LAMINATED ROTOR CORE FOR A ROTOR, AND METHOD FOR PRODUCING A LAMINATED ROTOR CORE

Abstract

A laminated rotor core for a rotor of a permanently excited electric machine and to a method for producing same are provided. The laminated rotor core consists of a plurality of stacked lamination rings, each lamination ring consisting of a plurality of circular segments. Each circular segment has multiple receiving openings, which are arranged in a V-shaped manner relative to each other in pairs, for permanent magnets and multiple passages for respective fixing elements. The laminated rotor core is mounted on a holding disc using the fixing elements, which run in the passages of the laminated rotor core.

Claims

1. A laminated rotor core for a rotor of a permanently excited electric machine, wherein the laminated rotor core comprising: a plurality of lamination rings, each of the lamination rings consists of including a plurality of circular segments, and each of the circular segments has, in a circumferential direction, a first end face with a connection system and a second end face with a complementary connection system; wherein each said circular segment has a plurality of receiving openings, which are arranged in a V-shape relative to each other in pairs, configured for receiving permanent magnets; and a plurality of passages defined in the circular segments, each configured for a fixing element of the laminated rotor core, are provided, wherein the receiving openings for the permanent magnets and the plurality of passages are arranged symmetrically about a central axis of the circular segment and homogeneously along an arc length of the circular segment and a number of the receiving openings in pairs is larger than a number of the passages.

2. The laminated rotor core according to claim 1, wherein the first connection system has formed a first connecting element, a second connecting element and a third connecting element, which differ in shape, the complementary connection system has formed a first complementary connecting element, a second complementary connecting element and a third complementary connecting element, which differ in shape, and the first connecting element interacts with the first complementary connecting element of a subsequent circular segment, the second connecting element interacts with the second complementary connecting element of the subsequent circular segment and the third connecting element interacts with the third complementary connecting element of the subsequent circular segment in a form-fitting manner.

3. The laminated rotor core for the rotor according to claim 1 one of the preceding claims, wherein the passages of the lamination rings formed of the circular segments are aligned and a respective fixing element means extends through each of the passages of the laminated rotor core, all of which are fixed to a holding disc for the laminated rotor core.

4. The laminated rotor core for the rotor according to claim 3, wherein the fixing elements comprise screws or rivets.

5. The laminated rotor core for the rotor according to claim 1, wherein the lamination rings formed of the circular segments are stacked individually or in groups in such a way such that joints of the lamination rings are aligned in a direction of an axis of the laminated rotor core.

6. The laminated rotor core for the rotor according to claim 1, wherein the lamination rings formed consisting of the circular segments are stacked individually or in groups in such a way such that joints of all of the lamination rings of the laminated rotor core or the joints of the groups of the laminated rings are offset from one another by half an angular amount of the circular segment.

7. The laminated rotor core for the rotor according to claim 1, wherein each said lamination ring of the laminated rotor core is comprised of three of the segments or of five of the segments.

8. A method for producing a laminated rotor core for a rotor of a permanently excited electric machine, the method comprising the following steps: punching a plurality of circular and identical segments are punched out of a metal sheet, so that each of the circular segments has formed in a circumferential direction on a first end face a connection system, on a second end face a complementary connection system, a plurality of receiving openings configured for permanent magnets arranged in pairs and in a V-shape relative to each other, and a plurality of passages for a fixing elements; forming a lamination ring is formed from a defined number of the plurality of circular and identical segments by the connection system of the first end face of one said circular segment interacting interacts in a form-fitting manner with the complementary connection system on the second end face of a subsequent of the circular segments; stacking the lamination rings completed with the circular segments in such a way that the receiving openings for the permanent magnets and the passages for the fixing elements of all of the lamination rings stacked in the laminated rotor core are aligned; and fixing the laminated rotor core is fixed to a holding disc using a fixing element in each case through one of the passages of the laminated rotor core.

9. The method according to claim 8, wherein the lamination rings formed of the circular segments are stacked individually or in groups such that joints of the lamination rings of the laminated rotor core are aligned in a direction of an axis of the laminated rotor core.

10. The method according to claim 8, wherein the lamination rings formed of the circular segments are stacked individually or in groups in such a way such that joints of all of the lamination rings of the laminated rotor core or the joints of the groups are offset from one another by half an angular amount of the circular segment.

11. A laminated rotor core for a rotor of a permanently excited electric machine, the laminated rotor core comprising: a plurality of lamination rings, each of the lamination rings including a plurality of circular segments, and each of the circular segments has, in a circumferential direction, a first end face with a connector and a second end face with a complementary connector; each said circular segment has a plurality of receiving openings, which are arranged in a V-shape relative to each other in pairs, configured for receiving permanent magnets; and a plurality of passages defined in the circular segments, each configured for a fastener used for assembling of the laminated rotor core, wherein the receiving openings for the permanent magnets and the plurality of passages are arranged symmetrically about a central axis of the circular segment and uniformly spaced along an arc length of the circular segment and a number of pairs of the receiving openings is larger than a number of the passages.

12. The laminated rotor core according to claim 11, wherein the first connector includes first, second and third connecting elements which differ in shape from one another, the second complementary connector first, second and third complementary connecting elements configured to respectively interact with the first, second, and third connecting elements of a subsequent circular segment in a form-fitting manner such that the circular segments are interconnected to one another.

13. The laminated rotor core for the rotor according to claim 11, wherein the passages of the lamination rings formed of the circular segments are aligned and a fastener extends through at least some of the passages of the laminated rotor core, all of which are fixed to a holding disc for the laminated rotor core.

14. The laminated rotor core for the rotor according to claim 13, wherein the fasteners comprise screws or rivets.

15. The laminated rotor core for the rotor according to claim 11, wherein the lamination rings formed of the circular segments are stacked individually or in groups such that joints between the circular segments of the lamination rings are aligned in a direction of an axis of the laminated rotor core.

16. The laminated rotor core for the rotor according to claim 11, wherein the lamination rings formed of the circular segments are stacked individually or in groups such that joints between the circular segments of all of the lamination rings of the laminated rotor core or the joints of the groups of the laminated rings are offset from one another by half an arc length of the circular segment.

17. The laminated rotor core for the rotor according to claim 1, wherein each said lamination ring of the laminated rotor core comprises three of the segments or five of the segments.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0040] With reference to the accompanying drawings, the disclosure and its advantages will now be explained in more detail by means of exemplary embodiments, without thereby limiting the disclosure to the exemplary embodiment shown. The proportions in the figures do not always correspond to the real proportions, since some shapes are simplified and other shapes are shown enlarged in relation to other elements for better illustration.

[0041] FIG. 1 shows a plan view of a metal sheet from which a lamination ring is punched out according to the prior art for a laminated rotor core.

[0042] FIG. 2 shows a side view of the laminated rotor core formed from a plurality of lamination rings of FIG. 1.

[0043] FIG. 3 shows a schematic plan view of a lamination ring which is formed from a plurality of circular segments.

[0044] FIG. 4 shows a schematic plan view of a metal sheet; from which, according to the disclosure, the circular segments for the lamination ring of FIG. 3 are punched out.

[0045] FIG. 5 shows a plan view of a lamination ring which is formed from a plurality of circular segments according to the disclosure.

[0046] FIG. 6 shows a perspective view of the lamination ring formed from the plurality of circular segments according to the disclosure.

[0047] FIG. 7 shows a plan view of a circular segment according to the disclosure.

[0048] FIG. 8 shows a side view of the laminated rotor core, which according to one embodiment is formed from a plurality of segmented lamination rings of FIG. 5.

[0049] FIG. 9 shows a side view of the laminated rotor core, which according to a further embodiment is formed from a plurality of segmented lamination rings of FIG. 5.

[0050] FIG. 10 shows a perspective view of an assembled laminated rotor core.

[0051] FIG. 11 shows a sectional view of an assembled laminated rotor core.

[0052] FIG. 12 shows a perspective view of an assembled laminated rotor core of FIG. 11.

DETAILED DESCRIPTION

[0053] Identical reference symbols are used for elements of the disclosure that are the same or have the same effect. Furthermore, for the sake of clarity, only reference symbols are shown in the individual figures that are necessary for the description of the respective figure. The figures merely represent exemplary embodiments of the disclosure without, however, restricting the disclosure to the exemplary embodiments shown.

[0054] FIG. 1 shows a plan view of a metal sheet 9, from which a lamination ring 10 according to the prior art is punched for the removal of a laminated rotor core 1. In FIG. 2, a side view of the laminated rotor core 1 is shown, which is formed from the plurality of lamination rings 10 according to the prior art. Due to the assembly conditions, such as, for example, transverse interference fit, screwing, riveting and the like, the lamination rings 10 of the laminated rotor core 1 are designed as full rings. However, this means extremely high punching waste in the production of these full rings (individual cores).

[0055] FIG. 3 shows a schematic plan view of a lamination ring 10 which is formed from a plurality of circular ring segments 12. FIG. 4 shows a schematic plan view of a metal sheet 9, from which, according to the disclosure, the circular ring segments 12 for the lamination ring 10 of FIG. 3 are punched out. All of the punched out circular ring segments 12 are identical. The lamination ring 10 is created from the circular ring segments 12. The arrangement of the circular ring segments 12 enables a significantly higher utilization of the metal sheet 9. It is possible, for example, to use a punching tool (not shown) with a plurality of nests, or to move the metal sheet 9 under the punching tool. All circular ring segments 12 are designed to be geometrically identical.

[0056] FIG. 5 shows a plan view of two lamination rings 10 arranged one above the other, both of which are formed from a plurality of circular ring segments 12 according to the disclosure. The plan view shows two segment levels. The circular ring segments 12 of the upper lamination ring 10 are identified by the dashed lines. The circular ring segments 12 of the lower lamination ring 10 are identified by the dashed-dotted lines. The passages 22 for the fixing means (not shown here) and the receiving openings 20 arranged in pairs for the permanent magnets are distributed in a rotationally symmetrical manner on each of the lamination rings 10. In the embodiment shown here, each of the lamination rings 10 consists of five circular segments 12. The upper lamination ring 10 is rotated by half an angular range (arc length B) of the circular segment 12 relative to the lower lamination ring 10. From FIG. 5 it can be clearly seen that, despite the rotation, the passages 22 of the stacked two lamination rings 10 consisting of the circular segments 12 are in alignment. Likewise, the receiving openings 20 for permanent magnets, arranged in pairs (not shown here), are aligned. By rotating the upper lamination ring 10 relative to the lower lamination ring 10, the joints 25 between the circular segments 12 of the upper lamination ring 10 and the circular segments 12 of the lower lamination ring 10 are correspondingly rotated.

[0057] FIG. 6 shows a perspective view of the lamination ring 10 formed from a plurality of circular ring segments 12 according to the disclosure. The dashed lines mark one of the plurality of circular ring segments 12. Likewise, the receiving openings 20 and the passages 22, which are evenly distributed along the circumference of the lamination ring 10 and are arranged in pairs, can be seen.

[0058] FIG. 7 shows a plan view of a possible embodiment of a circular segment 12 according to the disclosure. Each circular segment 12 has a first end face 14 with a connection system 4 in the circumferential direction U. The circular segment 12 also has a second end face 16. The first end face 14 has a connection system 4 that is formed during the punching process. A connection system 6 complementary to the connection system 4, which is also formed during the punching process, is formed on the second end face 16.

[0059] In the embodiment shown here, which should not be understood as a limitation of the disclosure, the first connection system 4 consists of a first connecting element 5.sub.1, a second connecting element 5.sub.2 and a third connecting element 5.sub.3, which differ in their shape. The second connection system 6 consists of a first complementary connecting element 7.sub.1, a second complementary connecting element 7.sub.2 and a third complementary connecting element 7.sub.3, which also differ in their shape. The first connecting element 5.sub.1 interacts with the first complementary connecting element 7.sub.1 of a subsequent circular segment 12 in a form-fitting manner. The second connecting element 5.sub.2 interacts with the second complementary connecting element 7.sub.2 of the subsequent circular segment 12 in a form-fitting manner. The third connecting element 5.sub.3 interacts with the third complementary connecting element 7.sub.3 of the subsequent circular segment 12 in a form-fitting manner.

[0060] Each of the circular segments 12 has formed punched out receiving openings 20 for permanent magnets and the plurality of passages 22, which are arranged symmetrically around a central axis M of the circular segment 12. Furthermore, the receiving openings 20 for permanent magnets and the plurality of passages 22 are arranged homogeneously along an arc length B of the circular segment 12.

[0061] FIG. 8 shows a side view of the laminated rotor core 1, which according to one embodiment is formed from a plurality of segmented lamination rings 10 of FIG. 5. The lamination rings 10 consisting of the individual circular segments 12 assembled according to the disclosure are stacked individually or in groups in such a way that the joints 25 of all the lamination rings 10 are aligned in the direction of an axis A of the laminated rotor core 1.

[0062] FIG. 9 shows a side view of the laminated rotor core 1, which according to a further embodiment is formed from a plurality of segmented lamination rings 10 of FIG. 5. The lamination rings 10 consisting of the circular segments 12 can be stacked individually or in groups. In the embodiment shown here, the lamination rings 10 are stacked in such a way that the joints 25 of all the lamination rings 10 of the laminated rotor core are offset from one another by half an angular amount of the circular segment 12.

[0063] FIG. 10 shows a perspective view of an assembled laminated rotor core 1. In the embodiment shown here, screws are used as fixing means 23 to fix the lamination rings 10 of the laminated rotor core 1 consisting of the circular segments 12 (see FIG. 7) to a holding disc 11. By using a screw connection or riveting, the lamination rings 10 consisting of the circular segments 12 (see FIG. 7) can be used. A cylindrical rotor carrier 30 can be used to stack the individual lamination rings 10, which merely provides a centering seat for the lamination rings 10. Thus, a completely cylindrical rotor carrier 30 is no longer necessary for the assembly of the lamination rings 10. As mentioned above, the individual lamination rings 10 are stacked in such a way that the passages 22 for the fixing means 23 and the receiving openings 20 for permanent magnets are aligned over the entire axial length of the laminated rotor core 1.

[0064] FIG. 11 shows a sectional view of an assembled laminated rotor core 1 and FIG. 12 shows a perspective view of an assembled laminated rotor core 1 of FIG. 11. In the embodiment shown in FIGS. 11 and 12, the rotor carrier 30 as a tubular carrier element is omitted completely and the laminated rotor core 1 is fastened to the holding disc 11. As can be seen from FIG. 11, the fixing means 23 are designed as screws. The screws 23 run in the passages 22 of the stacked lamination rings 10 and interact with the holding disc 11 to fix the laminated rotor core 1.

[0065] It is believed that the present disclosure and many of the advantages noted therein will be understandable from the preceding description. It will be apparent that various changes in the shape, construction and arrangement of the components can be made without departing from the disclosed subject matter. The form described is illustrative only and it is the intent of the appended claims to embrace and incorporate such changes. Accordingly, the scope of the disclosure should be limited only by the appended claims.

LIST OF REFERENCE SYMBOLS

[0066] 1 Laminated rotor core [0067] 4 Connection system [0068] 5.sub.1 First connecting element [0069] 5.sub.2 Second connecting element [0070] 5.sub.3 Third connecting element [0071] 6 Complementary connection system [0072] 7.sub.1 First complementary connecting element [0073] 7.sub.2 Second complementary connecting element [0074] 7.sub.3 Third complementary connecting element [0075] 9 Metal sheet [0076] 10 Lamination ring [0077] 11 Holding disc [0078] 12 Circular segment [0079] 14 First end face [0080] 16 Second end face [0081] 20 Receiving openings for permanent magnets [0082] 22 Passage [0083] 23 Fixing means [0084] 25 Joint [0085] 30 Rotor carrier [0086] A Axis [0087] B Arc length [0088] M Central axis [0089] U Circumferential direction