Rotor for an electronically commutated motor and improved method for the mass production thereof

1. Rotor for an electronically commutated motor that comprises:

a sub-assembly formed by a core of magnetic laminations and by a plurality of segments of a cylinder made of preferably sintered magnetizable materials positioned on the outer surface of the core,

a substantially cylindrical wrapper, made of a non-magnetic material preferably an austenitic steel, surrounding said segments of a cylinder, and having an inside diameter that is not smaller than the outside diameter of the said sub-assembly,

at least a pair of plane elements, in the form of rings made of a non-magnetic material, preferably aluminum, which are joined to the end portions of said wrapper at the extremities of the core by first elastic means having a length that is not smaller that the length of the core, and are supported by means that are integrally provided in the core parallel to the axis of rotation of the rotor, which are adapted to interfere with contiguous longitudinal edges of said segments of a cylinder so as to keep said segments circumferentially spaced from each other,

characterized in that it also comprises second elastic means which are supported by means that are integrally provided in the said core, adapted to ensure that the outer surface of the said segments keeps in contact with the inner surface of the wrapper and are the sole means: provided in the rotor to make up for the longitudinal and radial plays of the various parts.

2. Rotor according to claim 1 , characterized in that the supporting means for said second elastic means are grooves extending parallelly to the axis of rotation of the rotor and provided in a number that is equal to or a multiple of the number of the supporting means for said first elastic means.

3. Rotor according to claim 1 , characterized in that said second elastic means are elementary undulated springs.

4. Rotor according to claim 1 , characterized in that said second elastic means comprise a cylindric cage made of metal wire and consisting of first parallel, preferably undulated portions provided in a number equal to the supporting means thereof, second portions formed in the shape of arcs of a circle, and preferably undulated, which are subdivided into two groups of equal number between the ends of said first portions, and radial joining portions that are provided between the ends of each one of said first portions and the adjacent second portions.

5. Rotor according to claim 4 , characterized in that a radial extension of said radial joining portions is smaller than the thickness of the segments of a cylinder as measured on a plane that is orthogonal to the axis rotation of the rotor.

6. Rotor according to claim 1 , characterized in that the means for supporting said first elastic means substantially consist of peripherally arranged slots that are provided, regularly spaced from each, other on the outer surface of the core and have a cross-section in the shape of a “Ω”, said slots being adapted to accommodate the first elastic means which are also in the shape of a “Ω” with their end portions bent to the shape of a “V” interfering with the contiguous longitudinal edges of the segments of a cylinder.

7. Rotor according to claim 1 , characterized in that the end portions of the: wrapper are joined to said plane elements solely by means of a simple mechanical deformation.

8. Method for producing a rotor, comprising substantially the phases of:

making a core by stacking a plurality of magnetic laminations;

associating second elastic means to respective supporting means integrally provided on the core;

obtaining a rotor sub-assembly formed by the core, said second elastic means, and segments of a cylinder arranged along the outer surface of the core;

providing a cylindrical wrapper along an axis of rotation around said rotor sub-assembly with a radial play with respect thereto,

inserting first elastic means in the respective supporting means provided integrally on the core so as to obtain a circumferential spacing of the segments of a cylinder from each other due to the first elastic means interfering with contiguous longitudinal edges of the segments of a cylinder;

inserting plane elements so as to enable them to come into contact with end portions of the core;

submitting the end portions of the wrapper and/or the plane elements to a circumferential mechanical deformation so as to enable them to mutually join to form a cylindrical, substantially sealed shell;

magnetizing the rotor so as to enable the contiguous longitudinal edges of the segments of a cylinder to become opposite magnetic poles.