ROTOR ARRANGEMENT AND METHOD FOR MANUFACTURING A ROTOR ARRANGEMENT

Abstract

A rotor arrangement (1a, 1b) for an electric machine of a vehicle. The rotor arrangement (1a, 1b) comprises a rotor lamination stack (4) and the rotor arrangement further comprises a rotor support (2a, 2b). The rotor support (2a, 2b) carries the rotor lamination stack (4), which is arranged on the radially outer side (6a, 6b) of the rotor support (2a, 2b). A retaining element is arranged on the outer side (6a, 6b) of the rotor support at the end on the rotor lamination stack (4). The retaining element is a one-piece, closed retaining ring (5a, 5b) with an axial ring width (SR) and with at least a first ring diameter (R1). The first ring diameter (R1) is smaller than or equal to the rotor support diameter (TR), so that the rotor laminate stack (4) is secured axially in a rotationally fixed manner. The invention also relates to two production methods.

Claims

1-15. (canceled)

16. A rotor arrangement (1a, 1b) for an electric machine of a vehicle, wherein the rotor arrangement (1a, 1b) comprises a rotor lamination stack (4), and the rotor arrangement (1a, 1b) further comprises a rotor support (2a, 2b) that extends in an axial direction (A) along a rotational axis (D1) with a radially outer side (6a, 6b) and with a rotor support diameter (TR), the rotor support (2a, 2b) carries the rotor lamination stack (4), which stack is arranged on the radially outer side (6a, 6b) of the rotor support (2a, 2b) and has a retaining element, which element is arranged on the outer side (6a, 6b) of the rotor support (2a, 2b) at the end on the rotor lamination stack (4), the retaining element is in the form of a one-piece, closed, rotationally symmetrical retaining ring (5a, 5b) with an axial ring width (SR) and with at least a first ring diameter (R1), and the first ring diameter (R1) is smaller than or equal to the rotor support diameter (TR) so that the rotor lamination stack (4) is secured axially in a rotationally fixed manner.

17. The rotor arrangement (1a, 1b) according to claim 16, wherein the first ring diameter (R1) is smaller than the rotor support diameter (TR).

18. The rotor arrangement (1a) according to claim 16, wherein the rotor support (2a) has an all-round groove (7) in which the retaining ring (5a) is hooked/arranged.

19. The rotor arrangement according to claim 18, wherein the retaining ring has a plurality of radially inward-directed projections (8) not diametrically opposite one another, which extend over a partial region of the axial ring width (SR), whereby a second ring diameter (R2) is formed.

20. The rotor arrangement (1a) according to claim 19, wherein the projections (8) are arranged on a side of the retaining ring (5a) that faces away from the rotor lamination stack (8).

21. The rotor arrangement according to claim 19, wherein the projections (8) are hooked/arranged in the all-round groove (7).

22. The rotor arrangement (1a) according to claim 19, wherein by virtue of the all-round groove (7), the rotor support (6a) forms a groove base diameter at the all-round groove (7), and the groove base diameter is smaller than the second ring diameter.

23. The rotor arrangement (1a) according to claim 18, wherein the rotor support (2a) has axial longitudinal grooves (9) that extend to the all-round groove (7), so that by virtue of the projections (8) position-related fitting of the retaining ring (5a) is enabled.

24. The rotor arrangement (1a) according to claim 23, wherein a number of projections (8) is equal to a number of axial longitudinal grooves (9) in the rotor support (2a).

25. The rotor arrangement according to claim 18, wherein the retaining ring (5a) has axial longitudinal retaining ring grooves (10).

26. The rotor arrangement (1b) according to claim 16, wherein the rotor support (2b) has a plurality of outward-directed radial appendages, which are arranged uniformly at the end a distance away from the rotor lamination stack (4), and the retaining ring (5b) is positioned between the rotor lamination stack (4) and the appendages in order to secure the rotor lamination stack (4) axially in a rotationally fixed manner.

27. The rotor arrangement according to claim 26, wherein the plurality of outward-directed radial appendages form an all-round outward-directed ridge (11).

28. The rotor arrangement according to claim 26, wherein the retaining ring (5b) has axial longitudinal retaining ring grooves.

29. A method for producing and/or assembling a rotor arrangement (1a), wherein the rotor arrangement (1a) comprises a rotor support (2a) that extends in an axial direction (A) along a rotational axis (D1) and has a radial outer side (6a) on which a rotor lamination stack (4) is arranged, and with a rotor support diameter (TR), the rotor support (2a) also has an all-round groove (7) and a plurality of axial longitudinal grooves (9) that extend to the all-round groove (7), the method comprising: producing a retaining ring (5a) in which the retaining ring (5a) has a first ring diameter (R1) and comprises radially inward-directed projections (8) not diametrically opposite one another positioned over a partial region of an axial ring width, whereby a second ring diameter (R2) is formed, such that the first ring diameter (R1) is larger than the second ring diameter (R2), and a number of axial longitudinal grooves (9) is equal to or larger than a number of projections (8), and the first ring diameter (R1) is smaller than or equal to the diameter (TR) of the rotor support, heating the retaining ring (5a) in order to expand the retaining ring (5a), positioning the projections (8) in the axial longitudinal grooves (9) and pushing the retaining ring (5a) along the axial longitudinal grooves (9) until the projections (8) become hooked into the all-round groove (7) and the retaining ring (5a) is fitted with its first ring diameter (R1) at the end on the rotor lamination stack (4), and cooling the heated retaining ring (5a).

30. The method for producing and/or assembling a rotor arrangement (1a), wherein the rotor arrangement (1a) comprises a rotor support (2a) that extends in an axial direction (A) along a rotational axis (D1) and has a radial outer side (6a) on which a rotor lamination stack (4) is arranged, and with a rotor support diameter (TR), wherein the outer side (6b) has an outward-directed appendage (11) which is arranged at the end a distance away from the rotor laminate stack (4), the method comprising: producing a retaining ring (5b) such that the retaining ring (5b) has a first ring diameter (R1) and the first ring diameter (R1) is smaller than or equal to the rotor support diameter (TR), heating the retaining ring (5b) in order to expand the retaining ring (5b), pushing the heated retaining ring (5b) along the rotor support (4) and sliding over the appendage (11) until the retaining ring (5b) is positioned between the rotor lamination stack (4) and the appendage (11) at the end, cooling the heated retaining ring (5b) in order to secure the rotor lamination stack axially and in a rotationally fixed manner.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0041] Further features, properties and advantages of the present invention emerge from the description that follows, with reference to the attached figures. Variations thereof can be derived by those with knowledge of the subject without departing from the protective scope of the invention as defined by the claims that follow.

[0042] The figures show, in each case schematically:

[0043] FIG. 1: A first embodiment of a rotor arrangement according to the invention, shown schematically,

[0044] FIG. 2: A retaining ring, shown schematically,

[0045] FIG. 3: A rotor support with longitudinal axial grooves, in detail,

[0046] FIG. 4: A retaining ring with longitudinal retaining ring grooves,

[0047] FIG. 5: A method according to the invention for fitting the retaining ring, shown schematically,

[0048] FIG. 6: A second embodiment of a rotor arrangement according to the invention, shown schematically.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0049] FIG. 1 shows a first embodiment of a rotor arrangement 1a according to the invention, represented schematically.

[0050] This comprises a rotor support 2a which is arranged, for example, on a shaft 3.

[0051] The shaft 3 and the rotor support 2a have a rotational axis D1, which at the same time defines the axial direction A.

[0052] Furthermore, the rotor arrangement 1a comprises a rotor lamination stack 4, and the rotor lamination stack 4 is supported by the rotor support 2a on the radially outer surface 6a of the rotor support 2a. A rotor lamination stack of this type usually consists of a plurality of stamped-out sheet-metal lamellae, which are arranged on the said outer surface 6a of the rotor support 2a. The rotor support 2a has a rotor support diameter TR.

[0053] In this, the rotor lamination stack 4 and the rotor support 2a are usually parts of a rotor which also has windings (not shown), which can be arranged along the rotor lamination stack 4.

[0054] Such a rotor (not shown) is part of an electric machine, which also comprises a stator (not shown). The shaft 3, onto which the rotor is fixed, ensures that the rotor and thus also the rotor support 2a and the rotor lamination stack 4 can rotate along the stator. For that purpose the rotor lamination stack 4 has to be fixed onto the rotor support 2a in a rotationally fixed manner.

[0055] The rotor arrangement 1a also comprises a retaining ring 5a, which is arranged at the end on the outside 6a on the rotor lamination stack 4 of the rotor support 2a.

[0056] In this case, the retaining ring 5a is in the form of a closed, rotationally symmetrical retaining ring 5a. The retaining ring 5a has an axial ring width SR. The retaining ring 5a forms a first ring diameter R1. In this case, the first ring diameter R1 of the retaining ring 5a is smaller than the rotor support diameter TR. In this way, a centering seat is formed, which corresponds to the rotor support diameter TR. Thus, the rotor lamination stack 4 is axially secured.

[0057] Furthermore, the retaining ring 5a has projections 8 which are directed radially inward.

[0058] FIG. 2 shows a retaining ring 5a of that type in detail. The said projections 8 extend only over a partial region of the axial ring width SR (FIG. 1), and this, over a partial region facing away from the rotor lamination stack 4. The projections 8 are arranged facing inward and, in each case, are not diametrically opposite one another. In that way, over the said partial region a second ring diameter R2 is formed. This second ring diameter R2 is smaller than the first ring diameter R1.

[0059] As can also be seen in FIG. 1, the rotor support 2a has an all-round groove 7 which is arranged in such a manner that the projections 8 are positioned in this all-round groove 7. At the location of the all-round groove 7 the rotor support 2a has a groove base diameter which is smaller than the second ring diameter R2. Thus, the retaining ring 5a is not in contact with the groove base.

[0060] If an axial displacement takes place, then owing to its projections 8 the retaining ring 5a hooks into the groove 7 and is axially secured. In addition, the outer surface 6a of the rotor support 2a has axial longitudinal grooves 9 (FIG. 3). These extend at least on one side of the rotor support 2a as far as the groove 7. The number of axial longitudinal grooves 9 (FIG. 3) corresponds to the number of projections 8.

[0061] The retaining ring 5a is first heated to fit the retaining ring 5a. It expands due to the heating. For example, for that purpose the retaining ring 5a is made from case-hardening steel 16MnCr5 which, on the one hand, has high wear resistance and, on the other hand, expands substantially. For the fitting, the projections 8 of the heated and expanded retaining ring 5a are positioned in the axial longitudinal grooves 9 (FIG. 3) and slid along them until they engage in the all-round groove 7 or are positioned therein.

[0062] Thanks to the structure of the axial longitudinal grooves 9 (FIG. 3), position-related assembly is possible. Thereafter, the retaining ring 5a is cooled, for example due to the ambient temperature.

[0063] FIG. 3 shows the axial longitudinal grooves 9 of the rotor support 2a in detail.

[0064] In addition, the retaining ring 5a has axial longitudinal retaining ring grooves 10, i.e., longitudinal grooves along the retaining ring 5a.

[0065] These retaining ring longitudinal grooves 10 are shown in more detail in FIG. 4. Through them oil, which is used for the cooling and/or lubrication of the rotor and rotor lamination stack 4, can make its way in easily.

[0066] In this case, the retaining ring longitudinal grooves 10 are arranged over the projections 8, i.e., above them in the radial direction. Thus, the retaining ring longitudinal grooves 10 and the axial longitudinal grooves 9 (FIG. 3) of the rotor support 2a form a line through which the oil can emerge.

[0067] By virtue of such a closed retaining ring 5a with a cylindrical centering seat, which has a ring diameter R1 (FIG. 2) which is smaller than the rotor support diameter TR (FIG. 3), and also the rear-hook configuration, the rotor lamination stack 4 can be axially secured in a manner unaffected by rotation speed.

[0068] Dismantling is not possible without destroying the retaining ring 5a according to the invention.

[0069] FIG. 5 illustrates the method, according to the invention, for fitting the retaining ring 5a (FIG. 1).

[0070] For this, in a first step S1 the retaining ring 5a (FIG. 1) is heated to expand it.

[0071] In a second step S2, the retaining ring 5a (FIG. 1) is now positioned with the projections 8 (FIG. 1) in the axial longitudinal grooves 9, and pushed along the rotor support (2a) (FIG. 1). Owing to the expansion, the retaining ring 5a can now be fitted onto the rotor support 2a (FIG. 1) despite originally having a smaller ring diameter R2 (FIG. 2). The retaining ring 5a is pushed along the axial longitudinal grooves 9 (FIG. 3) of the rotor support 2a (FIG. 1) until the projections 8 (FIG. 1) have hooked into the all-round groove 7 (FIG. 1) and the retaining ring 5a (FIG. 1) with its first ring diameter R1 (FIG. 2) is arranged at the end on the rotor lamination stack 4 (FIG. 1).

[0072] In a third step S3, the heated retaining ring 5a (FIG. 1) is cooled. In that way, the retaining ring 5a (FIG. 1) can be fitted without the use of force.

[0073] FIG. 6 shows a further design of a rotor arrangement 1b with a retaining ring 5b according to the invention.

[0074] This rotor arrangement 1b has a rotor support 2b which is arranged, for example, on a shaft 3.

[0075] The shaft 3 and also the rotor support 2b have a rotational axis D1 and an axial direction A.

[0076] Furthermore, the rotor arrangement 2b comprises the rotor lamination stack 4, wherein the rotor lamination stack 4 is carried by the rotor support 2b on the radially outer surface 6b of the rotor support 2b.

[0077] Such a rotor lamination stack 4 usually consists of a plurality of stamped-out sheet-metal laminations, which are arranged on the outer surface 6b of the rotor support 2a. The rotor support 2b has a rotor support diameter TR.

[0078] In this case, the rotor lamination stack 4 and the rotor support 2b are usually part of a rotor, which also has windings (not shown) which can be arranged along the rotor lamination stack 4.

[0079] Such a rotor (not shown) is part of an electric machine which, in addition, comprises a stator (not shown). The shaft 3 on which the rotor is fixed ensures that the rotor and thus also the rotor support 2b and the rotor lamination stack 4 can rotate along the stator.

[0080] For this, the rotor lamination stack 4 must be attached rotationally fixed onto the rotor support 2b.

[0081] The rotor arrangement 1b also comprises a retaining ring 5b, which is arranged on the outside 6b of the rotor lamination stack 4 of the rotor support 2.

[0082] The retaining ring 5b has a ring diameter R1. This ring diameter R1 is smaller than the diameter TR of the rotor support of the rotor support 2b.

[0083] In addition, the rotor support 2b has an all-round appendage 11, which is likewise arranged at the end a distance away from the rotor lamination stack 4. The said appendage is arranged radially, directed outward.

[0084] The retaining ring 5b is arranged between the rotor lamination stack 4 and the appendage 11, in a rear-hook formation. By virtue of the smaller ring diameter R1 compared with the rotor support diameter TR, a cylindrical centering seat is formed.

[0085] In that way, the appendage 11 creates a rear hooking configuration which prevents the axial displacement of the retaining ring 5b.

[0086] Furthermore, the retaining ring 5b has axial longitudinal retaining ring grooves (not shown), i.e., longitudinal grooves along the retaining ring 5b. Through these, the oil used to cool and/or lubricate the rotor and rotor lamination stack 4 can pass through easily.

[0087] For assembly, the retaining ring 5b is heated in order to expand it.

[0088] Thereafter, the heated retaining ring 5b is fitted onto the rotor support 2b and slid along it. Owing to the heating, the retaining ring 5b now has a larger diameter than the diameter TR of the rotor support. The retaining ring 5b is pushed over the radially outward-directed appendage 11 so that the retaining ring 5b is positioned at the end between the rotor lamination stack 4 and the appendage 11. After cooling, the retaining ring 5b rests against the rotor support 2b in a manner unaffected by rotation speed, to secure the rotor lamination stack 4 in an axially and rotationally fixed manner. This enables fitting of the retaining ring 5b without the use of force.

INDEXES

[0089] 1a, 1b Rotor arrangement [0090] 2a, 2b Rotor support [0091] 3 Shaft [0092] 4 Rotor lamination stack [0093] 5a, 5b Retaining ring [0094] 6 Outer surface [0095] 7 Groove [0096] 8 Projection [0097] 9 Axial longitudinal groove [0098] 10 Longitudinal retaining ring grooves [0099] 11 Appendage [0100] TR Rotor support diameter [0101] R1 First ring diameter [0102] R2 Second ring diameter [0103] D1 Rotational axis [0104] A Axial direction