External Rotor Device Having Integrated Sensor System, and Use

Abstract

The invention relates to an external rotor device with a rotor housing designed to receive at least one rotor and with at least one sensor magnet provided on the rotor housing. The sensor magnet is arranged/can be arranged in sensory correlation with and in a predefinable relative position relative to the rotor. According to the invention, the external rotor device is characterised in that the external rotor device has at least one ring which is integrally formed on the rotor housing, the ring having at least one pocket which is arranged to receive the sensor magnet, the sensor magnet being arranged/arrangeable in the pocket in such a way and the ring being arranged/arrangeable in a predefinable relative position relative to the rotor on/in the rotor housing in such a way that the relative position of the sensor magnet relative to the rotor in at least one spatial direction is predefined by the materially integral formation, in particular at least with regard to the radial direction and also with regard to the circumferential direction and/or the axial direction.

Claims

1-21. (canceled)

22. An external rotor device having a rotor housing adapted to receive at least one rotor and having at least one sensor magnetprovided on the rotor housing, the at least one sensor magnet being arranged in sensory correlation with and in a predefined relative position relative to the at least one rotor, wherein the external rotor device has at least one ring which is integrally formed on the rotor housing , wherein the at least one ring has at least one pocket, which is set up to receive the at lesat one sensor magnet, the at least one sensor magnet being arranged in the at least one pocket, and the at least one ring being arranged in a predefined relative position relative to the at least one rotor on or in the rotor housing in such a way in that the relative position of the at least one sensor magnet relative to the at least one rotor in at least one spatial direction is predefined by a materially interlocking formation, at least with regard to a radial direction and also with regard to a circumferential direction and/or an axial direction, the at least one ring and the rotor housing having geometrically corresponding circumferential surfaces, by means of which a fully circumferential materially interlocking interface is provided which has a maximum degree of mold separation of 0.1.

23. The external rotor device according to claim 22, wherein the at least one ring has an inner circumferential surface by means of which the at least one ring is integrally formed on the outer circumferential surface of the rotor housing.

24. The external rotor device according to claim 22, wherein the at least one ring and the rotor housing have the geometrically corresponding circumferential surfaces, by means of which a materially interlocking interface is provided, in which the materially interlocking interface is fully circumferentially.

25. The external rotor device according to claim 22, wherein a material-locking interface is defined between the at least one ring and the rotor housing, at which a material lock between the at lesat one ring and the rotor housing is ensured.

26. The external rotor apparatus according to claim 22, wherein a material interface is defined between the at least one ring and the rotor housing, which is adapted for material closure by injection molding or gating, wherein the material interface is defined on an outer side of the rotor housing.

27. The external rotor device according to claim 22, wherein the external rotor device is arranged to integrate a sensor system or the at least one sensor magnet into the rotor housing by adding a further housing component.

28. The external rotor device according to claim 22, wherein the at least one ring is integrally formed on the rotor housing by injection molding.

29. The external rotor device according to claim 22, wherein the at least one ring is connected to the rotor housing in a substance-to-substance bond without an additional substance-to-substance component.

30. The external rotor device according to claim 22, wherein the at least one ring is materially connected to the rotor housing by a primary molding process.

31. The external rotor device according to claim 22, wherein the at least one ring is physically connected to the rotor housing.

32. The external rotor device according to claim 22, wherein the at least one ring is connected to the rotor housing by plasticising material of the at least one ring and/or the rotor housing.

33. The external rotor device according to claim 22, wherein the at lesat one ring is bonded to the rotor housing by a primary molding process selected from the group consisting of: thermoset injection molding, elastomer injection molding, multi-component injection molding, in-mold injection molding, hot embossing or injection compression molding or swelling flow embossing, powder injection molding, and extrusion injection molding.

34. The external rotor device according to claim 22, wherein the rotor housing has at least one bore , wherein the at least one pocket or the at least one sensor magnet is arranged in radial alignment with the at least one bore.

35. The external rotor device according to claim 22, wherein the at least one pocket encloses the at least one sensor magneton at least four or five sides.

36. The external rotor device according to claim 35, wherein the at least one pocket encloses the at least one sensor magnet on five sides, wherein the sixth side is a side subsequently sealed after the at least one ring has been formed.

37. The external rotor device according to claim 22, wherein the rotor housing and/or the at least one ring are made of plastic material.

38. The external rotor device according to claim 22, wherein the at least one ring is materially bonded to the rotor housing without an additional material bonding component, wherein the at least one ring is materially bonded to the rotor housing by an original molding process from the following group: thermoset injection molding, elastomer injection molding, mulit-component injection molding, in-mold injection molding, hot embossing or injection embossing or swelling flow embossing, powder injection molding, and extrusion injection molding.

39. A method of providing an additional housing component in a form of a ring in an external rotor device, for providing a receiving cavity as a pocket for sensors integrated in a rotor housing of the external rotor device, the method comprising setting up the additional housing component for an initial molding process for a material-locking molding of the additional housing component on the rotor housing with the receiving cavity in a predefined relative position relative to the rotor housing, the ring and the rotor housing having geometrically corresponding lateral surfaces, by means of which a fully circumferential material-locking interface is provided which has a maximum degree of mold separation of 0.1.

40. An external rotor device with sensors integrated in a rotor housing, produced by forming an additional housing component in the form of a ring with at least one pocket for the sensors, to the rotor housing and thereby forming an integral housing part at least from the rotor housing and the ring, by connecting the ring to an outer lateral surface of the rotor housing by primary molding in the form of injection molding, wherein the ring and the rotor housing have geometrically corresponding lateral surfaces, by means of which a fully comprehensive material-locking interface is provided, which has a maximum degree of mold separation of 0.1.

41. The external rotor device according to claim 40, wherein the pocket is closed after insertion of the sensor or sensor magnet.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0050] The disclosure is described in further detail in the following drawing figures, with reference being made to the other drawing figures for reference signs that are not explicitly described in a respective drawing figure.

[0051] FIGS. 1A and 1B area top view and a side view schematic representation of an external rotor rotor device according to an embodiment example;

[0052] FIGS. 2A and 2B are a top view and in a side view cut along the semicenter axis indicated in FIG. 2A, an external rotor rotor device according to a further example of an embodiment; and

[0053] FIGS. 3A, 3B and 3C are side views of an external rotor rotor according to the state of the art.

DESCRIPTION OF THE DISCLOSURE

[0054] In FIGS. 1A, 1B, a first embodiment of an external rotor rotor device 10 is illustrated in a schematic manner, whereby a rotor or an external rotor is not explicitly shown. The rotor housing 15 is rotationally symmetrical, with an at least approximately cylindrical outer circumferential surface. Three bores 16 are provided in the housing 15 on its upper end face: one at least approximately central bore 16 and two relatively smaller bores arranged radially therefrom, in particular in alignment radially with one another. The number of bores is chosen as an example. The bores 16 can, for example, assume a function for the arrangement of a rotor and/or external rotor. The bores 16 are all provided, for example, in a section of the lateral surface of the housing 15 provided on the front side and are designed, for example, as through bores and/or blind bores.

[0055] A ring 20 (additional housing component) is molded onto the housing 15. The fastening is ensured via a material-locking interface 18, at which an inner lateral surface 20a of the ring 20 and an outer lateral surface 15a of the housing 15 contact each other. Preferably, the material-locking interface 18 is provided in its entirety. Both surface sections 15a, 20a are at least approximately cylindrical, possibly also slightly conical, and are geometrically designed to correspond to each other.

[0056] A pocket or cavity 21 is provided in the ring in which a sensor magnet 30 (or alternative sensor technology) is accommodated. The pocket 21 or the sensor magnet 30 is radially aligned with all three holes 16. In this example, the pocket 21 is provided comparatively far radially inside the ring. The pocket 21 defines an enclosure for the sensor magnet 30 on five of six sides, and on the sixth side (here: underside or front lower side) the pocket can be closed after insertion of the sensor (with reversibly removable sensor, or also irreversibly by materially sealing off).

[0057] In FIG. 1B, the mutually contacting or fused or joined lateral surfaces 15a, 20a are identified with reference to the dotted line (which is intended to symbolise the material interface 18).

[0058] In FIGS. 2A, 2B, a further embodiment is shown in which the external rotor rotor device 10 has an integral pocket 21 which can be provided by molding the ring 20 to the rotor housing 15 in an integral (preferably one-piece) housing component. This allows the sensor assembly to be secured for particularly reliable operation and also to be positioned and aligned in a comparatively accurate manner. The ring 20 forms a collar of the housing after injection molding. This can facilitate relative positioning. Optionally, the ring 20 can also take over other housing functions, for example a fastening function for the entire housing (as indicated by the holes in FIG. 2A). This functional integration in the additional housing part allows further variations and can also favour an advantageous relative position of the sensor system, especially in the radial direction.

[0059] The pocket 21 has an at least approximately rectangular cross-sectional geometry. The radial extension r21 is e.g. in the range of 30 to 70% of the radial thickness of the ring 20. The pocket 21 is integrated into the ring at least approximately radially centrally with respect to the radial extension (radial thickness) of the ring 20. The ring 20 is preferably designed as a solid component made of solid material, for example plastic. The rotor housing 15 or at least its outer side can also be made of plastic.

[0060] The three holes 16 are at least approximately aligned. The sensor magnet 30 is at least approximately aligned with the holes 16. The pocket 21 is at least approximately aligned with the holes 16. The three holes 16 are arranged in radial alignment with the pocket. The ring 20 enables a comparatively exact relative arrangement or alignment, on the one hand with respect to the circumferential position, and on the other hand also with respect to the height position (in particular flat plane underside of the housing 15, defined both by the lower end face of the ring 20 and by the lower end face of the housing 15).

[0061] FIG. 2B shows in detail the relative arrangement of the ring 20 relative to the rotor case 15: Towards the bottom of the housing opening (i.e. in the axial direction), the ring 20 slightly overlaps the housing edge; this can be useful, for example, with regard to a mounting interface for the entire housing 15, especially if the mounting interface is to be defined as far as possible solely by the underside of the ring 20.

[0062] In particular for an application in the field of pump or fan technology, the dimensions of the housing 15 including the molded-on ring 20 are, for example:

[0063] Outer diameter (outer sheath surface) approx. 30 to 50 mm;

[0064] radial extension of the ring 20 approx. 2 to 5 mm;

[0065] Outer diameter of the ring approx. 35 to 60 mm;

[0066] Diameter of the smaller holes 16 approx. 1.5 to 2.5 mm;

[0067] radial extension of the pocket 21 approx. 1 to 4 mm; and

[0068] Circumferential extension of the pocket 21 approx. 2 to 6 mm;

[0069] In FIG. 2B, a plane E of the mold separation is also indicated. For the interface 18, for example, a permissible degree of mold separation of a maximum of 0.1 can be defined (in particular in relation to the other millimeter or size specifications available). Position and size tolerances can also be defined in particular according to DIN ISO 2768 and/or ISO 14405. Non-measured draft angles are e.g. in the range of 0.5 to 1.5°, in particular approx. 1°.

[0070] FIGS. 3A, 3B, 3C show an example of an external rotor 1 with a housing 5 with bores 6 according to the state of the art, with a sensor attached or glued to the outside of the housing surface. The sensor magnet 3 is provided on the outside of the housing 5 and protrudes from the housing in a radial direction, thus creating a radial unevenness or protrusion. The relative positioning of the sensor magnet 3 relative to other components of the external rotor 1 is comparatively difficult or remains comparatively inaccurate (disadvantageously high position tolerances or also assembly errors). This arrangement and mounting of the sensor magnet 3 is also rather disadvantageous, for example, with regard to contact or collision with objects or stripping by any colliding components.

[0071] FIG. 3C illustrates in enlarged scale the north-south (N-S) orientation of the sensor magnet 3.

LIST OF REFERENCE SIGNS

[0072] 1 External rotor according to the state of the art

[0073] 3 Sensor magnet for standard housing

[0074] 5 Rotor housing according to the state of the art

[0075] 6 Borehole

[0076] 10 External rotor rotor device

[0077] 15 Rotor case

[0078] 15a Outer shell surface

[0079] 16 Borehole

[0080] 16 Material interface or contact surface

[0081] 18 Ring or collar, especially plastic ring

[0082] 20a Inner surface area

[0083] 21 Pocket or cavity in the ring

[0084] 30 Sensor or sensor system, in particular sensor magnet

[0085] E—Level of mold separation

[0086] N North

[0087] S South

[0088] r21Radial extension of the pocket