JP2009050074A - Rotary electric machine, and manufacturing method thereof - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To obtain a rotary electric machine capable of improving reliability of magnet holding, improving assemblability of a magnet by simplifying a magnet holding structure, and reducing manufacturing cost and mass-productivity, and to obtain a manufacturing method thereof. <P>SOLUTION: The rotary electric machine has a structure in which first and second magnet holding pedestals 30, 40 are provided so as to integrally protrude on second and first yoke portions 23, 19 facing the inner circumferential surface of the tip side of first and second claw-like magnetic pole portions 20, 24, first and second magnet holder holding apertures 31, 41 penetrate from one end to the other end of an axial direction so that the center of apertures may match the first and second magnet holding pedestals 30, 40 and are provided on a C-shaped arc cross section opened outside in a diameter direction over the entire region from one end of an axial direction toward the other end. First and second magnet holders 33, 43 having built-in first and second permanent magnets 37, 47 are inserted and held in the first and second magnet holding apertures 31, 41 by inserting engaging portions 34, 44. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a rotating electrical machine such as an AC generator for a vehicle and a manufacturing method thereof, and more particularly to a permanent magnet holding structure in a Landel type rotor.

  Vehicle alternators using Landel rotors have been used in automobiles for decades. Due to environmental problems in recent years, the load of electrical components mounted on the vehicle has increased rapidly, and a further increase in the power generation amount of the Landel rotor has been demanded.

  Conventionally, in order to solve such a problem, a means for arranging a permanent magnet between claw-shaped magnetic poles facing the circumferential direction of a Landel-type rotor has been taken (for example, see Patent Documents 1 and 2). .

  Further, the permanent magnet is held in a pocket formed integrally with the fan, and the pocket is press-fitted between the upper surface of the body of the first pole piece and the lower surface of the pole finger of the second pole piece, and the fan is inserted into the first pole. The fan is attached to the second pole piece by attaching the pocket to the piece and press-fitting the pocket between the upper surface of the body of the second pole piece and the lower surface of the pole finger of the first pole piece. 3).

JP-A-61-85045 US Pat. No. 4,959,577 JP-T-2002-527015

  In Patent Documents 1 and 2, in order to hold the permanent magnet between the claw-shaped magnetic pole portions, it is necessary to position the permanent magnet with high accuracy with respect to the opposing claw-shaped magnetic pole portion, and a magnet holding member is added, or It was necessary to form a magnet holding groove in the claw-shaped magnetic pole portion by machining, resulting in an increase in production cost and a decrease in mass productivity. Further, since relative displacement occurs between adjacent claw-shaped magnetic pole portions during high-speed rotation, a structure in which the centrifugal force applied to the permanent magnet is held between the claw-shaped magnetic pole portions cannot stably hold the permanent magnet. .

  In the device described in Patent Document 3, the pocket for holding the permanent magnet is formed in a substantially rectangular cross-sectional shape that fits into the fitting space between the body of one pole piece and the pole finger of the other pole piece. In order to strengthen the holding of the pocket holding the permanent magnet, it is necessary to process the fitting surface of the pole piece with high accuracy. However, the mating surface with the pocket of the pole piece is a flat surface or a gently curved surface, and post-processing of the pole piece with a high-performance machine tool is required, which requires enormous processing costs and processing time. Further, since the tip of the claw-shaped magnetic pole portion is displaced radially outward during high-speed rotation, the structure in which the centrifugal force applied to the permanent magnet is held by the claw-shaped magnetic pole portion cannot stably hold the permanent magnet.

  The present invention has been made to solve such a problem, and the displacement of the tip of the claw-shaped magnetic pole part due to centrifugal force and the relative displacement between adjacent claw-shaped magnetic pole parts are held by the magnet. Rotating electrical machine that can improve the reliability of holding the magnet without directly affecting the magnet, simplify the magnet holding structure, improve the assembly of the magnet, reduce the production cost, and increase the mass productivity The purpose is to obtain.

  The rotating electrical machine according to the present invention includes a boss portion, a pair of yoke portions extending radially outward from both axial end edges of the boss portion, and an axial direction alternately from each of the pair of yoke portions. A pole core that has a plurality of claw-shaped magnetic pole portions that extend and mesh with each other and are arranged in the circumferential direction. The pole core is fixed to a rotating shaft that is inserted through the axial center of the boss portion, the boss portion, and the pair of joints. A rotor having an iron portion and a field coil housed in a space surrounded by the plurality of claw-shaped magnetic pole portions, and an outer periphery of the rotor is disposed so as to surround a predetermined air gap. And a fixed stator. Further, a permanent magnet holding portion integrally projecting from the yoke portion at the portion of the pair of yoke portions facing the inner peripheral surface on the front end side of the plurality of claw-shaped magnetic pole portions, and the permanent magnet holding portion Each having a hole direction directed in the axial direction, at least one end in the axial direction being open and opening radially outward, and having a C-shaped arc-shaped magnet folder holding hole, and the magnet A cross section inserted and held in the folder holding hole is a C-shaped arc-shaped fitting portion, and protrudes radially outward integrally from the fitting portion, and radially outward from the magnet folder holding hole. A projecting section having a quadrangular projecting section, a magnet folder made of a magnetic material having a quadrangular magnet mounting hole penetrating from one end to the other end in the axial direction in the projecting section and the fitting section, and a quadrangular section The columnar body is inserted and held in each of the magnet mounting holes. It comprises a permanent magnet magnetically oriented in the direction of the magnetic field and opposite to make the magnetic coil.

  According to this invention, the magnet folder incorporating the permanent magnet is held on the yoke part side. Therefore, since the displacement of the claw-shaped magnetic pole portion due to the centrifugal force does not affect the permanent magnet, the permanent magnet can be easily held and the reliability of the magnet holding is increased. Further, since the permanent magnet is located on the inner diameter side of the claw-shaped magnetic pole portion, the centrifugal force acting on the permanent magnet is reduced, the permanent magnet can be easily held, and the magnet holding reliability is increased. Moreover, since the permanent magnet is built in the magnet folder, the occurrence of cracks and chipping of the permanent magnet is suppressed.

  In addition, since the magnet folder with a built-in permanent magnet is inserted and held in the cylindrical magnet folder holding hole having a C-shaped cross section, the magnet folder holding structure is simplified and the magnet folder can be assembled. Becomes easy. Moreover, the magnet folder holding hole can be easily and accurately produced using a rotary cutting tool such as a drill or a reamer, and rattling of the fitting portion between the magnet folder and the magnet folder holding hole can be suppressed. Furthermore, since the hole direction of the magnet folder holding hole is oriented in the axial direction, the magnet folder can be inserted into the magnet folder holding hole from the axial direction, and the assembly of the magnet folder becomes easy. For these reasons, the production cost can be reduced and the mass productivity can be improved.

  1 is a cross-sectional view schematically showing an automotive alternator according to an embodiment of the present invention, and FIG. 2 shows a rotor applied to the automotive alternator according to an embodiment of the present invention. FIG. 3 is an exploded perspective view, FIG. 3 is a perspective view showing a magnetic thin plate constituting a magnet folder in an AC generator for a vehicle according to an embodiment of the present invention, and FIG. 4 is an AC power generation for a vehicle according to an embodiment of the present invention. FIG. 5 and FIG. 6 are schematic views for explaining the flow of magnetic flux in the vehicle alternator according to the embodiment of the present invention. is there.

  1 to 4, the vehicle alternator 1 supports a case 4 composed of a substantially bowl-shaped aluminum front bracket 2 and a rear bracket 3, and a rotating shaft 16 supported by the case 4 via a bearing 5. The rotor 13 rotatably disposed in the case 4, the pulley 6 fixed to the end of the rotating shaft 16 extending to the front side of the case 4, and both ends of the rotor 13 in the axial direction The fan 7 fixed to the surface, the stator 10 having a constant air gap with respect to the rotor 13, surrounding the outer periphery of the rotor 13 and fixed to the case 4, and the rear side of the rotating shaft 16 And a pair of slip rings 8 for supplying a current to the rotor 13 and a pair of brushes 9 disposed in the case 4 so as to slide on the slip rings 8. Although not shown, a rectifier that rectifies alternating current generated in the stator 10 into direct current, a voltage regulator that adjusts the magnitude of the alternating voltage generated in the stator 10, and the like are disposed in the case 4. .

  The stator 10 is wound around a cylindrical stator core 11 and the stator core 11, and an alternating current is generated by a change in magnetic flux from a field coil 14 (to be described later) as the rotor 13 rotates. And.

The rotor 13 includes a field coil 14 that generates a magnetic flux when an excitation current is passed, a pole core 15 that is provided so as to cover the field coil 14, and a magnetic pole is formed by the magnetic flux, and an axial center position of the pole core 15. And a rotating shaft 16 penetrating the shaft.
The pole core 15 is divided into first and second pole core bodies 17 and 21 made of a low carbon steel such as S10C by a cold forging method.

  The first pole core body 17 has a cylindrical outer peripheral surface, a first boss portion 18 formed with a rotation shaft insertion hole 18a penetrating the axial center position, and a radially outer side from one end edge of the first boss portion 18. A thick ring-shaped first yoke portion 19 extended to the first yoke portion 19 and a first claw-shaped magnetic pole portion 20 extended from the outer peripheral portion of the first yoke portion 19 to the other axial end side. Yes. The first claw-shaped magnetic pole portion 20 has a substantially trapezoidal outermost surface shape, the circumferential width gradually decreases toward the distal end side, and the radial thickness gradually decreases toward the distal end side. It is formed in a tapered shape, and eight, for example, are arranged on the outer peripheral portion of the first yoke portion 19 at an equiangular pitch in the circumferential direction.

  The second pole core body 21 has a cylindrical outer peripheral surface, a second boss portion 22 formed with a rotation shaft insertion hole 22a penetrating the axial center position, and a radial direction from the other end edge of the second boss portion 22. A thick ring-shaped second yoke portion 23 extending outward, and a second claw-shaped magnetic pole portion 24 extending from the outer periphery of the second yoke portion 23 to one end in the axial direction. Yes. The second claw-shaped magnetic pole portion 24 has a substantially trapezoidal outermost surface shape, its circumferential width gradually decreases toward the distal end side, and its radial thickness gradually decreases toward the distal end side. For example, eight taper shapes are arranged on the outer peripheral portion of the second yoke portion 23 at an equiangular pitch in the circumferential direction.

  The first and second pole core bodies 17 and 21 configured as described above mesh with the first and second claw-shaped magnetic pole portions 20 and 24 alternately, and the other end surface of the first boss portion 18 is connected to the second boss. It abuts on one end surface of the portion 22 and is fixed to the rotary shaft 16 inserted through the rotary shaft insertion holes 18a, 22a. A field coil 14 wound around a bobbin (not shown) includes first and second boss portions 18 and 22, first and second yoke portions 19 and 23, and first and second claw-shaped magnetic poles. It is mounted in a space surrounded by the parts 20 and 24. Here, the first and second boss portions 18 and 22 and the first and second yoke portions 19 and 23 correspond to the boss portion of the pole core 15 and the pair of yoke portions, respectively.

  The 1st magnet holding base 30 as a permanent magnet holding part is integrally formed by the 1st pole core body 17 by the cold forging manufacturing method. The first magnet holding pedestal 30 is integrally projected on the outer peripheral surface of the first yoke portion 19 that faces the inner peripheral surface of the tip end side of each second claw-shaped magnetic pole portion 24. The first magnet folder holding hole 31 extends through the first magnet holding pedestal 30 from the one end to the other end in the axial direction with the hole center aligned in the axial direction and from one end to the other end in the axial direction. A cross section that opens outward in the radial direction and is orthogonal to the center of the hole is formed in a C-shaped arc. The first axial opening 32 that opens the first magnet folder holding hole 31 radially outward across the entire region from one end to the other end in the axial direction is formed on the tip side inner peripheral surface of the second claw-shaped magnetic pole portion 24. Opposite.

  The first magnet folder 33 is integrally formed from an arcuate fitting portion 34 having a C-shaped cross section that matches the inner diameter shape of the first magnet folder holding hole 31 and the arcuate chord portion of the fitting portion 34. A projecting portion 35 having a trapezoidal cross section protruding outward in the radial direction, and a trapezoidal hole-shaped magnet mounting hole 36 penetrating the fitting portion 34 and the projecting portion 35 from one end to the other end in the axial direction are provided. It is made into a columnar body. The first magnet folder 33 is produced by laminating and integrating a predetermined number of magnetic thin plates 49 that are press-molded. Each magnetic thin plate 49 has an outer shape in which a trapezoid protrudes radially outward from a C-shaped arcuate chord portion, and a hole portion 49a constituting the magnet mounting hole 36 is formed in a trapezoidal hole shape. ing. The first permanent magnet 37 is formed into a columnar body having an outer shape that matches the inner shape of the magnet mounting hole 36, that is, a trapezoidal cross section, and is inserted and held in the first magnet mounting hole 36 from the axial direction.

  In the first magnet folder 33, the fitting portion 34 is inserted and held in the first magnet folder holding hole 31 from the axial direction. At this time, the protruding portion 35 protrudes from the first axial opening 32 and opposes the inner peripheral surface on the front end side of the second claw-shaped magnetic pole portion 24. The first permanent magnet 37 is disposed with the upper side of the trapezoidal cross section close to the inner peripheral surface of the tip end side of the second claw-shaped magnetic pole portion 24.

  The 2nd magnet holding base 40 as a permanent magnet holding part is integrally formed by the 2nd pole core body 21 by the cold forging manufacturing method. The second magnet holding pedestal 40 is integrally projected on the outer peripheral surface of the second yoke portion 23 that faces the inner peripheral surface of the tip end side of each first claw-shaped magnetic pole portion 20. The second magnet folder holding hole 41 extends through the second magnet holding base 40 from the one end to the other end in the axial direction with the hole center aligned in the axial direction and from the one end to the other end in the axial direction. A cross section that opens outward in the radial direction and is orthogonal to the center of the hole is formed in a C-shaped arc. The second axial opening 42 that opens the second magnet folder holding hole 41 radially outward across the entire region from one end to the other end in the axial direction is formed on the tip side inner peripheral surface of the first claw-shaped magnetic pole part 20. Opposite.

  The second magnet folder 43 is integrally formed from an arcuate fitting portion 44 having a C-shaped cross section matching the inner diameter shape of the second magnet folder holding hole 41 and the arcuate chord portion of the fitting portion 44. A projecting portion 45 having a trapezoidal cross section protruding outward in the radial direction, and a trapezoidal hole-shaped magnet mounting hole 46 penetrating the fitting portion 44 and the projecting portion 45 from one end to the other end in the axial direction are provided. It is made into a columnar body. The second magnet folder 43 is produced by laminating and integrating a predetermined number of magnetic thin plates 49 that are press-molded. Each magnetic thin plate 49 has an outer shape in which a trapezoid protrudes radially outward from a C-shaped arcuate chord portion, and a hole portion 49a constituting a magnet mounting hole 46 is formed in a trapezoidal hole shape. ing. The second permanent magnet 47 is made into a columnar body having an outer shape that matches the inner shape of the magnet mounting hole 46, that is, a trapezoidal cross section, and is inserted and held in the second magnet mounting hole 46 from the axial direction.

  The second magnet folder 43 has the fitting portion 44 inserted and held in the second magnet folder holding hole 41 from the axial direction. At this time, the projecting portion 45 projects from the second axial opening 42 and faces the inner peripheral surface of the front end side of the first claw-shaped magnetic pole portion 20. The second permanent magnet 47 is arranged with the upper side of the trapezoidal cross section close to the inner peripheral surface of the first claw-shaped magnetic pole part 20.

  Further, in the first and second permanent magnets 37 and 47, the magnetization direction 50 is opposite to the direction of the magnetic field 51 formed in the plane in which the field current flowing through the field coil 14 is orthogonal to the axis of the rotor 13. It is so magnetized. That is, as shown in FIG. 1, when the field coil 14 is energized and the magnetic field 51 is generated in the direction of the arrow, the first and second permanent magnets 37 and 47 are magnetized in the opposite direction to the magnetic field 51. Is done. Here, the magnetization directions 50 of the first and second permanent magnets 37 and 47 coincide with the radial direction, and the first and second claw-shaped magnetic pole portions 20, which are opposed to the extension lines of the magnetization direction 50, 24 toward the inner peripheral surface on the tip side. In the case of a design in which the direction of the magnetic field 51 generated by the field current flowing through the field coil 14 is reversed, the first and second permanent magnets 37 and 47 are also magnetized and oriented in opposite directions.

Next, the operation of the vehicular AC generator 1 configured as described above will be described.
First, a current is supplied from a battery (not shown) to the field coil 14 of the rotor 13 via the brush 9 and the slip ring 8, and a magnetic flux is generated. By this magnetic flux, the first claw-shaped magnetic pole part 20 of the first pole core body 17 is magnetized to the N pole, and the second claw-shaped magnetic pole part 24 of the second pole core body 21 is magnetized to the S pole.
On the other hand, the rotational torque of the engine is transmitted to the rotating shaft 16 via a belt (not shown) and the pulley 6 and the rotor 13 is rotated. Therefore, a rotating magnetic field is applied to the stator coil 12 of the stator 10, and an electromotive force is generated in the stator coil 12. This AC electromotive force is rectified into a DC current by a rectifier, and the battery is charged or supplied to an electric load.

Next, the operation of the magnetic flux will be described with reference to FIGS.
First, when the field coil 14 is energized, a magnetic flux 51a is generated. The magnetic flux 51 a enters the teeth portion of the stator core 11 from the first claw-shaped magnetic pole portion 20 through the air gap 29. Then, the magnetic flux 51a moves in the circumferential direction from the tooth portion of the stator core 11 through the core back portion, and passes through the air gap 29 from the tooth portion facing the adjacent second claw-shaped magnetic pole portion 24, and the second. The claw-shaped magnetic pole part 24 is entered. Next, the magnetic flux 51 a that has entered the second claw-shaped magnetic pole portion 24 passes through the second yoke portion 23, the second boss portion 22, the first boss portion 18, and the first yoke portion 19, and thus the first claw-shaped magnetic pole portion. 20 is reached. Here, in the conventional Landell type rotor, the first and second pole core bodies are designed to be limited, so that magnetic saturation occurs due to the magnetic field generated by the field coil, and the magnetic flux generated in the rotor decreases.

  In this embodiment, the first and second permanent magnets 37 and 47 are magnetized and oriented so as to be opposite to the direction of the magnetic field 51 generated by the field coil 14. Therefore, the direction of the magnetic field generated by the first and second permanent magnets 37 and 47 is opposite to that of the magnetic field 51 generated by the field coil 14. In order for the magnetic flux 52 generated from the first and second permanent magnets 37 and 47 to interlink with the stator core 11, it is necessary to reciprocate through the air gap 29 having a large magnetic resistance. The first and second permanent magnets 37 and 47 are disposed on the inner diameter side of the second and first claw-shaped magnetic pole portions 24 and 20, and the first and second claw-shaped magnetic pole portions 20 and 24 It arrange | positions so that it may circulate with a shorter magnetic path length with respect to the surrounding surface side. Therefore, most of the magnetic flux 52 forms a closed magnetic circuit inside the rotor 13 without detouring to the stator core 11.

That is, the magnetic flux 52 generated from the first permanent magnet 37 is transmitted from the first magnet holding base 30 to the first yoke part 19, the first boss part 18, the second boss part 22, the second yoke part 23, and the second claw. Return to the first permanent magnet 37 through the magnetic pole portion 24. Further, the magnetic flux 52 generated from the second permanent magnet 47 enters the first claw-shaped magnetic pole part 20 through the air gap, and the first yoke part 19, the first boss part 18, the second boss part 22, and the second joint. It passes through the iron part 23 and the second magnet holding base 40 and returns to the second permanent magnet 47.
Therefore, the magnetic flux 52 generated by the first and second permanent magnets 37 and 47 is opposite to the magnetic flux 51a generated by the field coil 14, and the magnetic flux constituting the first and second pole core bodies 17 and 21 is reversed. The density can be greatly reduced and magnetic saturation can be eliminated.

According to this embodiment, since the first and second permanent magnets 37 and 47 are disposed, magnetic saturation is eliminated, the magnetic flux linked to the stator 10 is increased, and the power generation amount is increased. Can do. In particular, the amount of power generation in the low-speed idling region where magnetic saturation is remarkable can be greatly increased.
In addition, since the first and second permanent magnets 37 and 47 are disposed so as to face the inner peripheral surfaces of the first and second claw-shaped magnetic pole portions 20 and 24, the first and second permanent magnets 37 are disposed. , 47 are located radially inward with respect to the outermost peripheral surface of the rotor 13. Therefore, the stator slot harmonics remain on the outermost peripheral surface portions of the first and second claw-shaped magnetic pole portions 20 and 24, and do not act to directly heat the first and second permanent magnets 37 and 47. As a result, the first and second permanent magnets 37 and 47 are prevented from being heated and demagnetized.

  Further, since the first and second permanent magnets 37 and 47 are disposed so as to oppose the inner peripheral surfaces of the first and second claw-shaped magnetic pole portions 20 and 24, the first and second permanent magnets 37 are disposed. , 47 become a magnetic circuit closed inside the rotor, and the magnetic flux component linked to the stator 10 is eliminated. Therefore, the generation of the induced voltage of the first and second permanent magnets 37 and 47 during no load and no excitation is suppressed. As a result, the magnet amount of the first and second permanent magnets 37 and 47 can be increased.

  Further, the first and second permanent magnets 37 and 47 are attached to the first and second yoke portions 19 and 23. Therefore, since the first and second permanent magnets 37, 37 are located on the inner diameter side of the first and second claw-shaped magnetic pole portions 20, 24, the centrifugal force applied to the first and second permanent magnets 37, 47 is reduced. It becomes small and the holding structure of the 1st and 2nd permanent magnets 37 and 47 can be simplified. Further, since the first and second permanent magnets 37 and 47 are not affected by the first and second claw-shaped magnetic pole portions 20 and 24 that are largely displaced with respect to the centrifugal force, the first and second permanent magnets 37 and 47 are not affected. Is easy to hold. From these things, the reliability of holding | maintenance of the 1st and 2nd permanent magnets 37 and 47 is improved.

Here, since the 1st and 2nd pole core bodies 17 and 21 are produced by the cold forging manufacturing method, it is difficult to obtain a highly accurate magnet holding shape. Therefore, in order to obtain a highly accurate magnet holding shape, the first and second pole core bodies 17 and 21 manufactured by the cold forging method have to be cut using an NC processing machine or the like.
In this embodiment, since the hole shape of the first and second magnet folder holding holes 31 and 41 for holding the magnet is an arc-shaped cylinder having a C-shaped cross section, it is manufactured by a cold forging manufacturing method. First and second magnet folder holding holes 31 and 41 having high-precision hole dimensions are formed by performing simple additional machining with a rotary cutting tool such as a drill or a reamer on the first and second pole core bodies 17 and 21. it can. As a result, the fitting surfaces of the first and second magnet folder holding holes 31 and 41 can be produced by cutting with a rotary cutting tool, and three-dimensional cutting using an NC processing machine is not necessary, and the manufacturing time is reduced. The manufacturing cost can be reduced while being shortened.

In addition, since the processing accuracy of the fitting surfaces of the first and second magnet folder holding holes 31 and 41 can be increased, the first and second magnet folders in which the first and second permanent magnets 37 and 47 are incorporated. 33 and 43 can be firmly held in the first and second magnet folder holding holes 31 and 41 in a stable state without rattling. Therefore, even if the rotor 13 rotates at a high speed, the first and second magnet folders 33, 43 come out of the first and second magnet folder holding holes 31, 41 and are scattered, and the first and second permanent magnets 37, The situation where 47 is damaged is avoided.
In addition, since the first and second permanent magnets 37 and 47 are built in the first and second magnet folders 33 and 43, the first and second permanent magnets 37 and 47 are not affected by vibrations caused by the automobile engine applied to the vehicle alternator 1. Generation | occurrence | production of the crack and notch | missing of the 2nd magnet folders 33 and 43 is suppressed.

  In addition, the first and second magnet folder holding holes 31 and 41 are formed in an arcuate cylindrical shape having a C-shaped cross section with the hole centers aligned in the axial direction, and the first and second magnet folders 33, 43 is inserted and held in the first and second magnet folder holding holes 31 and 41 from the axial direction. Therefore, the holding structure of the magnet folders 33 and 43 is simplified, the assembling property is improved, the production cost is reduced, and the mass productivity is improved.

Further, since the contact surfaces of the first and second magnet folder holding holes 31 and 41 and the first and second magnet folders 33 and 43 are cylindrical surfaces, there is no local stress concentration, and the first and second magnets Generation | occurrence | production of the damage of the holding bases 30 and 40 is suppressed.
In addition, since the first and second permanent magnets 37 and 47 are formed in a columnar body having a trapezoidal cross section, the first and second permanent magnets 37 and 47 can be efficiently cut out from the magnet base material using a grindstone. , Material yield is increased.

  Further, since the first and second magnet folders 33 and 43 are formed by laminating the magnetic thin plates 49 punched by press working, the first and second magnet folders 33 and 43 are adapted to the hole shapes of the first and second magnet folder holding holes 31 and 41. The first and second magnet folders 33 and 43 having complicated outer shapes composed of the fitting portions 34 and 44 and the protruding portions 35 and 45 extending from the first and second axial openings 32 and 42 can be obtained with high accuracy. And it can produce simply. Therefore, the first and second magnet folders 33 and 43 can be held in the first and second magnet folder holding holes 31 and 41 without rattling. Further, the magnet mounting holes 36 and 46 can be easily manufactured with high accuracy. Therefore, the first and second permanent magnets 37 and 47 can be held on the first and second magnet folders 33 and 43 without rattling. Furthermore, since the fitting parts 34 and 44 are interposed between the first and second permanent magnets 37 and 47 and the first and second magnet holding bases 30 and 40, the magnetic resistance between them is reduced. Therefore, the magnetic resistance of the magnet magnetic path is reduced, the amount of magnet magnetic flux is increased, the effect of relaxing the magnetic saturation of the rotor is increased, and the power generation output can be increased.

  Here, it is necessary to magnetize the permanent magnet in any step of manufacturing the rotor 13, and when handling the magnetized permanent magnet, it is necessary to demagnetize the entire apparatus. Therefore, the unmagnetized permanent magnet cut out from the magnet base material is inserted and held in the magnet mounting holes 36 and 46 of the first and second magnet folders 33 and 43, and then the unmagnetized permanent magnet is held. A magnetic field is applied to the first and second magnet folders 33 and 43 to magnetize an unmagnetized permanent magnet. Next, the first and second magnet cores 33 and 43 holding the magnetized permanent magnets (first and second permanent magnets 37 and 47) are connected to the first and second pole core bodies 17 and 21, respectively. It is preferable to insert and hold in the two-magnet folder holding holes 31, 41. That is, since the first and second magnet folders 33 and 43 holding the first and second permanent magnets 37 and 47 have the fitting portions 34 and 44 that can be gripped, handling by a robot or an automatic machine is easy. Therefore, it is not necessary to make all the devices non-magnetic.

  Moreover, in the said embodiment, the 1st magnet folder 33 which incorporated the 1st permanent magnet 37 protruded by the site | part of the 1st yoke part 19 between the 1st nail | claw-shaped magnetic pole parts 20 adjacent in the circumferential direction. Of the second yoke portion 23 between the second claw-shaped magnetic pole portions 24 that are held by all of the first magnet holding pedestals 30 and have the second permanent magnets 47 and that are adjacent to each other in the circumferential direction. Since it is held by all of the eight second magnet holding bases 40 protruding from the part, the first and second magnet folders 33 and 43 are arranged at an equiangular pitch. Therefore, the sum of the vectors from the center of the rotating shaft 16 toward the center of gravity of each of the first and second magnet folders 33 and 43 becomes zero, and centrifugal is caused by arranging the first and second permanent magnets 37 and 47. Generation of weight imbalance with respect to force is suppressed. Here, the center of gravity of the first magnet folder 33 is the center of gravity including the first permanent magnet 37 and the first magnet folder 33, and the center of gravity of the second magnet folder 43 is the second permanent magnet 47 and the second magnet. This is the center of gravity including the magnet folder 43.

  Here, in the said embodiment, although the 1st and 2nd magnet folders 33 and 43 shall be arrange | positioned by all the 1st and 2nd magnet holding bases 30 and 40, the 1st and 2nd magnet The folders 33 and 43 do not have to be disposed on all the first and second magnet holding bases 30 and 40, and the number of disposed first and second magnet folders 33 and 43 takes into consideration required performance and cost. What is necessary is just to select suitably. In this case, each of the first and second magnet folders 33 and 43 including the first and second permanent magnets 37 and 47 from the center of the rotating shaft 16 is provided in order not to cause a weight imbalance with respect to the centrifugal force. What is necessary is just to arrange | position the 1st and 2nd magnet folders 33 and 43 so that the sum total of the vector which goes to the gravity center of may become zero. In this case, magnetically, since the magnetic fluxes of the first and second permanent magnets 37 and 47 are closed inside the rotor, no magnetic imbalance occurs with respect to the stator.

  For example, in consideration of required performance and cost, when the number of the first and second magnet folders 33 and 43 is six, the position is point-symmetric with respect to the center of the rotating shaft 16. That is, the first and second magnet folders 33 and 43 are arranged on the six first and second magnet holding bases 30 and 40 except for the first and second magnet holding bases 30 and 40 at positions 180 degrees apart in the circumferential direction. What is necessary is just to arrange | position. As a result, the sum of vectors from the center of the rotating shaft 16 toward the center of gravity of each of the first and second magnet folders 33 and 43 including the first and second permanent magnets 37 and 47 becomes zero. Further, when the number of the first and second magnet folders 33 and 43 is set to four, the first and second magnet folders 33 and 43 are arranged at an equiangular pitch of 90 degrees, respectively. What is necessary is just to arrange | position to the 2 magnet holding bases 30 and 40. Also by this, the sum of vectors from the center of the rotating shaft 16 toward the center of gravity of each of the first and second magnet folders 33 and 43 including the first and second permanent magnets 37 and 47 becomes zero.

  Moreover, in the said embodiment, the 1st and 2nd nail | claw-shaped magnetic pole parts 20 and 24 in which the 1st and 2nd magnet holding bases 30 and 40 holding the 1st and 2nd magnet folders 33 and 43 adjoin the circumferential direction. However, the first and second magnet holding bases 30 and 40 holding the first and second magnet folders 33 and 43 are adjacent to each other in the circumferential direction. The number of the first and second magnet holding bases 30 and 40 may be appropriately selected in consideration of the required performance and cost. In this case, the first and second magnet holding bases 30 and 40 that hold the first and second magnet folders 33 and 43 from the center of the rotating shaft 16 are provided in order not to cause a weight imbalance with respect to the centrifugal force. What is necessary is just to arrange | position the 1st and 2nd magnet holding bases 30 and 40 so that the sum total of the vector which goes to the gravity center of each whole magnet holding base may become zero. Here, the center of gravity of the entire magnet holding base is the center of gravity including the first magnet holding base 30, the first permanent magnet 37 and the first magnet folder 33, and the second magnet holding base 40, the second permanent magnet 47 and This is the center of gravity including the second magnet folder 43. Even in this case, magnetically, the magnetic fluxes of the first and second permanent magnets 37 and 47 are closed inside the rotor, so that no magnetic imbalance occurs with respect to the stator.

  For example, in the case where the number of first and second magnet holding bases 30 and 40 holding the first and second magnet folders 33 and 43 is set to 6 in consideration of required performance and cost, The first and second magnet holding pedestals 30 and 40 are provided at six positions excluding a position that is point-symmetric with respect to the center of the rotating shaft 16, that is, a position that is 180 degrees apart in the circumferential direction. The first and second magnet folders 33 and 43 holding the first and second permanent magnets 37 and 47 may be disposed on the holding bases 30 and 40. As a result, the sum of the vectors from the center of the rotating shaft 16 toward the center of gravity of each of the first and second magnet holding bases 30 and 40 becomes zero. Further, when the number of the first and second magnet holding bases 30 and 40 holding the first and second magnet folders 33 and 43 is four, the four first and second magnets are provided. The holding bases 30 and 40 are provided at an equiangular pitch of 90 degrees, respectively, and the first and second magnet folders 33 in which the first and second permanent magnets 37 and 47 are held on the first and second magnet holding bases 30 and 40, respectively. , 43 may be provided. Also by this, the sum of the vectors from the center of the rotating shaft 16 toward the center of gravity of each of the first and second magnet holding bases 30 and 40 becomes zero.

  Moreover, although the material of the 1st and 2nd permanent magnets 37 and 47 is not demonstrated in the said embodiment, the big space for arrange | positioning a permanent magnet from a Landel-type rotor structure cannot be ensured. Therefore, in order to obtain a sufficient magnetic saturation relaxation effect with a small-volume magnet, it is preferable to use an anisotropic sintered rare earth magnet having an energy product BHMAX of 30 MGOe or more.

  In the above embodiment, the vehicle alternator has been described. However, the present invention is not limited to the vehicle alternator, and may be applied to a rotating electrical machine such as a vehicle motor or a vehicle generator motor. Have the same effect.

Moreover, in the said embodiment, although the protrusion parts 35 and 45 of the 1st and 2nd magnet folders 33 and 43 shall be formed in the cross-sectional trapezoid, the cross section of a protrusion part is not limited to a trapezoid. The cross section may be a square or a rectangular quadrangle. Needless to say, chamfering or rounding may be applied to the corners of the rectangular cross section.
In the above-described embodiment, the first and second permanent magnets 37 and 47 are formed as columnar bodies having a trapezoidal section, but the first and second permanent magnets 37 and 47 are columnar bodies having a trapezoidal section. It is not limited to. For example, if the cross-section is a quadrangular columnar body such as a trapezoid, square, or rectangle, the first and second permanent magnets 37 and 47 can be efficiently cut out from the magnet base material, and the material yield can be increased. Needless to say, chamfering or rounding may be applied to the corners of the rectangular cross section. Further, the magnet mounting hole 36 is formed in an inner shape of a square cross section that matches the outer shape of the square cross section of the first and second permanent magnets 37 and 47.

  Moreover, in the said embodiment, although the 1st and 2nd magnet folders 33 and 43 shall be produced by laminating | stacking the predetermined magnetic thin plate 49, a 1st and 2nd magnet folder is a lump shape of a magnetic material. It may be produced as an integral body.

Moreover, in the said embodiment, the 1st and 2nd magnet folder holding holes 31 and 41 make the hole center correspond to an axial direction at the 1st and 2nd magnet holding bases 30 and 40, and the other end from an axial direction The first and second magnet folder holding holes do not necessarily extend from one end to the other end in the axial direction. It is not necessary to penetrate, and at least one of the one end or the other end in the axial direction may be open.
Moreover, the hole centers of the first and second magnet folder holding holes do not necessarily coincide with the axial direction, and may be inclined with respect to the axial direction. For example, it is more preferable if the hole centers of the first and second magnet folder holding holes are substantially parallel to the inner peripheral surfaces on the front end side of the second and first claw-shaped magnetic pole portions facing each other.

1 is a cross-sectional view schematically showing an automotive alternator according to an embodiment of the present invention. It is a disassembled perspective view which shows the rotor applied to the alternating current generator for vehicles which concerns on one embodiment of this invention. It is a perspective view which shows the magnetic thin plate which comprises the magnet folder in the alternating current generator for vehicles which concerns on one embodiment of this invention. It is a perspective view explaining the mounting method to the magnet folder of the permanent magnet in the alternating current generator for vehicles concerning one embodiment of this invention. It is a schematic diagram for demonstrating the flow of the magnetic flux in the alternating current generator for vehicles which concerns on one embodiment of this invention. It is a schematic diagram for demonstrating the flow of the magnetic flux in the alternating current generator for vehicles which concerns on one embodiment of this invention.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 10 Stator, 13 Rotor, 14 Field coil, 15 Pole core, 16 Rotating shaft, 17 1st pole core body, 18 1st boss | hub part, 19 1st yoke part, 20 1st claw-shaped magnetic pole part, 21 2nd Pole core body, 22 Second boss part, 23 Second yoke part, 24 Second claw-shaped magnetic pole part, 29 Air gap, 30 First magnet holding base (permanent magnet holding part), 31 First magnet folder holding hole, 32 1st axial direction opening, 33 1st magnet folder, 34 fitting part, 35 protrusion part, 36 magnet mounting hole, 37 1st permanent magnet, 40 2nd magnet holding base (permanent magnet holding part), 41 2nd magnet folder Holding hole, 42 2nd axial direction opening, 43 2nd magnet folder, 44 fitting part, 45 protrusion part, 46 magnet mounting hole, 47 2nd permanent magnet, 49 Magnetic thin plate.

Claims (5)

A boss portion, a pair of yoke portions extending radially outward from both end edges in the axial direction of the boss portion, and a pair of yoke portions alternately extending in the axial direction from each of the yoke portions, meshing with each other. A pole core that has a plurality of claw-shaped magnetic pole portions arranged in a direction and is fixed to a rotating shaft that is inserted through the axial center of the boss portion; the boss portion; the pair of yoke portions; A rotor having a field coil housed in a space surrounded by the claw-shaped magnetic pole part;
In a rotating electrical machine comprising: a stator disposed so as to surround an outer periphery of the rotor via a predetermined air gap;
A permanent magnet holding portion integrally projecting from the yoke portion at a portion of the pair of yoke portions facing the inner peripheral surface on the tip side of the plurality of claw-shaped magnetic pole portions;
Each of the permanent magnet holding portions is provided with an arc-shaped magnet folder having a C-shaped cross section, which is provided with the hole direction directed in the axial direction, at least one end in the axial direction is open and radially outward. With holes,
A cross section inserted and held in the magnet folder holding hole is a C-shaped arc-shaped fitting portion, and protrudes radially outward from the fitting portion integrally, and radially outward from the magnet folder holding hole. A projecting portion having a quadrangular projecting section, and a magnet folder made of a magnetic material having a quadrangular magnet mounting hole penetrating from one end to the other end in the axial direction in the projecting portion and the fitting portion;
A permanent magnet having a cross-section formed into a quadrangular columnar body, inserted and held in each of the magnet mounting holes, and magnetized and oriented in a direction opposite to the direction of the magnetic field formed by the field coil. A rotating electric machine that is characterized.   2. The rotating electrical machine according to claim 1, wherein the magnet folder has an outer shape projecting radially outward from a circular arc-shaped chordal portion having a C-shape, and constitutes the magnet mounting hole. A rotating electrical machine characterized in that it is made by laminating a predetermined number of magnetic thin plates having a portion formed thereon. The rotating electrical machine according to claim 1 or 2, wherein the permanent magnet holding portion protrudes from a portion of the pair of yoke portions facing the inner peripheral surface on the tip side of all the claw-shaped magnetic pole portions. ,
The magnet folder in which the permanent magnet is inserted and held in the magnet mounting hole is arranged such that the sum of vectors from the center of the rotation axis toward the center of gravity including the permanent magnets of the magnet folder is zero. Rotating electric machine characterized by that. The rotating electrical machine according to claim 1 or 2, wherein the magnet folder in which the permanent magnet is inserted and held in the magnet mounting hole is inserted and held in all the magnet folder holding holes of the permanent magnet holding portion. And
The total sum of vectors from the center of the rotating shaft to the center of gravity of the permanent magnet holding part including the permanent magnet holding part and the permanent magnet holding part of the permanent magnet holding part from the center of the rotating shaft A rotating electrical machine characterized by being arranged to be zero. A method for manufacturing a rotating electrical machine according to any one of claims 1 to 4,
Inserting and holding an unmagnetized permanent magnet in the magnet mounting hole of the magnet folder;
Applying a magnetic field to the magnet folder holding the unmagnetized permanent magnet to magnetize the unmagnetized permanent magnet;
And a step of inserting and holding the magnet folder holding the magnetized permanent magnet in the magnet folder holding hole.

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