Granted Patent B2

US 12,749,936 · App. 18/659,220 · Granted Sep 29, 2026

Inventors: Johannes Glückler (Friedrichshafen, DE); Bernard Hunold (Friedrichshafen, DE); Alexander Thorwart (Langenargen, DE); Alexander Bäumle (Hamburg, DE); Michael Preuß (Friedrichshafen, DE); Niclas Raeder (Bermatingen, DE)

Assignee: ZF Friedrichshafen AG

H02K1/32H02K1/276H02K9/19H02K29/03

Abstract

Claims (69)

1 . A rotor arrangement for the improved cooling of a rotor, comprising a rotor core and a rotor shaft having an axial rotor axis, wherein the rotor core is arranged on the rotor shaft, wherein the rotor core comprises:

rotor laminae stacked one after another, embedded outer magnets arranged outside in the rotor core in axially extending magnet pockets;

at least four rotor segments arranged one after another, wherein at least a first rotor segment and a second rotor segment are stacked one after the other and form a first rotor section;

wherein, in an area of the outer magnets, the first rotor segment comprises axially through-going first flux barriers separate from the embedded outer magnets;

wherein, in the area of the outer magnets, the second rotor segment comprises axially through-going second flux barriers separate from the embedded outer magnets;

wherein the first rotor segment and the second rotor segment are offset at a first angle relative to one another;

wherein the first angle is chosen such that the first flux barriers and the second flux barriers overlap partially in a first overlap zone;

wherein at least a third rotor segment and a fourth rotor segment are stacked directly one after the other and form a second rotor section;

wherein, in the area of the embedded outer magnets, the fourth rotor segment comprises axially through-going fourth flux barriers separate from the embedded outer magnets;

wherein, in the area of the embedded outer magnets, the third rotor segment comprises axially through-going third flux barriers separate from the embedded outer magnets;

wherein the third rotor segment and the fourth rotor segment are offset at a second angle relative to one another;

wherein the second angle is chosen such that the third flux barriers and the fourth flux barriers overlap partially in a second overlap zone;

wherein between and adjacent to the first rotor section and the second rotor section an intermediate disk is arranged around the rotor shaft, the intermediate disk comprising a distributor ring in fluidic connection with the first fluid-guiding ducts and the second fluid-guiding ducts, the distributor ring configured for distributing the cooling fluid to the first fluid-guiding ducts and the second fluid-guiding ducts, and wherein the intermediate disk has radially extending first fluid-guiding ducts and second fluid-guiding ducts distributed around the circumference for guiding cooling fluid;

wherein by way of the rotor shaft cooling fluid can be passed into the intermediate disk;

wherein the first fluid-guiding ducts have first outlets and the second fluid-guiding ducts have second outlets to enable the cooling fluid to flow out; and

wherein the first outlets are connected fluidically with the adjacent flux barriers of the first rotor section and also the second outlets are connected fluidically with the adjust flux barriers of the second rotor section to enable the cooling fluid to flow into corresponding flux barriers, so that by virtue of the first overlap through-going axial cooling of the outer magnets of the first rotor section and by virtue of the second overlap through-going axial cooling of the outer magnets of the second rotor section with cooling fluid takes place.

2 . The rotor arrangement according to claim 1 , wherein the first overlap zone and also the second overlap zone are arranged in the outer periphery in the respective flux barriers, in the area of a radially outer side of the rotor core.

3 . The rotor arrangement according to claim 1 , wherein the distributor ring is arranged on an outside of the rotor shaft.

4 . The rotor arrangement according to claim 1 , comprising baffles arranged in the first fluid-guiding ducts and the second fluid-guiding ducts for the controlled adjustment of the quantity of cooling fluid flowing through.

5 . The rotor arrangement according to claim 1 , wherein the intermediate disk is adhesively bonded to the first rotor section and the second rotor section.

6 . A rotor arrangement for the improved cooling of a rotor, comprising a rotor core and a rotor shaft having an axial rotor axis, wherein the rotor core is arranged on the rotor shaft, wherein the rotor core comprises:

rotor laminae stacked one after another, embedded outer magnets arranged outside in the rotor core in axially extending magnet pockets;

at least four rotor segments arranged one after another, wherein at least a first rotor segment and a second rotor segment are stacked one after the other and form a first rotor section;

wherein, in an area of the outer magnets, the first rotor segment comprises axially through-going first flux barriers separate from the embedded outer magnets;

wherein, in the area of the outer magnets, the second rotor segment comprises axially through-going second flux barriers separate from the embedded outer magnets;

wherein the first rotor segment and the second rotor segment are offset at a first angle relative to one another;

wherein the first angle is chosen such that the first flux barriers and the second flux barriers overlap partially in a first overlap zone;

wherein at least a third rotor segment and a fourth rotor segment are stacked directly one after the other and form a second rotor section;

wherein, in the area of the embedded outer magnets, the fourth rotor segment comprises axially through-going fourth flux barriers separate from the embedded outer magnets;

wherein, in the area of the embedded outer magnets, the third rotor segment comprises axially through-going third flux barriers separate from the embedded outer magnets;

wherein the third rotor segment and the fourth rotor segment are offset at a second angle relative to one another;

wherein the second angle is chosen such that the third flux barriers and the fourth flux barriers overlap partially in a second overlap zone;

wherein between and adjacent to the first rotor section and the second rotor section an intermediate disk is arranged around the rotor shaft, wherein the intermediate disk has radially extending first fluid-guiding ducts and second fluid-guiding ducts distributed around the circumference for guiding cooling fluid;

wherein by way of the rotor shaft cooling fluid can be passed into the intermediate disk;

wherein the first fluid-guiding ducts have first outlets and the second fluid-guiding ducts have second outlets to enable the cooling fluid to flow out; and

wherein the first outlets are connected fluidically with the adjacent flux barriers of the first rotor section and also the second outlets are connected fluidically with the adjust flux barriers of the second rotor section to enable the cooling fluid to flow into corresponding flux barriers, so that by virtue of the first overlap through-going axial cooling of the outer magnets of the first rotor section and by virtue of the second overlap through-going axial cooling of the outer magnets of the second rotor section with cooling fluid takes place;

wherein the intermediate disk is formed by a first disk element and a second disk element identical thereto;

wherein the first disk element has fluid-guiding ducts arranged around its circumference and the second disk element has fluid-guiding ducts identical thereto; and

wherein the first disk element and the second disk element are arranged relative to one another so as to form the intermediate disk, in such manner that in the first disk element first fluid-guiding ducts comprise the first outlets and in the second disk element second fluid-guiding ducts comprise the second outlets.

7 . The rotor arrangement according to claim 6 , wherein the first disk element and the second disk element are welded to one another.

8 . The rotor arrangement according to claim 7 , wherein both the first disk element and also the second disk element are made of plastic, wherein one of the two disk elements is made of a transparent plastic, and wherein the two disk elements are joined by plastic welding along the fluid-guiding ducts.

9 . The rotor arrangement according to claim 8 , wherein the first disk element and the second disk element are adhesively bonded to one another.

10 . A rotor arrangement for the improved cooling of a rotor, comprising a rotor core and a rotor shaft having an axial rotor axis, wherein the rotor core is arranged on the rotor shaft, wherein the rotor core comprises:

rotor laminae stacked one after another, embedded outer magnets arranged outside in the rotor core in axially extending magnet pockets;

at least four rotor segments arranged one after another, wherein at least a first rotor segment and a second rotor segment are stacked one after the other and form a first rotor section;

wherein, in an area of the outer magnets, the first rotor segment comprises axially through-going first flux barriers separate from the embedded outer magnets;

wherein, in the area of the outer magnets, the second rotor segment comprises axially through-going second flux barriers separate from the embedded outer magnets;

wherein the first rotor segment and the second rotor segment are offset at a first angle relative to one another;

wherein the first angle is chosen such that the first flux barriers and the second flux barriers overlap partially in a first overlap zone;

wherein at least a third rotor segment and a fourth rotor segment are stacked directly one after the other and form a second rotor section;

wherein, in the area of the embedded outer magnets, the fourth rotor segment comprises axially through-going fourth flux barriers separate from the embedded outer magnets;

wherein, in the area of the embedded outer magnets, the third rotor segment comprises axially through-going third flux barriers separate from the embedded outer magnets;

wherein the third rotor segment and the fourth rotor segment are offset at a second angle relative to one another;

wherein the second angle is chosen such that the third flux barriers and the fourth flux barriers overlap partially in a second overlap zone;

wherein between and adjacent to the first rotor section and the second rotor section an intermediate disk is arranged around the rotor shaft, wherein the intermediate disk has radially extending first fluid-guiding ducts and second fluid-guiding ducts distributed around the circumference for guiding cooling fluid;

wherein by way of the rotor shaft cooling fluid can be passed into the intermediate disk;

wherein the first fluid-guiding ducts have first outlets and the second fluid-guiding ducts have second outlets to enable the cooling fluid to flow out; and

wherein the first outlets are connected fluidically with the adjacent flux barriers of the first rotor section and also the second outlets are connected fluidically with the adjust flux barriers of the second rotor section to enable the cooling fluid to flow into corresponding flux barriers, so that by virtue of the first overlap through-going axial cooling of the outer magnets of the first rotor section and by virtue of the second overlap through-going axial cooling of the outer magnets of the second rotor section with cooling fluid takes place;

wherein the first overlap zone and also the second overlap zone are arranged in the outer periphery in the respective flux barriers, in the area of a radially outer side of the rotor core; and

wherein the intermediate disk defines a plurality of annular segment recesses, each of which is in fluidic connection with the corresponding first fluid-guiding ducts and with the corresponding second fluid-guiding ducts in order to distribute the cooling fluid by way of the annular segment recesses to the first fluid-guiding ducts and the second fluid-guiding ducts.

11 . The rotor arrangement according to claim 10 , wherein the first fluid-guiding ducts and the second fluid-guiding ducts are made as recesses in the intermediate disk.

12 . The rotor arrangement according to claim 10 , wherein the intermediate disk is made in one piece and comprises at least one projection, and the rotor shaft has a corresponding recess such that the at least one projection is arranged in the corresponding recess.

13 . The rotor arrangement according to claim 10 , wherein the first fluid-guiding ducts and the second fluid-guiding ducts have constrictions for the control of the through-flowing cooling fluid.

14 . The rotor arrangement according to claim 10 , wherein the rotor shaft has rotor shaft openings distributed around its circumference, which open into the distributor ring or into the annular segment recesses.

15 . The rotor arrangement according to claim 14 wherein the rotor shaft defines an all-round catch groove facing toward the rotor axis, and the rotor shaft openings are arranged inside the catch groove.

16 . The rotor arrangement according to claim 15 , wherein the rotor shaft has a rotor shaft inside and comprises an all-round dam which is arranged on the rotor shaft inside facing toward the rotor axis, the dam being arranged next to the rotor shaft openings in such manner that the cooling fluid flowing along the inside of the rotor shaft flows into the rotor shaft openings.

17 . The rotor arrangement according to claim 16 , wherein at least on one of the rotor segments at the ends an all-round collecting channel is arranged, the collecting channel being open toward the rotor axis, in order to capture any cooling fluid that is sprayed away from a fluid inlet arranged a distance away from the corresponding end.

18 . The rotor arrangement according to claim 17 , wherein the rotor shaft has a rotor shaft outside and the rotor shaft outside defines longitudinal grooves distributed around its circumference, which grooves extend at least from the collecting channel to the intermediate disk in order to guide the captured cooling fluid from the annular collecting channel into the intermediate disk.

19 . The rotor arrangement according to claim 17 , wherein the rotor core defines recess grooves that extend at least from the collecting channel to the intermediate disk in order to guide the captured cooling fluid from the annular collecting channel into the intermediate disk.

Assignments (1)

Priority Claims (1)

Continuity (1)

References Cited (13)