Magnet holder, sensor magnet assembly, electric motor comprising a sensor magnet assembly, and method for producing a sensor magnet assembly

• US 11,108,314 B2
• Filed: 10/28/2019
• Issued: 08/31/2021
• Est. Priority Date: 10/29/2018
• Status: Active Grant

• Current Assignee: Buhler Motor GmbH
• Original Assignee: Buhler Motor GmbH
• Inventors: Gehring, Nils, Golditz, Paul-Peter, Schneider, Peter, Baudler, Bertram, Mehl, Gerhard, Kach, Stephan
• Primary Examiner(s): Islam, Muhammad S
• Application Number:
  US16/665,381
• Publication Number:
  US 20200136487A1
• Time in Patent Office: 673 Days
• CPC Class Codes: G01R 33/07 Hall effect devices
• CPC Class Codes: H02K 11/215 Magnetic effect devices, e.g. Hall-effect or magneto-resistive elements
• CPC Class Codes: H02K 29/08 using magnetic effect devices, e.g. Hall-plates, magneto-resistors H02K29/12 takes precedence

Abstract

A magnet holder for attaching a sensor magnet to a motor shaft of an electric motor, including a receiving recess for the sensor magnet and an attachment region for attachment to the motor shaft, wherein the receiving recess is radially delimited by a wall that, over the circumference thereof, includes a plurality of weak spots which have a reduced wall thickness and are designed so that free spaces remain between the weak spots and the sensor magnet arranged in the receiving recess. The invention further relates to a sensor magnet assembly, to an electric motor comprising a sensor magnet assembly, and to a method for producing a sensor magnet assembly. It is the object of the present invention to very reliably and durably attach a sensor magnet to the end of a motor shaft in a very economical and simple manner, wherein adhesive methods are to be dispensed with.

Claims

1. A magnet holder for attaching a sensor magnet to a motor shaft of an electric motor, the magnet holder comprising:

a receiving recess for receiving the sensor magnet;

an attachment region for attachment to the motor shaft;

the receiving recess being radially delineated by a wall having a circumference;

a plurality of weak spots over the circumference of the wall;

the weak spots having a reduced wall thickness and being designed in such a way that free spaces remain between the weak spots and the sensor magnet when the sensor magnet is arranged in the receiving recess; and

the sensor magnet being held in the receiving recess in a form-locked manner on both sides of the weak spots by wall regions having a larger wall thickness.

2. The magnet holder according to claim 1, the magnet holder being made of a magnetically non-conducting sintered metal.

3. The magnet holder according to claim 2, the magnetically non-conducting sintered metal comprising sintered brass.

4. The magnet holder according to claim 2, wherein the weak spots have a minimum wall thickness of no more than 1 mm.

5. The magnet holder according to claim 3, wherein the weak spots have a minimum wall thickness of no more than 0.8 mm.

6. The magnet holder according to claim 1, wherein the sensor magnet is rectangular and has four corners, and the weak spots are located opposite each of the corners of the sensor magnet, and the form fit is formed by spatially delineated sections of the wall on both sides of the weak spots.

7. Magnet holder according to claim 1, wherein the wall protrudes axially over rounded edges of the sensor magnet.

8. The magnet holder according to claim 1, wherein the receiving recess does not include any undercuts before the sensor magnet is installed.

9. The magnet holder according to claim 1, wherein the attachment region has a bushing-shaped design and is used for pressing onto the motor shaft or a projection of the motor shaft.

10. The magnet holder according to claim 9, further comprising an opening formed between the attachment region and the receiving recess.

11. The magnet holder according to claim 1, wherein an outer contour of the magnet holder has a polygonal geometry, in particular a tetragonal geometry.

12. The magnet holder according to claim 1, wherein the polygonal geometry is a tetragonal geometry.

13. Sensor magnet assembly according to claim 1, comprising the magnet holder and the sensor magnet, which is exclusively held in the receiving recess of the magnet holder in a form-locked manner by wall sections of the wall on both sides of the weak spots.

14. An electric motor comprising a sensor magnet assembly according to claim 1, wherein the motor shaft has an end face and the sensor magnet assembly is arranged so as to axially adjoin the end face of the motor shaft.

15. A method for producing a sensor magnet assembly according to claim 1, comprising the steps of:

a) providing a sintered magnet holder;

b) providing a rectangular sensor magnet;

c) inserting the magnet holder and the sensor magnet into a pressing device comprising four pressing jaws;

d) applying the pressing jaws to a respective weak spot of the wall opposite the corners of the sensor magnet;

e) applying a pressing pressure to the weak spots with little advance;

f) retracting the pressing jaws; and

g) removing the sensor magnet assembly from the pressing device.

16. The method for producing a sensor magnet assembly according to claim 15, wherein the pressing jaws are applied to the weak spots at an angle in the range of 10 to 45°

with respect to the longitudinal axis of the sensor magnet assembly.

17. The method for producing a sensor magnet assembly according to claim 15, wherein the pressing jaws are applied to the weak spots at an angle in the range of 15 to 30°

with respect to the longitudinal axis of the sensor magnet assembly.

18. The method for producing a sensor magnet assembly according to claim 15, wherein the pressing jaws are applied to the weak spots at an angle of 20°

with respect to the longitudinal axis of the sensor magnet assembly.