WO2010040536A1

WO2010040536A1 - Method and device for the production of a rotor for an electric motor, an use thereof

Info

Publication number: WO2010040536A1
Application number: PCT/EP2009/007242
Authority: WO
Inventors: Bernd Schottdorf; Franz Weissgerber
Original assignee: Pro Diskus Ag
Priority date: 2008-10-08
Filing date: 2009-10-08
Publication date: 2010-04-15
Also published as: DE102008050802A1; EP2332233A1

Abstract

The invention relates to a method for producing a fiber composite rotor (104; 500; 700; 904; 1004; 1508, 1510, 1512) comprising a main member (104; 200; 402; 502; 600; 802; 1300) for an electric motor (100; 800; 1000; 1500). Said method includes the following steps: fibers of a fiber material are combined with a matrix to obtain a fiber mixture (1322); the fiber mixture comprising diffusely arranged fibers is introduced into a female mold (1304, 1316, 1324) corresponding to the shape of the main member of the rotor; the fiber mixture (1308, 1318, 1326) is cured to obtain a main member (200; 402; 502; 600; 802; 1300) of the rotor, the fiber mixture being heated by a microwave source. The invention also relates to a female mold for producing the rotor as well as a use of the rotor in an electric motor.

Description

Method and device for producing a rotor for an electric machine and use thereof

Technical field of the invention

The present invention relates generally to electrical machines, and more particularly to rotors for electric machines.

State of the art

Electric machines, both in the form of electric motors and generators, are increasingly being used in areas of alternative power generation and supply. Here are conventional electrical machines u.a. due to size, weight and efficiency in many cases not suitable.

The patent DE 10 2006 036 707 B3 discloses a carrier ring made of fiber-reinforced plastic with cutouts for insertion of permanent magnets. One or more carrier rings can form a rotor construction.

The international application WO 01/11755 Al describes similar to DE 10 2006 036 707 B3 arranged on a shaft ironless, disk-shaped rotor having permanent magnets which are embedded in a fiber or fabric-reinforced plastic. The permanent magnets are each positively connected to the surrounding plastic. The plastic forms a dimensionally stable unit together with the permanent magnets and the machine shaft. Furthermore, the "Handbook Composite Materials" by Manfred Neitzel and Peter Mitschang, Hanser Verlag, 2004, 1st edition, describes various conventional methods for processing fiber-reinforced plastic composites. Fig. 14 shows an overview diagram of such conventional methods from Neitzel and Mitschang. The diagram divides the shape complexity of a fiber-plastic composite on the horizontal axis and an approximate component size on the vertical axis.

In particular, the diagram in FIG. 14 provides information about component types and processing methods. For example, the shape complexity of round or oval tubes is low, but their component size can vary from small to large. The fiber processing methods flow forming and injection molding are increasingly used in components of high shape complexity and small to medium size components, whereas the resin injection method according to Neitzel and Mitschang is more likely to be selected with high shape complexity and large component size. As further information, it can be seen from the diagram which processing method is suitable for a particular component. According to Neitzel and Mitschang, forming is therefore suitable for structural components and shells, while winding is more suitable for pressure vessels and round or oval tubes, for example. However, a disadvantage of all processes is the processing costs and the high energy requirement, for example, when using an autoclave for curing fiber-plastic composites.

EP 0 236 116 A1 describes a motor rotor having a shaft, a cylindrical ferrite and a polymer supporting element which holds the cylinder on the shaft. US Pat. No. 6,674,214 B1 describes the production of an ironless disc-shaped rotor by arranging a shaft and permanent magnets in a mold and then pouring preheated fiber-reinforced plastic under pressure into the mold.

DE 44 42 869 A1 describes the production of a jacket element and a flange element by injection molding, which together form a rotor for an electrical machine. Wirrfasern or extending substantially to the circumferential direction of the jacket element Faserarmierungsmaterial is introduced into an injection mold and then injected a two-component plastic material and cured.

DE 10 2007 047 715 A1, which was published only after the priority date of this application, describes the design of a rotor hub made of fiber-reinforced composite material, which consists of a matrix of a curable plastic and embedded therein serving for reinforcement fibers. In thermosetting plastics fiber strands, nonwoven fabrics or fiber webs are introduced by a winding or Handlaminierverfahren in the liquid matrix or alternatively preimpregnated semifinished products wound around a mandrel or placed and then cured in a heating oven. In the case of thermoplastics, fibers can be added to the plastic and introduced into the shape of the rotor hub by injection molding.

Disclosure of the invention Object of the present invention is to overcome the above-mentioned disadvantages of the prior art.

To achieve this object, the present invention provides articles, methods and use according to the independent claims. Variants and preferred embodiments of the invention will become apparent from the dependent claims, the following description and the drawings.

According to the present invention, there is provided a method of manufacturing a fiber composite rotor having a rotor main body for an electric machine, comprising: combining fibers of a fiber material with a matrix into a fiber amount, introducing the fiber amount with diffused fibers into one of the shape of the rotor main body corresponding negative mold, and curing the Fasergemenges to a rotor main body, wherein the amount of fiber is heated by a microwave source.

In particular, a method for producing a fiber composite material consisting of a rotor with a

A rotor main body for an electric motor is provided, comprising the following steps: merging fibers of a fiber material with a matrix into one

Amount of fiber, introduction of the fiber amount with diffusely arranged fibers in one of the shape of the

Rotor main body corresponding negative mold, compressing the introduced in the negative mold amount of fiber and

Curing the compressed Fasergemenges, which preferably takes place at a predetermined temperature and predetermined pressure. Preferably, the fibers of the fiber material are formed by cutting, cutting or the like of an endless fiber into fiber parts of a certain length. Preferably. These fiber parts are combined with a matrix. The matrix is preferably a binder or bonding agent that forms certain advantageous physical and mechanical properties in connection with the fibers.

A matrix may be selected, for example, from the group of thermosets (for example unsaturated polyester resins, vinyl ester resins, epoxy resins) or from the group of thermoplastics (for example polypropylene, polyamide, polyethylene terephthalate, polyphenylene sulfide, polyether ether ketone).

Diffusely arranged fibers advantageously allow rapid and inexpensive processing, since no intermediate step for aligning or deliberately arranging the fibers is necessary. Preferably, the merging of the fibers with the matrix takes place either before introduction into the negative mold as a fiber mixture or the diffusely arranged fibers are brought together after introduction into the negative mold with a liquid matrix.

The curing of the fiber mixture is preferably a process that causes a phase transition of the matrix from liquid to solid. For thermosets, this phase transition is irreversible, for example

Thermoplastics reversible. Curing in this context does not necessarily mean that the fiber composite formed after curing is hard or stiffened; Depending on the matrix and fiber type, it can have different mechanical and physical properties such as high toughness, low weight, electrical conductivity, high flexibility, etc.

In one embodiment, the fiber composite material and / or the fiber comprises carbon. Carbon is advantageously a particularly light and hard-wearing material which, as a fiber material, has many

Forms can form and through interaction with one

Binder such a form permanently. A made of carbon fiber composite material

Rotor main body is advantageously light and yet can withstand acting forces and moments.

The amount of fiber is heated by a microwave source. Since the fiber composite material preferably comprises carbon, the electrical conductivity of carbon may be used to be heated by a microwave source. This has the advantage over conventional autoclave processes of reduced energy requirements to cure the fiber mixture.

The amount of fiber may preferably be below a predetermined pressure during heating by a microwave in a negative mold, or the amount of fiber was pressed under predetermined pressure before being heated in the negative mold. Alternatively, a predetermined pressure, rather than a negative mold, may be caused by the gas pressure surrounding the fiber. This has the advantage that the amount of fiber reaches a high density of material and thereby low volume.

Since most carbon types have a negative

Have thermal expansion coefficient, is for the

Curing step of fiber introduced in a negative mold, it is preferable that the material of the Negative form also fiber composite material and in particular carbon has.

Furthermore, a negative mold is provided for producing a rotor main body according to the invention, in which at least one fiber lies in or on the negative mold and a binder or connecting means connects sections of the at least one fiber together.

Furthermore, the invention provides an electric machine with a stator and a rotor comprising a rotor main body according to the invention. Preferably, such an electric machine is a pancake electric motor / generator with permanently excited rotor and serves as a drive for an air, water or land vehicle or as a generator in a power generating device, wherein the

Power generating device according to a solution comprises wind or hydro power plants or is designed to convert generated by a vehicle rotational forces and / or moments in electrical energy.

In some embodiments, the rotor of the invention is used in an electric machine designed as a hub motor and / or generator for a vehicle.

Hereinafter, further preferred exemplary embodiments of the invention will be explained in more detail with reference to schematic drawings. Showing:

1 is an electrical machine,

2 shows a rotor main body, 3a shows an enlarged portion of a rotor main body,

3b shows an enlarged portion of a rotor main body,

4a is a side view of a rotor main body with cover layers,

4b is a side view of a rotor main body with a mounting flange,

5 a rotor,

6 shows a section of a rotor main body,

7 shows a rotor-shaft arrangement,

8 an electrical machine,

9a, 9b different storage devices, 9c and 9d

Fig. 10a further storage devices, and 10b

11 is a negative mold for rotor production,

12 shows a further negative mold for rotor production,

Fig. 13 is a flow chart for various

Hersteilverfahren,

Fig. 14 is a diagram according to the prior art Fig. 15 an electric machine,

Fig. 16 a hybrid system, and

Fig. 17a shows an electrical circuit arrangement of a and 17b motor-generator device.

Before going into the drawings in detail, general remarks on the present invention, variants and embodiments thereof are made below.

There is provided a rotor for an electric machine having a rotor main body comprising fiber composite material. In this case, the rotor main body may include one or a plurality of centrally disposed to the center of the rotor main body shots. Furthermore, the rotor may comprise a plurality of _, magnets which are arranged in at least one of the receptacles, wherein at least two magnets are arranged in at least one of the receptacles. Preferably, at least one of the magnets is a permanent magnet.

Preferably, the material of the magnet comprises rare earth metals or a chemical compound with rare earth metals. Additionally or alternatively, the material of the magnet can have neodymium and / or a chemical compound with neodymium. The material of the magnet may additionally or alternatively comprise the chemical compound neodymium-iron-boron or samarium-cobalt. It is envisaged that in each of the shots either no magnet or exactly two magnets are arranged. In a further embodiment of the invention, the centrally arranged receptacles are holes passing through the rotor main body.

Preferably, at least one cover layer is provided, wherein the at least one cover layer may be arranged on the rotor main body such that the magnets arranged in the central receptacles are at least partially covered. At least one of the cover layers may have fiber composite material. In one embodiment, the magnets are covered in such a way by at least one of the cover layers that they are not removable from the recordings.

In a further embodiment, in each case at least one cover layer is arranged on a front surface and / or a rear surface of the rotor main body.

The fiber composite material of the rotor may comprise carbon, epoxy resin and / or polypropylene.

Furthermore, an electric machine with a stator and a rotor according to the invention is provided.

In the manufacturing process, at least one fiber for the fiber composite material may be designed to be laid in / on a forming means. It can also be provided that semifinished product comprising fiber composite material is used to form the rotor main body. Preferably, at least one fiber for the fiber composite material is designed such that it is placed in / on a shaping means. The invention also provides for the use of the rotor in an electric machine as a drive for an air, water or land vehicle or as a generator in a power generating device. The

Power generation apparatus may include wind and hydro power plants and / or be configured to convert rotational forces generated by a vehicle and / or torques into electrical energy.

In addition, the invention provides a designed as a hub motor and / or generator for a vehicle electrical machine.

Further, a rotor for an electric machine is provided with a rotor main body made of fiber composite material. A mounting flange disposed on the rotor main body may also be made of fiber composite material. Preferably, the rotor main body and the mounting flange are integrally formed of fiber composite material and are collectively referred to as a rotor.

The mounting flange may be arranged flat on a front and a rear side of the rotor main body.

Preferably, the rotor is cylindrical and its front side, i. the cylinder cover, a circular surface, which is also the circular back, i. the cylinder bottom, opposite. Advantageously, the ratio is rotor main body diameter

Rotor main body thickness high, that is, the rotor main body is advantageously flat and therefore has a low weight. If the rotor is to be connected to a shaft in its center, it is advantageous if the rotor is thicker in the middle. This can be done at the front and / or rear of the rotor, a mounting flange are arranged. The attachment flange preferably increases the thickness of the rotor main body toward the center thereof.

The mounting flange may be configured to transmit torque from the rotor main body to the shaft disposed on the mounting flange. This allows e.g. an assembly of preferably interconnected components, the components comprising the rotor main body, the mounting flange and the shaft.

The mounting flange may be formed positively to the shaft. Preferably, the

Mounting flange on a fitting hole in which the shaft is fitted. Preferably, a tight fit

(e.g., press fit) is used to avoid or reduce attachment play, mechanical wear and losses, and rotor imbalances.

At least one fiber of a fiber material may form the rotor main body and the mounting flange. Preferably, the at least one fiber is wound, laid, tensioned, or otherwise arranged so that a solid such as the rotor main body and / or the fixing body can be integrally formed. This can have the advantage that rotor main body and the mounting flange have improved, high stability. Are the rotor main body and the

Mounting flange integrally formed, so an additional connection operation of two components can be omitted and a solid cohesion and rapid production can be achieved. The mounting flange may comprise at least one component which is formed from plate-like fiber composite semi-finished product. Preferably, the mounting flange is formed from one or more flat stacked components. Advantageously, such a component is an easily available, simply constructed component which can be produced easily and quickly. By means of components with different sizes and different mechanical properties, advantageously a mounting flange can be assembled in a "modular system" and formed in an application-specific manner. Under plate-like fiber composite semi-finished product is preferably understood to mean a plate formed from fiber composite raw material, which can be easily brought into a desired shape by conventional machining processes. The finishing process from the fiber composite semi-finished product to the mounting flange is advantageously short, inexpensive and can be handled with current machine tools. Under plate-like fiber composite semi-finished product may also or alternatively be prefabricated rods, spars, pipes, mats and sandwich panels, each of which may comprise fiber composite material understood.

The at least one fiber towards the center of the rotor can form a thickening. Preferably, with a uniformly radially guided arrangement of the at least one fiber, a natural thickening towards the center of the rotor is produced. Advantageously, the thickening can form a mounting flange.

There is provided a rotor of an electric machine having a rotor main body made of fiber composite material. The rotor has at least one receptacle for the arrangement of at least one magnet. The at least one fiber runs in the form of a loop around the at least one receptacle. The advantage of a fiber composite fiber is lower weight and higher stability compared to conventional soft iron rotors.

A "course in the form of a loop" is understood here as a closed, ring-like course of a fiber. In these embodiments, the rotor typically includes a plurality of such fiber rings. In the case of an endless fiber, the fiber is laid so that it returns one or more times in its course to a point (or at least approximately to a point) where it has ever been. The loop can also cut itself in its course. A course of a fiber in the form of a loop around a receptacle merely means that the receptacle lies somewhere inside the loop, but not necessarily that the loop runs completely at the edge of the receptacle. Thus, the snare may or may not extend completely or partially around the receptacle (i.e., at the edge of the receptacle).

In some embodiments, the at least one fiber is guided as a loop on the edge around the at least one receptacle, leaving at most one side of the edge of the at least one receptacle exposed. Preferably, a loop runs on the edge of a receptacle, which has four sides, for example, so that it leaves one side free.

In some embodiments, the receptacles are also formed circular or oval, so you do not from Pages can speak. In these cases, part of the circumference is left free.

In other embodiments, a sling extends around two adjacent seats.

The rotor main body may comprise at least one flange hole and / or a central shaft receiver and / or shaft passage around which at least one fiber is in the form of a loop.

The at least one fiber may at least partially wrap around the circumference of the rotor main body.

Preferably, the at least one fiber extends around at least two locations of the rotor main body, wherein a location comprises a receptacle, a central shaft receptacle, a flange hole or a specific area of the rotor main body.

The advantage of a fiber guided in the form of one or more sling (s) is a higher stability of the rotor. If the loop passes around a location, improved tensile strength to another location in the rotor main body can be produced there. A Schiingenführung from inner points of the rotor main body to outer locations counteracts, for example, the centrifugal force on outer locations of the rotor main body.

Preferably, the at least one fiber comprises an endless fiber and / or piecewise thickening fibers. The continuous fiber has the advantage that it is easy to work as a wound starting material. additionally Thickening fibers allow the manufacture of a rotor main body with a constant and uniform thickness.

If a disk-shaped rotor main body is formed by at least one fiber, then a natural

Material thickening to the center of the rotor main body a

Hub, form a mounting flange or shaft connection. Advantageously, at least one

Flange hole serve as a balancing means for the rotor main body, especially if it is disc-shaped.

Preferably, a method of manufacturing a rotor for an electric machine includes making a rotor main body as a rotor only of fiber composite material, and disposing a mounting flange made only of fiber composite material on the rotor main body.

Further, there is provided a rotor-shaft assembly for an electric machine comprising a shaft and a rotor disposed on the shaft with a rotor main body having a fiber composite, wherein the shaft and the rotor main body are coupled by means of at least one longitudinal pin connection. Preferably, it can be provided that the rotor-shaft assembly has a flange which is connected to the rotor main body, wherein the rotor main body and the flange are coupled by means of at least one of the longitudinal pin connections with the shaft.

Preferably, the longitudinal pin connection comprises at least one longitudinal pin made of a predetermined material, which is exchangeable with another longitudinal pin. Preferably, the predetermined material may be an elastic material. Furthermore, it can be provided be that the longitudinal pin connection shears the at least one longitudinal pin at high torque. Furthermore, the longitudinal pin connection allow startup and / or brake slip and / or mechanical damping.

Further, a hybrid system is provided with an engine unit or other rotary drive unit, a gear unit, and an electric motor unit having a shaft, wherein the gear unit sums the torque of the engine unit or other rotary drive unit with the torque of the electric motor unit and the motor unit comprises at least one fiber composite rotor is coupled by a longitudinal pin connection to the shaft of the electric motor unit.

Furthermore, the longitudinal pin connection for coupling the rotor main body to the shaft may comprise at least one longitudinal pin of a predetermined material, which is exchangeable against a longitudinal pin of another predetermined material. In this case, the predetermined material may be an elastic material. Furthermore, it can be provided that the longitudinal pin connection shears off at high torque. In addition, one is

Design of the hybrid system provided that allows startup and / or brake slip and / or mechanical damping.

Furthermore, an electric machine with a

Stator and the rotor-shaft assembly described above. Furthermore, a method for producing a rotor-shaft arrangement is provided, which comprises the following steps:

Providing a fiber composite material having rotor main body

Provide a wave

Arranging the rotor main body and the shaft so that the shaft and the rotor main body are coupled by means of at least one longitudinal pin connection.

Furthermore, a rotor-shaft arrangement described above, a hybrid system described above and / or an electric machine described above as and / or for a drive for an air, water or land vehicle or as a generator in a power generating device is provided the power generating device comprises wind and hydro power plants.

Furthermore, a storage arrangement is provided with a rotatably arranged on a rotational axis arranged rotor made of fiber composite material and at least one rotor bearing, which is in operative connection with the rotor in a radially spaced from the axis of rotation region. In this case, at least one of the bearings and in particular two bearings can be in operative connection with a radially outer region of the rotor. It can also be provided that at least two of the bearings on different sides of the rotor with this in

Active compound stand. In one embodiment, at least one of the bearings is operatively connected to the shaft. Furthermore, it can be provided that at least one of the bearings on or within a Stators of the electric motor is provided. At least one of the bearings, which is operatively connected to a radially outer region of the rotor, may be a sliding bearing.

For one of the storage devices described above, a magnetic bearing may be provided. In turn, magnets, in particular permanent magnets, may be provided on or within the rotor for the magnetic bearing. The magnetic bearing can be actively controlled. Preferably, it can be provided that a circular arrangement of a group of permanent magnets on or within the rotor and a corresponding circular arrangement of a group of external stationary permanent magnets or field coils in the vicinity of the rotor at repulsive field force exerts a radial centering effect on the rotor and relieved a radial bearing. Furthermore, it may be preferred that the shaft is supported by at least two bearings.

Furthermore, an electric machine with a stator, a rotor, a shaft and a bearing arrangement.

In addition, there is provided a method of manufacturing a bearing assembly for an electric motor, wherein a fiber composite rotor, shaft, and rotor bearing is provided, and wherein the rotor, shaft, and rotor bearing are arranged such that the rotor is rotatably disposed about an axis of rotation and wherein the at least one rotor bearing is in operative connection with the rotor in a region spaced radially from the axis of rotation. Furthermore, a method for producing an electrical machine described above is provided, wherein the method described above is used for the preparation of the storage arrangement.

Finally, a use of the storage device described above is provided in an electric machine as a drive for an air, water or land vehicle or as a generator in a power generating device, in particular in wind and hydroelectric power plants.

There is further provided a method of manufacturing a fiber composite rotor having a rotor main body for an electric motor, comprising the steps of: combining fibers of a fiber material with a matrix into a fiber amount, introducing the fiber amount with diffused fibers into one of the shapes of the fibers Rotor main body corresponding negative mold, compressing the introduced in the negative mold amount of fiber and curing of the compressed Fasergemenges, which preferably takes place at a predetermined temperature and predetermined pressure.

Preferably, the fibers of the fiber material are formed by cutting, cutting or the like of an endless fiber into fiber parts of a certain length. Preferably, these fiber parts are combined with a matrix. The matrix is preferably a binder or bonding agent that forms certain advantageous physical and mechanical properties in connection with the fibers.

A matrix can, for example, be selected from the group of thermosetting plastics (for example unsaturated polyester resins, vinyl ester resins). resins, epoxy resins) or from the group of thermoplastics (eg polypropylene, polyamide, polyethylene terephthalate, polyphenylene sulfide, polyether ether ketone).

The curing of the fiber mixture is preferably a process that causes a phase transition of the matrix from liquid to solid. In the case of thermosets, for example, this phase transition is irreversible and reversible for thermoplastics. Curing in this context does not necessarily mean that after the

Curing resulting fiber composite component is hard or stiffened; it may have different mechanical and physical properties depending on the matrix and fiber type, e.g. high toughness, low weight, electrical conductivity, high flexibility etc.

The fiber composite material and / or the fiber may comprise carbon. Carbon is a particularly light and durable material that can form many forms as fiber material and through interaction with a

Binder such a form permanently. A rotor main body made of carbon fiber composite material is lightweight and yet can withstand acting forces and moments. The amount of fiber can be heated by means of a microwave source. When the fiber composite material comprises carbon, the electrical conductivity of carbon may be used to be heated by a microwave source. This has the advantage over conventional autoclave processes of reduced energy requirements to cure the fiber mixture.

The amount of fiber may preferably be below a predetermined pressure during heating by a microwave in a negative mold, or the amount of fiber may be below predetermined in the negative mold prior to heating

Pressed. Alternatively, a predetermined pressure, rather than a negative mold, may be caused by the gas pressure surrounding the fiber.

This has the advantage that the amount of fiber is a high

Material density and low volume achieved.

Since most types of carbon have a negative coefficient of thermal expansion, it is preferable for the curing step of the amount of fiber introduced in a negative mold that the material of the negative mold also has fiber composite material and in particular carbon.

Furthermore, a negative mold for producing a rotor main body is provided, wherein at least one fiber is in or on the negative mold and a binder or connecting means interconnects portions of the at least one fiber.

An electric machine can be a stator and a

Rotor comprising the rotor main body according to one of the above solutions. Preferably, such an electric machine is a disc rotor Electric motor / generator with permanently energized rotor and serves as a drive for an air, water or

Land vehicle or as a generator in one

A power generating device, wherein the power generating device according to an embodiment comprises wind and hydro power plants.

FIG. 1 shows an electric machine including a stator 102 and a rotor main body 104. The rotor main body 104 may be disk-shaped, cylindrical, frusto-conical or double-frusto-conical. In addition, a mounting flange may be arranged on the rotor main body 104, wherein an arrangement of the rotor main body 104 with a mounting flange as a rotor is referred to.

Further, Fig. 1 shows two magnets 106 visible in the sectional view of the rotor main body 102, e.g. Permanent magnets, of which a plurality of annularly arranged in or on the rotor main body 104, and provided in the stator 102 stator windings (not shown). Furthermore, FIG. 1 shows a shaft 108 connected to the rotor main body 104 by the mounting flange, for example, such that rotational movement of the shaft 108 results in rotational movement of the rotor main body 104 and vice versa. The shaft 108 may be e.g. be a rod-shaped member made of solid material or a hollow cylindrical member, wherein the cross section of such a component may be completely or partially circular, rectangular, elliptical or toothed and as

Joint, hollow, gimbal or flexible shaft is executed.

Furthermore, FIG. 1 illustrates two bearings 110 which radially support the shaft 108, so that the shaft 108 and the with their associated rotor main body 104 are held radially in position even when rotating about its axis of rotation.

When the electric machine 100 is operated as a motor, the magnets 106 mounted on the rotor main body 104 magnetically interact with the stator windings on the stator 102 to cause the rotor main body 100 and the shaft 108 connected thereto to rotate about the rotor axis. On the other hand, in an operation of the electric machine as a generator, the operation of the electric machine is reversed. Rotation of the shaft 108 and the rotor main body 104 connected thereto results in electromagnetic interaction between the magnets 106 and the stator windings arranged on the rotor main body, thereby finally generating electric current is produced.

By means of the arrangement in FIG. 1, the rotor main body 104 can rotate at a diameter of preferably greater than two meters, four meters, six meters and more stable and with a small stator gap 112 at high rotational speeds in the stator, so that a good magnetic interaction between the magnets 106 and the stator is exploited.

In addition, a reversal of the mechanically moved components in Fig. 1 is possible. That is, a rotor 104 as an external component surrounds a stator as an internal component.

Fig. 2 shows a rotor main body 200 which is provided disc-shaped and with a predetermined thickness. The material of the rotor main body 200 comprises fiber composite material, preferably carbon fiber composite material. The rotor main body 200 further includes 172 (by way of example only) rectangular receptacles 202 that are centered about the axis of rotation of the rotor main body 200 and near its outer edge. Centrally located flange holes 204 and the shaft passage 206 centrally located in the rotor main body 200 provide connection to a shaft (not shown). The centrally arranged flange holes 204 are arranged between the centrally located shaft passage 206 and the close to the outer edge of the rotor main body 200 receptacles 202. The number and arrangement of the flange holes 204 may depend in particular on forces and moments to be transmitted.

The rectangular receptacles 202 serve to receive magnets, in particular permanent magnets. In each case at least one magnet can be arranged in all, a plurality, in particular two, three, four, five, eight, eleven or 16, or in exactly one shot. In this case, an arbitrary number of receptacles 202 are provided for the rotor main body 200, for example exactly one receptacle, two, three, four, five, eight, 13, 16, 65 or 172 recordings.

3a shows an enlarged view of a partial region of a rotor main body 200. The receptacles 302 on the outer edge of the rotor main body each receive a magnet 304. During operation of the electric machine, the magnets 312 magnetically interact with those on the stator

Stator windings (not shown) and thereby generate electricity (as far as the electric machine acts as a generator), or thereby trigger a rotational movement of the rotor (if the electric machine works as a motor). In Fig. 3a (and also in 3b), the north pole of the magnets 312 is denoted by N.

In the example shown in FIG. 3b, instead of one, in each case two smaller magnets 312, 314 are arranged alongside one another in the receptacles 302. The smaller magnets 312, 314 are separately magnetized magnets. Compared with Fig. 3a, the two smaller magnets 312, 314 have the total volume of one of the magnets 304 shown there. It is exploited the property that in the production of magnets smaller ferromagnetic body can be magnetized better than larger in the rule. Thus, two smaller magnets usually have a higher magnetization than a comparable magnet whose volume corresponds to the sum of the volumes of the two smaller magnets when magnetized in the same magnetic field in the same way as the two smaller magnets.

With the example shown in FIG. 3b, it can be achieved that the magnets in a receptacle have a greater magnetization for the same total volume and the same total weight than a comparably produced magnet twice as large in a receptacle as is used, for example. can be seen in Fig. 3a. Thus, a rotor with more powerful magnets with the same volume and weight can be provided. Because the rotor main body comprises fiber composite material, the weight of the rotor is further reduced as compared to an equally powerful conventionally manufactured rotor.

If there is talk that at least two magnets are arranged in at least one receptacle, so are under "at least two magnets" or similar formulations to understand such arrangements in which at least two ferromagnetic bodies were magnetized as a separate body, but then after their magnetization or after a first magnetization process, which can follow further magnetization processes, are joined together to form a body, in particular by gluing together or other methods of joining objects. The advantages presented here of using magnets which have been magnetized as smaller bodies also come into play in such embodiments.

In the example shown in FIG. 3b, the north poles of two magnets 312, 314 always point either to the center or to the edge of the motor. Other examples include arrangements in which the north poles of the two magnets in a receptacle point in different directions. Other examples further include arrangements in which the magnets of a receptacle are arranged not adjacent to their longitudinal edges but adjacent to their short edge surfaces. In further examples, three, four or more smaller individual magnets are arranged in at least one receptacle. While in the example shown in Fig. 3b, the north pole of the magnets always points in different directions in adjacent photographs, examples are also included in which the north poles of the magnets always point in the same direction. Furthermore, examples may be provided in which the poles of the individual magnets are arranged arbitrarily directed.

Fig. 4a shows a rotor main body 402 and a shaft

404 in a side view. The rotor main body 402 has rectangular recesses as shown in FIG 406, of which one can be seen in the sectional view above the symmetry line. On the front and back sides of the rotor main body 402, there are disposed two cover sheets 412, 414 made of carbon fiber composite plate-like semi-finished product. The cover layers 412, 414 cover the rectangular receptacles 406 and optionally arranged therein magnets, of which in the sectional view, a magnet 420 is visible.

The receptacles 406 of the rotor main body 402 are holes therethrough. In each case two of the magnets described above (not shown) are arranged in the receptacles 406. The two cover layers 412 and 414 are attached to the rotor main body and prevent falling out of the magnets. In one example, the cover layers 412, 414 comprise fiber composite material. This ensures that the magnets holding cover layers 412, 414 have low weight.

Further examples provide that the receptacles 406 merely represent recesses that are not holes passing through the rotor main body. In such a case, it can be provided that only one cover layer 412 for fastening the magnets 420 to the rotor main body 402 is arranged.

Fig. 4b shows a mounting flange 400. Further, Fig. 4b shows a side view of the rotor main body 104 shown in Fig. 1 and a shaft 404. The rotor main body 402, which is shown above the shaft 404 in sectional view, has a rectangular socket 406, as in Figs Fig. 1, on. At the front and back sides 408 and 410, respectively, of the rotor main body 402 are two cover layers 412 and 414 arranged, which are made of plate-like semi-finished carbon fiber composite material and both sides of the outer edge 416 of the rotor main body 402 to an inner mounting flange 418 range. The cover layers 412 and 414 cover the rectangular receptacles 406 and magnets arranged therein, eg permanent magnets, of which a permanent magnet 420 is visible in the sectional view.

Towards the center of the rotor main body 402, two inner and outer mounting flange disks 418 and 422 are arranged on the front side 408 and rear side 410 thereof. The inner mounting flange disks 418 are attached directly to the rotor main body 402 by an adhesive (not shown), and have a smaller diameter than the rotor main body 402 and a larger diameter than the outer mounting flange disks 422. The outer mounting flange disks 422 are in turn connected by an adhesive (not shown) to an adjacent inner mounting flange disk 418, respectively. The mounting flange discs 418 and 422 are made of plate-like carbon fiber composite semi-finished components. The entire mounting flange establishes a positive and non-positive connection to the shaft 404.

In connection with Figure 4b explained terms with the component - "disc" are not restrictive to understand cylindrical components. Rather, the rotor main body 402 and / or the mounting flange disks 418 and 422 may have a rectangular, elliptical, annular cross section or the like. The mounting flange 418 and 422 may be integrally formed with each other and to the Rotor main body 402 are arranged or the mounting flange 418 and 422 are integrally formed with the rotor main body 402.

The mounting flange disks 418 and 422 provide the rotor main body with an area and volume greater interface with the shaft 404, thereby enhancing the transmission of forces and moments between the rotor main body 402 and the shaft 404.

Fig. 5 shows a rotor 500. From the outside in turn in Fig. 5 can be seen: a rotor main body 502, integrally formed with the rotor main body 502 frusto-conical mounting flange 504, provided in the mounting flange 504 shaft passage 506 with recessed groove 508 and a provided with a driving lug 510 shaft 512 in cross-sectional view. The shaft 512 is disposed by suitable fit in the shaft passage 506 of the mounting flange 504. The interchangeable cam lug 510 engages the groove 508 and allows torques and forces to be transmitted between the shaft 512 and the rotor main body 502, such that the shaft 512, the rotor main body 502, and the mounting flange 504 are averaged at the same angular velocity in the two directions of rotation indicated by the double arrow 514 can rotate.

6 shows a section of a rotor main body 600. Exemplary carbon fiber shims 602, 604, 606, 608, 610 are illustrated in the sector-shaped section of the rotor main body 600 shown in FIG. A corrugated carbon fiber loop 602 passes around a shaft passage 612 and a receptacle 614. A mounting flange hole carbon fiber loop 610 passes around a mounting flange hole 616 and a plurality of receptacles 614. A multi-receptacle carbon fiber loop 606, 608 guides a plurality of receptacles 614. The above-mentioned carbon fiber rings can be combined, in series, alternately, can be realized according to a predetermined sequence pattern and, for example, by a continuous carbon fiber 618. In addition, the following fiber loop guides are possible: fiber loops are wound in eight, helical, or drum shape around one or more receivers 614 and / or one or more mounting flange holes 616 and / or the shaft bushing 612 and / or the outer edge of the rotor main body 600 or fiber loops are inserted into geodesic lines between two or more locations comprising one or more receptacles 614 and / or one or more mounting flange 616 and / or the shaft passage 612 and / or the outer edge of the rotor main body 600.

The fiber loops 606, 608 and 610 shown in Fig. 6 are drawn only schematically as closed, they may also be designed as opened on one side loops or at a position with overlapping parts of an endless fiber 618. Such an endless carbon fiber 618 is supplemented at the outer peripheral portion of the rotor main body 600 with additional piece-wise carbon fibers to make a predetermined thickness of the rotor main body 600. Toward the center of the _# rotor main body 600, the endless carbon fiber 618 thickens the rotor main body 600 along its vertical axis to a natural hub. FIG. 7 shows a rotor 700 of an electric machine and a hub 704 made of continuous carbon fiber. The shaft passage formed by the hub 704 positively receives a shaft 702. At the junction of shaft 702 and hub 704, four holes are coupled with longitudinally disposed pins 706 disposed thereon. The longitudinal pins may be, in particular, cylinder-pin-like, conical-pin-type or kerbstift-type longitudinal pins. Shaft and hub thus form a coupled connection. The number and arrangement of the longitudinal pins 706 at the junction of shaft 702 and hub 704 may depend in particular on the forces and moments to be transmitted. In the example shown in Fig. 7, four longitudinal pins were used. However, any number of longitudinal pins can realize the pin connection, in particular a longitudinal pin, two, three, four, five, eleven or 18 longitudinal pins. The material of the longitudinal pins 706 is elastic and shears off at high torque. Thus, the longitudinal pins 706 provide on the one hand start-up, brake slip and rotational damping and on the other hand at the same time a safety function to protect the rotor 700 and the shaft 702 from excessive torque. In addition, it is possible to replace a worn longitudinal pin 706 with a new one.

8 shows an electric machine 800. In FIG. 8, a stator 801 surrounds a rotor main body 802. The rotor main body 802 is formed integrally with a mounting flange 804 which is connected to a shaft 808 through a lug 806. The driving lug 806 engages in a recessed into the mounting flange 810 a. The shaft 408 becomes on both sides of the stator 801 by two fixed bearings 812 radially and / or axially supported.

The stator 801 in FIG. 8 includes electric stator coils (not shown) whose magnetic field interacts with a magnetic field of permanent magnets 814 arranged in an outer area of the rotor main body. The

Permanent magnets 814 are in hollow receptacles 817 of the

Rotor main body 802 arranged and disposed on both sides of the rotor main body 802 cover layers

816 and 818 completed to the outside.

The mounting flange 804 provides a large engagement surface for the driver lug 806 engaging the groove 810 thereby enabling the transmission of forces and torques between the shaft 808 and the mounting flange 804 disposed on the rotor main body 802.

The mounting flange 804, for example, allows higher forces and moments to be transmitted than is possible with an electrical machine 100 designed in comparable dimensions as shown in FIG.

The bearings 812 shown in Fig. 8 provide support for the shaft 808 and the rotor main body 802 connected thereto via the mounting flange 804. However, if only the bearings 812 are provided as the bearings, rapid rotation of the rotor main body 802 occurs without bearing in axial directions Vibration. It would be desirable to realize a bearing that ensures that the rotor main body 802 in such a rotational movement and / or vibrations, vibrations or the like Moves its axial intended position, especially at its edges, does not leave.

Fig. 9a shows a schematic storage device. In the exemplary embodiment shown, a rotor 904 is connected to a shaft 902 via a suitable rotor-shaft arrangement. The rotor 904 made of carbon fiber composite material in this case includes receptacles 906, 908 for magnets (not shown). Furthermore, the rotor 904 is supported by two radial bearings 912, 914. During operation of the electric machine, vibrations and / or vibrations are generated on the rotor 904 and the shaft 902. The radial bearings 912, 914 ensure that the shaft 902 and the rotor 904 attached thereto are held in their intended position in the radial direction R.

In addition to the radial bearings 912, 914 of the shaft 902, further bearings 916, 918 are provided according to the invention in the example shown in FIG. 9a, which support the rotor on both sides and provide axial support of the rotor 904. The thrust bearings 916, 918 ensure that the rotor 904 and its associated shaft 902 are maintained at a predetermined axial position A during operation of the electric machine. Depending on the specific characteristics of the electrical machine used, it is possible to arrange the thrust bearings 916, 918 close to the shaft 902 or near the edge of the rotor 904.

9b shows a storage arrangement with bearings 922,

924, which support the shaft axially. Preferably, further bearings 926, 928 are provided. These bearings 926, 928 are at a radially outer portion of the rotor 904 with this in operative connection. Preferably, such bearings 926, 928 in and / or on a stator (not shown). Such an arrangement of the bearings 926, 928 is particularly suitable for preventing vibration of the rotor from its axial position.

In the example of FIG. 9c, only bearings 936, 938 are provided. The outboard portion of the rotor 904 with this operatively connected bearing 936 and 938 support the rotor 904 in the axial and / or radial direction.

Fig. 9d shows another example of a storage arrangement. A bearing 948 provided on the outer portion of the rotor supports the rotor 904 so as to axially support the rotor 904. Another bearing 944 in turn supports the shaft 902 and its associated rotor 904 so as to be radially supported.

The schematic representation shown in FIG. 10a shows an inner side surface 1022 of a stator of an electric machine 1000, a cross section 1024 through the stator in the schematic representation shown, a shaft 1002, a rotor 1004 connected to the shaft, receptacles 1006, 1008 for magnets (not shown) in the rotor 1004 and inventively provided bearings 1012, 1014, 1016, 1018. The shaft 1002 is thereby radially supported by the provided bearings 1012, 1014. In addition, bearings 1016, 1018 are provided in the example shown, which are arranged on the stator and support the rotor 1004 axially. Preferably, the radially supporting bearings 1012, 1014 may be rolling bearings and the axially supporting bearings 1016, 1018 may be plain bearings. Due to the arrangement in Fig. 10a, the rotor 1004 may have a diameter of preferably about two Meters, four meters, six meters and more, stable and operated with a small stator gap at high speeds, so that a good magnetic interaction between the magnets and the stator can be used.

In the example of FIG. 10b, the bearings 1012, 1014 realize a radial bearing of shaft 1002. For the axial bearing of the rotor 1004, a magnetic bearing is preferably provided. For this purpose, further magnets 1030 and 1032 are arranged both on or in the rotor 1004 and on or in the stator. In this case, the magnets 1030 mounted centrally on or in the rotor 1004 and the stationary magnets 1032 arranged correspondingly to these in the vicinity of the rotor 1004 act on one another in an attractive and / or repulsive manner. In the case of a repulsive force effect, a radial centering effect is additionally produced on the rotor 1004, so that the radially supporting bearings 1012, 1014 are relieved. Another example additionally or alternatively provides another equivalent bearing, e.g. Air storage.

Fig. 11 shows a negative mold 1100 for rotor production. The female mold 1100 is designed along a longitudinal section mirror symmetrical to the axis of symmetry 1102 and has a negative mold outer edge 1104, a carbon fiber recess 1106, the receptacles 202 (of Fig. 2) corresponding pins 1108, a carbon fiber recess 1106 and the mounting flange holes 204 (of Fig. 2) corresponding pins 1110 on. Disposed in the center of the female mold 1100 is a washer 1112 corresponding to the shaft passage 206 (of Fig. 2).

The negative mold outer edge 1104, the pin 1108, the

Pins 1110 and the washer 1112 are integrally formed with the female mold 1100. The material of 7

Negative mold 1100 is made of aluminum or

Carbon fiber composite material and can by a the

Negative mold closing lid (not shown) to be completed.

Carbon fibers 1114 (thickness of fibers 1114 in Fig. 3 only schematically) are used e.g. deposited, stretched or laminated by a fiber lay-off device (not shown) into the carbon fiber recess 306 according to a predetermined pattern.

Fig. 12 shows a negative mold 1200 for rotor production. The negative mold 1200 is shown in cross section in FIG. By way of illustration, carbon fibers 1202 are shown lying in the negative mold 1200, also shown in cross-section. The location and orientation of the carbon fibers 1202 in the negative mold 1200 is merely qualitative. The carbon fibers 1202 may have any position and orientation in the negative mold 1200. The negative mold 1200 is symmetrical to the axis 1204, so that only one half of the negative mold 200 is explained in more detail.

The negative mold 1200 in FIG. 2 comprises pegs 1206, each having the shape and volume shown in FIGS. 4a, 4b

Recordings 406 correspond. Furthermore, the negative mold comprises

1200 in the middle a pin 1208, the one

Shaft passage corresponds. The cones 1206 and the

Pin 1208 are integrally formed with the negative mold 1200. The remaining space between the pins

1206, the pin 1208 and the negative mold 1200 itself forms a stepped cylindrical trough, the shape and

Volume corresponds to a rotor. This rotor includes a rotor main body corresponding to a rotor main body portion 1210 in the negative mold 1200, and a rotor main body unilaterally and integrally with the rotor main body designed mounting flange, which corresponds to a mounting flange 1212 in the female mold 200.

The material of the negative mold 1200 may be e.g. Aluminum or fiber composite material.

Fig. 13 shows a flow chart for a rotor manufacturing process. The flowchart provides four alternative procedures for making a rotor main body 1300 consisting of only carbon fiber composite material. Process 1302 includes the sequential steps of placing carbon fiber into a negative mold 1304, introducing epoxy resin into the negative mold carbon fiber 1306, and curing 1308 the carbon fiber and epoxy resin mixture at a predetermined pressure P _H and a predetermined temperature T _H The process flow 1310 includes the step of milling and drilling a plate-like carbon fiber composite semi-finished product 1312 so that the rotor main body is formed. Process 1314 includes the sequential steps of laminating fiber prepreg 1316 into a negative mold and curing 1318 the fiber prepreg at a predetermined pressure P _H and a predetermined temperature T _H. Process 1320 includes the sequential steps of mixing carbon fibers with polypropylene 1322 to formulate 1324 the mixture of carbon fiber with polypropylene in a negative mold and to cure 1324 and cure the mixture at a predetermined pressure P _H and a predetermined temperature T _H 1326. Two, several or all of the processes can also be partially combined.

FIG. 15 shows an electric machine 1500 in which three of the stators 1502, 1504 and 1506 shown in FIG. 8, each having rotatably mounted therein rotors 1508, 1510 and 1512, are arranged in series on a shaft 1514. Such a stator-rotor subunit of a stator and a rotor in this case corresponds to the electrical machine 800 shown in FIG. 8.

The shaft 1514 of the electric machine 1500 shown in FIG. 15 is supported radially and / or axially by two fixed rolling bearings 1516 similarly as shown in FIG. Since the diameter of the stator-rotor subunit shown in FIG. 15 is larger than the thickness of the stator-rotor subunit, the electric machine 1500 with two, three or more stator-rotor subunits arranged in series can achieve a more compact design, i. a ratio of machine diameter to machine thickness of about 1: 1 and thereby increasing the power and the torque.

For arranging the electric machine in a system, there is provided a housing 1518 enclosing the stator-rotor subunits shown in FIG. 15, which protects the electric machine 1500 from inward and outward influences (eg, dust, heat, moisture, electromagnetic radiation, etc.). protects.

Another aspect is illustrated in FIG. 16, which shows a hybrid system. The device Ml represents a motor-generator device according to one of the aforementioned embodiments. In contrast, motor M2 is a conventional internal combustion engine or comparable. The torques of the two motor-acting devices Ml and M2 are summed in a planetary gear 1602 and output from the hybrid system.

FIGS. 17a and 17b show an electrical circuit arrangement of a motor-generator device. 17a shows a circuit arrangement in a state in which the motor-generator device as a generator G1 converts mechanical energy into electrical energy and stores it in a battery 1702. In addition, in the circuit arrangement, a rectifier or commutator may be connected between battery 1702 and generator Gl if the generator supplies Gl power.

Fig. 17b shows a circuit arrangement in a state in which the motor-generator device as motor Ml acts to convert electrical energy from a battery 1702 into mechanical energy.

Applying the circuitry of FIGS. 17a and 17b to the hybrid system of FIG. 16, a vehicle drive may be implemented which, upon braking the vehicle, feeds kinetic energy back into a battery 1702 and selectably converts electrical energy of the battery 1702 into kinetic energy. A rotor-shaft arrangement of the motor-generator device can be designed so that drive and brake slip by elastic longitudinal pins allow soft starting and braking in the hybrid system and provided by the elastic longitudinal pins damping behavior of a backward non-constant rotation of the internal combustion engine via the planetary gear 1502 prevented on the motor-generator device. In one of the devices described above, in particular in one of the electrical machines described above, this may in particular as a drive device or other use in an aircraft (in particular a passenger aircraft, a powered aircraft, a glider with or without auxiliary engine or an electric machine for an airship ), Watercraft (in particular a ship or boat, for example a motorboat or a sailboat with or without an auxiliary engine) or land vehicle (especially a car, a motorcycle, a truck, a locomotive, a forklift) are used, the low weight and the high Stability of the rotor main body made of fiber composite allows high start-up and braking acceleration of the drive device. In addition, an application of such an electric machine for driving pumps; as a servomotor; lawnmowers, cranes, tanks; as a (servo) engine in aircraft, ship and car models; in vending machines (eg ATMs) toys, household appliances and electrical appliances (eg CD, DVD players, hard drives) possible.

Incidentally, the electric machine can take a combination of generator function and motor function, and e.g. in an electric vehicle or vehicle with

Hybrid drive optionally when braking the vehicle

Feeding energy into or out of an electric battery

Accelerating the vehicle to convert electrical energy from the battery as an engine back into kinetic energy.

Claims

claims

A method of manufacturing a fiber composite material rotor having a rotor main body (104; 200; 402; 502; 600; 802; 1300) for an electrical machine, comprising the steps of:

Merging fibers of a fiber material with a matrix into a fiber amount (1322),

- Introducing the amount of fiber with diffusely arranged fibers in one of the shape of the rotor main body corresponding negative mold (1304, 1316, 1324), and

- curing the fiber amount (1308, 1318, 1326) to a rotor main body (104; 200; 402; 502; 600; 802; 1300), the amount of fiber being heated by a microwave source.

2. The method of claim 1, wherein the fiber composite material comprises carbon.

3. The method according to any one of the preceding claims, wherein the curing takes place at a predetermined temperature and a predetermined pressure.

An electric machine comprising: a stator (102; 801; 1502, 1504, 1506) and a rotor (500; 700; 904; 1004; 1508, 1510, 1512) which has a rotor main body (104; 104) made according to any one of the preceding claims. 200, 40.2, 502, 600, 802, 1300).

A negative mold for producing a rotor (104; 500; 700; 904; 1004; 1508, 1510, 1512) comprising a rotor main body (104; 200; 402; 502; 600; 802; 1300) according to one of the preceding claims wherein at least one fiber (918; 1114; 1202) is in or on the female mold (1100; 1200) and a binder bonds at least two portions of the at least one fiber (918; 1114; 1202) together.

A negative mold according to claim 5, wherein the material of the negative mold (1100; 1200) comprises fiber composite material.

7. Use of the rotor according to one of claims 1 to 3 in an electric machine (100; 800; 1000; 1500) as a drive for an air, water or land vehicle or as a generator in a power generating device.

8. Use of the rotor according to claim 7, wherein the power generating device comprises wind or hydropower plants or is designed to convert generated by a vehicle rotational forces and / or moments into electrical energy.

9. Use of the rotor according to one of Claims 1 to 3 in an electric machine (100; 800; 1000; 1500) designed as a hub motor and / or generator for a vehicle.