JP2011109758A - Rotor used for permanent magnet synchronous motor and method of manufacturing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a rotor for a permanent magnet synchronous motor, which reduces its material cost and manufacture costs and improves the adhesiveness of a permanent magnet by widening the area of the mounting face of a mounting hole for a permanent magnet. <P>SOLUTION: Many hole section forming plates 42 are bent to be orthogonal to a bottom plate 37 at the peripheral edge of the bottom plate 37 that constitutes the main body 36 of a rotor. Mounting holes 39 for permanent magnets 32 are made of the first hole forming plates 43, the second hole forming plates 44, and the third hole forming plates 45 created at individual hole section forming plates 42. Before the hole section forming plates 42 are bent, the first hole forming plates 43 are plastically transformed by cold forge so as to create the mounting faces of the mounting holes 39. The ends of the individual hole section forming plates 42 are coupled to one another by a coupling ring 47 by inserting caulking pins 46 created at the ends of the individual hole section forming plates 42 into through holes 47c created at the coupling ring 47 and bending and pressing the caulking pins 46 to the top plate of the coupling ring 47. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a rotor used for a permanent magnet synchronous motor such as a double stator motor and a method for manufacturing the same.

  Conventional double stator motors are used as, for example, wheel-in motors that are attached to the inside of a vehicle wheel and directly rotate drive wheels. As this wheel-in motor, what was disclosed by patent document 1 is proposed. This motor will be described with reference to FIGS.

  As shown in FIG. 16, a wheel shaft 14 is rotatably supported in the center hole of the motor housing 12 of the motor 11 via a bearing 13. A hub 15 is integrally formed at the tip of the wheel shaft 14, and a wheel 16 is connected to the hub 15 by a hub stand bolt 17.

  The motor housing 12 is fixed by bolts (not shown) in a state where the respective open end edges of the outer housing 21 and the inner housing 22 are abutted. The inner housing 22 is connected to an upper arm and a lower arm of a double wishbone suspension of a suspension device (not shown) of the vehicle.

  A rotor mounting sleeve 23 is fitted and fixed to the outer peripheral surface of the wheel shaft 14 and is rotatably supported by the bearing 13. A rotor 25 is connected to the flange portion 23 a of the sleeve 23 by a bolt 24 so as to be positioned inside the motor housing 12. An inner stator 26 including a tooth 26a and a coil 26b is fitted and fixed to the outer peripheral surface of a cylindrical portion 22a formed integrally with the center portion of the inner housing 22. An outer stator 27 comprising teeth 27a and coils 27b is fitted and fixed to the inner peripheral surface of the outer housing 21.

  A bottomed short cylindrical rotor body 28 constituting the rotor 25 shown in FIG. 17 includes a bottom plate 29 connected to the flange portion 23a of the sleeve 23 by the bolt 24, as shown in FIG. It is comprised by the cylindrical part 30 curvedly formed integrally by the outer periphery. A shaft hole 29 a through which the wheel shaft 14 and the sleeve 23 pass is formed at the center of the bottom plate 29. A plurality of through holes 29b for penetrating the bolts 24 are formed at equal angular intervals on the outer periphery of the shaft hole 29a. Permanent magnets 32 are respectively inserted into a large number of mounting holes 31 formed in the cylindrical portion 30 and bonded by an adhesive. As shown in FIG. 18, the attachment surface 31 a of the attachment hole 31 formed in the cylindrical portion 30 is an inclined surface that is inclined with respect to the rotation direction P of the rotor 25.

  In order to generate a high torque, the wheel-in motor 11 has a gap g1 between the outer peripheral surface of the permanent magnet 32 and the inner peripheral surface of the teeth 27a of the outer stator 27 and the inner periphery of the permanent magnet 32, as shown in FIG. The gap g2 between the surface and the outer peripheral surface of the tooth 26a of the inner stator 26 is set to be as small as 0.5 mm, for example. For this reason, since the mounting surface 31a of the mounting hole 31 of the permanent magnet 32 is required to have high processing accuracy, the bottom plate 29 and the cylindrical portion 30 of the rotor body 28 are cut and formed from a stainless steel columnar block by machining. Is done. Next, the shaft hole 29a and the through hole 29b are cut and formed in the bottom plate 29 by machining, and the mounting hole 31 is cut and formed in the cylindrical portion 30 by machining.

  On the other hand, after the intermediate part which is the original shape of the rotor body 28 is drawn from a flat plate material by a drawing apparatus, as shown in FIG. 19A, the mounting hole 31 is formed in the cylindrical part 30 of the intermediate part by a pressing device. In order to increase the mounting area of the mounting surface 31a of the mounting hole 31 by machining as shown in FIG. 19 (b), a cutting process using the mounting surface 31a as an inclined surface may be performed. Conceivable.

JP 2009-184656 A (see paragraphs 0025 to 0036 of the specification, FIG. 1 and FIG. 2)

  However, since the machining method of the rotor 25 described above cuts and forms the bottom plate 29, the cylindrical portion 30, the mounting hole 31, and the like from a columnar block, the amount of material used is greatly increased, and the material cost is reduced. In addition to being unable to do so, there is a problem that the manufacturing time cannot be reduced because the processing time becomes long.

  On the other hand, since the rotor manufacturing method shown in FIGS. 19A and 19B uses a flat plate material, the material cost of the rotor can be reduced. However, not only a large molding apparatus for drawing the cylindrical portion 30 is required, but also a step of punching and molding the mounting hole 31 in a short cylindrical intermediate part, which is the original shape of the rotor body, and a mounting surface Cutting with the inclined surface 31a is very troublesome and cannot reduce the manufacturing cost. In addition, since the mounting hole 31 and the mounting surface 31a are processed in the cylindrical intermediate part, there is also a problem that the processing accuracy of the mounting surface 31a is lowered due to elastic deformation of the intermediate part during processing.

  The present invention eliminates the above-mentioned problems in the prior art, reduces the material cost, reduces the manufacturing cost, and further improves the processing accuracy of the mounting surface of the permanent magnet mounting hole. It is another object of the present invention to provide a permanent magnet synchronous motor rotor and method for manufacturing the same that can increase the area of the permanent magnet and improve the adhesion of the permanent magnet.

  In order to solve the above problems, the invention according to claim 1 is directed to a plate-like bottom plate having a shaft hole attached to a rotation shaft of a motor so as to be capable of synchronous rotation, and an annular outer peripheral edge of the bottom plate. A plurality of first hole forming plates integrally bent to be orthogonal to the bottom plate, a second hole forming plate integrally formed on both sides or one side of the base end portion of each first hole forming plate, The third hole forming plate integrally formed on both sides or one side of the front end portion of each first hole forming plate and the front end portions of the plurality of hole partition forming plates formed by the first to third hole forming plates are mutually connected. And a plurality of permanent magnets respectively attached to a plurality of mounting holes defined by the respective hole partition forming plates, wherein the bottom plate and each hole partition forming plate are in a flat plate state, A curved part with a concave cross section is formed by forging on a single hole forming plate. The top of each curved portion is a raised portion that is higher than the surfaces of the second hole forming plate and the third forming plate, and the forged surfaces on both sides of each curved portion are the mounting surfaces of the mounting holes of the permanent magnets The summary is as follows.

The invention according to claim 2 is summarized in that, in claim 1, the attachment surfaces formed on both side surfaces of the first hole forming plate are inclined surfaces inclined with respect to the rotation direction of the rotor. .
According to a third aspect of the present invention, in the first or second aspect, the connecting means includes a caulking pin formed at a tip portion of each hole partition forming plate and a plurality of through holes penetrating the caulking pins, respectively. The gist of the present invention is that the tip portions of the respective hole partition forming plates are connected to each other by bending the caulking pin that is formed by the connecting ring and that is bent through the through hole and caulking the caulking pin to the surface of the connecting ring.

The gist of a fourth aspect of the present invention is that, in the first or second aspect, the connecting means is a welded portion that connects both side edges of the tip end portions of the hole partition forming plates.
A fifth aspect of the present invention is that, in any one of the first to fourth aspects, the raised portion provided on the first hole forming plate is extended and formed on the front surface or the back surface of the bottom plate. And

  A sixth aspect of the present invention is that, in any one of the first to fifth aspects, an annular first step portion is formed on the bottom plate near the peripheral portion of the shaft hole, and the outer side of the first step portion is formed. A plurality of convex portions are formed on the bottom plate at a predetermined pitch so as to be positioned on the same circumference centered on the center of the shaft hole, and an annular second step is formed on the bottom plate on the outer peripheral side of each convex portion. The gist is that the part is molded.

  According to the seventh aspect of the present invention, a flat plate material is punched into a circular shape or a polygonal shape by a pressing device, and a shaft hole through which the rotation shaft of the motor passes is formed at the center, and a plurality of permanent members are formed on the outer peripheral side. A plurality of through holes serving as magnet mounting holes are stamped and formed at a predetermined pitch so as to be located on the same circumference centered on the center of the shaft hole, and a first shape of the rotor body is formed. And a first slit is punched out from the edge of each through hole toward the shaft hole to the shaft hole, and the respective through holes are formed from the outer periphery of the original shape. A second slit for forming a plurality of hole partition forming plates made of a first hole forming plate, a second hole forming plate, and a third hole forming plate in the original shape is formed by punching and forming a second slit connected to the outer edge of the second hole. And each of the first hole forming plates in a state where the original shape is a flat plate. A third step of forming a curved portion having a concave cross section by forging, raising the top of the curved portion from the surface of the original shape, and forming the raised portion; As a fourth step of forming a permanent magnet mounting hole between each hole partition forming plate by bending each hole partition forming plate so as to be orthogonal to the bottom plate, and after the fourth step, each hole partition forming The gist is to include a fifth step of configuring the rotor main body by connecting the leading end portion of the plate with a connecting means, and a sixth step of attaching a permanent magnet to each of the mounting holes.

  The invention according to claim 8 is the invention according to claim 7, wherein, in the first step or the second step, a caulking pin is located on the outer peripheral edge of the original shape so as to be located at a tip edge of each hole partition forming plate. In the fifth step, a connecting ring formed with a plurality of through holes penetrating the caulking pin is brought into contact with the tip of each hole partition forming plate, and the caulking pin penetrated through the through hole is connected to the connecting portion. The gist is that the tip portions of the hole partition forming plates are connected to each other by pressing against the surface of the ring.

The invention according to claim 9 is that, in claim 7, the fifth step is to form a welded portion by welding in a state where both side edges of the front end portion of each hole partition forming plate are abutted. The gist.
(Function)
In the present invention, the plurality of hole partition forming plates made of the first to third hole forming plates are bent and formed so as to be orthogonal to the bottom plate with respect to the outer peripheral edge of the bottom plate. The material cost can be reduced.

  In the present invention, when the bottom plate and each hole partition forming plate are in a flat plate state, a curved portion having a concave cross section is formed by forging on each first hole forming plate, and the top of each curved portion is The raised portions are higher than the surfaces of the two-hole forming plate and the third forming plate, and the forged surfaces on both sides of each curved portion are the mounting surfaces of the mounting holes of the permanent magnet. For this reason, it is possible to easily process the mounting hole of the permanent magnet, and it is possible to improve the processing accuracy of the mounting surface without performing a cutting process. By adjusting the height of the raised portion, the area of the mounting surface of the mounting hole can be increased, and the adhesive strength of the permanent magnet can be improved.

  According to the present invention, the material cost can be reduced, the manufacturing cost can be reduced, the processing accuracy of the mounting surface of the mounting hole of the permanent magnet can be improved, and the area of the mounting surface is increased, The adhesion of the permanent magnet can be improved.

The perspective view of the state which isolate | separated the rotor main body and connecting ring which actualized the rotor of the permanent-magnet synchronous motor of this invention. The perspective view of a rotor. The partial expanded sectional view of a rotor. The longitudinal cross-sectional view of a wheel in motor. The perspective view which shows the original form of the rotor main body which shape | molded the several through-hole used as the attachment hole of a shaft hole and a permanent magnet by a 1st manufacturing process. The perspective view which shows the original form of the rotor main body which shape | molded the penetration hole of the volt | bolt, the 1st slit, the 2nd slit, and the crimp pin by the 2nd manufacturing process. The perspective view which shows the original form of the rotor main body which shape | molded the curved part and the protruding part by cold forging by the 3rd manufacturing process. FIG. 8 is an enlarged cross-sectional view taken along line 1-1 of FIG. (A) is the 2-2 line expanded sectional view of FIG. 7, (b) is the 3-3 line expanded sectional view. The perspective view which shows the rotor main body and connection ring obtained by the 4th manufacturing process. The top view which shows the manufacturing process of a connection ring. The top view which shows the manufacturing process of a connection ring. The perspective view which shows another embodiment of the rotor of this invention. (A) And (b) is a partial expanded sectional view which shows another embodiment of a rotor. The fragmentary perspective view which shows another embodiment of a rotor. The center part longitudinal cross-sectional view of the conventional wheel-in motor. The perspective view of the rotor of the conventional wheel-in motor. The partial expanded sectional view of the rotor of the conventional wheel-in motor. (A) And (b) is a partial expanded sectional view which shows the manufacturing process of the conventional rotor.

Hereinafter, an embodiment in which the present invention is embodied in a rotor of a wheel-in motor used for driving wheels of an automobile will be described with reference to FIGS.
The configuration of the motor 11 shown in FIG. 4 is the same as the configuration of the wheel-in motor 11 described in the background section, except for the rotor 35. Therefore, related members are denoted by the same reference numerals and described. Simplify.

  As shown in FIG. 2, the rotor main body 36 of the rotor 35 of the present embodiment includes a disk-shaped bottom plate 37 and a cylindrical portion 38 that is integrally bent and formed on the outer peripheral edge thereof so as to be orthogonal to the bottom plate 37. It is configured. Permanent magnets 32 are fitted into a large number of mounting holes 39 formed in the cylindrical portion 38 at a predetermined pitch in the circumferential direction, and are bonded by an adhesive (not shown).

  As shown in FIG. 1, the bottom plate 37 is formed with shaft holes 37a penetrating the wheel shaft 14 and the sleeve 23, and insertion holes 37b of the bolts 24 are formed at a plurality of locations on the outer periphery of the shaft hole 37a. Has been. In the outer peripheral portion of the bottom plate 37, first slits S1 are formed at regular intervals at a predetermined pitch at a large number (29 in this embodiment). A large number of hole partition forming plates 42 for partitioning the mounting holes 39 so as to be positioned between the first slits S1 on the outer peripheral edge of the bottom plate 37 so as to be orthogonal to the bottom plate 37 (this embodiment) In the form, it is bent at 28). Since each hole division formation board 42 is constituted similarly, based on Drawing 1, two adjacent hole division formation boards 42 are explained below.

  The hole partition forming plate 42 is integrally formed on the outer peripheral edge of the bottom plate 37 so as to be bent so as to be orthogonal to the bottom plate 37, and on both sides of the base end portion of the first hole forming plate 43. A pair of formed second hole forming plates 44 and a pair of third hole forming plates 45 integrally formed on both sides of the front end portion of the first hole forming plate 43 are configured. The first slits S <b> 1 are formed so as to extend between the adjacent second hole forming plates 44 formed in the two first hole forming plates 43 adjacent to each other. An upper end surface of the second hole forming plate 44 adjacent to the first slit S1 serves as a position restricting surface 44a for restricting the end surface of the lower side of the permanent magnet 32.

  As shown in FIG. 3, the first hole forming plate 43 is formed into a concave portion (also a mountain shape) by cold forging, which will be described later, to form a curved portion 43a. A top portion of the curved portion 43 a is formed into a raised portion 43 b that protrudes by a predetermined height outward from the outer surfaces of the second hole forming plate 44 and the third hole forming plate 45. As shown in FIG. 3, the forged surfaces on both sides of the curved portion 43a of the first hole forming plate 43 form a pair of mounting holes 39 for bonding the two side end surfaces of the permanent magnet 32 with an adhesive. The mounting surface 43c. The mounting surface 43c is an inclined surface inclined at a predetermined angle (45 ° in this embodiment) with respect to the rotation direction P of the rotor 35. As shown in FIG. 1, the lower side edges of the two adjacent third hole forming plates 45 serve as position regulating surfaces 45 a that regulate the position of the end surface of the upper side of the permanent magnet 32. A predetermined second slit S <b> 2 is formed between the opposing end surfaces of the two adjacent third hole forming plates 45.

Next, connection means for connecting the tip portions of the first hole forming plates 43 to each other will be described.
As shown in FIG. 1, the hole section forming plate 42 is integrally formed so that two caulking pins 46 protrude upward so as to be positioned between the pair of third hole forming plates 45 as shown in FIG. 1. Has been. The tip of each hole partition forming plate 42 is connected as shown in FIG. 2 using a connecting ring 47 that constitutes a connecting means. As shown in FIG. 1, the connecting ring 47 is formed in a polygonal (28-angled in this embodiment) ring shape, and the connecting ring 47 is formed with an annular groove 47a having a U-shaped cross section. The upper plate 47b of the annular groove 47a of the connecting ring 47 is formed with a large number (28) of through holes 47c into which the pair of caulking pins 46 are inserted. In FIG. 1, the tip of each hole partition forming plate 42 is fitted into the annular groove 47a of the connecting ring 47, and the caulking pin 46 protrudes upward from the through hole 47c. In this state, as shown in FIG. 2, the caulking pin 46 is bent approximately 90 degrees in a direction away from each other by a tool (not shown), and the caulking pin 46 is pressed against the upper surface of the upper plate 47 b of the connecting ring 47. By this operation, the connecting ring 47 is connected to the tip of each hole partition forming plate 42. Each of the mounting holes 39 is fitted with a permanent magnet 32 and is adhered by an adhesive (not shown).

  As shown in FIG. 4, an annular first step portion 37c concentric with the shaft hole 37a is formed by cold forging at a position near the shaft hole 37a of the bottom plate 37 to improve the rigidity of the bottom plate 37. Like to do. On the outer peripheral side of the stepped portion 37c, a large number of convex portions 37d having a substantially quadrangular shape in plan view are extruded and formed inside the cylindrical portion 38 by cold forging at a predetermined pitch in the circumferential direction. To increase. The bottom plate 37 is formed with an annular second step portion 37e by cold forging so as to be positioned between the convex portion 37d and the first slit S1, so as to increase the rigidity of the bottom plate 37. Yes. As shown in FIGS. 1 and 4, the raised portion 43 b of the curved portion 43 a formed in the first hole forming plate 43 is between the second hole forming plates 44 and the second stepped portion 37 e of the bottom plate 37. It is extended until.

Next, a method for manufacturing the rotor body 36 constituting the rotor 35 configured as described above will be described.
In the first step, as shown in FIG. 5, a flat plate material 51 made of, for example, non-magnetic stainless steel (JIS standard: SUS304) is punched into a polygon (or may be circular) by a pressing device (not shown). A shaft hole 37a through which the wheel shaft 14 of the motor 11 passes is formed at the center. At the same time, a plurality of (in this embodiment, 28) through-holes 39A in the plan view, which are the attachment holes 39 of the plurality of permanent magnets 32 in a later step, are formed at equal pitches in the circumferential direction. Thus, the flat original shape 52 of the rotor body 36 is formed.

  In the second step, as shown in FIG. 6, the first slit S <b> 1 is punched and formed at the edge on the shaft hole 37 a side of the plurality of through holes 39 </ b> A with respect to the original shape 52 in a flat plate state, A second slit S2 is formed by punching from the outer peripheral edge of the original shape 52 to the outer edge of each through hole 39A. By this operation, the hole section forming plate 42 (the first hole forming plate 43, the second hole forming plate 44, and the third hole forming plate 45) is formed in the original shape 52. In the second step, the caulking pin 46 is integrally formed on the outer peripheral edge of the original shape 52 simultaneously with the formation of the second slit S2, and a plurality of the insertion holes 37b are punched in the vicinity of the outer periphery of the shaft hole 37a. Mold.

  In the third step, as shown in FIG. 7, each hole section forming plate 42 of the original shape 52 in a flat plate state is forged from the vertical direction by a cold forging device (not shown) to form the first hole forming plate 43. A curved portion 43a having a concave cross section is formed, and the top of the curved portion 43a is raised from the surface of the original shape 52, so that the second hole forming plate 44 and the third hole forming plate 45 are formed as shown in FIGS. A raised portion 43b that protrudes from the surface is formed. Simultaneously with the third step, the first stepped portion 37c, the convex portion 37d, and the second stepped portion 37e are simultaneously formed by cold forging as shown in FIGS. As shown in FIGS. 7 and 9B, the raised portion 43b of the first hole forming plate 43 is formed from the second hole forming plate 44 to the second stepped portion 37e.

  In the fourth step, using a press device (not shown), the base end portion of the hole partition forming plate 42 formed by the second and third steps, that is, the second hole forming plate 44 and the first slit S1. An intermediate portion is a bent portion (see an annular line L indicated by a two-dot chain line in FIG. 7), and the hole partition forming plate 42 is orthogonal to the bottom plate 37 and the raised portion around the bent portion. The portion 43b is bent so as to be positioned on the outer peripheral side of the cylindrical portion 38. By this step, as shown in FIG. 1, the rotor body 36 having the mounting holes 39 for the permanent magnets 32 is formed.

  In the fifth step, the rotor main body 36 (bottom plate 37 and cylindrical portion 38) shown in FIG. 10 is housed in a holding jig (not shown) with respect to the tip of each hole partition forming plate 42 as shown in FIG. The connecting ring 47 (manufacturing method will be described later) is fitted to cause the caulking pins 46 to protrude from the through holes 47 c of the connecting ring 47. Thereafter, a caulking tool (not shown) is inserted between the pair of caulking pins 46, and the caulking pins 46 are bent and pressed against the upper surface of the upper plate 47b of the connecting ring 47 as shown in FIG. Are connected to the tip of each hole partition forming plate 42.

  In the final sixth step, the production of the rotor 35 is completed by bonding the permanent magnets 32 to the mounting surfaces 43c forming the plurality of mounting holes 39 of the rotor body 36 with an adhesive. The mounting hole 39 is permanently disposed between the position regulating surface 44 a of the second hole forming plate 44 and the position regulating surface 45 a of the third hole forming plate 45 that form the mounting hole 39 and the end surface of the permanent magnet 32. In order to easily fit the magnet 32, a slight gap is formed.

Here, the manufacturing method of the said connection ring 47 is demonstrated using FIG.11 and FIG.12.
As shown in FIG. 11, a flat plate 61 made of stainless steel (SUS304) is punched into a polygon (in this embodiment, a 28-gon) using a pressing device (not shown), and the original 62 of the connecting ring 47 is formed. Is molded. The original shape 62 may be stamped and formed into a circular shape. At the time of this molding, a large number of through holes 47c of the connecting ring 47 are punched and formed near the outer peripheral edge of the original shape 62.

Next, as shown by a two-dot chain line in FIG. 11, the original shape 62 is punched into a polygonal ring shape by a pressing device (not shown), and a flat ring 63 is formed as shown in FIG. 12.
Next, the ring 63 is drawn from above and below by a drawing apparatus (not shown) to form a polygonal connecting ring 47 shown in FIG.

According to the rotor 35 of the motor 11 of the above embodiment, the following effects can be obtained.
(1) In the above embodiment, as shown in FIG. 5, a flat plate-shaped original shape 52 having a shaft hole 37 a made of the plate material 51 and a through hole 39 A to be the attachment hole 39 is formed, and the through hole 39 A of the original shape 52 is shown in FIG. The first slit S1 and the second slit S2 are formed as shown in FIG. 5, and the curved portion 43a is formed by cold forging the first hole forming plate 43 in the state of the flat original shape 52 as shown in FIG. And the protruding part 43b was shape | molded. Then, each hole partition forming plate 42 is bent so as to be orthogonal to the bottom plate 37, a cylindrical portion 38 having a mounting hole 39 for the permanent magnet 32 is formed, and the tip of each hole partition forming plate 42 is connected by a connecting ring 47. The rotor main body 36 is manufactured by coupling. For this reason, material cost can be reduced compared with the method of cutting and forming the rotor body 36 from a stainless steel block by machining. Further, the forming operation of the mounting surface 43c formed in the first hole forming plate 43 for forming the mounting hole 39 of the permanent magnet 32 that requires machining accuracy can be easily performed with high accuracy by cold forging, Manufacturing cost can be reduced.

(2) In the above-described embodiment, the tip of each hole partition forming plate 42 is connected by the caulking pin 46 and the connecting ring 47, so that the connecting operation can be easily performed.
(3) In the above embodiment, in the state of the flat original shape 52, the step portion 37c, the convex portion 37d and the step portion 37e are formed on the bottom plate 37, and the raised portion 43b of the first hole forming plate 43 is The two-hole forming plate 44 and the bottom plate 37 were extended to the stepped portion 37e. For this reason, the rigidity of the bottom plate 37 and the second hole forming plate 44 can be increased.

  (4) In the above embodiment, as shown in FIG. 5, the first slit S <b> 1 having a tapered shape in a plan view is formed in which the interval increases with approaching the through hole 39 </ b> A with respect to the original shape 52, and the first slit S <b> 1. The intermediate portion in the longitudinal direction of the second hole forming plate 44 is a bent portion. For this reason, when each hole partition forming plate 42 is bent so as to be orthogonal to the bottom plate 37, it is not necessary to use a drawing apparatus, so that the bending operation can be easily performed and the manufacturing cost can be reduced.

  (5) In the above embodiment, as shown in FIG. 3, since the top of the curved portion 43a of the first hole forming plate 43 is the raised portion 43b, the width dimension of the mounting surface 43c formed on both sides of the curved portion 43a. Can be increased to increase the bonding area of the permanent magnet 32, and the bonding strength of the permanent magnet 32 with the adhesive can be improved. The width dimension of the mounting surface 43c can be appropriately set by adjusting the deformation amount of the curved portion 43a by cold forging.

In addition, you may change the said embodiment as follows.
As shown in FIG. 13, the adjacent third hole forming plate 45 formed at the tip of each first hole forming plate 43 is abutted, and the abutting end surface is welded by a laser beam welding apparatus (not shown), for example. Thus, a welded portion 71 as a connecting means may be formed. In this embodiment, the above-described connecting ring 47 is not necessary, and the caulking pin 46 does not need to be formed in the manufacturing process shown in FIG. 6, so that the number of parts can be reduced and also shown in FIG. The material 52 can be reduced by reducing the diameter of the original shape 52.

-You may abbreviate | omit at least any one of the said level | step-difference part 37c, the convex part 37d, and the level | step-difference part 37e.
In the embodiment, as shown in FIG. 3, the first hole forming plate 43 is formed so that the raised portion 43 b is located outside the cylindrical portion 38, but as shown in FIG. You may shape | mold so that it may be located inside. In this embodiment, the mounting surface 43 c of the first hole forming plate 43 is formed so that the width dimension becomes narrower toward the outer side in the radial direction of the rotor 35. For this reason, when the rotor 35 is rotated, the permanent magnet 32 receives the centrifugal force received in the radial direction, and there is an advantage that the permanent magnet 32 is difficult to separate from the mounting hole 39.

  -As shown in Drawing 14 (b), you may shape so that attachment surface 43c of curved part 43a of the 1st hole formation board 43 may become almost parallel. Also in this embodiment, since the area of the attachment surface 43c can be increased, the adhesive strength of the permanent magnet 32 can be improved.

  As shown in FIG. 15, the second hole forming plate 44 may be formed so as to be located on one side of the base end portion of the first hole forming plate 43. Similarly, the third hole forming plate 45 may be formed so as to be located on one side of the tip of the first hole forming plate 43. In this embodiment, the caulking pin 46 is omitted, the second slit S2 is set to zero, and the contact surface between the side surface of the first hole forming plate 43 and the third hole forming plate 45 is connected by welding. Good.

  Although not shown, the third hole forming plate 45 formed at the tip of the first hole forming plate 43 may be formed into an arc shape in the manufacturing process shown in FIG. In this case, the connecting ring 47 can be formed into a simple annular shape instead of a polygonal ring, and the shape of the forming die of the drawing device of the connecting ring 47 can be simplified.

Although not shown, the base end portion of the second hole forming plate 44 may be bent around the inner end portion of the first slit S1.
-Although not shown in figure, you may make it shape | mold the curved part 43a and the protruding part 43b of the 1st hole formation board 43 by warm forging or hot forging.

  Although not shown, the raised portion 43 b of the first hole forming plate 43 may be formed on the inner peripheral side of the cylindrical portion 38, and the raised portion 43 b may be extended to the back surface of the bottom plate 37.

  P ... rotational direction, S1 ... first slit, S2 ... second slit, 11 ... motor, 32 ... permanent magnet, 35 ... rotor, 36 ... rotor body, 37 ... bottom plate, 37a ... shaft hole, 37c ... first step portion , 37d ... convex portion, 37e ... second stepped portion, 39 ... mounting hole, 39A ... through hole, 42 ... hole partition forming plate, 43 ... first hole forming plate, 43a ... curved portion, 43b ... raised portion, 43c ... Mounting surface 44 ... second hole forming plate 45 ... third hole forming plate 46 ... caulking pin 47 ... connecting ring 47c ... through hole 51,61 ... plate material 52,62 ... original shape, 71 ... weld.

Claims (9)

A plate-like bottom plate having a shaft hole that is attached to the rotation shaft of the motor so as to be capable of synchronous rotation;
A plurality of first hole forming plates that are integrally bent so as to be orthogonal to the bottom plate with respect to the annular outer peripheral edge of the bottom plate;
A second hole forming plate integrally formed on both sides or one side of the base end portion of each first hole forming plate;
A third hole forming plate integrally formed on both sides or one side of the tip of each first hole forming plate;
A connecting means for connecting tip portions of a plurality of hole partition forming plates configured by the first to third hole forming plates, and
A plurality of permanent magnets respectively attached to a plurality of attachment holes defined by the respective hole partition formation plates;
When the bottom plate and each hole partition forming plate are in a flat plate state, a curved portion having a concave cross section is formed by forging on each first hole forming plate, and the top of each curved portion is formed on the second hole forming plate and A rotor used for a permanent magnet synchronous motor, characterized in that the raised portion is higher than the surface of the third forming plate, and the forged surfaces on both sides of each curved portion are the mounting surfaces of the mounting holes of the permanent magnet. 2. The rotor used in a permanent magnet synchronous motor according to claim 1, wherein the mounting surfaces formed on both side surfaces of the first hole forming plate are inclined surfaces inclined with respect to the rotation direction of the rotor. 3. The connecting means according to claim 1, wherein the connecting means includes a caulking pin formed at a tip portion of each hole partition forming plate and a connecting ring having a plurality of through holes penetrating the caulking pins, respectively. A rotor used in a permanent magnet synchronous motor, wherein the tip portions of the hole partition forming plates are connected to each other by bending the caulking pin penetrating from the hole and caulking the caulking pin to the surface of the connecting ring. 3. The rotor used in a permanent magnet synchronous motor according to claim 1, wherein the connecting means is a welded portion that connects both side edges of the tip end portions of the hole partition forming plates. 5. The permanent magnet synchronous motor according to claim 1, wherein the raised portion provided on the first hole forming plate is formed by extension on the front surface or the back surface of the bottom plate. 6. Rotor. In any 1 item | term of Claims 1-5, the cyclic | annular 1st level | step-difference part is shape | molded by the baseplate near the peripheral part of the said shaft hole, and several convex part is formed in the baseplate outside this 1st level | step-difference part. It is formed so as to be located on the same circumference centered on the center of the shaft hole at a predetermined pitch, and an annular second step portion is formed on the bottom plate on the outer peripheral side of each convex portion. A rotor used for a permanent magnet synchronous motor. A flat plate material is punched into a circular shape or a polygonal shape by a pressing device, and a shaft hole through which the rotation shaft of the motor is penetrated is formed at the center, and a plurality of transparent magnets serving as mounting holes for a plurality of permanent magnets are formed on the outer peripheral side. A first step of punching and forming a hole at a predetermined pitch so as to be positioned on the same circumference centered on the center of the shaft hole, and forming a rotor body original shape;
A first slit is punched out from the edge of each through hole toward the shaft hole to a predetermined depth, and the outer edge of each through hole is formed from the outer periphery of the original shape. A second step of forming a plurality of hole partition forming plates made of the first hole forming plate, the second hole forming plate and the third hole forming plate into the original shape by punching and forming a second slit connected to the portion;
In a state where the original shape is flat, a curved portion having a concave cross section is formed by forging each first hole forming plate, and a top portion of the curved portion is raised from the surface of the original shape to form a raised portion. And the process of
A fourth step of forming a permanent magnet mounting hole between each hole partition forming plate by bending each hole partition forming plate so that the base end of each hole partition forming plate is a bending point and orthogonal to the bottom plate; ,
After the fourth step, a fifth step of configuring the rotor body by connecting the tip of each hole partition forming plate with a connecting means;
And a sixth step of attaching a permanent magnet to each of the attachment holes. A method of manufacturing a rotor used in a permanent magnet synchronous motor. In Claim 7, in the first step or the second step, a caulking pin is formed on the outer peripheral edge of the original shape so as to be located at a tip edge of each hole partition forming plate, and in the fifth step, Each of the connecting rings formed with a plurality of through holes penetrating the caulking pin is brought into contact with the tip of each hole partition forming plate, and the caulking pin penetrated through the through hole is pressed against the surface of the connecting ring. A method of manufacturing a rotor for use in a permanent magnet synchronous motor, wherein tip portions of hole partition forming plates are connected to each other. 8. The permanent magnet synchronous motor according to claim 7, wherein the fifth step is to form a welded portion by welding in a state where both side edges of the front end portion of each hole section forming plate are abutted. A method of manufacturing a rotor to be used.

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