METHOD FOR CORRECTING A PORTION OF A MATERIAL LAYER, MATERIAL LAYER, AND DYNAMOELECTRIC MACHINE

Abstract

In a method for correcting a portion, in particular a tooth, of a material layer of a dynamoelectric machine, with the material layer including a soft-magnetic material and having a layer thickness between 0.5 and 500 μm, an actual geometry of the portion of the material layer is ascertained and compared to a target geometry. A deviation of the actual geometry from the target geometry is determined. Before the deviation is corrected by partially plastically deforming the material layer using a light source, the material layer is partially heated by a further light source.

Claims

1.-17. (canceled)

18. A method for correcting a portion, in particular a tooth, of a material layer of a dynamoelectric machine, with the material layer comprising a soft-magnetic material and having a layer thickness between 0.5 and 500 μm, said method comprising: ascertaining an actual geometry of the portion of the material layer; comparing the actual geometry to a target geometry; determining a deviation of the actual geometry from the target geometry; and before subjecting the material layer to a partial plastic deformation by a light source to correct the deviation, partially heating the material layer by a further light source.

19. The method of claim 18, wherein the material layer has a layer thickness between 10 and 100 μm.

20. The method of claim 18, wherein the actual geometry of the portion is ascertained by an optical unit.

21. The method of claim 18, wherein the material layer is partially heated to cause a partial melting.

22. The method of claim 18, wherein the partial plastic deformation is a partial thermal plastic deformation.

23. The method of claim 18, wherein the plastic deformation is a partial melting.

24. The method of claim 18, wherein the light source is a laser.

25. The method of claim 18, wherein the light source is an LED,

26. The method of claim 18, further comprising plastically deforming, in particular melting, the material layer at a tooth base of a tooth.

27. The method of claim 18, wherein the light source has a beam intensity of between 80 kW/cm.sup.2 and 120 kW/cm.sup.2, in particular between 90 kW/cm.sup.2 and 110 kW/cm.sup.2.

28. The method of claim 18, wherein the further light source has a beam intensity between 1 kW/cm.sup.2 and 10 kW/cm.sup.2.

29. The method of claim 26, wherein the tooth base is partially deformed, in particular melted, in such a way that a warpage occurring upon re-solidification is such that a tooth head of the tooth adapts to the target geometry.

30. The method of claim 18, wherein the light source has a focus size between 0.005 mm and 10 mm, preferably between 50 μm and 150 μm.

31. The method of claim 18, wherein the further light source has a focus size between 1 mm and 5 cm, preferably between 1 cm and 5 cm.

32. The method of claim 18, wherein the light source has an exposure time between 0.1 ms and 100 ms.

33. The method of claim 18, wherein the further light source has an exposure time between 1 ms and 100 ms.

34. A material layer for a dynamoelectric machine, said material layer being corrected by a method as set forth in claim 18, said material layer having a layer thickness between 0.5 and 500 μm, in particular between 10 and 100 μm, and comprising a soft-magnetic material.

35. A material layer microstructure for a dynamoelectric machine, said material layer microstructure including a plurality of material layers arranged one on top of another, each said material layer being corrected by a method as set forth in claim 18, said material layer having a layer thickness between 0.5 and 500 μm, in particular between 10 and 100 μm, and comprising a soft-magnetic material.

36. A dynamoelectric machine, comprising a material layer microstructure as set forth in claim 35.

Description

[0068] The invention is described and explained in more detail hereinafter on the basis of the exemplary embodiments shown in the figures. In the figures:

[0069] FIG. 1 shows a possible sequence of the method according to the invention,

[0070] FIG. 2 shows a possible method for ascertaining an actual geometry of a portion,

[0071] FIG. 3 shows partial melting,

[0072] FIG. 4 shows a tooth before a correction,

[0073] FIG. 5 shows the tooth after a correction, and

[0074] FIG. 6 shows a dynamoelectric rotational machine.

[0075] FIG. 1 shows a possible sequence of the method according to the invention for correcting a portion of a material layer 1.

[0076] The method according to the invention is explained on the basis of the example “melting”. However, the method can be carried out similarly by means of “plastic deformation”, in particular “thermal plastic deformation”.

[0077] The portion is preferably a tooth of a material layer.

[0078] In a method step S1, an actual geometry of the portion is ascertained by means of an optical unit. The ascertainment of the actual geometry is described in more detail in FIG. 2.

[0079] In a method step S2, the ascertained actual geometry is compared to a target geometry.

[0080] In a method step S3, a deviation of the actual geometry from the target geometry is determined.

[0081] In a method step S4, the material layer is partially melted by means of a light source. The light source is preferably embodied in this case as a laser, however, it is also possible that the partial melting is carried out by means of an LED.

[0082] The partial melting is described in more detail in FIG. 3. FIG. 2 shows a possible method for ascertaining the actual geometry of the portion.

[0083] The ascertainment of the actual geometry is carried out by means of an optical unit. For example, a flatbed scanner or a line scanner or also a camera can be used. Other scanners or devices which enable a representation by means of an imaging method are also suitable.

[0084] A scanner offers the advantage that the component to be measured can be depicted particularly well at a high resolution on a large area. For example, details in the range between 10.sup.−2 and 10.sup.−3 mm can be recorded and reproduced on an area between 10.sup.4 and 10 mm.sup.2.

[0085] In a method step E1, a material layer is measured using the optical unit, in particular using a scanner.

[0086] In a method step E2, a raw file of the material layer is generated. This is advantageously a raw image of the material layer in front of a preferably monochromatic and/or matte background.

[0087] In a method step E3, the raw file is cropped and binarized, in particular in a color-based manner. The file is advantageously converted into a black-and-white image.

[0088] The resulting image can then optionally be aligned on the basis of a marking mark in method step E4.

[0089] In a method step E5, by ascertaining the black/white transitions, the actual geometry of at least one tooth, preferably each tooth, is determined.

[0090] In a method step E6, a deviation with respect to a target geometry is quantified and in method step E7, it is visualized. Misalignments which are smaller than 5 μm can be recognized in this method.

[0091] FIG. 3 shows the partial melting.

[0092] The example “melting” in this Figure is selected for better comprehension. It is possible to carry out the method similarly by means of thermal plastic deformation.

[0093] The Figure shows a detail of a material layer 1, which is suitable for a stator 22 of a dynamoelectric machine 20.

[0094] The material layer 1 has a layer thickness d between 0.5 and 500 μm, in particular between 10 and 100 μm. The material layer 1 comprises a soft-magnetic material. The material layer 1 can comprise an insulation material 2 on at least one layer side.

[0095] The Figure shows a plurality of teeth 3. Each tooth 3 has a tooth head 5, a tooth neck 4, and a tooth base 7. The Figure furthermore shows an end face 9 and a lateral surface 11. Moreover, a straightening laser beam 13 and a preheating laser beam 15 are shown in the Figure.

[0096] The straightening laser beam 13 in the Figure is the above-explained light source or melting light source. Another type of light source can also be used, for example, an LED.

[0097] The preheating laser beam 15 in the Figure is the above-explained further light source or preheating light source. Another type of light source can also be used, for example, an LED.

[0098] Partial misalignments, in particular of the teeth, are selectively corrected by means of the straightening laser beam 13. In this case, a warpage occurring upon melting by means of the straightening laser beam 13 and subsequent re-solidification of the material is utilized to achieve a shape change.

[0099] In order, for example, to rotate a tooth 3 in the material layer plane and correctly align it, a straightening laser beam 13 having a focus size f13 having preferably low beam intensity (advantageously up to about 100 kW pro cm.sup.2) is focused in the area of the tooth base 7 on the lateral surface 11 and the material is melted once or multiple times in spots or in a planar manner. A small warpage in the area of the tooth base is sufficient here to effectuate a sufficiently large rotation of the tooth head 5.

[0100] The strength of the rotation can be controlled in this case via various dimensions, for example, via the laser intensity, focus size, and/or exposure time, The focus size corresponds in this case to a diameter of the respective light source at the moment of incidence on the material layer. The focus size is advantageously less than the layer thickness of the material layer.

[0101] The area of the tooth base 7 can optionally be preheated via the preheating laser beam 15 having a focus size f15. The preheating laser beam 15 is preferably aimed at the end face 9, as shown in the Figure. An even higher penetration depth of the melt pool is thus achieved.

[0102] Targeted straightening of the material layer is possible by way of the straightening laser beam 13 and the optional preheating laser beam 15. Misalignments of, for example, 100 μm can be corrected to less than 20 μm.

[0103] The statements on FIG. 3 also apply to other light sources, for example LEDs.

[0104] FIG. 4 shows the tooth 3 before the correction. FIG. 5 shows the tooth 3 after the correction.

[0105] The two Figures show the tooth 3 having the tooth head 5 and the tooth base 7.

[0106] Furthermore, the two Figures show an actual geometry 16 and a target geometry 17.

[0107] Moreover, an exposure zone of the straightening laser 131 is shown in FIG. 4. A dear deviation of the actual geometry 16 from the target geometry 17 is shown in FIG. 4, before the straightening laser beam 13 acts.

[0108] FIG. 5 clearly shows that the actual geometry 16 of the corrected tooth 3 only still has a very minor deviation, which is sometimes to be neglected, with respect to the target geometry 17. The before and after comparison from FIGS. 4 and 5 shows how the action of the laser on the tooth base 7 enables a rotation of the tooth head 5.

[0109] FIG. 6 shows a dynamoelectric rotational machine 20 having a rotor 21, a stator 22, and a shaft 23.

[0110] The stator 22 preferably has a plurality of material layers 1. These are arranged as a stator material layer microstructure 221.

[0111] The rotor 21 has a plurality of material layers 24. These are arranged as a rotor material layer microstructure 211.

[0112] The material layers 24 can experience a similar correction using the described method. For example, the invention can be used for a correction of material layers of grooved rotors or also for the shape change of pockets for internal permanent magnets. Moreover, a roundness of reluctance rotors can be improved to achieve a uniform air gap.