Method for producing a housing assembly, housing assembly and ram device

Abstract

The invention relates to a method for producing a housing assembly (1), in particular for an electric machine, wherein a region (26) of a closure part (3) is reshaped in the form of an indentation (26), in order to thus press material of the closure part (3) against a housing part (16) for a non-positive engagement between the closure part (3) and the housing part (16).

Claims

1. A method for producing a housing arrangement for an electric machine, the method comprising a step of shaping a region of a closure part in the form of an indent, and by the step of shaping the region, pressing material of the closure part against a housing part so as to create a non-positive connection between the closure part and the housing part, wherein the shaping step is carried out using a stamp which is rotated about a middle axis of the indent to be formed and is inclined at a varying angle with respect to the middle axis, wherein the stamp is advanced axially in relation to the middle axis and the contact point of the stamp on the region follows a hypocycloid, thereby the material essentially flows in an axial direction and tangential direction in relation to the middle axis.

2. The method of claim 1, wherein a plurality of regions of the closure part are each shaped in the form of an indent at the same time.

3. The method of claim 1, wherein the closure part is formed with at least one lug which engages into a corresponding recess in the housing part, wherein the indent is formed in the lug.

4. The method of claim 1, wherein the closure part has a plurality of lugs which are received in corresponding recesses in the housing part.

5. The method of claim 1, wherein the housing part is formed as a motor housing case and/or the closure part is formed as a bearing plate.

6. A method for producing a housing arrangement for an electric machine, the method comprising: a step of shaping a region of a closure part in the form of an indent, and thereby pressing material of the closure part against a housing part so as to define a non-positive connection between the closure part and the housing part, wherein the shaping step is carried out using a stamp and the region is shaped using a conical surface of the stamp.

7. The method of claim 6, wherein the shaping step is carried out using the stamp which is rotated about a middle axis of the indent to be formed and is inclined at a varying angle with respect to the middle axis, wherein the stamp is advanced axially in relation to the middle axis and the contact point of the stamp on the region follows a hypocycloid, thereby the material essentially flows in an axial direction and tangential direction in relation to the middle axis.

8. The method of claim 6, wherein the shaping step is carried out using the stamp which is rotated about a middle axis of the indent to be formed and is inclined at a constant angle with respect to the middle axis, wherein the stamp is advanced axially in relation to the middle axis and the contact point of the stamp on the region follows an inclined spiral, thereby the material essentially flows in an axial direction and tangential direction in relation to the middle axis.

9. The method of claim 6, wherein a plurality of regions of the closure part are each shaped in the form of an indent at the same time.

10. The method of claim 6, wherein the closure part is inserted into a receiving region of the housing part before the shaping step and is clamped to the receiving region by the shaping step.

11. The method of claim 6, wherein the closure part is formed with at least one lug which engages into a corresponding recess in the housing part, wherein the indent is formed in the lug.

12. The method of claim 6, wherein an opening in a carrier part is placed onto a spigot on the closure part, wherein the spigot is shaped to engage behind the carrier part.

13. The method of claim 6, wherein the housing part is formed as a motor housing case, the closure part is formed as a bearing plate and/or the carrier part is formed as a brush carrier part.

14. The method of claim 6, wherein the closure part has a plurality of lugs which are received in corresponding recesses in the housing part.

15. A method for producing a housing arrangement for an electric machine, the method comprising a step of shaping a region of a closure part in the form of an indent, and by the step of shaping, pressing material of the closure part against a housing part so as to create a non-positive connection between the closure part and the housing part; wherein the shaping step is carried out using a stamp which is rotated about a middle axis of the indent to be formed and is inclined at a constant angle with respect to the middle axis, wherein the stamp is advanced axially in relation to the middle axis and the contact point of the stamp on the region follows an inclined spiral, thereby the material essentially flows in an axial direction and tangential direction in relation to the middle axis.

16. The method of claim 15, wherein a plurality of regions of the closure part are each shaped in the form of an indent at the same time.

17. The method of claim 15, wherein the closure part is formed with at least one lug which engages into a corresponding recess in the housing part, wherein the indent is formed in the lug.

18. The method of claim 15, wherein the closure part has a plurality of lugs which are received in corresponding recesses in the housing part.

19. The method of claim 15, wherein the housing part is formed as a motor housing case and/or the closure part is formed as a bearing plate.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The present invention will be explained in more detail hereinunder with the aid of the exemplified embodiments illustrated in the figures of the drawing in which:

(2) FIG. 1 shows a partially cut-away and partially schematic plan view of a housing arrangement in accordance with an exemplified embodiment of the present invention in a first state;

(3) FIG. 2 illustrates the housing arrangement of FIG. 1 in a second state;

(4) FIG. 3 illustrates a cross-sectional view A-A from FIG. 2;

(5) FIG. 4 illustrates a stamping apparatus in accordance with an exemplified embodiment of the present invention;

(6) FIG. 5 illustrates a process flow in accordance with an exemplified embodiment of the present invention;

(7) FIG. 6 illustrates a detail X indicated in FIG. 3 in a state before an indent is formed; and

(8) FIG. 7 illustrates a detail X indicated in FIG. 3 after an indent has been formed.

(9) Unless stated otherwise, in the figures of the drawing, like components, elements and features are designated with like reference numbers.

DESCRIPTION OF EXEMPLARY EMBODIMENTS

(10) Exemplified embodiments of a housing arrangement 1, see FIGS. 1-3, of a method for producing this arrangement, see FIG. 5, and a stamping apparatus 2, see FIG. 4, for use in the method are explained in more detail hereinunder with reference to all the figures.

(11) Step S1:

(12) In a step S1, see FIG. 5, an e.g. approximately annular bearing plate 3, see FIG. 3, is first provided. The bearing plate 3 is preferably formed as one piece with a plurality of spigots 4. The spigots 4 extend essentially perpendicular to a main plane of extension H of the bearing plate 3. The spigots 4 are formed on a rear side 5 of the bearing plate 3.

(13) FIG. 1 shows the front side 6 of the bearing plate 3. Furthermore, FIG. 1 also shows that a plurality of lugs 11 are formed on an outer circular periphery 7 of the bearing plate 3. Preferably, four of the lugs 11 are disposed along the periphery 7 of the bearing plate 3. These can, for example, each be disposed at an angle W of 90 to each other about a middle axis M1.

(14) The bearing plate 3 is produced from metal, preferably steel.

(15) Step S2:

(16) In a step S2, a brush carrier part 12, see FIG. 3, is provided. The brush carrier part 12 has through-openings 13. The through-openings 13 can be formed in the region of indentations 14 in the brush carrier part 12.

(17) The brush carrier part 12 is preferably produced from synthetic material.

(18) Step S3:

(19) In a step S3, the brush carrier part 12 is pushed with its through-openings 13 onto the spigots 4 of the bearing plate 3. Subsequently, the spigots 4 are shaped by means of wobble or radial riveting in such a way that a head 15 is formed as shown for spigot 4, see FIG. 3. The head 15 engages behind the brush carrier part 12 and therefore fixedly connects the brush carrier part 12 to the bearing plate 3. During radial or wobble riveting of the spigots 4, the introduction of force into the brush carrier part 12, which is inherently sensitive (because it is produced from synthetic material), is only slight and is precisely controllable.

(20) Step S4:

(21) In a step S4, a motor housing case 16 with a preferably annular cross-section is provided. The motor housing case 16 is formed with recesses 21 on its inner periphery 17, see FIG. 1. The recesses 21 are formed to be suitable to receive lugs 11. Furthermore, the motor housing case 16 is formed with a shoulder 22 as an abutment for the lugs 11 in the axial direction in relation to the middle axis M1.

(22) The motor housing case 16 is formed from metal, preferably steel.

(23) Step S5:

(24) In a step S5, the unit consisting of the bearing plate 3 and brush carrier part 12 is inserted into the receiving region, designated generally as 23, see FIG. 3, in the motor housing case 16. The receiving region 23 is defined by the recesses 21, the inner periphery 17 and the shoulders 22.

(25) During insertion of the bearing plate 3 into the motor housing case 16, the lugs 11 of the bearing plate 3 come into engagement with the recesses 21. This engagement ensures a positive locking connection between the bearing plate 3 and the motor housing case 16 in the peripheral direction U in relation to the middle axis M1. In the exemplified embodiment illustrated in FIG. 1, the lugs 11 are essentially rectangular, being defined by surfaces 24, 25 of the recess 21. The surfaces 25 thus lie opposite each other in the peripheral direction U and ensure the afore-mentioned positive locking connection in the peripheral direction U. The surface 24, on the other hand, ensures a positive locking connection in the radial direction R in relation to the middle axis M1.

(26) Step S6:

(27) In a step S6, the bearing plate 3 is fixedly connected to the motor housing part 16. To this end, regions 26, see FIG. 1, in corner regions of the essentially rectangular lugs 11 are each shaped in the form of an indent 26, see FIG. 2. For this purpose, the arrangement consisting of the bearing plate 3 and motor housing 16 is disposed below the stamping apparatus 2, see FIG. 4.

(28) The stamping apparatus 2 has eight stamps 31. However, it would be equally possible to provide two, three or more stamps 31. The stamps 31 are each formed with a conical surface 32. The conical surface 32 forms a tip 33 in the direction of the bearing plate 3 disposed thereunder. The eight stamps 31 are attached to a holder 34 which, on the inside thereof, has a mechanism, not shown, for movement of each stamp 31 in the manner described below. This movement is explained in more detail hereinunder by way of example with the aid of only one stamp 31.

(29) The stamp 31 is rotated about the middle axis M2 of a respective indent 26 which is to be formed. At the same time, the angle W2 by which the stamp 31 is inclined with respect to the middle axis M2 is varied. Furthermore, at the same time, the stamp 31 is advanced axially, i.e. along the middle axis M2 in the direction of the bearing plate 3. The contact point of the stamp 31 on the region 26 follows a hypocycloid, whereby the material essentially flows in an axial direction F1, F2 (see FIG. 2) and tangential direction in relation to the middle axis M2.

(30) Each of the stamps 31 of the stamping apparatus 2 is moved in this way. The axial advancement can be effected by movement of the holder 34 along the axis M1, that is in the direction of the bearing plate 3, i.e. in this respect the stamps 31 are moved jointly.

(31) The above-described movement of a stamp 31 corresponds to that in radial riveting. Alternatively, it would also be feasible to keep the angle W2 constant, wherein then the point of the stamp 31 on the region 26 follows a downwardly inclined spiral. The resulting movement corresponds to the movement during wobble riveting.

(32) The formed indents 26 are of a shape which is convex in cross-section, see FIG. 3, and circular in plan view, see FIG. 2.

(33) Step S7:

(34) In a step S7, the housing arrangement 1 produced is further fitted out. Thus, for example, a bearing 35, see FIG. 3, can be installed in the bearing plate 3. Furthermore, the brush carrier part 12 can be provided with brushes, not shown. An electric motor is therefore ultimately produced.

(35) The material flow in the radial direction, which results from the above-described wobble or radial shaping method, is identified in FIG. 2 with two arrows F1 and F2 for the indents 26. The material flow F1, F2 causes the bearing plate 3 to be enlarged in the main plane of extension H, in which the indents 26 lie. As shown in FIG. 2, the material flow F1 causes clamping of the bearing plate 3 or of the mutually diagonally opposing lugs 11 with the surfaces 24 of the motor housing case 16. Furthermore, the material flow F2 leads to clamping of a respective lug 11 between the two surfaces 25 of the motor housing case 16.

(36) By means of the stamping apparatus 2 in accordance with the present exemplified embodiment, the four lugs 11 can be formed at the same time with two indents 26 each. This produces a uniform force distribution during the shaping step, whereby a tipping of the bearing plate 3 about the middle axis M1 can be avoided. Furthermore, it saves time to form the plurality of indents 26 simultaneously.

(37) Although the invention has been described with the aid of exemplified embodiments it is not limited thereto but can be modified in many ways. In particular, the designs and exemplified embodiments described for the housing arrangement in accordance with the invention can be applied in a corresponding manner to the method in accordance with the invention and to the stamping apparatus in accordance with the invention, and vice versa. Furthermore, reference is made to the fact that a does not exclude a plurality in this case.

REFERENCE LIST

(38) 1 housing arrangement

(39) 2 stamping apparatus

(40) 3 bearing plate

(41) 4 spigot

(42) 4 spigot

(43) 5 rear side

(44) 6 front side

(45) 7 periphery

(46) 11 lug

(47) 12 brush carrier part

(48) 13 through-opening

(49) 14 indentation

(50) 15 head

(51) 16 motor housing case

(52) 17 periphery

(53) 21 recess

(54) 22 shoulder

(55) 23 receiving region

(56) 24 surface

(57) 25 surface

(58) 26 region

(59) 26 indent

(60) 31 stamp

(61) 32 conical surface

(62) 33 tip

(63) 34 holder

(64) 35 bearing

(65) F1 flow direction

(66) F2 flow direction

(67) H main plane of extension

(68) M1 middle axis

(69) M2 middle axis

(70) R radial direction

(71) U peripheral direction

(72) W1 angle

(73) W2 angle