ROTOR TUBE FOR AN ELECTRIC MACHINE OF A VEHICLE

Abstract

A rotor tube for an electric machine of a vehicle includes an outer tube and first and second coupling sections coupled to the outer tube at opposite end regions of the outer tube relative to a longitudinal axis of the rotor tube. First and second hubs are coupled to the outer tube at the opposite end regions of the outer tube relative to the longitudinal axis of the rotor tube. A ventilation element is coupled to the outer tube. An inner tube is disposed within the outer tube relative to the longitudinal axis of the rotor tube such that the outer tube surrounds the inner tube. At least two components selected from the first coupling section, second coupling section, first hub, second hub, outer tube, ventilation element and inner tube are formed in one piece as a cast component.

Claims

1-13. (canceled)

14. A rotor tube for an electric machine of a vehicle, the rotor tube comprising: a longitudinal axis of the rotor tube; an outer tube having opposite end regions; a first coupling section and a second coupling section each coupled to a respective one of said opposite end regions of said outer tube relative to said longitudinal axis of the rotor tube; a first hub and a second hub each coupled to a respective one of said opposite end regions of said outer tube relative to said longitudinal axis of the rotor tube; a ventilation element coupled to said outer tube; and an inner tube disposed inside said outer tube relative to said longitudinal axis of the rotor tube, said inner tube being surrounded by said outer tube; said first coupling section, said second coupling section, said first hub, said second hub, said outer tube, said ventilation element and said inner tube being components, and at least two of said components being formed in one piece as a cast component.

15. The rotor tube according to claim 14, wherein said first hub, said second hub and said outer tube form said cast component in one piece.

16. The rotor tube according to claim 15, wherein said first coupling section and said second coupling section also form said cast component in one piece.

17. The rotor tube according to claim 15, wherein said ventilation element also forms said cast component in one piece.

18. The rotor tube according to claim 16, wherein said ventilation element also forms said cast component in one piece.

19. The rotor tube according to claim 14, wherein said ventilation element is integrated into said second hub.

20. The rotor tube according to claim 14, wherein said first hub and said second hub are disposed on an inner side of said outer tube facing said inner tube.

21. The rotor tube according to claim 20, wherein: said first coupling section is coupled to said inner side of said outer tube by said first hub; and said second coupling section is coupled to said inner side of said outer tube by said second hub.

22. The rotor tube according to claim 14, which further comprises at least one positioning element configured to position said inner tube relative to said outer tube in a predefined position relative to said longitudinal axis of the rotor tube.

23. The rotor tube according to claim 22, wherein said at least one positioning element is formed in one piece with said cast component.

24. An electric machine for a vehicle, comprising a rotor tube according to claim 14.

25. The electric machine according to claim 24, wherein the electric machine is a permanent magnet-excited synchronous machine for a direct drive of a vehicle or a wheelset shaft of a rail vehicle.

26. A vehicle, comprising at least one electric machine according to claim 24.

27. The vehicle according to claim 26, wherein the vehicle is a rail vehicle.

Description

[0024] Exemplary embodiments of the invention are described in greater detail in the following, making reference to the schematic drawings, in which:

[0025] FIG. 1 shows a schematic representation of a rail vehicle,

[0026] FIG. 2 shows an exemplary embodiment of a rotor tube for an electric machine of the rail vehicle in accordance with FIG. 1, and

[0027] FIG. 3 shows a schematic representation of the rotor tube coupled to an electric machine of the rail vehicle in accordance with FIGS. 1 and 2.

[0028] Elements of the same construction and function are marked with the same reference characters across all figures.

[0029] FIG. 1 shows, in a schematic side view, a rail vehicle 10 with an electric machine 12, which is coupled to a wheelset shaft 14 by means of a rotor tube 1 and a coupling 16 (see FIG. 3). By means of the rotor tube 1, the torque of the machine 12 is transferred to the wheelset shaft 14 and air is also circulated in an inner cooling circuit. As explained below with reference to FIG. 2, the construction of the rotor tube 1 enables cost savings during manufacturing and also a safe and reliable functionality of the rotor tube 1 and the associated machine 12.

[0030] FIG. 2 shows a possible embodiment of the rotor tube 1 in a perspective view. The rotor tube 1 comprises a cast component 3 which surrounds an inner tube 4 in a cylindrical manner. The cast component 3 is embodied in one piece by means of casting and has an outer tube 35, a first and a second coupling section 31, 32, which are coupled to the outer tube 35 at opposite end regions of the outer tube 35 in relation to the longitudinal axis L of the rotor tube 1, and a first and second hub 33, 34, which are coupled to the outer tube 34 at the opposite end regions of the outer tube 35 in relation to the longitudinal axis L of the rotor tube 1. The cast component 3 further comprises a ventilation element 36, which is coupled to the outer tube 35 and is embodied such that it is integrated in the second hub 34. In this manner, it is possible to realize a particularly space-saving and material-saving construction of the rotor tube 1. Moreover, the cast component 3 has an annular positioning element 37, which is embodied on an inner side 38 of the outer tube 35.

[0031] Moreover, two further positioning elements 5 are present, which, as with the positioning element 37 of the cast component, enable a holding and positioning of the inner tube 4 and a simplified assembly of the rotor tube 1, acting as an assembly aid. The inner tube 4 is arranged inside the outer tube 35 in relation to the longitudinal axis L of the rotor tube 1, so that the outer tube 35 surrounds the inner tube 4. The positioning element 37 preferably has a plurality of finger elements, which extend radially toward the inside in the direction of the longitudinal axis L and, in an assembled state of the rotor tube 1, contact an outer side of the inner tube 4, which faces the outer tube 35.

[0032] The illustrated rotor tube 1 is therefore substantially constructed from two individual structural parts: the cast component 3 and the inner tube 4. In an alternative embodiment of the rotor tube 1, a different breakdown of the integration of individual parts may also be provided. For example, the inner tube 4 may be designed as a cast structural part in a reinforced design with the coupling sections 31, 32, the hubs 33, 34 and the ventilation element 36, and may realize a common cast component, onto which the outer tube 35 is slid.

[0033] The first and second coupling section 31, 32 form respective bearing points and in each case may be embodied in one piece with the inner tube 4 by means of casting on the outer tube 35 or the cast component, or a coupling section 31 may be designed such that it is integrated with the outer tube 35 and the other coupling section 32 may be designed such that it is integrated with the inner tube 4.

[0034] At least two components, consisting of first coupling section 31, second coupling section 32, first hub 33, second hub 34, the outer tube 35, the ventilation element 36 and the inner tube 4, are embodied in one piece by means of casting as a cast component 3, in order to realize a compact and advantageous construction of the rotor tube 1. In accordance with the exemplary embodiment shown in FIG. 2, seven functional structural parts are embodied in one piece in a common cast component 3: the first coupling section 31, which is coupled to the inner side 38 of the outer tube 35 by means of the first hub 33; the second coupling section 32, which is coupled to the inner side 38 of the outer tube 35 by means of the second hub 34; the ventilation element 36, which is embodied such that it is integrated in the second hub 36; and the positioning element 37, which is embodied on the inner side 38 of the outer tube 35.

[0035] Alternatively, the inner tube 4 with the first hub 33 and the outer tube 35 with the second hub 34 and optionally with the ventilation element 36 may also be embodied as a cast component in each case, which realize an embodiment of the rotor tube 1 when coupled together. The outer tube 35 may also be provided as a rolled tube or embodied in a thin-walled manner by means of centrifugal casting.

[0036] The inner tube 4 seals off the inner cooling circuit of the rotor tube 1 and prevents contamination of the interior. By means of the construction described, it is not necessary to press further structural parts onto the inner tube 4, and a flow of force and a torque transfer onto the outer tube 35 also take place by way of the coupling sections 31, 32. The inner tube 4 may therefore be embodied from stainless steel with a relatively low wall thickness of a few millimeters, for example. Compared to conventional rotor tubes, the inner tube 4 of the rotor tube 1 described can be embodied with considerably thinner walls, preferably by way of metal spinning or rolling, so that a contribution is made to saving material, weight and costs. Alternatively, the inner tube 4 may also be manufactured from a glass-fiber-reinforced plastic and embodied in a particularly lightweight manner.

[0037] The inner tube 4 forms a segment, which in an assembled state of the rotor tube 1 connects to an overall inner tube, which is interrupted in the region between the first hub 33 and the second hub 34 for casting-related and machining-related reasons, in order to be able to postprocess the inner side 38 of the outer tube 35 inter alia following the casting. In order to close such an interrupting opening following the machining, the inner tube 4 is installed in the rotor tube 1, for example as a kind of protective tube made of sheet metal, and is coupled to the overall inner tube of an associated machine. The inner tube 4 therefore represents an integrated protective tube, which closes the interrupted overall inner tube off again in relation to the associated machine in an assembled state.

[0038] The bearing points or the coupling sections 31, 32 serve to accommodate respective bearings and for screwing or attaching the coupling 16 of the machine 12. The hubs 33, 34 have recesses, which function as air holes and, together with the ventilation element 36, enable a predefined cooling air flow. The ventilation element 36 has a plurality of air ducts for example, which extend obliquely through the second hub 34 with a predefined incline.

[0039] As a result of at least two, or as shown seven, structural parts being embodied as a common cast component 3, these individual structural parts are integrated in a single structural part with a plurality of functions. Compared to a multi-part construction, fewer structural parts are therefore required and the rotor tube 1 can be manufactured in a material-saving manner, meaning that it is possible to realize a corresponding weight advantage. Due to the fewer structural parts to be manufactured, an assembly of the rotor tube 1 can be performed with less outlay and more time saved. It is thus possible to save further costs and it is also easier to meet technical requirements for the rotor tube.

[0040] Moreover, parting lines between the individual structural parts are avoided or reduced, which in each case represent a potential problem location, for example in relation to fit and corrosion. Due to the integration of a plurality of components in one integrated cast part, such parting lines are dispensed with and a contribution may be made to a reliable operation and an increased service life of the rotor tube 1 and to the machine 12 provided with the rotor tube 1. Additionally, the described embodiment of the rotor tube 1 contributes to a higher level of stability, and to a safe and reliable operation as a result.

[0041] FIG. 3 schematically illustrates the rotor tube 1 in a built-in state in the electric machine 12 of the rail vehicle 10. The rotor tube 1 surrounds the wheelset shaft 14 and is coupled thereto by means of the coupling 16.

LIST OF REFERENCE CHARACTERS

[0042] 1 rotor tube [0043] 10 vehicle [0044] 12 electric machine of the vehicle [0045] 14 wheelset shaft of the vehicle [0046] 16 coupling of the vehicle [0047] 3 cast component [0048] 31 first coupling section of the cast component [0049] 32 second coupling section of the cast component [0050] 33 first hub of the cast component [0051] 34 second hub of the cast component [0052] 35 outer tube of the cast component [0053] 36 ventilation element of the cast component [0054] 37 positioning element of the cast component [0055] 4 inner tube [0056] 5 positioning element [0057] L longitudinal axis