Electric direct-current motor with flexible rotor assembly and method for the manufacture thereof

A method for manufacturing an electric direct current motor comprising:

• a shaft;
• a winding support;
• a printed circuit board;
• a collector with several collector wires;
• and
• an air-cored outer rotor winding with several winding terminations, wherein the outer rotor winding is connected at one end to the shaft via the winding support in a torque-proof manner, and the outer rotor winding is electrically connected to the collector, and wherein the printed circuit board is a winding bearing component of glass-fiber reinforced thermosetting plastics, is configured with at least one layer, and is connected with the shaft via a metal hub,
• wherein for assembling the rotor, the method comprises:
• pressing first the printed circuit board with the metal hub onto the shaft;
• subsequently welding the metal hub and the shaft to each other;
• placing the collector with the collector wires as a separate unit onto the shaft;
• electrically connecting the collector wires to a pertaining winding termination via respective suited contact surfaces after the outer rotor winding has been placed;
• and
• subsequently casting electrical and mechanical connection points with a casting compound.

An electric direct current motor comprising:

• a shaft;
• a winding support;
• a collector with several collector wires;
• and
• an air-cored outer rotor winding with several winding terminations, wherein the outer rotor winding is at one end connected to the shaft via the winding support in a torque-proof manner, and the outer rotor winding is electrically connected to the collector;
• wherein the winding support is a metallic plate having a central bore for connection with the shaft;
• and wherein an insulation ring of plastics or ceramics is provided at an outer periphery of the metallic plate for electric insulation from the outer rotor winding.

A method for manufacturing an electric direct current motor comprising:

• a shaft;
• a winding support;
• a collector with several collector wires;
• and
• an air-cored outer rotor winding with several winding terminations, wherein the outer rotor winding is at one end connected to the shaft via the winding support in a torque-proof manner, and the outer rotor winding is electrically connected to the collector;
• an air-cored outer rotor winding with several winding terminations, wherein the outer rotor winding is at one end connected to the shaft via the winding support in a torque-proof manner, and the outer rotor winding is electrically connected to the collector;
• wherein the winding support is a metallic plate having a central bore for connection with the shaft;
• and wherein an insulation ring of plastics or ceramics is provided at an outer periphery of the metallic plate for electric insulation from the outer rotor winding;
• wherein for assembling the rotor, the method comprises:
• pressing the metallic plate onto the shaft;
• subsequently welding the metallic plate and the shaft to each other, in one of the following steps wherein:
• the collector with the collector wires is placed as a separate unit onto the shaft, the collector wires are electrically connected to a pertaining winding termination via respective suited contact surfaces after the outer rotor winding has been placed, and then the electrical and mechanical connection points are cast with a casting compound.