Miniature electrical drive and magnetic return path element, and method for its production

• US 8,143,760 B2
• Filed: 07/15/2008
• Issued: 03/27/2012
• Est. Priority Date: 07/13/2007
• Status: Active Grant

• Current Assignee: Dr. Fritz Faulhaber GmbH & Co.
• Original Assignee: Dr. Fritz Faulhaber GmbH & Co.
• Inventors: Teufel, Jurgen, Reutter, Kornelius
• Primary Examiner(s): LE, DANG D
• Application Number:
  US12/218,461
• Publication Number:
  US 20090015093A1
• Time in Patent Office: 1,351 Days
• Field of Search: 310/254.1, 310/216.058, 310/216.113, 310/216.114, 310/216.118, 310/216.124, 310/216.001, 310/216.004, 310/216.013, 310/216.044, 310/216.087, 310/428, 310/431
• US Class Current: 310/216.058
• CPC Class Codes: H02K 1/187 to inner stators
• CPC Class Codes: H02K 15/028 for fastening to casing or support, respectively to shaft or hub
• CPC Class Codes: H02K 5/04 Casings or enclosures characterised by the shape, form or construction thereof
• CPC Class Codes: Y10T 29/49009 Dynamoelectric machine

Abstract

The present invention relates to a miniature electrical drive (1), in particular a rotating field drive with permanent magnet excitation, having a stator (2) and a soft-magnetic return path element (6) which cylindrically surrounds the stator (2) and has a multiplicity of sheet-metal laminates (22) which are in the form of annular disks and are arranged in layers to form a cylindrical laminated core (20). The sheet-metal laminates (22) in the laminated core (20) are held prestressed exclusively with a force fit and in an interlocking manner in the axial and radial directions, and without adhesive or integral joint means such as this, in a supporting sleeve (24) which coaxially surrounds said sheet-metal laminates (22).

Claims

1. Miniature electrical drive, in particular a rotating field drive with permanent magnet excitation, comprising a stator, a rotor and a soft-magnetic return path element, the stator including a stator core formed of stator windings, the rotor being mounted to rotate within the stator, the return path element cylindrically surrounding the stator and having a multiplicity of sheet-metal laminates in the form of annular disks and arranged in layers to form a cylindrical laminated core, whereby the sheet-metal laminates in the laminated core are held prestressed with a force fit exclusively in the radial direction in a supporting sleeve, whereby the sheet-metal laminates of the laminated core make touching contact with the supporting sleeve in the area of an external circumference of the sheet-metal laminates just at contact points distributed around the external circumference, and are therefore held with a force fit, and the sheet metal laminates in the laminated core are held axially prestressed in an interlocking manner in the axial direction, and without adhesives in the supporting sleeve which coaxially surrounds the sheet-metal laminates, whereby the layered sheet-metal laminates in the laminated core are held axially between holding embossed areas on the supporting sleeve, the holding embossed areas being distributed around the external circumference on each axial face of the laminated core and projecting radially inwards from the supporting sleeve and contacting each axial face.

2. Miniature drive according to claim 1, whereby the supporting sleeve has embossed areas, which are shaped radially inwards, in order to hold the laminated core.

3. Miniature drive according to claim 1, whereby the supporting sleeve is formed from a thin stainless-steel sheet.

4. Miniature drive according to claim 1, whereby the sheet-metal laminates are composed of magnetic sheet steel, preferably with each individual sheet-metal laminate in its own right having an insulating coating.

5. Miniature drive according to claim 1, whereby the circumferential contact points of the laminated core are formed by at least three, and preferably six, longitudinal beads on the supporting sleeve , which longitudinal beads project like ribs pointing radially inwards and run in particular parallel to the axis, at least over the entire axial length of the laminated core, with the inner surface, located between the longitudinal beads, of the supporting sleeve, and with the longitudinal beads of said supporting sleeve forming an interference fit with the laminated core.

6. Miniature drive according to claim 1, whereby the supporting sleeve is stamped as a blank from an originally flat sheet-metal material and is formed into its cylindrical shape, with two mutually adjacent longitudinal edges in the circumferential direction being connected via interlocking elements which engage in one another.

7. Miniature drive according to claim 6, whereby the longitudinal edges are in addition integrally connected at least at points, in particular by means of spot welds, to the interlocking elements which engage in one another.

8. Miniature drive according to claim 1, whereby an end frame is mounted on both axial faces of the supporting sleeve, to be precise preferably by a holding section on each end frame engaging axially in the supporting sleeve and being attached by means of holding embossed areas which are arranged distributed over the circumference, project radially inwards and each engage behind a holding edge on the end frame.

9. Miniature drive according to claim 8, whereby the end frames are centered by means of the longitudinal beads.

10. Miniature drive according to claim 8, whereby the end frames are fitted with a rotating bearing arrangement for a rotor shaft of a rotor which is arranged within the stator.

11. Miniature drive according to claim 1, wherein there are at least three of the contact points.

12. Miniature drive according to claim 1, wherein there are six of the contact points.

13. Method for production of a miniature electric drive, in particular a rotating field drive with permanent magnet excitation, comprising providing a stator, a rotor and a soft magnetic return path element the stator including a stator core formed of stator windings, the rotor being mounted to rotate within the stator, and the return path element cylindrically surrounding the stator and having arranging a multiplicity of individual sheet-metal laminates which are in the form of annular disks in layers to form a cylindrical laminated core and, in order to hold them, inserting the sheet-metal laminates into a supporting sleeve such that the sheet-metal laminates are held prestressed with a force fit exclusively in the radial direction, causing the sheet-metal laminates in the laminated core to make touching contact with the supporting sleeve in the area of an external circumference of the sheet-metal laminates just at contact points distributed around the external circumference and are therefore held with a force fit, and holding the sheet-metal laminates in the laminated core axially prestressed in an interlocking manner in the axial direction, and without adhesive or integral joint means, in the supporting sleeve which coaxially surrounds the sheet-metal laminates, whereby the layered sheet-metal laminates in the laminated core are held axially between holding embossed areas on the supporting sleeve, the holding embossed areas being distributed around the external circumference on each axial face of the laminated core and projecting radially inwards from the supporting sleeve and contacting each axial face.

14. Method according to claim 13, further comprising the following method steps:

a) A flat blank for the supporting sleeve is stamped out from a sheet-metal material, in particular from a stainless-steel sheet,

b) the flat blank is provided with all the necessary embossed areas, to be precise with the longitudinal beads and the holding embossed areas for the laminated core and preferably for the end frames,

c) the holding embossed areas are deformed back onto the plane of the flat blank with the exception of those holding embossed areas which are provided on an axial face in order to make contact with the laminated core,

d) the flat blank is formed into the cylindrical shape of the supporting sleeve, with two longitudinal edges being connected via the interlocking elements which engage in one another, and preferably via additional spot welds,

e) a cylindrical laminated core is formed by stacking one on top of the other a multiplicity of sheet-metal laminates which have previously been stamped out individually in the form of annular disks and have preferably been individually coated with insulation,

f) the sheet-metal laminates are pressed together with a specific pressure force,

g) the laminated core is inserted axially into the supporting sleeve in the compressed state, with the pressure force applied, of the sheet-metal laminates and with a force-fitting contact with the longitudinal beads until axial contact is made with the holding embossed areas,

h) the holding embossed areas are once again stamped in radially on the other axial face of the laminated core,

i) the axial pressure force is released from the sheet-metal laminates, with the laminated core making contact in an interlocking manner between the holding embossed areas that are provided axially on both sides, by axial elastic expansion while maintaining axial prestressing.