recesses 40. In the circumferential direction U, an additional recess 40 follows each recess 30 at a regular spacing angle β with a magnitude of 30°, followed by the next recess 30, and so on, as shown in Fig. 1.
[0039] The recesses 30 and the additional recesses 40 are arranged offset from each other in the radial extension direction R of the rotor 10 on the inner surface 22 of the end cover 20, as also shown in Fig.
[0040] 1. It can be seen that the recesses 30 are located further outwards in the radial direction R on the inner surface 22 of the end cover than the additional recesses 40.
[0041] By comparing Fig. 1 with Fig. 2, Fig. 3, or Fig. 4, it can be seen that the recesses 30 and the additional recesses 40 are shaped differently. Looking at Fig. 2, it becomes clear from a single recess 30 that each recess 30 has a recess center area 32, which is arranged between a first recess side area 34 and a second recess side area 36 with respect to the circumferential direction U. Starting from the recess center area 32, both recess side areas 34, 36 are curved inwards in the radial extension direction R, so that both a first recess end 35 assigned to the first recess side area 34 and a second recess end 37 opposite the first recess end 35 in the circumferential direction U, which is assigned to the second recess side area 36, are each located further inwards in the radial extension direction R than the recess center area 32.This advantageously causes the recesses 30 to seal the end cover 20 against a 24-1714 PIF based on the castable compound 80 solidified therein.
[0042] This can prevent unwanted rotation in the circumferential direction U relative to the lamination stack and other rotor components.
[0043] The same applies to the additional recesses 40, one of which is shown in detail in Fig. 4. The additional recess 40 has an additional recess center region 42, which is arranged with respect to the circumferential direction U between a first additional recess side region 44 and a second additional recess side region 46. In contrast to the recesses 30, however, both additional recess side regions 44, 46 of the additional recesses 40 are curved outwards in the radial direction R starting from the additional recess center region 42.As a result, both a first additional recess end 45 assigned to the first additional recess side area 44 and a second additional recess end 47 opposite the first additional recess end 45 in circumferential direction U, which is assigned to the second additional recess side area 46, are located further outwards in radial extension direction R than the additional recess center area 42.
[0044] Because the recess side areas 32, 34 are curved inwards in the radial extension direction R and the additional recess side areas 42, 44 are curved outwards in the radial extension direction R, the solidified potting compound 80 in the recesses 30 and the additional recesses 40 causes a blocking of relative movements of the end cover 20 relative to the other rotor components in all mentioned spatial directions A, R, U particularly reliably.
[0045] In general, the recesses 30 and additionally or alternatively the additional recesses 40 prevent the offset of the end cover 20 relative to the other rotor components, in particular to the star disk, in the axial direction A, in the radial direction R and in the circumferential direction U as the respective spatial directions A, R, U of the rotor 10.
[0046] The end cover 20 can be securely fixed to the other rotor components, especially the star disk, without screws and thus without screw elements, solely by means of the potting compound 80 that has solidified in the recesses 30 and additionally or alternatively by means of the potting compound 80 that has solidified in the additional recesses 40.
[0047] In summary, the recesses 30 and additional recesses 40 of the end cover 20 create respective geometric undercuts, which are shown on the24-1714 PIF
[0048] The inner surface 22 of the end cover is arranged in recesses and is filled with the initially liquid potting compound 80 during the potting of the rotor 10. After the potting compound 80 has hardened, it exists as a solidified potting compound 80 and, by engaging the recesses 30 and additionally or alternatively the auxiliary recesses 40, blocks any undesired twisting or migration of the end cover 20 in various spatial directions A, R, II, which include, in particular, the axial direction A of the rotor 10 and the end cover 20, the radial direction R of the rotor 10 and the end cover 20, and the circumferential direction U of the rotor 10 and the end cover 20.This advantageously eliminates the need for screw elements or at least reduces the number of screw elements required for mounting the end cap 20, resulting in simplified assembly and a reduction in potential leakage points.24-1714 PIF.
[0049] Reference symbol list
[0050] 10 Rotor
[0051] 12 Rotation axis
[0052] 20 end caps
[0053] 21 Rotor shaft mounting opening
[0054] 22 Inside of end cover
[0055] 30 Exclusion
[0056] 32 Exclusionary measures area
[0057] 34 first exclusion side area
[0058] 35 first exception end
[0059] 36 second exclusion side area
[0060] 37 second exclusion end
[0061] 40 Additional exemption
[0062] 42 Additional exemption area
[0063] 44 first additional exclusion page area
[0064] 45 first additional exception end
[0065] 46 second additional exclusion side area
[0066] 47 second additional exception end
[0067] 80 potting compound
[0068] 100 drive machine
[0069] a Interior angle
[0070] A Axial extension direction
[0071] β distance angle
[0072] K motor vehicle
[0073] R Radial extension direction
[0074] U circumferential direction
Claims
-1714 PIF Claims 1. Rotor (10) for an electric drive machine (100), with an end cover (20) having an inner surface (22) of the end cover which faces a lamination stack of the rotor (10) on which at least one recess (30) is arranged, which is designed as an undercut for receiving potting compound (80) during the manufacture of the rotor (10) and on which the end cover (20) is fixed in at least one spatial direction (A, R, II) against an offset relative to the lamination stack by the at least one recess (30) and by the potting compound (80) solidified therein.
2. Rotor (10) according to claim 1, characterized by the fact that the end cover (20) is connected via the at least one recess (30) and by the potting compound (80) solidified therein to a star disk of the rotor (10) and to rotor windings of the rotor (10).
3. Rotor (10) according to claim 1 or 2, characterized by the fact that the at least one recess (30) prevents the offset in the axial extension direction (A) as the at least one spatial direction (A, R, II) of the rotor (10).
4. Rotor (10) according to any one of the preceding claims, characterized by the fact that the at least one recess (30) prevents the offset in the circumferential direction (U) as the at least one spatial direction (A, R, U) of the rotor (10).
5. Rotor (10) according to any one of the preceding claims, characterized by the fact that The end cap (20) has, on its inner surface (22), in addition to the at least one recess (30), at least one additional recess (40) designed as an additional undercut, which prevents offset in the circumferential direction (U) and / or axial extension direction (A) of the rotor (10).-1714 PIF 6. Rotor (10) according to claim 5, characterized by the fact that the at least one recess (30) and the at least one additional recess (40) are arranged offset from each other in the radial extension direction (R) of the rotor (10) on the inside of the end cover (22) of the end cover (20).
7. Rotor (10) according to claim 5 or 6, characterized by the fact that which have at least one recess (30) and at least one additional recess (40) of a different shape.
8. End cover (20) for a rotor (10) according to one of the preceding claims.
9. Drive machine (100) with a rotor (10) according to one of claims 1 to 7.
10. Motor vehicle (K) with a drive motor (100) according to claim 9.