JP2011104607A - Integral rotor for permanent-magnet generator and method of manufacturing the same from steel sheet by cold forging forming - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To make a hub and a yoke so as to have sufficient strength and accuracy as one body. <P>SOLUTION: A first intermediate body 51 of a concave cone, on which a thickened part 511 having larger diameter than the hub is generated is made on the circumference of the hole 11 by pressurizing the center part of a disk-like steel sheet 1 while pressing the outer peripheral end. Next, a predetermined part 521 of the hub is formed by contracting the diameter by ironing the center part including the thickened part 511 and extending the height, further, the predetermined part 522 of a bottom wall is formed by pressurizing the outer peripheral side and a second intermediate body 52 thickening the side of the predetermined part 521 of the hub is made. By arranging the inner periphery of the predetermined part 521 of the hub by pressurizing and compressing the upper end after ironing the outer periphery, the hub is formed. Meanwhile, the bottom wall is formed by pressurizing the predetermined part 522 of the bottom wall and a third intermediate body on which the predetermined part of the sidewall on the outer periphery is made, is formed. After that, the integral rotor for the power generators is completed by performing the drawing and ironing of the predetermined part of the sidewall at the same time while holding the shape of the hub. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to an integrated rotor for a magnet generator in which a hub portion and a substantially bottomed cylindrical yoke portion comprising a bottom wall portion and a side wall portion with the hub portion positioned at the center thereof are integrally formed, and a steel rotor cooled from a steel plate. The present invention relates to an integrated rotor for a magnet generator manufactured by hot forging and a manufacturing method by cold forging from a steel plate.

  As described above, this type of rotor for a generator consists of a hub portion and a yoke portion. However, since the strength and accuracy of the rotor affect the performance of the generator, it is hard and strong. By manufacturing a high hub part and a yoke part in combination, the mounting strength to the rotating shaft and the accuracy during rotation have been ensured. In recent years, a technique for integrally forming them has been proposed for the purpose of reducing the number of manufacturing steps and reducing costs. It has also been implemented in some mechanical rotors other than generators.

The technique of patent document 1 is a manufacturing method of a magnet generator, and is one of the techniques related to integral molding of the hub part and the yoke part.
This is a magnet for integrally forming a rotor having a boss part and a flywheel part, which includes a pre-processing step of pressing a plate material to form an intermediate shape of the rotor and a finishing step of finishing the intermediate shape. A method of manufacturing a generator, wherein the finishing step includes a cold forging step for cold forging the intermediate shape and a cutting step for cutting the cold forged intermediate shape. is there.

The technique of this patent document 1 is compared with the technique of joining the hub part and the yoke part which were created individually before that and the technique of integral molding performed by cold forging or hot forging using a block-shaped raw material as a workpiece. Thus, the number of steps can be reduced, and an advantage in that respect can be recognized.
However, in the manufacturing method disclosed in Patent Document 1, it is difficult to appropriately control the flow of the material to make the boss side thicker and the flywheel side thinner, and further increase the hardness of the boss side. Cannot be strengthened enough. In other words, the rotor shape is almost completed before the hub is sufficiently strong, making cold forging difficult to obtain sufficient strength, which is required for this type of magnet generator. Therefore, it cannot be said that the strength and accuracy are not compatible.

The technique of Patent Document 2 is also a method for manufacturing a magnet generator, and is one of the techniques related to integral molding of the hub part and the yoke part.
This is because the thickness of the boundary between the bottom wall portion and the side wall portion of the yoke is formed at the final stage thickness of the bottom wall portion in the initial stage of cold forging of the plate material, thereby the cold forging of the plate material. Thereafter, the flow of the material of the plate material to the side wall portion and the flow to the bottom wall portion of the yoke are clearly distributed. In the machine, the material of the bottom wall portion of the plate material is brought closer to the radial direction of the boss portion, the side wall portion is formed by sequentially raising the material of the plate material, and the boss portion is repeated in the axial direction. Compressed may be applied.

  Therefore, according to the technology of this Patent Document 2, the material on the bottom wall portion side is not the side wall portion side in the subsequent cold forging process by the flow control unit formed at the boundary in the initial stage of cold forging, Since it can be made to flow appropriately to the boss side, it is possible to form the wall thickness of the side wall and bottom wall of the yoke and the thickness of the boss as set in advance, and cold forging repeated further It is said that work hardening occurs in the process, which increases the surface hardness of each part and makes the subsequent quenching treatment unnecessary.

However, according to the technique of Patent Document 2, as described above, the flow control unit is located at the boundary between the bottom wall portion and the side wall portion of the yoke, and the increase in thickness of the boss portion is from the bottom wall portion. It depends only on the flow of the steel, and it is doubtful that the expected thickness of the boss can be obtained by cold forging with a small number of processes.
Further, as described in Patent Document 1, since the rotor shape is almost completed before the strength of the boss portion is sufficiently secured, the strength and accuracy required for this type of magnet generator Must be said to be incompatible.

In addition, in the integrated rotor as another machine part, the inner and outer surfaces of the side wall portion of the rotor are cut to ensure accuracy, and the cost reduction effect has been diminished.
Furthermore, since there is no special consideration for the generator in the rotor shape, it is impossible to attach the generator parts to the rotor or cause resonance with the drive source of the rotor.

JP 08-331814 A JP 2002-369464 A

The present invention eliminates the problems of the prior art as described above, and is a manufacturing method for forming a rotor in which a hub portion and a yoke portion are integrated from a steel plate by cold forging, and ensures the required strength. Therefore, in the production process, a method for producing an integrated rotor for a generator by cold forging from a steel plate, in which the thickness of each part is appropriately set and the necessary forging process is repeated to ensure hardness and accuracy. Providing it is a problem to be solved.
It is another object of the present invention to provide an integrated rotor for a generator having a desirable shape.

In the present invention, a hub portion and a bottomed cylindrical yoke portion comprising a bottom wall portion extending radially from a base portion thereof and a side wall portion extending from an outer peripheral end thereof in a direction parallel to the axial direction of the hub portion are integrated. A method for producing an integrated rotor for a generator by cold forging from a steel plate, wherein the formed rotor for a magnet generator is formed by cold forging from a steel plate,
Press the center part of the disk-shaped steel plate with a hole in the center part while pressing the outer edge of the disk-shaped steel sheet, and press the hub part diameter around the hole in the center part. Generating a large-diameter thickened portion, and forming a first intermediate body by forming the periphery of the thickened portion into a conical container shape with the thickened portion at the bottom; and
The conical container-shaped portion including the thickened portion in the vicinity of the central portion of the first intermediate body is handled to reduce the diameter while extending the height to form the hub portion planned portion, and subsequently the hub portion planned portion. The outer peripheral side is pressurized to form the planned bottom wall portion of the yoke portion, and the excess material of the planned bottom wall portion is caused to flow toward the hub portion planned portion side, thereby increasing the thickness of the hub portion planned portion. A second step of creating two intermediates;
By pressing the inner periphery of the hub portion planned portion of the second intermediate body and handling the outer periphery of the hub portion planned portion, the upper end of the hub portion is pressed and compressed to complete the forming of the hub portion. In the meantime, the third step of pressurizing the planned bottom wall portion of the yoke portion to complete the molding of the bottom wall portion and creating the third intermediate body molded with the planned side wall portion of the outer periphery,
While maintaining the shape of the hub portion of the third intermediate body, the side wall portion of the yoke portion is simultaneously drawn and handled to ensure the coaxiality of the hub portion and the yoke portion and the roundness of the yoke portion. A fourth step of completing the integrated rotor for the generator;
It is a manufacturing method of the integrated rotor for generators by the cold forging forming from the steel plate which performs sequentially.

2 of the present invention is a method for producing an integrated rotor for a generator by cold forging from the steel sheet of 1 of the present invention,
The pressing of the central part of the disk-shaped steel plate in the first step is performed by an upper punch having a tip diameter corresponding to the diameter of the thickened part, and the outer peripheral edge of the disk-shaped steel plate is restrained on an annular shape. The die is pressed against the outer peripheral edge, and the thickened portion is generated by pushing the central portion of the disk-shaped steel plate into the central opening of the lower die by the pressurization of the upper die punch. ,
Forming into a conical container shape with the thickened portion around the thickened portion at the bottom is the outer periphery with the central opening of the lower mold at the bottom in the pressurizing process. This is performed by deforming into a shape along a tapered surface inclined upward in the direction.

3 of the present invention is a method for producing an integral rotor for a generator by cold forging from the steel sheet 1 or 2 of the present invention,
In the second step, the handling of the conical container-like portion including the thickened portion in the vicinity of the central portion of the first intermediate body is arranged in the lower mold by vertically inverting the first intermediate body, whereby the central portion The conical container-shaped part including the thickened portion in the vicinity is put on the upper part of the lower mandrel, and the hole in the center of the conical container-shaped part is used as a cylindrical locking protrusion at the upper center of the lower mandrel. The outer mold is performed by operating the conical container-like portion including the thickened portion near the center,
The pressure on the outer peripheral side of the conical container-shaped portion including the thickened portion in the vicinity of the central portion is the conical container-shaped portion including the thickened portion in the vicinity of the central portion following the handling operation of the upper mold. This is done by pressing the outer peripheral side.

4 of the present invention is a method for producing an integrated rotor for a generator by cold forging from the steel sheet of 1, 2 or 3 of the present invention,
The pressurization of the inner periphery and the handling of the outer periphery of the hub portion planned portion in the third step are performed by arranging the second intermediate body on the annular lower mold, and thereby the hub portion planned portion at the center of the second intermediate body. Is mounted on a cylindrical lower mandrel that molds the inner periphery of the large-diameter base portion of the hub portion projecting from the center portion of the annular lower die, and at the same time, at the center of the hub portion planned portion. A hole is externally mounted on a cylindrical pin projecting from the central part of the cylindrical lower mold mandrel, and the upper part of the hub part and the outer periphery of the base part are molded by forming an annular molded upper mold into the hub part planned part. Is done by handling and lowering,
Pressurization of the upper end of the hub portion planned portion is performed by lowering the cylindrical punch from the center of the molding upper die and performing a pressure operation with this,
Further, the pressurization of the planned bottom wall of the yoke part is performed by lowering the molding upper die following the handling and lowering of the planned hub part and pressurizing the planned bottom wall. Is.

5 of the present invention is a method for producing an integral rotor for a generator by cold forging from the steel sheet of 1, 2, 3 or 4 of the present invention,
In the fourth step, the shape of the hub portion is maintained by inserting and holding the upper outer periphery of the hub portion of the third intermediate body in the inner peripheral portion of the cylindrical upper die, and the annular upper die in the exterior state in the cylindrical upper die. The base outer periphery of the hub portion is inserted and held at the lower inner periphery of the punch, and the bottom wall portion of the yoke portion of the third intermediate body is brought into contact with the lower end of the annular upper punch,
The drawing of the side wall portion of the yoke portion and the handling are performed by lowering the cylindrical upper die and the annular upper die punch at the same time, and between the inner periphery of the lower die and the yoke portion of the third intermediate body. This is performed by drawing and handling the side wall planned portion.

6 of the present invention is an integrated rotor for a magnet generator mounted on a magnet generator,
The yoke portion includes a hub portion and a yoke portion, and the yoke portion includes a bottom wall portion extending in a radial direction from a base portion of the hub portion, and a bottomed portion including a side wall portion extending from an outer peripheral end thereof in a direction parallel to the axial direction of the hub portion. A cylindrical shape,
The bottom wall portion has a flat surface in which an inner portion continuous with the hub portion extends in a radial direction (radial direction), and has a thicker wall thickness than an outer portion continuous with the side wall portion (shaft Having a thick thickness dimension in the direction),
The outer side portion is an integral rotor for a magnet generator formed to be inclined or curved so as to be separated from the inner side plane toward the opening end side of the side wall portion.

  According to the method for manufacturing an integrated rotor for a generator by cold forging from a steel plate according to the present invention, for a magnet generator in which a hub portion and a yoke portion are integrated from a single disk-shaped steel plate. The rotor can be manufactured with a small number of steps while ensuring sufficient strength of the hub portion, high roundness and coaxiality between the hub portion and the yoke portion.

By forming the first intermediate body in which the thickened portion having an appropriate diameter is formed in the central portion in the first step, it is possible to favorably increase the thickness of the hub portion planned portion in the next step.
In the second step, the hub part planned part is molded and the bottom wall planned part is pressure-molded. In this process, excess material in the part is flowed to the hub part planned part side, and the hub part planned part is sufficiently thickened. Thus, in the next step, a hub portion having a predetermined thickness and having sufficient strength from internal work hardening by plastic flow can be formed.

In the third step, the molding of the hub portion and the bottom wall portion of the yoke portion is completed. In the fourth step, which is the final step, the shaping of the side wall portion of the yoke portion, the coaxiality of the hub portion and the yoke portion, and Only the roundness can be ensured. That is, until this third step, in order to form a hub portion having sufficient strength, most of the time is spent in the forging step to ensure a sufficient thickness and hardness, and the desired result is obtained. It is what.
In the fourth step, as described above, the coaxiality of the hub portion and the yoke portion and the roundness of the yoke portion are ensured.

Thus, according to the method for manufacturing an integrated rotor for a generator by cold forging from a steel plate according to the present invention, a rotor in which a hub portion and a yoke portion are integrated from one disc-shaped steel plate is obtained. Therefore, the number of steps can be reduced and the cost can be reduced. Further, as described above, the hub portion is processed in preference to the yoke portion processing, and the necessary thickness and hardness are ensured, so that sufficient strength of the obtained rotor can be obtained. Furthermore, as described above, sufficient accuracy can be secured, so that when applied to a generator, stable rotation can be secured, noise generation and the like can be reduced, and the life can be extended. . In addition, it is a manufacturing method by cold forging, and the required hardness by work hardening can be obtained at a required site, so that quenching or the like is unnecessary. Therefore, heating at the time of molding such as hot forging is unnecessary, and naturally, heating for quenching is also unnecessary, and the CO ₂ emissions generated during such heating are reduced. There is also.

  Further, according to the generator-integrated rotor of the present invention 6, the generator parts can be securely attached and supported on the outer surface, and the frequency characteristics with respect to vibration from the rotor drive source are preferably shifted from the resonance point. Can be changed.

  According to the method for producing an integral rotor for a generator by cold forging from the steel plate of 2 of the present invention, a thickened portion having a sufficient thickness suitable for the purpose is formed in the central portion of the first intermediate, And it can shape | mold itself in the shape of a conical container centering on the thickening part. Therefore, in the subsequent process, a hub portion having a predetermined thickness and strength can be easily formed.

  According to the method of manufacturing an integral rotor for a generator by cold forging from the steel plate of 3 of the present invention, a hub portion planned portion having a thickness suitable for forming the hub portion in the next process is easily formed. can do. Also, the planned bottom wall portion of the yoke portion can be formed into a shape suitable for forming the bottom wall in a later process while flowing the excess material toward the hub portion planned portion side.

  According to the method for manufacturing an integral rotor for a generator by cold forging from the steel plate of 4 of the present invention, the bottom wall portion of the hub portion and the yoke portion having the desired shape, accuracy and strength can be formed. Moreover, the side wall planned part of the yoke part which can ensure roundness at the next process can also be formed.

  According to the method of manufacturing an integral rotor for a generator by cold forging from a steel plate of 5 of the present invention, the yoke and the bottom wall of the yoke formed in the third step are securely held while the yoke is securely held. The side wall portion of the portion can be molded while ensuring the coaxiality and roundness of the hub portion and the yoke portion.

(a) is a cross-sectional view of a disk-shaped steel sheet as a forming material, (b) a cross-sectional view of a first intermediate formed in the first step, and (c) is a second intermediate formed in the second step. FIG. (a) is sectional drawing of the 3rd intermediate body shape | molded at the 3rd process, (b) is sectional drawing of the integrated rotor for generators completed at the 4th process. The top view of the integrated rotor for generators which the shaping | molding completed in the 4th process. Sectional drawing which shows the 1st process which shape | molds with a forging apparatus. Sectional drawing which shows the 2nd process which shape | molds with a forging apparatus. Sectional drawing which shows the 3rd process which shape | molds with a forging apparatus. Sectional drawing which shows the 4th process which shape | molds with a forging apparatus.

  A mode for carrying out the present invention will be described in detail with reference to the drawings.

As shown in FIG. 1 and FIGS. 4 to 7, the method for manufacturing an integrated rotor for a generator by cold forging from the steel plate of this embodiment is basically as follows.
In the first step, while holding the outer peripheral end 12 of the disc-shaped steel plate 1 with the movable annular upper die 21 at the center of the disc-shaped steel plate 1 having the hole 11 opened at the center, the annular upper die The upper die 31 is pressurized by the upper die 31 disposed in the center of the lower die 21 and is pushed into the central opening 411 of the fixed lower die 41 so that the upper punch 31 is placed around the hole 11 in the central portion. A thickened portion 511 having a diameter D1 substantially corresponding to the diameter of the front end surface is generated, and the periphery of the thickened portion 511 is pressed by the upper die punch 31 in the above-described process of the central opening 411 of the lower die 41. The first intermediate body 51 is formed by forming an upward tapered side plate portion 512 along the tapered surface 412 that is inclined upward in the outer peripheral direction with the uppermost end as the lowermost portion (by forming it as a conical container as a whole). And
In the second step, the first intermediate body 51 is turned upside down and placed on the upper surface of the fixed annular lower mold 42, whereby a conical container-like recess including the thickened portion 511 at the center is formed in the annular lower part. A hole 11 that is externally mounted on the conical portion 611 of the lower mandrel 61 fixed in a protruding state at the central portion of the mold 42 and that is opened at the center of the thickened portion 511 that corresponds to the upper end of the conical container-shaped recess, A movable upper mold 22 that is externally mounted on a cylindrical locking projection 612 configured to protrude from the center upper end of the conical portion 611 of the lower mold mandrel 61 and has a central hole 221 for handling, The hub portion planned portion 521 is formed by extending the height while treating the vicinity of the central portion of the conical container-like portion including the thickened portion 511 at the central portion while reducing the diameter, and subsequently, using the upper mold 22 Pressing the outer peripheral part of the hub part planned part 521 to press the bottom of the yoke part Thereby forming the scheduled portion 522, by flowing the excess material said site to the hub portion scheduled portion 521 side, and forming a second intermediate 52 by thickening the hub portion scheduled portion 521,
In the third step, the second intermediate body 52 is disposed on the upper surface of the fixed annular lower mold 43, whereby the central hub portion planned portion 521 is projected from the central portion of the annular lower mold 43. The cylindrical lower mold mandrel 62 is fixedly mounted on the conical section 621, and at the same time, the central hole 11 in the central hub section 521 protrudes similarly to the central section of the cylindrical lower mold mandrel 62. The cylindrical pin 63 fixed in the state is put into an exterior state, and then the movable annular molding upper die 23 is pressed down, and the cylindrical lower die is placed on the inner peripheral side of the hub portion planned portion 521. The inner peripheral shape of the large diameter base portion 5411 of the hub portion 541 according to the outer shape of the upper conical portion 621 of the mandrel 62 and the inner shape of the small diameter upper portion 5412 of the hub portion 541 according to the outer shape of the cylindrical pin 63 are formed. Furthermore, on the outer peripheral side of the hub portion planned portion 521, the hub portion 541 The outer shape of the upper diameter portion 5412 and the outer circumference of the large diameter of the base portion 5411 are molded, and in addition, the bottom wall portion 542 of the yoke portion is molded, and the central cavity portion 231 of the annular molding upper die 23 is lowered, thereby At the lower part, the cylindrical pin 24 relatively moves the cylindrical pin 63 into its central cavity 241 to pressurize the upper end of the hub portion planned portion 521 to compress its height dimension, and the hub portion. By forming the shape of the upper end portion of 541, the hardness of the hub portion 541 is increased, and further, the excess material at the portion becomes the side wall portion planned portion 531 of the yoke portion by pressure molding of the bottom wall portion 542 of the yoke portion. Flowing to the outer peripheral side, forming the hub part 541 and the bottom wall part 542 of the yoke part, molding the third intermediate 53 formed the side wall part planned part 531 of the yoke part,
In the fourth step, the third intermediate body 53 is engaged with the inner peripheral portion of the movable cylindrical upper mold 25 with the small-diameter upper portion 5412 of the hub portion 541, and the base portion 5411 of the hub portion 541 is The cylindrical upper die 25 is engaged with the lower inner periphery of the annular upper die punch 26 in the exterior state and is held by both upper dies 25, 26, and the bottom wall portion 542 of the yoke portion of the third intermediate body 53. In contact with the lower end of the annular upper die punch 26, the cylindrical upper die 25 and the annular upper die punch 26 are simultaneously lowered, and between the inner periphery of the fixed lower die 44, Simultaneously drawing and handling the side wall planned portion 531 of the yoke portion of the third intermediate body 53 to form a side wall portion 543 that secures its own roundness and coaxiality with the hub portion 541, thereby This completes the production of the generator integrated rotor 54.

  Hereinafter, the manufacturing method of the integrated rotor for generators by the cold forging forming from the steel plate shown above is demonstrated one by one in detail.

  The disc-shaped steel plate 1 in the first step is a literal disc-shaped steel plate having a hole 11 in the center as described above and shown in FIG. In terms of material, in addition to being sufficiently malleable, it should also be a suitable material suitable as a rotor for a generator.

In the first step, as shown in FIG. 4, the upper surface of the annular upper die 21 having a flat bottom surface and the through hole in the center of the annular upper die 21 are arranged so as to be movable up and down. This is performed using a die punch 31, a lower die 41, and an annular guide lower die 413 fixed to the peripheral edge of the upper surface of the lower die 41.
As shown in the figure, the lower die 41 has a central opening 411 having a diameter slightly larger than that of the upper die punch 31 at the center thereof, and is directed upward around the central opening 411. An inclined tapered surface 412 is provided. The tapered surface 412 can be said to be a conical concave surface as a whole. The annular guide lower mold 413 serves as a guide for arranging the center of the disk-shaped steel plate 1 so as to coincide with the center of the lower mold 41, and has an inner diameter of the disk-shaped steel sheet 1. It corresponds to the diameter.

In the first step, the disk-shaped steel plate 1 is disposed on the lower die 41 with the central hole 11 corresponding to the center of the lower die 41. The disk-shaped steel plate 1 is in a state where its peripheral edge is placed on the annular upper surface of the lower mold 41. Note that this naturally occurs when the disc-shaped steel plate 1 is inserted into the lower guide 413.
Thereafter, the upper die punch 31 and the annular upper die 21 are lowered, and the upper die punch 31 is pressed against the central portion of the disk-shaped steel plate 1 and squeezed. During this time, the lower surface of the annular upper mold 21 comes into pressure contact with the peripheral end of the disk-shaped steel sheet 1 being constricted into a conical concave shape, and functions to suppress its radial extension. The pressurization by the upper die punch 31 is continued, and as shown in FIG. 4, the central portion of the disk-shaped steel plate 1 squeezed into a conical concave shape is pushed into the central opening 411 of the lower die 41, The periphery thereof is formed into an upwardly tapered side plate portion 512 along the tapered surface 412 of the lower mold 41 (as a whole, formed into a conical container shape), and the first intermediate body 51 is formed. One step ends.

  In the first step, as shown in FIGS. 1B and 4, the periphery of the hole 11 in the center of the first intermediate body 51 substantially corresponds to the diameter of the tip surface of the upper punch 31. A thickened portion 511 having a diameter D1 is generated. Such a thickened portion 511 is pressed and squeezed by the upper die punch 31 as described above, and a portion to be the thickened portion 511 is pushed into the central opening 411 of the lower die 41, and at this time, As described above, it is obtained as a result of restraining the peripheral edge of the portion around the portion to be the thickened portion 511 with the lower surface of the annular upper mold 21 and restraining its extension. In addition, the smaller diameter D1 can enhance the effect of increasing the thickness, but it should be larger than the intended diameter of the hub portion 541.

As shown in FIG. 5, the second step is performed using an annular lower mold 42 whose upper surface is basically a flat ring, and a lower mold mandrel 61 and an upper mold 22 fixed in the center hole. Is called.
The lower mold mandrel 61 is configured as a conical portion 611 whose upper portion is narrowed. Further, the lower mandrel 61 is opened to the center of the thickened portion 511 of the first intermediate body 51 at the center of the upper end of the conical portion 611. A cylindrical locking projection 612 that can be inserted into the hole 11 without looseness is formed. In addition, the upper mold 22 corresponds to the central hole portion 221 in order to handle the thickened portion 511 of the inverted first intermediate body 51 and the side plate portion 512 in the vicinity thereof to form the hub portion planned portion 521. Further, the upper die 22 is formed by drawing the side plate portion 512 on the outer peripheral side from the thickened portion 511 of the inverted first intermediate body 51 and the side plate portion 512 in the vicinity thereof. In order to form the portion into the planned bottom wall portion 522 of the yoke portion, an annular lower end surface is formed.

  In the second step, the first intermediate body 51 is turned upside down and placed on the annular upper surface of the annular lower mold 42, and at the same time, the first intermediate body 51 is placed in the central recess of the first intermediate body 51. The conical section 611 of the lower mold mandrel 61 fixed at the center of the mold 42 is inserted, and the upper end of the conical section 611 is inserted into the hole 11 opened in the thickening section 511 at the upper end of the recess. The locking protrusion 612 raised at the center is set in the inserted state. When the locking protrusion 612 is inserted into the central hole 11 of the first intermediate body 51, the first intermediate body 51 is accurately positioned at the center of the mold. Thereafter, as shown in FIG. 5, in this state, the upper die 22 is lowered, and the central hole 221 handles the thickened portion 511 of the first intermediate 51 and the side plate portion 512 in the vicinity thereof. The hub portion planned portion 521 is formed by extending the height while processing and reducing the diameter, and subsequently, the side plate portion 512 on the outer peripheral side of the hub portion planned portion 521 is formed on the annular lower end surface of the upper mold 22. The bottom wall planned portion 522 of the yoke portion is formed by pressurizing (upsetting). Further, at this time, the excess material of the part for creating the planned bottom wall portion 522 is caused to flow toward the hub portion planned portion 521 side, and the hub portion planned portion 521 is increased in thickness. Thus, the second intermediate 52 is formed, and the second step is completed.

  In the second step, as described above and as shown in FIGS. 1C and 5, the hub portion planned portion 521 is formed from the thickened portion 511 of the first intermediate body 51 and the side plate portion 512 in the vicinity thereof. The The degree of thickness increase of the planned hub portion 511 is determined by the diameter D2 and the height H of the planned hub portion 521. The hub portion planned portion 521 obtained when the large-diameter thickening portion 511 and the side plate portion 512 around the large-diameter portion 511 are handled so as to have a smaller diameter and the height H is not too low, and subsequently the surroundings are installed. Will be thinned if it is handled in the opposite manner and subsequently upset. As in the present case, when a thickening is required, the diameter D1 of the thickening portion 511 is naturally larger than the diameter D2 of the hub portion planned portion 521 and the hub portion is planned, as in the former case. The height H of the part 521 should be set high.

As shown in FIG. 6, the third step includes an annular lower mold 43 having a flat inner portion and an annular upper surface inclined upward in the circumferential direction toward the outer circumferential direction, and a central cavity of the annular lower mold 43. A cylindrical lower mandrel 62 fixed in a state protruding from here, a cylindrical pin 63 fixed in a state protruding further from the hollow portion of the cylindrical lower mandrel 62, an annular shape This is carried out using a cylindrical punch 24 disposed in a freely movable manner in the central cavity portion 231 of the molding upper mold 23 and the annular molding upper mold 23.
As shown in FIG. 6, the cylindrical lower mandrel 62 is located inside the hub portion planned portion 521 at the center of the second intermediate body 52, and inside the large-diameter base portion 5411 of the hub portion 541. A conical portion 621 for forming the circumference is provided. Further, as shown in the figure, the conical portion 621 does not have a conical shape at the uppermost end so as to correspond to the inner peripheral shape of the base portion 5411 of the hub portion 541, and corresponds to the diameter of the inner peripheral upper end of the base portion 5411. It has a circular end face.

  As shown in FIG. 6, the cylindrical pin 63 is a cylindrical member having a diameter corresponding to the inner diameter of the small diameter upper portion 5412 of the hub portion 541. The annular molding upper die 23 is configured such that the inner peripheral lower portion thereof has an inner peripheral shape corresponding to the outer peripheral shapes of the small diameter upper portion 5412 and the base portion 5411 of the hub portion 541, and the lower surface is basically the bottom wall of the yoke portion. The shape corresponding to the upper surface shape of the portion 542 is used. Further, as shown in the figure, the cylindrical punch 24 is a cylindrical member that opens to the lower end, and the cylindrical pin 63 positioned in a downward projecting state is lowered while being in an exterior state at the central cavity portion 241 thereof. It is configured to be able to. Further, the cylindrical punch 24 is configured such that the lower end thereof corresponds to the upper end shape of the small diameter upper portion 5412 of the hub portion 541.

In the third step, the second intermediate body 52 is disposed on the upper surface where the inner portion of the annular lower mold 43 is flat and the outer portion is inclined upward toward the outer peripheral direction, and a central hub portion planned portion The inner peripheral side of the cylindrical lower mold mandrel 62 is externally attached to the conical section 621 of the cylindrical lower mold mandrel 62, and the upper central hole 11 of the hub section planned section 521 is fixed to the central section of the cylindrical lower mold mandrel 62. The installed cylindrical pin 63 is put into an exterior state.
Thereafter, the annular molding upper die 23 is lowered from above, and as shown in FIG. 6, the hub portion planned portion 521 is pressurized at the inner peripheral lower portion thereof, whereby the small diameter upper portion 5412 and the base portion 5411 of the hub portion 541 are pressed. The outer peripheral shape is formed, the inner peripheral shape of the base portion 5411 of the hub portion 541 is formed by the conical portion 621 of the cylindrical lower mandrel 62, and the inner peripheral shape of the small-diameter upper portion 5412 of the hub portion 541 is formed by the cylindrical pin 63. Is molded. Furthermore, the bottom wall planned portion 522 of the yoke portion of the second intermediate body 52 is pressurized on the lower surface of the molding upper mold 23, and the bottom wall portion 542 of the yoke portion is molded. At the same time, a side wall portion planned portion 531 of the yoke portion is also formed on the outer peripheral side of the bottom wall portion 542. At the same time as the molding upper mold 23 is lowered, the cylindrical punch 24 is also lowered in the central cavity 231, and the upper end of the small-diameter upper portion 5412 of the hub portion 541 extending upward is pressurized and compressed to mold the upper end portion. Thus, the third intermediate 53 is formed, and the third step is completed. FIG. 2A shows a cross section of the third intermediate 53 manufactured in this way.

  In the molding process of the bottom wall portion 542 of the yoke portion by the molding upper die 23 described above, excess material in that portion flows to the hub portion 541 side and increases in thickness, and the necessary thickness of the hub portion 541 is secured. On the other hand, sufficient hardness can be secured in the hub portion 541 by the work hardening by the pressure forming operation of the forming upper mold 23 and the cylindrical punch 24.

As shown in FIG. 7, the fourth step is performed using a cylindrical upper mold 25, and an annular upper mold punch 26 and a lower mold 44 that are externally mounted on the cylindrical upper mold 25.
As shown in FIG. 7, the cylindrical upper mold 25 has its lower inner circumference substantially matched with the outer diameter of the small-diameter upper portion 5412 of the hub portion 541 of the third intermediate body 53, and the small-diameter upper portion 5412 as the center. It is a member formed to have an inner diameter that can be externally held. As shown in the figure, the annular upper die punch 26 covers the cylindrical upper die 25 immediately above the lowermost portion of the central portion, and the inner periphery of the lowermost portion is the base portion of the hub portion 541. This is a member formed so as to have an inner diameter dimension that can substantially match the outer peripheral shape and outer diameter of 5411 and can hold the base portion 5411 at its center. Further, as described above, the annular upper die punch 26 has a lower end that is favorable to the bottom wall portion 542 of the yoke portion of the third intermediate body 53 with the base portion 5411 of the hub portion 541 being externally held at the center thereof. It is comprised so that it can join. Further, the lower die 44 has a cylindrical inner periphery so as to form the side wall portion 543 of the yoke portion of the third intermediate body 53 that is held and lowered by the annular upper die 26 and the cylindrical upper die 25. It is the type | mold member comprised on the inner surface.

In the fourth step, as shown in FIG. 7, the third intermediate body 53 is held by the cylindrical upper mold 25 and the cylindrical upper mold 25 held by the annular upper mold punch 26 in the exterior state. The side wall portion 543 is formed by subjecting the planned side wall portion 531 of the yoke portion to peripheral drawing and handling.
As shown in the figure, the third intermediate body 53 is held by holding the outer periphery of the small-diameter upper portion 5412 of the third intermediate body 53 at the center of the lower inner periphery of the cylindrical upper mold 25 in the exterior state. The outer periphery of the base portion 5411 of the hub portion 541 of the third intermediate body 53 is similarly held at the center of the outer periphery of the hub portion 541 of the third intermediate body 53 at the center thereof. The lower end of the annular upper die punch 26 is brought into contact with the bottom wall portion 542 of the yoke portion of the third intermediate body 53.

  Thereafter, as shown in FIG. 7, the cylindrical upper die 25 and the annular upper die punch 26 are lowered and the side wall of the yoke portion of the third intermediate body 53 is planned between the inner periphery of the lower die 44. The drawing and handling of the part 531 are performed simultaneously to form the side wall part 543 of the yoke part, thereby completing the production of the generator-integrated rotor 54, and the fourth step ends. FIG. 2B shows a cross section of the generator-integrated rotor 54, and FIG. 3 shows a plane. The fourth step is a handling method.

  By the above drawing process and handling, the side wall 543 of the yoke part obtained has its own roundness, and the coaxiality between the side wall part 543 of the yoke part and the hub part 541 is also ensured. Will be.

The final product generator-integrated rotor 54 is given the shape described later by the above-described steps.
The bottom wall portion 542 of the yoke portion includes an inner portion 5421 closer to the hub portion 541 and an outer portion 5422 closer to the side wall portion 543, as shown in FIGS. 2B and 7, and the inner portion 5421 is an outer portion. It is thicker than 5422 and has a flat portion 5423 on the outer surface of the rotor, and the outer portion 5422 has a side wall end surface side (bottomed cylindrical opening) as it goes from the flat portion 5423 toward the side wall portion 543. A portion 5424 having an inclined or curved shape so as to be separated from the side end surface side) is provided.

  The flat portion 5423 is formed in a certain range, and as shown in FIG. 2 (b) in particular, for example, it is provided in a range of a diameter D3 of 1/3 to 2/3, more preferably about half of the outer diameter of the rotor. The angle θ of the inclined or curved portion 5424 is inclined at 3 ° to 10 °, more preferably about 5 ° with respect to the temporary extension surface of the flat portion 5423, or from the temporary extension surface at the outer peripheral end thereof. Curved to a distance l of 0.7 to 2 times the thickness t, more preferably about 0.8 times, the outer portion 5422 and the side wall portion 543 of the bottom wall portion 542 are continuously at a gentler angle than a right angle. Yes.

The wall thickness t of the outer portion 5422 is thicker than the wall thickness of the side wall portion 543.
Furthermore, it is not hindered to provide an opening for a stator (not shown) located inside the rotor.

  With the above-described shape, a support surface for securely fixing a generator component (not shown) to the rotor is secured on the outer surface, and the frequency characteristics with respect to vibration from the drive source (not shown) of the bottom wall portion 542 are peaked. Can be shifted from the resonance point by 100 Hz or more to a preferable one. In addition, the continuity at a gentle angle between the bottom wall portion 542 and the side wall portion 543 of the yoke portion improves the fluidity.

  The method for producing an integral rotor for a generator by cold forging from a steel plate according to the present invention can be effectively used in the field of producing a rotor for a generator.

DESCRIPTION OF SYMBOLS 1 Disk shaped steel plate 11 Hole of the center part of a disk shaped steel plate 12 Outer peripheral edge of a disk shaped steel plate 21 An annular upper die used in the first step 22 An upper die used in the second step 221 A center of the upper die used in the second step Hole 23 Upper molding die used in the third step 231 Central cavity portion of the upper molding die used in the third step 24 Upper cylindrical punch used in the third step 241 Central cavity portion of the cylindrical punch
25 Cylindrical upper die used in the fourth step 26 Circular upper die punch used in the fourth step 31 Upper die punch used in the first step 41 Lower die used in the first step 411 Lower central opening of the die used in the first step 412 Tapered surface of lower mold used in the first process 413 Guide lower mold used in the first process 42 Annular lower mold used in the second process 43 Annular lower mold used in the third process 44 Lower mold used in the fourth process 51 First intermediate Body 511 Thickening part 512 Side plate part of first intermediate body 52 Second intermediate body 521 Preliminary part of hub part 522 Preliminary wall part of yoke part 53 Third intermediate part 531 Preferential side wall part of yoke part 54 Integral type for generator Rotor 541 Hub portion 5411 Base portion of hub portion 5412 Upper portion of small diameter of hub portion 542 Bottom wall portion of yoke portion 5421 Inner portion of bottom wall portion near hub portion 5422 Outer portion of bottom wall portion near side wall portion 5 23 Planar part that is the outer surface of the inner part 5424 Inclined or curved part that is the outer surface of the outer part 543 Side wall part of the yoke part 61 Lower mandrel 611 Conical part of the lower mandrel 612 Conical part Locking projection 62 Cylindrical lower mandrel used in the third step 621 Conical portion of the cylindrical lower mandrel used in the third step 63 Columnar pin used in the third step D1 Diameter of the thickened portion D2 Diameter of the hub portion planned portion D3 The diameter of the flat surface portion H The height of the hub portion planned portion θ The angle of the inclined portion or curved portion of the outer portion t The thickness of the outer portion l The outermost end and the inner portion of the inclined portion or curved portion of the outer portion The distance from the flat part that is the outer surface to the disguise extension line

Claims (6)

A magnet generator in which a hub portion and a bottom wall portion extending radially from the base portion and a bottomed cylindrical yoke portion including a side wall portion extending from an outer peripheral end thereof in a direction parallel to the axial direction of the hub portion are integrally formed. Forming a rotor for steel from a steel plate by cold forging, a method for producing an integrated rotor for a generator by cold forging from a steel plate,
The central portion of the disc-shaped steel plate having a hole in the central portion is pressurized while suppressing the outer peripheral end of the disc-shaped steel plate, and the hub portion of the final stage is formed around the hole in the central portion. A first step of generating a thickened portion having a diameter larger than the diameter, and forming a first intermediate body by molding the periphery of the thickened portion into a conical container shape having the thickened portion as a lowermost portion;
The conical container-shaped part including the thickened part in the vicinity of the center part of the first intermediate body is handled and the height is increased while the diameter is reduced to form the hub part planned part. Subsequently, from the hub part planned part, Secondly, the outer peripheral side is pressurized to form the planned bottom wall portion of the yoke portion, and the excess material of the planned bottom wall portion is caused to flow toward the hub portion planned portion side to increase the thickness of the hub portion planned portion. A second step of creating an intermediate;
After the inner circumference of the hub portion planned portion of the second intermediate body is pressure-regulated and the outer circumference of the hub portion planned portion is handled, the upper end is pressurized and compressed to complete the molding of the hub portion. In the meantime, the third step of pressurizing the planned bottom wall portion of the yoke portion to complete the molding of the bottom wall portion and creating the third intermediate body molded with the planned side wall portion of the outer periphery,
While maintaining the shape of the hub portion of the third intermediate body, the side wall portion of the yoke portion is simultaneously drawn and handled to ensure the coaxiality of the hub portion and the yoke portion and the roundness of the yoke portion. A fourth step of completing the integrated rotor for the generator;
A method for manufacturing an integrated rotor for a generator by cold forging from a steel plate that is sequentially performed. The pressing of the central part of the disk-shaped steel plate in the first step is performed by an upper punch having a tip diameter corresponding to the diameter of the thickened part, and the outer peripheral edge of the disk-shaped steel plate is restrained on an annular shape. The die is pressed against the outer peripheral edge, and the thickened portion is generated by pushing the central portion of the disk-shaped steel plate into the central opening of the lower die by the pressurization of the upper die punch. ,
Forming into a conical container shape with the thickened portion around the thickened portion at the bottom is the outer periphery with the central opening of the lower mold at the bottom in the pressurizing process. The manufacturing method of the integrated rotor for generators by the cold forging from the steel plate of Claim 1 performed by making it deform | transform into the shape along the taper surface which inclines upward toward a direction. In the second step, the handling of the conical container-like portion including the thickened portion in the vicinity of the central portion of the first intermediate body is arranged in the lower mold by vertically inverting the first intermediate body, whereby the central portion The conical container-shaped part including the thickened portion in the vicinity is put on the upper part of the lower mandrel, and the hole in the center of the conical container-shaped part is used as a cylindrical locking protrusion at the upper center of the lower mandrel. The outer mold is performed by operating the conical container-like portion including the thickened portion near the center,
The pressure on the outer peripheral side of the conical container-shaped portion including the thickened portion in the vicinity of the central portion is the conical container-shaped portion including the thickened portion in the vicinity of the central portion following the handling operation of the upper mold. The manufacturing method of the integrated rotor for generators by the cold forging forming from the steel plate of Claim 1 or 2 decided to make it press to the outer peripheral side more. The pressurization of the inner periphery and the handling of the outer periphery of the hub portion planned portion in the third step are performed by arranging the second intermediate body on the annular lower mold, and thereby the hub portion planned portion at the center of the second intermediate body. Is mounted on a cylindrical lower mandrel that molds the inner periphery of the large-diameter base portion of the hub portion projecting from the center portion of the annular lower die, and at the same time, at the center of the hub portion planned portion. A hole is externally mounted on a cylindrical pin projecting from the central part of the cylindrical lower mold mandrel, and the upper part of the hub part and the outer periphery of the base part are molded by forming an annular molded upper mold into the hub part planned part. Is done by handling and lowering,
Pressurization of the upper end of the hub portion planned portion is performed by lowering the cylindrical punch from the center of the molding upper die and performing a pressure operation with this,
Further, the pressurization of the planned bottom wall of the yoke part is performed by lowering the molding upper die following the handling and lowering of the planned hub part and pressurizing the planned bottom wall. The manufacturing method of the integrated rotor for generators by the cold forging forming from the steel plate of Claim 1, 2, or 3. In the fourth step, the shape of the hub portion is maintained by inserting and holding the upper outer periphery of the hub portion of the third intermediate body in the inner peripheral portion of the cylindrical upper die, and the annular upper die in the exterior state in the cylindrical upper die. The base outer periphery of the hub portion is inserted and held at the lower inner periphery of the punch, and the bottom wall portion of the yoke portion of the third intermediate body is brought into contact with the lower end of the annular upper punch,
The drawing of the side wall portion of the yoke portion and the handling are performed by lowering the cylindrical upper die and the annular upper die punch at the same time, and between the inner periphery of the lower die and the yoke portion of the third intermediate body. The manufacturing method of the integrated rotor for generators by the cold forging from the steel plate of Claim 1, 2, 3, or 4 performed by carrying out the drawing process and handling operation of the side wall scheduled part. An integrated rotor for a magnet generator attached to a magnet generator,
The yoke portion includes a hub portion and a yoke portion, and the yoke portion includes a bottom wall portion extending in a radial direction from a base portion of the hub portion, and a bottomed portion including a side wall portion extending from an outer peripheral end thereof in a direction parallel to the axial direction of the hub portion. A cylindrical shape,
The bottom wall portion has a flat surface extending in the radial direction at the inner portion continuous with the hub portion, and has a thicker wall thickness in the axial direction than the outer portion continuous with the side wall portion,
The magnet generator-integrated rotor is formed such that the outer side portion is inclined or curved so as to be separated from the inner side plane toward the opening end side of the side wall portion.

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