JP2002361345A - Rotor for electromagnetic clutch, production method therefor, and electromagnetic clutch - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a rotor for an electromagnetic clutch which is easy in production, excellent in mass-productiveness and highly reliable. SOLUTION: A circular cap-shaped part having one protruded face is firstly formed by pressing a disc obtained by punching a metallic plate material and then, an inner base 52 having a circular recess on the other face side and an outer base which is positioned at the outer periphery of the inner base 52 and has a ring-shaped groove opening toward one face side and a flange positioning at the outer periphery of the groove, are formed by pressing the cap-shaped part. An inner ring-shaped projection 57 projecting toward one face side is formed on the outer peripheral edge of the outer base 52 by pressing it. Further, a through-hole 59 through which a shaft is inserted is formed by punching the center of the inner base 52 and also, the through-holes 60 are formed by punching the bottom of the ring-shaped groove. Finally, the flange of the outer base is stood up by pressing that base to form an outer ring-shaped projection 61 projecting toward one face side.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an electromagnetic clutch for electrically connecting a shaft rotatable around an axis and an input-side rotating body rotatably fitted to the shaft. The present invention relates to an electromagnetic clutch rotor, a manufacturing method thereof, and an electromagnetic clutch.

[0002]

2. Description of the Related Art An electromagnetic clutch is used in a paper feeding mechanism of a copying machine, and a rotor is fixed to a shaft penetrating a field containing the exciting coil, facing the exciting coil, and facing the rotor. The provided armature is attached via an elastic member to an input-side rotating body such as a gear rotatably attached to a shaft. In such an electromagnetic clutch, when the exciting coil is energized, the armature is magnetically attracted to the rotor, so that the torque of the input-side rotator is transmitted to the shaft, and the shaft rotates.

In such an electromagnetic clutch, the rotor is configured as shown in FIGS. 27 and 28. FIG.
7 is a front view of the rotor, and FIG. 28 is a sectional side view taken along line AA of FIG. That is, the rotor 100
Has a through hole (shaft hole) 101 formed in the center,
A shallow groove 103 is formed around the through hole 101. An inner ring-shaped protrusion 104 is formed on the outer peripheral edge of the groove 103 so as to surround the through hole 101, and a ring-shaped groove 105 deeper than the groove 103 is formed on the outer periphery of the inner ring-shaped protrusion 104. An outer ring-shaped protrusion 106 is formed so as to surround the inner ring-shaped protrusion 104. Further, three arc-shaped slits 107 are formed at the bottom of the groove 105.

[0004] Such a rotor 100 can be obtained by cutting, but the grooves 103 and 105 and the slit 1
07, the manufacturing efficiency is low due to the complicated shape, and an inner portion (inner base) 108 including the inner ring-shaped protrusion 104 and an outer ring shape having a fitting hole 109 of the inner portion 108 formed in the center. Outer part (outer base) including protrusion 106
110 are separately created, and the inner part 108 is
Are manufactured by fitting them into fitting holes 109 and caulking them.

[0005]

However, the rotor 10
0 is fitted to the inner portion 108 and the outer portion 110 as described above, and the inner portion 108 and the outer portion 11
Although 0 can be created relatively easily, there is a problem that mass production is lacking due to the labor required for swaging work. Further, the rotor 100 includes an inner portion 108 and an outer portion 110.
When the crimping state is bad, the inside portion 108 and the outside portion 110 are displaced and deformed during use of the electromagnetic clutch, and there is a possibility that the electromagnetic clutch may not operate correctly, and there is also a problem of lack of reliability. Was.

The present invention has been made in view of such circumstances, and has as its object to provide a rotor for an electromagnetic clutch which is easy to manufacture, has excellent mass productivity, and has high reliability, a method of manufacturing the same, and an electromagnetic clutch. I do.

[0007]

According to a first aspect of the present invention, there is provided a method of manufacturing a rotor for an electromagnetic clutch, wherein a shaft hole is formed at a central portion, and an inner ring-shaped projection is provided at a position surrounding the shaft hole. The outer ring-shaped projection is formed at a position surrounding the inner ring-shaped projection, and a through hole is formed between the inner ring-shaped projection and the outer ring-shaped projection. A step of forming a disk portion held by the metal plate material with a peripheral holding piece by punching a part of the metal plate material; and Forming a circular cap-shaped portion having a convex shape on the side, pressing the cap-shaped portion to form an inner base having a circular concave portion on the other surface, and positioning the cap on the outer periphery of the inner base. Forming a ring-shaped groove opening on one surface side and an outer base having a flange positioned on the outer periphery of the ring-shaped groove; and pressing the inner base to form an outer portion of the inner base. Forming an inner ring-shaped projection projecting to one side on the peripheral edge, punching a center of the inner base, forming a shaft hole, and punching a bottom of a ring-shaped groove of the outer base, Forming a through hole in the bottom portion, pressing the outer base portion to form an outer ring-shaped projection that protrudes toward one surface by erecting a flange portion of the outer base portion, and the respective steps. Cutting the holding piece after the operation in is completed.

According to this method, press working is performed on the same working area of the metal plate material in order. For this reason,
Even a rotor for an electromagnetic clutch having a complicated shape can be easily manufactured as an integral product, and is excellent in mass productivity. Further, since it is manufactured as an integral object from the beginning, deformation due to displacement does not occur, so that an electromagnetic clutch having excellent operation reliability can be configured.

According to a second aspect of the present invention, in the method for manufacturing an electromagnetic clutch rotor according to the first aspect, a central portion of the inner base portion is punched before the step of forming the inner ring-shaped projection. The method includes a step of forming a small-diameter through hole in the central portion. According to this method, since the molded product is evacuated and the metal material is evacuated through the small-diameter through-hole, the press working on the processing region of the metal plate material is performed accurately.

According to a third aspect of the present invention, in the method for manufacturing a rotor for an electromagnetic clutch according to the first or second aspect, the step of forming the inner ring-shaped projection comprises simultaneously forming the inner ring-shaped projection. The circular concave portion on the other surface side of the base is arranged in a predetermined shape. According to this method, the circular concave portion of the inner base portion is adjusted to a predetermined shape, so that the dimensional accuracy of the molded product in the subsequent step can be improved.

According to a fourth aspect of the present invention, in the method for manufacturing a rotor for an electromagnetic clutch according to any one of the first to third aspects, the step of forming the shaft hole includes the step of forming the inner ring-shaped projection. It is provided at the subsequent stage. According to this method, since the shaft hole is formed after the inner ring-shaped projection, distortion that deforms the shaft hole does not occur, and a shaft hole having an accurate dimension can be obtained.

According to a fifth aspect of the present invention, in the method for manufacturing an electromagnetic clutch rotor according to any one of the first to fourth aspects, the step of forming the outer ring-shaped projection includes penetrating a bottom of the ring-shaped groove. It is provided after the step of forming a hole. According to this method, a through hole can be formed at an accurate position, and a highly reliable electromagnetic clutch rotor can be obtained.

According to a sixth aspect of the present invention, in the electromagnetic clutch rotor, a shaft hole is formed in a central portion, an inner ring-shaped projection is formed at a position surrounding the shaft hole, and an outer ring is formed at a position surrounding the inner ring-shaped projection. Ridges are formed,
A through hole is formed between the inner ring-shaped protrusion and the outer ring-shaped protrusion, and is obtained by pressing one disk portion obtained from a metal plate material.

According to this structure, the rotor for the electromagnetic clutch can be obtained by pressing one disk portion obtained from the metal plate material. Therefore, even a rotor for an electromagnetic clutch having a complicated shape is manufactured as an integral body, and the rotor for the electromagnetic clutch has excellent reliability.

According to a seventh aspect of the present invention, in the electromagnetic clutch rotor according to the sixth aspect, a shaft hole is formed at a center portion from the disc portion by the pressing.
And an inner base on which an inner ring-shaped projection is formed on the outer peripheral edge, and a ring-shaped groove which is located on the outer periphery of the inner base and has a through hole formed on the bottom, and an outer ring-shaped on the outer peripheral edge. An outer base on which the projection is formed is formed.

According to this structure, the inner base and the outer base are formed from the disk portion, thereby forming the rotor for the electromagnetic clutch. Therefore, even a rotor for an electromagnetic clutch having a complicated shape can be easily manufactured as an integral product, and the rotor for the electromagnetic clutch has high dimensional accuracy and excellent reliability.

According to an eighth aspect of the present invention, in the rotor for an electromagnetic clutch according to the seventh aspect, the inner base has a circular cap-shaped portion which is formed by pressing the disc portion and has a convex surface on one side. The cap-shaped part is formed by press molding, and the outer base is formed by pressing the cap-shaped part and opening a ring-shaped groove on one side, and a flange positioned on the outer periphery of the ring-shaped groove. It is formed by providing a portion.

According to this configuration, the inner base portion and the outer base portion are formed based on the cap-shaped portion obtained by pressing the disk portion. Therefore, the inner base portion and the outer base portion can be formed to have an accurate positional relationship, and the electromagnetic clutch rotor with high dimensional accuracy and excellent reliability can be obtained.

According to a ninth aspect of the present invention, in the rotor for an electromagnetic clutch according to the eighth aspect, the inner ring-shaped projection is formed by pressing the inner base, and the shaft hole is formed in the inner base. The through hole is formed by punching the bottom of a ring-shaped groove of the outer base, and the outer ring-shaped projection is formed by erecting the flange. is there.

According to this configuration, the inner ring-shaped projection and the shaft hole are formed on the inner base, and the through hole and the outer ring-shaped projection are formed on the outer base. For this reason, the inner ring-shaped projection, the shaft hole, the through-hole, and the outer ring-shaped projection are respectively formed at predetermined positions, and the rotor for the electromagnetic clutch has high dimensional accuracy and excellent reliability.

According to a tenth aspect of the present invention, in the electromagnetic clutch, a shaft is rotatably mounted on a field in which the exciting coil is housed, and a rotor is fixed to the shaft in opposition to the exciting coil, and a rotational force transmitting member is provided. Is rotatably mounted, and the armature disposed rotatably with the rotating force transmitting body is attracted to the rotor by magnetism from the exciting coil against the elastic force of an elastic member. A rotor for transmitting rotation of a force transmitting body to the shaft, wherein the rotor for an electromagnetic clutch according to any one of claims 6 to 9 is used as the rotor.

According to this structure, since the rotor for the electromagnetic clutch is manufactured as a single piece from the beginning, there is no possibility that the rotor for the electromagnetic clutch will be deformed even in a long-term use, so that the operation reliability is excellent. The electromagnetic clutch is easily realized.

[0023]

FIG. 1 is a sectional view of an electromagnetic clutch to which an electromagnetic clutch rotor according to an embodiment of the present invention is applied, and FIG. 2 is an exploded perspective view thereof. In these figures, the electromagnetic clutch 10 has a one-sided open field (housing) 11 in which a through hole 112 is formed in a bottom portion 111 and a rotation preventing portion 113 protruding outward is fixed.
It has. The field 11 is made of a magnetic material such as an iron-based metal, and has an exciting coil 1 described later on its opening side.
Notch 11 for drawing out the second lead wire 127 to the outside
4 are formed.

An excitation coil 12 is immovably housed in the field 11. This exciting coil 12 has 3
Bobbin 1 having two flanges 121, 122, 123
The coil 125 is formed by winding a conductive wire between the 24 flanges 121 and 122, and an insulating sheet 126 is wound around the outer periphery of the coil 125.
25, the lead wires 127 at both ends are sandwiched and fixed between the flanges 122 and 123, and the cutout portion 11 of the field 11 is formed.
4 to the outside. The through hole 128 formed in the axial direction of the bobbin 124 has substantially the same diameter as the through hole 112 of the field 11.

The shaft 13 is rotatably inserted into a through hole 128 of the exciting coil 12 housed in the field 11. The shaft 13 is formed by resin molding, has a through hole 131 through which an external shaft is inserted in the axial direction, and has a flange 132 at one end which is in contact with the outer surface of the bottom 111 of the field 11. A ring-shaped groove 133 into which a ring-shaped locking member 14 such as a washer is fitted is formed on the outer periphery of the other end. A cylindrical body 15 made of a magnetic material such as an iron-based metal that forms a magnetic path of the exciting coil 12 together with the field 11 is fitted on the outer peripheral surface of the shaft 13.

The shaft 13 has a D-shaped cross section (a D-shaped cross section orthogonal to the axial direction of the shaft 13) on the left end side of the through hole 131 in the drawing, and the flange 1
The outer peripheral surface from the position where 32 is formed to the position closer to the other end than the center is a detent-shaped polygonal cross section (in this embodiment, a regular decagonal cross section). The formed portion constitutes a fitting portion 134 in which the cylindrical body 15 and a rotor 16 described later are fitted. A gear 1 to be described later is located at a position adjacent to the fitting portion 134 of the shaft 13.
7 are formed.

The cylindrical body 15 has an inner peripheral surface
Is formed so as to have a polygonal cross section (in this embodiment, a regular decagonal cross section) having a detent shape equal to the shape of the outer peripheral surface of the fitting portion 134, and is inserted from the other end side of the shaft 13. As a result, it is inserted to a position where it comes into contact with the flange 132 at one end. The outer diameter of the cylindrical body 15 is set to be slightly smaller than the diameter of the through hole 128 of the bobbin 124, and the length of the cylindrical body 15 is equal to the thickness of the bottom 111 of the field 11. The length is set to be substantially equal to the sum of the lengths of the bobbins 124. It is sufficient that the cylindrical body 15 is attached to at least the shaft 13 in a non-rotating state.
May have a slight gap formed between them.

On the opening side in the field 11, a rotor 16 as an output side rotating body is fitted at a position facing the exciting coil 12 of the shaft 13. This rotor 1
Numeral 6 is made of a magnetic material such as an iron-based metal, and is not formed by caulking an inner portion (inner base) and an outer portion (outer base) which are individually formed as in the related art, and will be described later. A polygonal (decagonal in this embodiment) through-hole (shaft hole) which is manufactured as a single piece from the beginning and has a detent shape at the center which is the same detent shape as the outer peripheral surface of the fitting portion 134 of the shaft 13. ) 161 is formed, and this through hole 1 is formed.
61 is inserted into the fitting portion 134 of the shaft 13 and attached to the shaft 13 in a detented state.

The rotor 16 is connected to the exciting coil 12
A shallow groove 162 is formed at a position surrounding the through hole 161 on the opposite side to the inner ring-shaped protrusion 163, and a deep ring-shaped groove 164 is formed at a position surrounding the inner ring-shaped protrusion 162. The outer ring-shaped protrusion 165 is formed by the formation, and a plurality of (three in this embodiment) slit-shaped through holes 166 are formed at the bottom of the ring-shaped groove 164.
Are formed.

A gear 17 which is an input-side rotating body is externally fitted to the shaft 13 at a position opposite to the exciting coil 12 with respect to the rotor 16 so as to be rotatable around the shaft 13. The gear 17 is formed by, for example, resin molding. A plurality of teeth 171 are formed at an equal pitch on an outer peripheral surface, and a cylindrical portion 172 through which the shaft 13 is inserted is formed at a radially central portion so as to protrude toward the rotor 16. The end of the cylindrical portion 172 on the rotor 16 side is arranged in a state of contact with the bottom surface of the concave portion 162 of the rotor 16.

A plurality of (three in this embodiment) position regulating portions 175 composed of a pair of position regulating protrusions 173 and 174 formed in the circumferential direction are provided on the outer periphery of the cylindrical portion 172.
They are formed at equal intervals in the circumferential direction so as to protrude from the seven surfaces. The position regulating projections 173 and 174 are set such that the thickness dimension in the axial direction of the shaft 13 is slightly larger than the plate thickness dimension of the armature 18 described later. Is set to a value slightly larger than a width dimension of a later-described convex portion 182 of the armature 18.

Further, on the outer periphery of the cylindrical portion 172, a retaining projection 176 is formed at a tip end thereof and corresponding to a position between the adjacent position regulating portions 175, which protrudes in the radial direction. In the present embodiment, since three sets of the position restricting portions 175 are formed, three retaining projections 176 are formed. The retaining projection 176 and the position regulating projections 173, 17
4 is set to a value substantially equal to a thickness dimension of the ring body 19 described later. Also,
The retaining projection 176 is an inclined surface that is separated from the rotor 16 as the surface on the rotor 16 side is separated radially outward from the peripheral surface of the cylindrical portion 172.

On the surface of the gear 17 on the rotor 16 side,
In the center, a through hole 181 having a diameter larger than the outer diameter of the cylindrical portion 172
An annular armature 18, which is a transmission body formed with, is arranged so that the through hole 181 is inserted into the cylindrical portion 172. The armature 18 is made of a magnetic material such as an iron-based metal, has an outer diameter set to a size substantially equal to the outer diameter of the rotor 16, and has a plurality of (three in this embodiment) at predetermined intervals around the periphery of the through hole 181. The projections 182 are formed so as to protrude inward in the radial direction. Each projection 182 is held by the gear 17 in a state where it is fitted between the pair of position regulating projections 173 and 174 and is prevented from rotating. 17 and rotates together.

The cylindrical portion 172 is made of a synthetic resin such as polyester, an elastic high polymer material such as rubber, or an elastic metal material such as stainless steel.
The ring body 19 as an elastic member, which is slightly larger than the outer diameter of the armature and is set so that the outer diameter is smaller than the through hole 181 of the armature 18, is provided with position regulating protrusions 173, 174.
And the stopper projection 176 is disposed so as to be fitted outside.
Even if the armature 18 moves in the direction away from the gear 17, the armature 18 is prevented from coming off the gear 17 by the projections 182 abutting on the ring body 19. This ring body 19 is, for example,
After being placed on the inclined surface of No. 6, a pressing force is applied to the gear 17 side to be stretched in the radial direction along the inclined surface of the retaining projection 176, and is fitted over the cylindrical portion 172 by climbing over the retaining projection 176. You.

The ring-shaped groove 1 at the other end of the shaft 13
A ring-shaped locking member 14 such as a washer, which is locking means, is fitted to 33. Thus, the positioning of each component on the shaft 13 is performed by the flange 132 of the shaft 13 and the ring-shaped locking member 14.

The electromagnetic clutch 10 constructed as described above
For example, an external shaft such as a paper feed mechanism in an image forming apparatus such as a copying machine is inserted into the through hole 131 of the shaft 13, and the detent portion 11 attached to the field 11.
3 is fixed to a fixing member inside a device such as an image forming apparatus, and attached so that the field 11 does not rotate. In this state, when a rotational force is applied to the gear 17 from an external drive source, the gear 17 and the armature 18
Rotate around 3.

When the excitation coil 12 is energized in this state, a magnetic flux generated by the excitation coil 12 is generated in a magnetic path formed by the field 11, the cylindrical body 15, and the rotor 16. Is increased by the presence of the through hole 166, the magnetic flux
6 will be generated via the armature 18 located in the vicinity. For this reason, a magnetic attraction force for attracting the armature 18 to the rotor 16 is generated, and as shown in FIG. 3, the armature 18 moves toward the rotor 16 against the elastic force of the ring body 19 and is attracted to the rotor 16. Will be. The symbol M in FIG. 3 indicates a magnetic flux generated via the armature 18.

That is, the armature 18 is
Is pulled toward the rotor 16 by the magnetic attraction force, the pressing force is applied by the convex portions 182 of the armature 18 to the portion of the ring member 19 corresponding to the area between the adjacent retaining projections 176. As a result, the armature 18 is attracted to the rotor 16 against the elastic force of the ring body 19. Therefore, as a result of the rotation of the rotor 16 together with the armature 18, the rotational force of the gear 17 is transmitted to the shaft 13, and the shaft 13 rotates according to the rotation of the gear 17.

On the other hand, when the power supply to the exciting coil 12 is cut off, the magnetic flux M disappears, so that the magnetic attraction force in the rotor 16 disappears, and the armature 18 causes the ring body 19 to move.
The pressing force applied to is released. For this reason, the armature 18 is pulled back to the original position separated from the rotor 16 by the return force of the ring body 19 that has been bent and deformed to return to the original state without bending, and the rotational force of the gear 17 with respect to the shaft 13 is reduced. The transmission is interrupted, and the rotation of the shaft 13 is stopped.

Electromagnetic clutch 1 according to one embodiment of the present invention
Reference numeral 0 indicates that the rotor 16 is manufactured as a single body from the beginning as described above, so that the inner portion including the inner ring-shaped protrusion and the outer portion including the outer ring-shaped protrusion are formed by the electromagnetic clutch 10 as in the related art. Since there is no danger of misalignment and deformation during use, stable electrical characteristics are exhibited over a long period of time, resulting in excellent reliability. The electromagnetic clutch 1
The overall configuration of 0 is not limited to the above embodiment. For example, an armature 18 attached to the gear 17 via a leaf spring or the like, or a rotor 1
The sixth through-hole 161 may be a circular one.

Next, a rotor (rotor for electromagnetic clutch) used in the electromagnetic clutch 10 according to one embodiment of the present invention.
16 will be described. FIG. 4 is a diagram illustrating a schematic configuration of a main part of a rotor manufacturing apparatus to which the method for manufacturing the electromagnetic clutch rotor 16 according to the embodiment of the present invention is applied.

That is, the rotor manufacturing apparatus 30 includes, for example, a pedestal section 31 for performing press working on a metal plate material at a predetermined position, and a length supplied from a material supply section (not shown) on the left side. The long metal plate material 32 is intermittently conveyed rightward. This base 31
A plurality of lower dies 33 are set along the transport direction of the metal plate material 32, and the lower dies 3
A plurality of upper dies 34 are arranged to face up and down by a lifting mechanism (not shown). These multiple lower molds 33
The upper mold 34 is for performing different press working on the metal plate material 32.

The pedestal portion 31 is provided with positioning pins 35 at the front and rear positions of each of the lower molds 33 in the conveying direction of the metal plate material 32 and at both ends in the width direction which is the depth direction of the drawing by an elevation mechanism (not shown). It is movably arranged. Also,
As shown in FIG. 5, the metal plate blank 32 has positioning holes 36 formed at both ends in the width direction at the same intervals as the positioning pins 35. In the present embodiment, a region surrounded by the four front, rear, left, and right positioning holes 36 is a processing region.

The rotor manufacturing apparatus 30 configured as described above
When the metal plate material 32 is intermittently conveyed and each processing region reaches each processing position (station) where the lower die 16 and the upper die 20 are disposed, the metal plate material 32 is buried in the pedestal portion 31. The respective positioning pins 35 are lifted and inserted into the respective positioning holes 36 of the metal plate material 32 to fix the position of the metal plate material 32. In this state, predetermined press working is performed simultaneously on each of the continuous processing regions. Be executed.

FIGS. 6 to 26 show the rotor manufacturing apparatus 3 described above.
Metal plate material 3 in each press working process for explaining a method of manufacturing a rotor for an electromagnetic clutch manufactured by the method of Example 1
FIG. 2 is a diagram showing a main part of FIG. Here, FIG. 6 to FIG.
It is a top view which shows one processing area of the metal plate raw material 32,
19 to 26 are cross-sectional views of one processing region of the metal plate material 32 along the transport direction.

First, a long metal plate material 32 shown in FIG.
Is transported by a material supply unit (not shown) and the first processing area K
When 1 reaches the first mold position, as shown in FIG. 6, a substantially inverted U-shaped through hole 40 having a semicircular downstream side with respect to the upstream half of the processing area K1 is formed. It is stamped and formed (first step).

When the first step is completed, the metal plate material 3
The second processing area K1 is transported to the next mold position. In this station, the processing region K1 in which the through hole 40 is formed is pressed flat, and the metal plate material 32 generated in the first step is removed (second step). However, this second step is not always essential.

Next, when the second step is completed, the processing area K1 is transported to the next mold position. In this station, as shown in FIG. 7, a substantially U-shaped through-hole 4 having a semicircular shape on the upstream side with respect to the downstream half of the processing area.
1 is stamped and formed with a slight gap G provided between it and the through hole 40 formed in the first step (third step).
By completing the operation in the third step, the disk portion 42 is formed at the center in the first processing area K1, and
On both sides in the width direction, holding pieces 43 and 44 for holding the disk portion 42 on the metal plate material 32 are formed.

In the first and third steps, the through holes 4
The purpose of forming the holes 0 and 41 is to form the disk portion 42 held by the holding pieces 43 and 44 at the center of each processing area, so that the shapes of the through holes 40 and 41 are substantially inverted. It is not limited to a shape or a substantially U-shape, as long as a space of a predetermined shape necessary for performing press working on the disk portion 42 in a subsequent process is formed around the disk portion 42. Good. Further, in the processing areas K2, K3,... Following the first processing area K1 of the metal plate material 32, the same press processing as described above and the press processing described later are sequentially performed.

When the third step is completed, the processing area K1
Is transported to the next mold position. In this station, as shown in FIG. 8, slit-shaped through-holes 45, 46 along the conveying direction are punched out on both sides in the width direction of the processing area K1 (fourth step). The through-holes 45 and 46 serve as relief holes for absorbing distortion and the like generated at the time of pressing in the subsequent step of the disk portion 42, and are not necessarily required.

When the fourth step is completed, the processing region K1
Is transported to the next mold position. In this station, as shown in FIG. 9, the disk portion 42 is pressed flat to reduce its thickness and increase its diameter (fifth step). If the thickness of the metal plate material 32 is set to the thickness obtained in the fifth step from the beginning, and the diameter is set to the size obtained in the fifth step from the beginning, the fifth step can be performed. It is not necessary.

When the fifth step is completed, the processing area K1
Is transported to the next mold position. In this station, as shown in FIG. 10 and FIG. 19, by pressing (drawing) the disc portion 42 whose diameter has been increased, one surface side (the upper surface side in the present embodiment) is applied. Is formed to form a circular cap-shaped portion 49 having a convex shape.
Note that the holding pieces 43 and 44 are present in the same plane as the outer peripheral edge indicated by the reference symbol Z in FIG.

When the sixth step is completed, the processing area K1
Is transported to the next mold position. In this station, as shown in FIG. 11 and FIG.
By press working (press forming), an inner base 52 having a circular concave portion 50 on the other surface side (the lower surface side in the present embodiment) and a concave portion 51 in a central portion on one surface side;
An outer base 55 having a ring-shaped groove 53 opening on one side and a flange 54 located on the outer periphery of the ring-shaped groove 53 is formed at an outer peripheral position of the inner base 52 (seventh step). The holding pieces 43 and 44 exist in the same plane as the flange 54 of the outer base 55.

When the seventh step is completed, the processing area K1
Is transported to the next mold position. In this station, as shown in FIGS. 12 and 21, a small-diameter through hole 56 is formed at the center of the concave portion 51 by stamping out the concave portion 51 in the inner base portion 52 (eighth step). This through hole 56 is used for venting air during press working, escaping a metal material, or the like, and is not always necessary.

When the eighth step is completed, the processing region K1
Is transported to the next mold position. In this station, as shown in FIG. 13 and FIG. 22, the inner base 52 is pressed (press-formed) so that the inner base 52 is pressed.
An inner ring-shaped protrusion 57 (corresponding to the inner ring-shaped protrusion 162 of the rotor 16 shown in FIG. 1) is formed on the outer peripheral edge of the inner base 52, and the circular concave portion 50 on the other surface of the inner base 52. Is adjusted to a predetermined shape (ninth step). The adjustment of the shape of the circular concave portion 50 in the ninth step is not essential.

When the ninth step is completed, the processing region K1
Is transported to the next mold position. In this station, press working (press forming) is performed on the inner base 52, and fine adjustment is performed so that the inner base 52 has a predetermined dimension (tenth step). The tenth step is not always necessary when the inner base 52 has an accurate dimension in the ninth step.

When the tenth step is completed, the processing area K
1 is transported to the next mold position. In this station, as shown in FIGS. 14 and 23, the center of the inner base 52 is stamped and formed so that the center of the inner base 52 has a circular through hole 58 smaller than the outer diameter of the shaft of the electromagnetic clutch. Is formed (eleventh step).

When the eleventh step is completed, the processing region K
1 is transported to the next mold position. In this station, as shown in FIGS. 15 and 24, the central portion of the inner base 52 is stamped and formed to form a regular decagonal through-hole (shaft) for inserting the shaft of the electromagnetic clutch through the center of the inner base 52. Holes 59 are formed (twelfth step). This through hole 59 corresponds to the through hole 161 of the rotor 16 shown in FIG. As described above, since the through-hole 59 through which the shaft is inserted is formed through two steps, the through-hole 59 having an accurate dimension can be easily obtained. However, it is also possible to form a through hole for inserting the shaft only in the eleventh step, and in this case, the twelfth step becomes unnecessary. In the present embodiment, the through-hole 59 through which the shaft is inserted has a regular decagonal shape. However, the through-hole 59 may be, for example, a polygon or a round hole having another shape.

When the twelfth step is completed, the processing area K
1 is transported to the next mold position. In this station, as shown in FIG. 16 and FIG. 25, the bottom of the ring-shaped groove 53 of the outer base 55 is stamped and formed.
Three arc-shaped and slit-shaped through holes 60 (corresponding to the through holes 166 of the rotor 16 shown in FIG. 1) are formed (a thirteenth step). In addition, this through-hole 60 may be formed by continuously forming a plurality of small circles at a predetermined pitch.

When the thirteenth step is completed, the processing area K
1 is transported to the next mold position. In this station, the inner base 52 and the outer base 55 are pressed flat, and the entire strain is removed (the fourteenth step). This fourteenth step is not necessarily an essential step.

When the fourteenth step is completed, the processing area K
1 is transported to the next mold position. In this station, as shown in FIGS. 17 and 26, the outer base 55 is pressed (punched) to erect the flange 54 of the outer base 55, thereby protruding toward one surface. An outer ring-shaped projection 61 (corresponding to the outer ring-shaped projection 165 of the rotor 16 shown in FIG. 1) is formed (fifteenth step). The overall size of the outer ring-shaped projection 61 is set so as to be at the same height position as the inner ring-shaped projection 57 formed in the ninth step. The outer base 55
When the flange portion 54 is erected, the holding pieces 43 and 44 are simultaneously lifted upward, and the completed electromagnetic clutch rotor is held on the metal plate material 32 when the work in the fifteenth step is completed. ing. That is, the holding pieces 43 and 44 are lifted upward and the outer ring-shaped projection 6 is lifted.
1 is connected to the upper end surface.

When the fifteenth step is completed, the processing region K
1 is transported to the next mold position. In this station, the holding pieces 43 and 44 are cut at the roots of the outer ring-shaped projections 61, whereby the electromagnetic clutch rotor is separated from the metal plate blank 32 (16th step). FIG. 18 shows the metal plate material 32 after the electromagnetic clutch rotor has been separated.

Since the rotor for the electromagnetic clutch according to one embodiment of the present invention is manufactured continuously using the long metal plate material as described above, the rotor for the electromagnetic clutch is integrally formed from the beginning. Can be easily obtained. In addition, since a large number of electromagnetic clutch rotors can be continuously manufactured in a short time, cost can be effectively reduced, and by using this electromagnetic clutch rotor, an electromagnetic clutch having excellent operation reliability can be obtained. It can be easily manufactured.

In the above embodiment, the metal plate material 32
Mold 31 and upper mold 3 arranged along the transport direction of
4 describes that different press working is performed on the metal plate blank 32, but the present invention is not limited to this. For example, if a plurality of identical lower dies 331 and upper dies 34 are continuously arranged in each step along the transport direction of the metal plate material 32, a plurality of processing areas K1 are provided in each step. , K2, K3,... Can be subjected to the same press working at the same time, and can be more excellent in mass productivity.

The lower mold 33 and the upper mold 34 in the direction of transport of the metal plate material 32 are arranged in a plurality of rows so that the metal plate material 32 can be transported in a plurality of rows at the same time. When the material 32 is transported, the same press working can be simultaneously performed on the plurality of processing areas K1, K2, K3,... In each step, and the mass productivity can be further improved.

Further, in the above embodiment, the press working in each station is performed in a state where the disk portion 42 is held on the metal plate material 32 by the holding pieces 43 and 44, but the present invention is not limited to this. . For example, it is also possible to form a disk portion 42 that is independent from the metal plate material 32 by punching the metal plate material 32 and to perform press working at each station using the independent disk portion 42. .

[0067]

As described above, according to the method for manufacturing a rotor for an electromagnetic clutch according to any one of claims 1 to 5, a part of the metal plate material is punched out to be held on the metal plate material by the peripheral holding piece. Forming a disc portion in a set state, forming a circular cap-shaped portion having a convex surface on one side by pressing the disc portion, and pressing the cap-shaped portion to form another cap-shaped portion. Forming an inner base having a circular recess on the side, and an outer base having a ring-shaped groove located on the outer periphery of the inner base and opening on one surface and a flange located on the outer periphery of the ring-shaped groove; A step of forming an inner ring-shaped projection on the outer peripheral edge of the inner base by pressing the inner base so as to protrude to one side, and punching a center of the inner base to form a shaft. Forming a through-hole in the bottom of the outer base by punching the bottom of the ring-shaped groove, and pressing the outer base to make the flange of the outer base stand upright, The step of forming an outer ring-shaped projection protruding from the step and the step of cutting the holding piece after the operation in each step is completed, so that it is easy to manufacture, excellent in mass productivity and highly reliable for an electromagnetic clutch. A rotor can be obtained.

According to the rotor for an electromagnetic clutch according to the sixth to ninth aspects, since it is obtained by pressing one disk portion obtained from a metal plate material, it is easy to manufacture and mass-produced. And a highly reliable electromagnetic clutch rotor can be realized.

According to the electromagnetic clutch of the tenth aspect, the shaft is rotatably disposed around the axis through the field in which the exciting coil is housed, and the rotor faces the exciting coil on the shaft. At the same time, the rotating force transmitting body is rotatably mounted, and the armature arranged to be able to rotate with the rotating force transmitting body is attracted to the rotor by magnetism from the exciting coil against the elastic force of the elastic member. In the electromagnetic clutch configured to transmit the rotation of the rotational force transmitting body to the shaft by using the electromagnetic clutch rotor according to any one of claims 6 to 9 as a rotor, a highly reliable electromagnetic clutch is provided. Can be easily realized.

[Brief description of the drawings]

FIG. 1 is a sectional view of an electromagnetic clutch to which an electromagnetic clutch rotor according to an embodiment of the present invention is applied.

FIG. 2 is an exploded perspective view of the electromagnetic clutch shown in FIG.

FIG. 3 is an exploded perspective view for explaining the operation of the electromagnetic clutch shown in FIG.

FIG. 4 is a schematic diagram of a main part of an apparatus for manufacturing a rotor for an electromagnetic clutch according to an embodiment of the present invention.

5 is a plan view of a metal plate material used in the manufacturing apparatus of the electromagnetic clutch rotor shown in FIG.

FIG. 6 is a plan view of a processing region of a metal plate material for describing a method of manufacturing an electromagnetic clutch rotor according to an embodiment of the present invention.

FIG. 7 is a plan view of a processing region of a metal plate material for describing a method of manufacturing an electromagnetic clutch rotor according to an embodiment of the present invention.

FIG. 8 is a plan view of a processing region of a metal plate material for describing a method of manufacturing an electromagnetic clutch rotor according to an embodiment of the present invention.

FIG. 9 is a plan view of a processing region of a metal plate material for describing a method of manufacturing an electromagnetic clutch rotor according to an embodiment of the present invention.

FIG. 10 is a plan view of a processing region of a metal plate material for describing a method of manufacturing an electromagnetic clutch rotor according to one embodiment of the present invention.

FIG. 11 is a plan view of a processing region of a metal plate material for explaining a method of manufacturing the electromagnetic clutch rotor according to one embodiment of the present invention.

FIG. 12 is a plan view of a processing region of a metal plate material for describing a method of manufacturing an electromagnetic clutch rotor according to an embodiment of the present invention.

FIG. 13 is a plan view of a processing region of a metal plate material for describing a method of manufacturing a rotor for an electromagnetic clutch according to an embodiment of the present invention.

FIG. 14 is a plan view of a processing region of a metal plate material for explaining a method of manufacturing a rotor for an electromagnetic clutch according to an embodiment of the present invention.

FIG. 15 is a plan view of a processing region of a metal plate material for explaining a method of manufacturing an electromagnetic clutch rotor according to an embodiment of the present invention.

FIG. 16 is a plan view of a processing region of a metal plate material for describing a method of manufacturing an electromagnetic clutch rotor according to one embodiment of the present invention.

FIG. 17 is a plan view of a processing region of a metal plate material for describing a method of manufacturing an electromagnetic clutch rotor according to one embodiment of the present invention.

FIG. 18 is a plan view of a processing area of a metal plate material for describing a method of manufacturing an electromagnetic clutch rotor according to an embodiment of the present invention.

FIG. 19 is a cross-sectional view of a processing region of a metal plate material for describing a method of manufacturing an electromagnetic clutch rotor according to an embodiment of the present invention.

FIG. 20 is a cross-sectional view of a processing region of a metal plate material for describing a method of manufacturing an electromagnetic clutch rotor according to an embodiment of the present invention.

FIG. 21 is a cross-sectional view of a processing region of a metal plate material for describing a method of manufacturing a rotor for an electromagnetic clutch according to an embodiment of the present invention.

FIG. 22 is a cross-sectional view of a processing region of a metal plate material for describing a method of manufacturing an electromagnetic clutch rotor according to an embodiment of the present invention.

FIG. 23 is a cross-sectional view of a processing region of a metal plate material for explaining a method of manufacturing an electromagnetic clutch rotor according to an embodiment of the present invention.

FIG. 24 is a cross-sectional view of a processing region of a metal plate material for describing a method of manufacturing a rotor for an electromagnetic clutch according to an embodiment of the present invention.

FIG. 25 is a cross-sectional view of a processing region of a metal plate material for explaining a method of manufacturing an electromagnetic clutch rotor according to an embodiment of the present invention.

FIG. 26 is a cross-sectional view of a processing region of a metal plate material for explaining a method of manufacturing an electromagnetic clutch rotor according to an embodiment of the present invention.

FIG. 27 is a front view of a conventional rotor.

28 is a sectional side view of the rotor shown in FIG. 27, taken along the line AA.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 10 Electromagnetic clutch 11 Field 12 Excitation coil 13 Shaft 16 Rotor 17 Gear (input side rotating body) 18 Armature 32 Metal plate material 40, 41, 45, 46, 56, 58, 59, 60 Through hole 42 Disk part 43, 44 Retaining piece 49 Cap-shaped portion 50 Circular concave portion 51 Depressed portion 52 Inner base 53 Ring-shaped groove 54 Flange 55 Outer base 57 Inner ring-shaped protrusion 61 Outer ring-shaped protrusion 161 Through hole 162 Groove 163 Inner ring-shaped protrusion 164 Ring-shaped groove 165 Outer ring-shaped projection 166 Through hole K1, K2, K3 Processing area

Claims (10)

[Claims] 1. A shaft hole is formed at a central portion, and an inner ring-shaped projection is formed at a position surrounding the shaft hole.
An outer ring-shaped projection is formed at a position surrounding the inner ring-shaped projection, and a method for manufacturing a rotor for an electromagnetic clutch, wherein a through hole is formed between the inner ring-shaped projection and the outer ring-shaped projection, A step of forming a disk portion held by the metal plate material with a peripheral holding piece by punching out a part of the metal plate material, and pressing one side of the disk portion so that one surface side is convex. Forming a circular cap-shaped portion having a shape, and pressing the cap-shaped portion to form an inner base having a circular concave portion on the other surface side, and being located on the outer periphery of the inner base portion and having one side surface Forming an outer base having a ring-shaped groove and a flange located on the outer periphery of the ring-shaped groove, and pressing the inner base to form an outer peripheral edge of the inner base. Forming an inner ring-shaped protrusion protruding to one surface side; forming a shaft hole by punching a center of the inner base; and punching a bottom of a ring-shaped groove of the outer base to form the bottom portion. Forming a through hole in the outer base; pressing the outer base to form an outer ring-shaped projection that protrudes to one side by erecting a flange of the outer base; Cutting the holding piece after the completion of the step (a), and a method for manufacturing a rotor for an electromagnetic clutch. 2. The method according to claim 1, further comprising a step of forming a small-diameter through-hole in the center of the inner base by punching out a center of the inner base before the step of forming the inner ring-shaped protrusion. Item 7. A method for manufacturing a rotor for an electromagnetic clutch according to Item 1. 3. The step of forming the inner ring-shaped protrusion, wherein a circular recess on the other surface side of the inner base is formed into a predetermined shape simultaneously with the formation of the inner ring-shaped protrusion. 3. The method for manufacturing an electromagnetic clutch rotor according to 1 or 2. 4. The step of forming the shaft hole,
The method for manufacturing a rotor for an electromagnetic clutch according to any one of claims 1 to 3, wherein the method is provided after the step of forming the inner ring-shaped protrusion. 5. The method according to claim 1, wherein the step of forming the outer ring-shaped projection is provided after the step of forming a through-hole at the bottom of the ring-shaped groove. A method for manufacturing a rotor for an electromagnetic clutch. 6. A shaft hole is formed at a central portion, and an inner ring-shaped projection is formed at a position surrounding the shaft hole.
An electromagnetic clutch rotor comprising an outer ring-shaped projection formed at a position surrounding the inner ring-shaped projection, and a through hole formed between the inner ring-shaped projection and the outer ring-shaped projection. A rotor for an electromagnetic clutch obtained by pressing one disk portion obtained from the above. 7. An inner base having a shaft hole formed at the center and an inner ring-shaped projection formed at an outer peripheral edge from the disk portion by the press working, and is located at an outer periphery of the inner base. 7. The electromagnetic clutch according to claim 6, wherein a ring-shaped groove having a through hole is formed at a bottom portion, and an outer base portion having an outer ring-shaped projection formed at an outer peripheral edge. Rotor. 8. The inner base portion is formed by pressing the disc portion to form a circular cap-shaped portion having a convex surface on one surface side, and press-forming the cap-shaped portion. 8. The base according to claim 7, wherein the base is formed by press-working the cap-shaped portion to provide a ring-shaped groove opened on one surface side and a flange located on the outer periphery of the ring-shaped groove. Rotor for electromagnetic clutch. 9. The inner ring-shaped protrusion is formed by pressing the inner base, the shaft hole is formed by punching a center of the inner base, and the through hole is formed by pressing the outer base. The outer ring-shaped projection is formed by punching out the bottom of the ring-shaped groove,
9. The electromagnetic clutch rotor according to claim 8, wherein the rotor is formed by erecting the flange. 10. A shaft is rotatably disposed around an axis through a field in which an exciting coil is housed, and a rotor is fixed to the shaft in opposition to the exciting coil. Is rotatably mounted,
An armature arranged to be able to rotate with the torque transmitting member is attracted to the rotor by magnetism from the exciting coil against the elastic force of an elastic member, thereby rotating the torque transmitting member to the shaft. An electromagnetic clutch, wherein the electromagnetic clutch rotor according to any one of claims 6 to 9 is used as the rotor.