The invention relates to an electric machine, particularly a transversal flux machine, comprising a rotor designed as outer rotor or inner rotor, comprising at least one reflux ring having a longitudinal axis, permanent magnets having alternating magnetic polarity being disposed in an angular offset manner on said reflux ring.
Electric machines of the stated type are known from prior art. Particularly transversal flux machines are characterized by a high degree of efficiency on account of a high yield of copper and a high torque density. A rotor of the electric machine can be designed in the form of an inner rotor or outer rotor. A stator of the transversal flux machine in the form of at least one annular coil or at least one annular magnet is provided in the peripheral direction around the rotor or within the rotor. The poles of said rotor are typically formed from a large number of small permanent magnets or by a large annular magnet, which is surrounded by a large number of claws which conduct the magnetic flux thereof. In the case of the transversal flux machine, said magnetic flux of the rotor runs transversally with respect to the annular coil. Said transversal flux machine constitutes an electric machine, which can be operated by a motor or by a generator.
The manufacture particularly of transversal flux machines is very complex on account of the rotor because a large number of individual components have to be assembled due to the large number of magnetic poles required. In the case of this assembly, the permanent magnets are already polarized because a multi-polar magnetization of the rotor, i.e. an alternating magnetization in sections is only possible when the magnet height is small. A multiphase system in the transversal flux machine is possible in the axial direction of the rotor by a plurality of individual systems (phases) being stacked one on top of the other. In so doing, the individual systems have to be offset to one another in the peripheral direction in order to prevent a mutual interference. The exact alignment of the individual systems is very complex.
Because many permanent magnets, which differ in their magnetic polarity, are placed next to each other in a small space due to the large number of poles on the rotor, an assembly of already magnetized permanent magnets is likewise very complex.
It is the aim of the invention to provide an electric machine comprising a rotor which can be easily produced and at the same time facilitate an arrangement of the strongly magnetized permanent magnets for providing a high torque density.
According to the invention, the reflux ring comprises at least two axially adjacently joined reflux partial rings and the permanent magnets are located in the gaps between the permanent magnets of the other reflux partial ring when joining the two reflux partial rings. This advantageously ensures that initially assemblies consisting of at least one of the reflux partial rings and at least one permanent magnet are joined together during the production of the rotor, which allows for a simple production. The assemblies are subsequently joined to form the rotor. Thus, each assembly separately comprises a certain number of permanent magnets, which are disposed at a distance from one another on said reflux partial rings. Only the joined rotor has the alternating magnetic polarity; thus enabling the entire manufacturing process to be considerably simplified. The rotor especially constitutes a rotor, which rotates in or around a stator, wherein a working air gap is designed between the stator and said rotor. Provision is preferably made for the permanent magnets of the rotor to be disposed such that they border on the working air gap within the electrical machine during the operation thereof. In the present application, particularly a rotating electric machine, i.e. an electric machine comprising a rotor, is understood by the term electric machine.
Provision is made according to one modification to the invention for the permanent magnets to be cylindrical magnets, in particular rectangular cylinder magnets. The use of cylindrical magnets allows the reflux partial rings comprising said permanent magnets to be easily joined without the assemblies having to be deformed or bent. Furthermore, cylindrical magnets can be easily manufactured and are easy to handle. Cylindrical magnets additionally make a dense arrangement of permanent magnets on the reflux partial rings possible. By the term rectangular cylinder magnets, magnets are understood which are substantially of block-shaped design. It is conceivable to manufacture the permanent magnets from ferromagnetic ceramic materials and/or rare earth.
Provision is made according to one modification to the invention for the reflux partial rings to have an anti-rotation locking means and/or a centering device for positioning said reflux partial rings relative to one another. The anti-rotation locking means is preferably configured in such a manner that said reflux partial rings in the peripheral direction can no longer rotate relative to one another in the peripheral direction. This prevents the permanent magnets of the one reflux partial ring from being pressed against the permanent magnets of the other reflux partial ring when the rotor is in use. Such an action could result in damage to the rotor. The centering device is advantageous when producing said rotor because it enables a simple, fast and reliable joining of the two reflux partial rings in the correct position thereof
Provision is made according to one modification to the invention for the anti-rotation locking means and/or the centering device to comprise at least one radial fixing tongue and/or at least one radial fixing groove on the reflux partial rings. The fixing tongue and/or the fixing groove is/are preferably disposed in the interior region of said reflux partial rings. They serve as a centering device by their use as markings In this case, the assemblies have to be rotated around the longitudinal axis until said fixing tongues and/or said fixing grooves of said two reflux partial rings are brought to overlap in relation to one another. A correct joining of said two reflux partial rings is then possible. In addition, fixing tongues and/or fixing grooves can be used as an anti-rotation locking means by the interaction thereof with guide rails which comprise a corresponding counter fixing groove and/or counter fixing tongue. These guide rails can either be used for assembly purposes or be embodied as an output shaft of the electric machine.
Provision is made according to one modification to the invention for the anti-rotation locking means and/or the centering device to be formed by at least one centering pin extending axially on one of the reflux partial rings and at least one centering opening associated with the centering pin on the other reflux partial ring. The advantage of said anti-rotation locking means being embodied in this manner is that very high forces can be transferred between the reflux partial rings without said reflux partial rings being able to rotate relative to one another in the peripheral direction. A cross section—transverse to the longitudinal extension of the centering pin—can be embodied round or also polygonal. The polygonal embodiment makes it possible for a single centering pin to prevent the rotation between said reflux partial rings. When using a round cross section, preferably two or more centering pins, having respectively a corresponding centering opening, are to be used. When used as a centering device, the centering pin provides the option of said reflux partial rings not having to be perfectly aligned relative to one another. This results from the reflux partial rings automatically correctly aligning relative to one another by means of the insertion of said centering pin in said centering opening.
Provision is made according to one modification to the invention for at least one of the reflux ring back parts to be composed of a plurality of ring cutout pieces. This provides the advantage of being able to produce the entire reflux partial ring in individual small components so as to subsequently assemble these components into a reflux partial ring. This process takes place before the reflux partial rings are joined together.
In addition, it is conceivable for the electric machine according to the invention to be a single-phase or multi-phase embodiment. In the case of a multi-phase embodiment, a plurality of rotors of the aforementioned kind is used.
The invention relates additionally to a method for producing an electric machine, particularly a transversal flux machine, preferably according to the preceding description, comprising a rotor designed as outer rotor or inner rotor, comprising at least one reflux ring having a longitudinal axis, permanent magnets having alternating magnetic polarity being disposed in an angular offset manner on said reflux ring. In so doing, provision is made for the following steps: disposal of magnetizable magnetic flux pieces on at least two reflux partial rings, magnetization of the magnetic flux pieces of the reflux partial rings to permanent magnets having in each case the same magnetic polarities, alignment of said reflux partial rings comprising the permanent magnets relative to one another and joining of said reflux partial rings comprising the permanent magnets to form the rotor in such a way that the alternating magnetic polarity is formed. By means of the stated procedural steps, at least two assemblies are initially created, which in each case consist of at least one of said reflux partial rings and one of said permanent magnets. Each assembly is separately magnetized at least in some regions. This magnetization takes place with assemblies having the same magnetic polarity, whereby a like direction of magnetization for all of the permanent magnets results. This like direction of magnetization leads to a dramatic simplification of the manufacturing process. Afterwards the assemblies, that is to say said reflux partial rings comprising said permanent magnets, can initially be aligned relative to one another in order to then easily be joined; thus enabling the rotor having alternating magnetic polarity to subsequently form. The joining particularly takes place by a pushing of the assemblies together. When disposing the magnetizable magnetic flux pieces on said reflux partial rings, provision is particularly made for said magnetizable magnetic flux pieces to be attached to said reflux partial rings. According to the invention, the joining of said reflux partial rings occurs in such a manner that said reflux partial rings are axially aligned with the permanent magnets having the opposite direction of polarization. This facilitates a largely similar embodiment of said assemblies and in so doing a similar magnetization of the same. In the present application, the term magnetic flux piece describes a component which consists of a magnetizable, magnetically hard material.
Provision is made according to one modification to the invention for the magnetic flux pieces to be axially disposed on the reflux partial rings in the longitudinal extension of said magnetic flux pieces. It is particularly advantageous if the longitudinal extension of said magnetic flux pieces preferably corresponds to the axial extension of the reflux ring.
Provision is made according to one modification to the invention for the magnetic flux pieces to be disposed on the outer periphery and/or on the inner periphery of the reflux partial rings. The disposal on said outer and/or inner periphery enables a particularly proximal disposal of the magnetic flux pieces—which later become permanent magnets—with respect to the working air gap between the rotor and the stator. By designing the magnetic flux pieces in such a manner that said magnetic flux pieces axially project above the outer and/or inner edge of the reflux ring parts, said magnetic flux pieces work themselves as holding elements for the respective other reflux ring part. As a result of this embodiment, a crown-like structure results for each assembly as a whole. By joining the assemblies, the crown-like structures engage in one another, whereby on the one hand the magnetic polarity is formed and on the other hand a torsional force can be formed between the magnetic flux pieces.
Provision is made according to one modification to the invention for the magnetic flux pieces to be disposed, particularly simultaneously, using a holding template. It is particularly advantageous that the non-magnetized magnetic flux pieces can be easily disposed in a holding template and using the holding template can be disposed on the reflux partial rings. Provision is thereby preferably made for the holding template to hold the magnetic flux pieces when attaching said magnetic flux pieces to the reflux partial rings. After said magnetic flux pieces have been disposed on the reflux partial rings, said holding template is removed and consequently used to assist assembly. In this way, the amount of work in manufacturing the rotor is reduced because the magnetic flux pieces can be disposed in groups and do not have to be individually disposed, as is the case for prior art, on the reflux ring. The holding template is preferably configured in the form of a rake or a crown.
Provision is made according to one modification to the invention for the magnetic flux pieces in each case of one of the reflux partial rings to be simultaneously magnetized. In this advantageous modification, all of the magnetic flux pieces of an individual reflux partial ring are mutually magnetized in the same direction. This can take place using a single magnetizing device in a single procedural step. This advantage results from the fact that the alternating magnetic polarity is formed only after the joining of the assemblies and consequently no multi-pole magnetization is necessary.
Provision is made according to one modification to the invention for the reflux partial rings comprising the magnetized magnetic flux pieces to be aligned relative to one another before joining using an assembly device. Due to the large number of said magnetic flux pieces and the magnetic forces thereof, it is necessary for the assemblies to be exactly aligned with respect to one another for joining in order that the magnetized magnetic flux pieces—that is to say the permanent magnets of one of the reflux partial rings—can be inserted into the gaps between the permanent magnets of the other reflux partial ring. For this purpose, an assembly device can advantageously be provided, which initially receives both assemblies in correct alignment when separated from one another and which facilitates the joining of the two assemblies.
Provision is made according to one modification to the invention for at least one centering device to be used as the assembly device.
Provision is made according to one modification to the invention for a guide ring comprising guide grooves for the magnetic flux pieces, which run in the peripheral direction, to be used as the assembly device. The guide ring is configured in a fashion that allows an assembly to be slid from one side into or onto the ring. In so doing, the magnetized magnetic flux pieces are received by the guide grooves in sections and thereby guide the assembly. In the same manner, another assembly can be received by the other side of said guide ring and the assemblies can be joined together in or on said guide ring by said guide ring being pushed together in the axial direction.
The drawings illustrate the invention with the aid of an exemplary embodiment. The following are shown:
a guide ring,
fixing tongue,
A joining of the reflux partial rings 35 and 43 including the permanent magnets 38 and 44 leads to the alternating magnetic polarity being formed. The fixing tongue 42 thereby serves as the centering device 47. Said fixing tongues 42 are used as markings 46, which are to be brought into superposition with each other in the axial direction, whereby a correct alignment of said reflux partial rings 35 and 43 with respect to each other ensues. In particular, the permanent magnets 44 and 37 are disposed correctly in an angular offset manner to one another. Furthermore, the option exists for the fixing tongues 42 to be used for an alignment with a guide rail, which is not depicted here. The guide rails are inserted into the ring opening 40 and have a counter fixing groove associated with said fixing tongue 42, the counter fixing groove correctly orienting said reflux partial rings 35 and 43. Said fixing tongues 42 can furthermore be used as an anti-rotation locking means 47 by said tongues 42 interacting with the guide rail, which is embodied as the output shaft of the transversal flux machine. Said output shaft preferably has the inner diameter of said reflux partial rings 35 and 43 for the diameter thereof and comprises a counter fixing groove for receiving said fixing tongues 42. Said output shaft is inserted into the ring opening 40 for the purpose of securing said reflux partial rings 35 and 43.
Number | Date | Country | Kind |
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10 2008 054 381.0 | Dec 2008 | DE | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/EP09/65305 | 11/17/2009 | WO | 00 | 8/29/2011 |