Abstract
A lamination ring for constructing a laminated rotor core for a rotor of an electric machine and a method for producing a laminated rotor core made of multiple lamination rings for a rotor is disclosed. The lamination ring has multiple receiving openings for permanent magnets, and multiple structural elements are arranged homogeneously in the lamination ring at the same distance to one another in the circumferential direction in a rotated manner by an offset angle relative to the axis of symmetry such that the arrangement of structural elements is not symmetrical relative to the axis of symmetry of the lamination ring.
Claims
1. A lamination ring for constructing a laminated rotor core for a rotor of an electric machine, the lamination ring comprising: a plurality of receiving openings for permanent magnets formed in pairs and in a V-shape to one another in a circumferential direction and distributed symmetrically to an axis of symmetry in the lamination ring; and a plurality of structural elements formed homogeneously in the lamination ring at a same distance to one another in the circumferential direction, rotated by an offset angle relative to the axis of symmetry such that an arrangement of the structural elements is not symmetrical relative to the axis of symmetry of the lamination ring.
2. The lamination ring according to claim 1, wherein the lamination ring comprises a plurality of identical annular segments which each have a plurality of the receiving openings arranged in pairs and in a V-shape to one another and at least two structural elements formed in such a manner that each of the structural elements is displaced by an angle relative to a center line of the receiving openings for permanent magnets in the circumferential direction.
3. The lamination ring according to claim 2, wherein each of the annular segments for producing the lamination ring has a first end face with a connection system and a second end face with a complementary connection system in the circumferential direction.
4. The lamination ring according to claim 2, wherein two structural elements are formed on each of the annular segments.
5. The lamination ring according to claim 2, wherein the structural elements are designed as passages for receiving a respective fixing element for mounting the laminated rotor core on a holding disc.
6. The lamination ring according to claim 2, wherein the structural elements have a form-fit geometry to hold multiple lamination rings against one another or to secure the lamination ring of the laminated rotor core to a holding disc, respectively.
7. A method for producing a laminated rotor core made of multiple lamination rings for a rotor of a permanently excited electric machine, comprising the following steps: a) forming a plurality of identical lamination rings, wherein each lamination ring has multiple receiving openings for permanent magnets, which are distributed in pairs and in a V-shape to one another in a circumferential direction symmetrically to an axis of symmetry of the lamination ring, and wherein multiple structural elements are formed homogeneously in the lamination ring at a same distance to one another in the circumferential direction, rotated by an offset angle relative to the axis of symmetry such that an arrangement of structural elements is not symmetrical relative to the axis of symmetry of the lamination ring; b) rotating a lamination ring of the plurality of identical lamination rings by 180° about the axis of symmetry; c) placing the rotated lamination ring as a subsequent lamination ring on a previous, non-rotated lamination ring; d) placing a non-rotated lamination ring of the plurality of identical lamination rings on the previous lamination ring; e) carrying out steps b to d until the laminated rotor core is finished and the laminated rotor core is fixed to a holding disc with one fixing element for each structural element.
8. The method according to claim 7, wherein the lamination rings are stacked in such a way that the structural elements of the lamination rings of two successive lamination rings are offset from one another by the offset angle in the circumferential direction.
9. The method according to claim 7, comprising punching out of a metal sheet a plurality of identical annular segments, so that in the circumferential direction on a first end face a connection system, on a second end face a complementary connection system, multiple receiving openings for permanent magnets arranged in pairs and in a V-shape relative to one another, and at least two structural elements are formed on each of the annular segments; wherein the at least two structural elements are formed such that each structural element is displaced by half an offset angle relative to an axis of symmetry of the receiving openings for permanent magnets in the circumferential direction.
10. The method according to claim 9, wherein each lamination ring is formed from a defined number of the plurality of identical annular segments in that the connection system of the first end face of an annular segment interacts in a form-fitting manner with the complementary connection system on the second end face of the subsequent annular segment.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0045] 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.
[0046] FIG. 1 shows a plan view of a metal sheet from which a lamination ring is punched out according to the background of the art for a laminated rotor core.
[0047] FIG. 2 shows a schematic plan view of a lamination ring which is formed from a plurality of annular segments.
[0048] FIG. 3 shows a schematic plan view of a metal sheet; from which, according to the disclosure, the annular segments for the lamination ring of FIG. 3 are punched out.
[0049] FIG. 4 shows a plan view of a lamination ring which is formed from multiple annular segments according to the disclosure.
[0050] FIG. 5 shows a plan view of an annular segment according to the disclosure.
[0051] FIG. 6 shows a sectional view of a mounted laminated rotor core.
[0052] FIG. 7 shows, in a plan view of one of the annular segments, the formation of the passages (bores) in order to form the offset angle.
[0053] FIG. 8 shows a schematic view of two layers of stacked lamination rings or groups of lamination rings without a displacement of the structural elements (passages).
[0054] FIG. 9 shows a schematic view of two layers of stacked lamination rings or groups of lamination rings with a displacement of the structural elements (passages) to the right by half the offset angle.
[0055] FIG. 10 shows a schematic view of two layers of stacked lamination rings or groups of lamination rings with a displacement of the structural elements (passages) by the entire offset angle.
[0056] FIG. 11 shows a schematic side view without a displacement of the structural elements (internal toothing).
[0057] FIG. 12 shows a schematic side view of the displacement of the structural elements (internal toothing) to the right by half the offset angle.
[0058] FIG. 13 shows a schematic side view of the displacement of the structural elements (internal toothing) by the offset angle, wherein the top lamination ring or the top group of lamination rings are rotated by 180°.
DETAILED DESCRIPTION
[0059] 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 numerals 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.
[0060] FIG. 1 shows a plan view of a metal sheet 9, from which a lamination ring 10 according to the background of the art is punched for the removal of a laminated rotor core 1. Due to the assembly conditions, such as, for example, cross-interference, 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).
[0061] FIG. 2 shows a schematic plan view of a lamination ring 10 which is formed from a plurality of annular ring segments 12. FIG. 3 shows a schematic plan view of a metal sheet 9, from which, according to the disclosure, the annular ring segments 12 for the lamination ring 10 of FIG. 3 are punched out. All of the punched out annular ring segments 12 are identical. The lamination ring 10 is created from the annular ring segments 12. The arrangement of the annular 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 multiple nests, or to move the metal sheet 9 under the punching tool. All annular ring segments 12 are designed to be geometrically identical.
[0062] FIG. 4 shows a plan view of two lamination rings 10 arranged one above the other, both of which are formed from multiple annular segments 12 according to a possible embodiment of the disclosure. The plan view shows two segment levels. The annular ring segments 12 of the upper lamination ring 10 are identified by the dashed lines. The annular segments 12 of the lower lamination ring 10 are identified by the dashed-dotted lines. The structural elements 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 of the annular segments 12 shown here, the structural elements 22 are designed as passages or bores, which is not to be understood as a limitation of the disclosure. In the embodiment shown here, each of the lamination rings 10 consists of five annular segments 12. The upper lamination ring 10 is rotated by half an angular range (arc length B) of the annular segment 12 relative to the lower lamination ring 10.
[0063] From FIG. 4 it can be clearly seen that, despite the rotation, the structural elements 22 of the stacked two lamination rings 10 consisting of the annular segments 12 are in alignment. The receiving openings 20 for permanent magnets (not shown here), which are arranged in pairs, are also aligned. By rotating the upper lamination ring 10 relative to the lower lamination ring 10, the joints 25 between the annular segments 12 of the upper lamination ring 10 and the annular segments 12 of the lower lamination ring 10 are correspondingly rotated. The lamination ring 10 is axially symmetrical relative to the axis of symmetry S1.
[0064] FIG. 5 shows a plan view of a possible embodiment of an annular segment 12 according to the disclosure. Each annular segment 12 has a first end face 14 with a connection system 4 in the circumferential direction U. The annular 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. The second end face 16 has a connection system 6 which is complementary to the connection system 4 and which is also formed during the punching process.
[0065] 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 annular 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 annular 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 annular segment 12 in a form-fitting manner.
[0066] Each of the annular segments 12 has the punched-out receiving openings 20 for the permanent magnets, which are all arranged axially symmetrically to an axis of symmetry S2 of the annular segment 12. Due to the displacement by the offset angle 40 (see FIG. 7), the multiple structural elements 22 are not arranged axially symmetrically about the axis of symmetry S2 of the annular segment 12. Furthermore, the receiving openings 20 for permanent magnets and the multiple structural elements 22 are arranged homogeneously along an arc length B of the annular segment 12.
[0067] FIG. 6 shows a sectional view of an assembled laminated rotor core 1. In the embodiment shown here, the rotor carrier, as a tubular carrier element, can be completely omitted and the laminated rotor core 1 is fastened to the holding disc 11. The fixing means 23 are designed as screws. The screws run in the structural elements 22 of the stacked lamination rings 10 or the stacked groups of lamination rings 10 and interact with the holding disc 11 to fixate the laminated rotor core 1.
[0068] FIG. 7 shows a plan view of one of the annular segments 12, in which the formation of the structural elements 22 (such as, for example, passages or bores) is offset by an offset angle 40. The solid line 42 marks the center between the receiving openings 20 for the permanent magnets. The dashed cross 44 marks the center of the structural element 22. In the embodiment shown here, the annular segment 12 has two structural elements 22 which are arranged homogeneously and at the same distance to one another in the circumferential direction U. The structural elements 22 are arranged at an angle 40 relative to the center line 42 of the receiving openings 20 for the permanent magnets. The rotation of the structural elements 22 of the annular segment 12 by the angle 40 is clear from the deviation of the cross 44 marking the center of the structural element 22 and the center line 42 of the receiving openings 20 for the permanent magnets. The angle 40 of the rotation is defined as half the offset angle.
[0069] FIG. 8 shows a schematic view of a first, lowermost layer 17 and a second, uppermost layer 18 of stacked lamination rings 10 or groups of lamination rings 10 consisting of annular segments 12. Here there is no displacement of the structural elements 22 of the annular segments 12 (passages) relative to the center line (represented here by the solid line 42) of the receiving openings 20 (not shown here) for permanent magnets. The angle 40 is equal to zero and the solid line 42 coincides with the dashed line 44 which marks the center of the structural element 22.
[0070] FIG. 9 shows a schematic view of two layers 17 and 18 of stacked lamination rings 10 or groups of lamination rings 10 with the structural elements 22 (passages) displaced to the right by half an angle 40. The displacement of the structural elements 22 of the annular segments 12 (passages) relative to the center line (represented here by the solid line 42) of the receiving openings 20 for permanent magnets is illustrated by the fact that the solid line 42 does not match the dashed line 44, which marks the center of the structural element 22.
[0071] FIG. 10 shows a schematic view of two layers 17 and 18 of stacked lamination rings 10 or groups of lamination rings 10 with a displacement of the structural elements 22 (passages) by the angle 40 (offset angle). The displacement or rotation by the angle 40 is achieved by placing the top lamination ring 10 (top layer 18) or the top group (top layer 18) of lamination rings 10 with an upper side 26.sub.18 on the top side 26.sub.17 of the lower lamination ring 10 (lowermost layer 17) or the lower group (lowermost layer 17) of lamination rings 10. This is achieved in that the top lamination ring 10 (top layer 18) or the top group (top layer 18) of lamination rings 10 is rotated by 180° around the axis of symmetry S1 (see FIG. 4).
[0072] FIG. 11 shows a schematic side view, wherein there was no displacement of the structural elements 22 of the lamination ring 10 (not shown) or the annular segments 12 (not shown) of the lamination ring 10, which are formed as internal teeth 22.sub.IN. Consequently, the angle 40 is zero.
[0073] FIG. 12 shows a schematic side view of the displacement of the structural elements (internal toothing) 22.sub.INV to the right by half the angle 40 (offset angle). The angle 40 results from the comparison of the non-displaced internal toothing 22.sub.IN and the displaced internal toothing 22.sub.INV. The displacement occurs in a manner analogous to that already explained in the description of FIG. 9.
[0074] FIG. 13 shows a schematic side view of the displacement of the structural elements (internal toothing) 22.sub.INV by the angle 40 (full offset angle). Analogously to the description of FIG. 10, the uppermost lamination ring 10 or the uppermost group of lamination rings 10 was rotated by 180°. The result is the angle 40 (full offset angle), which results from the comparison of the non-displaced internal toothing 22.sub.IN and the displaced internal toothing 22.sub.INV of the two lamination rings 10 or the two groups of lamination rings 10.
[0075] It is believed that the present disclosure and many of the advantages noted therein will be understandable from the preceding description. Obviously, 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
[0076] 1 Laminated rotor core
[0077] 4 Connection system
[0078] 5.sub.1 First connecting element
[0079] 5.sub.2 Second connecting element
[0080] 5.sub.3 Third connecting element
[0081] 6 Complementary connection system
[0082] 7.sub.1 First complementary connecting element
[0083] 7.sub.2 Second complementary connecting element
[0084] 7.sub.3 Third complementary connecting element
[0085] 9 Metal sheet
[0086] 10 Lamination ring
[0087] 11 Holding disc
[0088] 12 Annular segment
[0089] 14 First end face
[0090] 16 Second end face
[0091] 17 First or lowermost layer
[0092] 18 Second or uppermost layer
[0093] 20 Receiving openings for permanent magnets
[0094] 22 Structural elements
[0095] 22.sub.IN Internal toothing
[0096] 22.sub.INV Displaced internal toothing
[0097] 23 Fixing means
[0098] 25 Joint
[0099] 26.sub.17 Top side
[0100] 26.sub.18 Top side
[0101] 40 Offset angle; angle
[0102] 42 Solid line
[0103] 44 Dashed cross, dashed line
[0104] B Arc length
[0105] S1 Axis of symmetry of the lamination ring
[0106] S2 Axis of symmetry of the lamination ring
[0107] U Circumferential direction
