Rotor for an Electric Machine, Method for Producing a Rotor, and Electric Machine for a Motor Vehicle

Abstract

A rotor for an electric machine includes a rotor main part which has at least one pole core, at least one winding device which is received on the at least one pole core, and at least one contact device which is rotationally fixed to the rotor main part and which is coupled to the at least one winding device to conduct a current. The at least one winding device includes at least one winding that is plugged onto the at least one pole core and has two winding wire ends, at least one winding wire end of which is coupled to the at least one contact device to conduct a current via at least one plug connection.

Claims

1-10. (canceled)

11. A rotor for an electric machine, the rotor comprising: a rotor body which has at least one pole core, at least one winding device which is mounted on the at least one pole core, and at least one contact device which is non-rotatably connected to a rotor base body and is conductively coupled to the at least one winding device, wherein the at least one winding device contains at least one winding which is attached to the at least one pole core and has two winding wire ends, of which at least one winding wire end is coupled in a conductive manner via at least one plug-in connection to the at least one contact device.

12. The rotor according to claim 11, wherein: the at least one winding is in a form of a prefabricated winding.

13. The rotor according to claim 11, wherein: the at least one winding device has at least one alignment element which keeps at least one of the winding wire ends oriented in a predetermined orientation.

14. The rotor according to claim 13, wherein: the at least one alignment element has at least one through opening through which the at least one winding wire end is passed and kept oriented in the orientation.

15. The rotor according to claim 13, wherein: the at least one winding wire end is joined to the at least one alignment element.

16. The rotor according to claim 11, wherein: the contact device contains at least one spring element, by way of which the at least one winding wire end is coupled to the contact device with formation of the plug-in connection.

17. The rotor according to claim 11, further comprising: at least one pole shoe which is connected to the at least one pole core and which prevents a centrifugal detachment of the at least one winding device from the at least one pole core while the rotor is being used.

18. A method for producing the rotor according to claim 11, the method comprising: a) attaching at least one winding device to the at least one pole core; and b) coupling the at least one winding of the at least one winding device to the at least one contact device by coupling the at least one winding wire end to the at least one contact device by way of the at least one plug-in connection.

19. The method according to claim 18, wherein: the coupling according to b) is carried during of the attaching according to step a).

20. The method according to claim 18, wherein: the coupling according to b) is carried out as a result of the attaching according to step a).

21. An electric machine for a motor vehicle, the electric machine comprising at least one rotor according to claim 11.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0025] FIG. 1 shows a schematic perspective view of a rotor base body of a rotor for an electric machine, wherein the rotor base body has four rotor cores regularly arranged in the circumferential direction of the rotor and a prefabricated winding device is attached to one of the rotor cores.

[0026] FIG. 2 shows an enlarged detailed representation of an obliquely sectioned part of a contact device of the rotor, to which two winding wire ends of the winding device are fed when they are attached in order to establish a respective plug-in connection for conductive contacting between the contact device and the winding wire ends.

[0027] FIG. 3 shows a further enlarged detailed representation of the obliquely sectioned part of the contact device, which shows the established plug-in connection between the contact device and the winding wire ends.

[0028] FIG. 4 shows an enlarged sectional representation of the connection between the contact device and one of the winding wire ends.

[0029] FIG. 5 shows a schematic perspective view of the rotor base body to which one of the prefabricated winding devices is joined.

[0030] FIG. 6 shows a schematic side view of the rotor base body shown in FIG. 5 with the winding device, wherein two parallel sectional planes A and B pass through the contact device.

[0031] FIG. 7 shows a sectional representation according to the sectional plane A in FIG. 6.

[0032] FIG. 8 shows another sectional representation according to the sectional plane B in FIG. 6.

DETAILED DESCRIPTION OF THE DRAWINGS

[0033] FIG. 1 shows a schematic perspective view of a rotor base body 30 of a rotor 20 for an electric machine 10 shown abstracted in FIG. 5. The electric machine 10 contains a stator 12, which can also be used as the housing of the electric machine 10 and is designed as a traction machine of a motor vehicle K, which is also illustrated in a highly abstracted manner. Thus, the electric machine 10 serves to drive, i.e., to move, the motor vehicle K.

[0034] In the case of a method for the production of the rotor 20, in a first step (a) respective winding devices 50 of the rotor 20 are attached to respective pole cores 40, 42, 44, 46 of the rotor base body 30. In the present case, the rotor 20 contains the four pole cores 40, 42, 44, 46, which are arranged in the circumferential direction of the rotor 20 at 90 intervals from each other and distributed over the rotor base body 30. As a result, for example, the pole cores 40 and 44 include an angle of 180 with each other, as do the pole cores 42 and 46.

[0035] In FIG. 1, FIG. 5 and FIG. 6 for clarity only one of the total of four winding devices 50 is shown, which is attached to the pole core 40 according to step a) of the method. The attachment of the remaining three winding devices 50 to the remaining pole cores 42, 44, 46 carried out for the completion of the rotor 20, is not shown. However, the following remarks on the individual winding device 50 apply to all winding devices 50.

[0036] The rotor 20 also contains a contact device 90, which is non-rotatably connected, for example screwed, to the rotor base body 30 and is conductively coupled to the respective winding devices 50. The contact device 90 can preferably be in the form of a ring body, as can be seen, for example, in FIG. 1. For the at least indirect transfer of electrical energy from an energy storage device, here not shown further, of the motor vehicle K via power electronics, also not shown further, of the motor vehicle K to the winding devices 50, respective contacts 100, 102 of the contact device 90 can be arranged on an end face 91 of a contact ring element 98 of the contact device 90. The contacts 100, 102 can extend in an axial extent direction x, depicted in FIG. 6 by an arrow, of the rotor 20 in the direction of the rotor base body 30, as can be seen from an overall view of FIG. 1, FIG. 5 and FIG. 6. The contacts 100, 102 can each contain a recess into which plug elements not shown here can be plugged to establish the conductive connection between the energy storage device or power electronics and winding devices 50. A sliding contact, which is not shown in detail here, can be made by way of the connector elements and can be used to maintain the conductive connection when the rotor is rotating 20.

[0037] Each of the winding devices 50 contains at least one prefabricated winding 60, which is attached to the respective pole cores 40, 42, 44, 46 in the prefabricated rotor 20. Each winding contains two winding wire ends 62, 64, each conductively coupled to the contact device 90 via plug-in connections 66, 68. The winding wire ends 62, 64 are each joined to the contact device 90 in an attachment direction and with an orientation O indicated by an arrow. The orientation O as well as the attachment direction are at least essentially parallel to a radial extent direction R of the rotor 20 and of the rotor base body 30 indicated by a further arrow in FIG. 4 and FIG. 5 and relative to the respective pole cores 40, 42, 44, 46, as shown in FIG. 4 in the enlarged representation of the plug-in connection 66 between the first winding wire end 62 and the contact device 90 relating to the pole core 40. The expression essentially parallel can be understood to mean that the orientation O and the radial extent direction R include an angle of less than 10, preferably less than 5. In order to compensate for manufacturing tolerances, the respective winding wire ends 62, 64 can also be elastically deformed, in particular elastically bent in some areas, during the formation of the respective plug-in connection 66, 68.

[0038] The plug-in connections 66, 68 can be established in a further step (b) of the method, in which the coupling of the winding device 50 to the contact device 90 is carried out by coupling both winding wire ends 62, 64 of the winding 60 to the contact device 90 via the respective plug-in connection 66, 68 in the present case. The respective winding wire ends 62, 64, at least in some areas, are free of an insulation sheath enclosing a metal wire of a winding wire of the respective winding 60 for electrical insulation in a region of the winding wire different from the winding wire ends 62, 64.

[0039] The coupling according to step b) takes place during and as a result of the attachment according to step a), which saves one assembly step, namely the separate performance of steps a) and b) in succession. Step (b) of this method is illustrated by an overall view of FIG. 2 and FIG. 3. It should be noted that FIG. 2 and FIG. 3 each show sectional representations according to an oblique sectional plane that intersects both a sectional plane A and a sectional plane B in FIG. 6. In other words, this oblique sectional plane is not perpendicular to the axial extent direction x. The section representation according to the oblique sectional plane is used to show both plug-in connections 66, 68 sectioned together, especially since the plug-in connections 66, 68 are offset relative to each other in the axial extent direction x, as will be explained below.

[0040] To keep the winding wire ends 62, 64 oriented in the predetermined orientation O during assembly, each winding device 50 has at least one alignment element 80. The respective alignment element 80 has a through opening 82, 84 for each of the winding wire ends 62, 64, through which the respective winding wire end 62, 64 is passed and kept oriented in the orientation O. Each of the winding wire ends 62, 64 can be joined to the corresponding alignment element 80, for example glued in the position thereof inserted into the through opening 82, 84.

[0041] On the basis of FIG. 4 it can be seen that the contact device 90 contains two spring elements 92, 94 for each plug-in connection 66, 68, which are arranged one behind the other in the orientation O. As a result, the spring element through openings of the spring elements 92, 94, which are arranged one behind the other in the orientation O and thus in the attachment direction, align. If, for example, one of the winding wire ends 62, 64 is joined to the contact device 90 in the attachment direction during the formation of the respective plug-in connection 66, 68, the respective winding wire end 62, 64 is contacted with the respective spring elements 92, 94 by inserting the corresponding winding wire end 62, 64 into the respective spring element through opening of the respective spring element 92, 94 and is thereby conductively connected, for example tightly, to the respective spring element 92, 94. The spring elements 92, 94 are accommodated in a respective sheath element 96 for each plug-in connection 66, 68, preferably crimped and connected to the contact ring element 98 of the contact device together with the respective sheath element 96. The contact device 90 can be connected, preferably screwed, to the rotor base body 30 on the contact ring element 98. The contact device 90 therefore contains at least the contact ring element 98, on which the contacts 100, 102 are also arranged, as well as one of the sheath elements 96 and two of the spring elements 92, 94 for each plug-in connection 66, 68.

[0042] The respective pole shoes of the rotor 20 are not shown in FIG. 1 to FIG. 8. In each case, one of the pole shoes may be connected to at least one of the pole cores 40, 42, 44, 46 and a centrifugal force detachment of the respective winding device 50 from the respective pole core 40, 42, 44, 46 is prevented while the rotor is being used as intended 20.

[0043] FIG. 7 and FIG. 8 each show sectional views of the contact device 90, wherein FIG. 7 shows a section along a sectional plane A and FIG. 8 shows a section along another sectional plane B. The sectional planes A and B are oriented parallel to each other and have an offset relative to each other in the axial extent direction x.

[0044] As already described, the respective plug-in connections 66, 68 for each of the winding devices 50 also have this offset. Since the rotor 20 in the present case has four pole cores 40, 42, 44, 46 and four winding devices 50 attached thereto, for each winding 60 of the respective winding device 50 four of the plug-in connections 66 lie in the sectional plane A for the four first winding wire ends 62 and for the four second winding wire ends 64 four of the plug-in connections 68 lie in the sectional plane B. The present total of eight plug-in connections 66, 68 are conductively connected to one another via multiple conductor elements 70, which partially extend over both sectional planes A and B and thus through the contact ring element 98 with the offset in the axial extent direction x, in such a way that a power supply to the four windings 60 or winding devices 50 can take place via the contacts 100, 102, as can be seen by examining FIG. 7 and FIG. 8 with FIG. 5. For this purpose, a respective contact 100, 102 is connected to a respective one of the total of eight plug-in connections 66, 68 and the eight plug-in connections 66, 68 are conductively connected to each other via the mentioned conductor elements 70.

REFERENCE SIGN LIST

[0045] 10 electric machine [0046] 12 stator [0047] 20 rotor [0048] 30 rotor base body [0049] 40 pole core [0050] 42 pole core [0051] 44 pole core [0052] 46 pole core [0053] 50 winding device [0054] 60 winding [0055] 62 first winding wire end [0056] 64 second winding wire end [0057] 66 plug-in connection [0058] 68 plug-in connection [0059] 70 conductor element [0060] 80 alignment element [0061] 82 through opening [0062] 84 through opening [0063] 90 contact device [0064] 91 end face [0065] 92 spring element [0066] 94 spring element [0067] 96 sheath element [0068] 98 contact ring element [0069] 100 contacts [0070] 102 contacts [0071] K motor vehicle [0072] O orientation [0073] R radial extent direction [0074] X axial extent direction