Rotor for Separately Excited Inner Rotor Synchronous Machine, Inner Rotor Synchronous Machine, Motor Vehicle and Method

Abstract

A rotor for a separately excited inner rotor synchronous machine of an electrically drivable motor vehicle, having a plurality of rotor windings for forming a rotor magnetic field and a rotor core for holding the rotor windings, wherein the rotor core has an annular rotor yoke with a number of rotor poles corresponding to a number of rotor windings. The poles are arranged along a rotor circumference on the rotor yoke and the rotor windings are arranged on the poles, wherein the rotor poles are formed of multiple parts and each has a rotor tooth and at least one pole shoe element separate therefrom. The rotor teeth are formed as a single piece with the rotor yoke, and the pole shoe elements are mechanically connectable to the rotor teeth after arranging the rotor windings on the rotor teeth. Also provided are the synchronous machine, a motor vehicle and a method.

Claims

1.-12. (canceled)

13. A rotor for a separately excited inner rotor synchronous machine of an electrically drivable motor vehicle, the rotor comprising: a plurality of rotor windings for forming a rotor magnetic field; and a rotor core for holding the rotor windings, wherein the rotor core has an annular rotor yoke with a number of rotor poles corresponding to a number of rotor windings, which poles are arranged along a rotor circumference on the rotor yoke and on which the rotor windings are arranged; wherein the rotor poles are formed of multiple parts and each have a rotor tooth and at least one pole shoe element separate therefrom, and wherein the rotor teeth are formed in a single piece with the rotor yoke, and the pole shoe elements are mechanically connectable to the rotor teeth after arranging the rotor windings on the rotor teeth.

14. The rotor according to claim 13, wherein each rotor pole has two pole shoe elements, which are arranged on two opposite sides of the rotor tooth in the tangential direction and are connectable to the rotor tooth.

15. The rotor according to claim 13, wherein the pole shoe elements and the rotor teeth are connected in a form-fitting manner and have mutually corresponding connecting elements, which are pluggable together in the axial direction.

16. The rotor according to claim 15, wherein the rotor tooth has a first connecting element in the form of a groove, and the pole shoe element has a second connecting element corresponding thereto in the form of a pin, wherein the groove and the pin interact according to the key-lock principle.

17. The rotor according to claim 13, wherein mutually adjacent pole shoe elements of two rotor poles that are adjacent along the rotor circumference are mechanically connected to each other via a reinforcing element to increase mechanical strength of the rotor core in the tangential direction.

18. The rotor according to claim 17, wherein the reinforcing elements are formed in the shape of a T-piece and each has a tangential reinforcing region, via which the pole shoe elements are mechanically connected to each other, and each has a radial reinforcing region, which is connectable to the rotor yoke to increase the mechanical strength of the rotor core in the radial direction.

19. The rotor according to claim 18, wherein the radial reinforcing region and the rotor yoke are connectable in a form-fitting manner and, to this end, have connecting elements corresponding to one another, which are pluggable together in the axial direction.

20. The rotor according claim 17, wherein two mutually adjacent pole shoe elements and the associated reinforcing element are formed in a single piece.

21. The rotor according to claim 13, wherein a winding wire of the rotor windings has a rectangular cross section.

22. A method for producing a rotor for a separately excited inner rotor synchronous machine of an electrically drivable motor vehicle, the rotor including a plurality of rotor windings for forming a rotor magnetic field and a rotor core for holding the rotor windings, wherein the rotor core has an annular rotor yoke with a number of rotor poles corresponding to a number of rotor windings, which poles are arranged along a rotor circumference on the rotor yoke and on which the rotor windings are arranged; wherein the rotor poles are formed of multiple parts and each have a rotor tooth and at least one pole shoe element separate therefrom, and wherein the rotor teeth are formed in a single piece with the rotor yoke, and the pole shoe elements are mechanically connectable to the rotor teeth after arranging the rotor windings on the rotor teeth, the method comprising: providing the rotor core with the rotor teeth; pushing the pre-wound rotor windings onto the rotor teeth; and connecting the pole shoe elements to associated rotor teeth holding the pushed-on rotor windings.

23. A separately excited inner rotor synchronous machine for an electrically drivable motor vehicle, the separately excited inner rotor synchronous machine comprising: a stator with a hollow cylindrical laminated core; and a rotor surrounded by the hollow cylindrical laminated core, wherein the rotor includes a plurality of rotor windings for forming a rotor magnetic field; and a rotor core for holding the rotor windings, wherein the rotor core has an annular rotor yoke with a number of rotor poles corresponding to a number of rotor windings, which poles are arranged along a rotor circumference on the rotor yoke and on which the rotor windings are arranged; wherein the rotor poles are formed of multiple parts and each have a rotor tooth and at least one pole shoe element separate therefrom, and wherein the rotor teeth are formed in a single piece with the rotor yoke, and the pole shoe elements are mechanically connectable to the rotor teeth after arranging the rotor windings on the rotor teeth; and wherein the rotor is rotatably mounted within the hollow cylindrical laminated core of the stator.

24. A motor vehicle comprising: a separately excited inner rotor synchronous machine for an electrically drivable motor vehicle, the separately excited inner rotor synchronous machine comprising: a stator with a hollow cylindrical laminated core; and a rotor surrounded by the hollow cylindrical laminated core, wherein the rotor includes a plurality of rotor windings for forming a rotor magnetic field; and a rotor core for holding the rotor windings, wherein the rotor core has an annular rotor yoke with a number of rotor poles corresponding to a number of rotor windings, which poles are arranged along a rotor circumference on the rotor yoke and on which the rotor windings are arranged; wherein the rotor poles are formed of multiple parts and each have a rotor tooth and at least one pole shoe element separate therefrom, and wherein the rotor teeth are formed in a single piece with the rotor yoke, and the pole shoe elements are mechanically connectable to the rotor teeth after arranging the rotor windings on the rotor teeth; and wherein the rotor is rotatably mounted within the hollow cylindrical laminated core of the stator.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The invention will now be explained in detail by using an exemplary embodiment and with reference to the drawings, in which:

[0025] FIG. 1 shows a schematic illustration of a rotor according to the prior art;

[0026] FIGS. 2a and 2b show a schematic illustration of a first embodiment of a rotor according to the invention during production of the rotor;

[0027] FIG. 3 shows a schematic illustration of a second embodiment of a rotor according to the invention; and

[0028] FIG. 4 shows a schematic illustration of a third embodiment of a rotor according to the invention.

DETAILED DESCRIPTION OF THE DRAWINGS

[0029] In the figures, the same and functionally identical elements are provided with the same designations.

[0030] FIG. 1 shows a rotor 1 for an inner rotor synchronous machine according to the prior art, not shown here, during manufacture. The rotor 1 has a single-piece rotor core 2, which is composed of an annular rotor yoke 3 and a multiplicity of rotor poles 4. The rotor poles 3 each have a rotor tooth 5 and a pole shoe 6, which is wider as compared with the rotor tooth 5. The rotor poles 3 thus have a diameter which is inhomogeneous and widens toward the outside in a radial direction R. Between two adjacent rotor poles 3, a rotor groove 7 is formed in each case and, on account of the pole shoes 6, has a narrowed access opening 8. Via the access opening 8, a tool 9 is introduced into the rotor groove 7, by means of which tool a winding wire 10 for forming a rotor winding 11 is wound around the rotor tooth 5. Because of the narrowed access opening 8, winding around the rotor teeth 5 is very time-consuming; often only a low winding quality and therefore a low filling factor can be provided.

[0031] FIG. 2a and FIG. 2b show a detail of an embodiment of a rotor 12 according to the invention during production. The rotor 12 has a rotor core 13 with an annular rotor yoke 14 and rotor poles 15 formed of many parts (see FIG. 2b). The rotor poles 15 have rotor teeth 16, which are formed in a single piece with the rotor yoke 14. The rotor teeth 16 extend outward in the radial direction R, starting from the rotor yoke 14, and have a homogeneous diameter along the radial direction R. In addition, the rotor poles 15 here each have two pole shoe elements 17 separate from the rotor teeth 16 (see FIG. 2b), which can be connected to the rotor teeth 16.

[0032] In FIG. 2a, the pole shoe elements 17 are not arranged on the rotor teeth 16, so that rotor grooves 18 between the rotor teeth 16 are completely open. A respective access opening 19 to the rotor grooves 18 is thus not narrowed. As a result, pre-wound rotor windings 20 can be pushed onto the rotor teeth 16 in a fitting direction S, which is oriented counter to the radial direction R. After the rotor windings 20 have been fitted, the pole shoe elements 17 can be fixed to the rotor teeth 16. Here, two pole shoe elements 17 can be arranged on tangentially opposite sides 21 of the rotor teeth 16. The pole shoe elements 17 extend in the tangential direction T and widen the diameter of the rotor poles 15 toward the outside.

[0033] To fix the pole shoe elements 17 to the rotor teeth 16, the rotor teeth and the pole shoe elements 17 have mutually corresponding connecting elements 22, which can be plugged together in the axial direction A (into the plane of the drawing) and, as a result, connect the pole shoe elements 17 and the respective rotor tooth 16 in a form-fitting manner. The connecting elements 22 of the rotor teeth 16 are formed here as grooves 23 extending in the axial direction A, which are arranged on the sides 21 of rotor teeth 16. The connecting elements 22 of the pole shoe elements 17 are formed as pins 24 extruded in the axial direction A, which can be pushed into the grooves 23 in the axial direction A.

[0034] FIG. 3 shows a development of the rotor 12 which has more reinforcing elements 25. The reinforcing elements 25 have a tangential reinforcing region 26, by which the pole shoe elements 17 of two adjacent rotor poles 15 are mechanically connected to each other. By means of the tangential reinforcing region 26, the access opening 19 to a rotor groove 18 is in particular completely closed, so that the mechanical rigidity of the rotor core 13 is increased. In FIG. 4, the reinforcing elements 25 have radial reinforcing regions 27 in addition to the tangential reinforcing regions 26, so that the reinforcing elements 25 have a cross section in the shape of a T-piece. The radial reinforcing regions 27 are arranged in the rotor groove 18 between two rotor windings 20 and are mechanically connected to the rotor yoke 14. To this end, the rotor yoke 14 and the radial reinforcing regions 27 have mutually corresponding connecting elements 28, by which the rotor yoke 14 and the radial reinforcing region 27 are connected in a form-fitting manner. For this purpose, the rotor yoke 14 can have a groove 29, into which a pin 30 of the radial reinforcing region 27 can be pushed in the axial direction A for the form-fitting connection.

[0035] The pole shoe elements 17 connected in pairs via a reinforcing element 25, and the reinforcing element 25 are formed in a single piece. To finish the rotor 12 after the rotor windings 20 have been fitted onto the rotor teeth 16, the monolithic units, which each comprise two adjacent pole shoe elements 17 and a reinforcing element 25, are plugged in the axial direction onto the monolithic unit which comprises the rotor yoke 14 and the rotor teeth 16, by the pins 24 of the pole shoe elements 17 being pushed into the grooves 29 of the rotor teeth 16, and the pins 30 of the radial reinforcing regions 27 being pushed into the grooves 29 of the rotor yoke 14. The monolithic units can also be joined together at elevated temperature, so that after the monolithic units have cooled, the reinforcing elements 25 for increasing the mechanical rigidity of the rotor core 13 are prestressed.

LIST OF DESIGNATIONS

[0036] 1 Rotor [0037] 2 Rotor core [0038] 3 Rotor yoke [0039] 4 Rotor pole [0040] 5 Rotor tooth [0041] 6 Pole shoe [0042] 7 Rotor groove [0043] 8 Access opening [0044] 9 Tool [0045] 10 Winding wire [0046] 11 Rotor winding [0047] 12 Rotor [0048] 13 Rotor core [0049] 14 Rotor yoke [0050] 15 Rotor pole [0051] 16 Rotor tooth [0052] 17 Pole shoe element [0053] 18 Rotor groove [0054] 19 Access opening [0055] 20 Rotor windings [0056] 21 Sides [0057] 22 Connecting elements [0058] 23 Groove [0059] 24 Pin [0060] 25 Reinforcing element [0061] 26 Tangential reinforcing region [0062] 27 Radial reinforcing region [0063] 28 Connecting elements [0064] 29 Groove [0065] 30 Pin [0066] R Radial direction [0067] T Tangential direction [0068] A Axial direction [0069] S Fitting direction