JP2012182900A - Rotor of rotary electric machine and manufacturing method therefor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide the rotor of a rotary electric machine in which an uncured resin can be made to flow smoothly between the tongue of a bobbin and the claw of a core while exhibiting significant magnetic noise prevention effect, and to provide a manufacturing method therefor.SOLUTION: In the rotor 1 where a magnetic field coil 6 wound around an insulation bobbin 5 is arranged between a pair of pole cores 3, 4, and a Lundell type pole core is bonded by a shaft 2, a folding part is provided near the root of the tongue 56(57) of the insulation bobbin 5 and tilted to the outside. A swollen streak 18 (a concave groove 19 having both open ends) is formed in the tongue 56(57) when it is pressed against the inner wall surface of the claw 33(43) of the pole cores 3, 4 and deformed to the inside. When the magnetic field coil 6 is coated with an uncured resin and impregnated therewith, the uncured resin flows smoothly into the concave groove 19, and the tongue 56 and the inner wall surface of the claw 33 are bonded rigidly by making the resin thermosetting.

Description

  The present invention relates to a rotor (rotor) of a rotating electrical machine including a Landel rotor core in which a pair of pole cores are combined to face each other, and a method for manufacturing the same.

  As a rotor of a rotating electrical machine such as an AC generator for a vehicle, a cylindrical boss part, a disk part radially extended from one end of the boss part, and the other end in the axial direction at equal intervals from the outer periphery of the disk part A Landel type rotor core is used in which a pair of pole cores (claw poles) having a plurality of extended claw portions are combined to face each other.

  Between the adjacent claw parts of each pole core is a V-shaped groove (V groove) reaching the outer periphery of the disk part, and the claw part of the other core enters the V groove of one core, and the cage shape Presents. A magnetic field coil is accommodated in the cylindrical space between the claw portion and the boss portion of the pair of pole cores that mesh with each other with a required gap. The pair of pole cores and magnetic field coils are integrated by pressing a shaft into the shaft center to form a rotor core assembly.

  The magnetic field coil includes an insulating bobbin and a conductive wire (winding) densely wound around the insulating bobbin. An insulating bobbin is manufactured by injection molding of a resin such as nylon, and has a cylindrical body having a winding wound in a cylindrical shape on the outer periphery, and a flange that extends radially outward from both ends of the body. is doing. Each flange portion has an annular plate-like collar portion whose inner side surface is in contact with both end faces of the cylindrical winding, and a tongue portion extending radially from the collar portion and corresponding to the inner wall surface of the pawl portion of the pole core. It consists of. Between adjacent tongues, there is a V-shaped notch (V notch) corresponding to the V-groove.

  The body portion of the insulating bobbin is externally fitted to the boss portions of the pair of pole cores in a state where the outer side surfaces of both flange portions are in contact with the inner side surfaces of the disk portions of the pair of pole cores. One flange portion is provided with a protrusion that engages with the bottom of the V-groove of the pole core on the outer surface at a position corresponding to the bottom of the V-notch. The protrusions have a function of preventing the magnetic coil from rotating, and the two opposing protrusions serve as terminal portions for locking the lead lines on the winding start side and winding end side of the winding.

  In a rotating electrical machine equipped with a Landel rotor core, the outer peripheral portion of the claw portion is oscillatingly displaced by centrifugal force accompanying rotation of the rotor and magnetic reaction force accompanying power generation. It is known that when this displacement amount is large, the air gap between the rotor core and the stator core becomes non-uniform and magnetic noise increases. In order to reduce this magnetic noise, a pressing part (tongue part) is formed on the bobbin, the pressing part is brought into full contact between the inner surface of the pawl part of the pole core and the magnetic field coil, and is adhered with an adhesive such as varnish. It has been proposed to attenuate vibrations (see Patent Document 1).

  Patent Document 2 proposes a structure in which ribs are provided on the outer surface of the tongue of the bobbin so that the adhesive such as the varnish can smoothly enter between the tongue of the bobbin and the inner wall surface of the claw. .

Japanese Patent Laid-Open No. 2004-60806 Japanese Patent No. 2941636

  In the configuration in which the rib is provided on the outer surface of the tongue portion of the bobbin described in Patent Document 2, an optimal filling structure that effectively prevents vibrational displacement of the outer peripheral portion of the claw portion is sufficient when filling the adhesive such as varnish. There is no consideration. In addition, the rib has a problem that the structure of the mold used for molding the flange portion of the bobbin is complicated, the manufacturing cost is increased, and the productivity is lowered. Further, the presence of the rib itself prevents the varnish from entering, and the portion where the rib is in contact with the inner peripheral surface of the pawl portion of the pole core is difficult for the varnish to enter. As a result, there is a drawback that the presence of the rib itself becomes a starting point of peeling of the adhesive surface due to vibrational displacement of the outer peripheral portion of the claw portion due to centrifugal force.

The object of the present invention is to form a circumferential concave groove having both ends opened on the tongue of the bobbin so that an appropriate amount of uncured resin flows into a predetermined position on the inner peripheral surface of the nail base, And firmly fixing the inner peripheral surface of the nail base.
In addition, the rotor of a rotating electrical machine is easy to injection-mold bobbins, has excellent productivity, can easily form windings, and can reliably remove the non-intruding portion of the resin (varnish) that is the starting point of peeling. And the production method thereof.

The gist of the present invention is that the curved tongue portion of the tongue portion of the insulating bobbin is bulged over the entire width to the coil side (inner side), and the concave groove whose both ends are open on the inner wall surface side of the claw portion of this bulging strip Is to form.
Thereby, when apply | coating uncured resin to the coil | winding of an electromagnetic coil and fixing a coil | winding, the uncured resin in the gelatinization which has fluidity | liquidity is formed in the both sides of a ditch | groove (bulging strip). It smoothly flows into the groove from the gap (opening) with the inner wall surface of the claw part, and fills the space between the groove and the inner wall of the base part of the claw part of the pole core.

  Thereby, the tongue part of the bobbin and the claw base part of the pole core are firmly fixed than the resin layer filled in the concave groove, and the outer peripheral part of the claw part is strongly prevented from being displaced by vibration due to the magnetic reaction force. . As a result, the magnetic noise caused by the non-uniformity of the air gap between the rotor core and the stator core is reliably reduced.

  In addition, according to the present invention, a concave groove of a desired size can be reliably formed over the entire width of the tongue by a simple means of forming a bent portion at a predetermined position of the tongue when the bobbin is molded. Can be formed. Since both ends of the concave groove are open, it is possible to smoothly flow in the uncured resin. The position of the bent portion and the bending angle are design items that are appropriately selected depending on the material of the bobbin, the plate thickness, and the like.

  According to a third aspect of the present invention, in the rotor of the rotating electric machine according to the first aspect, the outer peripheral radius of the winding of the electromagnetic coil is a, the distance (radius size) from the center of the concave groove is b, and the bobbin tongue is When the distance (radial dimension) from the center of the inner diameter side end of the curved tongue portion is c, a <b <c is set.

  As a result, it is possible to reliably form the groove extending over the entire width of the curved tongue portion on the winding side, and the gelled uncured resin dropped on the outer periphery of the winding It can flow smoothly into the groove from the openings at both ends. As a result, the uncured resin supplied to the outer periphery of the winding is properly filled in the inner wall surface of the base portion of the claw portion, and the tongue portion of the bobbin and the claw portion of the rotor core are more firmly fixed than the resin layer.

Invention of Claim 2 is the manufacturing method of the rotor which manufactures the rotor of the rotary electric machine of Claim 1, Comprising:
1) It has a cylindrical body, an annular plate-shaped flange extending radially outward from both ends of the body, and a large number of tongues extending radially from the periphery of each flange. Forming an electromagnetic coil by a bobbin molding step of molding an insulating bobbin provided with an outward bent portion located in the same circumference, a winding step of winding a winding around the bobbin,
2) A pair of pole cores having a cylindrical boss part, a disk part extended from one end of the boss part, and a plurality of claw parts extended from the outer periphery of the disk part to the other end side at equal intervals. The claws are arranged to face each other with a required gap therebetween, and the electromagnetic coil is accommodated between the pair of pole cores,
3) A core assembly process is adopted in which a shaft is press-fitted and integrated into a pair of pole cores and an electromagnetic coil disposed therebetween.

  In the assembly process of the core, the tongue of the bobbin is bent toward the center along the inner peripheral side surfaces of the base and tip of the claw. With this inward bending (center side), the tip tongue of the bobbin and the bent part in the middle of the tongue tilt toward the coil center from the outer diameter side position of the outer periphery of the winding, and the bent part Transforms into a bulge with the bending angle at the time of molding. And a ditch | groove is formed in the back surface side (outside) of a bulging strip. This deformation behavior can be explained by the fact that the bent part at the time of molding has an obtuse angle, and therefore has higher rigidity than the flat part.

It is the partial cross section figure and the principal part enlarged view of the rotor of a rotary electric machine. It is the side view and sectional drawing of a bobbin. It is a manufacturing process of a bobbin. It is an assembly | attachment process figure of the rotor of a rotary electric machine. It is an assembly | attachment process figure of the rotor of a rotary electric machine. FIG. 6 is a detailed view of part A in FIG. 5. It is an application process figure of resin to a rotor.

  A mode for carrying out the present invention will be described together with an embodiment shown in the drawings.

  FIG. 1 shows an embodiment of the present invention. A rotor 1 of an automotive alternator is driven by an engine and operates as a field element for power generation. The rotor 1 includes a shaft 2 and a Landell-type pole that is fitted on the shaft 2 with a pair of pole cores (claw poles) 3 and 4 facing each other. Between the pole cores 3 and 4, a magnetic field coil 7 including an electrically insulating bobbin 5 and a conductive wire (winding) 6 tightly wound around the bobbin 5 is disposed.

  The pair of pole cores 3 and 4 have the same shape, and are extended in the radial direction from cylindrical boss portions 31 and 41 fitted on the shaft 2 and from one end sides (outside) of the boss portions 31 and 41, respectively. Disk units 32 and 42. A plurality of claw portions 33 and 43 forming claw-shaped magnetic poles are extended from the outer peripheral portions of the disk portions 32 and 42 to the other end side in the axial direction. In the embodiment of FIG. 1, the pawl cores 3, 4 have eight claw portions 33, 43 each having the same shape and equally spaced, and the outer peripheral wall surfaces 331, 431 of the claw portions 33, 43 are connected to the shaft 2. It is located in a cylindrical surface having a coaxial center.

  The inner wall surfaces 332 and 432 of the claw portions 33 and 43 are conical surfaces whose radius (inner diameter) gradually increases toward the tip (the other end side), and are discs that extend perpendicular to the axis of the shaft 2. The portions 32 and 42 are connected to the inner wall surfaces 324 and 424 via curved inner wall surfaces 325 and 425 having a small curvature radius. The circumferential widths of the claw portions 33 and 43 gradually decrease toward the tip (the other end in the axial direction) to form a wedge shape, and the tips are top surfaces 333 and 433, respectively. Between the adjacent claw portions 33 and 43, substantially U-shaped or substantially V-shaped grooves (V-grooves) 34 and 44 are formed in the axial direction. The outer end portions of the V grooves 34 and 44 are formed so as to bite into the outer periphery of the disk portions 32 and 42.

  The pair of pole cores 3 and 4 are arranged to face each other, and the tip surfaces of the boss parts 31 and 41 are arranged to face each other. The claw portions 33 of the pole core 3 and the claw portions 43 of the pole core 4 are alternately meshed, and the corrugated gap 10 having a required width is formed in a cylindrical shape between the claw portions 33 and the claw portions 43. is doing. The magnetic field coil 7 is accommodated in a cylindrical hollow portion surrounded by the boss portions 31 and 41 of the pair of pole cores 3 and 4, the disk portions 32 and 42, and the claw portions 33 and 43.

  In this state, the shaft 2 is press-fitted, and the pair of pole cores 3 and 4 and the magnetic field coil 7 are fixedly assembled to the shaft 2 and assembled. The core assembly 9 assembled in this manner is coated and impregnated on the surface of the winding 6 of the magnetic field coil 7 with the uncured epoxy resin 8 (from the sol state to the gelation state) through the corrugated gap 10. Subsequently, the epoxy resin 8 is thermally cured to fix the surface and the inside of the winding 6.

  The insulating bobbin 5 is a molded body of resin such as nylon, and as shown in FIG. 2, a cylindrical body 51 around which the winding 6 is wound, and 2 extending radially outward from both ends of the body 51. And two flange portions 52 and 53. The flange portions 52 and 53 include annular plate-like flange portions 54 and 55 corresponding to the inner wall surfaces 324 and 424 of the disk portions 32 and 42, and a plurality of tongues extending outward from the outer periphery of the flange portions 54 and 55. Parts 56 and 57. The tongue portions 56 and 57 have shapes similar to the inner wall surfaces 332 and 432 of the claw portions 33 and 43, and are formed at equal intervals corresponding to the claw portions 33 and 43. V-shaped notches 58 and 59 are formed in a valley between adjacent tongues 56 and 57.

  The tongue portions 56 and 57 have shapes corresponding to the inner wall surfaces 332 and 432 of the claw portions 33 and 43 of the cores 3 and 4, and the outer peripheral portion of the inner wall surface of the core disk portions 32 and 42 and the claw portions 33, Tongue base portions 561 and 571 extending radially along the inner wall surface of the base portion 43, curved tongue portions 562 and 572 bent in the axial direction along the curved inner wall surfaces 325 and 425 of the claw portions 33 and 43, and a curved tongue portion 562 and 572 and tip tongue portions 563 and 573 that abut against the tip inner wall surfaces 332 and 432 of the claw portions 33 and 43, respectively.

  When the winding 6 is wound around the body 51, the outer periphery of the end face of the winding 6 reaches the outer peripheral position of the annular plate-shaped flanges 54 and 55. On the outer surface of one flange portion 52, a protrusion 50 is provided at the innermost part of the notch 58 to engage the bottom of the V groove 34 of the pole core 3 and prevent the insulating bobbin 5 from rotating. At least two of the protrusions 50 are formed with terminal portions 15 through which the lead wires 14 at the start and end of winding of the magnetic coil are inserted and locked. Two slip rings 16, 16 are arranged at one end of the shaft 2, and are connected to a lead wire 14 at the beginning and end of winding of the winding 6, respectively.

In the injection molding of the insulating bobbin 5, the tongue base portions 561 and 571 of the tongue portions 56 and 57 are inclined outward from the base portion via the bent portions 17 and 17, as shown in FIG.
Thus, when the magnetic field coils 6 wound around the insulating bobbin 5 are arranged facing each other and interposed between the cores 3 and 4, the tongue portions 56 and 57 are connected to the pawl portions of the pole cores 3 and 4. The inner wall surfaces 332 and 432 of 33 and 43 are pressed and bent inward to be deformed.

  At this time, as shown in FIG. 5, the bent portions 17 and 17 are deformed on the winding 6 side (inner side) as if they bulge inward while substantially maintaining the bent form of the bent portion 17. . Thus, the bulging strips 18 and 18 are formed, and the concave grooves 19 and 19 having both ends opened are formed on the inner wall surfaces 332 and 432 of the claw portions 33 and 43 over the entire width. This is because the bending rigidity of the bent portions 17 and 17 is larger than the bending rigidity of the other portions, such as changing the plate thickness and width of the tongue portions 56 and 57, and the tongue portions 56 and 57 are near the bent portion 17. Therefore, the moment force in each region applied from the bent tongues 562 and 572 to the tip tongues 563 and 573 is the smallest at the tip side and increases as it goes to the inner diameter side. This is due to the maximum at around 17.

  The positions at which the bulging strips 18 and 18 or the concave grooves 19 and 19 of the tongue portions 56 and 57 are formed (radial dimension is b) are different from the center positions of the curved inner wall surfaces 325 and 425 (radial dimension is c). It is set on the minute center side. Due to the ridges 18, 18, the inner wall surfaces 332, 432 and the curved inner wall surfaces 325, 425 of the pawl portions 33, 43 of the pole cores 3, 4 and the concave grooves 19, 19 of the tongue portions 56, 57 are formed. The gaps 20 and 20 having the largest thickness are formed in the vicinity of the center positions of the curved inner wall surfaces 325 and 425.

  FIG. 3 shows a method of manufacturing the insulating bobbin 5, and the bobbin 5 is manufactured by injecting a resin such as nylon into an injection molding die 21. The mold 21 includes a lower mold 2A, an upper mold 2B, and a divided horizontal mold 2C. When the mold is clamped, a molding chamber 3D corresponding to the outer shape of the insulating bobbin 5 is formed as shown in FIG. Resin is injected from the resin injection path 3E formed in the upper mold 2B, and after molding, it is separated from each other and a molded product is taken out.

  FIG. 4 shows an assembling jig 22 for the rotor 1. The core 3 is installed on the base 23 with the disk part 32 down and the claw part 33 up, the magnetic field coil 6 is externally fitted to the boss part 31, and the claw part 43 is placed down on the disk part 42. Stack the core 4 with the top facing up. In this state, the shaft 2 is press-fitted. Thereby, the core assembly 9 is formed.

  At this time, the tongues 56 and 57 of the flanges 52 and 53 of the bobbin 5 are inclined from the inclined state expanded outward at the start of assembly shown in the left half of FIG. 5 to the inner side when the assembly shown in the right half of FIG. It is deformed into a state of being bent into That is, the bent portions 17 and 17 of the tongue portions 56 and 57 are automatically formed while forming the bulging strips 18 and 18 on the inside, and the concave grooves 19 and 19 are formed on the back surfaces of the bulging strips 18 and 18. Is done. Due to the bending deformation of the tongue portions 56 and 57, the bulging portion 18 and the concave groove 19 can be easily formed because of ensuring the rigidity associated with the corner portion shape of the bending portion 17 or bending applied to the bending portion 17 during molding. The magnitude of the moment depends on being maximized in the whole tongue.

  FIG. 6 shows an enlarged cross section of the bulging strip 18. When the outer peripheral radius of the winding 6 of the magnetic field coil 7 is a, the central position of the curved tongue of the tongue 56 (57) of the bobbin 5 is the radial dimension b, and the central positions of the curved inner wall surfaces 325 and 425 are the radial dimension c. In addition, a <b <c is set. Thereby, while the formation of the bulging strip 18 can be made smoothly, the cross-sectional shapes of the bulging strip 18 and the concave groove 19 can be appropriately formed.

  That is, the bending deformation start position of the tongue 56 (57) The bulge starts slightly from the radial position of the radius a of the winding 6, and the radial position c of the bent portion 17 where the width of the cross section is maximum. Thus, a space (gap) in which resin can be filled can be formed along the curved inner wall surface 325 (425) of the claw portion 33 (43) while the width of the cross section gradually decreases. Accordingly, when the epoxy resin is applied and impregnated in the winding 6, the resin surely flows into the concave groove 19. And when thermosetting, the tongue part 56 and the inner peripheral surface of the claw part 33 are firmly fixed.

  FIG. 7 shows an outline of a resin application device 24 for applying a resin for fixing the winding 6 to the core assembly 9. The resin coating device 24 includes a sol-shaped resin supply device 25, a nozzle 26, a driving unit 27 for the nozzle 26, and a rotating unit 28 that horizontally arranges and rotates the assembly 9. The uncured resin is dropped from the nozzle 26 while rotating the assembly 9 by the rotating means 28, and applied to the surface of the winding 6 through the window 13.

  As a result, the resin is applied to the surface of the winding 6, and at this time, flows into the concave grooves 19, 19 from both side openings, and the inner wall surface of the claw portion 33 and the tongue portion 56 around the curved inner wall surface 325 (425). Flows into the outer surface (groove surface of the concave groove 19). In order to make the inflow of the resin into the concave grooves 19 and 19 smooth, the above condition of a <b <c is effective.

  In the above embodiment, the curvature and the inclination angle of the bent portion 17 of the tongue portion 56 are appropriately selected according to the plate thickness of the tongue portion 56 and the inclination angle of the inner wall surface of the claw portion 33. Moreover, the bending part 17 of the tongue part 56 may be plural, and may be a two-stage or three-stage bent part.

  In the rotor of the rotating electrical machine according to the present invention, the bent portion 17 is provided on the tongue portion 56, and the bent portion 17 is bent when the tongue portion 56 is bent in the reverse direction by the inclination angle of the inner wall surface of the claw portion 33 during assembly. Forms an effective gap with the inner wall surface of the claw portion 33. When uncured resin flows into this gap and is cured by heat, the resin adheres the tongue 56 to the inner wall surface of the claw 33 and reduces magnetic vibration. That is, a resin layer having an optimal cross-sectional shape can be formed with a simple configuration in which the tongue 56 is formed on the bobbin 5 in a shape inclined outward via the bent portion 17. For this reason, a large magnetic vibration reducing effect can be obtained at low cost.

DESCRIPTION OF SYMBOLS 1 Rotor of AC generator for vehicles 2 Shaft 3, 4 Pole core 31, 41 Cylindrical boss part 32, 42 Disk part 33, 43 Claw part 34, 44 V-shaped groove (V groove)
5 Insulating bobbin 51 Cylindrical body portion 52, 53 Flange portion 54, 55 Ring plate-like flange portion 56, 57 Tongue portion 58, 59 Notch portion 50 Projection 6 Winding 7 Magnetic field coil 8 Epoxy resin 9 Core assembly DESCRIPTION OF SYMBOLS 10 Corrugated gap 11, 12 Turn part 13 Window 14 Leader 15 Terminal part 17 Bending part 18 Swelling strip 19 Concave groove

Claims (3)

It consists of a cylindrical boss part, a disk part extended from this boss part, and a plurality of claw parts extending in the axial direction from the outer periphery of the disk part, and a V-shape reaching the outer periphery of the disk part between adjacent claw parts A magnetic field coil composed of an insulating bobbin and a winding in which a conductive wire is wound around the insulating bobbin many times is accommodated between the pair of pole cores. A rotor of a rotating electrical machine having a Landel-type rotor core in which these are fixed to a shaft, an uncured resin is applied to the surface of the winding, the winding is impregnated, and the uncured resin is thermally cured. ,
The claw portion includes a claw base inner wall surface located on an outer periphery of the disk portion, a claw tip inner wall surface constituting a conical surface, and a curved inner portion connecting between the claw base inner wall surface and the claw tip inner wall surface. Consisting of walls,
The insulating bobbin has a cylindrical barrel portion on which the winding is sheathed, and a flange portion extended in an outer peripheral direction from both ends of the barrel portion, and the flange portion is in close contact with the inner wall surface of the claw base portion. And a plurality of tongues extending radially from the collar,
The tongue portion has a shape corresponding to the inner wall surface of the claw portion, a tongue base portion extending radially along the inner wall surface of the claw base portion, and a curved tongue portion bent in the axial direction along the curved inner wall surface A tip tongue portion contacting the inner wall surface of the tip of the nail,
A concave groove having both ends in the width direction facing the curved inner wall surface is formed over the entire width of the curved tongue portion, and an uncured resin is filled between the curved tongue portion and the curved inner wall surface. A rotor of a rotating electrical machine characterized by that. A manufacturing method for manufacturing a rotor of a rotating electrical machine according to claim 1,
A cylindrical body, an annular plate-shaped flange extending radially outward from both ends of the body, and a plurality of tongues extending radially from the outer periphery of each flange, and a predetermined position of the tongue In addition, an electromagnetic coil is formed by a bobbin molding process for molding an insulating bobbin provided with a bent portion whose front end side extends outward, and a winding process for winding a winding around the bobbin,
A pair of pole cores having a cylindrical boss part, a disk part extended from one end of the boss part, and a plurality of claw parts extended to the other end side at equal intervals from the outer periphery of the disk part, Each of the claw portions is arranged facing each other so as to mesh with each other with a required gap therebetween, and the electromagnetic coil is accommodated between the pair of pole cores,
In the assembly process of press-fitting and integrating a shaft into the pair of pole cores and the electromagnetic coil disposed between them,
The tip of the tongue is bent and deformed inward along the inner wall surface of the claw, and the tongue is formed with a concave groove in which the bent part is displaced inward and both ends are opened. A method for manufacturing a rotor of a rotating electrical machine. In the rotor of the rotating electrical machine manufactured by the manufacturing method according to claim 2,
For the outer peripheral radius a of the winding, the radial dimension b at the radial arrangement position of the concave groove and the radial dimension c at the radial arrangement position of the bent portion are set as a <b <c. A rotor of a rotating electrical machine characterized by

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