JP2009011038A - Method of manufacturing rotor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a technique capable of wholly magnetizing magnetic bodies without damaging a coil even in case of multiple poles. <P>SOLUTION: The manufacturing method has: a step of holding a plurality of first magnetic bodies 14 with a first spacing 15 between them on one surface of a first holding member 12 and magnetizing the first magnetic bodies 14 in a direction perpendicular to the direction where the first magnetic bodies 14 are circularly arranged, thereby obtaining first permanent magnets 14M; a step of holding a plurality of second magnetic bodies 18 with a second spacing 19 between them on one surface of a second holding member 16 and magnetizing the second magnetic bodies 18 in a direction perpendicular to the direction where the second magnetic bodies 18 are circularly arranged, thereby obtaining second permanent magnets 18M; and a step of arranging the first permanent magnets 14M in the second spacings 19 of the second holding member 16, the second permanent magnets 18M in the first spacings 15 of the first holding member 12 so that the magnetization directions are circularly alternated to assemble the rotor 10. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a method for manufacturing a rotor that constitutes a motor so as to face a stator via a predetermined gap.

  2. Description of the Related Art Conventionally, a so-called axial gap type motor in which a stator as an armature and a rotor as a field element are disposed so as to face each other along the rotation axis direction is known. There is also known a so-called radial gap type motor in which a stator and a rotor are arranged to face each other along a radial direction of a rotating shaft. In order to obtain a high rotational force (torque), the rotors of these motors are generally provided with many permanent magnets.

  When manufacturing such a rotor, a permanent magnet that is pre-magnetized is disposed, or a plurality of magnetic bodies are disposed on a holding member that can be used as a rotor, and the magnetic body is magnetized to be permanent. I got a magnet. Alternatively, a magnetic material that is not magnetized is disposed in a holding member that can be used as a rotor, and after assembling the holding member and the stator, a current is passed through the coil of the stator to generate a magnetic flux in the teeth portion, A permanent magnet may be obtained by applying a magnetic flux to the magnetic body from the teeth portion.

  A related manufacturing method of an axial gap type motor is disclosed in, for example, Patent Document 1.

JP-A-5-137300

However, the above-described rotor manufacturing method has the following problems. That is,
1. In the case of disposing a pre-magnetized permanent magnet, the efficiency of the disposition process may be reduced due to the influence of magnetism;
2. When a non-magnetized magnetic material is disposed on a holding member that can be used as a rotor, and after the holding member and the stator are assembled, the magnetic material is magnetized using the stator to obtain a permanent magnet. Since it is necessary to pass a large current as a magnetizing current, the stator coil may be damaged;
3. 2. However, in the case of magnetizing a plurality of magnetic bodies together, especially in the case of multiple poles (4 poles or more, especially 8 poles or more), different magnetic poles exist in close proximity, and each magnetic body It is difficult to magnetize the whole.

  Therefore, in view of the above problems, the present invention has an object to provide a technique capable of magnetizing the entire magnetic body even in the case of multiple poles without damaging the coil in the rotor manufacturing method. And

  In order to solve the above-mentioned problem, the first invention is a method of manufacturing a rotor (10, 10a to 10e) that constitutes a motor so as to face the stator (20) through a predetermined gap, and includes a first holding member. A plurality of first magnetic bodies (14) held in an annular shape at a first interval (15) at (12, 12a to 12e) are magnetized in a direction orthogonal to the annular arrangement direction of the first magnetic bodies. The first magnetizing step for obtaining the first permanent magnet (14M) and a plurality of second magnetic bodies held annularly by the second holding members (16, 16a to 16e) at a second interval (19) (18) is magnetized in a direction orthogonal to the annular arrangement direction of the second magnetic bodies to obtain a second permanent magnet (18M), and the first permanent magnet is separated from the second interval. In addition, the second permanent magnets are arranged at the first intervals with the respective magnetizing directions alternately arranged in an annular shape. And a rotor assembly process for assembling the serial rotor.

  2nd invention is 1st invention, Comprising: The said 1st holding member (12,12a) and the said 2nd holding member (16,16a) exhibit flat form, In the said rotor assembly process, said 1st The inner periphery of the holding member (12, 12a) and the inner periphery of the second holding member (16, 16a), and the outer periphery of the first holding member (12, 12a) and the second holding member (16, 16a) The outer peripheries of each face each other.

  3rd invention is 1st or 2nd invention, Comprising: The said 1st holding member (12) and the said 2nd holding member (16) exhibit flat form, and the said 1st holding | maintenance is carried out in the said rotor assembly process. A plurality of annular members (32) sandwiching the member and the second holding member are joined together.

  4th invention is 1st or 2nd invention, Comprising: In the said rotor assembly process, the said 1st holding member (12,12a-12e) and the said 2nd holding member (16,16a-16e) are adhere | attached. To join.

  5th invention is 1st or 2nd invention, Comprising: In the said rotor assembly process, the pin member (34) which penetrates both of the said 1st holding member (12a) and the said 2nd holding member (16a). ) To join.

  6th invention is 1st or 2nd invention, Comprising: The said 1st holding member (12b) and the said 2nd holding member (16b) exhibit flat form, and in the said rotor assembly process, it is an annular member (36). ) Is joined to the outer periphery of the first holding member and the outer periphery of the second holding member.

  A seventh invention is any one of the first to sixth inventions, wherein the first holding member (12a) is nonmagnetic provided between the first magnetic bodies (14) adjacent to each other in an annular shape. The second holding member (16a) has a nonmagnetic body (60) provided between the second magnetic bodies (18) adjacent to each other in a ring shape.

  The eighth invention is any one of the first to sixth inventions, wherein only one of the first holding member (12c, 12d) and the second holding member (16c, 16d) is magnetic. Is the body.

  A ninth invention is any one of the first to sixth inventions, wherein the first holding member (12d, 12e) is connected to the first connecting portion (13 on one side with respect to the first magnetic body (14). ) To magnetically connect the first magnetic bodies to each other, and the second holding member (16d, 16e) is connected to the second magnetic body at the second connecting portion (17) on one side with respect to the second magnetic body (18). In the rotor assembling step, the first connection portion and the second connection portion are mutually connected to the first permanent magnet (14M) and the second permanent magnet (18M). Arranged on the opposite side.

  A tenth aspect of the invention is any one of the first to sixth aspects, wherein the first holding member (12a to 12c) is a third magnetic member that covers the first magnetic body (14) from one side thereof. A body (42) and a fourth magnetic body (44) provided at the first interval (15). In the rotor assembly step, the first holding member (12a to 12c) and the second holding member (16a to 16c) are arranged to face each other via the first permanent magnet (14M) and the second permanent magnet (18M).

  The eleventh invention is the tenth invention, wherein the first holding member (12, 12b, 12c) connects the third magnetic body (42) and the fourth magnetic body (44) to each other. It further has a thin part (43).

  The twelfth invention is the tenth or eleventh invention, wherein the first holding member (12a, 12b) is disposed between the third magnetic body (42) and the fourth magnetic body (44). The fifth magnetic body (46) is further included.

  A thirteenth invention is the twelfth invention, wherein the first holding member (12b) further includes a sixth magnetic body (48) for connecting the plurality of fifth magnetic bodies (46) on the inner peripheral side. Have.

  The fourteenth invention is the invention according to any one of the eleventh to thirteenth inventions, wherein the fifth magnetic body (46) is connected to the third magnetic body (42) and the above-mentioned through the thin-walled portion (43). It is connected to the fourth magnetic body (44).

  A fifteenth invention is the thirteenth or fourteenth invention, wherein the second holding member (16b) is magnetically coupled to the sixth magnetic body (48).

  A sixteenth aspect of the invention is any one of the first to fifteenth aspects of the invention, wherein the first magnetizing step and the second magnetizing step employ an air-core coil (72) to perform magnetization. Is called.

  The seventeenth invention is the invention according to any one of the first to fifteenth inventions, wherein the first magnetizing step and the second magnetizing step employ a magnetizing yoke (74) to perform magnetization. Is called.

  According to the first invention, since the first magnetic body and the second magnetic body are magnetized while being held by the first holding member and the second holding member, respectively, the first magnetization step and the second magnetization are performed. In each of the steps, the magnetic body as a whole can be magnetized even if it has multiple poles by only generating a magnetic field in one direction. Therefore, it is avoided that the stator coil is damaged by a large current during magnetization, which is a concern when the stator and the rotor are assembled and then the stator is used to magnetize the magnetic body in the rotor. .

  According to the second invention, when employed in the axial gap type motor, deformation of the first and second holding members, and hence deformation of the rotor, is prevented.

  According to the third invention, it is easy to firmly join the first and second holding members. In particular, when the motor is an axial gap type motor, it is easy to resist the attractive force acting with the stator.

  According to the fourth invention, it is easy to firmly join the first and second holding members.

  According to the fifth aspect, it is easy to firmly join the first and second holding members.

  According to the sixth aspect, when employed in the axial gap type motor, the first and second holding members are firmly joined.

  According to the seventh aspect, the leakage magnetic flux between adjacent ones of the first and second magnetic bodies can be reduced.

  According to the eighth aspect of the invention, only one of the first and second holding members functions as the back yoke after assembly, so there is no need to separately join the back yoke. For this reason, the junction part of the back yoke becomes unnecessary, and the magnetic resistance due to the junction part can be suppressed.

  According to the ninth aspect, the first and second holding members can be applied as the back yoke.

  According to the tenth invention, the third and fourth magnetic bodies are cores that reduce eddy currents in the first and second permanent magnets caused by the magnetic field from the stator or the back yoke for the first and second permanent magnets, respectively. Function.

  According to the eleventh aspect, since the thin wall portion is easily magnetically saturated, it functions substantially as a magnetic barrier between the first permanent magnet and the second permanent magnet, and leakage flux is reduced.

  According to the twelfth invention, since the fifth magnetic body increases so-called q-axis inductance, a rotor that contributes to a motor that uses reluctance torque can be obtained.

  According to the thirteenth aspect, the q-axis inductance is further increased. Further, when the stator is disposed on both sides of the rotor, the number of times that the magnetic flux that generates the reluctance torque passes through the air gap can be reduced from four to two.

  According to the fourteenth aspect, the position of the fifth magnetic body with respect to the first and second permanent magnets is fixed, and the reluctance torque is stabilized.

  According to the fifteenth aspect, when the stator is disposed on both sides of the rotor, the number of times the magnetic flux passes through the air gap can be halved from four times to two times.

  According to the sixteenth aspect, the first and second magnetic bodies respectively held by the first and second holding members can be easily attached before magnetization and removed after magnetization.

  According to the seventeenth aspect, the magnetizing current can be reduced.

  Preferred embodiments of the present invention will be described below with reference to the drawings. In the following drawings including FIG. 1, only elements related to the present invention are shown.

<First Embodiment>
FIG. 1 is an exploded perspective view of a motor for explaining the steps of the method for manufacturing the rotor 10 according to the present invention, which is shown exploded along the rotation axis A of the rotor 10. 2 and 3 are schematic diagrams for explaining a magnetizing apparatus employed in the magnetizing process. FIG. 4 is a perspective view of the assembled rotor 10. The manufacturing method includes a first magnetization process, a second magnetization process, and a rotor assembly process.

  First, as a preparatory step for the first magnetization step, a first holding member 12 having a flat plate shape, preferably a substantially annular shape, is formed by punching a magnetic plate such as high permeability iron (soft magnetic material). The first holding member 12 is provided with a plurality of holes 41 radially from the center of the ring, and a thin portion 43 is provided on each of the inner peripheral side and the outer peripheral side of the hole 41. Thereby, the 1st holding member 12 can be grasped | ascertained by dividing into the thin part 43 and the magnetic bodies 42 and 44 mutually connected by the thin part 43 cyclically | annularly.

  On one surface of the first holding member 12 formed in this way, a plurality of (for example, four) magnetized magnetic bodies (hard magnetic materials) 14 are transferred from one side of the first holding member 12 to the magnetic body 42. Provide. FIG. 1 exemplifies a mode in which the magnetic body 14 is provided from below with respect to the first holding member 12. Since the magnetic bodies 42 and 44 are alternately arranged in a ring shape, the magnetic body 14 is also held in a ring shape with the magnetic body 44 interposed therebetween. In other words, the magnetic body 14 is held in an annular shape with a first interval 15 therebetween.

  In addition, as a preparatory step for the second magnetization step, a substantially disc-shaped second holding member 16 having substantially the same size and shape as the first holding member 12 is formed. For example, the second holding member 16 also has the thin portions 43 and the magnetic bodies 42 and 44 that are alternately connected to each other by the thin portions 43 like the first holding member 12. A hole 41 is provided between 42 and 44.

  On one surface of the second holding member 16 formed in this way, a plurality of (for example, four as many as the magnetic bodies 14 (hereinafter also referred to as first magnetic bodies 14)) magnetized second magnetic bodies ( (Hard magnetic material) 18 is held in an annular shape with a second interval 19. Specifically, the second magnetic body 18 is provided on the magnetic body 44, and the second magnetic body 18 is also held in an annular shape with the magnetic body 42 interposed therebetween. In the second interval 19, the magnetic body 42 is positioned.

  Here, the first interval 15 provided by the first holding member 12 is larger than the width of the second magnetic body 18 held by the second holding member 16, and the second interval provided by the second holding member 16. 19 is larger than the width of the first magnetic body 14 held by the first holding member 12.

  The magnetic body 42 and the magnetic body 44 are also referred to as a third magnetic body 42 and a fourth magnetic body 44, respectively.

  In the first magnetizing step, the plurality of first magnetic bodies 14 held in an annular shape with the first interval 15 spaced by the first holding member 12 are magnetized in a direction orthogonal to the annular arrangement direction of the first magnetic bodies 14. The first permanent magnet 14M is obtained by magnetizing. Specifically, as shown in FIG. 2, in the first magnetizing step, the air-core coil 72 is used for magnetization. More specifically, the first magnetic body 14 is placed by placing the first holding member 12 holding the first magnetic body 14 inside the air-core coil 72 and causing a large current to flow through the air-core coil 72 in one direction. The upper surface of 14 (the surface on the side not in contact with the first holding member 12) is magnetized so as to have, for example, an N pole. 2 is a schematic diagram, and the air-core coil 72 is actually wound longer along the axial direction. In addition, a fixing means or the like that is actually hardened with a resin or the like and that fixes the adherend by a known means is also provided.

  In the second magnetizing step, the plurality of second magnetic bodies 18 held in an annular shape by the second holding member 16 with a second interval 19 therebetween are magnetized in a direction orthogonal to the annular arrangement direction of the second magnetic bodies 18. The second permanent magnet 18M is obtained by magnetizing. Specifically, as in the first magnetization step, as shown in FIG. 2, the second holding member 16 holding the second magnetic body 18 is placed inside the air-core coil 72, and the first magnetization is performed. By flowing a large current in a direction opposite to the large current that flows in the process, the upper surface of the second magnetic body 18 (the surface that is not in contact with the second holding member 16) has a polarity opposite to that of the first permanent magnet ( For example, it is magnetized so as to be S pole).

  In the first and second magnetizing steps described above, as shown in FIG. 3, a magnetized yoke 74 provided with a coil 82 is used instead of the air-core coil 72 so that magnetization is performed. May be. Here, the arrows shown in FIGS. 2 and 3 indicate the directions of the polarities magnetized by the air-core coil 72 or the coil 82, respectively. The first magnetic body 14 and the second magnetic body 18 are The upper side is magnetized to the N or S pole, and the lower side of the arrow is magnetized to the S or N pole.

  In the rotor assembling process, the rotor 10 is assembled by arranging the first permanent magnets 14M at the second intervals 19 and the second permanent magnets 18M at the first intervals 15 with the respective magnetizing directions alternately arranged in an annular shape. Specifically, in the rotor assembly process, the inner periphery of the first holding member 12 and the inner periphery of the second holding member 16, and the outer periphery of the first holding member 12 and the outer periphery of the second holding member 16 are opposed to each other. Thus, the rotor 10 is assembled by arranging the first permanent magnets 14M at the second intervals 19 and the second permanent magnets 18M at the first intervals 15 with the magnetizing directions alternately arranged in an annular shape. Further, in the rotor assembly process, a plurality of annular members 32 sandwiching the first holding member 12 and the second holding member 16 may be joined.

  With respect to the rotor 10 thus assembled, the stator 20 as an armature including the back yoke 22, the tooth portion 24 and the armature winding (coil) 26 is provided with a predetermined gap along the rotation axis A direction of the rotor 10. Axial gap type motor is configured by arranging them opposite to each other. That is, the first holding member 12 and the second holding member 16 function as a rotor core. In FIG. 1, the stator 20 is disposed only on the lower side of the rotor 10, but may be disposed on the upper side of the rotor 10 together. In this embodiment, the rotor 10 and the stator 20 are opposed to each other on a plane that is completely orthogonal to the rotation axis A, but the surface that faces both is a plane that is completely orthogonal to the rotation axis A. It is not necessary and may be inclined. Even at this time, the magnetization direction of the first permanent magnet 14M and the second permanent magnet 18M is preferably a minute angle even if it is the direction of the rotation axis A or tilted.

  Unless otherwise specified in the present application, the armature winding does not indicate each of the conductive wires constituting the armature winding, but indicates an aspect in which the conductive wires are wound together. The same applies to the drawings. In addition, the drawing lines at the start and end of winding and their connections are also omitted in the drawings.

<Effects of First Embodiment>
As described above, the first magnetic body 14 and the second magnetic body 18 are independently held in the first magnetizing step and the second magnetizing step while being held by the first holding member 12 and the second holding member 16, respectively. Therefore, in each of the first magnetizing step and the second magnetizing step, it can be magnetized only by generating a magnetic field in one direction. Therefore, after assembling the stator 20 and the rotor 10, there is a concern when the stator 20 is used to magnetize the magnetic bodies 14 and 18 in the rotor 10. Taking damage is avoided.

  Further, when the rotor 10 is employed in an axial gap type motor, the first holding member 12 and the second holding member 16 are prevented from being deformed, and hence the rotor 10 is prevented from being deformed. Further, when the plurality of annular members 32 are sandwiched and joined, the first holding member 12 and the second holding member 16 can be easily joined firmly. Such joining has an advantage that it is easy to resist the attractive force acting between the stator 20 particularly when the motor is an axial gap type motor. Moreover, even if it has multiple poles (in this case, 8 poles), it can be completely magnetized to the vicinity of the pole boundary.

  The third magnetic body 42 and the fourth magnetic body 44 of the second holding member 16 function as a core that reduces eddy currents in the second permanent magnet 18M due to the magnetic field from the stator 20. When the stator 20 is opposed from the first holding member 12 side, the third magnetic body 42 and the fourth magnetic body 44 of the first holding member 12 reduce the eddy current in the first permanent magnet 14M (hereinafter referred to as “the core”). It also functions as a “head core”. Furthermore, since the thin portion 43 is easily magnetically saturated, it substantially functions as a magnetic barrier between the first permanent magnet 14M and the second permanent magnet 18M, and leakage flux is reduced.

  Further, if the annular member 32 is a magnetic body, the third magnetic body 42 and the fourth magnetic body 44 can also function as a back yoke for the first permanent magnet 14M and the second permanent magnet 18M. In order to avoid the saturation of magnetic flux in order to function as a back yoke, the thickness (dimension in the direction of the rotation axis A) of the third magnetic body 42 and the fourth magnetic body 44 is larger than in the case of functioning as a head core. Is desirable.

  In addition, by adopting the air-core coil 72 in the magnetization process, the first magnetic body 14 and the second magnetic body 18 held by the first holding member 12 and the second holding member 16, respectively, are attached before magnetization. And can be easily removed after magnetization. Furthermore, if the magnetizing yoke 74 is employed in the magnetizing process, the magnetizing current can be reduced.

Second Embodiment
In the first embodiment, the aspect in which the rotor 10 is assembled by joining the first holding member 12 and the second holding member 16 to each other by joining the plurality of annular members 32 in the rotor assembling process has been described. It is not limited to. Here, as a second embodiment of the present invention, an aspect in which the first holding member 12a and the second holding member 16a are bonded or joined by the pin member 34 will be described with reference to the drawings. In the following description of the embodiment, unless otherwise specified, elements having the same functions as those in the first embodiment are denoted by the same reference numerals and description thereof is omitted.

  FIG. 5 is an exploded perspective view of the rotor 10a for explaining the steps of the method for manufacturing a rotor according to the present invention, which is exploded in the direction of the rotation axis. FIG. 6 is a perspective view of the rotor 10a assembled by bonding. FIG. 7 is an exploded perspective view illustrating a process of assembling with the pin member 34. In the rotor 10a manufactured in the present embodiment, the first holding member 12a has a nonmagnetic material. The first holding member 12 a has a third magnetic body 42 and a fourth magnetic body 44. Further, the first holding member 12 a has a fifth magnetic body 46 disposed between the third magnetic body 42 and the fourth magnetic body 44.

  Specifically, the 1st holding member 12a has the nonmagnetic body 60 formed in substantially wheel shape. The nonmagnetic body 60 includes an outer ring portion 62 corresponding to a wheel, a boss portion 64 corresponding to a wheel stiffness (boss), and a plurality of spoke portions 66 corresponding to wheel radiation (spoke). The first holding member 12 a holds the first magnetic body 14 between the outer ring portion 62 and the boss portion 64 of the nonmagnetic body 60 and between the one spoke portion 66 and the other spoke portion 66.

  In the region surrounded by the outer ring portion 62, the boss portion 64, and the plurality of spoke portions 66, the third magnetic body 42 is disposed in the region holding the first magnetic body 14, and the region corresponds to the first interval 15. A fourth magnetic body 44 is disposed on the surface. The fifth magnetic body 46 is disposed between the third magnetic body 42 and the fourth magnetic body 44 in the region surrounded by the outer ring portion 62, the boss portion 64, and the plurality of spoke portions 66. A plurality of first magnetic bodies 14 held by the first holding member 12a are magnetized in a direction orthogonal to the annular arrangement direction of the first magnetic bodies 14 to obtain a first permanent magnet 14M.

  Further, the second holding member 16a is configured as follows. That is, the second holding member 16 a also includes the third magnetic body 42, the fourth magnetic body 44, the fifth magnetic body 46, and the nonmagnetic body 60.

  A fourth magnetic body 44 is disposed in a region that holds the second magnetic body 18 in a region surrounded by the outer ring portion 62, the boss portion 64, and the plurality of spoke portions 66. A third magnetic body 42 is disposed at a position facing the magnetic body 14. The fifth magnetic body 46 is disposed between the third magnetic body 42 and the fourth magnetic body 44 in the region surrounded by the outer ring portion 62, the boss portion 64, and the plurality of spoke portions 66. A plurality of second magnetic bodies 18 held by the second holding member 16a are magnetized in a direction orthogonal to the annular arrangement direction of the second magnetic bodies 18 to obtain a second permanent magnet 18M.

  Using the first holding member 12a and the second holding member 16a, the first holding member 12a and the second holding member 16a are joined in the rotor assembling process as shown in FIG. For the bonding, for example, an adhesive can be used. Alternatively, as shown in FIG. 7, the first holding member 12a and the second holding member 16a are joined using a pin member 34 that penetrates both. If a specific example is given, a through-hole will be suitably provided in the boss | hub part 64 of the 1st holding member 12a and the 2nd holding member 16a, and this through-hole will be caulked with the pin member 34, and it will join.

  Note that the first permanent magnet 14M and the second permanent magnet 18M shown in FIG. 5 protrude from the surfaces of the first holding member 12a and the second holding member 16a, respectively. Moreover, the 3rd magnetic body 42 and the 4th magnetic body 44 are dented from the surface of the side where the 1st holding member 12a and the 2nd holding member 16a oppose, respectively. Here, the height of the protrusion from the surface of the first holding member 12a and the second holding member 16a and the depth of the recess from the surface of the first holding member 12a and the second holding member 16a are substantially equal (at least, As shown in FIGS. 6 and 7, the first holding member 12a and the second holding member 16a are arranged on the inner peripheral side and the outer peripheral side as shown in FIGS. Contact.

<Effects of Second Embodiment>
As described above, if the first holding member 12a and the second holding member 16a are bonded or joined together by the pin member 34, both can be firmly joined easily. Moreover, since both the 1st holding member 12a and the 2nd holding member 16a have a nonmagnetic body, a leakage magnetic flux can be reduced. The third magnetic body 42 and the fourth magnetic body 44 function as a back yoke or a head core for the first permanent magnet 14M and the second permanent magnet 18M, respectively. Furthermore, since the fifth magnetic body 46 increases the so-called q-axis inductance, the rotor 10a that contributes to a motor that uses reluctance torque is obtained.

<Third Embodiment>
Here, as a third embodiment of the present invention, an aspect in which the first holding member 12b and the second holding member 16b are joined on the inner periphery of the annular member 36 will be described with reference to the drawings.

  8 and 9 are exploded perspective views of the rotor 10b for explaining the steps of the method for manufacturing the rotor 10b according to the present invention, both of which are exploded along the rotation axis of the rotor 10b. The first holding member 12b further includes a sixth magnetic body 48 that connects the plurality of fifth magnetic bodies 46 on the inner peripheral side. Here, the fifth magnetic body 46 is also coupled to the third magnetic body 42 and the fourth magnetic body 44 via the thin portion 43.

  Specifically, the first holding member 12b includes a third magnetic body 42 that covers the first magnetic body 14 from one side thereof, and a fourth magnetic body 44 that is provided at the first interval 15, and these are: The thin portions 43 are connected alternately in a ring shape. The first holding member 12 b further includes a plurality of fifth magnetic bodies 46 disposed between the third magnetic body 42 and the fourth magnetic body 44, and these are formed by the sixth magnetic body 48 on the inner peripheral side. It is connected. Further, each fifth magnetic body 46 is connected to the third magnetic body 42 and the fourth magnetic body 44 through the thin portion 43. A plurality of first magnetic bodies 14 held by the first holding member 12b are magnetized in a direction orthogonal to the annular arrangement direction of the first magnetic bodies 14 to obtain a first permanent magnet 14M.

  Thereby, the 3rd magnetic body 42, the 4th magnetic body 44, the 5th magnetic body 46, and the 6th magnetic body 48 become united, and the 1st magnetic body 14 can be hold | maintained reliably. A plurality of first magnetic bodies 14 held by the first holding member 12b are magnetized in a direction orthogonal to the annular arrangement direction of the first magnetic bodies 14 to obtain a first permanent magnet 14M.

  Furthermore, the second holding member 16b may be configured as follows. That is, the second holding member 16 b is magnetically coupled to the sixth magnetic body 48. If a specific example is given, as shown in FIG. 8, the 2nd holding member 16b also has the structure similar to the 1st holding member 12b.

  More specifically, the second holding member 16b has a fourth magnetic body 54 that covers the second magnetic body 18 from one side thereof, and a third magnetic body 52 provided at the second interval 19, and these are The thin portions 53 are alternately connected in a ring shape. The second holding member 16b further includes a plurality of fifth magnetic bodies 56 disposed between the third magnetic body 52 and the fourth magnetic body 54, and these are formed by the sixth magnetic body 58 on the inner peripheral side. It is connected. Further, each fifth magnetic body 56 is connected to the third magnetic body 52 and the fourth magnetic body 54 through the thin portion 53. A plurality of second magnetic bodies 18 held by the second holding member 16b are magnetized in a direction orthogonal to the annular arrangement direction of the second magnetic bodies 18 to obtain a second permanent magnet 18M.

  The plurality of fifth magnetic bodies 46 and 56 are not formed to have the same width in the radial direction, but are formed wider toward the inner peripheral side. Since these do not function as magnetic poles by permanent magnets, they may be short-circuited by the sixth magnetic bodies 48 and 58 on the inner peripheral side. Thereby, the site | part by which the 1st holding member 12b and the 2nd holding member 16b are hold | maintained at the axis | shaft (illustration omitted) of the rotor 10b is securable. However, the sixth magnetic bodies 48 and 58 are not opposed to the stator teeth (not shown) in order to keep the difference between the d-axis inductance value and the q-axis inductance value equal to or greater than a predetermined value. Further, by providing the fifth magnetic bodies 46 and 56 and the sixth magnetic bodies 48 and 58 on the inner peripheral side, when the third magnetic body 42 and the fourth magnetic body 44 function as a head core, the magnetically There is no need to short circuit.

  In FIGS. 8 and 9, in order to distinguish the fifth magnetic bodies 46 and 56 and the sixth magnetic bodies 48 and 58 from each other, a dotted line is provided between them. It is desirable that both are formed integrally.

  Using the first holding member 12b and the second holding member 16b as described above, in the rotor assembly process, as shown in FIG. 9, the first holding member 12b and the second holding member 16b have the first permanent magnet 14M and the first holding member. The two permanent magnets 18M are opposed to each other. Further, in the rotor assembly process, the outer periphery of the first holding member 12b and the outer periphery of the second holding member 16b are preferably joined to the inner periphery of the annular member 36 made of a nonmagnetic material.

<Effect of the third embodiment>
As described above, when the first holding member 12b and the second holding member 16b are joined to the inner periphery of the annular member 36, when the rotor 10b is employed in an axial gap type motor, the first holding member 12b and the second holding member 12b. The holding member 16b is firmly joined.

  Further, since the thin portions 43 and 53 are easily magnetically saturated, the thin portions 43 and 53 substantially function as a magnetic barrier between the first permanent magnet 14M and the second permanent magnet 18M, and leakage magnetic flux is reduced.

  In addition, since the plurality of fifth magnetic bodies 46 and 56 are coupled on the inner peripheral side by the sixth magnetic bodies 48 and 58, respectively, the q-axis inductance is further increased. The fifth magnetic bodies 46 and 56 and the sixth magnetic bodies 48 and 58 are preferably in contact with each other, but may not be in contact with each other. Further, since each of the fifth magnetic bodies 46 and 56 is connected to the third magnetic bodies 42 and 52 and the fourth magnetic bodies 44 and 54 through the thin portions 43 and 53, the first permanent magnet 14M and the first The positions of the fifth magnetic bodies 46 and 56 with respect to the two permanent magnets 18M are fixed, and the reluctance torque is stabilized.

  Further, if the second holding member 16b and the sixth magnetic body 48 are magnetically coupled, the number of times that the magnetic flux passes through the air gap is four times when the stator 20 is disposed on both sides of the rotor 10b. Can be halved to 2 times.

<Fourth embodiment>
Here, as a fourth embodiment of the present invention, a mode in which only one of the first holding member 12c and the second holding member 16c functions as a back yoke of the motor will be described with reference to the drawings.

  FIG. 10 is an exploded perspective view of the rotor 10c for explaining the steps of the method for manufacturing the rotor 10c according to the present invention, which is shown exploded in the direction along the rotation axis. FIG. 11 is a perspective view of the assembled rotor 10c. In the present embodiment, a case where only the second holding member 16c is a magnetic body will be described.

  Specifically, like the first holding member 12 of the first embodiment, the first holding member 12c is formed of a magnetic material, and includes a hole 41, a third magnetic body 42, a thin portion 43, and a fourth portion. A magnetic body 44 is provided. The plurality of first magnetic bodies 14 are held on one surface of the first holding member 12 c, specifically on the third magnetic body 42. A plurality of first magnetic bodies 14 held by the first holding member 12c are magnetized in a direction orthogonal to the direction in which the first magnetic bodies 14 are arranged in an annular shape to obtain a first permanent magnet 14M.

  One second holding member 16 c is formed in a substantially annular shape, but does not have the hole 41, the third magnetic body 42, the thin portion 43, and the fourth magnetic body 44. The second holding member 16c has a smaller inner diameter and a larger outer diameter than the first holding member 12c. This is because the magnetic flux leaks when the first holding member 12c is close to another magnetic structural member (rotary shaft or motor frame). Further, since the second holding member 16c functions as a back yoke that short-circuits the surfaces of the first permanent magnet 14M and the second permanent magnet 18M opposite to the magnetic pole surfaces, the second holding member 16c may be in close proximity to other magnetic structural members. In particular, a rotating shaft is fixed to the inner diameter. Although it is not desirable that the outer diameter is in contact with the structural member, there is no fear of leakage of magnetic flux, and the outer diameter may be close enough not to contact. A plurality of second magnetic bodies 18 are held on one surface of the second holding member 16c, and the second magnetic bodies 18 are worn in a direction orthogonal to the direction in which the first magnetic bodies 14 are arranged in an annular shape. The second permanent magnet 18M is obtained by magnetizing.

  Such 1st holding member 12c and 2nd holding member 16c are joined by adhesion, for example.

<Effect of the fourth embodiment>
As described above, since the second holding member 16c functions as a back yoke after assembly, there is no need to separately join the back yoke. For this reason, the junction part of the back yoke becomes unnecessary, and the magnetic resistance due to the junction part can be suppressed.

<Fifth Embodiment>
Here, as a fifth embodiment of the present invention, a mode in which both the first holding member 12d and the second holding member 16d can be applied as a back yoke will be described with reference to the drawings.

  FIG. 12 is an exploded perspective view of the rotor for explaining the steps of the method for manufacturing a rotor according to the present invention, which is shown exploded in the direction along the rotation axis. FIG. 13 is a perspective view of the assembled rotor 10d. In the rotor 10d manufactured in the present embodiment, the first holding member 12d includes a substantially annular first ring 82 formed of a magnetic material, an inner circumferential side of the first ring 82, and a first ring. A plurality of first convex portions 84 extending toward the center of the first ring body 82 at the same height (position in the rotation axis direction) as the body 82 are provided. That is, a hole is formed at a position corresponding to the first interval 15.

  In the present embodiment, the first ring body 82 and the first convex portion 84 are integrally formed, and the first convex portion 84 is also a magnetic body. The first magnetic body 14 is held on one surface of the first convex portion 84. Therefore, the first holding member 12 d magnetically couples the first magnetic bodies 14 to each other at the first coupling portion 13 on one side with respect to the first magnetic body 14. A first permanent magnet 14M is obtained by magnetizing the first magnetic body 14 in a direction orthogonal to the direction in which the first magnetic bodies 14 are arranged in an annular shape.

  One of the second holding members 16d has a second annular body 90 having an outer circumference that is substantially the same size as the first holding member 12d and an inner circumference that is smaller than the inner circumference of the first convex portion 84, and A third ring body 92 formed in a region from the inner circumference of the second ring body 90 to the inner diameter of the first convex portion 84 on one surface of the two ring body 90, and the same height as the third ring body 92 And a plurality of second convex portions 94 extending radially from the outer periphery of the third annular body 92. That is, the position corresponding to the second interval 19 is lower than the surface of the second convex portion 94. More precisely, the second ring body 90 and the second convex portion 94 present a concave portion at a position corresponding to the second interval 19.

  The thicknesses of the third ring body 92 and the second convex portion 94 are the same as the thicknesses of the first holding member 12d, that is, the first ring body 82 and the first convex portion 84. Moreover, in this embodiment, the 2nd ring body 90, the 3rd ring body 92, and the 2nd convex part 94 are integrally formed by injection molding etc., and these are also a magnetic body. And the 2nd magnetic body 18 is hold | maintained on the surface of the 2nd convex part 94. FIG. Therefore, the second holding member 16 d magnetically couples the second magnetic bodies 18 at the second coupling portion 17 on one side with respect to the second magnetic body 18. A second permanent magnet 18M is obtained by magnetizing the second magnetic body 18 in a direction orthogonal to the direction in which the second magnetic bodies 18 are annularly arranged.

  Using the first holding member 12d and the second holding member 16d as described above, in the rotor assembly process, the first connecting portion 13 and the second connecting portion 17 are connected to the first permanent magnet 14M and the second permanent magnet 18M. Arranged on opposite sides of each other. Specifically, the first convex portion 84 that holds the first permanent magnet 14M is set to the second interval 19, the second convex portion 94 that holds the second permanent magnet 18M is set to the first interval 15, and the magnetization direction is set respectively. The rotor 10d is assembled by arranging the ring in an alternating manner.

<Effect of Fifth Embodiment>
As described above, if the first magnetic bodies 14 and the second magnetic bodies 18 are magnetically coupled to each other, and arranged on the opposite sides and magnetically separated from each other, the first The holding member 12d and the second holding member 16d can be applied as a back yoke.

<Sixth Embodiment>
In the fifth embodiment, the aspect in which the stator 20 (see FIG. 1) can be arranged only on one side of the rotor 10d has been described, but here, for the aspect in which the stator 20 can be arranged on both sides of the rotor 10e, refer to the drawings. While explaining.

  FIG. 14 is an exploded perspective view of the rotor 10e for explaining the steps of the method for manufacturing the rotor 10e according to the present invention. In the rotor 10e manufactured in the present embodiment, the first holding member 12e has the same structure as the first holding member 12d of the fifth embodiment, and has the first annular body 82 and the first convex portion 84. Then, they are connected by the first connecting portion 13. And the 1st convex part 84 hold | maintains the 1st magnetic body 14 on the one surface. Furthermore, the 1st convex part 84 hold | maintains the 1st magnetic body 14 also on another surface (surface facing this one surface). In the present embodiment, it is assumed that the separate first magnetic body 14 is held on both surfaces of the first convex portion 84, but through holes that penetrate both surfaces of the first convex portion 84 are provided. A single first magnetic body 14 may be inserted and held in the through hole. In this way, the first magnetic body 14 is held on both surfaces of the first convex portion 84, and the first magnetic body 14 is magnetized in the direction orthogonal to the direction in which the first magnetic body 14 is arranged in a ring shape. A permanent magnet 14M is obtained.

  One second holding member 16e is a form obtained by removing the second ring body 90 from the second holding member 16d of the fifth embodiment, and has a third ring body 92 and a second convex portion 94, and has a second shape. They are connected by a connecting portion 17. And the 2nd convex part 94 hold | maintains the 2nd magnetic body 18 on the one surface. Furthermore, the 2nd convex part 94 also hold | maintains the 2nd magnetic body 18 on another surface (surface facing this one surface). As described above, the second magnetic body 18 is held on both surfaces of the second convex portion 94, and the second magnetic body 18 is magnetized in the direction orthogonal to the direction in which the second magnetic body 18 is arranged in an annular shape. A permanent magnet 18M is obtained.

  Using the first holding member 12e and the second holding member 16e as described above, in the rotor assembling step, the first convex portion 84 holding the first permanent magnet 14M is set to the second interval 19 as in the fifth embodiment. The rotor 10e is assembled by arranging the second convex portions 94 holding the second permanent magnets 18M at the first intervals 15 so that the magnetization directions are alternately arranged in an annular shape.

<Effect of the sixth embodiment>
As described above, the first magnetic body 14 is held by both surfaces of the first convex portion 84, that is, both surfaces of the first holding member 12e, and both surfaces of the second convex portion 94, that is, both surfaces of the second holding member 16e. By holding the second magnetic body 18, the first holding member 12e and the second holding member 16e can be applied as the back yoke even when the stator 20 (see FIG. 1) is disposed on both sides of the rotor 10e.

It is a disassembled perspective view of the motor explaining the process of the manufacturing method of the rotor which concerns on this invention. It is a schematic diagram explaining the magnetization apparatus employ | adopted at the magnetization process. It is a schematic diagram explaining the magnetization apparatus employ | adopted at the magnetization process. It is a perspective view of the assembled rotor. It is a disassembled perspective view of the rotor explaining the process of the manufacturing method of the rotor which concerns on this invention. It is a perspective view of the rotor assembled by adhesion. It is a disassembled perspective view explaining the process assembled with a pin member. It is a disassembled perspective view of the rotor explaining the process of the manufacturing method of the rotor which concerns on this invention. It is a disassembled perspective view of the rotor explaining the process of the manufacturing method of the rotor which concerns on this invention. It is a disassembled perspective view of the rotor explaining the process of the manufacturing method of the rotor which concerns on this invention. It is a perspective view of the assembled rotor. It is a disassembled perspective view of the rotor explaining the process of the manufacturing method of the rotor which concerns on this invention. It is a perspective view of the assembled rotor. It is a disassembled perspective view of the rotor explaining the process of the manufacturing method of the rotor which concerns on this invention.

Explanation of symbols

10, 10a-10e Rotor 12, 12a-12e 1st holding member 13 1st connection part 14 1st magnetic body 14M 1st permanent magnet 15 1st space | interval 16, 16a-16e 2nd holding member 17 2nd connection part 18 1st 2 Magnetic body 18M 2nd permanent magnet 19 2nd space | interval 32 Annular member 34 Pin member 36 Annular member 42 3rd magnetic body 43 Thin part 44 4th magnetic body 46 5th magnetic body 48 6th magnetic body 58 7th magnetic body 72 Air-core coil 74 Magnetized yoke

Claims (17)

A method for manufacturing a rotor (10, 10a to 10e) constituting a motor facing a stator (20) through a predetermined gap,
A plurality of first magnetic bodies (14) held in an annular shape with a first interval (15) by the first holding members (12, 12a to 12e) are orthogonal to the annular arrangement direction of the first magnetic bodies. A first magnetization step of magnetizing in the direction to obtain a first permanent magnet (14M);
A plurality of second magnetic bodies (18) held annularly by the second holding members (16, 16a to 16e) at a second interval (19) are orthogonal to the annular arrangement direction of the second magnetic bodies. A second magnetizing step of magnetizing in the direction to obtain a second permanent magnet (18M);
A rotor assembling step for assembling the rotor by arranging the first permanent magnets at the second interval and the second permanent magnets at the first interval, with the magnetizing directions alternately arranged in an annular shape. Manufacturing method. A method for manufacturing a rotor (10, 10a) according to claim 1,
The first holding member (12, 12a) and the second holding member (16, 16a) have a flat plate shape,
In the rotor assembly step, the inner periphery of the first holding member (12, 12a) and the inner periphery of the second holding member (16, 16a), the outer periphery of the first holding member (12, 12a), and the The method for manufacturing a rotor, wherein the outer circumferences of the second holding members (16, 16a) face each other. A method for manufacturing a rotor (10) according to claim 1 or claim 2,
The first holding member (12) and the second holding member (16) have a flat plate shape,
In the rotor assembling step, a plurality of annular members (32) sandwiching the first holding member and the second holding member are joined together. A method for manufacturing a rotor (10, 10a to 10e) according to claim 1 or 2,
In the rotor assembling step, the first holding member (12, 12a to 12e) and the second holding member (16, 16a to 16e) are joined by bonding. A method for manufacturing a rotor (10a) according to claim 1 or claim 2,
In the rotor assembling step, the first holding member (12a) and the second holding member (16a) are joined using a pin member (34) penetrating both of them. A method for manufacturing a rotor (10b) according to claim 1 or 2,
The first holding member (12b) and the second holding member (16b) have a flat plate shape,
In the rotor assembling step, the rotor is manufactured by joining the outer periphery of the first holding member and the outer periphery of the second holding member to the inner periphery of the annular member (36). A method for manufacturing a rotor (10a) according to any one of claims 1 to 6,
The first holding member (12a) has a nonmagnetic body (60) provided between the first magnetic bodies (14) adjacent to each other in an annular shape,
The method for manufacturing a rotor, wherein the second holding member (16a) includes a nonmagnetic body (60) provided between the second magnetic bodies (18) adjacent to each other in an annular shape. A method for manufacturing a rotor (10c, 10d) according to any one of claims 1 to 6,
The rotor manufacturing method, wherein only one of the first holding member (12c, 12d) and the second holding member (16c, 16d) is a magnetic body. A method for manufacturing a rotor (10d, 10e) according to any one of claims 1 to 6,
The first holding members (12d, 12e) magnetically connect the first magnetic bodies to each other at a first connection portion (13) on one side with respect to the first magnetic body (14),
The second holding member (16d, 16e) magnetically couples the second magnetic bodies to each other at a second coupling portion (17) on one side with respect to the second magnetic body (18),
In the rotor assembling step, the first connection portion and the second connection portion are disposed on opposite sides of the first permanent magnet (14M) and the second permanent magnet (18M). Manufacturing method. It is a manufacturing method of the rotor (10a-10c) as described in any one of Claim 1 thru | or 6, Comprising:
The first holding member (12a to 12c) includes a third magnetic body (42) that covers the first magnetic body (14) from one side thereof, and a fourth magnetic body (4) provided at the first interval (15). 44)
In the rotor assembly process, the first holding member (12a to 12c) and the second holding member (16a to 16c) are opposed to each other through the first permanent magnet (14M) and the second permanent magnet (18M). A method for manufacturing a rotor. A method for manufacturing a rotor (10, 10b, 10c) according to claim 10,
The first holding member (12, 12b, 12c) further includes a thin part (43) for connecting the third magnetic body (42) and the fourth magnetic body (44) to each other. A method for manufacturing a rotor (10a, 10b) according to claim 10 or 11,
The first holding member (12a, 12b) further includes a fifth magnetic body (46) disposed between the third magnetic body (42) and the fourth magnetic body (44). . A method for manufacturing a rotor (10b) according to claim 12,
The method for manufacturing a rotor, wherein the first holding member (12b) further includes a sixth magnetic body (48) that connects the plurality of fifth magnetic bodies (46) on the inner peripheral side. A method for manufacturing a rotor (10b) according to any one of claims 11 to 13,
The fifth magnetic body (46) is a method for manufacturing a rotor, wherein the fifth magnetic body (46) is connected to the third magnetic body (42) and the fourth magnetic body (44) via the thin-walled portion (43). A method for manufacturing a rotor (10b) according to claim 13 or 14,
The method of manufacturing a rotor, wherein the second holding member (16b) is magnetically coupled to the sixth magnetic body (48). A method for manufacturing a rotor (10, 10a to 10e) according to any one of claims 1 to 15,
In the first magnetizing step and the second magnetizing step, an air core coil (72) is used for magnetization, and the rotor is manufactured. A method for manufacturing a rotor (10, 10a to 10e) according to any one of claims 1 to 15,
In the first magnetizing step and the second magnetizing step, a magnetizing yoke (74) is used for magnetizing, so that the rotor is manufactured.

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