The present invention relates to a rotor for a permanent magnet electric machine and the use thereof.
Electric machines are electric motors or electric generators, for example, wherein said electric motors or electric generators perform a wide variety of tasks in particular in motor vehicles.
DE 10 2010 061 778 A1 describes a spider-type rotor of an electric machine, in which the permanent magnets are arranged in the form of a spider in a rotor basic body, wherein the rotor axis represents the fictitious point of intersection and the permanent magnets are oppositely polarized alternately in the circumferential direction. The magnetic flux is guided via pole segments arranged between the permanent magnets to the air gap in order to achieve a concentration of the magnetic flux. The magnetic south pole and the magnetic north pole therefore alternate in the circumferential direction of the rotor.
In order to reduce leakage fluxes and increase the efficiency of the machine, DE 10 2010 061 778 A1 describes a connecting sleeve connecting the rotor shaft and a rotor basic body, which connecting sleeve consists of a diamagnetic or paramagnetic material.
Since the magnetic remanance of ferretic permanent magnets is comparatively low at 0.4 to 0.45 tesla, for example, materials which comprise, inter alia, rare earth metals are often used for applications in permanent magnet electric machines. With the neodymium-iron-boron (NdFeB) magnets which are often used, with a proportion of neodymium of approximately 30% and a proportion of dysprosium of approximately 1.7 to 7%, a remanance of approximately 1.2 to 1.3 tesla is achieved at present. A further group of materials for permanent magnets comprises the Samarium-cobalt magnets, with which a remanance of approximately 1 tesla is achieved at present.
The physical size of a permanent magnet electric machine is dependent on the magnetic flux density which can be achieved in the gap between the rotor and the stator. Owing to the relatively low remanance, a machine designed on the basis of ferrite magnets would need to have approximately three times the total length as a machine including NdFeB magnets for a comparable performance. Using permanent magnets with a high remanance, therefore, machines can be developed which can be dimensioned in a more space-saving manner given the same performance or with an increased performance given the same space requirement than machines with permanent magnets having a lower remanance, such as consisting of ferrite, for example.
In addition to a low weight or low physical volume, it is also desired to avoid undesired magnetic short circuits, so-called leakage fluxes of the magnetic flux, since these reduce the efficiency of a machine. Leakage fluxes between the pole pieces, for example in the region of the air gap or towards the shaft, can be reduced by avoiding magnetically conductive materials between the pole pieces, as is described in DE 10 2010 061 778 A1.
The magnetic field is influenced by the geometry of the pole segments, wherein, in a manner known per se, circle radii with radii which become smaller towards the edge of the pole segments, are provided. In these embodiments, meaningful field shaping is not possible in the region between the pole segments, in a radially outer region (with respect to the rotor axis) of the permanent magnets, since no material is provided in this region which can have an influencing effect. Owing to the extension of the pole pieces in the radially outer region (with respect to the rotor axis) of the pole segments and permanent magnets, at the limit up to the formation of a continuous bridge, the leakage flux increases and the efficiency of the machine is reduced. In addition, torque ripple results from the harmonic content of the magnetic flux, in the gap between the rotor and the stator. In this case, the fifth and seventh harmonics result in sixth-order torque ripple. This results owing to frequency mixing, described by the multiplication of the fifth harmonic and the fundamental of the current (5+1=6; 7−1=6). The further harmonics occurring are integrally divisible by 6 (6, 12, 18, 24, . . . ), wherein the corresponding ones always result from the respective integers +/−1 (5 and 7, 11 and 13, . . . ). Depending on the embodiment of the motor topology (for example 8 poles on the rotor and 12 pole shoes on the stator), these harmonics are suppressed to a differing extent.
High raw material prices in particular for rare earth metals and uncertain access to the distribution and markets thereof are factors facing the high cost pressure in the automotive industry. Furthermore, existing electromachines do not sufficiently meet requirements for modern applications in motor vehicles, in particular in respect of efficiency, low cogging torque and torque uniformity.
The object of the present invention consists in providing a permanent magnet electric machine, in particular for use in motor vehicles, whose efficiency and/or cogging torque is reduced and/or whose torque uniformity is further improved.
This object is achieved by a rotor for a permanent magnet electric machine as described herein.
The rotor according to the invention for a permanent magnet electric machine, in particular a brushless DC machine, which rotor is arranged concentrically around a rotor axis and has a through-opening extending along the rotor axis for receiving a shaft, including permanent magnets and pole segments extending along the rotor axis, wherein the permanent magnets and the pole segments are arranged alternately in the circumferential direction around the rotor axis and a cross-sectional area of at least one, in particular each, pole segment is formed in at least one first pole segment region so as to be asymmetrical with at least one shaped portion arranged in a radially outer (with respect to the rotor axis) region of the pole segment, wherein the shaped portion extends substantially in a circumferential direction.
In accordance with a preferred embodiment of the invention, at least one, in particular each, pole segment includes at least one second pole segment region, in which at least one shaped portion, which forms asymmetrically a cross-sectional area, is provided in a radially outer (with respect to the rotor axis) region in a substantially opposite circumferential direction with respect to the shaped portion in the first pole segment region.
Preferably, at least one, in particular each, pole segment includes at least one third pole segment region, wherein the third pole segment region is substantially symmetrical and without a shaped portion.
Further preferably, for an, in particular each, pole segment, the proportion of the first pole segment region(s) is approximately 25%, the proportion of the second pole segment region(s) is approximately 25%, and the proportion of the third pole segment region(s) is approximately 50% of all the pole segments making up the rotor.
Preferably, at least one, in particular each, pole segment consists of a substantially magnetically conductive, in particular ferromagnetic and/or ferrimagnetic material. Preferably, ferrites are used as the materials for the permanent magnets.
Preferably, a maximum spacing between the shaped portion and the rotor axis is less than or equal to an outer radius of the rotor.
In a preferred embodiment, at least one torque transfer disk is provided on at least one end face of the rotor, which at least one torque transfer disk has an opening extending in the direction of the rotor axis for receiving and mechanically connecting a shaft, wherein the opening in the torque transfer disk in particular has a smaller diameter than the through-opening.
Preferably, at least one means for fixing the torque transfer disc is provided on the pole segment(s), wherein in particular at least one opening and/or cutout is provided in at least one pole segment, into which at least one rod-shaped element is inserted, which rod-shaped element is mechanically connected to the torque transfer disc.
In accordance with a further embodiment, at least one shaped portion is formed in the region of a, in particular each, pole segment on the torque transfer disc in a radially outer region (with respect to the rotor axis) of the torque transfer disc, wherein the shaped portion extends substantially in a circumferential direction.
Particularly preferably, the torque transfer disc consists of a substantially magnetically nonconductive and/or slightly conductive, in particular a diamagnetic and/or paramagnetic material.
Preferably, the shaft has at least one form element for receiving recesses surrounded by the pole segments and/or pole segment regions and/or at least one knurl is provided on the circumference of the shaft.
In accordance with a preferred development of the invention, magnetically conductive connecting webs are provided, which connect only pole segments and/or magnetically identically polarized pole segment regions of different pole segments.
The invention also relates to an electric machine including a rotor in accordance with the above-described preferred embodiments and the use of the rotor and/or the permanent magnet machine in a motor vehicle, in particular in a motor vehicle braking system and/or motor vehicle steering system.
Despite a comparatively low remanance of ferrite magnets or comparatively available permanent magnets, without rare earth metals, by means of the invention it is possible to design an electric machine which, in comparison with permanent magnet machines with rare earth metals, has only a slightly increased space requirement and is more space-saving than alternative motor concepts such as asynchronous and reluctance machines. By avoiding the rare earth metals which are cost-intensive and sometimes difficult to obtain and owing to the simple basic construction, in addition costs are saved and access to materials is simplified. In the case of such materials and in the case of the use of permanent magnets which contain rare earth metals, improved efficiency, increased torque uniformity and lower cogging torque are achieved.
Further preferred embodiments result from the description below relating to exemplary embodiments with reference to the figures, in which:
In order to make it possible to describe the exemplary embodiments briefly and easily, identical elements have been provided with the same reference symbols and in each case only the details which are essential to the invention are explained.
The field coils 12 are arranged around the circumference of the rotor 2 on pole shoes 13 of the stator 11 and are actuated electrically in a manner known per se in order to bring about a rotary movement of the rotor by generation of a rotating magnetic field. The rotor 2 includes the permanent magnets 3 and the pole segments 4, which extend along the rotor axis, and, surrounding the rotor axis 1′ concentrically, are arranged around the rotor axis alternately in a circumferential direction. As already described in the prior art, the permanent magnets are oppositely polarized, alternating in the circumferential direction. In order to achieve a concentration of the magnetic flux, the magnetic flux is guided via the pole segments 4 to the air gap, wherein the permanent magnets 3 each adjoin a pole segment 4 with the same magnetic polarization. Therefore, the magnetic south pole and the magnetic north pole alternate in the circumferential direction of the rotor.
The rotor 2 is mechanically connected, rotatably about the rotor axis 1′, to a shaft (not illustrated) of the electric motor via the torque transfer discs 7 provided on both end faces of the rotor 2. In order to pass through and fasten the shaft, openings 8′ are provided in the torque transfer discs 7 in the direction of the rotor axis 1′. The rotor 2 furthermore has a through-opening 8 extending in the direction of the rotor axis 1′ in order to pass through the shaft.
In order to avoid leakage fluxes of the rotor in particular with respect to the shaft, the torque transfer discs 7 consist of a substantially magnetically nonconductive or slightly conductive material, such as copper or aluminum, for example. In particular when a shaft consisting of a material which is substantially magnetically conductive is used, the openings 8′ in the torque transfer discs 7 are embodied with a smaller diameter than the through-opening 8. As a result, leakage fluxes of the permanent magnets 3 and pole segments 4 with respect to the shaft are reduced depending on the spacings therebetween.
As an alternative or in addition to the torque transfer discs 7, at least one connecting sleeve consisting of a diamagnetic and/or paramagnetic material could be introduced between the shaft and the rotor 2, for example, which connecting sleeve firstly transfers torque to the shaft and/or to the rotor 2 or can support the transfer of torque to the shaft and/or to the rotor 2 and secondly suppresses leakage fluxes.
In accordance with this exemplary embodiment, in each case two rods having circular cross sections are introduced into openings 10 provided therefor in each pole segment 4 and the torque transfer discs 7 and are in particular mechanically connected to the torque transfer discs 7 in such a way that the torques arising during operation can be transferred. In order to illustrate this,
In order to avoid eddy currents, the pole segments 4, in a manner known per se, consist of laminate stacks, but regions of the pole segments 4 consisting of solid material can also be provided. The pole segments 4 have pole segment regions 5, which have shaped portions 6 forming the cross-sectional area 14 asymmetrically in a radially outer (with respect to the rotor axis 1′) region. The cross-sectional area 14 is illustrated for clarification purposes in
As already explained, owing to harmonics of the magnetic flux, torque nonuniformities arise in the gap between a rotor and a stator. A frequently used embodiment of an electric machine has 8 poles on the rotor side and 12 pole shoes on the stator side, but does not demonstrate any suppression of these harmonics, for which reason a sinusoidal air-gap field needs to be sought, which in turn is determined by the geometry of the pole segments.
An exemplary profile of the magnetic flux density B as a function of the rotor angle W of a 10-pole rotor corresponding to an embodiment known per se of an electric motor is illustrated in
The number and arrangement of the pole segment regions 5, 5′, 5″ in each pole segment 4 can be configured depending on the requirement for efficiency and torque uniformity, wherein differences between the individual pole segments can also be realized. In the exemplary embodiment shown in
If the pole segment regions 5, 5′, 5″ of a pole segment 4 are further combined, for example in such a way that in each case a cohesive first pole segment region 5 with a shaped portion 6 in the circumferential direction 1′, then a third pole segment region 5″ without a shaped portion, and thereafter a second pole segment region 5′ with a shaped portion 6 in the opposite circumferential direction 1′, the shaped portions 6 of the pole segment regions 5, 5′ could optionally also be arranged on the torque transfer disc 7.
Corresponding to the embodiment in
The further ones which are provided in the circumferential direction and have opposite magnetic potential in comparison with the pole pieces 4 and/or pole segment regions 5, 5′, 5″ just described are connected by means of connecting webs 27. The respective connecting webs 26 and 27 of the oppositely polarized pole segments 4 in this case have an axial spacing of 4 mm, for example, as a result of which leakage fluxes are advantageously limited or avoided. Pole segment regions 5, 5′, 5″ of a pole segment plane, arranged perpendicular to the rotor axis 1′, of the rotor 2 are illustrated in
The permanent magnets 3 are arranged in the circumferential direction between the pole segments 4, as already described for the further exemplary embodiments. The rotor 2 can be configured, in accordance with the invention, in such a way that the permanent magnets 3 extend towards the rotor axis 1′ partially or completely in the form of a wedge, which means that the planes of the permanent magnets 2, which planes are arranged in the circumferential direction of the rotor 2, approach one another towards the rotor axis. Owing to the wedge shape, in particular the space requirement required by the connecting webs 26, 27 is found.
Owing to the pole segment regions 5, 5′, 5″ of a pole segment plane of the rotor 2 which are arranged in particular in the axial end regions of the rotor 2 and are highlighted in
While the above description constitutes the preferred embodiment of the present invention, it will be appreciated that the invention is susceptible to modification, variation and change without departing from the proper scope and fair meaning of the accompanying claims.
Number | Date | Country | Kind |
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10 2012 216 431.6 | Sep 2012 | DE | national |
10 2013 009 115.2 | May 2013 | DE | national |
This application claims priority to German Patent Application Nos. 10 2012 216 431.6, filed on Sep. 14, 2012; 10 2013 009 115.2, filed on May 29, 2013; and PCT/EP2013/068324, filed Sep. 5, 2013.
Filing Document | Filing Date | Country | Kind |
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PCT/EP2013/068324 | 9/5/2013 | WO | 00 |