ROTOR FOR AN ELECTRIC DRIVE MACHINE FOR DRIVING A COMPRESSOR, A TURBINE OR A CHARGER SHAFT OF A TURBOCHARGER, AND TURBOCHARGER COMPRISING AN ELECTRIC DRIVE MACHINE AND SUCH A ROTOR

Abstract

An exhaust-gas turbocharger having an electric drive unit for driving a compressor, a turbine, or a turbocharger shaft of the exhaust-gas turbocharger. The electric drive unit has a rotor and a stator. The rotor is equipped with a rotor body embodied around a rotation axis of the rotor. A receptacle for at least one permanent magnet is embodied on the rotor body. A permanent magnet is disposed in the receptacle of the rotor body. The rotor body is mountable using a threaded bushing on a turbocharger shaft of the exhaust-gas turbocharger. The rotor body has a further receptacle which extends in the direction of the rotation axis and in which the threaded bushing is disposed inside the rotor body. The further receptacle is disposed in the rotor body with an offset in the direction of the rotation axis relative to the receptacle.

Claims

1-11. (canceled)

12. A rotor for an electric drive unit for driving a compressor, or a turbine, or a turbocharger shaft of an exhaust-gas turbocharger, comprising: a rotor body embodied around a rotation axis of the rotor and being mountable using a threaded bushing on a turbocharger shaft of the exhaust-gas turbocharger; a receptacle for at least one permanent magnet embodied on the rotor body; at least one permanent magnet disposed in the receptacle of the rotor body; wherein the rotor body has a further receptacle which extends in a direction of the rotation axis and in which the threaded bushing is disposed inside the rotor body, the further receptacle being disposed in the rotor body with an offset in a direction of the rotation axis relative to the receptacle of the at least one permanent magnet.

13. The rotor as recited in claim 12, wherein the threaded bushing has an internal thread and an outer envelope, wherein the outer envelope of the threaded bushing comes into abutment against an inner wall of the further receptacle upon a rotation around the rotation axis relative to the rotor body.

14. The rotor as recited in claim 12, wherein an inside diameter of the further receptacle is larger than an outside diameter of the threaded bushing, so that perpendicularly to the rotation axis a clearance exists in a radial direction between the threaded bushing and the rotor body.

15. The rotor as recited in claim 12, wherein the rotor has a sleeve surrounding the at least one permanent magnet, the sleeve being disposed on an attachment element of the rotor body, and the further receptacle for the threaded bushing is disposed in the attachment element.

16. The rotor as recited in claim 15, wherein the attachment element has an outer envelope, an inner side that faces toward the at least one permanent magnet, and an outer side that faces away from the at least one permanent magnet, and wherein the further receptacle is a depression embodied on the inner side of the attachment element.

17. The rotor as recited in claim 16, wherein a backing washer, covering the threaded bushing on the inner side of the attachment element, is provided between the inner side of the attachment element and the at least one permanent magnet.

18. The rotor as recited in claim 17, wherein the rotor body has a further backing washer on a side of the permanent magnet which faces away from the threaded bushing.

19. The rotor as recited in claim 12, wherein the rotor body has, concentrically with the rotation axis, a cylindrical bore, an inside diameter of the cylindrical bore being smaller than an inside diameter of the further receptacle, forming a step which constitutes a support for the threaded bushing.

20. An exhaust-gas turbocharger, comprising: an electric drive unit configured to drive a compressor, or a turbine, or a turbocharger shaft of the exhaust-gas turbocharger; the turbocharger shaft mounted rotatably around a rotation axis; and the electric drive unit having a rotor and a stator, the stator having a drive winding for generation of a driving magnetic field driving the rotor, the rotor having a rotor body embodied around the rotation axis, a receptacle for at least one permanent magnet being embodied on the rotor body, at least one permanent magnet being disposed in the receptacle of the rotor body, the rotor body being thread-mounted by way of a threaded bushing onto an external thread of the turbocharger shaft in such a way that a clamping force acting in a direction of the rotation axis presses the rotor body indirectly or directly against a stop on the turbocharger shaft, wherein the rotor body has a further receptacle which extends in the direction of the rotation axis and in which the threaded bushing is disposed inside the rotor body, the further receptacle being disposed in the rotor body with an offset in the direction of the rotation axis relative to the receptacle of the at least one permanent magnet.

21. The exhaust-gas turbocharger as recited in claim 20, wherein the clamping force acting in the direction of the rotation axis presses the rotor body against a compressor wheel of the compressor, and presses the compressor wheel at least indirectly against a stop on the turbocharger shaft.

22. The exhaust-gas turbocharger as recited in claim 20, wherein the rotor body has, concentrically with the rotation axis, a cylindrical bore, an inside diameter of the cylindrical bore being embodied to create a clearance fit or an interference fit between the turbocharger shaft and an inner wall of the bore.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0025] FIG. 1 is a schematic section view of an exhaust-gas turbocharger having an electric drive unit in accordance with an example embodiment of the present invention.

[0026] FIG. 2 shows a rotor of the electric drive unit in a second example embodiment of the present invention slightly modified as compared with FIG. 1.

[0027] FIG. 3 is a perspective view of a rotor in accordance with a third example embodiment of the present invention.

[0028] FIG. 4 is a perspective view of a rotor in accordance with a fourth example embodiment of the present invention.

[0029] FIG. 5 is a perspective view of a clamping tool in accordance with an example embodiment of the present invention.

[0030] FIGS. 6a to 6c are cross sections through a magnet subassembly during production, in accordance with an example embodiment of the present invention.

[0031] FIGS. 7a to 7e are further cross sections through the magnet subassembly and the rotor body during production of the rotor, in accordance with an example embodiment of the present invention.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

[0032] FIG. 1 is a longitudinal section through an exhaust-gas turbocharger 2 of an internal combustion engine, having an electric drive unit 1. The exhaust-gas turbocharger encompasses a housing 6, depicted here merely schematically, which in particular can also be embodied in multiple parts with a bearing housing, a compressor housing (not depicted) and a turbine housing. The exhaust-gas turbocharger encompasses a compressor 3 and a turbine 4. A compressor wheel 13 of compressor 3, and a turbine wheel 14 of turbine 4, are schematically shown in FIG. 1. Compressor wheel 13 and turbine wheel 14 can be disposed nonrotatably on a shared turbocharger shaft 5. Turbocharger shaft 5 is mounted rotatably around a rotation axis A in bearing bushings 15 in housing 6 of exhaust-gas turbocharger 2.

[0033] Turbine 4 can be understood as a rotating flow machine that is configured to convert a drop in the internal energy of a flowing fluid into a mechanical power output that it delivers via turbocharger shaft 5. A portion of an internal energy, in particular encompassing energy of motion, energy of position, and/or energy of pressure, can be extracted from a fluid flow by way of a maximally turbulence-free laminar flow around turbine blades, and can transfer to guide vanes of the turbine. Turbocharger shaft 5 can then be caused to rotate by a portion of the internal energy, and a usable power output can be delivered to a connected working machine, such as a compressor 3. Turbine 4 can be configured to be driven by exhaust gases of a combustion engine.

[0034] Compressor 3 is configured to increase a pressure and/or a density of a flowing gas, and in particular of flowing air. The compressor can be in particular a radial compressor. The radial compressor can be used to add energy to a flowing fluid by way of a rotating rotor, in accordance with the laws of fluid mechanics. The radial compressor can be embodied in such a way that the gas flows substantially axially into a compressor wheel 13 and is then deflected radially, i.e., outward.

[0035] Electric drive unit 1 is configured to generate a rotational motion of a rotor by application of an electric current. The electric drive unit is configured entirely or partly as an electric motor. The electric drive unit is used in particular to drive the compressor, the turbine, or turbocharger shaft 5 of exhaust-gas turbocharger 2. Electric drive unit 1 can be installed, in particular like the electric drive machine described in German Patent Application No. DE 10 2017 207 532 A1, in an exhaust-gas turbocharger, the electric drive unit presented here having a configuration of the rotor which is novel as compared with German Patent Application No. DE 10 2017 207 532 A1 and which enables an advantageous connection to the turbocharger shaft.

[0036] The electric drive unit has a rotor 100 and a stator 20. Stator 20 constitutes a stationary component of electric drive unit 1 and has, for example, an annular stator yoke as well as stator teeth which project radially inward from the stator yoke and are disposed in uniformly distributed fashion with a spacing from one another when viewed in a circumferential direction. The stator teeth are usually wound with a multi-phase drive winding 21; energization of the phases of drive winding 21 by way of a power electronics system provided therefor causes generation of the rotating driving magnetic field by which rotor 100, rotatably mounted by turbocharger shaft 5, is driven with a predefinable torque. Rotor 100 has a rotor body 101 that is configured to receive at least one permanent magnet 130. Rotor body 101 can, however, also receive more than one permanent magnet 130. Rotor 100 interacts with the rotating magnetic field of stator 20. Rotor body 101 of rotor 100 is embodied as a solid of revolution around a rotation axis A, in particular is embodied concentrically around rotation axis A. Rotation axis A of rotor body 101 is preferably identical to the rotation axis of turbocharger shaft 5. A receptacle 190 for the at least one permanent magnet 130 is embodied on rotor body 101. Rotor body 101 is thread-mounted by way of a threaded bushing 140 onto an external thread 51 of turbocharger shaft 5, in such a way that an axial clamping force resulting from the thread mounting and acting in the direction of rotation axis A presses rotor body 101 directly, or indirectly with interposition of compressor wheel 13 and optionally of further components, for example an axial bearing of turbocharger shaft 5, against a stop 52 on turbocharger shaft 5. Turbocharger shaft 5 can be embodied in one piece, as depicted. Turbocharger shaft 5 can also, however, be embodied in multiple parts and can have a rotor shaft that is attached to the rotor and is nonrotatably couplable to the turbocharger shaft, for example via a coupling apparatus. Turbocharger shaft 5 has a cylindrical outer envelope that is equipped, at its end facing toward rotor 100, with external thread 51.

[0037] The configuration of rotor 100 will firstly be described in more detail with reference to FIG. 2. Rotor 100 is preferably constructed in several pieces, and has at least rotor body 101, threaded bushing 140, and the at least one permanent magnet 130. The permanent magnet has, as depicted, at least one north and one south pole, and can be, for example, a magnet made of SmCo, Sm2Co17, or NdFeB. Rotor body 101 is particularly preferably also constructed in several pieces. Rotor body 101 has in particular a sleeve 120 surrounding permanent magnet 130, sleeve 120 being disposed on an attachment element 110 of rotor body 101. The term “sleeve” refers in principle to any elongated hollow body. The hollow body can have a length and a diameter. The length can be greater than the diameter, for example by a factor of 1.5, preferably by a factor of 2, particularly preferably by a factor of 3. The diameter can have, in particular, a round shape. Other configurations are, however, possible. The sleeve can therefore also be referred to as a “tube.” The internal cylindrical wall of sleeve 120 constitutes a receptacle 190 for permanent magnet 130. Permanent magnet 130 is, in particular, press-fitted into sleeve 120, as will be explained in further detail below. The sleeve can be produced in particular from a nonmagnetic material. Influence by the sleeve on magnetic properties of the permanent magnet and/or of the stator can thereby be avoided or at least more greatly reduced. The sleeve can furthermore be configured to protect the permanent magnet, in particular radially, from corrosion. In a context of higher rotation speeds, the permanent magnet can be more intensely pressed and/or “bandaged” so that it is not damaged by centrifugal force. Greater pressure can result in an increase in stress in the sleeve, which can be reduced in turn by increasing the wall thickness. For example, the sleeve can have a wall thickness of 0.1 to 5 mm, in particular of 0.5 mm to 2 mm, preferably of 0.8 mm to 1.5 mm, and particularly preferably of 1.025 mm.

[0038] Attachment element 110 can have a cylindrical outer envelope, an inner side 113 that faces toward the at least one permanent magnet 130, and an outer side 112 that faces away therefrom. Attachment element 110 can be produced from stainless steel, for example as a simple lathe-turned part. Configured on inner side 113 of attachment element 110, concentrically with rotation axis A, is a depression 182 that constitutes a further receptacle 180 for threaded bushing 140. A backing washer 160, which covers threaded bushing 140 on inner side 113 of attachment element 110, is disposed between inner side 113 of attachment element 110 and the at least one permanent magnet 130. On that side of permanent magnet 130 which faces away from threaded bushing 140, rotor body 101 has a further backing washer 170 that will also be referred to hereinafter as an “outer” backing washer. Attachment element 110 furthermore has a cylindrical bore 150 concentric with rotation axis A. Inside diameter D1 of cylindrical bore 150 is embodied to be smaller than inside diameter D2 of further receptacle 180, thereby forming a step 114 that forms a support 115 for threaded bushing 140.

[0039] Threaded bushing 140 can preferably be inserted into further receptacle 180 from inner side 113. As is further evident from FIG. 2, threaded bushing 140 has an internal thread 142 and an outer envelope 141. Outer envelope 141 of the threaded bushing and inner wall 181 of further receptacle 180 are embodied in such a way that upon a rotation around rotation axis A relative to rotor body 101, outer envelope 141 comes into abutment against an inner wall 181 of further receptacle 180. Outer envelope 141 can have for that purpose a projection (not depicted) that, upon a rotation around rotation axis A relative to rotor body 101, comes into abutment against a step (also not depicted) of inner wall 181. For example, outer envelope 141 of threaded bushing 140 can be constituted by a hexagon.

[0040] Correspondingly thereto, inner wall 181 of attachment element 110 can likewise be constituted as a complementary hexagon. In addition, inside diameter D2 of further receptacle 180 is embodied to be somewhat larger than the outside diameter of threaded bushing 140. This ensures that a clearance S1 exists in a radial direction, perpendicularly to rotation axis A, between threaded bushing 140 and rotor body 101, as is apparent from FIG. 2. Threaded bushing 140 is thus inserted with a clearance into further receptacle 180, but can nevertheless come into abutment against inner wall 181 of further receptacle 180 upon a rotation around axis A. Alternatively, it is also possible to equip outer envelope 141 of the threaded bushing with a harmonic triangular profile or P3G profile. The harmonic polygonal profile having a continuous P3-shaped curve results in an “equal thickness” in all angular positions, and thus yields a high-quality profile for torque transfer.

[0041] Before the mounting of rotor 100 on turbocharger shaft 5 is discussed, a method for producing rotor 100, and the further construction of rotor 100, will be explained with reference to FIGS. 6a to 6c and 7a to 7e.

[0042] In a first step for producing rotor 100, for example, in FIG. 6a a not-yet-magnetized blank 130a for the subsequent permanent magnet 130, having cylindrical dimensions, is furnished. The end faces of blank 130a are ground off at the axial end faces depicted in FIG. 6a by the dashed line. A backing washer 160 and a further backing washer 170 are then adhesively bonded onto the end faces of blank 130a which face away from one another, as depicted in FIG. 6b. Backing washers 160, 170 can be produced as stamped parts from nonmagnetic material, and can then have been subjected to a heat treatment and a grinding process.

[0043] As depicted in FIG. 6c, the subassembly made up of blank 130 and the bonded-on backing washers 160, 170 can be subjected at the surface to a further grinding operation. This subassembly is then introduced into sleeve 120, as depicted in FIG. 7a. This can be effected, for example, by press-fitting. In supplementary or alternative fashion, a heat treatment of sleeve 120 can also be performed. It is also possible to heat up the sleeve, introduce the subassembly into the sleeve, and then cool the entire combined unit. The compressive force between the sleeve and permanent magnet must be sufficient to allow the necessary torques to be transferred. Backing washers 160, 170 protect, in particular, the edges of blank 130a from damage when sleeve 120 is pressed on. Sleeve 120 preferably has an encircling collar 121 that constitutes an axial prolongation in the direction of rotation axis A and protrudes from the subassembly beyond backing washer 160. As is evident from FIG. 7a, blank 130a fills up the entire space between the inner side of sleeve 120 and backing washers 160, 170.

[0044] As shown in FIG. 7b, the assembled magnet subassembly from FIG. 7a can be disposed on the above-described attachment element 110. Firstly, threaded bushing 140 is inserted into further receptacle 180 of attachment element 110, and then the magnet subassembly is slid or pressed, with collar 121, over a shoulder 116 on inner side 113 of the attachment element.

[0045] Then, as shown in FIG. 7c, the encircling collar 121 can be welded encirclingly in a radial direction to attachment element 110 at position 202. In addition, a further welding operation takes place at position 201, in an axial direction or also (not depicted) a radial direction, between the encircling rim of further backing washer 170 and sleeve 120.

[0046] In a further step that is indicated in FIG. 7d, the almost completely manufactured rotor 100 is balanced in planes at positions W1 and W2 in FIG. 7d.

[0047] Lastly, as shown in FIG. 7e, blank 130a can be magnetized and thereby converted into permanent magnet 130.

[0048] As can be gathered best from FIG. 2, in the completely manufactured rotor 100 a further clearance S2 exists between inner backing washer 160 and threaded sleeve 140. Threaded sleeve 140 is movable thereby in an axial direction (i.e., in the direction of rotation axis A), and as a result of clearance S1 in a radial direction (perpendicularly to the rotation axis), and is movable in further receptacle 180, so to speak, as a “floating” bushing. As is further evident from FIG. 2, the cylindrical outer wall of sleeve 120 can be embodied in particular to be aligned with outer wall 111 of attachment element 110, so that overall a cylindrical conformation of rotor body 101 exists; this is not, however, obligatorily necessary.

[0049] FIG. 3 is a perspective view of a rotor body 101 in accordance with a further exemplifying embodiment. In order to facilitate the installation of rotor 100 on turbocharger shaft 5, rotor body 101 can have a shape that allows placement of an installation tool. As shown in FIG. 3, rotor body 101 has on outer envelope 111 of attachment element 110 a wrench flat 117 for placement of a wrench. In the exemplifying embodiment shown in FIG. 3, wrench flat 117 has two flats.

[0050] FIG. 4 is a perspective view of a rotor body 101 in accordance with a further exemplifying embodiment. Only the differences with respect to the exemplifying embodiment of FIG. 3 will be described below, and identical components are labeled with identical reference characters. As shown in FIG. 4, wrench flat 117 can be embodied hexagonally. Alternatively, wrench flat 117 can be embodied in square or similar fashion.

[0051] FIG. 5 is a perspective view of a collet 300. The collet represents a clamp for clamping workpieces or tools rapidly and nonpositively with high accuracy. It is made up of a externally wedge-shaped radially slotted sleeve having a round (occasionally also square or hexagonal) bore of defined size. A collet includes a collet chuck having an inner taper that matches the collet. Clamping is effected by tightening a coupling nut, with which the collet is pushed into the internal taper of the collet chuck. Because of the slots in the collet, the bore becomes uniformly compressed in its interior, with the result that the workpiece or tool becomes nonpositively retained. Collets clamp unfinished or machined parts quickly, immovably, and with accurate centering. Outer envelope 111 of attachment element 110 can have a mounting portion for mounting collet 300. Rotor 100 can be correspondingly mounted on turbocharger shaft 5 by way of collet 300, in particular by retaining and/or counter-tightening the turbocharger shaft in the region of the turbine wheel.

[0052] It is furthermore also possible to equip rotor 100 in the region of further backing washer 170 with a torx socket (not depicted) into which a tool for bolting rotor 100 onto turbocharger shaft 5 can be inserted.

[0053] In all embodiments, rotor 100 can be thread-mounted onto turbocharger shaft 5 by way of a threaded connection, and at the same time can be aligned, for example with a cylindrical press fit, with respect to rotation axis A of turbocharger shaft 5. As already stated, attachment element 110 of rotor 100 has a cylindrical bore 150 concentric with rotation axis A. Inside diameter D1 of this cylindrical bore 150 is embodied to constitute a clearance fit or an interference fit between turbocharger shaft 5 and inner wall 151 of the bore.

[0054] A “fit” is to be understood as a dimensional relationship between two components that are intended to fit together without reworking. These components have the same contour at the join, one as an internal shape and one as an external shape. The two contours have the same nominal dimension. What differs are the two tolerance zones within which the respective actual dimension, resulting in the context of fabrication, of the internal shape and external shape must lie.

[0055] A “press fit” is a dimensional relationship between two components, in the form of an internal shape and an external shape, in which the maximum dimension of an inner contour of the outer shape is in all cases smaller than a minimum dimension of an outer contour of the inner shape. The press fit can also be referred to as an “interference fit.” The interference, or “overdimension,” should in principle be embodied to be as small as possible based on an expected torque increase upon installation of the rotor on the turbocharger shaft. In principle, the torsional moment can increase as a higher pressure is selected.

[0056] Turbocharger shaft 5 has, at its end provided for the mounting of rotor 100, a first portion having an external thread 51 (FIG. 1). Adjoining the portion equipped with external thread 51 in a direction of rotation axis A, on the side of external thread 51 facing away from the rotor, is a region in which turbocharger shaft 5 has a cylindrical outer envelope 53 that is provided as a press-fitting region. In the exemplifying embodiment depicted in FIG. 1, cylindrical outer envelope 53 has a diameter D3 that is greater than inside diameter D1 of cylindrical bore 150.

[0057] When rotor 100 is secured on turbocharger shaft 5, the region equipped with external thread 51 is pushed through bore 150 of rotor body 101 and screwed into threaded bushing 140. At the same time, inner wall 151 of bore 150 is pressed onto cylindrical outer envelope 53.

[0058] As rotor 100 is screwed onto turbocharger shaft 5, threaded bushing 140 functions as a floating threaded bushing and permits a radial tolerance compensation as a result of clearance S1. Threaded bushing 140 has an internal thread 142 that can be a fine or standard internal thread. The fine thread can have an advantage over a standard thread in terms of greater self-locking. The standard thread can be a standardized thread having metric dimensions. It usually has a 62° bevel angle. Such threads are standardized, for example, in accordance with DIN 13-1. The standard thread can furthermore be a UNF thread. A “fine thread” is to be understood in the context of the present invention as a thread that has a narrower thread profile as compared with the standard thread. For differentiation it is usually identified, in addition to the outside diameter, with the dimension of its (likewise smaller) pitch.

[0059] Upon mounting of rotor 100, centering of the rotor relative to rotation axis A of turbocharger shaft 5 occurs by way of the press fit between inner wall 151 of bore 150 and outer envelope 53 of turbocharger shaft 5. An axial clamping force is generated by way of threaded bushing 140: threaded bushing 140 braces against support 115 of attachment element 110 and thereby generates a clamping force that presses attachment element 115 with its outer side 112 against a stop surface on compressor wheel 13, as is most clearly evident from FIG. 1. Compressor wheel 13 in turn braces against a stop 52 of turbocharger shaft 5, so that compressor wheel 13 becomes clamped between stop 52 and attachment element 110 of rotor 100. A defined axial preload force can thus be exerted on the compressor wheel by way of rotor 100.

[0060] If a clearance fit is used instead of the press fit between inner wall 151 and the outer envelope, subsequent balancing of the subassembly is advisable. With a clearance fit there exists between two components, in the form of an inner shape and an outer shape, a dimensional relationship in which the maximum dimension of an inner contour of the outer shape is somewhat larger than a maximum dimension of an outer contour of the inner shape.