ELECTRICALLY CONTROLLABLE COMPONENT ASSEMBLY

Abstract

An electrically controllable component assembly and an electronically slip-controllable brake system having such a component assembly. The component assembly has an electric machine including a rotor, a machine shaft connected to a rotor in a torsionally fixed manner, and a signal transducer, revolving with the rotor, of a sensor device for the electronic sensing and evaluation of the angle of rotation of the machine shaft. The signal transducer has first regions and second regions, which are situated in mutual alternation in sequence in the circumferential direction of the signal transducer and differ from one another in their respective electrical conductivity. The signal transducer includes a shaped sheet metal part, which rests in a flush manner against the rotor and is anchored in a torsionally fixed manner to the machine shaft.

Claims

1-9 (canceled)

10. An electrically controllable component assembly for actuating a pressure generator of an electronically slip-controllable vehicle brake system, comprising: an electronically commutated motor, having a rotor executing a rotational movement, and a machine shaft, which is connected to the rotor in a torsionally fixed manner, and a signal transducer, which revolves with the rotor, of a sensor device configured to sense an angle of rotation of the rotor, first regions and second regions being developed on the signal transducer, which are positioned in mutual alternation in sequence with one another in a circumferential direction of the signal transducer and which differ from one another in their electrical conductivity; wherein the signal transducer includes a shaped sheet metal part, which is flush-mounted against the rotor and is fixed in place on the machine shaft in a torsionally fixed manner.

11. The component assembly as recited in claim 10, wherein the torsionally fixed fastening of the signal transducer and the machine shaft is a press-fit connection.

12. The component assembly as recited in claim 11, wherein the press-fit connection includes a serration, in which at least one radially projecting serration is provided on a periphery of the machine shaft, which extends in a direction of a longitudinal axis of the machine shaft and is configured to displace material of a wall of a shaft channel of the signal transducer when the signal transducer is fixed to the machine shaft.

13. The component assembly as recited in claim 10, wherein the signal transducer is fixed in place by a frictional and/or a keyed connection on the rotor in addition to the torsionally fixed fastening to the machine shaft.

14. The component assembly as recited in claim 13, wherein the frictional connection between the signal transducer and the rotor is induced using an elastic preloading element, which is situated on the machine shaft on a side of the signal transducer facing away from the rotor and presses the signal transducer against the rotor at a preloading force acting in a direction of a longitudinal axis of the machine shaft.

15. The component assembly as recited in claim 13, wherein the keyed connection between the signal transducer and the rotor has a tab, which is developed on the shaped sheet metal part of the signal transducer and projects in a direction of a longitudinal axis of the machine shaft and protrudes into an associated receiving opening of the rotor.

16. The component assembly as recited in claim 15, wherein an end of the tab protruding into the receiving opening is plastically deformed.

17. The component assembly as recited in claim 15, wherein an end of the tab protruding into the receiving opening is bent.

18. The component assembly as recited in claim 13, wherein the keyed connection between the signal transducer and the rotor has a stud, which is developed on the shaped sheet metal part of the transducer and projects in a direction of a longitudinal axis of the machine shaft and protrudes into an associated receiving opening of the rotor.

19. The component assembly as recited in claim 18, wherein an end of the stud protruding into the receiving opening is plastically deformed.

20. The component assembly as recited in claim 19, wherein an end of the stud protruding into the receiving opening is axially caulked.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Exemplary embodiments of the present invention are shown in the figure and are described in detail in the following description.

[0019] FIG. 1 shows a three-dimensional representation of a rotor module according to an example embodiment of the present invention.

[0020] FIG. 2 shows a machine shaft and a signal transducer, which are connected to each other by a conventional press-fit connection, according to an example embodiment of the present invention.

[0021] FIG. 3 shows a perspective representation of a machine shaft having serrations developed thereon, according to an example embodiment of the present invention.

[0022] FIG. 4 shows a preloading element in a cross-section, which presses the signal transducer against the rotor, according to an example embodiment of the present invention.

[0023] FIG. 5 shows a rotor having receiving openings for tabs or studs projecting from the cross-sectional surface of a signal transducer, according to an example embodiment of the present invention.

[0024] FIG. 6 schematically and in a simplified manner shows a tab which projects from the cross-sectional surface of the signal transducer and protrudes into an opening of the rotor, according to an example embodiment of the present invention.

[0025] In the individual figures, the same reference numerals have been used for matching components.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

[0026] Rotor 10 of an electric machine shown in FIG. 1 includes a rotor lamination 12, a plurality of magnets 14, which are situated next to one another on rotor laminations 12 along an outer periphery, a signal transducer 16 of a sensor device, resting flush against an end face of rotor lamination 12, for sensing an angle of rotation of rotor 10 as well as a machine shaft 18, which carries rotor lamination packet 12 with its magnets 14 and projects through an allocated shaft opening 30 on signal transducer 16. Machine shaft 18 and rotor 10 are connected to one another in a torsionally fixed manner.

[0027] Rotor lamination packet 12 is made up of a plurality of rotor laminations 20 which are stacked on top of one another and attached to one another. These rotor laminations 20 essentially are flat, largely circular formed parts of a magnetically soft material, also known as electrical steel. Individual rotor laminations 20 are fastened to one another, have a mutually congruent outer contour, and are provided with uninterrupted recesses 22 which accommodate magnets 14 of rotor 10 on the inside.

[0028] According to the present invention, transducer 16 as shown in FIG. 1 is also developed as a formed sheet metal part. This part is made from a metallic material, in particular from the same material as rotor laminations 20 of rotor 10, and it has a plurality of recesses 32 in the region along its outer periphery, which are set apart from one another in the circumferential direction by wing-shaped sections 34 in each case. Recesses 32 form electrically non-conductive regions, and wing-shaped sections 34 form electrically conductive regions of signal transducer 16. For instance, recesses 32 are open toward the periphery of the shaped sheet metal part, their geometrical form also largely corresponding to the geometrical form of wing-shaped sections 34 by way of example.

[0029] Radially toward the inside, recesses 32 or wing-shaped sections 34 of signal transducer 16 are adjoined by an annular region provided with cutouts 26, which are situated next to one another in the circumferential direction. Cutouts 26 surround a hub region 28 of signal transducer 16 featuring a shaft channel 30 developed in the center of this hub region 28 for the insertion of machine shaft 18.

[0030] According to the present invention, signal transducer 16 rests against rotor 10 in a flush manner and is furthermore mounted in a torsionally fixed manner on machine shaft 18. By way of example, the torsionally fixed mounting is implementable in the form of a conventional press-fit connection 24. In a first exemplary embodiment of such a press-fit connection 24 shown in FIG. 2, machine shaft 18 as well as shaft channel 30 have a cylindrical cross-section in hub region 28 of signal transducer 16. The outer diameter of machine shaft 18 is larger than the inner diameter of shaft channel 30 of signal transducer 16 so that the oversize that exists between the two components induces a radial preloading force when the components are joined to one another, by which signal transducer 16 is anchored to machine shaft 18 in a torsionally fixed manner.

[0031] A serration is used in a second, alternative exemplary embodiment of a press-fit connection between signal transducer 16 and machine shaft 18. For this purpose, as illustrated in FIG. 3 by way of example, a plurality of serrations 40 are developed at regular intervals along the periphery of machine shaft 18, these serrations radially projecting relative to each other and extending in the direction of a longitudinal axis L of this machine shaft 18. Serrations 40 extend from one end of machine shaft 18 to rotor 10 situated on the machine shaft 18; signal transducer 16 is situated in the region of these serrations 40 on machine shaft 18. Serrations 40 have joining chamfers 42 at their end facing away from rotor 10, via which signal transducer 16 centers itself when mounted on machine shaft 18 via its shaft channel 30. In the region of the maximum height of serrations 40, a sharply tapering tooth head 44 is formed by way of example, so that respective serration 40 displaces material of shaft channel 30 of signal transducer 16 during the joining process without dislodging shavings. The cross-sectional form of serration 40 is able to be specified in an application-specific manner.

[0032] In the pressed-on state of signal transducer 16 on machine shaft 18, the components are thus connected to one another in a relatively rigid manner by a combination of a frictional and a keyed connection. Such a connection exhibits an extremely robust behavior with regard to relative movements in the circumferential direction of machine shaft 18 even under changing environmental conditions.

[0033] In one advantageous further refinement of the present invention, in addition to the described torsionally fixed fastening to machine shaft 18, signal transducer 16 is fixed in place on rotor 10. This makes it possible to further counteract relative movements in the circumferential direction, which are undesired because of their adverse effect on the measuring result. The fastening of signal transducer 16 to rotor 10 may include a frictional and/or a keyed connection.

[0034] One example of a frictional connection between signal transducer 16 and rotor 10 is illustrated in FIG. 4. This frictional connection is achieved with the aid of an elastic preloading element 50, which is situated on machine shaft 18 on the side of signal transducer 16 facing away from rotor 10. A disk spring is preferably used as a preloading element 50, which is supported on signal transducer 16 on one side and on a rolling bearing 52 supporting machine shaft 18 in the machine housing on the opposite side. The distance between rolling bearing 52 and signal transducer 16 is selected in such a way that the inserted preloading element 50 loads signal transducer 16 by an axial force acting in the direction of the longitudinal axis L of machine shaft 18 in the direction of a rotor lamination 20 of rotor 10. On the one hand, this axial force ensures that signal transducer 16 is securely held in flush contact against rotor 10 under operational conditions, and it induces a frictional force between signal transducer 16 and rotor 10 on the other hand, which potentially counteracts relative movements between the components taking place in the circumferential direction. In the illustrated example, transducer 16 is implemented as a three-dimensional structure having a bowl- or cup-shaped cross-section, for example, but this does not necessarily preclude a flat or largely two-dimensional shape of signal transducer 16.

[0035] FIGS. 5 and 6 show a variant in which signal transducer 16 and rotor 10 are connected to each other by a keyed connection. To this end, a tab 60 is developed on signal transducer 16, which projects at a right angle from the cross-sectional surface of signal transducer 16 and thus is coaxially aligned with longitudinal axis L of machine shaft 18. Tab 60 is situated on the side of signal transducer 16 facing rotor 10 and, by way of example, is able to be developed in the form of a U-shaped cutout on the shaped sheet metal part of signal transducer 16, the inner part of this cutout being subsequently bent.

[0036] A receiving opening 64 is developed on rotor 10, which is allocated to tab 60 or into which tab 60 extends when signal transducer 16 is resting against rotor 10 in a flush manner. If signal transducer 16 were not already situated on machine shaft 18 in a torsionally fixed manner anyway, tab 60 would thus form a driver with the aid of which the rotational movement of rotor 10 would be transmittable to signal transducer 16. It is of course possible to distribute a plurality of such tabs 60 along the cross-section of signal transducer 16. FIG. 5 shows a rotor 10 provided with a plurality of receiving openings 64 to accommodate tabs 60.

[0037] Instead of tabs 60, studs 62, which likewise project from the cross-sectional surface at a right angle, may be formed on the signal transducer as an alternative. Such studs, for example, can be developed on the signal transducer with the aid of a punch and die using forming and molding technology. This connection technique is also known as clinching or Tox clinching among experts.

[0038] Modifications or supplementations of the described exemplary embodiments are of course possible without deviating from the basic idea of the present invention, disclosed herein.

[0039] In this context it should be mentioned that the ends of tabs 60 or studs 62 protruding into openings 64 of rotor 10 are able to be plastically deformed after signal transducer 16 has come to rest against rotor 10 in a flush manner. To this end, for example, a punch is introduced into receiving opening 64 of rotor 10 from the end situated opposite transducer 16. In the interior of rotor 10, the free end of tab 60 is then bent or studs are axially caulked with the aid of this punch. In this way, a firm connection is able to be realized between signal transducer 16 and at least one rotor lamination 20 of rotor 10. The latter at least largely precludes both radially directed relative movements, i.e., movements taking place in the circumferential direction of machine shaft 18, and axially directed relative movements, i.e., movements between signal transducer 16 and rotor 10 in the direction of longitudinal axis L of machine shaft 18, which means that even more precise measuring results are achievable with regard to the angle of rotation of rotor 10.