JP2010136525A - Method for manufacturing axial gap motor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for manufacturing an axial gap motor that allows common use of a die while maintaining processing accuracy of a rotor core. <P>SOLUTION: The method for manufacturing the axial gap motor is configured to repeat the following steps, that is, a transfer step of transferring a magnetic plate 14 and a punching step of simultaneously punching a punched hole A<SB>M</SB>on the front side in the transfer direction and a punched hole B<SB>M</SB>on the rear side in the transfer direction in the magnetic plate 14. In the punching step, the punched hole on the rear side in the transfer direction that is previously punched is transferred by a prescribed pitch and lapped on the punched hole on the rear side in the transfer direction so as to form the punched hole on the front side in the transfer direction, thereby forming a main-magnet-piece opening 15a. A main-magnet piece storage part 15 is configured by a plurality of the radially-arranged main-magnet-piece openings 15a by winding the magnetic plate 14. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a method for manufacturing an axial gap type motor.

  Conventionally, for example, a rotor that can rotate around a rotation axis and a stator that is disposed to face the rotor from at least one side in the direction of the rotation axis are provided. An axial gap type motor that forms a loop is known (for example, Patent Document 1).

  As shown in FIG. 14, in the axial gap type motor 100 described in Patent Document 1, the rotor core 101 is formed by winding a tape-shaped electromagnetic steel plate 102, and the magnet piece 103 is stored in the wound rotor core 101. Openings 104 are provided at equal intervals in the circumferential direction.

JP 2006-166635 A

  However, forming the opening 104 after winding the electromagnetic steel sheet 102 may cause a positional shift of the wound electromagnetic steel sheet 102, and may reduce the processing accuracy. Further, when the magnetic steel sheet 102 is punched before winding and the openings 104 are provided, the pitches of the openings 104 and 104 adjacent to each other in the circumferential direction are different between the inner diameter side and the outer diameter side, and the die is changed for each punching pitch. Therefore, there is a problem that the apparatus becomes large and the processing cost becomes high.

  The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a method of manufacturing an axial gap type motor that can share a mold while maintaining the processing accuracy of the rotor core.

In order to achieve the above object, the invention described in claim 1
A plurality of main magnet pieces (for example, a main permanent magnet piece 41 in an embodiment described later) magnetized in the rotation axis direction and arranged at a predetermined interval in the circumferential direction, and a tape-shaped magnetic plate (for example, an embodiment described later) Magnetic plate 14), and a plurality of yoke portions (for example, yoke portions 42 in the embodiments described later) and a plurality of main magnet piece housing portions (for example, described later) that respectively hold the main magnet pieces. A rotor core (for example, a rotor core 13 in an embodiment described later) having a rotor core (for example, a rotor 11 in an embodiment described later). )When,
Manufacture of an axial gap type motor (for example, an axial gap type motor 10 in an embodiment to be described later) including a stator (for example, a stator 12 in an embodiment to be described later) disposed opposite to the rotor from at least one of the rotation axis directions A method,
A transporting step for transporting the magnetic plate, a punching hole on the front side in the transporting direction (for example, a front punching hole A _M in an embodiment described later) and a punching hole on the rear side in the transporting direction (for example, an embodiment described later) rear punched holes B _M) repeating the punching step of punching out at the same time, the in stamping process, the transport direction rear side of the punching hole by conveying the conveying direction rear side of the punching holes punched previously by a predetermined pitch in Forming a main magnet piece opening (for example, a main magnet piece opening 16a in an embodiment described later)
Winding the magnetic plate to configure the main magnet piece housing portion by a plurality of openings for the main magnet pieces arranged in the radial direction;
A manufacturing method of an axial gap type motor characterized by the above.

In addition to the structure of Claim 1, the invention of Claim 2 is
The punchable length on the front side in the transport direction is longer than the punchable length on the rear side in the transport direction,
It is characterized by that.

In addition to the structure of Claim 1 or 2, the invention of Claim 3 is
Along with the punching of the opening for the main magnet piece, a positioning opening (for example, a positioning opening 16a in an embodiment described later) is formed by punching between the openings for the main magnet piece adjacent in the circumferential direction.
A plurality of the positioning openings arranged in the radial direction by winding the magnetic plate constitutes a positioning hole (for example, a positioning hole 16 in an embodiment described later).
It is characterized by that.

In addition to the structure of Claim 3, the invention of Claim 4 is
The axial gap type motor further includes a plurality of secondary magnet pieces (for example, secondary permanent magnet pieces 43 in the embodiments described later) magnetized in a direction orthogonal to the rotation axis direction and the radial direction,
Along with the punching of the opening for the main magnet piece, the opening for the submagnet piece (for example, the opening for the subpermanent magnet piece 17a in an embodiment described later) is formed by punching at least one of the positioning openings in the rotation axis direction,
A plurality of openings for the secondary magnet pieces arranged in the radial direction by winding the magnetic plate accommodates the secondary magnet pieces (for example, a secondary permanent magnet piece cut in an embodiment described later). Constituting the notch 17),
It is characterized by that.

In addition to the structure in any one of Claims 1-4, the invention of Claim 5 is
The punching pressure on the front side in the transport direction and the punching pressure on the rear side in the transport direction are substantially the same at a portion corresponding to the substantially intermediate diameter of the rotor core when the magnetic plate is wound.
It is characterized by that.

In addition to the structure in any one of Claims 2-5, the invention of Claim 6 is
The punchable lengths on the transport direction front side and the transport direction rear side are shorter than the length of the opening for the main magnet piece on the innermost diameter side, respectively, and the punchable lengths on the transport direction front side and the transport direction rear side are respectively The added length is longer than the opening for the main magnet piece on the outermost diameter side,
It is characterized by that.

  According to the invention of claim 1, the punching hole on the rear side in the transport direction punched first and the punching hole on the front side in the transport direction punched after transporting the magnetic plate by a predetermined pitch are wrapped twice. To form the opening for each main magnet piece, adjust the feed amount of the magnetic plate from the inner diameter side to the outer diameter side of the rotor core, that is, adjust the wrap amount of the punching holes on the front side in the transport direction and the rear side in the transport direction Thus, a plurality of openings for main magnet pieces having different pitches can be formed using the same mold. By winding this, a rotor core in which a plurality of main magnet piece accommodating portions are formed by a plurality of main magnet piece openings arranged in the radial direction can be manufactured. As a result, the processing accuracy of the rotor core can be improved as compared with the case where an opening is provided in the rotor core after winding the magnetic plate, and the die can be shared without having to change the die for each pitch. Downsizing and manufacturing cost can be reduced.

  According to the second aspect of the present invention, the punchable length on the front side in the transport direction in which the part is punched again is made longer than the punchable length on the rear side in the transport direction for punching the solid magnetic plate. Further, the imbalance between the punching pressures on the front side in the transport direction and the rear side in the transport direction can be suppressed, and the life of the manufacturing apparatus can be extended.

  According to the third aspect of the present invention, the positioning opening can be formed at the same time in one punching step, and the manufacturing efficiency can be improved. Also, the rotor core can be positioned with respect to the rotor frame by attaching the rib of the rotor frame to the positioning hole portion constituted by a plurality of positioning openings arranged in the radial direction, and the main magnets adjacent to each other in the circumferential direction. Short-circuiting of magnetic flux between pieces can be suppressed.

  According to invention of Claim 4, the opening for submagnet pieces which comprises the accommodating part for submagnet pieces at the same time by one punching process can be formed, and manufacturing efficiency can be improved. In addition, a magnetic lens that restricts the direction of the magnetic flux of the main magnet piece by forming the sub magnet piece in a housing portion for the secondary magnet piece that is configured by a plurality of openings for the secondary magnet pieces arranged in the radial direction. The effective magnetic flux generation amount can be relatively increased by the effect.

  According to the invention of claim 5, the punching pressure on the front side in the transport direction and the punching pressure on the rear side in the transport direction are set to be substantially the same in the portion corresponding to the substantially intermediate diameter of the rotor core when the magnetic plate is wound. By doing so, the pressure difference between the punching pressures on the front side in the transport direction and the rear side in the transport direction when manufacturing one rotor core can be reduced.

  According to the sixth aspect of the present invention, it is possible to punch from one opening to the outermost diameter main magnet piece opening to the outermost diameter main magnet piece opening.

  Hereinafter, an axial gap type motor according to an embodiment of the present invention will be described in detail with reference to the accompanying drawings. The drawings are viewed in the direction of the reference numerals.

  An axial gap type motor 10 according to the present embodiment includes, for example, a substantially annular rotor 11 provided to be rotatable around a rotation axis O of the axial gap type motor 10, as shown in FIGS. A pair of stators 12 and 12 having a plurality of stator windings that are arranged opposite to each other so as to sandwich the rotor 11 from both sides in the direction of the axis O and generate a rotating magnetic field that rotates the rotor 11. Yes.

  The axial gap type motor 10 is mounted as a drive source in a vehicle such as a hybrid vehicle or an electric vehicle, for example, and an output shaft is connected to an input shaft of a transmission (not shown), whereby the driving force of the axial gap type motor 10 is obtained. Is transmitted to drive wheels (not shown) of the vehicle via a transmission.

  Further, when the driving force is transmitted from the driving wheel side to the axial gap type motor 10 during deceleration of the vehicle, the axial gap type motor 10 functions as a generator to generate a so-called regenerative braking force, and the kinetic energy of the vehicle body is electrically converted. Recover as energy (regenerative energy). Further, for example, in a hybrid vehicle, when the rotating shaft of the axial gap type motor 10 is connected to the crankshaft of an internal combustion engine (not shown), the axial gap motor 10 is also axially transmitted when the output of the internal combustion engine is transmitted to the axial gap type motor 10. The gap type motor 10 functions as a generator and generates power generation energy.

  Each stator 12 faces the rotor 11 along the direction of the rotation axis O from a substantially annular plate-shaped yoke portion 21 and a position at a predetermined interval in the circumferential direction on the facing surface of the yoke portion 21 facing the rotor 11. A plurality of teeth 22,..., 22 that protrude and extend in the radial direction, and stator windings (not shown) mounted between the appropriate teeth 22, 22 are configured.

  Each stator 12 is, for example, a 6N type having six main poles (for example, U +, V +, W +, U−, V−, W), and each stator 12 has U +, V +, W + poles. On the other hand, the U-, V-, and W-poles of the other stator 12 are set to face each other in the direction of the rotation axis O. For example, with respect to a pair of stators 12 and 12 opposed in the direction of the rotation axis O, three teeth 22 of one stator 12 corresponding to one of U +, V +, W + poles and one of U−, V−, W− poles, 22, 22 and the three teeth 22, 22, 22 of the other stator 12 corresponding to the other of the U +, V +, W + pole and the U−, V−, W− pole face each other in the direction of the rotation axis O. Thus, the energized state of the teeth 22 of one stator 12 and the teeth 22 of the other stator 12 facing each other in the direction of the rotation axis O is set so as to be reversed by an electrical angle.

  For example, as shown in FIG. 2, the rotor 11 includes a rotor core 13, a plurality of main magnet portions 31,..., 31, a plurality of sub magnet portions 32,. The rotor core 13 is accommodated in the rotor frame 33 in a state where the main magnet portions 31 and the sub magnet portions 32 are alternately arranged in the circumferential direction in the rotor core 13.

  The rotor frame 33 includes an inner annular ring shaft portion 36 and an outer circumferential annular ring rim portion 37 connected by a plurality of radial ribs 35,... 35 arranged at predetermined intervals in the circumferential direction. An output shaft connected to an external drive shaft (for example, an input shaft of a vehicle transmission) can be connected to the inner peripheral portion of the shaft portion 36.

  The rotor core 13 is formed by winding a magnetic plate 14 made of a tape-shaped electromagnetic steel plate, which will be described later, and as shown in FIG. The main permanent magnet piece holes 15 and the columnar positioning holes 16 are alternately formed at predetermined intervals in the circumferential direction, and the secondary permanent magnets to be described later are provided on both sides of the positioning hole 16 in the rotation axis O direction. A columnar sub permanent magnet piece cutout portion 17 for accommodating the piece 43 is formed. In other words, the rotor core 13 is adjacent to the plurality of yoke portions 42,..., 42 arranged so as to sandwich the main permanent magnet pieces 41 from both sides in the rotation axis O direction at predetermined intervals in the circumferential direction. A pair of axial connecting portions 14a, 14a that connect the yoke portions 42, 42 and a yoke portion 42, 42 connected by the pair of axial connecting portions 14a, 14a are replaced with the adjacent yoke portions 42, 42 in the circumferential direction. And a pair of circumferential connecting portions 14b, 14b to be connected.

  Here, as shown in FIG. 4, the rotor core 13 has a positioning hole 16 with a width of Ta, a longitudinal length of Tp, and a secondary permanent magnet piece notch 17 with a longitudinal length of Lsp and positioning. The distance between the notch portions 17 and 17 for the secondary permanent magnet pieces disposed on both sides in the width direction of the hole portion 16 is Lsa, the width of the main permanent magnet piece hole portion 15 is Lma, and the adjacent main permanent magnet piece hole portion 15 is Lma. In this embodiment, the distance 15 is set to satisfy the relationship of Ta = Lma <Lsa and Tp <Lsp <Lmp.

  In the main magnet portion 31, a substantially sector plate-shaped main permanent magnet piece 41 magnetized in the thickness direction (that is, the direction of the rotation axis O) is disposed in the main permanent magnet piece hole portion 15 of the rotor core 13, and in the circumferential direction. The main permanent magnet pieces 41 and 41 of the adjacent main magnet portions 31 and 31 are set so that the magnetization directions are different from each other.

  The sub-magnet portion 32 includes a pair of sub-permanent magnet pieces 43 and 43 magnetized in the direction (substantially circumferential direction) perpendicular to the rotation axis O direction and the radial direction, respectively, and the rotation axis O of the positioning hole 16 of the rotor core 13. A pair of secondary permanent magnet pieces 43, 43 arranged in the secondary permanent magnet piece cutout portions 17, 17 formed on both sides in the direction and opposed in the direction of the rotation axis O have mutually different magnetization directions. ing.

  Further, the pair of sub permanent magnet pieces 43 and 43 facing each other in the circumferential direction via the main magnet portion 31 have different magnetization directions. The pair of sub permanent magnet pieces 43 and 43 arranged on one side in the direction of the rotation axis O have the same polarity as the magnetic pole on one side of the main permanent magnet piece 41 magnetized in the direction of the rotation axis O. A pair of sub-permanent magnet pieces 43, 43 that are opposed to each other and arranged on the other side in the direction of the rotation axis O are magnetic poles having the same polarity as the magnetic pole on the other side of the main permanent magnet piece 41 magnetized in the direction of the rotation axis O. Are arranged to face each other.

  That is, for example, with respect to the main permanent magnet piece 41 in which one side in the rotation axis O direction is an N pole and the other side is an S pole, a pair of the yoke portion 42 is sandwiched from both sides in the circumferential direction on one side in the rotation axis O direction. The sub permanent magnet pieces 43, 43 are arranged so that their N poles face each other in the circumferential direction, and a pair of sub permanent magnet pieces 43 sandwiching the yoke portion 42 from both sides in the circumferential direction on the other side in the rotation axis O direction. , 43 are arranged so that their S poles face each other in the circumferential direction. As a result, a so-called permanent halbach arrangement of permanent magnets is obtained, and the magnetic fluxes of the main permanent magnet piece 41 and the sub permanent magnet pieces 43 and 43 are converged by the magnetic flux lens effect that regulates the direction of the magnetic flux of the main permanent magnet piece 41. The effective magnetic flux linked to the stators 12 and 12 is relatively increased.

  As shown in FIG. 5, the rotor frame 33 has a plurality of shaft portion side rib mounting holes 36 a that are circular through holes in which the radial ribs 35 are mounted on the shaft portion 36. A plurality of rim portion side rib mounting holes 37a, which are rectangular through holes in which the radial ribs 35 are mounted to the portion 37, are formed at equal intervals in the circumferential direction.

  Further, the radial rib 35 has a substantially T-shape, and the radially inner end portion 35a has a substantially circular cross section and is formed with a male thread portion. The radially outer end portion 35b and the radially intermediate portion The portion 35c has a rectangular cross section, and the radially outer end portion 35b gradually increases in length in the circumferential direction from the radially intermediate portion 35c toward the radially outer side, and has a uniform axial length. It is configured.

  Then, the rotor core 13 having the main permanent magnet piece 41 and the sub permanent magnet piece 43 is sandwiched between the shaft portion 36 and the rim portion 37 from the inner diameter side and the outer diameter side, and inserted through the rim portion side rib mounting hole 37a. The formed radial rib 35 is fitted into the positioning hole 16 in the radial intermediate portion 35c, the radially inner end 35a is mounted in the shaft portion side rib mounting hole 36a, and the inner diameter side of the shaft portion 36 is provided. The nuts 38 are screwed together, and the radial ribs 35 are fixed to the shaft portion 36.

  Next, a method for manufacturing the axial gap motor 10 of the present invention will be described. Hereinafter, the width direction of the magnetic plate 14 corresponds to the rotation axis O direction of the rotor 11, and the longitudinal direction of the magnetic plate 14 corresponds to the circumferential direction of the rotor 11.

First, a main permanent magnet piece opening 15a constituting the main permanent magnet piece hole 15 using a press molding machine on the tape-like magnetic plate 14, a positioning opening 16a constituting the positioning hole 16 and positioning. A process of punching the secondary permanent magnet piece openings 17a, 17a constituting the secondary permanent magnet piece cutout portions 17, 17 on both sides in the width direction of the opening 16a will be described in detail based on two embodiments.
<First Embodiment>
As shown in FIG. 8, the press molding machine 80 includes one die 81 having five punching blades arranged in a cross shape, and is disposed on a conveyance path for conveying the magnetic plate 14, and conveys the magnetic plate 14. The conveyance process and the punching process for punching the magnetic plate 14 are repeated.

  The die 81 is disposed near the cross-shaped intersection and forms a reference punching blade 82 that forms the positioning opening 16a, and a pair of sub permanent magnet piece openings 17a and 17a that are disposed on both sides of the reference punching blade 82 in the width direction. Side punching blades 83, 83, a front punching blade 84 that is disposed in front of the reference punching blade 82 in the conveying direction of the magnetic plate 14 and forms a part of the main permanent magnet piece opening 15 a, and a reference punching blade 82. On the other hand, it is provided with a rear punching blade 85 that is arranged behind the magnetic plate 14 in the conveying direction and forms a part of the opening 15a for the main permanent magnet piece. The reference punching blade 82 has substantially the same shape as the cross-sectional shape of the positioning hole 16 viewed from the circumferential direction, and the pair of side punching blades 83 and 83 respectively provide the secondary permanent magnet piece cutout portion 17 in the circumferential direction. It has substantially the same shape as the cross-sectional shape seen from the side. The front punching blade 84 and the rear punching blade 85 have a substantially rectangular shape, and the widths of the front punching blade 84 and the rear punching blade 85 are substantially equal to the width of the main permanent magnet piece hole 15. The length in the longitudinal direction of the rear punching blade 85 is shorter than the main permanent magnet piece opening 15a on the innermost diameter side when wound, and is the length obtained by adding the lengths in the longitudinal direction of the front punching blade 84 and the rear punching blade 85 together. Is set longer than the length in the longitudinal direction of the main permanent magnet piece opening 15a on the outermost diameter side. In the present embodiment, the longitudinal length of the front punching blade 84 is set longer than the longitudinal length of the rear punching blade 85.

By performing press molding using such a mold 81, the opening for main permanent magnet piece 15a, the opening for positioning 16a, and the openings for secondary permanent magnet pieces 17a and 17a on both sides in the width direction of the positioning opening 16a are provided. It is formed.
Here, since the magnetic plate 14 is wound in a spiral shape on the winding core 70 as will be described later, the pitch between the centers of the adjacent positioning openings 16a and 16a as shown in FIG. P gradually increases from the innermost diameter side to the outermost diameter side as the first, second, third,..., And the main permanent magnet piece 41 expands as it goes radially outward. Since it has a substantially fan-shaped plate shape, the length in the longitudinal direction of the main permanent magnet piece hole 15 gradually increases from the innermost diameter side to the first, second, third,... Along the radial direction. Accordingly, the feed amount of the magnetic plate 14 (the amount by which the magnetic plate 14 is conveyed at every punching interval) is set in consideration of these relationships.

Hereinafter, the punching process of the main permanent magnet piece openings 15a having different lengths will be described with reference to FIG. In the figure, Lf represents the front side punchable length which is the longitudinal length of the front punching blade 84, and Lr represents the rear side punchable length which is the longitudinal direction length of the rear punching blade 85. In this embodiment, as described above, the relationship is Lf> Lr. A region surrounded by a dotted line is a portion punched by M-th punching (M = 1 to N: N is a multiple of 6), of which A _M and B _M are front punched Represents a punching hole and a rear punching hole, and LA _M and LB _M are the lengths in the longitudinal direction of the magnetic plate 14 on the front side actually punched in the M-th time (the wrapping described later from the front punchable length Lf). The length obtained by subtracting the length, hereinafter referred to as the front punching length), and the longitudinal length of the rear magnetic plate 14 (the length equal to the rearward punchable length Lr, hereinafter referred to as the rear punching length). .)

In the first punching, a front punching hole A ₁ punched by the front punching blade 84 and a rear punching hole B ₁ punched by the rear punching blade 85 are formed. At this time, the front punching length LA ₁ is longer than the rear punching length LB ₁ . Then, the distal end portion of the rear punching holes B ₁ is allowed to carry the predetermined feed amount by the magnetic plate 14 such that the distal end of the main permanent magnet piece for the opening 15a of the radially innermost side, by a second round of punching. At this time, the rear punching hole B1 punched by the rear punching blade 85 by the _first punching and the front punching hole A2 punched by the front punching blade 84 by the _second punching are partially overlapped and punched again. An opening 15a for the main permanent magnet piece on the inner diameter side is formed. In this second punching, the front punching length LA ₂ is shorter than the rear punching length LB ₂ .

By repeating this in sequence, an N / 2th main permanent magnet piece opening 15a is formed which is positioned at a substantially intermediate diameter of the rotor core 13 when the magnetic plate 14 is wound by the N / 2nd punching. At this time, the front punching length LA _{N / 2} and the rear punching length LB _{N / 2} are equal. Then, the outermost main permanent magnet piece openings 15a are formed by the Nth punching, and N main permanent magnet piece openings 15a are formed in total. In the N-th punching, it is longer than the length LB _N punching rear forward punching length LA _N.

<Second Embodiment>
The die 81 used in the second embodiment has five punching blades arranged in a cross shape like the first embodiment, and the longitudinal direction of the front punching blade 84 is the length of the rear punching blade 85 in the longitudinal direction. It differs from the metal mold | die 81 used in 1st Embodiment by the point set equally.

  The punching process of the main permanent magnet piece openings 15a having different lengths using such a die 81 will be described with reference to FIG. Note that the reference numerals in the figure are the same as those in FIG. 6 of the first embodiment, but in this embodiment, the relationship is Lf = Lr as described above.

In the first punching, a front punching hole A ₁ punched by the front punching blade 84 and a rear punching hole B ₁ punched by the rear punching blade 85 are formed. At this time, the front punching length LA ₁ and the rear punching length LB ₁ are equal. Then, the distal end portion of the rear punching holes B ₁ is allowed to carry the predetermined feed amount by the magnetic plate 14 such that the distal end of the main permanent magnet piece for the opening 15a of the radially innermost side, by a second round of punching. At this time, the rear punching hole B1 punched by the rear punching blade 85 by the _first punching and the front punching hole A2 punched by the front punching blade 84 by the _second punching are partially overlapped and punched again. The opening 15a for the main permanent magnet piece on the innermost diameter side is formed. In this second punching, the front punching length LA ₂ is shorter than the rear punching length LB ₂ .

When this is repeated in sequence, the N / 2th main permanent magnet piece opening 15a located at the substantially intermediate diameter of the rotor core 13 is formed when the magnetic plate 14 is wound by the N / 2nd punching. The outermost diameter main permanent magnet piece openings 15a are formed by the second punching, and N main permanent magnet piece openings 15a are formed in total. In the present embodiment, the front punching length LA _{N / 2} is shorter than the rear punching length LB _{N / 2} even in the _{N /} 2th punching, and the front punching length LA _N is still the same in the _Nth punching. It is shorter than the rear punching length LB _N.

Thus, the magnetic plate 14 in which the main permanent magnet piece opening 15a, the positioning opening 16a, and the sub permanent magnet piece openings 17a and 17a are formed by the method shown in the first or second embodiment is the first plate. times eyes are wound and fixed on the front punching holes a core 70 of the part to cut spiral as Maki started 14d therethrough ₁ in punching. In the rotor core 13 formed by winding, a main permanent magnet piece hole 15 is constituted by a plurality of main permanent magnet piece openings 15a,... The positioning openings 16a,..., 16a constitute a positioning hole 16, and the plurality of sub permanent magnet piece openings 17a,. In addition, substantially fan-shaped main permanent magnet piece holes 15 and columnar positioning holes 16 that accommodate the main permanent magnet pieces 41 are alternately formed in the circumferential direction in the central portion of the rotor core 13 in the rotation axis O direction. On both sides of the positioning hole 16 in the rotation axis O direction, columnar sub permanent magnet piece notches 17 and 17 for accommodating the sub permanent magnet pieces 43 are formed. Then, as shown in FIG. 9, the winding start 14 d and the winding end 14 e of the magnetic plate 14 wound to a predetermined size finish winding at the same position in the radial direction from the center of the winding core 70. The rotor core 13 is formed by welding the winding start 14d and the winding end 14e of the magnetic plate 14 thus formed. The magnetic plate 14 may be bonded with an adhesive while winding or after winding.

  Then, the main permanent magnet piece 41 is attached to the hole 15 for the main permanent magnet piece of the rotor core 13, and the sub permanent magnet piece 43 is attached to the notch 17 for the sub permanent magnet piece.

  Subsequently, the shaft portion 36 is provided on the inner diameter side of the rotor core 13 including the main permanent magnet piece 41 and the sub permanent magnet piece 43, the rim portion 37 is provided on the outer diameter side, and the rim portion side rib mounting hole 37a of the rim portion 37 is provided. The radial ribs 35 are inserted from. At this time, the radially intermediate portion 35c of the radial rib 35 is fitted into the positioning hole 16, the radially inner end portion 35a is attached to the shaft portion side rib attachment hole 36a, and the inner diameter side of the shaft portion 36 is provided. Then, the radial rib 35 is fixed to the shaft portion 36 by screwing the nut 38. In this way, the rotor core 13 is accommodated in the rotor frame 33, and the rotor 11 is manufactured.

  As described above, according to the manufacturing method of the axial gap type motor of the first and second embodiments, the punched holes on the rear side in the transport direction and the magnetic plate 14 punched after the punching are transported by a predetermined pitch. Since each main permanent magnet piece opening 15a is formed by wrapping a punching hole on the front side in the conveying direction to form each main permanent magnet piece opening 15a, the feed amount of the magnetic plate 14 is changed from the inner diameter side of the rotor core 13 to the outer diameter side. A plurality of main permanent magnet piece openings 15a having different pitches can be formed by using the same mold 81 by adjusting, that is, adjusting the lap amount of the punching holes on the front side in the transport direction and the rear side in the transport direction. By winding this, the rotor core 13 in which a plurality of main permanent magnet piece holes 15 are formed by a plurality of main permanent magnet piece openings 15a, ..., 15a arranged in the radial direction can be manufactured. As a result, the machining accuracy of the rotor core 13 can be improved as compared with the case where an opening is provided in the rotor core 13 after winding the magnetic plate 14, and the mold 81 is shared without the need to change the mold for each pitch. Thus, the apparatus can be downsized and the manufacturing cost can be reduced.

  In addition, according to the manufacturing method of the axial gap type motor of the first and second embodiments, the punchable length on the front side in the conveying direction, which is the longitudinal length of the front punching blade 84, and the longitudinal length of the rear punching blade 85. The punchable length on the rear side in the transport direction is shorter than the length of the main permanent magnet piece opening 15a on the innermost diameter side, and the sum of the punchable lengths on the front side in the transport direction and the rear side in the transport direction is the maximum. Since it is longer than the outer diameter side main permanent magnet piece opening 15a, it is possible to punch out all the main permanent magnet piece openings 15a,..., 15a from the innermost diameter side to the outermost diameter side.

  Moreover, according to the manufacturing method of the axial gap type motor of 1st and 2nd embodiment, it is between the main permanent magnet piece opening 15a, 15a adjacent in the circumferential direction at the punching process which forms the opening 15a for main permanent magnet pieces. Since the positioning openings 16a are formed together, the positioning openings 16a can be formed at the same time in one punching process, and the manufacturing efficiency can be improved. Moreover, according to the axial gap type motor 10 manufactured by these manufacturing methods, the positioning plate is composed of the plurality of positioning openings 16a, ..., 16a arranged in the radial direction by winding the magnetic plate 14. By mounting the radial rib 35 of the rotor frame 33 in the hole portion 16, the rotor core 13 can be positioned with respect to the rotor frame 33, and the magnetic flux between the main permanent magnet pieces 41, 41 adjacent in the circumferential direction is short-circuited. Can be suppressed.

  Moreover, according to the manufacturing method of the axial gap type motor 10 of 1st and 2nd embodiment, it is a subpermanent magnet on both sides of the rotation axis O direction of the positioning opening 16a at the punching process which forms the opening 15a for main permanent magnet pieces. Since the openings for pieces 17a and 17a are formed together, the openings for auxiliary permanent magnet pieces 17a and 17a can be formed at the same time in one punching process, and the manufacturing efficiency can be improved. Further, according to the axial gap type motor 10 manufactured by these manufacturing methods, the magnetic plate 14 is wound, and the plurality of sub permanent magnet piece openings 17a,. By attaching the sub permanent magnet piece 43 to the notch portion 17 for the sub permanent magnet piece, a substantially Halbach structure is obtained, and the effective magnetic flux generation amount is relatively increased by the magnetic lens effect that regulates the direction of the magnetic flux of the main permanent magnet piece 41. be able to.

Here, the pressure difference between the relative punching pressures acting on the front punching blade 84 and the rear punching blade 85 of the mold 81 in the first embodiment and the second embodiment will be examined. Punching pressure acting on the front punching blade 84 and the rear punching blade 85, actually punched proportional forward punching length LA _M and the rear punching length LB _M in each round of the punching.

Here, in the first embodiment, as shown in FIG. 6, the relationship of LA ₁ > LB ₁ is satisfied in the _first punching, and LA 2 to N / 2 is satisfied from the second time to the N / _2-1st time. ₋₁ <LB _{2−N / 2−1} , LA _{N / 2} = LB _{N / 2} at the N / 2nd time, LA _{N / 2 + 1 to N} > LB _{N / 2 + 1−1 at the N / 2 + 1th} time to the Nth time _N relationship is satisfied.
On the other hand, in the second embodiment, as shown in FIG. 7, the relationship of LA ₁ = LB ₁ is satisfied in the _first punching, and the relationship of LA _2−N <LB _{2− N} is satisfied from the second time to the Nth time. Meet.

  FIG. 10 replaces this with a punching pressure relationship. The vertical axis shows the pressure difference between the punching pressures acting on the front punching blade 84 and the rear punching blade 85, and the horizontal axis shows the number of punches. In the vertical axis, 0 indicates that the punching pressures acting on the front punching blade 84 and the rear punching blade 85 are equal. This means that the punching pressure acting on the is large.

  As shown in FIG. 10, in the first embodiment, the punching pressure acting on the front punching blade 84 and the punching pressure acting on the rear punching blade 85 in the first punching are biased compared to the second embodiment. However, it can be seen that the pressure difference as a whole (vibration from 0) is small.

Thereby, according to the manufacturing method of the axial gap type motor of the first embodiment, the front punching blade 84 is made by making the punchable length on the front side in the transport direction longer than the punchable length on the rear side in the transport direction. The imbalance between the punching pressure acting on the punching pressure and the punching pressure acting on the rear punching pressure can be suppressed, and the life of the manufacturing apparatus, particularly the mold 81, can be extended.
In the method of manufacturing the axial gap motor according to the second embodiment, since the load of the rear punching blade 85 is larger than the load of the front punching blade 84, the front punching blade 84 and the rear punching blade 85 are replaced at a predetermined time. Thus, the life of the mold 81 can be extended similarly.

  Moreover, according to the manufacturing method of the axial gap type motor 10 of 1st Embodiment, when the punching pressure and the back punching pressure which act on the front punching blade 84 wind the rotor core 13, it is substantially the same in the part corresponding to a substantially intermediate diameter. Therefore, the pressure difference between the punching pressure acting on the front punching blade 84 and the punching pressure acting on the rear punching pressure can be reduced.

In addition, this invention is not limited to each embodiment mentioned above, A deformation | transformation, improvement, etc. are possible suitably.
For example, as shown in FIG. 11, the mold 81 is formed so that projections 19 and 19 extending from the yoke portions 42 and 42 on both sides in the longitudinal direction are formed on the outer side in the width direction of the sub permanent magnet piece opening 17a. The shape of the side punching blades 83, 83 may be changed. Thereby, it is possible to prevent the auxiliary permanent magnet piece 43 from falling off in the direction of the rotation axis O.

  As shown in FIG. 12, tapered chamfered portions 14c and 14c are provided at both longitudinal ends of the yoke portion 42 constituting the rotor core 13, and further satisfy the relational expressions Ta <Lsa = Lma and Tp = Lsp <Lmp. Thus, the mold 81 may be changed. These dimensional relationships can be changed as appropriate. Further, the polar arc angle is adjusted by changing the shape of the side punching blades 83 and 83 and selecting the inclination of the chamfered portion 14c, thereby suppressing a rapid change in the magnetic resistance between the stators 12 and 12. The generation of torque ripple can be suppressed.

  Further, as shown in FIG. 13, the side punching blades 83, 83 of the mold 81 are formed so that the projections 19, 19 are formed from the chamfered portions 14c, 14c shown in FIG. The shape may be changed. Accordingly, it is possible to prevent a sudden change in the magnetic resistance between the stators 12 and 12 and prevent the sub permanent magnet piece 43 from dropping in the direction of the rotation axis O while suppressing the generation of torque ripple.

  Moreover, the manufacturing method of the axial gap type motor of 1st and 2nd embodiment is applicable also to the axial gap type motor from which a stator opposes a rotor only from one direction of a rotating shaft. In this case, the notch portion 17 for the sub permanent magnet piece can be provided only on one side in the rotation axis direction, and the other side in the rotation axis direction can be a back yoke on the ring.

  The axial gap motor manufacturing method according to the first and second embodiments is not limited to the Halbach type, and a non-magnetic member is provided in the secondary permanent magnet piece cutout portion 17 instead of the secondary permanent magnet piece 43. It can also be applied to a space axial gap motor.

  Furthermore, the axial gap type motor manufacturing method according to the first and second embodiments may be wound while punching the magnetic plate 14 or may be wound after punching the magnetic plate 14.

1 is an overall perspective view of an embodiment of an axial gap type motor manufactured by an axial gap type motor manufacturing method according to the present invention. It is a disassembled perspective view of the axial gap type motor shown in FIG. It is a disassembled perspective view of the rotor of the axial gap type motor shown in FIG. It is the figure which looked at the tape-shaped magnetic board which comprises a rotor core from the circumferential direction. It is a disassembled perspective view of the rotor frame of the axial gap type motor shown in FIG. It is explanatory drawing explaining the punching process which concerns on 1st Embodiment. It is explanatory drawing explaining the punching process which concerns on 2nd Embodiment. It is explanatory drawing explaining a winding process. It is a fragmentary perspective view of the wound rotor core. It is a graph which shows the relationship of the punching pressure which acts on the front punching blade in a punching process, and a back punching blade. It is the figure which looked at the magnetic board punched using another metal mold | die from the circumferential direction. Furthermore, it is the figure which looked at the magnetic board punched using another metal mold | die from the circumferential direction. Furthermore, it is the figure which looked at the magnetic board punched using another metal mold | die from the circumferential direction. 2 is an exploded perspective view of a rotor core of an axial gap type motor described in Patent Document 1. FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Axial gap type motor 11 Rotor 12 Stator 13 Rotor core 14 Tape-like magnetic plate 15 Hole for main permanent magnet piece (main magnet piece receiving part)
15a Main permanent magnet piece opening (Main magnet piece opening)
16 Positioning hole 16a Positioning opening 17 Secondary permanent magnet piece notch (secondary magnet piece housing)
17a Opening for secondary permanent magnet piece (opening for secondary magnet piece)
41 Main permanent magnet piece (main magnet piece)
42 Yoke part 43 Sub permanent magnet piece (sub magnet piece)
A _M Front punched hole punched in the Mth time (Punched hole on the front side in the transport direction)
B _M the M-th in the stamped rear punched holes (conveying direction rear side of the punching hole)
O Rotating shaft

Claims (6)

A plurality of main magnet pieces magnetized in the rotation axis direction and arranged at predetermined intervals in the circumferential direction, and a plurality of yoke portions and a plurality of the main magnet pieces respectively held by winding a tape-like magnetic plate A rotor core having a main magnet piece housing portion, and a rotor rotatable around a rotation axis;
A stator disposed opposite to the rotor from at least one of the rotation axis directions, and a method of manufacturing an axial gap motor,
The conveyance step of conveying the magnetic plate and the punching step of simultaneously punching a punching hole on the front side in the conveyance direction and a punching hole on the rear side in the conveyance direction on the magnetic plate are repeated. Forming the opening for the main magnet piece by forming the punching hole on the front side in the transport direction by wrapping the punching hole on the rear side in the transport direction by wrapping the punching hole on the rear side in the transport direction by transporting the punching hole on the rear side in the direction by a predetermined pitch;
Winding the magnetic plate to configure the main magnet piece housing portion by a plurality of openings for the main magnet pieces arranged in the radial direction;
A manufacturing method of an axial gap type motor characterized by the above. The punchable length on the front side in the transport direction is longer than the punchable length on the rear side in the transport direction,
The method of manufacturing an axial gap type motor according to claim 1. Along with the punching of the opening for the main magnet piece, a positioning opening is formed by punching between the openings for the main magnet piece adjacent in the circumferential direction,
A plurality of positioning openings arranged in the radial direction by winding the magnetic plate constitute a positioning hole.
The method of manufacturing an axial gap type motor according to claim 1 or 2, wherein: The axial gap type motor further includes a plurality of sub-magnet pieces magnetized in a direction perpendicular to the rotation axis direction and the radial direction,
Along with punching the opening for the main magnet piece, forming the opening for the sub magnet piece in at least one of the positioning openings in the rotational axis direction,
A plurality of openings for the secondary magnet pieces arranged in the radial direction by winding the magnetic plate constitutes a secondary magnet piece housing portion for housing the secondary magnet piece.
The method of manufacturing an axial gap type motor according to claim 3. The punching pressure on the front side in the transport direction and the punching pressure on the rear side in the transport direction are substantially the same at a portion corresponding to the substantially intermediate diameter of the rotor core when the magnetic plate is wound.
A method for manufacturing an axial gap motor according to any one of claims 1 to 4. The punchable lengths on the transport direction front side and the transport direction rear side are shorter than the length of the opening for the main magnet piece on the innermost diameter side, respectively, and the punchable lengths on the transport direction front side and the transport direction rear side are respectively The added length is longer than the opening for the main magnet piece on the outermost diameter side,
A method for manufacturing an axial gap motor according to any one of claims 2 to 5.

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