Patent Publication Number: US-2023142750-A1

Title: Rotor of a dynamo-electric rotary machine, dynamo-electric machine having a rotor, and method for producing the rotor

Description:
The invention relates to a rotor of a dynamo-electric rotary machine, a dynamo-electric machine having a rotor, and a method for producing the rotor. 
     Rotors of asynchronous machines are often embodied as squirrel-cage rotors. The rotor in this type of configuration has a cage comprising cage bars and a short-circuiting ring in each case at the respective axial ends of the short-circuiting bars. Due to its low material strength, however, the short-circuiting ring deforms at high rotational speeds. 
     DE 10 2013 218 473 A1 describes a method for producing a squirrel-cage rotor of an asynchronous machine comprising: providing a laminated core having a plurality of openings for receiving bars of a rotor cage; positioning a mold part for a short-circuiting ring at an end face of the laminated core; and casting the bars and the short-circuiting ring. The mold part is cast onto the laminated core in this case, and remains there for the purpose of stabilizing the short-circuiting ring on the squirrel-cage rotor. 
     It is however disadvantageous in this case that a supporting function of the cast-in mold part is no longer provided after cooling. Due to the shrinkage of the material for the short-circuiting ring during cooling, a hollow space is produced between short-circuiting ring and mold part. During operation, this results in a deformation of the short-circuiting ring due to the centrifugal forces. 
     An object of the invention can therefore be considered to be improving a stabilization of the short-circuiting ring. 
     The object is achieved by claim  1 , i.e. a rotor of a dynamo-electric rotary machine, having:
     a rotor core arranged concentrically relative to the rotor axis, wherein the rotor core has slots, wherein the slots are filled with at least one electrically conductive material,   a front ring arranged concentrically relative to the rotor axis at the front axial end of the slots, wherein the front ring comprises at least one electrically conductive material,   a rear ring arranged concentrically relative to the rotor axis at the rear axial end of the slots, wherein the rear ring comprises at least one electrically conductive material,   
 wherein a surface of the front and/or rear ring facing away from the rotor core at least partially has a bevel in an axial direction from an outer circumference to an inner circumference of the ring, with a bevel angle, 
   at least one support element, wherein the support element is designed in such a way that the support element at least partially is connected to the ring with a positive fit.   

     The object is further achieved by claim  10 , i.e. a dynamo-electric rotary machine, in particular an asynchronous machine, having such a rotor. 
     The rotor core is preferably a structure having material layers, said material layers being riveted, welded, batch-stamped, adhesively bonded and/or baked together. 
     The material layers are advantageously laminations. However, other types of material layers are also conceivable. 
     The rotor core is advantageously a laminated core. 
     The slots are preferably closed. However, half-open and open slots are also possible. 
     The filled slots represent short-circuiting bars of the cage winding. The ring represents a short-circuiting ring of the cage winding. 
     The slots are preferably filled with the electrically conductive material by means of die casting. The front and/or the rear ring are preferably formed by means of die casting using the electrically conductive material. 
     Alternatively, the slots are filled with the electrically conductive material by means of 3D printing. Alternatively, the front and/or the rear ring are formed by means of 3D printing using the electrically conductive material. Other methods are however also conceivable. 
     Alternatively, it is also possible for extruded bars, for example copper bars, to be inserted into the slots and for the respective ring to be formed by means of die casting or 3D printing, for example. 
     The ring is advantageously connected to the filled slots with a material fit. 
     The electrically conductive material is preferably copper or aluminum. This is advantageous because greater efficiency can be achieved thereby. However, a copper alloy or an aluminum alloy is also possible. 
     Aluminum advantageously has a temperature-dependent tensile strength of 20 to 60 N/mm 2 . 
     It is conceivable for the ring and/or the slots to comprise shaped inserts. These shaped inserts can comprise an electrically non-conductive material. 
     With regard to the end face, the ring can have more than one bevel angle in the rotary sense. 
     The ring advantageously fits closely against the rotor core without any clearance. In other words, the ring advantageously fits closely against the last material layer, preferably the last lamination, or against an end ring which enables stacking of the material layers. 
     In an advantageous embodiment, the support element has, at a surface facing toward the ring, at least one section which has a bevel in an axial direction from the outer circumference to the inner circumference, with a bevel alternate angle which is an alternate angle to the bevel angle. 
     Ring and support element can therefore be effectively connected with a positive fit. 
     The slots can be skewed or non-skewed. 
     In an advantageous embodiment, the bevel angle has a value of 3° to 30°. 
     This value is advantageous because optimal stabilization of the short-circuiting ring can be achieved thereby. 
     The material which is present in the ring and/or the slots preferably has greater electrical conductivity than the material which is present in the support element. 
     The material which is present in the support element preferably has greater mechanical tensile strength than the material which is present in the ring and/or the slots. 
     In an advantageous embodiment, the support element comprises a material having a tensile strength of 800 N/mm 2  to 1200 N/mm 2 , in particular 1000 N/mm 2   .   
     The described tensile strength allows the rotors to be used in the high-speed range, for example in the range of 1500 to 3000 rotations per minute (RPM) in the case of an external rotor diameter of 100 to 200 mm. 
     In an advantageous embodiment, the support element comprises steel. For example, a quenched and tempered steel containing chromium and/or nickel and/or molybdenum is suitable for this purpose. A case-hardened steel containing chromium and/or nickel and/or molybdenum is also suitable. 
     The support element can also comprise titanium. 
     Steel is particularly suitable due to its high strength, good hardenability, stiffness and elongation at rupture. Moreover, steel is affordable and can be formed hot or cold. 
     In an advantageous embodiment, the surface of the front and/or rear ring facing away from the rotor core has at least one first region having a first part-bevel in an axial direction from an outer circumference to an inner circumference of the ring, with a first part-bevel angle, and at least one second region having a second part-bevel in an axial direction from an outer circumference to an inner circumference of the ring, with a second part-bevel angle, wherein the first part-bevel angle and the second part-bevel angle differ. 
     In an advantageous embodiment, the support element has, at the surface facing toward the ring, at least one first region having a bevel in an axial direction from the outer circumference to the inner circumference, with a part-bevel alternate angle which is an alternate angle to the first part-bevel angle, wherein the support element has, at the surface facing toward the ring, at least one second region having a bevel in an axial direction from the outer circumference to the inner circumference, with a part-bevel alternate angle which is an alternate angle to the second part-bevel angle. 
     Provision is preferably made for the engagement of at least those regions of the ring and support element which are subjected to a centrifugal force during operation. 
     This embodiment allows greater absorption of a radial force component. 
     In an advantageous embodiment, the support element can be connected to a shaft by means of an interference fit. 
     This is advantageous because the support element can then simultaneously serve as a balancing element. 
     Alternatively, the support element can also be connected to the shaft by means of a reinforcing ring. For example, the reinforcing ring here can be connected to the shaft by means of for example an interference fit and the support element clamped between ring and reinforcing ring. Other embodiments are also conceivable. 
     In an advantageous embodiment, the support element has at least one recess and/or at least one thickening in order to correct an imbalance in particular. 
     A recess is for example a drilled hole while a thickening is for example a material coating at specific locations. 
     A recess, obtained by negative weighting, is also referred to as boring out. It is particularly advantageous since this type of rotor balancing can be effected automatically by calculating an imbalance and implementing a corresponding drilled hole with diameter and drilled depth. 
     The thickening is achieved for example by means of a welding method, for example friction welding of preprepared cylinders. In this case, the support element and for example a preprepared cylinder are preferably moved relative to each other under pressure, said support element and cylinder touching at the contact surfaces. The resulting friction causes the material to heat up and plasticize. 
     The recess can also be a channel for rear ventilation of the rotor. 
     The object described above is also achieved by claim 11, i.e. a method for producing such a rotor having a rotor core that is arranged concentrically relative to the rotor axis, said rotor core having slots, for a dynamo-electric rotary machine, comprising the following steps:
     providing the rotor core,   filling the slots with at least one electrically conductive material,   depositing at least one electrically conductive material at the front and/or rear axial end of the slots in order to form a front and/or rear ring by means of a shaping device, wherein the shaping device is embodied in such a way that a surface of the front and/or rear ring facing away from the rotor core is at least partially given a bevel in an axial direction from an outer circumference to an inner circumference of the ring, with a bevel angle,   pressing a support element on.   

     The filling of the slots is advantageously achieved by inserting preprepared bars, in particular copper bars, or by means of die casting, for example aluminum die casting, or a combination thereof. It is also conceivable to introduce other types of shaped insert. The filling of the slots can also be achieved by means of 3D printing. 
     The formation of the ring is advantageously achieved by means of die casting, for example aluminum die casting. It is also conceivable to introduce shaped inserts made from for example aluminum or another material. The formation of the ring can also be achieved by means of 3D printing. 
     In an advantageous embodiment, the support element is shrunk onto a shaft. 
     In an advantageous embodiment, the support element is heated up to a temperature of 100° C. to 140° C., preferably 120° C., for the purpose of shrinking on. 
     In an advantageous embodiment, the support element is pressed onto the ring in an axial direction. 
     In an advantageous embodiment, the support element is pressed on with a bonding force of 20 to 40 t, preferably 30 t. 
     The invention is particularly suitable for asynchronous machines with squirrel-cage rotors. Such dynamo-electric rotary machines are used in various fields, for example for ventilators, pumps, compressors, machine tools and for drives in electric vehicles and hybrid vehicles. The invention is also highly suitable for motors in high-power blowers. 
     The invention is particularly suitable for dynamo-electric rotary machines in the high-speed range. 
     The invention is suitable for pure asynchronous machines but is also suitable for other dynamo-electric rotary machines, for example for hybrid machines such as an asynchronous machine with permanent magnets, for example. 
     The asynchronous machine with permanent magnets runs up to a high rotational speed asynchronously and then switches to synchronous operation. This is advantageous because high levels of efficiency and power can be achieved thereby. 
     The invention offers the advantage that the rotors can be operated at circumferential speeds exceeding 90 m/s without any risk of deformation of the short-circuiting rings. 
     Even a circumferential speed of 150 m/s is possible. Such a circumferential speed at the outer circumference of the rotor is required in particular in the field of industrial engineering and technology and for drives in the field of electromobility. 
    
    
     
       The invention is described and explained in greater detail below with reference to the exemplary embodiments illustrated in the figures, in which: 
         FIG.  1    shows a first embodiment of a rotor according to the invention, 
         FIG.  2    shows a second embodiment of the rotor, 
         FIG.  3    shows a third embodiment of the rotor, 
         FIG.  4    shows a fourth embodiment of the rotor, 
         FIG.  5    shows a fifth embodiment of the rotor, 
         FIG.  6    shows the rotor from  FIG.  5   , viewed from an end face, 
         FIG.  7    shows a dynamo-electric rotary machine with the rotor, and 
         FIG.  8    shows a method for producing the rotor. 
     
    
    
       FIG.  1    shows a first embodiment of a rotor  11  according to the invention. 
       FIG.  1    shows a rotor core  4  which is arranged concentrically relative to the rotor axis  6 , wherein the rotor core  4  has slots  3 , said slots  3  being filled with an electrically conductive material.  FIG.  1    shows a short-circuiting ring  2  which is arranged concentrically relative to the rotor axis  6  at a rear axial end  9  of the slots  3  and comprises an electrically conductive material. 
     In the figure, a surface of the ring  2  facing away from the rotor core  3  has a bevel in an axial direction  7  from an outer circumference  21  to an inner circumference  22  of the ring  2 , with a bevel angle a. 
     The figure shows a support element  1  which is at least partially connected to the ring  2 . In the figure, the rotor core  4  and the support element  1  adjoin a shaft  5 . 
     At a surface facing toward the ring  2 , the support element  1  has a section which has a bevel in an axial direction  7  from the outer circumference  21  to the inner circumference  22 , with a bevel alternate angle a′ which is an alternate angle to the bevel angle a. The bevel angle in the figure has a value of 13° C. A value of the bevel angle α preferably lies in a range from 3° C. to 30° C., in particular 10° C. to 20° C. The figure shows that a radial positive engagement is present between short-circuiting ring  2  and support element  1 . 
     The invention offers the advantage that greater suitability for speed is achieved for a rotor  11 , in particular a rotor of an asynchronous machine. Under stress of rotational speed, there is no risk that the short-circuiting ring will tilt or that the short-circuiting material will yield. 
     The support element  1  is preferably pressed onto the short-circuiting ring  2  axially. The support element  1  is supported on the shaft  5 . This means that the support element  1  and therefore the short-circuiting ring  2  are mechanically braced by the shaft  5 . 
       FIG.  2    shows a second embodiment of the rotor  11 .  FIG.  2    shows that the surface of the ring  2  facing away from the rotor core  4  has at least one first region having a first part-bevel in an axial direction  7  from the outer circumference  21  to the inner circumference  22  of the ring  2 , with a first part-bevel angle β, and at least one second region having a second part-bevel in an axial direction  7  from the outer circumference  21  to the inner circumference  22  of the ring  2 , with a second part-bevel angle y, wherein the first part-bevel angle β and the second part-bevel angle y differ. 
     The figure shows three first regions with the part-bevel angle β and two second regions with the part-bevel angle y. 
     The figure also shows the support element  1 . The figure shows that the support element  1  has, at the surface facing toward the ring  2 , at least one first region having a bevel in an axial direction  7  from the outer circumference  21  to the inner circumference  22 , with a part-bevel alternate angle β′ which is an alternate angle to the first part-bevel angle β, and that the support element  1  has, at the surface facing toward the ring  2 , at least one second region having a bevel in an axial direction  7  from the outer circumference  21  to the inner circumference  22 , with a part-bevel alternate angle y′ which is an alternate angle to the second part-bevel angle y. 
     The figure here shows three first regions with the part-bevel angle β′ and two second regions with the part-bevel angle y′. 
     Such an embodiment of the invention allows greater absorption of a radial force component. 
       FIG.  3    shows a third embodiment of the rotor  11 . The embodiment shown is suitable for particularly high circumferential speeds at the outer circumference of the rotor  11 . Circumferential speeds of up to 180 m/s are possible. 
     The figure shows a support element  1  which has an inner support disc  101  and an outer support device  102 . In the figure, the inner support disc  101  and the outer support device  102  are connected with a material fit, preferably by means of welding. 
     A connection between the support disc  101  and the support device  102  is preferably realized at or at least close to the outer circumference. The inner support disc  101  advantageously has recesses, the number of recesses corresponding to the number of slots  3  in the rotor core  4 . 
     The inner support disc  101  is advantageously incorporated when the ring  2  is formed. The inner support disc  101  is preferably cast in during the formation of the ring  2  by means of die casting. The outer support disc  102  is attached after cooling, in particular by means of a bonding force in an axial direction. The welding is preferably performed subsequently. A weld seam is therefore present at the outer circumference of the rotor  11 . The welding is optional. 
       FIG.  4    shows a fourth embodiment of the rotor  11 . In addition to the embodiment described above in  FIG.  1   , the embodiment in  FIG.  4    has a recess  13  in the support element  1 , said recess being used to correct an imbalance. 
     The advantage here is that balancing does not take place in the short-circuiting ring as before, but in the support element  1 . This means that the support element  1  additionally functions as a balancing disc. 
     It is also possible to apply a thickening to the support element  1 , said thickening being used to correct an imbalance. This is not illustrated in the figure. 
       FIG.  5    shows a fifth embodiment of the rotor  11 . The figure shows channels  14  and  15 , which allow rear ventilation of the rotor  11 . This is explained in greater detail in  FIG.  6   . 
       FIG.  6    shows the rotor  11  from  FIG.  5   , viewed from an end face. Both figures show channels  14  and  15 , which are used for rear ventilation of the rotor  11 . The channels  14  can be cast in, for example. The channels  15  are present in the support element  1 . By virtue of the recesses, air is sucked in during the rotation of the rotor  11 . This provides the rear ventilation. 
     By virtue of these recesses in the support element  1 , the air is sucked in during rotation and expelled at the outer circumference of the short-circuiting ring  2 . 
       FIG.  7    shows a dynamo-electric rotary machine  10  with the rotor  11 . The figure shows a stator  12 , the shaft  5  and the rotor axis  6 . Viewed in an axial direction  7 , the rotor  11  has a support element  1  at the front axial end  8 . The rotor  11  also has a support element  1  at the rear axial end  9 . 
       FIG.  8    shows a method for producing the rotor  11 , a rotor core thereof being arranged concentrically relative to the rotor axis and having slots. 
     In a method step S 1 , the rotor core is provided. 
     In a method step S 2 , the slots  3  are filled with an electrically conductive material. In this case, the slots  3  can be filled with preprepared bars or by means of die casting. A combination of preprepared bars or other shaped inserts and die casting is also possible. 
     In a method step S 3 , electrically conductive material is deposited at the front and/or rear axial end of the slots  3  in order to form a front and/or rear ring  2 . This is advantageously achieved by means of die casting. 
     In a method step S 4 , the support element  1  is pressed on. The support element  1  is advantageously guided on the shaft during this pressing operation. By virtue of the previously described bevel of the ring  2  and the support element  1 , any out-of-round of the short-circuiting ring  2 , this being cast in particular, is corrected by the support element  1  and a coaxiality of the whole short-circuiting ring  2  relative to the shaft  5  and hence to the rotor core is improved. 
     The support element  1  is advantageously shrunk onto a shaft and pressed onto the short-circuiting ring  2  axially under force. As a consequence, the surfaces of the support element  1 , these preferably being oriented axially inward, and the outer surfaces of the short-circuiting ring  2  fit tightly together. A bonding force is preferably maintained for approximately 20 to 30 seconds in order to ensure full placement. A bonding force of approximately 30 t is advantageously applied in the case of a short-circuiting ring having a diameter of 130 to 170 mm, in particular 150 mm. The support element is preferably heated up to approximately 120° C. for the purpose of shrinking on. 
     The invention has the advantage that a casting skin which forms during the die casting of the short-circuiting ring strengthens the short-circuiting ring. 
     The rotor produced by this method significantly reduces the risk of material displacement due to centrifugal forces, by virtue of the strength of the support element.