JP2007028718A - Method of manufacturing rotor of permanent magnet synchronous dynamo-electric machine - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To enhance the torque property, the load property, and the rotational balance of a permanent magnet synchronous dynamo-electric motor. <P>SOLUTION: In this manufacturing method for a permanent magnet synchronous dynamo-electric machine, a plurality of disc-shaped permanent magnet pieces M are stuck circumferentially to the surface of the magnetic pole forming part B<SB>0</SB>of a rotor shaft 1 being a rotor core so as to form a magnetic pole ring part D in the first stage J<SB>1</SB>, and then, the magnetic pole ring part D in the second stage J<SB>2</SB>is made in the same way in a position being dislocated axially by the length of the permanent magnet piece M, thereafter, a magnetic ring part D in the final stage (the sixth stage) J<SB>6</SB>is made in the same way. A magnetic pole forming part B<SB>0</SB>is halved axially in advance by fitting a center ring 11 in a position C which becomes the center in the axial direction of the magnetic pole forming part B<SB>0</SB>of the rotor shaft 1. In each divided magnetic pole forming part B<SB>1</SB>, the magnetic pole ring parts D in each stage are made in order toward both shaft ends of the rotor shaft 1 from the side of the center ring 11. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a method for manufacturing a rotor of a permanent magnet synchronous rotating electric machine in which a permanent magnet piece is attached to an outer peripheral surface of a rotor shaft to form a magnetic pole.

  For example, there is a “simulated dynamo test apparatus” that uses a permanent magnet synchronous rotating electric machine as a generator to generate a pseudo load as an engine load in order to test the characteristics of an engine as a specimen. Thus, when using a permanent magnet synchronous rotating electric machine as a generator of a "test device", or when using it as an electric motor, good torque characteristics and balance characteristics directly lead to improvement in test accuracy, On the contrary, if each of the above characteristics is bad, the test accuracy is lowered.

  As a method for manufacturing a rotor of a permanent magnet synchronous rotating electric machine, the one described in Patent Document 1 is known. In Patent Document 1, a magnet block structure in which a plurality of magnet pieces formed in a columnar shape are arranged in series and joined together is machined and inserted into a thin cylindrical holding cylindrical member by shrink fitting. A technique for manufacturing a rotor by magnetizing the magnet block structure after being integrated with each other is disclosed.

  Unlike the rotor manufacturing method described above, a plurality of permanent magnet pieces in the shape of arc plates are pasted along the circumferential direction from one end in the axial direction of the portion that becomes the magnetic pole part of the rotor shaft. A first-stage magnetic pole ring portion is formed, and then connected to the first-stage magnetic pole ring portion at a position displaced in the axial direction by the length of the permanent magnet piece along the axial direction. The second stage magnetic ring part is formed, and thereafter the same operation is repeated to form the final stage magnetic ring part at the other axial end of the magnetic pole part, and the magnetic pole is formed on the outer periphery of the rotor shaft. There is also a method for manufacturing a rotor.

However, in the rotor manufacturing method described above, all the “sticking errors” along the axial direction of the permanent magnet pieces in the first to last stage magnetic ring parts are concentrated in the final stage magnetic ring part. As a result, irregularities occur on the outer end surface of the magnetic pole ring part at the final stage, and the generated magnetic flux is slightly disturbed by the presence of the irregularities, resulting in the characteristics of torque generated as a motor or a generator used as a pseudo load. Adversely affects the load characteristics. In addition, the occurrence of irregularities on the outer end surface of the magnetic pole ring part at the final stage means that the balance along the axial direction of the rotor is slightly lost, but the rotational balance of the rotor is reduced and the rotor is rotating. As a result, an axial force is generated in the rotor, and a thrust load acts on the bearing mainly supporting the radial load, which also adversely affects the bearing.
Japanese Patent Laid-Open No. 2003-88018

  The present invention relates to a permanent magnet synchronous rotating electrical machine in which a permanent magnet piece is attached to the outer peripheral surface of a rotor shaft to form a magnetic pole.By improving the method of attaching the permanent magnet piece, torque characteristics in a motor, load characteristics in a generator, And to improve both the rotation balance.

  In order to solve the above-mentioned problem, the invention of claim 1 is to stick a plurality of permanent magnet pieces in the shape of a circular arc plate along the circumferential direction to the surface of the magnet forming portion of the rotor shaft that is the rotor core. After forming the first-stage magnetic pole ring portion, the second-stage magnetic pole ring portion is similarly formed at a position shifted by the length of the permanent magnet piece along the axial direction. A method for manufacturing a rotor of a permanent magnet synchronous rotating electric machine, wherein a last-stage magnetic pole ring portion is formed, and N and S poles are formed alternately on the surface of the rotor shaft along the circumferential direction. The magnetic pole forming portion is divided into two along the axial direction by fitting a center ring at a position that becomes a midpoint along the axial direction of the magnetic pole forming portion of the rotor shaft, and each of the divided magnetic pole forming portions In the direction of both shaft ends of the rotor shaft from the center ring side Toward is characterized by sequentially forming a magnetic pole ring of each stage.

  According to the first aspect of the present invention, the magnetic pole forming portion on the outer peripheral surface of the rotor shaft is divided into two by the center ring that is fitted at the midpoint along the axial direction. Compared to the conventional permanent magnet piece pasting method, in order to form the magnetic pole ring part by sticking the permanent magnet pieces of each stage sequentially from the center ring side toward both shaft ends of the rotor shaft The number of magnetic pole rings is halved. In this way, with the center ring fitted at the axial center of the magnetic pole forming portion of the rotor shaft as a reference, in order to affix the permanent magnet pieces sequentially on both sides thereof, the final stage of each divided magnetic pole forming portion The size of the irregularities of the permanent magnet piece formed on the outer end face of each magnetic pole ring portion is halved.

  For the above reasons, the disturbance of the magnetic flux generated from each magnetic pole of the magnetic pole ring part at the final stage of each divided magnetic pole forming part is suppressed, and the generated torque characteristics as a motor or used as a pseudo load in the “test equipment” The load characteristics as a generator to be improved. For the same reason, there are two final-stage magnetic pole ring portions, and the unevenness formed on the outer end surface of the magnetic pole ring portion is dispersed along the axial direction of the rotor. Since the balance is achieved along the axial direction, the rotation balance of the rotor is improved as a result, and the adjustment work of the rotation balance of the rotor is facilitated.

  According to a second aspect of the present invention, in the first aspect of the present invention, a plurality of ring-shaped separators interposed between the end faces of the permanent magnet pieces constituting the adjacent magnetic pole ring portions are provided along the circumferential direction. It is characterized by being divided into two.

  Each permanent magnet piece in the shape of a circular arc plate attached to the rotor of a permanent magnet synchronous rotating electric machine is for the purpose of preventing a decrease in generated torque, etc., in order to cut off the current flowing through the permanent magnet piece when the rotor rotates. In addition, a separator made of an insulator is interposed at both the circumferential and axial contact portions of the permanent magnet pieces. Here, when the permanent magnet pieces are continuously attached along the axial direction, the "sticking error" appears as irregularities on the outer end surface of the magnetic pole ring portion at the final stage. In the case where the separator interposed in the contact portion along the axial direction of the single ring is a ring shape, if the unevenness in the axial direction generated in the part is already large, it is not possible to cope with only the curvature of the separator. Thus, a slight gap may be generated at the connection portion of each magnetic pole ring portion near the final stage.

  Therefore, as in the invention of claim 2, when a separator divided into a plurality along the circumferential direction is used, each divided piece of the separator can easily correspond to the unevenness along the axial direction of the permanent magnet piece of that portion. Therefore, the permanent magnet piece can be continuously attached along the axial direction of the rotor with no or almost no gap. Further, even if there is a slight gap in the connecting portion along the axial direction of the permanent magnet piece, the generated magnetic flux from the magnetic pole of the rotor composed of the permanent magnet piece becomes orderly, and the motor In this case, the generated torque is not reduced.

  According to the present invention, the magnetic pole forming portion is divided into two by the center ring fitted at the midpoint along the axial direction of the magnetic pole forming portion on the surface of the rotor. Compared with the conventional permanent magnet piece pasting method, the permanent magnet pieces in each stage are stuck in order from the side toward the ends of the rotor shaft to form the magnetic pole ring part. In addition, the size of the irregularities of the permanent magnet piece formed on the outer end face of each magnetic pole ring part at the final stage of each magnetic pole forming part is halved. For this reason, the disturbance of the magnetic flux generated from each magnetic pole of the magnetic pole ring part at the last stage of each divided magnetic pole forming part is suppressed, and the characteristics of the torque generated as a motor, or as a pseudo load in the “test device” Load characteristics as a generator to be used are improved. In addition, there are two last-stage magnetic pole ring portions, and unevenness formed on the outer end surface of the magnetic pole ring portion is distributed along the axial direction of the rotor, and each distributed unevenness is along the axial direction. As a result of the balance, the rotation balance of the rotor is also good.

Hereinafter, the present invention will be described in more detail with reference to the best mode. FIG. 1 is an exploded perspective view of a rotor R of a permanent magnet synchronous rotating electrical machine manufactured by the method of the present invention. 2 to 9 are diagrams showing each step of the method for manufacturing the rotor R according to the present invention. FIG. 2 shows the center ring 11 at the midpoint position in the axial direction of the magnetic pole forming portion B ₀ of the rotor shaft 1. And FIG. 3 is a front view showing a process of dividing the magnetic pole forming part B ₀ into two, and FIG. 3 shows the center ring 11 fitted in the midpoint position of the rotor shaft 1 in the axial direction of the magnetic pole forming part B ₀ . FIG. 4 is a front view showing a process of fitting a ring-shaped first separator K ₁ on both sides, and FIG. 4 shows a _{first in} the spacer groove 5 of the first stage J ₁ of each divided magnetic pole forming part B ₁ divided into two. FIG. 5 is a diagram illustrating a process of fitting the spacer A ₁ , and FIG. 5 is a diagram illustrating a process of attaching the permanent magnet piece M between the first spacers A ₁ adjacent in the circumferential direction. is a front view of a state where the first stage J ₁ to the magnetic pole ring part D of the divided magnetic pole forming portion B ₁ is formed, FIG. 7 Is a partial perspective view showing a magnetic pole ring part D of the first stage J ₁ has been completed, FIG. 8, the final stage of the divided magnetic pole forming portion B ₁ that is divided into two (level 6 J ₆₎ FIG. 9 is a front view showing a process of fitting the second spacer A ₂ on the outer side of FIG. 9, and FIG. 9 shows a state in which the shrink ring 14 is fitted on the outside of each permanent magnet piece M affixed to the surface of the rotor shaft 1. it is a front view showing a step of fitting the retaining ring 15 on the outside of the pole ring part D located at both ends of the divided magnetic pole forming portions B _1.

  As shown in FIGS. 1, 2, and 4, the rotor shaft 1 is a portion that occupies most of the remainder excluding both ends along the axial direction, and a permanent magnet piece M that forms a magnetic pole on the outer peripheral surface. A large-diameter portion 2 to be pasted, a support portion 3 that is continuously provided on both sides of the large-diameter portion 2 and supported by a bearing (none of which is shown) fitted to the casing, and one support The connecting part 4 is provided continuously to the part 3 and connected to a load-side or power-side shaft via a coupling (not shown). On the outer peripheral surface of the large-diameter portion 2 of the rotor shaft 1, spacer grooves 5 which are positions that are equally divided into four along the circumferential direction and that have a linear groove shape at portions excluding both ends of the large-diameter portion 2 are shafts. It is formed continuously in the direction.

First, the center ring 11 is press-fitted from one end of the rotor shaft 1 to the midpoint position C in the axial direction of the large diameter portion 2 (FIG. 2). The midpoint C defined by the center ring 11 is a reference position when the paste permanent magnet pieces M on both sides, divided into the left and right magnetic pole forming portions B ₀ of the rotor shaft 1 at the midpoint position Will do. In each of the divided magnetic pole forming portions B ₁ divided into two, the magnetic pole ring portions D formed into a ring shape by attaching the permanent magnet pieces M along the circumferential direction are the same number of steps (in the embodiment, 6 steps). It is formed. The spacer groove 5 formed in the axial direction of the large diameter portion 2 of the rotor shaft 1 is slightly longer than the length of the magnetic pole forming portions B _0. The material of the center ring 11 may be either a magnetic material or a nonmagnetic material.

Next, ring-shaped first separators K ₁ are fitted into both sides of the center ring 11 press-fitted from both ends of the rotor shaft 1 into the axial center point C of the large diameter portion 2, respectively. 11 are closely attached to both side surfaces (FIG. 3). The first separator K ₁ cooperates with a later-described second separator K ₂ for the purpose of interrupting the current flowing through the permanent magnet piece M attached to the surface of the rotor shaft 1 when the rotor R rotates. Therefore, it is made of an insulating material.

Next, the permanent magnet piece M is affixed to the first stage J ₁ of each of the two divided magnetic pole forming portions B ₁ . First, the first spacer A ₁ having a key shape is fitted into the spacer groove 5 of the first stage J ₁ of each divided magnetic pole forming portion B ₁ (FIG. 4). The first spacer A ₁ includes a fitting portion 12 fitted in the spacer groove 5 and an exposed portion 13 exposed on the outer periphery of the rotor shaft 1. The length of the first spacer A ₁ is the same as the length of the permanent magnet piece M in the shape of a circular arc plate piece, and its width gradually increases from the fitting side toward the non-fitting side. The part 12 has a step with respect to the exposed part 13. The first spacer A ₁ is made of a nonmagnetic material such as aluminum. When the rotating electrical machine is a motor, the basic action of the first spacer A ₁ is the rotation generated by the attractive force and repulsive force between each magnetic pole of the rotor R and the magnetic pole generated by the rotating magnetic field of the stator (not shown) during rotation. This is to ensure transmission of torque to the rotor R.

Next, in the first stage J ₁ of each of the two divided magnetic pole forming portions B ₁ , a plurality of identical poles (in the embodiment, between the adjacent first spacers A ₁ on the surface of the rotor shaft 1). Four permanent magnet pieces M are pasted with an adhesive (FIG. 5). A second separator K ₂ made of an insulating material is interposed between the adjacent permanent magnet pieces M and between the permanent magnet pieces M and the first spacer A ₁ . The permanent magnet pieces M are pasted so that N poles and S poles are alternately formed along the circumferential direction of the rotor shaft 1. As a result, a quadrupole magnetic ring portion D is formed in the first stage J ₁ of each of the divided magnetic pole forming portions B ₁ divided into two (FIGS. 6 and 7).

Thereafter, from the second stage J _{2 of} each divided magnetic pole forming part B ₁ to the sixth stage J ₆ which is the final stage, exactly the same as the first stage J ₁ described above, in FIG. As indicated by an arrow Q, magnetic pole ring portions D are sequentially formed from the center ring 11 toward both ends of the rotor shaft 1. A first separator K ₁ is interposed between the permanent magnet pieces M forming the adjacent magnetic pole ring portions D of each stage.

Next, the second spacer A ₂ divided into four along the circumferential direction is fitted to the outside of each permanent magnet piece M of the sixth stage J ₆ (FIG. 8). After that, a CFRP shrink ring 14 is fitted from one end of the rotor shaft 1 to the outside of each permanent magnet piece M affixed to the outer peripheral surface of the rotor shaft 1, and then as a final step, from both ends of the rotor shaft 1. The presser ring 15 is press-fitted (FIG. 9).

Thus, the center ring 11 is press-fitted into the midpoint position along the axial direction of the magnetic pole forming portion B ₀ of the rotor shaft 1, and the divided magnetic pole forming portions on both sides of the center ring 11 are used as a reference. Since the permanent magnet pieces M are sequentially attached to B ₁ , the rotor shaft 1 is compared with the conventional method in which the permanent magnet pieces M are sequentially attached on the basis of one axial end of the magnetic pole forming portion B ₀ of the rotor shaft 1. The sticking error of the permanent magnet piece M along the axial direction is distributed to the magnetic pole ring part D at the final stage of each divided magnetic pole forming part B ₁ . As a result, the size of the irregularities of the permanent magnet piece M formed on the outer end surface of the magnetic pole ring portion D of the final stage (sixth stage J ₆ ) of each divided magnetic pole forming part B ₁ is halved.

For this reason, the disturbance of the magnetic flux generated from each magnetic pole of the magnetic pole ring part D of the final stage (sixth stage J ₆ ) of each divided magnetic pole forming part B ₁ is suppressed, and the characteristics of torque generated as a motor, Alternatively, load characteristics as a generator used as a pseudo load in the “test apparatus” are improved.

In addition, the unevenness formed on the outer end surface of the magnetic pole ring portion D at the final stage (sixth stage J ₆ ) that exists in two is distributed along the axial direction of the rotor R, and each of the distributed unevennesses is the axis. Since the balance is achieved along the direction, as a result, the rotation balance of the rotor R becomes good and the adjustment work of the rotation balance of the rotor becomes easy. Furthermore, since the ring-shaped first separator K ₁ is fitted from both ends of the rotor shaft 1, compared to the conventional method of attaching the permanent magnet piece M, the rotor shaft 1 of the plurality of first separators K ₁ is provided. The total travel distance along the axial direction is almost halved, which also contributes to the simplification of the rotor manufacturing method.

FIG. 10 is a development view of a part of the magnetic pole ring portion D using the first separator K ₁ ′ divided into four in the circumferential direction. In FIG. 10, L indicates a line in a direction perpendicular to the axial direction of the rotor shaft 1. Further, in FIG. 10, the second separator K ₂ is not shown. When the first separator K ₁ ′ divided into a plurality of parts such as four in the circumferential direction is used, each of the divided pieces K ₁₁ ′ of the first separator K ₁ ′ is an axis of the end face of the permanent magnet piece M of the part. In order to easily cope with the unevenness along the direction, the permanent magnet piece M can be continuously attached along the axial direction of the rotor shaft 1 with no or almost no gap. Further, even if there is a slight gap in the connecting portion along the axial direction of the permanent magnet piece M, the generated magnetic flux from the magnetic pole of the rotor R composed of the permanent magnet piece M becomes orderly. In the case of a motor, the generated torque is not reduced.

  In the motor using the rotor R described above, each magnetic pole of the rotating magnetic field formed by the stator and each magnetic pole formed on the outer peripheral portion of the rotor R are attracted and repelled to each other, so that the rotor R becomes a rotating magnetic field. The generator using the rotor rotates synchronously without slipping, and a rotating magnetic field synchronized with the rotation of the rotor R is formed in the stator so that a current flows through the stator coil.

It is a disassembled perspective view of the rotor R of the permanent magnet synchronous rotary electric machine manufactured by the method of this invention. FIG. 7 is a front view showing a process of fitting the center ring 11 at a midpoint position C in the axial direction of the magnetic pole forming part B ₀ of the rotor shaft 1 and dividing the magnetic pole forming part B ₀ into two parts. FIG. 5 is a front view showing a process of fitting a ring-shaped first separator K ₁ on both sides of a center ring 11 fitted at an axial midpoint C of a magnetic pole forming part B ₀ of the rotor shaft 1. It is a diagram showing the bisected each divided magnetic pole forming portion B ₁ of the first stage J ₁ of the first step of fitting the spacer A ₁ in the spacer groove 5. During each first spacer A ₁ adjacent in the circumferential direction is a diagram showing a step of attaching the permanent magnet pieces M. It is a front view of a state where the first stage J ₁ to the magnetic pole ring part D of the divided magnetic pole forming portion B ₁ is formed. It is a partial perspective view of a magnetic pole ring part D of the first stage J ₁ was completed. 2 is a front view showing a second step of fitting the spacer A ₂ on the outside of the final-stage divided the divided pole forming portions B ₁ was (level 6 J _6). After the shrink ring 14 is fitted on the outer side of each permanent magnet piece M affixed to the surface of the rotor shaft 1, the presser ring 15 is placed on the outer side of each magnetic pole ring part D positioned at both ends of each divided magnetic pole forming part B _1. It is a front view which shows the process of inserting. FIG. 5 is a development view of a part of a magnetic pole ring portion D having a first separator K ₁ ′ divided into four in the circumferential direction.

Explanation of symbols

B ₀ : Magnetic pole forming part of the rotor shaft
B ₁ : Divided magnetic pole forming part of the rotor shaft
C: Axial midpoint position of the magnetic pole forming part of the rotor shaft
D: Magnetic pole ring part K ₁ , K ₁ ': First separator
K ₁₁ ': Split piece of the first separator
M: Permanent magnet piece
R: Rotor
1: Rotor shaft
11: Center ring

Claims (2)

A plurality of permanent magnet pieces in the shape of arc plates are attached along the circumferential direction on the surface of the rotor core magnet forming portion which is the rotor core to form the first-stage magnetic pole ring portion. Similarly, a second-stage magnetic pole ring portion is formed at a position shifted by the length of the permanent magnet piece along the direction, and thereafter the final-stage magnetic pole ring portion is formed in the same manner to form the rotor shaft. A method of manufacturing a rotor of a permanent magnet synchronous rotating electric machine, wherein N poles and S poles of permanent magnets are alternately formed along the circumferential direction on the surface of the permanent magnet,
By fitting a center ring at a position that becomes a midpoint along the axial direction of the magnetic pole forming portion of the rotor shaft, the magnetic pole forming portion is divided into two along the axial direction,
In each of the divided magnetic pole forming portions, each stage magnetic pole ring portion is formed sequentially from the center ring side toward both ends of the rotor shaft. Production method. The ring-shaped separator interposed between the end faces of the permanent magnet pieces constituting the adjacent magnetic pole ring portions is divided into a plurality of portions along the circumferential direction. A method of manufacturing a rotor of a permanent magnet synchronous rotating electric machine.

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