DE102022004622A1 - Rotor for an axial flow machine, in particular of a motor vehicle, axial flow machine and method for producing such a rotor - Google Patents

Abstract

The invention relates to a rotor (10) for an axial flow machine, with a spirally wound laminated core (12) which has an opening (20) in which at least one longitudinal region (L) of a carrier or shaft element (18) is arranged, which is connected to the laminated core (12) in a rotationally fixed manner via the longitudinal region (L), wherein the opening (20) has a non-circular, polygonal shape on the inner circumference side and the longitudinal region (L) on the outer circumference side.

Description

The invention relates to a rotor for an axial flow machine, in particular of a motor vehicle. Furthermore, the invention relates to an axial flow machine, in particular for a motor vehicle. The invention also relates to a method for producing such a rotor.

The EN 10 2004 054 277 A1 A rotor arrangement for an electrical machine is known, having a substantially cylindrical rotor body and a shaft to which the rotor body is mounted.

The object of the present invention is to provide a rotor for an axial flow machine, an axial flow machine and a method for producing such a rotor, so that a particularly advantageous operation of the axial flow machine can be realized.

This object is achieved by a rotor having the features of patent claim 1, by an axial flow machine having the features of patent claim 4 and by a method having the features of patent claim 5. Advantageous embodiments with expedient further developments of the invention are specified in the remaining claims.

A first aspect of the invention relates to a rotor for an axial flux machine, also referred to as an axial flux motor, in particular of a motor vehicle. The axial flux machine is an electrical machine designed as an axial flux machine. The rotor has a spirally wound laminated core. This means, for example, that the laminated core is formed or manufactured from at least or exactly one strip made of sheet metal and therefore also referred to as a sheet metal strip, in particular such that the strip is wound spirally around a winding axis, in particular an imaginary one, to form the laminated core. This forms, for example, layers of the strip arranged one on top of the other in the radial direction of the rotor, wherein the layers are formed in one piece, in particular because the strip is formed in one piece, i.e. formed from a single piece. In this case, for example, respective ends of the strip are connected to the rest of the strip, in particular to a respective one of the layers, in particular bonded and welded, for example. This can prevent the strip from unwinding undesirably.

The laminated core has an opening which is produced, i.e. formed, in particular by the winding of the laminated core, which is also referred to as winding, and which is thus preferably delimited or formed by the band in the radial direction of the rotor towards the outside and in the circumferential direction of the rotor completely encircling it.

The rotor, whose axial direction runs perpendicular to the radial direction of the rotor, also has an element that is formed separately from the laminated core, which can be a carrier element or a shaft element, in particular a shaft. The circumferential direction of the rotor and thus of the opening runs around the axial direction of the rotor. In the fully manufactured state, the axial flux machine has, for example, a stator and the rotor, which can be driven by means of the stator and can therefore be rotated about a machine axis of rotation relative to the stator. The machine axis of rotation coincides with the axial direction of the rotor.

At least one length region of the support or shaft element, and therefore of the element, is arranged in the opening, so that, for example, the laminated core is arranged on the length region, and therefore on the element. The element (support or shaft element) is connected to the laminated core in a rotationally fixed manner via the length region. In other words, the length region and therefore the element (support or shaft element) are connected to the laminated core in a rotationally fixed manner. In this case, for example, the length region and therefore the element has an outer peripheral surface, wherein the laminated core, in particular an inner peripheral surface of the laminated core, which directly delimits the opening, in particular directly, directly touches the length region and thereby in particular the outer peripheral surface. In other words, the inner peripheral surface sits directly on the outer peripheral surface.

In order to be able to transmit particularly high torques between the laminated core and the element and thus to achieve particularly advantageous operation of the axial flow machine, it is provided according to the invention that the opening on the inner circumference and the length area on the outer circumference have a non-circular, polygonal shape. In other words, the inner circumference surface is polygonal and thus non-circular, and the outer circumference surface is also polygonal and thus non-circular. In particular, it is provided that the non-circular, polygonal, inner circumference shape of the opening or the inner circumference surface is adapted to the non-circular, polygonal, outer circumference shape of the length area and thus the outer circumference surface. As a result, for example, the laminated core and the element are connected to each other in a form-fitting, rotationally fixed manner, so that even particularly high torques can be transmitted between the element and the laminated core without any relative rotation occurring between the laminated core and the element.

In order to be able to transmit particularly high torques between the laminated core and the element, it is provided in an advantageous embodiment of the invention that the longitudinal region is pressed into the opening, thus the outer circumferential surface is pressed into the inner circumferential surface, so that the longitudinal region and thus the element are connected to the laminated core by a press fit which is formed between the longitudinal region and the laminated core. The invention enables, in particular, secure torque transmission in carrier-less rotors for axial flow machines, i.e. in particular when the rotor according to the invention is designed as a carrier-less rotor.

A second aspect of the invention relates to an axial flow machine which has at least or exactly one rotor according to the first aspect of the invention. Advantages and advantageous embodiments of the first aspect of the invention are to be regarded as advantages and advantageous embodiments of the second aspect of the invention and vice versa.

A third aspect relates to a method for producing a rotor according to the first aspect of the invention. Advantages and advantageous embodiments of the first aspect and the second aspect of the invention are to be regarded as advantages and advantageous embodiments of the third aspect of the invention and vice versa.

In the process, for example, the laminated core is wound non-circularly with a polygonal profile, whereby the non-circular, polygonal shape of the opening on the inner circumference is produced. In other words, the opening, which is preferably designed as a through-opening, is or forms a first polygonal profile on the inner circumference. Then, for example, the laminated core is pressed onto the element, which is designed as a polygonal shaft, for example. In other words, for example, the length range is or forms a second polygonal profile, which is adapted to the first polygonal profile, for example. The first polygonal profile is pressed onto the second polygonal profile, or the second polygonal profile is pressed into the first polygonal profile. Since the element is designed as a shaft element, in particular as a shaft, for example, and the element has the non-circular, polygonal shape on the outer circumference side at least in the length range mentioned and is thus designed as the second polygonal profile, the element can be, for example, a polygonal shaft that is non-circular at least in the length range, whereby particularly high torques can be advantageously, i.e. safely, transmitted between the element and the laminated core.

• - Funktionsintegration: Entfall eines Rotorträgers aus Stahl
• - höhere Drehmomentübertragung durch Polygonprofil
• - Entfall von Zusatzprozessen wie Schrauben, Schweißen etc.
• - Anwendung bei Statorblechpaketen: Integration ins Lagerschild möglich über Wellenschulter in einem Lagerschild

Conventionally, rotors for axial flow machines designed as double rotors, for example, are constructed from a respective rotor carrier, a respective laminated core and respective magnets. The laminated core can, for example, be attached directly to a shaft. However, due to high torques and the spiral structure of the laminated core, this is hardly possible with conventional connection options such as screws, laser welding, etc. A simple cross-press connection between the laminated core and the element has proven to be insufficient to be able to transmit high torques safely. Thus, according to the invention, the opening is polygonal on the inner circumference and the length range is polygonal on the outer circumference. This means that particularly high torques can also be transmitted safely. Since the laminated core is wound spirally, the laminated core has the aforementioned spiral structure, so that the laminated core is also referred to as a ring laminated core or is designed as a ring laminated core. In particular, the invention can realize at least the following advantages:

• - Functional integration: elimination of a steel rotor carrier
• - higher torque transmission due to polygon profile
• - Elimination of additional processes such as screwing, welding, etc.
• - Application for stator laminations: Integration into the bearing shield possible via shaft shoulder in a bearing shield

This means that the previous and following statements regarding the rotor can easily be transferred to the stator of the axial flux machine and vice versa.

Further advantages, features and details of the invention emerge from the following description of a preferred embodiment and from the drawing. The features and combinations of features mentioned above in the description as well as the features and combinations of features mentioned below in the description of the figures and/or shown alone in the figures are not only in the respective combination specified, but also in other combinations. combinations or alone without departing from the scope of the invention.

• 1 eine schematische Vorderansicht eines Rotors für eine Axialflussmaschine; und
• 2 eine schematische Perspektivansicht des Rotors.

The drawing shows in:

• 1 a schematic front view of a rotor for an axial flow machine; and
• 2 a schematic perspective view of the rotor.

In the figures, identical or functionally identical elements are provided with identical reference symbols.

1 shows a schematic front view of a rotor 10 for an electrical machine designed as an axial flux machine, in particular of a motor vehicle. This means that the motor vehicle, also simply referred to as a vehicle and preferably designed as a motor vehicle, in particular as a passenger car, has the axial flux machine in its fully manufactured state and can be driven by means of the axial flux machine, in particular purely electrically. The axial flux machine is preferably a high-voltage component whose electrical voltage, in particular electrical operating or nominal voltage, is preferably greater than 50 volts, in particular greater than 60 volts, and very preferably several hundred volts. In its fully manufactured state, the axial flux machine has the rotor 10 and a stator, by means of which the rotor 10 can be driven and can therefore be rotated about a machine axis of rotation relative to the stator. The axial flux machine can, for example, provide drive torques for driving the motor vehicle, in particular purely electrically, via the rotor 10.

The rotor 10 has a spiral-wound laminated core 12. Furthermore, the rotor 10 has magnets 14, which are formed separately from the laminated core 12, for example. In particular, the magnets 14 are formed separately from one another. In particular, the respective magnet 14 is a permanent magnet. 1 it can be seen that the magnets 14 are held on the laminated core 12 and are thus supported by the laminated core 12. In particular, for example, the respective magnet 14 is at least partially accommodated in a respective, corresponding pocket of the laminated core 12. The rotor 10 can have a rotor carrier 16 which, for example, is formed separately from the laminated core 12 and is connected to the laminated core 12. In particular, it is conceivable that the laminated core 12 is at least partially arranged in the rotor carrier 16 at least in the axial direction of the rotor 10.

The rotor 10 also has a 1 and 2 In the embodiment shown, the rotor 10 has an element 18 designed as a shaft, in particular as a hollow shaft, which is preferably designed separately from the laminated core 12. The laminated core 12 has an opening 20 which is central in the present case and designed as a through-opening, which is directly delimited by an inner circumferential surface 22 of the laminated core 12 in the circumferential direction of the rotor 10 in a completely circumferential manner.

Out of 1 it can be seen that at least a length region L of the element 18 is arranged in the opening 20. The length region L and thus the element 18 are connected to the laminated core 12 in a rotationally fixed manner. In other words, the element 18 is connected to the laminated core 12 in a rotationally fixed manner over its length region L. The length region L has an outer peripheral surface 24. It can be seen that the inner peripheral surface 22 points inwards in the radial direction of the rotor 10 and faces the outer peripheral surface 24, which thus points outwards in the radial direction and faces the inner peripheral surface 22.

In order to be able to transmit particularly high torques between the element 18 and the laminated core 12, the opening 20 or the inner peripheral surface 22 has a non-circular, polygonal first shape on the inner peripheral side, and the length region L or the outer peripheral surface 24 has a non-circular, polygonal second shape that is adapted to the first shape or corresponds to the first shape. As a result, the laminated core 12 and the element 18 are connected to one another, in particular in a form-fitting, rotationally fixed manner. In addition, the length region L is pressed into the opening 20, for example, so that the laminated core 12 is pressed onto the length region L. In other words, a press fit, also referred to as a transverse press fit or designed as a transverse press fit, is formed between the outer surfaces 22 and 24, that is to say between the length region L and the laminated core 12, so that the laminated core 12 and the element 18 are connected to one another particularly firmly.

In particular, the opening 20 or its first shape is formed by the aforementioned winding of the laminated core, wherein the winding is designed as non-circular winding, by means of which the polygonal and thus non-circular, inner peripheral, first shape of the opening 20 is produced. In other words, it is preferably provided that the first shape of the opening 20, also referred to as the inner shape, is produced at the same time as the winding of the laminated core 12, which is realized, for example, by a mandrel which has the first shape or the second shape on the outer peripheral side. For example, For example, a sheet metal strip is wound onto the mandrel so that, for example, a first layer or first ply of the sheet metal strip or of a sheet metal strip spiral, viewed from the inside outward in the radial direction of the rotor 10, which is formed by the sheet metal strip being wound spirally, i.e. being wound spirally to thereby form the spirally wound laminated core 12, is formed and adapted to the polygonal shape of the mandrel. In particular, for example, the inner peripheral surface 22 is formed by the first layer, i.e. an inner peripheral surface of the first layer. For example, the first layer is actively pressed against the polygonal mandrel or its polygonal shape to ensure, for example, that the sheet metal strip is also stable in terms of its strength and does not wrap around corners of the polygonal shape of the mandrel.

2 shows the rotor 10 in a schematic perspective view. As can be seen from 1 and 2 As can be seen particularly clearly, the element 18 has a, in particular central, through-opening 26. For example, the element 18 can be arranged via the through-opening 26, for example on a, in particular further, shaft and can be connected to the further shaft in a rotationally fixed manner.

List of reference symbols

10

rotor

12

Sheet metal package

14

magnet

16

Rotor carrier

18

element

20

opening

22

inner circumferential surface

24

outer peripheral surface

26

Passage opening

L

Length range

QUOTES INCLUDED IN THE DESCRIPTION

This list of documents listed by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions.

Cited patent literature

• DE 102004054277 A1 [0002]

Claims (5)

Rotor (10) for an axial flow machine, with a spirally wound laminated core (12) which has an opening (20) in which at least one longitudinal region (L) of a carrier or shaft element (18) is arranged, which is connected to the laminated core (12) in a rotationally fixed manner via the longitudinal region (L), wherein the opening (20) has a non-circular, polygonal shape on the inner circumference side and the longitudinal region (L) on the outer circumference side. Rotor (10) after Claim 1 , characterized in that the length region (L) is pressed into the opening (20). Rotor (10) after Claim 1 or 2 , characterized in that the opening (20) is designed as a through opening. Axial flow machine, with at least one rotor (10) according to one of the preceding claims. Method for producing a rotor (10) according to one of the Claims 1 until 3 .

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