Rotor for an electric drive machine, drive machine having a rotor, and motor vehicle having a drive machine

Abstract

The invention relates to a rotor (10) for an electric drive machine (100), having a laminated rotor core (20) which has at least one laminated core slot (30) which runs in the axial extension direction (A) of the rotor (10) and in which rotor windings (40) of the rotor (10) extend. The rotor (10) has at least one support wedge element (50), which secures a first subset (42) of rotor windings (40) against an offset thereof relative to the laminated rotor core (20) in the at least one laminated core slot (30), and at least one wrapping component (60), which secures a second subset (44) of rotor windings (40) against an offset thereof relative to the laminated rotor core (20) in the at least one laminated core slot (30). Further aspects of the invention relate to an electric drive machine (100) and to a motor vehicle (K).

Description

[0001] 24-1750 PIF

[0002] Rotor for an electric drive motor, drive motor with a rotor, and motor vehicle with a drive motor

[0003] The invention relates to a rotor for an electric drive machine, with a rotor lamination stack which has at least one lamination stack groove extending in the axial direction of the rotor, in which rotor windings of the rotor extend. Further aspects of the invention relate to a drive machine with such a rotor and a motor vehicle with a drive machine.

[0004] Rotors, especially those of electrically excited electric drive machines, are subjected to particularly high loads at high speeds, primarily in the form of centrifugal forces.

[0005] If the rotor windings are not adequately secured against centrifugal force-induced displacement relative to a rotor lamination stack or relative to the teeth (rotor teeth) around which the windings are wound, undesirable movement of the windings will occur. This can lead to damage to the windings and imbalances in the rotor, which in the worst case can result in component failure. Various approaches are known in the prior art that address problems of rotor shape stability at high speeds or the positioning of rotor windings under high centrifugal forces.

[0006] For example, DE 3001 040 A1 discloses a slot wedge engaging with iron for arrangement in the teeth of winding slots of a dynamoelectric machine. The slot wedge comprises a glass fiber core impregnated with a cured, thermosetting resin and covered on at least two sides with a covering layer consisting of a mat of aromatic polyamide fibers impregnated with a cured, thermosetting resin.

[0007] DE 102021 109899 A1 discloses a rotor, in particular for a current-excited electric machine, comprising a winding in which a support element made of a composite material, comprising matrix material and fiber material, is arranged on or at the winding. 24-1750 PIF

[0008] From DE 102021 213072 A1, a rotor for an electric machine is known, which has teeth, coil windings around the teeth, and a stabilizing winding which is wound at least partially around the coil windings and is designed to support the coil windings against centrifugal forces. The stabilizing winding has at least a portion of a carbon fiber wire.

[0009] DE 102023202573 A1 discloses a coil element for an electric machine, comprising at least one tooth and at least one winding provided around the tooth. The tooth encloses the winding on at least one radial and one tangential side. At least one retaining element is provided, which is supported on the tooth and covers a circumferential area of ​​the winding not enclosed by the tooth. The winding is not potted.

[0010] The object of the present invention is to provide a rotor of the type mentioned above which is dimensionally stable under high centrifugal forces and can be manufactured sustainably. Furthermore, it is an object of the invention to provide a drive motor with such a rotor and a motor vehicle with such a drive motor.

[0011] This problem is solved by a rotor with the features of claim 1, by a drive motor with the features of claim 8, and by a motor vehicle with the features of claim 9. Advantageous embodiments with expedient further developments of the invention are specified in the dependent claims.

[0012] A first aspect of the invention relates to a rotor for an electric drive machine, with a rotor lamination stack which has at least one lamination stack groove extending in the axial direction of the rotor, in which rotor windings of the rotor extend.

[0013] According to the invention, the rotor has at least one support wedge element which fixes a first subset of the rotor windings against their offset relative to the rotor lamination stack in the at least one lamination stack slot, and at least one winding component which fixes a second subset of the rotor windings against their offset relative to the rotor lamination stack in the at least one lamination stack slot. This is advantageous because the rotor windings are thus held partly by the support wedge element and partly by the winding component in the lamination stack slot. While the support wedge element can be inserted into the rotor lamination stack slot and thereby hold the rotor windings, for example, against a rotor tooth that engages the lamination stack, the support wedge element provides additional support for the rotor windings.

[0014] In rotors where pressure is limited to a specific area, the winding component can be wound around the rotor tooth, particularly in a band-like fashion, thereby circumferentially enclosing the second subset of rotor windings and pressing them against the rotor tooth. This results in a lower overall requirement for supporting material to fix the rotor windings within the laminated core slot compared to conventional rotors, where the laminated core slot is completely filled by the rotor windings and a slot-closing wedge that secures them, with the additional use of a resin or resin mixture as a potting compound. In contrast, fixing the rotor windings by both the winding component and the supporting wedge element represents a particularly durable method of securing them. The rotor can, in particular, be designed without potting, i.e., without the use of a potting compound to fix the rotor windings.The winding component can be spaced apart from the first subset of rotor windings, i.e., arranged without contact with the first subset of rotor windings in the laminated core slot. This prevents any contact between the winding component and the first subset of rotor windings. Similarly, the support wedge element can be spaced apart from the second subset of rotor windings, i.e., arranged without contact with the second subset of rotor windings in the laminated core slot. This also prevents any contact between the support wedge element and the second subset of rotor windings.

[0015] The invention is based on the general understanding that fixing, and in particular automatically fixing, all rotor windings by means of the winding component in the area of ​​a groove base of the rotor lamination stack groove is difficult to implement due to space constraints. Fixing the first subset of rotor windings by means of the support wedge element and the second subset by means of the winding component, on the other hand, is simpler and more durable.

[0016] In an advantageous embodiment of the invention, the first subset of the rotor windings is arranged closer to a rotation axis of the rotor in the radial direction of the rotor than the second subset of the rotor windings. This is advantageous because the slot wedge element is thus arranged closer to the rotation axis than the winding component, resulting in lower centrifugal forces acting on the slot wedge element than would be the case with an arrangement at a greater distance in the radial direction from the rotation axis. Furthermore, it is advantageous to arrange the support wedge element closer to the rotation axis in the radial direction because space is limited in this area (the area of ​​the slot base of the rotor lamination stack slot).24-1750 PIF

[0017] which would make rewinding the rotor windings using the rewinding component more difficult.

[0018] In a further advantageous embodiment of the invention, the at least one winding component is wound around at least one salient pole of the rotor, which separates the at least one laminated core slot from at least a second laminated core slot, and the second subset of the rotor windings is fixed to the at least one salient pole by means of the at least one winding component. This is advantageous because winding the at least one salient pole enables a particularly stable fixing of the second subset of the rotor windings to this salient pole. A further advantage is that winding the at least one salient pole also enables the second subset of the windings to be fixed along their extension within the adjacent, second laminated core slot.In other words, the wrapping of the second subset of the rotor windings contributes to their fixation both within the lamination stack slot and within the adjacent, second lamination stack slot.

[0019] In a further advantageous embodiment of the invention, at least one winding component is designed as a fiber fabric. This is advantageous because fiber fabrics exhibit particularly high tensile strength, which allows the rotor windings to be secured with particularly high stability against unwanted misalignment. The rotor windings can be fixed particularly reliably if the fiber fabric comprises carbon fibers, glass fibers, aramid fibers, and / or sisal fibers.

[0020] In a further advantageous embodiment of the invention, the at least one winding component secures the at least one support wedge element against its outward movement from the at least one laminated core slot in the radial direction of the rotor. This represents a particular advantage, as the winding component thus has a dual function: on the one hand, it fixes the second subset of the rotor windings by means of the winding component, and on the other hand, it holds the at least one support wedge element in the at least one laminated core slot. In this way, the at least one support wedge element can, for example, be held in the laminated core slot without potting compound.

[0021] In a further advantageous embodiment of the invention, at least one wrapping component is designed as a bandage. This advantageously allows for a 24-1750 PIF

[0022] Large-area and therefore quickly produced wrapping and fixing of the second subset of rotor windings.

[0023] In a further advantageous embodiment of the invention, the at least one support wedge element is formed from a foam material. This is advantageous because, in a rotor manufacturing process, the support wedge element can first be introduced as a foam mass into the at least one laminated core slot and harden in contact with the first subset of rotor windings, particularly before the wrapping component is arranged to fix the second subset of rotor windings to them. The design of the at least one support wedge element as a foam material results in a particularly low mechanical load on the first subset of rotor windings when the at least one support wedge element is inserted into the at least one laminated core slot.

[0024] A second aspect of the invention relates to an electric drive machine with a rotor according to the first aspect of the invention. Such a drive machine can be manufactured in a particularly sustainable manner and exhibits high dimensional stability.

[0025] A third aspect of the invention relates to a motor vehicle with a drive unit according to the second aspect of the invention. Such a motor vehicle has a particularly dimensionally stable and durable drive component in the form of this drive unit.

[0026] 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.

[0027] 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.

[0028] Further advantages, features and details of the invention will become apparent from the claims, the following description of preferred embodiments and the drawings. 24-1750 PIF

[0029] The invention is explained again below using a specific embodiment. This is illustrated by:

[0030] Fig. 1 is a schematic representation of a motor vehicle with an electric drive machine, the rotor of which is shown in a schematic sectional view according to a section plane oriented perpendicular to an axial extension direction of the rotor.

[0031] Fig. 1 shows a schematic perspective view of a motor vehicle K with an electric drive motor 100, which can also be referred to as an electric drive motor 100 or simply E-machine. The drive motor 100 is designed here as a separately excited electric machine, in particular as a separately excited salient-pole machine.

[0032] In addition to other components, such as a stator (not shown here), the drive machine 100 has a rotor 10, shown in a schematic sectional view in Fig. 1. The plane underlying this sectional view is oriented perpendicular to an axis of rotation 12, meaning that the normals of this plane are parallel to the axis of rotation 12. An axial direction A of the rotor 10 also runs parallel to the axis of rotation 12. Double arrows in the sectional plane indicate a radial direction R of the rotor 10 and a circumferential direction U of the rotor 10, respectively.

[0033] The rotor 10 comprises a rotor lamination stack 20, which forms a rotor core 14 with a rotor yoke 15 and several salient poles 13 projecting radially from the rotor yoke 15, i.e., in the radial direction R, each of which has a rotor tooth 17 and a pole shoe 18. The rotor 10 also has rotor windings 40 for exciting a rotor magnetic field, with winding conductors wound in several layers around the rotor teeth 17 of the salient poles 16 and forming winding heads (not shown) on axially opposite end faces of the rotor core 14, i.e., in the axial direction A. The rotor yoke 15 encloses a rotor shaft 16 of the rotor 10, which is rotationally fixed to the rotor lamination stack 20, in particular to its rotor core 14.

[0034] The rotor lamination stack 20 has several slots extending in the axial direction A of the rotor 10, in which the rotor windings 40 of the rotor 10 extend. For example, the rotor lamination stack 20 can have a total of six slots. 24-1750 PIF

[0035] exhibiting, with reference to Fig. 1 only to a first sheet metal stack groove 30 and a second sheet metal stack groove 70 adjacent in the circumferential direction U.

[0036] To ensure the rotor 10 is durable and dimensionally stable even at high rotor speeds, the rotor 10 has a support wedge element 50 in each lamination core slot. This support wedge element secures a first subset 42 of the rotor windings 40 against their displacement relative to the rotor lamination core 20 in at least one lamination core slot 30. The support wedge element 50 also has at least one winding component 60 that secures a second subset 44 of the rotor windings 40 against their displacement relative to the rotor lamination core 20 in at least one lamination core slot 30. The support wedge element 50 holds the first subset 42 of the rotor windings 40 in the first lamination core slot 30, primarily by exerting pressure. During assembly of the rotor 10, the support wedge element 50 can be inserted into the lamination core slot 30 in the axial direction A, thus simplifying installation.

[0037] The wrapping component 60 can then be mounted.

[0038] The support wedge element 50 is generally spaced apart from the pole shoes 18, which define the outer boundaries of the lamination stack grooves 30, 70 in the radial direction R. In contrast to conventional groove closure wedges, the support wedge element 50 is therefore arranged without contact with the pole shoes 18 in the corresponding lamination stack groove 30, 70.

[0039] For the sake of clarity, the support wedge element 50 and the wrapping component 60 are only fully shown in the first lamination stack groove 30. However, it is clear that each of the lamination stack grooves can be configured as shown with reference to the first lamination stack groove 30. In other words, for example, each of the lamination stack grooves can contain, for instance, another support wedge element and at least one further wrapping component.

[0040] The first subset 42 of the rotor windings 40 is arranged closer to the rotation axis 12 of the rotor 10 in the radial extension direction R of the rotor 10 than the second subset 44 of the rotor windings 40.

[0041] The winding component 60 is wound around the respective salient pole 13 of the rotor 10, which separates the first laminated core slot 30 from the second laminated core slot 70. The second subset 44 of the rotor windings 40 is thereby fixed to the salient pole 13 by means of the winding component 60, in particular clamped between the winding component 60 and the salient pole 13. 24-1750 PIF

[0042] When the corresponding salient pole 13 is completely wrapped, the wrapping component 60 extends partially into the first lamination stack groove 30 and the adjacent second lamination stack groove 70, whereby the corresponding second subset 44 of the rotor windings 40 is fixed in each of the lamination stack grooves 30, 70 by means of the wrapping component 60. This complete wrapping can be achieved with particularly low effort by designing the wrapping component 60 as a bandage. To give the rotor 10 particularly high dimensional stability and to reliably prevent the undesired misalignment of the rotor windings 40 even at high rotor speeds, the wrapping component 60 is designed as a fiber layup.

[0043] The rotor 10 is particularly recyclable and therefore especially sustainable because the wrapping component 60 secures the support wedge element 50 against its outward movement from the first lamination stack groove 30 in the radial direction R of the rotor 10. The wrapping component 60 can press the support wedge element 50 inward in the radial direction R, thereby holding the support wedge element 50 securely in the respective lamination stack groove 30, 70, and in particular without any material bond.

[0044] The winding component 60 can preferably be supported outwards on the pole shoe 18 in the radial direction R and secure the second subset 44 of the rotor windings 40 against centrifugal displacement, whereas the support wedge element 50 can in turn be supported outwards on the winding component 60 in the radial direction R to secure the first subset 42 of the rotor windings 40 against centrifugal displacement. Thus, the support wedge element 50 can be supported on the pole shoe via the winding component 60, allowing for a particularly simple fixing of the support wedge element 50. This eliminates the need to fix the support wedge element 50 with, for example, a poorly recyclable potting compound, especially resin. Such potting compounds are typically used in conventional rotor systems for the metallurgical bonding of various components.

[0045] To achieve a particularly advantageous shape for the support wedge element 50 adapted to the first subset 42 of the rotor winding, the support wedge element 50 can be made of a foam material. The foam material can be injected in liquid form into the corresponding lamination stack groove 30, 70 and thereby formed against the rotor windings 40, advantageously creating a positive fit between the 24-1750 PIF

[0046] Rotor windings 40 and the support wedge element 50, which subsequently solidifies into a solid, can be formed.

[0047] The described rotor 10 can generally have a recess 11 in each lamination core slot 30, 70 as a partial area of ​​the lamination core slot 30, 70, which extends in the circumferential direction U of the rotor 10 between two adjacent winding components 60 and in the radial direction R outside the support wedge element 50. The recess can therefore be bounded in the circumferential direction U within the respective lamination core slot 30, 70 by the adjacent winding components 60 and inwards in the radial direction R within the respective lamination core slot 30, 70 by the support wedge element 50. Since the support wedge element 50 and the winding component 60 provide good insulation of the rotor windings 40, the recess 11 can, for example, be used to accommodate any (not shown) heat sinks, in particular coolant-carrying heat sinks.Alternatively, the recess 11 can remain free of other components, which allows the rotor 10 to have a particularly low weight.

[0048] The rotor 10 can generally be manufactured without or at least with only a very small amount of resin or potting compound for fixing the rotor windings 40.

[0049] Resin or potting compound is difficult to recycle, heavy, expensive to use, and introduces process uncertainties in rotor manufacturing. Furthermore, it requires an additional process step in rotor production, increasing time and space requirements, as well as the extra effort of sealing various rotor areas during the potting process, for example, by using cover slides. Without additional measures to support the windings, potting compound cannot be easily omitted in conventional rotor systems, as the winding wires do not have sufficient support within the slots at high rotor speeds due to centrifugal forces. Consequently, without the use of resin or potting compound, the windings shift during operation of such conventional rotor systems, leading to imbalances and component failure.

[0050] In contrast, these disadvantages can be avoided in the rotor 10 presented here. Furthermore, in this rotor 10, a full-surface wrapping of the rotor windings 40 using the winding component 60 is not necessary, thus eliminating complications when arranging the winding component 60 in a groove base area of ​​the laminated core slots 24-1750 PIF.

[0051] 30, 70 can occur, especially since the support wedge element 50 in the slot base area ensures the stable fixation of the first subset 42 of the rotor windings 40. In other words, no space problems arise which would occur if the winding component 60 were arranged near the axis of rotation 12, i.e., in the area of ​​the slot base of the respective laminated core slots 30, 70. 24-1750 PIF

[0052] Reference symbol list

[0053] 10 Rotor

[0054] 11 recess

[0055] 12 Rotation item

[0056] 13. Lumen pole

[0057] 14 Rotor core

[0058] 15 Rotor yoke

[0059] 16 Rotor shaft

[0060] 17 Rotor tooth

[0061] 18 pole shoe

[0062] 20 Rotor lamination package

[0063] 30 first sheet metal package groove

[0064] 40 Rotor winding

[0065] 42 first subset

[0066] 44 second subset

[0067] 50 support wedge element

[0068] 60 Wrapping component

[0069] 70 second sheet metal package groove

[0070] 100 drive machine

[0071] A Axial extension direction

[0072] K motor vehicle

[0073] R Radial extension direction

[0074] U circumferential direction

Claims

-1750 PIF Claims 1. Rotor (10) for an electric drive machine (100), with a rotor lamination stack (20) which has at least one lamination stack groove (30) extending in the axial direction (A) of the rotor (10), in which rotor windings (40) of the rotor (10) extend, characterized by the fact that the rotor (10) has at least one support wedge element (50) which fixes a first subset (42) of the rotor windings (40) against their offset relative to the rotor lamination stack (20) in the at least one lamination stack slot (30) and has at least one winding component (60) which fixes a second subset (44) of the rotor windings (40) against their offset relative to the rotor lamination stack (20) in the at least one lamination stack slot (30).

2. Rotor (10) according to claim 1, characterized by the fact that the first subset (42) of the rotor windings (40) is arranged closer to a rotation axis (12) of the rotor (10) in the radial extension direction (R) of the rotor (10) than the second subset (44) of the rotor windings (40).

3. Rotor (10) according to claim 1 or 2, characterized by the fact that the at least one winding component (60) is wound around at least one salient pole (13) of the rotor (10) which separates the at least one laminated core slot (30) from at least one second laminated core slot (70), and the second subset (44) of the rotor windings (40) is fixed to the at least one salient pole (13) by means of the at least one winding component (60).

4. Rotor (10) according to any one of the preceding claims, characterized by the fact that which at least one wrapping component (60) is designed as a fiber lay-up.

5. Rotor (10) according to any one of the preceding claims, characterized by the fact that-1750 PIF which secures at least one wrapping component (60) the at least one support wedge element (50) against its outward movement from the at least one laminated core slot (30) in the radial extension direction (R) of the rotor (10).

6. Rotor (10) according to any one of the preceding claims, characterized by the fact that which at least one wrapping component (60) is designed as a bandage.

7. Rotor (10) according to any one of the preceding claims, characterized by the fact that that at least one support wedge element (50) is formed from a foam material.

8. Drive machine (100) of an electric type with a rotor (10) according to one of the preceding claims.

9. Motor vehicle (K) with a drive motor (100) according to claim 8.

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