CN117063379A - Method for manufacturing rotor for IPM motor and rotor for IPM motor - Google Patents
Method for manufacturing rotor for IPM motor and rotor for IPM motor Download PDFInfo
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- CN117063379A CN117063379A CN202280024297.8A CN202280024297A CN117063379A CN 117063379 A CN117063379 A CN 117063379A CN 202280024297 A CN202280024297 A CN 202280024297A CN 117063379 A CN117063379 A CN 117063379A
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- formed steel
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 35
- 238000000034 method Methods 0.000 title claims abstract description 35
- 229910000831 Steel Inorganic materials 0.000 claims abstract description 139
- 239000010959 steel Substances 0.000 claims abstract description 139
- 238000003780 insertion Methods 0.000 claims abstract description 36
- 230000037431 insertion Effects 0.000 claims abstract description 36
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical group [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims abstract description 11
- 238000004080 punching Methods 0.000 claims description 20
- 230000035515 penetration Effects 0.000 claims 1
- 230000002093 peripheral effect Effects 0.000 description 7
- 239000000463 material Substances 0.000 description 4
- 239000000470 constituent Substances 0.000 description 3
- 238000005520 cutting process Methods 0.000 description 3
- 230000004907 flux Effects 0.000 description 3
- 229910001224 Grain-oriented electrical steel Inorganic materials 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 230000014509 gene expression Effects 0.000 description 2
- 238000010030 laminating Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 1
- 238000003475 lamination Methods 0.000 description 1
- 230000000149 penetrating effect Effects 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 238000003672 processing method Methods 0.000 description 1
- 238000010008 shearing Methods 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
Classifications
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K1/00—Details of the magnetic circuit
- H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
- H02K1/22—Rotating parts of the magnetic circuit
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K1/00—Details of the magnetic circuit
- H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
- H02K1/22—Rotating parts of the magnetic circuit
- H02K1/27—Rotor cores with permanent magnets
- H02K1/2706—Inner rotors
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/02—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
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- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Manufacture Of Motors, Generators (AREA)
- Iron Core Of Rotating Electric Machines (AREA)
Abstract
The present invention provides a method for manufacturing a rotor for an IPM motor, the rotor for an IPM motor comprising: a rotor core having a plurality of disc-shaped rotor core plates stacked in a thickness direction and a plurality of rotor magnet insertion holes capable of accommodating rotor magnets; and a rotor magnet inserted into the rotor magnet insertion hole, the manufacturing method including: a blanking step of blanking a steel plate into an outer shape of a formed steel plate and forming a cut-off portion that separates the formed steel plate into a radially inner portion and a radially outer portion; and a through-hole forming step of forming the rotor iron core plate by moving the radially outer portion radially outward relative to the radially inner portion in the formed steel plate and forming a through-hole constituting a part of the rotor magnet insertion hole between the radially outer portion and the radially inner portion.
Description
Technical Field
The present invention relates to a method for manufacturing a rotor for an IPM motor and a rotor for an IPM motor.
Background
As a method of manufacturing a rotor core of an IPM motor, a method of forming a rotor core plate by punching a steel plate into a shape of the rotor core using a punching device or the like, and laminating a plurality of the formed rotor core plates in a thickness direction is known.
As a method for manufacturing the rotor core as described above, for example, a method for manufacturing a laminated rotor core disclosed in patent document 1 is known. The manufacturing method comprises the following steps: a blanking step of blanking a core piece from the grain-oriented electrical steel sheet; and a lamination step of laminating the core pieces in a die while punching the core pieces. In the grain-oriented electrical steel sheet punched in the punching step, permanent magnet mounting holes for housing permanent magnets therein are provided in advance.
Prior art literature
Patent literature
Patent document 1: japanese patent laid-open No. 2008-211948
Disclosure of Invention
Problems to be solved by the invention
However, as disclosed in patent document 1, in the case of punching a steel plate to form a rotor core plate of a rotor for an IPM motor, the steel plate is punched at a portion of a rotor magnet insertion hole as a permanent magnet mounting hole. Therefore, in the rotor core plate, a steel plate is not required at the portion where the rotor magnet insertion hole is formed. However, in the case of punching a steel plate to form a rotor core plate, in order to punch the outer shape of the rotor core plate including the rotor magnet insertion holes, it is necessary to use a steel plate having a size capable of punching the rotor core plate including the rotor magnet insertion holes. Therefore, the reduction in material cost in manufacturing the rotor core plate is limited.
In contrast, it is desirable to reduce the size of the steel plate used for forming the rotor core plate of the rotor for the IPM motor as much as possible and to reduce the material cost for manufacturing the rotor core plate.
The present invention provides a method for manufacturing a rotor for an IPM motor, which can reduce the size of a steel plate used for forming a rotor iron core plate of the rotor for the IPM motor.
Means for solving the problems
A method for manufacturing a rotor for an IPM motor according to an embodiment of the present invention is a method for manufacturing a rotor for an IPM motor, the rotor for an IPM motor including: a rotor core having a plurality of disc-shaped rotor core plates stacked in a thickness direction and a rotor magnet insertion hole capable of accommodating a rotor magnet; and a rotor magnet inserted into the rotor magnet insertion hole. The manufacturing method comprises the following steps: a blanking step of blanking a steel plate with the outer shape of a formed steel plate and forming a cut-off portion separating the formed steel plate into a radially inner portion and a radially outer portion; and a through-hole forming step of forming the rotor iron core plate by moving the radially outer portion radially outward relative to the radially inner portion in the formed steel plate and forming a through-hole constituting a part of the rotor magnet insertion hole between the radially outer portion and the radially inner portion.
The rotor for an IPM motor according to an embodiment of the present invention includes: a rotor core having a plurality of disc-shaped rotor core plates stacked in a thickness direction and a plurality of rotor magnet insertion holes capable of accommodating rotor magnets; and a rotor magnet inserted into the rotor magnet insertion hole. The rotor iron core plate has: a radially inner portion located radially inward of a through hole constituting a part of the rotor magnet insertion hole; a radially outer portion located radially outward of the through hole; and a connecting portion connecting the radially inner portion and the radially outer portion. The connecting portion has a plastic deformation portion that generates plastic deformation in a circumferential direction of the rotor core plate.
ADVANTAGEOUS EFFECTS OF INVENTION
According to the method for manufacturing the IPM motor rotor according to one embodiment of the present invention, the size of the steel plate used for forming the rotor iron core plate of the IPM motor rotor can be reduced.
Drawings
Fig. 1 is a view showing a schematic configuration of a motor according to an embodiment in a cross section including a central axis.
Fig. 2 is a perspective view showing a schematic structure of the rotor core.
Fig. 3 is a plan view showing a schematic structure of a rotor core plate.
Fig. 4 is an enlarged view of a part of the rotor core plate.
Fig. 5 is a flowchart illustrating a method of manufacturing a rotor core plate.
Fig. 6 is a plan view showing a schematic structure of a formed steel sheet.
Fig. 7 is an enlarged view of a part of the formed steel sheet.
Fig. 8A is a view schematically showing a case where the radially outer side portion of the formed steel sheet is moved radially outward.
Fig. 8B is a view schematically showing a case where the radially outer side portion of the formed steel sheet is moved radially outward.
Fig. 9A is a schematic diagram for explaining the push-back process.
Fig. 9B is a schematic diagram for explaining the push-back process.
Detailed Description
Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings. The same or corresponding portions in the drawings are denoted by the same reference numerals, and the description thereof will not be repeated. The dimensions of the constituent members in each drawing do not faithfully show the actual dimensions of the constituent members, the ratio of the dimensions of the constituent members, and the like.
In the following description, a direction parallel to the central axis P of the rotor 2 is referred to as an "axial direction", a direction orthogonal to the central axis P is referred to as a "radial direction", and a direction along an arc centered on the central axis P is referred to as a "circumferential direction". However, the direction of the motor 1 according to the present invention in use is not intended to be limited by the definition of the direction.
In the following description, the expressions "fixed", "connected" and "attached" include not only the case where the components are directly fixed to each other but also the case where the components are fixed via other components. That is, in the following description, the expression fixing and the like includes direct and indirect fixing and the like of the members to each other.
(Structure of Motor)
Fig. 1 is a view showing a schematic configuration of a motor 1 according to an exemplary embodiment of the present invention in a cross section including a central axis P. The motor 1 includes a rotor 2, a stator 3, and a housing 4. The rotor 2 rotates around a central axis P with respect to the stator 3. In the present embodiment, the motor 1 is a so-called inner rotor type motor in which a rotor 2 is rotatably disposed about a central axis P in a cylindrical stator 3.
The stator 3 is housed in the housing 4. In the present embodiment, the stator 3 is cylindrical, and the rotor 2 is disposed radially inward. That is, the stator 3 is disposed to face the rotor 2 in the radial direction.
The stator 3 includes a stator core 31 and a stator coil 32. The stator 3 has the same structure as the conventional one. Therefore, a detailed description of the stator 3 is omitted.
The rotor 2 includes a shaft 20, a rotor core 21, and rotor magnets 22. The rotor 2 is disposed radially inward of the stator 3 and rotatable relative to the stator 3.
Fig. 2 is a perspective view showing a schematic structure of the rotor core 21. As shown in fig. 2, the rotor core 21 has a cylindrical shape extending along the central axis P. The rotor core 21 is configured by stacking a plurality of rotor core plates 50 in the thickness direction, and the rotor core plates 50 are formed by punching electromagnetic steel plates into a predetermined shape.
The shaft 20 extending along the central axis P is fixed to the rotor core 21 in a state of penetrating in the axial direction. Thereby, the rotor core 21 rotates together with the shaft 20. In the present embodiment, the rotor core 21 has a rotor magnet insertion hole 21a through which the rotor magnet 22 is inserted in the axial direction. As described above, the motor 1 of the present embodiment is an IPM motor in which the rotor magnet 22 is positioned in the rotor magnet insertion hole 21a of the rotor core 21.
The rotor core 21 has a rotor core radially inner portion 21b which is a portion radially inward of the rotor magnet insertion hole 21a, and a rotor core radially outer portion 21c which is a portion radially inward of the rotor magnet insertion hole 21a. The shaft 20 penetrates the rotor core radially inner portion 21b in the axial direction. When the rotor core 21 is viewed in the axial direction, the outer peripheral side of the rotor core radially outer portion 21c is arcuate.
Fig. 3 is a plan view showing a schematic structure of the rotor core plate 50. Fig. 4 is an enlarged view of a part of the rotor core plate 50.
As shown in fig. 3, the rotor core plate 50 has a disk shape. The rotor core plate 50 has a through hole 51, a radially inner portion 52, a radially outer portion 53, and a connecting portion 55. The through hole 51 constitutes a part of the rotor magnet insertion hole 21a of the rotor core 21. The radially inner portion 52 constitutes a part of the rotor core radially inner portion 21b. The radially outer portion 53 constitutes a part of the rotor core radially outer portion 21c.
The through hole 51 is a polygon extending along the chord of the disk-shaped rotor core plate 50. In the present embodiment, the through-hole 51 has a hexagonal shape having three corners at both ends in the longitudinal direction. The long side portion of the through hole 51 is constituted by a radially inner portion 52 and a radially outer portion 53.
The radially inner portion 52 is located radially inward of the through-holes 51 in the rotor core plate 50. The radially outer portion 53 is located radially outward of the through-holes 51 in the rotor core plate 50.
The connecting portion 55 is located between the radially inner portion 52 and the pair of radially outer portions 53 adjacent in the circumferential direction, and connects the radially inner portion 52 and the pair of radially outer portions 53 adjacent in the circumferential direction. Specifically, the connecting portions 55 connect the ends of a pair of radially outer side portions 53 adjacent in the circumferential direction in the rotor core plate 50 to each other, and connect these ends with the radially inner side portions 52 of the rotor core plate 50.
As shown in fig. 4, the connection portion 55 has an inner connection portion 56 and a pair of outer connection portions 57.
One end of the inner connecting portion 56 is connected to the outer peripheral side of the radially inner portion 52 of the rotor core plate 50, and the other end is connected to one ends of a pair of outer connecting portions 57. The inner connecting portion 56 extends radially outward from the outer peripheral side of the radially inner portion 52 of the rotor core plate 50.
One end of each outer connecting portion 57 is connected to the other end of the inner connecting portion 56, and the other end is connected to the radially outer portion 53 of the rotor core plate 50. Each outer connecting portion 57 extends in the circumferential direction from the other end of the inner connecting portion 56.
With the above configuration, the connecting portion 55 is formed in a Y-shape, and connects the radially inner side portion 52 of the rotor core plate 50 with the pair of radially outer side portions 53 adjacent in the circumferential direction in the rotor core plate 50.
The connecting portion 55 having the above-described structure constitutes an end portion of the through hole 51 in the longitudinal direction. Therefore, the magnetic flux generated by the rotor magnet 22 located in the through hole 51 flows through the connection portion 55.
Each of the outer connecting portions 57 has a first connecting portion 57a at one end connected to the other end of the inner connecting portion 56, and a second connecting portion 57b at the other end connected to the radially outer portion 53 of the rotor core plate 50. The first connecting portion 57a and the second connecting portion 57b are thinner than other portions of the outer connecting portion 57. That is, the connection portion with the radially outer side portion 53 in the outer side connection portion 57 and the connection portion with the inner side connection portion 56 in the outer side connection portion 57 are thinner than the other portions of the outer side connection portion 57, respectively.
The first connecting portion 57a and the second connecting portion 57b have marks where plastic deformation occurs in the circumferential direction. That is, the pair of outer connecting portions 57 has a plastic deformation portion that generates plastic deformation in the circumferential direction. The first connection portion 57a and the second connection portion 57b are the plastic deformation portions.
Further, the radially inner side portion 52 of the rotor core plate 50 has a convex portion 52a at a portion to which the inner connecting portion 56 is connected. The protruding portion 52a forms a part of the longitudinal end of the through hole 51. By the protruding portion 52a, the rotor magnet 22 is positioned in the rotor magnet insertion hole 21a in the longitudinal direction of the rotor magnet insertion hole 21a.
(method for manufacturing rotor iron core plate)
Next, a method of manufacturing the rotor core plate 50 having the above-described structure will be described with reference to fig. 5 to 9B. Fig. 5 is a flowchart showing a method of manufacturing the rotor core plate 50. Fig. 6 is a plan view showing a schematic structure of the formed steel sheet 60. Fig. 7 is an enlarged plan view showing a part of the formed steel sheet 60 in an enlarged manner. Fig. 8A and 8B schematically show a case where the radially outer portion 53 of the formed steel sheet 60 is moved radially outward. Fig. 9A and 9B are schematic views for explaining the push-back process.
First, as shown in step S1 of the flowchart of fig. 5, a disk-shaped formed steel sheet 60 shown in fig. 6 is punched out from the steel sheet, and a cut portion 65 is formed in the formed steel sheet 60.
Specifically, the outer shape of the formed steel sheet 60 and the through holes 60a and 60b are formed by punching, while the cut-off portion 65 located on the outer peripheral side of the formed steel sheet 60 is formed by pushing back. The process is a blanking process. The cutting portion 65 by the push-back processing may be processed before or after the blanking processing of the formed steel sheet 60.
Specifically, when the outer shape of the shaped steel sheet 60 and the through holes 60a and 60b are punched, as shown in fig. 6, a plurality of circular arc portions 61 are formed at equal intervals in the circumferential direction on the outer circumferential side of the shaped steel sheet 60, and protruding portions 62 protruding radially outward are formed between circumferentially adjacent circular arc portions 61. That is, the formed steel sheet 60 has a plurality of circular arc portions 61 and a plurality of protruding portions 62. In the formed steel sheet 60, the circular arc portions 61 and the protruding portions 62 are alternately arranged in the circumferential direction.
As shown in fig. 6 and 7, the protruding portion 62 has a pair of openings 63, an outer deformed portion 64, and an inner connecting portion 56. The outer deformed portion 64 is located radially outward of the formed steel plate 60 in the protruding portion 62, and has an arch shape connecting the circular arc portions 61 adjacent in the circumferential direction. The inner connecting portion 56 connects the outer deforming portion 64 and the base end portion of the protruding portion 62 in the radial direction of the formed steel plate 60. The outer deforming portion 64 and the inner connecting portion 56 form a pair of openings 63.
As shown in fig. 7, the pair of opening portions 63 includes a hole portion 63a located at a connecting portion between the outer deformed portion 64 and the circular arc portion 61. Thus, the connecting portion between the outer deformed portion 64 and the arcuate portion 61 is thinner than the other portions of the outer deformed portion 64.
The hole 63a is located at a position overlapping with a cut portion 65 described later when the formed steel sheet 60 is viewed in plan. Specifically, when the formed steel sheet 60 is viewed in plan, the hole 63a is located at a position overlapping both end portions of the cut portion 65 in the circumferential direction of the formed steel sheet 60. Specifically, in the case of the shaped steel sheet 60 in plan view, the hole 63a is formed in the shaped steel sheet 60 in the vicinity of the connecting portion with the radially outer portion 53 in the outer deformed portion 64 and at a position overlapping both end portions of the cut portion 65 in the circumferential direction of the shaped steel sheet 60. In the formed steel sheet 60, the vicinity of the connecting portion with the radially outer side portion 53 in the outer side deformed portion 64 is a position where the rigidity of the connecting portion is lowered due to the hole portion 63a. In addition, the hole 63a may be formed at a position overlapping one end of the cut portion 65 in the circumferential direction of the formed steel sheet 60 when the formed steel sheet 60 is viewed from above.
The outer deformed portion 64 has a notch portion 64a in the vicinity of the connecting portion with the inner connecting portion 56 and radially outside the formed steel plate 60 in the outer deformed portion 64. Thus, in the outer deformed portion 64, the portion where the cutout portion 64a is provided is thinner than the other portions of the outer deformed portion 64.
The cutting portion 65 is located on the outer peripheral side of the formed steel plate 60 and is linear extending along the chord of the formed steel plate 60. The cut-off portion 65 is formed by push-back processing, thereby separating the radially inner portion 52 from the radially outer portion 53. As described later, the radially outer portion 53 is separated radially from the radially inner portion 52, whereby the cut portion 65 serves as the through-hole 51 of the rotor core plate 50.
The push-back processing will be described with reference to fig. 9A and 9B. As shown in fig. 9A and 9B, the push-back processing is performed using a first tool W1 having a pair of upper and lower tools that sandwich a part of the steel sheet X in the thickness direction, and a second tool W2 having a pair of upper and lower tools that sandwich a part of the steel sheet X in the thickness direction. The first tool W1 is movable in the thickness direction of the steel sheet X with respect to the second tool W2.
In the present embodiment, one of the first tool W1 and the second tool W2 has the same shape as a part of the outer peripheral side of the radially inner portion 52, and the other of the first tool W1 and the second tool W2 has the same shape as a part of the inner peripheral side of the radially outer portion 53.
As shown in fig. 9A, the first tool W1 moves to one side in the thickness direction of the steel sheet X with respect to the second tool W2, and thereby shearing is performed at the boundary between the portion clamped by the first tool W1 and the portion clamped by the second tool W2 in the steel sheet X. The movement distance of the first tool W1 with respect to the second tool W2 may be a movement distance for separating the steel plates X, or may be a movement distance for not separating the steel plates X.
Then, as shown in fig. 9B, the first tool W1 is returned to the original position by moving the first tool W1 to the other side in the thickness direction of the steel sheet X with respect to the second tool W2. Thereby, at the boundary, the portion of the steel plate X clamped by the first tool W1 is embedded in the portion clamped by the second tool W2.
In the cut-off portion 65 formed by such push-back processing, the radially inner portion 52 and the radially outer portion 53 are held by friction with each other.
In the punching step, after a part of the steel sheet X is punched in the thickness direction, the cut portion 65 is formed by a push-back process for returning the punched part to the original position of the steel sheet X. In this way, the cut portion 65 can be formed in the formed steel sheet 60, and when the formed steel sheet 60 is punched out and held in the die, the radially outer portion 53 of the formed steel sheet 60 can be restrained from being deformed radially inward, so that the formed steel sheet 60 can be held in the die.
That is, when the cut portion of the formed steel sheet is formed by punching, the radially outer portion and the radially inner portion are separated, and the outer shape of the formed steel sheet is easily changed, so that it is difficult to hold the formed steel sheet in the die. In contrast, by forming the cut portion 65 by the push-back processing as described above, the outer shape of the formed steel sheet 60 does not change, and therefore, a plurality of formed steel sheets 60 can be held in the mold. Accordingly, a plurality of formed steel plates 60 can be stacked in the mold.
Next, as shown in step S2 of the flowchart of fig. 5, in the formed steel sheet 60 formed as described above, the radially outer portion 53 located radially outward of the cut portion 65 is moved radially outward. The step is a through-hole forming step.
Specifically, as shown in fig. 8A and 8B, the pin T is inserted into the hole 63a included in the opening 63 of the protrusion 62 of the formed steel plate 60, and the pin T is moved radially outward, whereby the radially outer portion 53 is moved radially outward relative to the radially inner portion 52. In fig. 8A and 8B, the moving direction of the pin T is shown by solid arrows.
As described above, by moving the pin T in the insertion hole 63a radially outward and moving the radially outer portion 53 radially outward relative to the radially inner portion 52, the outer deformed portion 64 of the protruding portion 62 rotates radially outward about the connecting portion with the inner connecting portion 56. Thus, the outer deformed portion 64 becomes a pair of outer connecting portions 57 extending in the circumferential direction in the rotor core plate 50.
That is, in the through-hole forming step, the outer deformation portion 64 is deformed by the radially outward movement of the radially outer portion 53. As described above, the outer deformed portion 64 deforms by the radially outward movement of the radially outer portion 53, and thus, the magnetic flux is less likely to flow to the pair of outer connecting portions 57 in the rotor core plate 50. Therefore, leakage of magnetic flux in the rotor core 21 can be reduced.
In a plan view of the formed steel sheet 60, the hole 63a into which the pin T is inserted is located at a position overlapping the cut portion 65 in the formed steel sheet 60. That is, in the punching step, the hole 63a is formed in the formed steel sheet 60 at a position overlapping the cut portion 65 when the formed steel sheet 60 is viewed in plan. In the through-hole forming step, the pin T inserted into the hole 63a is moved radially outward, so that the radially outer portion 53 of the formed steel plate 60 is moved radially outward.
Thereby, the pin T can be positioned at the cut-off portion 65 located between the radially outer portion 53 and the radially inner portion 52 of the formed steel plate 60. Therefore, the radially outer portion 53 of the formed steel plate 60 can be easily moved radially outward relative to the radially inner portion 52 using the pin T.
In a plan view of the formed steel sheet 60, the hole 63a into which the pin T is inserted is located at a position overlapping with the end of the cut portion 65 in the circumferential direction of the formed steel sheet 60. That is, in the punching step, the hole 63a is formed in the circumferential direction of the formed steel sheet 60 at a position overlapping with the end of the cut portion 65 when the formed steel sheet 60 is viewed in plan. Thereby, the circumferential end of the radially outer portion 53 of the formed steel plate 60 can be moved radially outward by the pin T. Therefore, the radially outer portion 53 of the formed steel sheet 60 can be moved radially outward more reliably.
In the present embodiment, in a plan view of the formed steel sheet 60, the hole 63a is located at a position overlapping both end portions of the cut portion 65 in the circumferential direction of the formed steel sheet 60, and the radially outer portion 53 is moved radially outward relative to the radially inner portion 52 in a state where the pins T are inserted into the hole 63a. As a result, since a force for moving the radially outer portion 53 radially outward can be applied to the circumferential both ends of the radially outer portion 53, the outer deformation portions 64 connected to the circumferential both ends of the radially outer portion 53 can be deformed. Therefore, the radially outer portion 53 can be easily moved radially outward.
As described above, the outer deformed portion 64 has the notch portion 64a in the vicinity of the connecting portion with the inner connecting portion 56 and radially outside the formed steel plate 60 in the outer deformed portion 64. The opening 63 has a hole 63a, and thus the connection portion between the outer deformed portion 64 and the arcuate portion 61 is thinner than the other portions of the outer deformed portion 64.
That is, in the blanking process, the portion of the outer deformed portion 64 connected to the radially outer portion 53 and the portion of the outer deformed portion 64 connected to the inner connecting portion 56 are formed to be thinner than the other portions of the outer deformed portion 64. As a result, when the radially outer portion 53 is moved radially outward relative to the radially inner portion 52 in the formed steel sheet 60 as described above, the outer deformed portion 64 is likely to be deformed at the connecting portion with the radially outer portion 53 and the connecting portion with the inner connecting portion 56. Therefore, the radially outer portion 53 can be easily moved radially outward relative to the radially inner portion 52.
By the deformation of the outer deforming portion 64 as described above, the portion of the outer deforming portion 64 where the cutout portion 64a is located becomes the first connecting portion 57a of the pair of outer connecting portions 57 obtained by deforming the outer deforming portion 64. In the outer deforming portion 64, a connecting portion between the outer deforming portion 64 and the arcuate portion 61 is a second connecting portion 57b of the pair of outer connecting portions 57 obtained by deforming the outer deforming portion 64.
In the outer deformed portion 64 deformed as described above, plastic deformation occurs in the circumferential direction at the portion where the cutout portion 64a is located and at the connecting portion between the outer deformed portion 64 and the circular arc portion 61. That is, the first connecting portion 57a and the second connecting portion 57b of the pair of outer connecting portions 57 obtained by deforming the outer deforming portion 64 have marks that cause plastic deformation in the circumferential direction. The first connection portion 57a and the second connection portion 57b are plastic deformation portions of the present invention.
As described above, by moving the pin T radially outward in a state of being inserted into the hole 63a, the radially outer portion 53 is separated by the cutout portion 65 outward from the radially inner portion 52. Thus, a through hole 51 is formed between the radially outer portion 53 and the radially inner portion 52.
The through-hole forming step of moving the radially outer portion 53 radially outward relative to the radially inner portion 52 in the formed steel sheet 60 may be performed on one formed steel sheet 60 or may be performed on a plurality of formed steel sheets 60 stacked in the thickness direction.
The method for manufacturing the rotor iron core plate 50 of the present embodiment is a method for manufacturing a rotor for an IPM motor, the rotor for an IPM motor including: a rotor core 21 having a plurality of disc-shaped rotor core plates 50 stacked in the thickness direction and rotor magnet insertion holes 21a capable of accommodating the rotor magnets 22; and a rotor magnet 22 inserted into the rotor magnet insertion hole 21a. The manufacturing method comprises the following steps: a punching step of punching an outer shape of a disk-shaped formed steel sheet 60 from the steel sheet X and forming a cut portion 65 separating the formed steel sheet 60 into a radially inner portion 52 and a radially outer portion 53; and a through-hole forming step of forming the rotor iron core plate 50 by moving the radially outer portion 53 radially outward relative to the radially inner portion 52 in the formed steel plate 60, and forming the through-hole 51 constituting a part of the rotor magnet insertion hole 21a between the radially outer portion 53 and the radially inner portion 52.
Accordingly, when the rotor core plate 50 is formed of a steel plate, it is not necessary to punch a through hole constituting a part of the rotor magnet insertion hole in the rotor core, and therefore the area of the punched steel plate can be reduced accordingly. Therefore, the material cost of the rotor core plate 50 can be reduced.
The cut portion 65 extends along the chord of the formed steel plate 60. As a result, as will be described later, when the radially outer portion 53 is moved radially outward relative to the radially inner portion 52, the radially outer portion 53 can be easily moved radially outward relative to the radially inner portion 52. Accordingly, the formed steel sheet 60 can be deformed to easily obtain the rotor core plate 50.
In the blanking process, the inner connecting portion 56 and the outer deformed portion 64 of the outer connecting portion 57 serving as the connecting portion 55 are formed as part of the protruding portion 62 on the formed steel sheet 60. That is, in the blanking step, the inner connecting portion 56 connected to the radially inner portion 52 and the outer deformed portion 64 connecting the inner connecting portion 56 and the radially outer portion 53 of the formed steel sheet 60 are formed on the formed steel sheet 60.
Thus, the radially outer portion 53 can be moved radially outward in a state where the radially outer portion 53 is connected to the radially inner portion 52 by the inner connecting portion 56 and the outer deforming portion 64. Therefore, the radially outer portion 53 can be prevented from being a member different from the radially inner portion 52. Therefore, since it is not necessary to hold the radially outer portion 53 and the like with respect to the radially inner portion 52, the productivity of the rotor core 21 can be improved.
In the blanking step, in the vicinity of the connecting portion with the radially outer portion 53 in the outer deformed portion 64 and in the circumferential direction of the formed steel sheet 60, a hole 63a is formed at a position overlapping the end of the cut portion 65 when the formed steel sheet 60 is viewed from above. In the through-hole forming step, the pin T inserted into the hole 63a is moved radially outward, so that the radially outer portion 53 of the formed steel plate 60 is moved radially outward.
Thus, the hole 63a can be formed at a position overlapping with the end of the cut-off portion 65 in the circumferential direction, and the connecting portion with the radially outer portion 53 in the outer deformed portion 64 can be thinned. That is, with the above-described configuration, the radially outer portion 53 can be moved radially outward more reliably by the pin T, and the radially outer portion 53 can be moved radially outward more easily because the outer deformed portion 64 is deformed more easily.
The rotor manufactured using the rotor core plate 50 obtained by the above manufacturing method is the rotor 2 having the structure of the present embodiment. Specifically, the rotor 2 has the following structure.
The rotor 2 of the present embodiment is a rotor for an IPM motor, which has a rotor core 21 and rotor magnets 22, the rotor core 21 having a plurality of disc-shaped rotor core plates 50 stacked in the thickness direction and a plurality of rotor magnet insertion holes 21a in which the rotor magnets 22 can be accommodated, the rotor magnets 22 being inserted into the rotor magnet insertion holes 21a. The rotor core plate 50 has: a radially inner portion 52 located radially inward of the through hole 51 constituting a part of the rotor magnet insertion hole 21a; a radially outer portion 53 located radially outward of the through hole 51; and a connecting portion 55 connecting the radially inner portion 52 and the radially outer portion 53. The connection portion 55 has a first connection portion 57a and a second connection portion 57b that are plastically deformed in the circumferential direction of the rotor core plate 50.
After the cut-off portion 65 separated into the radially inner portion 52 and the radially outer portion 53 is provided, the radially outer portion 53 is moved radially outward relative to the radially inner portion 52 to form the rotor core plate 50 constituting the rotor core of the IPM motor rotor. Therefore, the area of the steel plate required for forming the rotor core plate 50 can be reduced. Therefore, the material cost of the rotor core plate 50 can be reduced.
The connection portion 55 includes: an inner connecting portion 56 connected to the radially inner portion 52 of the rotor core plate 50; and an outer connecting portion 57 connecting the inner connecting portion 56 and the radially outer portion 53 of the rotor core plate 50. The connection portion with the radially outer side portion 53 in the outer side connection portion 57 and the connection portion with the inner side connection portion 56 in the outer side connection portion 57 are thinner than the other portions of the outer side connection portion 57, respectively.
As a result, as described later, when the rotor core plate 50 is formed by moving the radially outer portion 53 radially outward relative to the radially inner portion 52, the outer connecting portion 57 can be easily deformed at the connecting portion with the radially outer portion 53 and the connecting portion with the inner connecting portion 56. Therefore, the rotor core plate 50 can be easily obtained.
(other embodiments)
While the embodiments of the present invention have been described above, the above embodiments are merely examples for implementing the present invention. Therefore, the present invention is not limited to the above-described embodiments, and can be implemented by appropriately modifying the above-described embodiments within a range not departing from the gist thereof.
In the above embodiment, in the through-hole forming step, the pin T inserted into the hole 63a of the shaped steel plate 60 is moved radially outward, so that the radially outer portion 53 of the shaped steel plate 60 is moved radially outward with respect to the radially inner portion 52. However, as long as the radially outer portion of the formed steel sheet can be moved radially outward with respect to the radially inner portion, the radially outer portion may be moved radially outward by a method other than the pin.
In the embodiment, the cut portion 65 of the formed steel sheet 60 extends along the chord of the formed steel sheet 60. However, the shape of the cut portion may be any shape as long as the radially outer portion of the formed steel sheet can be separated radially outward from the radially inner portion.
In the above embodiment, in the formed steel sheet 60, the hole 63a is located in the vicinity of the connecting portion with the radially outer portion 53 in the outer deformed portion 64 and is overlapped with the end of the cut portion 65 in the circumferential direction of the formed steel sheet 60 when the formed steel sheet 60 is viewed from above. However, the hole may be located at a position where the radially outer portion can be moved radially outward with respect to the radially inner portion by a pin inserted into the hole, and may be located at a position overlapping the cut portion or at another portion of the formed steel sheet 60 such as the radially outer portion.
In the above embodiment, in the punching step, the connecting portion with the radially outer side portion 53 in the outer side deforming portion 64 and the connecting portion with the inner side connecting portion 56 in the outer side deforming portion 64 are formed to be thinner than the other portions of the outer side deforming portion 64. However, in the pressing step, only one of the connecting portions may be provided with a portion thinner than the other portion of the outer deformed portion, or no portion thinner than the other portion of the outer deformed portion may be provided at the connecting portion. In the outer deformation portion, a portion thinner than the other portion of the outer deformation portion may be provided at a position other than the above-described connecting portion. The method of providing the outer deformed portion with a portion thinner than the other portion of the outer deformed portion may be a method other than punching.
In the embodiment, the connection portion 55 of the rotor core plate 50 has an inner connection portion 56 and an outer connection portion 57. That is, the inner connecting portion 56 connects the outer connecting portion 57 connected to the radially outer portion 53 adjacent in the circumferential direction of the formed steel sheet 60 to the radially inner portion 52. However, the connecting portion may directly connect the radially outer portion and the radially inner portion. The radially outer portion 53 and the radially inner portion 52 may not be connected.
In the embodiment, the cut portion 65 of the formed steel sheet 60 is formed by push-back processing. However, the cut portion may be formed by a processing method other than the push-back processing such as the punching processing.
In the above embodiment, the motor 1 is a so-called inner rotor type motor in which the rotor 2 is rotatably disposed in the cylindrical stator 3 around the central axis P. However, the motor may be a so-called outer rotor type motor in which a cylindrical rotor is arranged radially outside a stator.
Industrial applicability
The present invention is applicable to a method for manufacturing a rotor for an IPM motor having a rotor core including a plurality of disc-shaped rotor core plates stacked in a thickness direction and a rotor magnet insertion hole capable of accommodating a rotor magnet.
Symbol description
1-a motor; 2-a rotor; 3-a stator; 4-a shell; 20-axis; 21-a rotor core; 21 a-rotor magnet insertion holes; 22-rotor magnet; 31-stator core; 32-stator coils; 50-rotor iron core plate; 51-a through hole; 52-radially inner portion; 52 a-a protrusion; 53-radially outer side; 55-a connection; 56-an inboard connection; 57-an outboard connection; 57 a-a first connection; 57 b-a second connection; 60-forming a steel plate; 60a, 60 b-through holes; 61-arc part; 62-a protrusion; 63-an opening; 63 a-a hole portion; 64-an outer deformation; 64 a-a cutout portion; 65-a cutting section; p is a central axis; x-steel plate; w1-a first tool; w2-a second tool; t-pins.
Claims (11)
1. A method for manufacturing a rotor for an IPM motor, the rotor for an IPM motor comprising:
a rotor core having a plurality of disc-shaped rotor core plates stacked in a thickness direction and a rotor magnet insertion hole capable of accommodating a rotor magnet; and
a rotor magnet inserted into the rotor magnet insertion hole,
the method for manufacturing the rotor for the IPM motor is characterized by comprising the following steps:
a blanking step of blanking an outer shape of a disk-shaped formed steel plate from the steel plate and forming a cut portion separating the formed steel plate into a radially inner portion and a radially outer portion; and
and a through-hole forming step of forming the rotor iron core plate by moving the radially outer portion radially outward relative to the radially inner portion in the formed steel plate and forming a through-hole constituting a part of the rotor magnet insertion hole between the radially outer portion and the radially inner portion.
2. The method of manufacturing a rotor for an IPM motor according to claim 1, wherein,
the cut-off portion extends along a chord of the formed steel sheet.
3. The method for manufacturing a rotor for an IPM motor according to claim 1 or 2, wherein,
in the blanking step, a hole is formed in the formed steel plate at a position overlapping the cut portion when the formed steel plate is viewed in plan,
in the through-hole forming step, the pin inserted into the hole is moved radially outward, whereby the radially outer portion of the formed steel sheet is moved radially outward.
4. The method for manufacturing a rotor for an IPM motor according to claim 3, wherein,
in the blanking step, the hole is formed in a position overlapping with an end of the cut portion in a circumferential direction of the formed steel sheet when the formed steel sheet is viewed in plan.
5. The method for manufacturing a rotor for an IPM motor according to any one of claims 1 to 4, wherein,
in the blanking step, an inner connecting portion connected to a radially inner portion and an outer deforming portion connecting the inner connecting portion to a radially outer portion of the shaped steel plate are also formed in the shaped steel plate.
6. The method for manufacturing a rotor for an IPM motor according to claim 5, wherein,
in the through-hole forming step, the outer deformation portion is deformed by movement of the radially outer portion radially outward.
7. The method of manufacturing a rotor for an IPM motor according to claim 6, wherein,
in the blanking step, a hole portion is formed in the formed steel sheet at a position near a connecting portion with the radially outer side portion in the outer side deformation portion and overlapping an end portion of the cut portion in the circumferential direction of the formed steel sheet when the formed steel sheet is viewed in plan,
in the through-hole forming step, the pin inserted into the hole is moved radially outward, whereby the radially outer portion of the formed steel sheet is moved radially outward.
8. The method for manufacturing a rotor for an IPM motor according to claim 6 or 7, wherein,
in the blanking step, a connecting portion with the radially outer side portion of the outer side deforming portion and a connecting portion with the inner side connecting portion of the outer side deforming portion are formed to be thinner than other portions of the outer side deforming portion.
9. The method for manufacturing a rotor for an IPM motor according to any one of claims 1 to 8, wherein,
in the punching step, the cut portion is formed by a push-back process of punching a part of the steel sheet in the thickness direction and then returning the punched part to the original position of the steel sheet.
10. An IPM motor rotor comprising:
a rotor core having a plurality of disc-shaped rotor core plates stacked in a thickness direction and a plurality of rotor magnet insertion holes capable of accommodating rotor magnets; and
a rotor magnet inserted into the rotor magnet insertion hole,
the rotor for an IPM motor is characterized in that,
the rotor iron core plate has:
a radially inner portion that is located radially inward of a penetration hole that forms a part of the rotor magnet insertion hole;
a radially outer portion located radially outward of the through hole; and
a connecting portion connecting the radially inner portion and the radially outer portion,
the connecting portion has a plastic deformation portion that generates plastic deformation in a circumferential direction of the rotor core plate.
11. The rotor for an IPM motor according to claim 10, wherein,
the connection part has:
an inner connecting portion connected to a radially inner portion of the rotor core plate; and
an outer connecting portion connecting the inner connecting portion and a radially outer portion of the rotor core plate,
the connecting portions of the outer connecting portions with the radially outer side portions and the connecting portions of the outer connecting portions with the inner side connecting portions are respectively thinner than other portions of the outer connecting portions.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2021-061503 | 2021-03-31 | ||
| JP2021061503 | 2021-03-31 | ||
| PCT/JP2022/003784 WO2022209252A1 (en) | 2021-03-31 | 2022-02-01 | Method for manufacturing rotor for ipm motor and rotor for ipm motor |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN117063379A true CN117063379A (en) | 2023-11-14 |
Family
ID=83458682
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202280024297.8A Pending CN117063379A (en) | 2021-03-31 | 2022-02-01 | Method for manufacturing rotor for IPM motor and rotor for IPM motor |
Country Status (2)
| Country | Link |
|---|---|
| CN (1) | CN117063379A (en) |
| WO (1) | WO2022209252A1 (en) |
Family Cites Families (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2004328859A (en) * | 2003-04-23 | 2004-11-18 | Nissan Motor Co Ltd | Method of manufacturing rotor of motor, and rotor of motor |
| JP2014187828A (en) * | 2013-03-25 | 2014-10-02 | Mitsuba Corp | Rotor for motor, brushless motor, method of manufacturing rotor for motor |
| US11251685B2 (en) * | 2016-12-28 | 2022-02-15 | Nidec Corporation | Rotor core with concave portions between flake portions and base portions with dimensions |
-
2022
- 2022-02-01 WO PCT/JP2022/003784 patent/WO2022209252A1/en active Application Filing
- 2022-02-01 CN CN202280024297.8A patent/CN117063379A/en active Pending
Also Published As
| Publication number | Publication date |
|---|---|
| WO2022209252A1 (en) | 2022-10-06 |
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