Abstract: A method is provided for manufacturing a rotor (1) of an electric motor. The rotor (1) has a rotor shaft (2), inner sheet metal packets (4), outer sheet metal packets (4), buried magnets (5) arranged in the assembled state between the inner sheet metal packets (3) and the outer sheet metal packets (4), and surface magnets (6) arranged in the assembled state on the outer sheet metal packets (4). The method includes pushing the inner sheet metal packets (3) onto the rotor shaft (2) to achieve alignment rectangularly and coaxially. The rotor (1) is constructed by placing the buried magnets (5) and the outer sheet metal packets (4) on the inner sheet metal packets (3) and the surface magnets (6) on the outer sheet metal packets (4). A total run-out of the rotor (1) thus is set to a predetermined acceptable amount.

Abstract: A method for producing a rotor device, including providing a rotor shaft having at least one sheet metal packet joined to the rotor shaft. The at least one sheet metal packet includes magnetic units. The method includes performing a transfer molding process, in which the magnetic units are fixed in position in relation to the at least one sheet metal packet and at least one balancing disk is joined axially on the rotor shaft on at least one side of the at least one sheet metal packet such that a gap of a defined width is ensured between the at least one balancing disk and the at least one sheet metal packet. The gap is filled with a molding compound used for the transfer molding process. The method includes determining an imbalance of the rotor device and compensating the imbalance by removing material from the at least one balancing disk.

Abstract: A rotor (1) of an electric motor (20) has a rotor body (21) with a rotor shaft receptacle opening (22) for receiving a rotor shaft (3), and a rotor sheath (23) is on the rotor body (21) outward of the rotor shaft receptacle opening (22). Magnetic field-inducing components (10) are arranged in the rotor body (21). The rotor body (21) further has first and second end faces (14, 18) facing away from one another. The rotor (1) also includes a cooling device (4) with a supply channel (5), a drainage channel (6) and cooling channels (11) formed in the rotor body (21) between the rotor shaft receptacle opening (22) and the rotor sheath (23). The cooling channels (11) are arranged adjacent to the magnetic field-inducing components (10). A method for manufacturing a rotor having a cooling device also is provided.

Abstract: A rotor device (1) for an electric machine (10) has a rotatably supported shaft (2) and a rotor hub (3) connected to the shaft (2) in a rotationally fixed manner. The shaft (2) has multiple radially outwardly facing shaft protrusions (12), and the rotor hub (3) has multiple radially inwardly facing hub protrusions (13). A shaft protrusion (12) and a respective hub protrusion (13) abut one another in a touching manner in the radial direction at least in sections. Cavities (4) are formed between the rotor hub (3) and the shaft (2). The cavities (4) extend between adjacent shaft protrusions (12) and the hub protrusions (13) lying thereon. The cavities (4) are grouted with a material (14). The material (14) forms form-fit elements (24) that block relative movement of the rotor hub (3) and the shaft (2) in a form-fit manner.

Abstract: A joining tool (10) is provided for pressing a disk (12) to a shaft (14) that has opposite first and second ends. The first end (18) of the shaft (14) is received in a press table (22) and the second end (24) of the shaft (14) is received in a centering receptacle (26). A press plate (34) axially presses the disk (12) onto the shaft (14). A resilient ram (40) is provided on a side of the press plate (34) that faces toward the disk (12) and compensates for an axial run-out of the disk (12) relative to the press plate (34). The resilient ram (40) of the joining tool (10) enables the disk (12) that has an axial run-out to be pressed onto the shaft (14) in a correspondingly sloped manner, with the result that a rotor shaft (16) with a satisfactory bond is made possible.

Abstract: A rotor (1) with a rotation axis (2) is provided for an electric drive machine (3). The rotor (1) has a plurality of rotor assemblies (4), each of which has a plurality of laminated cores (5) and a number of magnets (7) corresponding to a pole pair arrangement (6). The rotor also has a rotor shaft (8) on which the rotor assemblies (4) are fixed. The rotor assemblies (4) are positioned on the rotor shaft (8) such that they are rectified in accordance with their axial runout (9), while taking into account the pole pair arrangement (6). The rotor can reduce a thermally induced change in imbalance.

Abstract: A laminated core (10) is provided for a stator or rotor of an electric machine. The laminated core (10) is formed from multiple laminations (12) that are stacked one on top of another in an axial direction (14) to form a lamination stack (16). A through-opening (18) is formed in the lamination stack (16) and extends parallel to the axial direction (14). A tie rod (20) of plastic is introduced, in particular injection molded, in the through-opening (18) to assemble the laminated core (10).

Abstract: A method is provided for producing a stator arrangement that has a stator core and a winding arrangement. The stator core has stator slots. The winding arrangement has winding elements with a conductor and an insulation layer. Each winding element has two interconnected winding element legs with two winding element end portions on each winding element leg. The method includes positioning the winding elements on the stator core so that the winding element legs extend through one of the stator slots with winding element end portions protruding on a first side of the stator core. The method then includes using a first laser arrangement to remove the insulation layer from regions of the winding element end portions. The method then includes pressing the first and second winding element end portions against one another and using a second laser arrangement to carry out welding.

Abstract: A rotor device (1) for an electric machine (10) has a rotatably supported shaft (2) and a rotor hub (3) connected to the shaft (2) in a rotationally fixed manner. The shaft (2) has multiple radially outwardly facing shaft protrusions (12), and the rotor hub (3) has multiple radially inwardly facing hub protrusions (13). A shaft protrusion (12) and a respective hub protrusion (13) abut one another in a touching manner in the radial direction at least in sections. Cavities (4) are formed between the rotor hub (3) and the shaft (2). The cavities (4) extend between adjacent shaft protrusions (12) and the hub protrusions (13) lying thereon. The cavities (4) are grouted with a material (14). The material (14) forms form-fit elements (24) that block relative movement of the rotor hub (3) and the shaft (2) in a form-fit manner.

Abstract: A rotor (1) of an electric motor (20) has a rotor body (21) with a rotor shaft receptacle opening (22) for receiving a rotor shaft (3), and a rotor sheath (23) is on the rotor body (21) outward of the rotor shaft receptacle opening (22). Magnetic field-inducing components (10) are arranged in the rotor body (21). The rotor body (21) further has first and second end faces (14, 18) facing away from one another. The rotor (1) also includes a cooling device (4) with a supply channel (5), a drainage channel (6) and cooling channels (11) formed in the rotor body (21) between the rotor shaft receptacle opening (22) and the rotor sheath (23). The cooling channels (11) are arranged adjacent to the magnetic field-inducing components (10). A method for manufacturing a rotor having a cooling device also is provided.

Abstract: A method is provided for manufacturing a rotor (1) of an electric motor. The rotor (1) has a rotor shaft (2), inner sheet metal packets (4), outer sheet metal packets (4), buried magnets (5) arranged in the assembled state between the inner sheet metal packets (3) and the outer sheet metal packets (4), and surface magnets (6) arranged in the assembled state on the outer sheet metal packets (4). The method includes pushing the inner sheet metal packets (3) onto the rotor shaft (2) to achieve alignment rectangularly and coaxially. The rotor (1) is constructed by placing the buried magnets (5) and the outer sheet metal packets (4) on the inner sheet metal packets (3) and the surface magnets (6) on the outer sheet metal packets (4). A total run-out of the rotor (1) thus is set to a predetermined acceptable amount.

Abstract: A method for producing a rotor device, including providing a rotor shaft having at least one sheet metal packet joined to the rotor shaft. The at least one sheet metal packet includes magnetic units. The method includes performing a transfer molding process, in which the magnetic units are fixed in position in relation to the at least one sheet metal packet and at least one balancing disk is joined axially on the rotor shaft on at least one side of the at least one sheet metal packet such that a gap of a defined width is ensured between the at least one balancing disk and the at least one sheet metal packet. The gap is filled with a molding compound used for the transfer molding process. The method includes determining an imbalance of the rotor device and compensating the imbalance by removing material from the at least one balancing disk.

Abstract: A rotor (1) with a rotation axis (2) is provided for an electric drive machine (3). The rotor (1) has a plurality of rotor assemblies (4), each of which has a plurality of laminated cores (5) and a number of magnets (7) corresponding to a pole pair arrangement (6). The rotor also has a rotor shaft (8) on which the rotor assemblies (4) are fixed. The rotor assemblies (4) are positioned on the rotor shaft (8) such that they are rectified in accordance with their axial runout (9), while taking into account the pole pair arrangement (6). The rotor can reduce a thermally induced change in imbalance.

Abstract: A joining tool (10) is provided for pressing a disk (12) to a shaft (14) that has opposite first and second ends. The first end (18) of the shaft (14) is received in a press table (22) and the second end (24) of the shaft (14) is received in a centering receptacle (26). A press plate (34) axially presses the disk (12) onto the shaft (14). A resilient ram (40) is provided on a side of the press plate (34) that faces toward the disk (12) and compensates for an axial run-out of the disk (12) relative to the press plate (34). The resilient ram (40) of the joining tool (10) enables the disk (12) that has an axial run-out to be pressed onto the shaft (14) in a correspondingly sloped manner, with the result that a rotor shaft (16) with a satisfactory bond is made possible.

Abstract: A laminated core (10) is provided for a stator or rotor of an electric machine. The laminated core (10) is formed from multiple laminations (12) that are stacked one on top of another in an axial direction (14) to form a lamination stack (16). A through-opening (18) is formed in the lamination stack (16) and extends parallel to the axial direction (14). A tie rod (20) of plastic is introduced, in particular injection molded, in the through-opening (18) to assemble the laminated core (10).

Abstract: A method is provided for producing a stator arrangement that has a stator core and a winding arrangement. The stator core has stator slots. The winding arrangement has winding elements with a conductor and an insulation layer. Each winding element has two interconnected winding element legs with two winding element end portions on each winding element leg. The method includes positioning the winding elements on the stator core so that the winding element legs extend through one of the stator slots with winding element end portions protruding on a first side of the stator core. The method then includes using a first laser arrangement to remove the insulation layer from regions of the winding element end portions. The method then includes pressing the first and second winding element end portions against one another and using a second laser arrangement to carry out welding.

Abstract: A rotor (10) of an electric machine has a shaft (11) a laminated core (12) arranged on the shaft (11) and balancing bodies (13) arranged on the shaft (11). The balancing bodies (13) have an aperture (15) situated outside the center of gravity. Each balancing body (13) is mounted by way of the aperture (15) on the shaft (11) of the rotor (10) in a defined angular position. Positioning sleeves (20) are arranged on the shaft (11) to define a distance between bearings (16, 17) of the shaft (11) and the laminated core (12) or the balancing bodies (13) and to provide an anti-rotational safeguard for the balancing bodies (13).

Abstract: A method is provided for balancing rotors (10) of electrical machines. Each rotor (10) has a shaft (11) and at least one laminated core (12) is arranged on the shaft. The method includes providing blanks (13) with a length (l) that is smaller than an outside diameter (d) of the laminated core (12) of the rotor (10). A magnitude and orientation of an initial unbalance of the rotor (10) then is ascertained. A recess (15) then is made in each blank (13) spaced from the center of gravity by a distance depending on the magnitude of the ascertained initial unbalance. The blank (13) is mounted by fitting the recess (15) on the shaft (11) of the rotor (10) and mounting the processed blank (13) on the rotor (11) in an angular position that is dependent on the orientation of the ascertained initial unbalance.

Abstract: A rotor (10) of an electric machine has a shaft (11) a laminated core (12) arranged on the shaft (11) and balancing bodies (13) arranged on the shaft (11). The balancing bodies (13) have an aperture (15) situated outside the center of gravity. Each balancing body (13) is mounted by way of the aperture (15) on the shaft (11) of the rotor (10) in a defined angular position. Positioning sleeves (20) are arranged on the shaft (11) to define a distance between bearings (16, 17) of the shaft (11) and the laminated core (12) or the balancing bodies (13) and to provide an anti-rotational safeguard for the balancing bodies (13).

Abstract: A method for balancing rotors (10) of electrical machines, where each rotor (10) has a shaft (11) and at least one laminated core (12) arranged on the shaft. The method includes providing a rotor (10) that is to be balanced, providing blanks (13), with a length (l) that is smaller than an outside diameter (d) of the laminated core (12) of the rotor (10), ascertaining a magnitude and orientation of an initial unbalance of the rotor (10) and processing the blanks (13) by making a recess (15) in the respective blank (13) outside the center of gravity depending on the magnitude of the ascertained initial unbalance. The blank (13) can be mounted by fitting the recess (15) on the shaft (11) of the rotor (10) and mounting the processed blank (13) on the rotor (11) in an angular position that is dependent on the orientation of the ascertained initial unbalance.