JP2002272033A - Rotor of permanent magnet synchronous motor and manufacturing method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To surely secure insulation of magnets, when they are incorporated in a rotor core, while dispensing with subjecting the magnet themselves to an insulation film forming treatment. SOLUTION: Magnets 17 are inserted into magnet holes 16, formed beforehand in a rotor core 15, with an adhesive 19 having a base material of epoxy resin, silicone resin, etc., between and bonded and fixed to the magnet holes 16. Non- conductive material particles 20, such as glass beads, ceramic particles, etc., whose particle diameters are at least two times the maximum height among values obtained by a surface roughness measurement of the surfaces of the magnets, are mixed beforehand in the adhesive 19, so that the thickness of the adhesive layer is not smaller than the particle diameter of the mixed particle 20.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a motor used as a power source for industrial equipment and automobiles, and more particularly to a rotor of a permanent magnet type synchronous motor having a permanent magnet built in the rotor and a method of manufacturing the same.

[0002]

2. Description of the Related Art As a rotor of a conventional permanent magnet type synchronous motor, for example, there is one described in Japanese Patent Application Laid-Open No. 2000-324736. This rotor has a built-in magnet in a rotor core made of a laminated steel sheet, and operates in an alternating magnetic field from the stator to generate an eddy current inside the magnet, thereby preventing a decrease in motor efficiency. More specifically, by dividing a single-pole magnet into a plurality of magnets and further providing an insulator on the surface thereof, the eddy current inside the magnets is divided into small pieces to reduce the loss.

[0003]

However, in such a conventional permanent magnet type synchronous motor rotor,
In order to apply an insulating film to the magnet surface, a process of winding an insulating tape around the magnet or applying an insulating resin is required. Although the loss is reduced by increasing the number of divided magnets as described above, the number of steps for insulating treatment is increased by the increase in the number of divided magnets, resulting in an increase in cost.

Further, when the magnet is divided and the insulating layer is provided, the volume of the magnet is relatively reduced by a volume corresponding to the thickness of the insulating layer, and the amount of magnetic flux generated from the rotor is reduced. There is also a problem that an output cannot be obtained for the motor physique.

The present invention has been made in view of such a conventional problem. In particular, the present invention is based on the premise that a magnet which is not previously subjected to insulation treatment is used as a magnet incorporated in a rotor core. It is an object of the present invention to provide a rotor core and a method of manufacturing the same, which can obtain equivalent or higher rotor performance.

[0006]

According to a first aspect of the present invention, there is provided a rotor core formed by laminating steel plates, a plurality of magnets embedded in the rotor core along an axial direction thereof, and a plurality of magnets embedded in the rotor core. Assuming that the rotor is a permanent magnet type synchronous motor composed of a resin material filled in the gap, the resin material has a non-magnetic particle having a particle size of at least twice the maximum height in the surface roughness measurement of the magnet surface. It is characterized by mixing conductive particles.

The above magnets are often arranged at equal positions in the circumferential direction of the rotor core. The resin material has an adhesive property due to the function of fixing the magnet to the rotor core. For example, an adhesive based on an epoxy resin or a silicone resin is used. Similarly, as the non-conductive particles, for example, glass beads or ceramic particles are used.

Therefore, according to the first aspect of the present invention, the magnet, which has not been subjected to insulation treatment in advance, is bonded and fixed to the inner wall surface of the magnet hole of the rotor core via the resin material. Since non-conductive particles are mixed in the resin material, the minimum approach distance between the rotor core and the inner wall surface of the magnet hole does not become smaller than the non-conductive particle diameter. That is, the non-conductive particles serve to secure an insulating distance between the magnet and the rotor core, and prevent electrical conduction between the rotor core and the magnet without performing an insulating film treatment on the magnet surface in advance. Will be able to do it.

According to a second aspect of the present invention, based on the rotor structure of the first aspect, the magnet is divided into a plurality of magnet segments in the axial direction of the rotor core. It is characterized in that a resin material containing a mixture of non-conductive particles having a particle diameter of at least twice the maximum height in the surface roughness measurement of the magnet element joint surface is filled in the joint surfaces of the magnet pieces.

Therefore, according to the present invention, in order to cut off the eddy current in the magnet which is to be placed in the alternating magnetic field, the one-pole magnet is divided into a plurality of magnet pieces. However, since non-conductive particles also exist between the magnet pieces, not only the electrical insulation between the rotor core and the magnet, but also the Electrical insulation can be performed at the same time.

According to a third aspect of the present invention, based on the rotor structure of the permanent magnet type synchronous motor of the first or second aspect of the present invention, at least the surface of the magnet or the surface of the magnet element joined to the resin material. In addition to non-conductive particles with a particle size more than twice the maximum height in roughness measurement,
It is characterized in that a filler of a high thermal conductivity material smaller than the particle size of the non-conductive particles is mixed.

As the filler of the high thermal conductivity material, for example, silica fiber or the like is used.

Therefore, according to the third aspect of the present invention, the thermal resistance between the magnet pieces divided by the non-conductive particles and the filler made of the high thermal conductivity material is mixed in the resin material. This makes it possible to contribute to the soaking of the entire magnet and the improvement of the heat dissipation of the magnet.

According to a fourth aspect of the present invention, based on the rotor structure of the permanent magnet synchronous motor of the first or second aspect of the present invention, at least the surface of the magnet or the surface of the magnet element joining surface is provided on the resin material. In addition to non-conductive particles with a particle size more than twice the maximum height in roughness measurement,
It is characterized in that a filler of a high magnetic permeability material smaller than the particle diameter of the non-conductive particles is mixed.

As the filler of the high magnetic permeability material, for example, a filler such as atomized silicon iron is used.

Therefore, according to the fourth aspect of the present invention, since the non-conductive particles and the filler of the high magnetic permeability material are mixed in the resin material, the magnetic permeability of the resin material portion increases, and the This can contribute to improvement in performance.

According to a fifth aspect of the present invention, a plurality of magnet holes are previously formed along the axial direction of a rotor core formed by laminating steel plates, and at least the surface roughness of the magnet surface is formed together with the magnet in each of the magnet holes. A method of manufacturing a rotor of a permanent magnet type synchronous motor in which a resin material mixed with non-conductive particles having a particle diameter of twice or more the maximum height in measurement is filled and a magnet is bonded and fixed, It is characterized in that the rotor core is rotated after the material is filled, and the magnet is displaced to a position near the outer peripheral surface of the cylinder of the rotor core by the centrifugal force.

Therefore, in the invention according to the fifth aspect, the centrifugal force due to the rotation of the rotor is applied at a stage where the resin material does not dry and harden, so that the magnet is pushed to the outside of the rotor core in the magnet hole, and Are also arranged at substantially constant positions.

According to a sixth aspect of the present invention, a plurality of magnet holes are previously formed along the axial direction of a rotor core formed by laminating steel plates, and at least the surface roughness of the magnet surface is formed in each of the magnet holes together with the magnet. As a method of manufacturing a rotor of a permanent magnet type synchronous motor in which a resin material mixed with non-conductive particles having a particle diameter of at least twice the maximum height in the height measurement is filled and a magnet is bonded and fixed, It is assumed that a jig having a cylindrical surface capable of interpolating is used.

The jig has, on its inner peripheral surface, a polarity opposite to the magnetic pole on the outer peripheral surface side of the magnet to be inserted into the magnet hole at a position corresponding to the magnet hole on the rotor core side of the cylindrical surface. A magnet is placed in the magnet hole of the rotor core with the rotor core inserted into the cylindrical surface of the jig, and the magnet is moved toward the outer peripheral surface of the rotor core by the attractive force of the magnet. It is characterized by being displaced to the position.

Therefore, according to the present invention, the resin material is not dried and hardened in the same manner as described above.
Since the magnets inserted into the respective magnet holes are attracted to the outside of the rotor core by the attraction magnet on the jig side, all the magnets are arranged at substantially constant positions. In addition, when inserting a magnet with a different polarity by mistake when inserting the magnet into the magnet hole, repulsive force acts on the magnet to be inserted. But it is effective.

According to a seventh aspect of the present invention, a plurality of magnet holes are previously formed along the axial direction of a rotor core formed by laminating steel plates, and at least the surface roughness of the magnet surface together with the magnet is formed in each of the magnet holes. As a method for manufacturing a rotor of a permanent magnet type synchronous motor in which a resin material mixed with non-conductive particles having a particle diameter of twice or more the maximum height in measurement is filled and a magnet is adhered and fixed,
It is assumed that an annular jig made of a magnetic material, which can insert the rotor core and has salient poles at positions corresponding to the magnet holes on the rotor core side, is used.

Then, a coil is wound around the salient pole of the jig to form an electromagnet. With the rotor core inserted into the jig, a magnet is inserted into a magnet hole of the rotor core together with a resin material. It is characterized in that the magnet is displaced to a position close to the outer peripheral surface of the cylinder of the rotor core by energizing the electromagnet.

Therefore, according to the present invention, the resin material is not dried and hardened as described above,
Since the magnets inserted into the respective magnet holes are attracted to the outside of the rotor core by the electromagnet on the jig side, all the magnets are arranged at substantially constant positions.

[0025]

According to the first aspect of the present invention, the resin material substantially functions as an adhesive and also functions as an insulating film, and is mixed in the resin material. Non-conductive particles secure the minimum separation distance between the rotor core and the magnet and prevent direct contact between them, so that electrical insulation between the rotor core and the rotor core is ensured without pre-insulating the magnet. Thus, there is an effect that a highly efficient motor can be obtained while reducing costs.

According to the second aspect of the present invention, not only electrical insulation between the rotor core and the magnet but also electrical insulation between the divided magnet pieces can be reliably ensured. In addition to preventing unnecessary temperature rise of the magnet and reduction in motor efficiency, the uniform thickness of the adhesive layer between the magnet pieces eliminates variations in the overall length of the magnet due to the cumulative variation of the adhesive layer. As a result, the dimensional accuracy of each magnet composed of a plurality of magnet pieces is improved, and the volume of the magnet can be increased, so that a decrease in output due to the division of the magnet can be suppressed.

According to the third aspect of the invention, since the filler of the high thermal conductivity material is mixed in the resin material in addition to the non-conductive particles, the heat generated between the divided magnet pieces is particularly high. By reducing the resistance, the entire magnet can be made more uniform, and at the same time, the thermal resistance between the rotor core and the rotor can be reduced, improving the heat dissipation performance of the magnet and increasing the motor output duration. .

According to the fourth aspect of the present invention, since the filler of the high magnetic permeability material is mixed in the resin material in addition to the non-conductive particles, the magnetic permeability particularly in the resin layer portion is improved,
There is an effect that the motor output is improved.

According to the fifth aspect of the present invention, by rotating the rotor core in a state where the resin material is not dried and applying a centrifugal force, the positions of the magnets become substantially constant at each pole. Motor output performance is stabilized and cogging torque is effectively reduced.

According to the sixth aspect of the present invention, among the jigs arranged on the outer periphery of the rotor core, the attraction magnet is arranged at a position corresponding to the outer periphery of the magnet on the rotor core side. Since the magnets to be configured are attracted to the outer peripheral side of the rotor core, variations in the positions of the magnets are reduced, and at the same time, even if a magnet having a different polarity is erroneously inserted, it is repelled by the magnet being inserted Since the force acts, a mis-insertion of the magnet can be recognized, and it is possible to prevent a mistake in inserting the magnet.

According to the present invention, a jig having salient poles is arranged at a position corresponding to the magnet position on the outer periphery of the rotor, and a coil is wound around the salient poles to form an electromagnet. Since the magnet on the rotor core side is attracted by the force, the magnet is attracted to the outer peripheral side of the magnet hole and the magnet position of each pole becomes constant, so that the motor output performance can be stabilized.

[0032]

Preferred embodiments of the present invention will be described below with reference to the drawings.

FIGS. 1 to 6 show a first embodiment of the present invention, and correspond to the first aspect of the present invention.

FIGS. 1 and 2 show an example of a permanent magnet synchronous motor (hereinafter simply referred to as a motor) used as a driving power source for an electric vehicle. A motor 1 used in an electric vehicle or the like is connected to a speed reducer 2. It is mounted in an engine room (power source mounting space) 3 of the vehicle body B in a state where the vehicle body B is in the upright position. A member member 4 is provided in the engine room 3 from a body frame member, and a mount bracket 5 attached to the member member 4 and a motor bracket 7 provided in a motor case 6 are mounted on an elastic body. 8 are supported by being connected to each other.

The power generated by the motor 1 is transmitted to wheels via a speed reducer 2. This reduction gear 2 is a motor case 6
It is integrated with the vehicle body frame member via the mount bracket 9 and the mount 10 and a member member (not shown), similarly to the motor case 6 side.

FIG. 3 shows details of the motor 1 alone. The motor 1 is roughly divided into a stator 11 fixed to the motor case 6, a rotor 12 rotatably disposed on the inner periphery of the stator 11 via a rotor bearing or the like (not shown), and an opening at both ends of the motor case 6. , And a bracket 13 for holding the rotor bearing.

The rotor 12 is rotatably supported by bearings provided on a bracket 13, rotates based on the reaction force of the electromagnetic force generated by the stator 11, and uses its rotational power via the speed reducer 2. To the wheels. In the case of the permanent magnet type synchronous motor, the rotor 12 has a shaft 14 penetrating the center thereof and an axial position substantially coincident with the stator 11 as shown in FIG.
The rotor core 15 is an iron core having an outer diameter so as to have a slight gap between the inner diameter of the rotor core 15 and the inner diameter of the rotor core 15. I have.

FIG. 4 shows details of the rotor 12. A plurality of slit-shaped magnet holes 16 are formed in a portion close to the cylindrical outer peripheral surface of the cylindrical rotor core 15 formed of a laminated body of thin steel plates along a circumferential direction. It penetrates in the axial direction of the rotor core 15. A substantially flat rectangular magnet 17 slightly smaller than the hole shape is inserted into each magnet hole 16 and is fixed with an adhesive. Also, the rotor core 1
A shaft hole is provided in the center portion of the shaft 5, the shaft 14 is fitted in the shaft hole portion, and both sides of the rotor core 15 are used to minimize leakage of magnetic flux from each magnet 17. Is provided with an end plate 18 made of a nonmagnetic material, and is fixed to the shaft 4.

FIGS. 5A and 5B show a state in which the magnet 17 is inserted into each magnet hole 16 of the rotor core 15 and fixed with the adhesive 19. An adhesive 19 for fixing the magnet 17 fills a space between the inner wall surface of the magnet hole 16 formed in the rotor core 15 and the magnet 17. As shown in the same figure (B) in which the bonding portion is enlarged, the magnet 17 and the rotor core 15 are shown.
Looking at the cross section of the above, an adhesive 19 is filled between the two, and the adhesive 19 has a non-conductive particle having a particle size of at least twice the maximum height in the surface roughness measurement of the magnet surface. Material particles 20 are premixed.

The adhesive 19 used here is based on, for example, an epoxy resin or a silicone resin, and the particles 20 of the non-conductive material mixed with the adhesive 19 are, for example, glass beads or particles having a substantially constant particle diameter. Use ceramic particles. The maximum height in the surface roughness measurement corresponds to the maximum height Rmax in the surface roughness measurement method specified in JIS.

In order to insert the magnet 17 into each magnet hole 16, as shown in FIG. 6, at least about the lower half of the inner surface of the magnet hole 16 of the rotor core 15, at least in the surface roughness measurement of the magnet 17 as described above. An adhesive 19 in which particles 20 of a non-conductive material having a particle size of twice or more the maximum height are mixed in advance is applied. Here, if the particle diameter of the non-conductive material particles 20 is less than twice the maximum height in the surface roughness measurement, the magnet hole 16 and the magnet 1
There is a possibility that the peak portion of the surface of No. 7 will make contact and conduct. Therefore, the grain size must be at least twice the maximum height of the surface roughness. The adhesive 19 is obtained by sufficiently stirring and mixing the resin base material and the particles 20 of the non-conductive material in a mixing container in advance.

A similar adhesive 19 is applied to the surface of the lower half region of the magnet 17. Thereafter, the magnet 17 is inserted into the magnet hole 16 so that the adhesive 1
When the magnet 9 is completely filled and the adhesive 19 dries, the magnet 17 is fixed to the rotor core 15.

Thus, a predetermined number of magnets 17
Are similarly inserted into the magnet holes 16, and the end plates 18 shown in FIG. 4 are attached to both ends of the rotor core 15 to assemble the rotor 12.

Therefore, according to the present embodiment, non-conductive material particles 20 having a particle size of at least twice the maximum height in the surface roughness measurement of the magnet surface are previously mixed in the adhesive 19. By doing so, the thickness of the adhesive layer 19A shown in FIG. 5 does not become smaller than the particle size of the particles 20 of the non-conductive material, so that each magnet 1
Even if the surface of 7 is not preliminarily treated with an insulating film or the like, the insulation between the rotor core 15 and the magnet 17 can be ensured by interposing the particles 20 of the non-conductive material between the rotor core 15 and the magnet 17,
The insulating film processing step becomes unnecessary.

FIG. 7 shows a second embodiment of the present invention. This embodiment corresponds to the second aspect of the present invention.

In this embodiment, the magnet 27 whose surface has not been subjected to insulation treatment is divided in advance into a plurality of magnet pieces 27a, and the magnet pieces 27a are bonded to each other. For this purpose, an adhesive 19 mixed with particles 20 of a non-conductive material having a particle diameter twice or more the maximum height in the surface roughness measurement is used in the same manner as described above.

More specifically, each magnet 27 is composed of a plurality of magnet pieces 27 in order to suppress eddy current loss due to operation in an alternating magnetic field.
a, 27a... Each magnet piece 27a,
At least two particles 20 of a non-conductive material having a particle diameter of at least twice the maximum height in the surface roughness measurement of a region desirably a joint surface of the magnet piece 27a are provided on the joint surface between the 27a. A predetermined amount of the mixed adhesive 19 is applied. Then, the joining surfaces of the magnet pieces 27a are pressed against each other and pressed. The adhesive 1
It is preferable that the application amount of No. 9 is such that it does not protrude from the side surface of the magnet element piece 27a when pressurized.

When the magnet pieces 27a, 27a are pressed together, the thickness of the adhesive 19 interposed therebetween gradually decreases, and finally, the particles 20 previously mixed in the adhesive 19 are reduced. The thickness of the adhesive 19 cannot be reduced below the particle size of the particles 20 by being interposed between the magnet pieces 27a, 27a, and as a result, the thickness of the adhesive layer can be made constant. The adhesive 19 in the state of FIG.
Is dried, and the magnet 27 composed of the plurality of magnet pieces 27a is integrally assembled.

As is apparent from FIG. 7, when the magnet 27 is divided into three or more magnet pieces 27a, the above-described steps are repeated for bonding, or the required The number of magnet pieces 27a,
It is also possible to pressurize and bond them collectively after stacking 27a.

The magnet 27 thus assembled
As shown in FIG. 8, is inserted and fixed in the magnet hole 16 of the rotor core 15 in exactly the same manner as in the first embodiment. That is, each magnet element 27a, 2 is formed using an adhesive 19 in which particles 20 of a non-conductive material are previously mixed.
7a are inserted into the magnet holes 16 and bonded and fixed such that the joining surfaces of the members 7a are parallel to the respective steel plates forming the rotor core 15.

According to this embodiment, the one-pole magnet 27 is divided into a plurality of magnet pieces 27a, 27a, and moreover, each magnet piece 27a, 27a,.
Even when no insulating film is provided, there is an advantage that the insulation between the magnet pieces 27a, 27a can be secured and the insulating film processing step can be omitted. In addition, by using the adhesive 19 in which particles 20 of a non-conductive material are mixed to fix the magnet pieces 27a, 27a, the thickness of the adhesive layer can be easily controlled and the magnet volume can be maximized. By doing so, it is possible to minimize the loss of output while minimizing the loss due to the heat generated by the magnet 27.

FIG. 9 shows a third embodiment of the present invention. This embodiment corresponds to the third aspect of the present invention.

In this embodiment, as in FIG. 7, the magnet pieces 27a,
In bonding and fixing the pieces 7a to each other, the particle size of at least twice the maximum height in the surface roughness measurement of the joint surface of the magnet piece 27a is set in the adhesive 29 based on epoxy resin or silicone resin. In addition to particles 20 of a non-conductive material such as ceramic particles and glass beads, fillers 21 of a high thermal conductivity material such as silica made of fibers finer than the particles 20 are previously mixed.
Of course, the magnet 27 formed by bonding and fixing the magnet pieces 27a, 27a is inserted into the magnet hole 16 of the rotor core 15 using the same adhesive 29 as in FIG.

According to the present embodiment, when the rotor 12 is actually used, an eddy current is generated in the magnet 27 moving in the alternating magnetic field as described above, and heat is generated. Since the heat generated from the magnet 27 is transmitted to the rotor core 15 via the adhesive 29 containing the filler 21 of the high thermal conductivity material, the heat radiation of the magnet 27 is further promoted, and the motor performance can be improved. Becomes

FIG. 10 shows a fourth embodiment of the present invention. This embodiment corresponds to the invention described in claim 4.

In the present embodiment, as in FIG. 9, the magnet pieces 27a, 27a,
In bonding and fixing the pieces 7a to each other, the particle size of at least twice the maximum height in the surface roughness measurement of the joint surface of the magnet piece 27a is set in the adhesive 39 based on the epoxy resin or the silicone resin. In addition to the particles 20 of a non-conductive material such as ceramic particles and glass beads, which have been previously mixed, a filler 22 of a high magnetic permeability material such as atomized silicon iron finer than the particles 20 is mixed in advance. is there. Of course, the magnet pieces 27a, 27a
The magnet 27 formed by bonding and fixing the two is inserted into the magnet hole 16 of the rotor core 15 using the same adhesive 39 as in FIG.

According to the present embodiment, when the rotor 12 is actually used, the magnetic field or the like generated from the stator passes through the rotor core 15, but the adhesive 39 is made of atomized silicon. Since the filler 22 such as elemental iron is mixed in advance, the magnetic permeability of the adhesive layer 39A itself is improved, and the magnetic flux easily passes through the rotor 12 itself. Although the silicon iron itself is conductive, its surroundings are covered with an insulating base resin such as an epoxy resin, so that the magnet element 27 via the adhesive layer 39A is provided.
Since the a and 27a do not conduct with each other, the magnet pieces 27a and 27a assure insulation from each other,
It is possible to provide a motor through which magnetic flux easily passes.

FIG. 11 shows a fifth embodiment of the present invention. This embodiment corresponds to the invention described in claim 5.

This embodiment shows an example of equipment in which the assembling work of the magnet 27 composed of the plurality of magnet pieces 27a, 27a, and the work of inserting and bonding the magnet 27 to the rotor core 15 as described above are automated. As is apparent from FIG. 11, an index table 24 that is rotatable every 90 degrees is disposed on the base 23, and a number of magnet pieces 27a, 27a,. Magnet magazine 25 in which is aligned and handling robot 2
6 and an adhesive supply device 28 are arranged respectively. The rotor core 15 is positioned and fixed to the index table 24. In this embodiment, an example is shown in which the magnet 27 of each pole is divided into three in the longitudinal direction as shown in FIG. 7 in the rotor core 15 having four magnetic poles.

As shown in FIG. 11 (A) and FIG. 12 (A), by indexing and rotating the index table 24 to which the rotor core 15 is fixed, one of the magnet holes 16 is moved to a position corresponding to the adhesive supply device 28. When the index is determined, a predetermined amount of the adhesive 19 is supplied to the magnet hole 16 from the nozzle 30 of the adhesive supply device 28.
Further, by rotating the index table 24 by 90 degrees, the adhesive 1 is also supplied to the next magnet hole 16.
9 is supplied as well. The index table 24 is again indexed and rotated, and the phase of the magnet hole 16 to which the adhesive 19 is first supplied is advanced by 180 degrees with respect to the original position. At this position, as shown in FIGS. As shown, the handling robot 26 is the magnet magazine 25
The magnet piece 27a is taken out from the magnet hole 16a by the hand 31 and the magnet hole 16 to which the adhesive 19 is first supplied is taken out.
The magnet piece 27a is inserted so as to fall under its own weight.

Such a series of operations are sequentially repeated, and a further 180 degrees from the position where the magnet element 27a is inserted.
At the position where the degree phase has advanced, the adhesive 19 is supplied again by the adhesive supply device 28 onto the magnet element 27 a already in the magnet hole 16. When the phase further advances by 180 degrees due to the rotation of the index table 24, the second-stage magnet pieces 27 a are similarly stacked in the magnet holes 16 by the handling robot 26.

Finally, by repeating these series of operations sequentially, as shown in FIG.
The three magnet pieces 27a are inserted into the respective magnet holes 16 of No. 5 via the adhesive 19 to form the magnet 27 similar to that of FIG. Thereafter, the rotor core 15 into which all the magnet pieces 27a have been inserted is removed from the index table 24, and the rotor 12 is assembled with the shaft 14 and the end plate 18 as shown in FIG. Thereafter, the rotor 12 is promptly supplied to a lathe 32 as a rotary drive shown in FIG. 13 before the adhesive 19 is dried.

As is well known, the lathe 32 has, for example, a chuck 33 of an outer diameter gripping type at the tip of its main shaft, and is firmly positioned and fixed with the cylindrical outer peripheral surface of the rotor core 15 as a gripping portion.

Here, when the rotor 12 held by the chuck 33 is rotated, as shown in FIG.
The centrifugal force F acts on the magnet 27 incorporated in the inside 5, and is pressed against the outer peripheral side of the magnet hole 16 (the side closer to the cylindrical outer peripheral surface of the rotor core 15). On the other hand, since the particles 20 of the non-conductive material previously mixed with the adhesive 19 are interposed between the magnet 27 and the inner wall surface of the magnet hole 16, the magnet 27 may not directly contact the rotor core 15. In addition, it is possible to prevent the generation of eddy current due to the contact with the rotor core 15 even with the magnet 27 having no insulating film in advance, and to prevent the loss from being reduced.

After the centrifugal force F is applied while the adhesive 19 filled with the magnet 27 is not dried, the rotor 12 is removed from the chuck 33 of the lathe 32 and the adhesive 19 is forcibly dried by an electric furnace or the like. By doing so, the rotor 12 is completed.

FIG. 15 shows a sixth embodiment of the present invention. This embodiment corresponds to the invention described in claim 6.

In the present embodiment, as a means for bringing the magnet 27 incorporated in the rotor core 15 as close as possible to the outer peripheral surface side of the cylindrical blade of the rotor core 15, an annular treatment for generating a magnet attraction force in place of the centrifugal force due to the rotation described above. The tool 34 is used.

More specifically, as shown in FIG. 15, each of the magnet holes 16 of the rotor core 15 is made of a non-conductive material having a grain size at least twice the maximum height in the surface roughness measurement of the magnet surface. The magnet 27 is inserted together with the adhesive 19 in which particles are mixed in advance. The operation of inserting the magnet 27 is performed by inserting the rotor core 15 into an annular jig 34 functioning as a yoke (FIG. 15).
State) for the first time. At a position corresponding to the outer peripheral side of the magnet hole 16 of the rotor core 15 on the inner peripheral surface of the jig 34, a magnetized attracting magnet 35 is disposed in advance.

In this embodiment, first, the attraction magnet 35 on the jig 34 side and the magnet hole 1 on the rotor core 15 side are used.
The rotor core 15 in a state where the magnet is not inserted is inserted into the center of the jig 34 so that the phase with the rotor core 6 is matched.
In this state, an adhesive 19 in which particles 20 of a non-conductive material are mixed is applied to a magnet 27 magnetized in advance and inserted into the magnet hole 16. In this case, as the magnet 27, a plurality of magnet pieces 27a, 2 as described above are used.
7a may be used, or the adhesive 19a may be inserted while a single magnet element 27a is inserted.
May be joined each time.

When the magnet 27 is inserted, the magnetic poles on the inner peripheral surface of the attracting magnet 35 and the magnetic poles on the outer peripheral side of the magnet 27 inserted into the rotor core 15 are inserted with opposite polarities. Is inserted so as to be drawn into the magnet hole 16,
After the insertion, the suction magnet 35 and the magnet 27
Since magnetically attracting force acts on each other, the magnet 27 existing in the undried adhesive 19 is attracted to the cylindrical outer peripheral surface side of the rotor core 15. On the other hand,
Since the particles 20 of the non-conductive material existing in the adhesive 19 are interposed between the inner wall surface of the magnet hole 16 and the magnet 27, even the low-cost magnet 27 whose surface is not subjected to the insulating film treatment in advance is used. The magnet surface and the rotor core 15 are not electrically conducted, and are fixed with a distance corresponding to the particle diameter. And
Waiting for the adhesive 19 to dry, the rotor core 15 is moved to the jig 3
Removed from 4.

FIG. 16 shows a seventh embodiment of the present invention. This embodiment corresponds to the invention described in claim 7.

In the present embodiment, as a jig 36 used for inserting the magnet 27 into the rotor core 15, a jig 34 of a suction magnet type shown in FIG.
Instead, an electromagnet type jig 36 is used.

As shown in FIG. 16, salient poles 37 are formed at positions on the inner peripheral surface of an annular jig 36 also serving as a yoke which correspond to the outer peripheral side of the magnet hole 16 of the rotor core 15. A coil 38 for generating a magnetic force is wound around the salient pole 37, and an electromagnet 40 is formed individually.

Therefore, according to the present embodiment, the rotor core 15 is previously inserted into the center of the jig 36 in the same manner as described above, and in this state, the magnet
The adhesive 19 is sequentially applied to the magnet holes 16 while being applied. After inserting a predetermined magnet 27 into each magnet hole 16, the magnet 27 inserted into the rotor core 15
Is applied to each coil 38 so as to attract the outside. Specifically, for example, when the outer peripheral side of the magnet 27 inserted into the rotor core 15 has the N pole, the current is supplied so that the surface of the salient pole 37 located on the outer periphery becomes the S pole. The magnet 27 is attracted to the outer peripheral surface of the cylinder of the rotor core 15 by this electromagnetic force, but the particles 20 of the non-conductive material previously mixed with the adhesive 19 are removed from the magnet hole 16 of the rotor core 15 as in the previous case. By being interposed between the inner wall surface of the magnet and the magnet 27, the two are not electrically connected to each other, and even the low-cost magnet 27 that has not been subjected to the insulating coating treatment can prevent the generation of eddy current, thereby improving the efficiency. Can be suppressed.

Here, in each of the above-described embodiments, it is assumed that the surface of the magnet is not previously subjected to the insulating coating treatment. However, for example, rare earth magnets are intended to prevent performance degradation due to corrosion. Since plating or the like may be applied, the present invention can be applied even when a magnet that has been subjected to a conductive surface treatment such as plating in advance is used. In addition, even in the case of a magnet composed of a plurality of magnet pieces or a magnet whose surface is preliminarily subjected to an insulating coating with an integral magnet, the method of the present invention may be adopted in order to easily control the thickness of the adhesive layer. It is possible, and as a result, it is possible to suppress variations in the position of each magnet.

[Brief description of the drawings]

FIG. 1 is a configuration explanatory view of a vehicle equipped with a permanent magnet type synchronous motor as a traveling drive source.

FIG. 2 is an enlarged explanatory view showing details of a motor and a speed reducer shown in FIG. 1;

FIG. 3 is an enlarged explanatory view of a main part of only the motor shown in FIG. 2;

FIG. 4 is an exploded perspective view showing a rotor structure of the motor shown in FIG. 3;

FIG. 5 is a diagram showing a first embodiment of the present invention, and FIG.
Is an enlarged perspective view of only the rotor core of the rotor shown in FIG. 4,
(B) is an enlarged sectional view along the AA line in FIG.

FIG. 6 is a process explanatory view showing a procedure of assembling the rotor core shown in FIG. 5;

FIG. 7 is an explanatory diagram showing details of a split magnet as a second embodiment of the present invention.

FIG. 8 is an explanatory view showing a state in which the magnet of FIG. 7 is incorporated in a rotor core.

FIG. 9 is a view showing a third embodiment of the present invention, and is an enlarged sectional view of a joint between magnet pieces.

FIG. 10 is a view showing a fourth embodiment of the present invention, and is an enlarged sectional view of a joint between magnet pieces.

FIG. 11 is a view showing a fifth embodiment of the present invention, and is an explanatory view showing an example of a rotor core assembling apparatus.

FIG. 12 is a process explanatory view showing an assembling procedure in the apparatus shown in FIG. 11;

FIG. 13 is an explanatory view of a process when a centrifugal force is applied to the rotor after the assembly is completed.

14 is a view showing details of FIG. 13, (A) is an enlarged view of a main part of FIG. 13, and (B) is an explanatory side view of FIG.

FIG. 15 is an explanatory view showing details of a jig for assembling a rotor core according to a sixth embodiment of the present invention.

FIG. 16 is an explanatory view showing details of a jig for assembling a rotor core as a seventh embodiment of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 12 ... Rotor 15 ... Rotor core 16 ... Magnet hole 17 ... Magnet 19 ... Adhesive (resin material) 20 ... Particles of non-conductive material 21 ... Filler of high thermal conductivity material 22 ... Filler of high magnetic permeability material 27 ... Magnet 27a ... Magnet element 29: Adhesive (resin material) 34: Jig 35: Attraction magnet 36: Jig 37: Salient pole 38: Coil 39: Adhesive (resin material) 40: Electromagnet

Claims (7)

[Claims] 1. A permanent magnet comprising: a rotor core formed by stacking steel sheets; a plurality of magnets embedded in the rotor core along the axial direction thereof; and a resin material filled in a gap between each magnet and the rotor core. A permanent magnet synchronous motor, comprising: a rotor of a magnet synchronous motor, wherein non-conductive particles having a particle size of at least twice the maximum height in the surface roughness measurement of the magnet surface are mixed with a resin material. Rotor. 2. The magnet according to claim 1, wherein each of the magnets is divided into a plurality of magnet pieces in the axial direction of the rotor core. Height 2
2. The permanent magnet synchronous motor rotor according to claim 1, wherein the rotor is filled with a resin material mixed with non-conductive particles having a particle size twice or more. 3. The resin material according to claim 1, further comprising a non-conductive particle having a particle diameter of at least twice the maximum height in the surface roughness measurement of the magnet surface or the magnet element joint surface, and the non-conductive particle. 3. The permanent magnet synchronous motor rotor according to claim 1, wherein a filler of a high thermal conductivity material smaller than the particle diameter of the rotor is mixed. 4. The resin material further includes non-conductive particles having a particle diameter of at least twice the maximum height in the surface roughness measurement of the magnet surface or the magnet element joint surface, and the non-conductive particles. 3. The permanent magnet synchronous motor rotor according to claim 1, wherein a filler made of a material having a high magnetic permeability smaller than the particle diameter of the material is mixed. 5. A plurality of magnet holes are formed in advance in a rotor core formed by laminating steel sheets along the axial direction of the rotor core. A method of manufacturing a rotor of a permanent magnet type synchronous motor in which a resin material mixed with non-conductive particles having a particle size of twice or more is filled and a magnet is bonded and fixed, and the rotor core is filled after the resin material is filled. A method for manufacturing a rotor of a permanent magnet type synchronous motor, wherein a magnet is displaced to a position near a cylindrical outer peripheral surface of a rotor core by applying rotation and centrifugal force. 6. A plurality of magnet holes are formed in advance in a rotor core formed by laminating steel plates along the axial direction of the rotor core, and each of the magnet holes together with the magnet has a maximum height of at least 2 in the surface roughness measurement of the magnet surface. What is claimed is: 1. A method for manufacturing a rotor of a permanent magnet type synchronous motor in which a resin material mixed with non-conductive particles having a particle size of twice or more is filled and a magnet is adhered and fixed, wherein a cylinder in which the rotor core can be inserted. For a jig having a surface, at the position corresponding to the magnet hole on the rotor core side of the cylindrical surface, a suction magnet having an inner peripheral surface having a polarity opposite to that of the magnetic pole on the outer peripheral surface side of the magnet to be inserted into the magnet hole is provided. With the rotor core inserted into the cylindrical surface of the jig, a magnet is inserted into the magnet hole of the rotor core together with the resin material, A method of manufacturing a rotor of a permanent magnet type synchronous motor, characterized in that a magnet is displaced to a position near a cylindrical outer peripheral surface of a rotor core by an attractive force of the attractive magnet. 7. A plurality of magnet holes are formed in advance in a rotor core formed by laminating steel plates along the axial direction of the rotor core, and each of the magnet holes together with the magnet has a maximum height of at least 2 in the surface roughness measurement of the magnet surface. A method of manufacturing a rotor of a permanent magnet type synchronous motor in which a resin material mixed with non-conductive particles having a particle size of twice or more is filled and a magnet is bonded and fixed, wherein the rotor core can be inserted and For an annular jig made of a magnetic material having salient poles at positions corresponding to the magnet holes on the rotor core side, a coil is wound around the salient poles to form an electromagnet, and the rotor core is inserted with the rotor core inserted into the jig. A magnet is inserted into the magnet hole together with the resin material. In this state, the magnet is energized by energizing the electromagnet to rotate the magnet around the rotor core. A method for manufacturing a rotor of a permanent magnet type synchronous motor, characterized in that the rotor is displaced to a position near a cylinder outer peripheral surface.