JP2013158076A - Rotor of dynamo-electric machine and manufacturing method therefor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a rotor of a dynamo-electric machine in which an end plate made of a non-magnetic material and covering the axial end face of a rotor core can be fixed by an inexpensive and simple structure while minimizing degradation in performance of the dynamo-electric machine, and the efficiency and reliability of the dynamo-electric machine can be enhanced while reducing the cost, and to provide a manufacturing method therefor.SOLUTION: Linear expansion coefficient of a retainer 20 is substantially equal to that of a rotor shaft 14, hardness of the retainer 20 is higher than that of a second end plate 18B, and one or more protrusion 52 is formed on the end face 20a of the retainer 20 on the second end plate 18B side. The retainer 20 is fixed to the rotor shaft 14 in such a state that at least the top 52a of the protrusion 52 of the retainer 20 is located closer to the inside than the outer surface of the end face 18a of the second end plate 18B on the retainer side.

Description

  The present invention relates to a rotor of a rotating electrical machine and a method for manufacturing the same.

  As a rotor of a conventional rotating electric machine, for example, a rotor described in Patent Document 1 is known.

  The rotor described in Patent Document 1 is adjacent to a shaft, a yoke (core) fixed to the outer peripheral side of the shaft, a permanent magnet disposed on the yoke, and an axial end of the permanent magnet. An end face plate that restricts movement of the permanent magnet in the axial direction, and a collar having an annular inner peripheral face that is press-fitted into the cylindrical outer peripheral face of the shaft and fixes the end face plate. I have. The collar is substantially the same as the linear expansion coefficient of the shaft, and the end face plate is made of a nonmagnetic material having a larger linear expansion coefficient than the shaft. Thereby, while preventing leakage of magnetic flux, the rotor diameter can be increased and the weight can be reduced.

Japanese Patent No. 4837288

  FIG. 15 schematically shows a configuration of a rotor according to a conventional example as shown in Patent Document 1. The rotor 100 according to this conventional example includes a rotor shaft 102, a rotor iron core 104, a permanent magnet 106, an end face plate 108, and a collar 110, similarly to the rotor according to Patent Document 1, and further, the rotor shaft 102. For example, a flange-like abutment 112 provided integrally is provided near one end portion 102a.

  In this case, the rotor core 104 is press-fitted into the rotor shaft 102. Further, when the end face plate 108 having a different linear expansion coefficient from the rotor shaft 102 is used, the end face plate 108 cannot be press-fitted into the rotor shaft 102. For this reason, the end face plate 108 cannot be rotated integrally with the rotor shaft 102 and the rotor iron core 104. As shown in the cross-sectional view of FIG. 16, a protrusion 120 inserted into the key groove 118 formed along the axial direction on the outer peripheral surface of the rotor shaft 102 is formed on the inner peripheral surface of the center hole 116 of the end face plate 108. Although provided (the projection 120 is also provided on the electromagnetic steel plate 114), the projection 120 is for determining the angular phase of the rotor core 104, and has no function of fixing the end face plate 108 or the rotor core 104. . For example, when the collar 110 is not present, the end face plate 108 moves toward the other end portion 102b of the rotor shaft 102 due to vibration accompanying rotation of the rotor shaft 102, and the laminated structure of the electromagnetic steel plates 114 constituting the rotor iron core 104. There is a risk of damage.

  Therefore, a collar 110 having a linear expansion coefficient substantially the same as the linear expansion coefficient of the rotor shaft 102 and separate from the end face plate 108 is press-fitted into the rotor shaft 102. As a result, the rotor core 104 and the end face plate 108 are sandwiched between the abutment 112 and the collar 110, so that the frictional force generated between the respective parts becomes a fixing force that also serves as a detent. As a result, the rotor core 104 and the end plate The face plate 108 can be rotated integrally with the rotor shaft 102.

The frictional force generated between parts is given by the following equation.
F (friction force) = μ (friction coefficient) × N (vertical load)

  Since the coefficient of friction μ is a substance-specific value, to increase the frictional force, it is necessary to increase the vertical load N, that is, the pressing load between parts along the axial direction of the rotor shaft 102. Comparing the frictional force between the parts, the contact area between the end face plate 108 and the collar 110 is small, and the distance from the rotor shaft 102 is also small, so the frictional force is much higher than between the rotor core 104 and the end face plate 108. small.

  Therefore, in order to always generate a large frictional force between the end face plate 108 and the collar 110, it is conceivable to press the collar 110 with a considerably high load and fix the collar 110 as it is.

  However, in a state where no compressive stress is applied to the electromagnetic steel sheet 114, the magnetic steel sheet 114 can obtain a good magnetic flux density, but when the compressive stress is applied to the electromagnetic steel sheet 114, the iron loss [w / kg] increases. As a result, the magnetic flux density decreases. That is, when the collar 110 is pushed into the end face plate 108 and the rotor core 104 with a high load, the electromagnetic steel plate 114 is strongly compressed, and thus there is a problem that the magnetic characteristics of the rotor core 104 deteriorate. This leads to a decrease in the performance of the rotating electrical machine.

  Therefore, the present invention has been made in consideration of such problems, and an end plate made of a nonmagnetic material that covers the axial end surface of the rotor iron core can be manufactured at a low cost while suppressing a decrease in the performance of the rotating electrical machine. An object of the present invention is to provide a rotor of a rotating electrical machine that can be fixed with a simple structure, improve the efficiency of the rotating electrical machine, improve the reliability, and reduce the cost, and a method for manufacturing the same. .

[1] The rotor of the rotating electrical machine according to the first aspect of the present invention is:
Rotor core,
A shaft,
An end plate made of a non-magnetic material that covers the axial end surface of the rotor core;
A retainer for sandwiching the end plate from both axial sides together with the rotor core;
A rotor of a rotating electric machine with
The linear expansion coefficient of the retainer is substantially equal to the linear expansion coefficient of the shaft,
The retainer has a hardness higher than that of the end plate,
One or more convex portions are formed on the end surface of the retainer on the end plate side,
The retainer is fixed to the shaft in a state where at least a top portion of the convex portion of the retainer is located on an inner side of an outer surface of an end surface of the end plate on the retainer side.

  In addition, as a convex part, a convex part with a dotted | punctate top part, a convex part etc. with which a top part extends linearly etc. are mentioned.

  Thereby, it can suppress that an end plate slips with respect to a rotor iron core and a shaft, when the convex part of a retainer bites into the end surface of an end plate, or forms meshing | engagement.

  Therefore, compared to the case where the end plate is locked (fixed) only by the frictional force generated by applying a pressing load (vertical load) to the end plate, the pressing load required for locking the end plate (fixed) Is small.

  Therefore, the compressive stress applied to the rotor core can be reduced, and deterioration of the magnetic characteristics of the rotor core can be suppressed.

  In addition, since the end plate is made of a non-magnetic material and the end plate is fixed so as to cover the rotor core, the leakage flux that does not intermingle with the opposing stator of the magnetic flux generated in the rotor core is reduced. can do. For this reason, the efficiency of the rotating electrical machine can be improved and the reliability can be improved. In addition, since it is only necessary for the convex portion of the retainer to bite into or form a mesh with the end face of the end plate, an inexpensive and simple structure can be adopted, which can contribute to lowering the cost of the rotating electrical machine. it can.

[2] In the first aspect of the present invention, a plurality of convex portions may be intermittently formed along the circumferential direction on the end surface of the retainer. In addition, as for the convex part of a retainer, the convex part which the top part extends linearly in the radial direction is mentioned, and the linear shape includes an arc shape, a sine wave shape, a triangular wave shape, a rectangular wave shape, and the like.

  Thereby, it can suppress that an end plate slips with respect to a rotor iron core and a shaft, when the convex part of a retainer bites into the end surface of an end plate, or forms meshing | engagement. Further, in this case, since the plurality of convex portions of the retainer are intermittently formed along the circumference, the plurality of convex portions of the retainer are not unevenly distributed, and the average is scattered. Thus, the end plate can be stably fixed (stopped).

[3] In the first aspect of the present invention, one or more convex portions are formed on the retainer side end surface of the end plate, and the convex portion of the retainer deforms the convex portion of the end plate. May be. Examples of the convex portion of the end plate include a convex portion having a dot-like top portion and a convex portion having a linearly extending top portion, similar to the convex portion of the retainer.

  Since the convex portion of the retainer deforms the convex portion of the end plate, the convex portion of the retainer and the convex portion of the end plate are engaged with each other, and the end plate is stably fixed (rotated). be able to.

  As a method for deforming the convex portion of the retainer by the convex portion of the retainer, since the hardness of the retainer is higher than the hardness of the end plate, for example, the retainer and the end plate are opposed to each other. For example, the retainer may be pressed toward the end plate. In this case, since it is only necessary to deform the convex portion of the end plate, the end surface of the end plate is compared with the case where the end surface is a flat surface having no convex portion (that is, the convex portion of the retainer on the flat surface of the end plate). Compared with the case of biting in), a small pressing load is required, and the compressive stress applied to the rotor core can be reduced. That is, it is possible to further effectively reduce the compressive stress applied to the rotor core while preventing the end plate from rotating, and to suppress the deterioration of the magnetic characteristics of the rotor core.

[4] In [3], a plurality of convex portions may be intermittently formed on the end face of the end plate along a direction intersecting the circumferential direction. In addition, as for the convex part of an end plate, the convex part which the top part linearly extends in the circumferential direction is mentioned, and the linear shape includes an arc shape, a sine wave shape, a triangular wave shape, a rectangular wave shape, and the like.

  As a result, the convex portions of the retainer can form a mesh by deforming (plastically deforming) a plurality of convex portions formed intermittently along the direction intersecting the circumferential direction on the side surface of the end plate. Therefore, the mesh can be formed with a smaller pressing load than when the convex portion of the retainer bites into the flat end surface of the end plate.

  Further, in this case, the convex portion of the retainer is meshed by deforming the convex portion of the end plate. However, a plurality of convex portions are intermittently formed along the circumferential direction on the end surface of the retainer. For example, since the plurality of convex portions of the end plate are intermittently formed along the direction intersecting the circumferential direction, the plurality of convex portions of the retainer and the plurality of convex portions of the end plate are both unevenly distributed. There is no average and scattered form, and since the plurality of convex portions of the retainer deforms the plurality of convex portions of the end plate, the plurality of convex portions of the retainer and the plurality of convex portions of the end plate And the end plate can be stably fixed (rotated).

[5] In [4], the plurality of convex portions formed on the end face of the end plate may have an acute corner shape along the radial direction. When the retainer is pressed toward the end plate to form engagement between the convex portion of the retainer and the convex portion of the end plate, the pressing force from the retainer is concentrated on the sharp top of the convex portion of the end plate. Therefore, the convex part of the end plate can be plastically deformed with a smaller pressing load. That is, the meshing between the convex portion of the retainer and the convex portion of the end plate can be formed with a smaller pressing load.

[6] In the first aspect of the present invention, the retainer may have a shape that always generates a pressing load on the end plate. Thereby, for example, when the retainer is pressed toward the end plate using a pressing jig, the pressing load can be reduced.

[7] A method for manufacturing a rotor of a rotating electrical machine according to the second aspect of the present invention includes:
Rotor core,
A shaft,
An end plate made of a non-magnetic material that covers the axial end surface of the rotor core;
A retainer for sandwiching the end plate from both axial sides together with the rotor core;
A method for manufacturing a rotor of a rotating electrical machine comprising:
The linear expansion coefficient of the retainer is substantially equal to the linear expansion coefficient of the shaft,
The retainer has a hardness higher than that of the end plate,
A convex portion forming step of forming one or more convex portions on the end face of the retainer on the end plate side;
An end plate fixing step of applying a pressing load and press-fitting the retainer into the shaft so that at least a top portion of the convex portion of the retainer is positioned inside an outer surface of an end surface of the end plate on the retainer side; ,
It is characterized by providing.

  As a result, the rotor can be easily manufactured, and the end plate made of a non-magnetic material that covers the axial end surface of the rotor core is inexpensive and simple while suppressing a decrease in the performance of the rotating electrical machine. The structure can be fixed and the efficiency of the rotating electrical machine can be improved, the reliability can be improved, and the cost can be reduced.

[8] In the second aspect of the present invention, the convex portion forming step may intermittently form a plurality of convex portions along the circumferential direction on the end surface of the retainer. In this case, the plurality of convex portions of the retainer bite into the end surface of the end plate or form a mesh, thereby stably fixing (stopping) the end plate.

[9] In the second aspect of the present invention, the method further includes a second projecting portion forming step of forming one or more projecting portions on the end surface of the end plate on the retainer side, The pressing load may be applied so that the convex portion of the retainer deforms the convex portion of the end plate, and the retainer may be press-fitted into the shaft. In this case, since the convex portion of the retainer deforms the convex portion of the end plate, the convex portion of the retainer and the convex portion of the end plate are engaged with each other, and the end plate is stably fixed (rotated). Can be stopped).

[10] In [9], the second convex portion forming step may intermittently form a plurality of convex portions on the end surface of the end plate along a direction intersecting a circumferential direction. Good. In this case, the convex portions of the retainer can form a mesh by deforming (plastically deforming) a plurality of convex portions formed intermittently along the direction intersecting the circumferential direction on the side surface of the end plate. Therefore, the mesh can be formed with a smaller pressing load than when the convex portion of the retainer bites into the flat end surface of the end plate. Further, if a plurality of convex portions are intermittently formed along the circumferential direction on the end face of the retainer, the plurality of convex portions of the retainer and the plurality of convex portions of the end plate mesh with each other. Thus, the end plate can be stably fixed (stopped).

[11] In the second aspect of the present invention, the end plate fixing step includes applying the pressing load so that the convex portion of the retainer is positioned inside the outer surface of the end surface of the end plate, You may make it press-fit the said retainer to the said shaft, reducing a pressing load.

  Since the pressing load can be reduced after the meshing is formed by plastically deforming the side surfaces of the end plates, the compressive stress applied to the rotor core can be further reduced, further reducing the deterioration of the magnetic properties of the rotor core. Can be suppressed.

  As described above, according to the rotor of the rotating electrical machine according to the present invention, the end plate made of a non-magnetic material that covers the axial end surface of the rotor core is inexpensive, while suppressing a decrease in the performance of the rotating electrical machine, And it can fix with a simple structure, and can improve the efficiency of a rotary electric machine, the improvement of reliability, and cost reduction.

It is sectional drawing which shows the rotor of the rotary electric machine which concerns on this Embodiment. It is sectional drawing on the II-II line in FIG. 3A is a cross-sectional view taken along line IIIA-IIIA in FIG. 1, and FIG. 3B is a cross-sectional view taken along line IIIB-IIIB in FIG. It is a perspective view which shows the shape which each determined the retainer and the 2nd end plate from the 2nd end plate side. It is a perspective view which shows the shape which each judged the retainer and the 2nd end plate from the retainer side. FIG. 6A is a plan view showing the shape of the end face of the retainer, and FIG. 6B is a plan view showing the shape of the end face of the second end plate. FIG. 7A is a plan view showing another shape of the end face of the retainer, and FIG. 7B is a plan view showing another shape of the end face of the second end plate. FIG. 8A is an explanatory view showing a cross section along the circumferential direction in a state where the convex portion of the retainer and the convex portion of the second end plate are engaged, and FIG. 8B is a convex portion of the retainer and the convex portion of the second end plate. It is explanatory drawing which shows the cross section along the radial direction in the meshing state. It is a perspective view which partially fractures and shows the meshing state of the convex part of a retainer and the convex part of a 2nd end plate. It is sectional drawing which shows the rotor of the rotary electric machine which concerns on a 1st comparative example. It is sectional drawing which shows the rotor of the rotary electric machine which concerns on a 2nd comparative example. It is a flowchart which shows an example of the manufacturing method of the rotor of the rotary electric machine which concerns on this Embodiment. It is a flowchart which shows the other example of the manufacturing method of the rotor of the rotary electric machine which concerns on this Embodiment. In the manufacturing method shown in FIG. 13, it is a graph which shows the change of the pressing load in step S8-step S9 with the case of a prior art example. It is sectional drawing which shows the rotor of the rotary electric machine which concerns on a prior art example. It is sectional drawing on the XVI-XVI line in FIG.

  Embodiments of a rotor of a rotating electrical machine according to the present invention will be described below with reference to FIGS.

  As shown in FIG. 1, the rotor 10 of the rotating electrical machine according to the present embodiment (hereinafter referred to as the rotor 10) includes a rotor iron core 12, a rotor shaft 14, a permanent magnet 16, and one shaft of the rotor iron core 12. The first end plate 18A made of a nonmagnetic material covering the directional end surface, the second end plate 18B made of a nonmagnetic material covering the other axial end surface of the rotor core 12, and the second end plate 18B 12 and a retainer 20 sandwiched from both sides in the axial direction.

  The rotor shaft 14 has, for example, a flange-like abutment 22 integrally provided at a position near one end portion 14a. Therefore, the first end plate 18 </ b> A is sandwiched and fixed by the abutment 22 and the rotor core 12. Further, as will be described later, a recess 24 (a recess along the circumference) for fixing the retainer 20 by press-fitting (caulking) is provided at a position near the other end 14b of the rotor shaft 14. The rotor shaft 14 is configured to be able to transmit the torque of the engine and the motor by being connected to a crankshaft (not shown) of the engine, for example.

  The rotor core 12 is configured by laminating a large number of electromagnetic steel plates 26 along the axial direction of the rotor shaft 14. As shown in FIG. 2, each electromagnetic steel plate 26 has a substantially annular shape in which a central hole 28 through which the rotor shaft 14 is inserted is formed at the center. A part of the inner peripheral surface of each electromagnetic steel sheet 26 is provided with a projection 32 (phase alignment projection) that is inserted into a key groove 30 formed along the axial direction on the outer peripheral surface of the rotor shaft 14. . Further, in each electromagnetic steel plate 26, for example, a plurality of rectangular through holes 34 into which the permanent magnets 16 are inserted are arranged at equal intervals along the circumference at positions closer to the outer peripheral surface. Each through-hole 34 has a rectangular portion 34a and a notched portion 34b provided on the inner peripheral side of the rectangular portion 34a. The rectangular portion 34a is a component of the magnet housing hole 36 (see FIG. 1) for housing the permanent magnet 16, and the notched portion 34b is a hole (fixing agent injection hole) for injecting the magnet fixing agent 38. 40). In the example of FIG. 2, an example in which eight through holes 34 are formed is shown. However, the present invention is not limited to this, and six, sixteen, etc. through holes may be formed. When the center hole 28 of the rotor core 12, which has been crimped and laminated in advance with a large number of electromagnetic steel plates 26 aligned in phase, is inserted (press-fitted) into the rotor shaft 14, the center hole 28 of the rotor core 12 is provided. By inserting (press-fitting) the phase alignment protrusion 32 into the rotor shaft 14 while inserting it into the key groove 30 of the rotor shaft 14, the angular phases of the rotor core 12 and the rotor shaft 14 are matched. As a result, the corresponding through holes 34 of each electromagnetic steel sheet 26 are aligned in the axial direction, a plurality of magnet housing holes 36 are formed, and a plurality of fixing agent injection holes 40 are formed. The permanent magnet 16 is accommodated in each magnet accommodation hole 36, and the magnet fixing agent 38 is injected through each fixing agent injection hole 40, so that the permanent magnet 16 is fixed in the magnet accommodation hole 36.

  As shown in FIGS. 3A and 3B, each of the first end plate 18A and the second end plate 18B has a substantially annular shape in which a central hole 42 through which the rotor shaft 14 is inserted is formed at the center. It is slightly larger than the diameter of the electromagnetic steel plate 26 and has a size that covers the end surface of the rotor core 12 at the end surface on the rotor core 12 side. The end surfaces of the first end plate 18A and the second end plate 18B on the rotor core 12 side extend so that the surface direction is substantially orthogonal to the axial direction. Protrusions 44 (phase alignment protrusions) that are inserted into the key grooves 30 of the rotor shaft 14 are respectively provided on part of the inner peripheral surfaces of the first end plate 18A and the second end plate 18B.

As shown in FIG. 1, the retainer 20 extends in the axial direction and has a cylindrical portion 48 having a hollow portion 46 through which the rotor shaft 14 is inserted, and one end portion (second end plate) of the cylindrical portion 48. An annular portion 50 that extends in a direction substantially orthogonal to the axial direction from the end portion on the 18B side) is integrally formed. Further, as shown in FIG. 1, the retainer 20 is fixed by press-fitting (caulking) a part of the cylindrical portion 48 into the recess 24 of the rotor shaft 14. Therefore, it is preferable that the retainer 20 has a linear expansion coefficient substantially equal to the linear expansion coefficient of the rotor shaft 14. Here, “substantially equal” is a preferable range for press-fitting, for example, when the linear expansion coefficient of the retainer 20 is Ka and the linear expansion coefficient of the rotor shaft 14 is Kb,
0.9Kb ≦ Ka ≦ 1.1Kb
Range.

  In the present embodiment, as shown in FIGS. 4 and 5, the end surface 20a of the retainer 20 on the second end plate 18B side (the end surface of the annular portion 50 on the second end plate 18B side) is 1 The above convex part 52 is formed. The retainer 20 is fixed to the rotor shaft 14 with at least the top 52a of the convex portion 52 of the retainer 20 positioned on the inner side of the outer surface of the end surface 18a on the retainer 20 side of the second end plate 18B. "At least the top 52a of the convex part 52 of the retainer 20 is located on the inner side of the outer surface of the end surface 18a on the retainer 20 side of the second end plate 18B" means that at least the top part 52a of the convex part 52 of the retainer 20 is For example, the state which bites into or meshes with the outer surface of the end face 18a of the second end plate 18B is shown. Therefore, the hardness of the retainer 20 is preferably higher than the hardness of the second end plate 18B.

  Therefore, in the present embodiment, for example, the rotor shaft 14 is made of an SC material (carbon steel for mechanical structure), and the second end plate 18B (first end plate 18A) is a nonmagnetic material such as an aluminum material or a stainless material. The retainer 20 is made of, for example, a SUP material (spring steel material). This is an example, and any combination of materials may be used as long as the above conditions are satisfied. For example, the second end plate 18B can be made of an aluminum material having a hardness of about HRB50, and the retainer 20 can be made of a SUP material having a hardness of about HRB95.

  As described above, one or more convex portions 52 are formed on the end surface 20a of the retainer 20, but one or more convex portions 54 are also formed on the end surface 18a on the retainer 20 side of the second end plate 18B. Also good.

  Here, FIG. 6A to FIG. 9 show preferred specific examples of one or more convex portions 52 formed on the end surface 20a of the retainer 20 and one or more convex portions 54 formed on the end surface 18a of the second end plate 18B. The description will be given with reference.

  As shown in FIGS. 4, 5, and 6 </ b> A, a plurality of convex portions 52 are intermittently formed on the end surface 20 a of the retainer 20 along the circumferential direction. In FIG. 6A, the top part 52a of the convex part 52 is shown with a dashed-dotted line, and the collar part (valley part) is shown with a broken line. In the example of FIGS. 4, 5, and 6 </ b> A, an example in which 16 convex portions 52 are formed is shown, but this is only an example. Each convex part 52 has a shape in which the top part 52a extends linearly in the radial direction of the end face 20a, and is arranged at equal intervals in the circumferential direction. The linear shape may be a linear shape as shown in FIG. 6A, a sine wave shape as shown in FIG. 7A, or an arc shape, a triangular wave shape, a rectangular wave shape, or the like. The length of the top portion 52a in the radial direction is the same as the length of the end surface 20a in the radial direction or about 1 to 5 mm. The height ha (see FIG. 8A) of the top 52a is the same over the entire length of the top 52a, as shown in FIG. 4, for example. Of course, it may be gradually increased toward the outer periphery, or may be gradually increased toward the inner periphery. Further, the shape of the top portion 52a of the convex portion 52, particularly, the shape of the top portion 52a along the circumferential direction is an acute angle, an obtuse angle shape, or a curved shape as shown in FIG. The angle is set to ° to 100 °. Although the preferred range of dimensions depends on the radius of the annular portion 50 of the retainer 20, for example, the apex angle θa of the apex portion 52a is 20 ° to 100 °, and the height ha of the convex portion 52 is 0.2 to 1. 0.0 mm, and the arrangement pitch Pa is 5 ° to 15 ° in the central angle (see FIG. 6A). As an example, the apex angle θa of the apex 52a is 60 °, and the height ha of the convex portion 52 is 0.5 mm. An arrangement pitch Pa of 10 ° or the like can be employed.

  On the other hand, as shown in FIGS. 4, 5 and 6B, a plurality of convex portions 54 are intermittently formed on the end surface 18a of the second end plate 18B along the direction intersecting the circumferential direction. . In FIG. 6B, the top part 54a of the convex part 54 is shown with a dashed-dotted line, and the ridge part (valley part) is shown with a broken line. 4, 5 and 6B show the end surface 18a of the second end plate 18B before the convex portion 52 of the retainer 20 bites into or meshes with the three convex portions along the direction orthogonal to the circumferential direction. The example which formed the part 54 is shown. Each convex portion 54 has a shape (circular shape) in which the top portion 54a extends linearly in the circumferential direction of the end face 18a, and is arranged at equal intervals in the radial direction. As the linear shape, in addition to the circular shape shown in FIG. 6B, a shape in which a sine wave is drawn along the circumference as shown in FIG. 7B may be used, and other shapes such as an arc shape, a triangular wave shape, and a rectangular wave shape may be used. The shape drawn along may be sufficient. The circumferential length of the top portion 54a is the same as the circumferential length where the top portion 54a is located. The height hb (see FIG. 8B) of the top 54a is the same over the circumference as shown in FIG. 5, for example. Further, the shape of the top 54a of the convex portion 54, in particular, the shape of the top 54a along the direction orthogonal to the circumferential direction is an acute angle, an obtuse angle, or a curved shape as shown in FIG. 8B. The angle θb is set to 20 ° to 100 °. Although the preferred range of dimensions depends on the radius of the second end plate 18B, for example, the apex angle θb of the apex 54a is 20 ° to 100 °, and the height hb of the convex 54 is 0.5 to 1.5 mm. The arrangement pitch Pb (see FIG. 8B) may be 0.5 to 1.5 mm. As an example, the apex angle θb of the top portion 54a is 60 °, the height hb of the convex portion 54 is 0.87 mm, and the arrangement pitch Pb 1.0 mm or the like can be adopted.

  Then, the end surface 20a of the retainer 20 is opposed to the end surface 18a of the second end plate 18B attached to the rotor shaft 14, and the retainer 20 is pressed toward the second end plate 18B, thereby FIG. As shown, the portion of the convex portion 54 of the second end plate 18B that faces the convex portion 52 of the retainer 20 is plastically deformed to the rotor core 12 side, and at the top 54a of the convex portion 54 of the second end plate 18B. The shape in the direction orthogonal to the circumferential direction is bent toward the rotor core 12 side. That is, a part of the convex portion 52 of the retainer 20 bites into the convex portion 54 of the second end plate 18B, and the convex portion 52 of the retainer 20 and the convex portion 54 of the second end plate 18B mesh with each other.

  As a result, the retainer 20 and the second end plate 18B are integrated, and the second end plate 18B rotates together with the retainer 20. As a result, the vertical load (pressing load) for the purpose of preventing the rotation of the second end plate 18B can be reduced. That is, the convex portion 52 of the retainer 20 is engaged with the convex portion 54 of the second end plate 18B, thereby preventing the second end plate 18B from idling with respect to the rotor core 12 and the rotor shaft 14. In addition, the second end plate 18B can be stably fixed (rotated).

  Accordingly, the second end plate 18B is prevented from rotating (fixed) only by the frictional force generated by applying a pressing load (vertical load) to the second end plate 18B. The pressing load required for detent (fixing) is small.

  Furthermore, in this Embodiment, as shown to FIG. 8B, the top part 54a of the convex part 54 protrudes in the retainer 20 side rather than the virtual surface 18c which extended the flat surface 18b of the outer peripheral part. Thereby, the convex part 52 of the retainer 20 and the convex part 54 of the 2nd end plate 18B can be meshed | engaged with a small pressing load. In this case, the outer surface of the end surface 18a of the second end plate 18B refers to the surface 18d configured by at least the top portion 54a of the convex portion 54.

  From this, the compressive stress applied to the rotor core 12 can be reduced, and the deterioration of the magnetic characteristics of the rotor core 12 can be suppressed.

  Further, since the first end plate 18A and the second end plate 18B are made of a nonmagnetic material, and the first end plate 18A and the second end plate 18B are fixed so as to cover the rotor core 12, the rotor core Among the magnetic fluxes generated at 12, the leakage magnetic flux not intermingled with the opposing stator (not shown) can be reduced. For this reason, the efficiency of the rotating electrical machine can be improved and the reliability can be improved. Further, since it is only necessary to form a mesh between the convex portion 52 of the retainer 20 and the convex portion 54 of the second end plate 18B, an inexpensive and simple structure can be adopted, and the cost of the rotating electrical machine can be reduced. Can also contribute.

  Here, two comparative examples (first comparative example) will be described with reference to FIGS. 10 and 11.

  As shown in FIG. 10, in the rotor 200A according to the first comparative example, the end surface 18a of the second end plate 18B does not have the convex portion 54 and is a flat surface, and the end surface 20a of the retainer 20 is also convex. It differs from the rotor 10 according to the present embodiment in that the portion 52 does not exist and is a flat surface.

  In the first comparative example, a part of the cylindrical portion 48 of the retainer 20 is press-fitted and fixed in a state where the second end plate 18B is pressed in the axial direction so as to compress the rotor core 12. At this time, since the rotor iron core 12 is configured by laminating a large number of electromagnetic steel plates 26, the rotor iron core 12 acts like a compressed spring, and the second end plate 18B is pressed against the rotor iron core 12 and the retainer 20. It is sandwiched with force and is firmly fixed and held. However, in order to compress the rotor core 12 strongly, it turned out that there exists a problem of reducing the magnetic characteristic of the rotor core 12 (many electromagnetic steel plates 26).

  As shown in FIG. 11, the rotor 200 </ b> B according to the second comparative example has substantially the same configuration as the rotor 100 according to the conventional example shown in FIG. 15, but a wave washer 202 is provided between the end face plate 108 and the collar 110. The end face plate 108 is fixedly held by giving a pressing force to the end face plate 108 by being sandwiched. However, it has been found that there are problems that the number of parts increases and the holding force for fixing the end face plate 108 (the force for suppressing idling of the end face plate) is low.

  In contrast, in the rotor 10 according to the present embodiment, as described above, the convex portion 54 of the second end plate 18B and the convex portion 52 of the retainer 20 mesh with each other, so that a resistance force in the rotation direction is generated. In addition, since the anti-rotation effect of the second end plate 18B is exhibited and the idling of the second end plate 18B is suppressed, it is not necessary to press the second end plate 18B and the retainer 20 with a frictional force due to a vertical load. . Therefore, it is sufficient to apply a vertical load (pressing load) sufficient to ensure the frictional force between the rotor core 12 and the second end plate 18B, and the pressing load is significantly larger than that of the first comparative example and the second comparative example. Can be reduced.

  Next, a method for manufacturing the rotor 10 according to the present embodiment will be described with reference to the flowchart of FIG.

  First, in step S1 of FIG. 12, when producing the 2nd end plate 18B, for example by press punching, the some convex part 54 is formed in the end surface 20a of the 2nd end plate 18B. Of course, after the second end plate 18B (the convex portion 54 is not formed) is produced by press punching, the convex portion 54 may be formed on the end surface 18a of the second end plate 18B, for example, by press molding. .

  In step S2, when producing a retainer by press molding, for example, the plurality of convex portions 52 are formed on the end surface 20a of the retainer 20. Of course, after producing the retainer 20 (the convex portion 52 is not formed) by press molding, the convex portion 52 may be formed on the end surface 20a of the annular portion 50 of the retainer 20, for example, by press molding. .

  In step S3, as shown in FIG. 1, the rotor shaft 14 is inserted through the center hole 42 of the first end plate 18A. At this time, as shown in FIG. 3A, the rotor shaft 14 is inserted while the protrusions 44 provided on the inner periphery of the first end plate 18 </ b> A are inserted into the key grooves 30 of the rotor shaft 14.

  Thereafter, in step S4, the center hole 28 of the rotor core 12 in which a large number of electromagnetic steel plates 26 are caulked and laminated in a state where the phases are aligned in advance is inserted (press-fitted) into the rotor shaft 14. At this time, as shown in FIG. 2, the phase adjustment protrusion 32 provided in the center hole 28 of the rotor core 12 is inserted (press-fitted) into the rotor shaft 14 while fitting into the key groove 30 of the rotor shaft 14. As a result, the angular phases of the rotor core 12 and the rotor shaft 14 are matched.

  Thereafter, in step S5, the permanent magnets 16 are respectively accommodated in the magnet accommodation holes 36 formed by stacking a large number of electromagnetic steel plates 26, and the permanent magnets 16 are injected by injecting the magnet fixing agent 38 through the fixing agent injection holes 40. Fix it.

  Thereafter, in step S6, the rotor shaft 14 is inserted through the center hole 42 of the second end plate 18B. At this time, as shown in FIG. 3B, the rotor shaft 14 is inserted while the protrusions 44 provided on the inner periphery of the second end plate 18 </ b> B are inserted into the key grooves 30 of the rotor shaft 14. Thereby, the laminated body by 18 A of 1st end plates, the rotor core 12, and the 2nd end plate 18B is comprised.

  Thereafter, in step S <b> 7, the rotor shaft 14 is inserted into the hollow portion 46 of the cylindrical portion 48 of the retainer 20. At this time, the convex portion 54 of the second end plate 18B and the convex portion 52 of the retainer 20 face each other.

  Thereafter, in step S8, the annular portion 50 of the retainer 20 is moved using a pressing jig (not shown) such that the above-described laminate is sandwiched between the abutment 22 of the rotor shaft 14 and the annular portion 50 of the retainer 20, for example. Press against the second end plate 18B side. At this time, since the hardness of the retainer 20 is higher than the hardness of the second end plate 18B, the portion of the convex portion 54 of the second end plate 18B facing the convex portion 52 of the retainer 20 is plastic on the rotor core 12 side. As a result, the shape of the top portion 54a of the convex portion 54 of the second end plate 18B in the direction orthogonal to the circumferential direction is bent toward the rotor core 12 side. As a result, a part of the convex portion 52 of the retainer 20 bites into the convex portion 54 of the second end plate 18B, and the convex portion 52 of the retainer 20 and the convex portion 54 of the second end plate 18B mesh with each other. At least the top part 52a of the part 52 is in a state located on the inner side of the outer surface on the end face 18a side of the second end plate 18B.

  Thereafter, in step S9, in the above-described state (at least the top portion 52a of the convex portion 52 of the retainer 20 is located inside the outer surface on the end surface 18a side of the second end plate 18B), the cylindrical portion 48 of the retainer 20 The retainer 20 is fixed by press-fitting (caulking) the portion 48 a into the recess 24 of the rotor shaft 14.

  Thereby, while being able to manufacture the rotor 10 easily, the 2nd end plate 18B which consists of a nonmagnetic material which covers the axial direction end surface of the rotor iron core 12 is inexpensive, suppressing the fall of the performance of a rotary electric machine. And it can fix with a simple structure, and can improve the efficiency of a rotary electric machine, the improvement of reliability, and cost reduction.

  In addition, it is possible to prevent the second end plate 18B from idling with respect to the rotor core 12 and the rotor shaft 14 by meshing the convex portion 52 of the retainer 20 with the convex portion 54 of the second end plate 18B. In addition, since the second end plate 18B can be stably fixed (rotated), as shown in FIGS. 13 and 14, after the pressing load is applied in step S8, the pressing is performed in step S8a. After the load is reduced, the retainer 20 may be fixed in step S9, and the rotor core 12 and the second end plate 18B may be held by the frictional force due to the reduced pressing load. In step S8a described above, as shown in FIG. 14, from the pressing load P1 applied in step S8 (the pressing load for meshing the convex portion 52 of the retainer 20 and the convex portion 54 of the second end plate 18B), for example, The vertical load P2 (pressing load) up to the minimum vertical load P3 (pressing load) that can hold the rotor core 12 and the second end plate 18B with frictional force, or the pressing load increased by 1 to 10% thereof. Minutes may be reduced (P1> P2> P3). In addition, although the vertical load P4 (pressing load) by the rotor which concerns on a prior art example is shown with a broken line, although the pressing load P1 in step S8 is 3/5-4/5 of the conventional pressing load P4, in step S8a The conventional pressing load P4 can be reduced to 1/5 to 2/5.

  Further, the shape of the retainer 20, particularly the shape of the annular portion 50, is a shape that always applies a pressing load to the second end plate 18 </ b> B, for example, a disc spring shape (the outer peripheral portion of the annular portion 50 is more than the inner peripheral portion. When the retainer 20 is caulked and fixed and the pressing jig is released, the pressing load applied by the pressing jig between the second end plate 18B and the rotor core 12 is determined. In addition to this, since a pressing load is applied by the annular portion 50 (disc spring shape) of the retainer 20, the pressing load by the pressing jig can be further reduced in step S8a.

  In addition, the convex part 52 of the retainer 20 mentioned above does not need to be formed over the radial direction full length of the annular part 50, and if it is formed in the position corresponding to the formation area of the convex part 54 of the 2nd end plate 18B at least. Good.

  Further, the number of convex portions 52 may be one or two. However, if there is a problem with the stability during pressing, three or more, preferably four or more convex portions 52 are evenly arranged in order to easily apply a load to the second end plate 18B. It is preferable.

  Similarly, the number of the convex portions 52 of the second end plate 18B may be only one circular convex portion 54 formed in a linear shape of the top portion 54a, or a convex portion having a short length in the circumferential direction. There may be only one 54. Of course, the convex part 54 does not exist and may be a flat surface. In this case, the convex part 52 of the retainer 20 functions as a detent by the biting into the flat surface. However, when the end surface 18a of the second end plate 18B is a flat surface, the pressing load becomes larger than the configuration of the present embodiment described above. That is, in the present embodiment, it is only necessary to deform the convex portion 54 of the second end plate 18B, so that the end surface 18a of the second end plate 18B is a flat surface where the convex portion 54 does not exist. In other words, a smaller pressing load is required and the compressive stress applied to the rotor core 12 can be reduced as compared with the case where the convex portion 52 of the retainer 20 is bitten into the flat surface of the second end plate 18B.

  The rotor of the rotating electrical machine according to the present invention is not limited to the above-described embodiment, and it is needless to say that various configurations can be adopted without departing from the gist of the present invention.

DESCRIPTION OF SYMBOLS 10 ... Rotor 12 ... Rotor iron core 14 ... Rotor shaft 16 ... Permanent magnet 18A ... 1st end plate 18B ... 2nd end plate 20 ... Retainer 20a ... End surface (end surface by the side of a 2nd end plate)
22 ... Butt 24 ... Dimple (for caulking)
26 ... Electromagnetic steel sheet 48 ... Cylinder part 50 ... Ring part 52 ... Convex part (retainer)
52a ... Top 54 ... Convex (second end plate)
54a ... top

Claims (11)

Rotor core,
A shaft,
An end plate made of a non-magnetic material that covers the axial end surface of the rotor core;
A retainer for sandwiching the end plate from both axial sides together with the rotor core;
A rotor of a rotating electric machine with
The linear expansion coefficient of the retainer is substantially equal to the linear expansion coefficient of the shaft,
The retainer has a hardness higher than that of the end plate,
One or more convex portions are formed on the end surface of the retainer on the end plate side,
The retainer is fixed to the shaft in a state where at least a top portion of the convex portion of the retainer is located on an inner side of an outer surface of an end surface of the end plate on the retainer side. Rotor. The rotor of the rotating electrical machine according to claim 1,
A rotor of a rotating electrical machine, wherein a plurality of convex portions are intermittently formed along a circumferential direction on the end surface of the retainer. In the rotor of the rotating electrical machine according to claim 1 or 2,
One or more convex portions are formed on the end surface of the end plate on the retainer side,
The rotor of a rotating electrical machine, wherein the convex portion of the retainer deforms the convex portion of the end plate. The rotor of the rotating electrical machine according to claim 3,
A rotor of a rotating electrical machine, wherein a plurality of convex portions are intermittently formed on the end face of the end plate along a direction intersecting a circumferential direction. The rotor of the rotating electrical machine according to claim 4,
The plurality of convex portions formed on the end surface of the end plate has a sharp top shape along the radial direction. In the rotor of the rotating electrical machine according to any one of claims 1 to 5,
The retainer has a shape that always generates a pressing load against the end plate. Rotor core,
A shaft,
An end plate made of a non-magnetic material that covers the axial end surface of the rotor core;
A retainer for sandwiching the end plate from both axial sides together with the rotor core;
A method for manufacturing a rotor of a rotating electrical machine comprising:
The linear expansion coefficient of the retainer is substantially equal to the linear expansion coefficient of the shaft,
The retainer has a hardness higher than that of the end plate,
A convex portion forming step of forming one or more convex portions on the end face of the retainer on the end plate side;
An end plate fixing step of applying a pressing load and press-fitting the retainer into the shaft so that at least a top portion of the convex portion of the retainer is positioned inside an outer surface of an end surface of the end plate on the retainer side; ,
A method for manufacturing a rotor of a rotating electrical machine. In the manufacturing method of the rotor of the rotating electrical machine according to claim 7,
The convex portion forming step includes
A method of manufacturing a rotor of a rotating electrical machine, wherein a plurality of convex portions are intermittently formed along the circumferential direction on the end surface of the retainer. In the manufacturing method of the rotor of the rotary electric machine according to claim 7 or 8,
Furthermore, it has the 2nd convex part formation process which forms one or more convex parts in the end surface by the side of the retainer of the end plate,
In the end plate fixing step, the pressing load is applied so that the convex portion of the retainer deforms the convex portion of the end plate, and the retainer is press-fitted into the shaft. Method of manufacturing the rotor. In the manufacturing method of the rotor of the rotating electrical machine according to claim 9,
The method for producing a rotor of a rotating electrical machine, wherein the second convex portion forming step intermittently forms a plurality of convex portions on the end face of the end plate along a direction intersecting a circumferential direction. . In the manufacturing method of the rotor of the rotating electrical machine according to any one of claims 7 to 10,
In the end plate fixing step, after the pressing load is applied so that the convex portion of the retainer is positioned inside the outer surface of the end surface of the end plate, the pressing load is reduced, and the retainer is A method for manufacturing a rotor of a rotating electrical machine, wherein the shaft is press-fitted into the shaft.

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