PERMANENT MAGNET ROTOR, METHOD FOR THE PRODUCTION THEREOF USING A MAGNETIZING FIXTURE

Abstract

A permanent magnet rotor (1) with a magnetically conductive magnetic core (2), which has a plurality of magnet retainers (3, 4) for radially arranged and essentially tangentially magnetized permanent magnet parts (9), and a method for the production thereof. With a common permanent magnet rotor, the object of the present invention is to ensure a simple installation for a low number of components to be installed, very good magnetizability, high strength of the mechanical connection of the permanent magnet parts in the magnet retainers, and a compact size.

Claims

1. A permanent magnet rotor comprising: a magnetically conductive magnetic core having a circumference, with a plurality of magnet retainers positioned about the circumference; radially arranged and essentially tangentially magnetized permanent magnet parts each being placed in one of the plurality of magnet retainers; and the magnetic core axially made up of at least first and second sub-cores with the permanent magnet parts extending across more than one sub-core.

2. The permanent magnet rotor according to claim 1, wherein each of the permanent magnet parts establishes a stronger mechanical connection with the first sub-core than with the second sub-core.

3. The permanent magnet rotor according to claim 2, wherein multiple permanent magnet parts are arranged in different magnet retainers along the periphery of a sub-core and establish a stronger mechanical connection to alternate with a less strong mechanical connection in the same sub-core.

4. The permanent magnet rotor according to claim 2, wherein the stronger mechanical connection is established through injection molding, bonding, press fitting, or clamping.

5. The permanent magnet rotor according to claim 2, wherein the less strong mechanical connection is a clearance fit in some of the magnet retainers.

6. The permanent magnet rotor according to claim 1, further comprising a rotor shaft, wherein the sub-cores are arranged on the rotor shaft and are firmly connected thereto.

7. The permanent magnet rotor according to claim 1, wherein each of the sub-cores consists of stacks of sheets or pressed metal powder.

8. The permanent magnet rotor according to claim 1, wherein each of the sub-cores has multiple permanent magnet parts inserted therein, and each of the sub-cores are formed almost identically.

9. A method for producing a permanent magnet rotor with a magnetically conductive magnetic core, which has a plurality of magnet retainers for radially arranged and essentially tangentially magnetized permanent magnet parts, the method comprising the steps of: providing multiple non-magnetized permanent magnet parts; magnetizing the permanent magnet parts in a conventional magnetizing fixture; providing at least one sub-core; Inserting the multiple magnetized permanent magnet parts having a subsection into every other magnet retainer of the sub-core about the periphery of the sub-core, whereby a rotor assembly is produced.

10. A method for producing a permanent magnet rotor with a magnetically conductive magnetic core, which has a plurality of magnet retainers for radially arranged and essentially tangentially magnetized permanent magnet parts, the method comprising the steps of: providing a sub-core and multiple permanent magnet parts; inserting the multiple non-magnetized permanent magnet parts having a subsection into every other magnet retainer of the sub-core about the periphery of the sub-core, whereby a rotor assembly is produced; inserting the rotor assembly into a magnetizing fixture, wherein magnetizing coils are inserted into the empty magnet retainers, not equipped with permanent magnet parts, of the sub-core of the rotor assembly and available subsections of the permanent magnet parts, which project from the sub-core, and are inserted into magnet recesses of a magnetizing element of the magnetizing fixture; simultaneously magnetizing both subsections of the permanent magnet parts; and ejecting the rotor assembly from the magnetizing fixture.

11. The method for producing a permanent magnet rotor according to claim 9, further comprising the steps of: combining of two rotor assemblies by inserting the available subsections of the multiple permanent magnet parts of one of the rotor assemblies into the available magnet retainers of the sub-core of the other respective rotor assembly.

12. The method for producing a permanent magnet rotor according to claim 11, further comprising the steps of: joining the rotor assemblies onto a rotor shaft and creating a strong connection therewith.

13. The method for producing a permanent magnet rotor according to claim 9, wherein two magnetized rotor assemblies are joined to a rotor shaft, simultaneously or one after the other, and firmly connected thereto, wherein the available subsections of the permanent magnet parts are inserted, simultaneously or subsequently, into the wide magnet retainers of the sub-core of the other respective rotor assembly.

14. A device for magnetizing a permanent magnet rotor (1) having a magnetically conductive magnetic coil, which has a plurality of magnet retainers for permanent magnet parts, which are arranged radially around a rotor axis of rotation of the permanent magnet rotor and are to be essentially tangentially magnetized, the device comprising: a magnetizing element with 2n magnet recesses, n magnetizing coils, which are retained in every other magnet recess, wherein a large part of the magnetizing coils protrudes axially from the magnetizing element and with a retaining device, which is arranged between at least two magnetizing coils.

15. The device according to claim 14, wherein the magnetizing coils, which are retained in the magnetizing element, protrude axially from the magnetizing element over at least one uniformly sized part.

16. The device according to claim 14, wherein the magnetizing coils, which are retained in the magnetizing element, protrude axially from the magnetizing element over a significantly larger part.

17. The device according to claim 14, wherein the magnetizing coils are wound onto magnetizing cores, which are firmly attached to a coil support plate.

18. The device according to claim 14, wherein the magnetizing coils are wound onto magnetizing cores, which consist of a magnetically conductive steel material, wherein a coil wire is pressed, in a positive-locking manner, into a groove on the periphery of the magnetizing cores.

19. The device according to claim 18, wherein the coil wire is secured in the groove by means of bonding or a UV-cured casting compound.

20. The device according to claim 18, wherein the coil wire is secured in the groove by means of injection molding.

21. The device according to claim 14, wherein connections of the magnetizing coils are cast in a base.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0042] The exemplary embodiments of the invention are subsequently further explained, based on the drawings. The following is shown:

[0043] FIG. 1 shows a permanent magnet rotor according to the invention;

[0044] FIG. 2 shows a first sub-core with preassembled permanent magnet parts;

[0045] FIG. 3 shows a second sub-core with preassembled permanent magnet parts;

[0046] FIG. 4 shows a permanent magnet rotor fully assembled;

[0047] FIG. 5 shows a sub-core with magnetizing coils;

[0048] FIG. 6 shows an empty magnetizing fixture;

[0049] FIG. 7 shows an occupied magnetizing fixture; and

[0050] FIG. 8 shows a closed magnetizing fixture.

DETAILED DESCRIPTION OF THE INVENTION

[0051] In describing preferred embodiments of the present invention illustrated in the drawings, specific terminology is employed for the sake of clarity. However, the invention is not intended to be limited to the specific terminology so selected, and it is to be understood that each specific element includes all technical equivalents that operate in a similar manner to accomplish a similar purpose.

[0052] FIG. 1 shows a permanent magnet rotor 1 (without rotor shaft), having a rotor axis of rotation 12, a magnetic core 2, and permanent magnet parts 9 installed in the magnet retainers 3, 4. The magnetic core 2 is axially composed of two identical sub-cores 5 (see separating line 29). The permanent magnet parts 9 are each retained with a first subsection 7 in the magnet retainers 3 of a sub-core 5 and retained with a second subsection 8 in the magnet retainers 4 of a second sub-core 5. In every other magnet retainer 3 of the two sub-cores 5, the first subsections 7 are installed with a press-fit and with a clearance or transition fit in the remaining magnet retainers 4. Each sub-core 5 forms one rotor assembly 6 with multiple permanent magnet parts 9. FIG. 1 shows twelve permanent magnet parts 9, in which six permanent magnet parts with a sub-core 5 form one rotor assembly 6. Two rotor assemblies 6, which are identical within the production and installation accuracy, are crossed with one another and connected to a permanent magnet rotor (shown here without the rotor shaft). The strength of the connection is sufficient for carrying out the installation; it is also subsequently sufficiently increased for operation through the connection to a rotor shaft.

[0053] FIG. 2 shows the rotor assembly 6 before its installation, consisting of a sub-core 5, with a plurality of magnet retainers 3, 4 arranged around a rotor axis of rotation 12, wherein a permanent magnet piece 9 is only retained and attached in every other magnet retainer 3. The permanent magnet parts 9 and the sub-core 5 are very firmly connected to one another (press-fit). The preassembled rotor assembly resembles a claw clutch, wherein the permanent magnet parts 9 are retained in the magnet retainers 3 up to about half of their length (subsections 7), and the other half of the permanent magnet parts 9 (subsections 8) protrude freely out of the sub-core 5 parallel to the axis. The permanent magnet parts 9 are tangentially magnetized. Furthermore, sub-poles 11 are shown, which are arranged between two magnet retainers, 3 and 4, each. The sub-poles 11 are single-part components of the sub-core 5, which consists of a punch-bundled stack of sheets. The available magnet retainers 4 are slightly broader than the magnet retainers 3 occupied with permanent magnet parts 9. The breadth of the available magnet retainers 4 should be dimensioned such that they can establish a clearance or transition fit with the permanent magnet parts 9.

[0054] FIG. 3 shows a second rotor assembly 6 with preassembled permanent magnet parts 9. The permanent magnet parts have first subsections 7, which are firmly held in magnetic retainers 3, and second subsections 8, which protrude out of the sub-core 5 parallel to the axis. The permanent magnet parts 9 are tangentially magnetized. The second rotor assembly 6 is identical to the first rotor assembly 6 from FIG. 2 within the scope of the production and installation accuracy. A rotation of the rotor axis of rotation 12 of the rotor assembly 6 from FIG. 2 by 180 and a swiveling of the rotor assembly 6 by one pole pitch (by 30 here) around the rotor axis of rotation 12 results in the geometric arrangement of a second rotor assembly 6 according to FIG. 3, which can be joined with the first rotor assembly 6. Both rotor assemblies are identical, including their magnetization. Due to the aforementioned rotation, the magnetization direction of the permanent magnet parts 9 from FIG. 3, in the described arrangement, is counterclockwise to the magnetization direction of the permanent magnet parts 9 from FIG. 2, such that the magnetic field lines mutually repel in the installed state and are diverted in the radial direction. The sub-poles 11 are a single piece with the sub-core 5 and are located between two magnet retainers, 3 and 4. The available magnet retainers 4 are slightly broader than the magnet retainers 3 occupied with permanent magnet parts 9. The breadth of the available magnet retainers 4 should be dimensioned such that they can establish a clearance or transition fit with the permanent magnet parts 9.

[0055] FIG. 4 shows a completely installed permanent magnet rotor 1, with the combined magnetic core 2, the permanent magnet parts 9, and a rotor shaft 28, onto which the magnetic core 2 is pressed. The magnetic core 2 has recesses 13 radially within the permanent magnet parts 9, which are used to suppress magnetic short-circuits. The tangential magnetization (only indicated partially) and the resulting polarity are clear. Webs 14 are provided between the recesses 13 as connecting areas between a central ring 15 and the poles 11. Protrusions 16 and stops 17 retain the permanent magnet parts radially in position.

[0056] FIG. 5 shows a rotor assembly 6 with a sub-core 5, having magnetizing coils 10 wound onto magnetizing cores 24, with the coils being arranged in any available magnet retainer 4 (=every other magnet retainer). In the remaining magnet retainers 3, the permanent magnet parts 9 are attached using a press-fit. Because only every other permanent magnet piece 9 is pressed, there is an N-S-N-S sequence. This enables a magnetization direction corresponding to a ring coil.

[0057] FIG. 6 shows a magnetizing fixture 20, having a base 18, a coil support plate 34, a ring cover 32, a retaining device 21, an ejector 22, and a magnetizing element 19, in which multiple magnetizing cores 24, each having a magnetizing coil 10, are retained. Magnet recesses 23 are provided between the magnetizing cores 24 in the magnetizing element 19, with the recesses being used to retain subsections 8 of the permanent magnet parts 9 (see FIGS. 2 and 3). The magnetizing coils 10 can be connected to a voltage source via connections 26. The retaining device 21 has retaining device fingers 25 and is used as a fixative means for a rotor assembly 6 (not shown heresee FIGS. 2 and 3). The retaining device 21 is pushed over an ejector 22, which is used to assist in the removal of the magnetized rotor assembly from the magnetizing fixture 20. To this end, the ejector 22 has a section with enlarged diameter (not discernible) at its end. The ring cover 32 is connected to the base 18 using cover screws 33. A retaining chamber 27 is used to retain the rotor assembly. The forces occurring during magnetization are accommodated in the axial direction by the retaining device 21. Housing screws 30 are used to attach a housing 31 (see FIG. 8) to the coil support plate 34. The magnetizing element 19 is attached to the coil support plate 34 (through bonding here). The magnetizing cores 24 are firmly connected to the coil carrier plate 34 (bolted here). The magnetizing coils consist of a small number of windings, which are retained in the grooves of the magnetizing cores 24 such that the windings are affixed radially. The windings are injection-molded with a plastic material as additional assurance. Hollow cavities between the base 18 and the coil support plate 34 are cast in order to affix the winding wire, particularly in the connection area, between the individual magnetizing coils and the connections. The retaining device fingers 25, the magnetizing coils 10, and the magnetizing cores 24 are designed to be longer as needed such that different rotor assemblies can be magnetized with the same magnetizing fixture.

[0058] FIG. 7 shows the magnetizing fixture 20, with the base 18, the ring cover 32, the ejector 22, the magnetizing element 19, magnetizing coils 10, and the retaining device 21. A rotor assembly 6 with sub-core 5 and permanent magnet parts 9 are retained within the magnetizing fixture 20. The permanent magnet parts 9 are pressed into the sub-core 5 on one side and protrude into the magnet recesses 23 on the other side (also see FIG. 6). The permanent magnet parts 9 can be magnetized in their first section, which is in the sub-core 5, and with their second section, which is in the magnet recesses 23, simultaneously by means of a magnetic flux (see FIGS. 1 to 4) extending around the rotor axis of rotation 12 (see also FIG. 5).

[0059] FIG. 8 shows a closed magnetizing fixture 20, with a sleeve-like housing 31, the coil support plate 34, the base 18, the retaining device 21, and the ejector 22, through which the magnetized rotor assembly can be removed axially from the housing 31. The housing is in the form of a cooling jacket, which can be connected to a coolant circuit to cool the magnetizing coils (connections for a cooling medium are not shown).

[0060] Modifications and variations of the above-described embodiments of the present invention are possible, as appreciated by those skilled in the art in light of the above teachings. It is therefore to be understood that, within the scope of the appended claims and their equivalents, the invention may be practiced otherwise than as specifically described.

TABLE-US-00001 LIST OF REFERENCE SYMBOLS 1 Permanent magnet rotor 2 Magnetic core 3 Narrow magnet retainer 4 Broad magnet retainer 5 Sub-core 6 Rotor assembly 7 Pressed-in subsection 8 Available subsection 9 Permanent magnet part 10 Magnetizing coil 11 Sub-pole 12 Rotor axis of rotation 13 Recess 14 Web 15 Ring 16 Protrusion 17 Stop 18 Base 19 Magnetizing element 20 Magnetizing fixture 21 Retaining device 22 Ejector 23 Magnet recess 24 Magnetizing core 25 Retaining device fingers 26 Connections 27 Retaining chamber 28 Rotor shaft 29 Dividing line 30 Housing screw 31 Housing 32 Ring cover 33 Cover screw 34 Coil support plate