JP2014147227A - Rotor for rotating electrical machine and method of manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a rotor for a rotating electrical machine and a method of manufacture thereof which ensure axial alignment of first and second rotary support members with a hollow rotor core part.SOLUTION: A hollow rotor core part 20 comprises a stack of electromagnetic steel sheets, has a cylindrical shape, forms gap surfaces on an inner circumferential surface and an outer circumferential surface, and has first bores 21 for tubular pins. A first rotary support member 30 has second bores 31 for tubular pins. A second rotary support member 40 has third bores 41 for tubular pins. Tubular pins 70 are inserted in the first bores 21, the second bores 31 and the third bores 41, flange portions 72 are formed at one end projecting from the second bores 31 of the first rotary support member 30, fitting portions 73 fit in the second bores 31, and tube expansion portions 74 are plastically deformed into close contact with the first bores 21, the second bores 31 and the third bores 41.

Description

  The present invention relates to a rotor of a rotating electrical machine having a cylindrical hollow rotor core portion and a method for manufacturing the same.

  In a rotating electrical machine, a rotor core portion fixed to a shaft is fixed using a flanged tubular member or the like as an example of a fastening method when two types of electromagnetic steel plates having different shapes are laminated (for example, Patent Literature 1). On the other hand, in the hollow rotor, it is necessary to ensure the coaxiality of the inner member and the outer member of the hollow rotor core, and it is necessary to improve the accuracy of the shaft center. For example, as a method of fixing a hollow rotor with a winding rotor on the inside and a winding stator on the outside, a hole is provided in the hollow rotor core, tightened with bolts and nuts, and cylindricity with axial tightening force Was secured.

JP 2005-102460 A

  By the way, in the case of forming a hollow rotor core portion by laminating electromagnetic steel plates, the hollow rotor core portion is fixed between the first rotation support member and the second rotation support member, and the first and second rotation support members are provided. The accuracy of the axis of the member and the axis of the hollow rotor core part is required.

  An object of the present invention is to provide a rotor for a rotating electrical machine that can reliably align the shafts of a hollow rotor core portion and first and second rotation support members, and a method for manufacturing the same.

  In the first aspect of the present invention, a hollow rotor core portion that is configured by laminating electromagnetic steel sheets, has a cylindrical shape, has an inner peripheral surface and an outer peripheral surface as a gap surface, and has a first hole for a tubular pin; The second rotation support member having the second hole for the tubular pin and the third rotation member having the third hole for the tubular pin and sandwiching the hollow rotor core portion with the first rotation support member A flange member is formed at one end of the support member and inserted into the first hole, the second hole, and the third hole, and protrudes from the second hole, and is fitted into the second hole. The gist is provided with a mating portion and a tubular pin having a tube expansion portion plastically deformed so as to be in close contact with the first hole, the second hole, and the third hole.

  According to the first aspect of the present invention, the hollow rotor core portion is formed by laminating electromagnetic steel plates, has a cylindrical shape, and has an inner peripheral surface and an outer peripheral surface as a gap surface. Has holes. The hollow rotor core portion is sandwiched between the first rotation support member and the second rotation support member, and the tubular pin is the first hole of the hollow rotor core portion, the second hole of the first rotation support member, and the second It is inserted into the third hole of the rotation support member. A flange portion is formed at one end of the tubular pin protruding from the second hole. By fitting the fitting portion of the tubular pin into the second hole, the tubular pin and the second hole of the first rotation support member are aligned. In addition, the tube expansion portion is plastically deformed so as to be in close contact with the first hole, the second hole, and the third hole, so that the first hole of the tubular pin and the hollow rotor core portion and the second rotation support member 3 holes are aligned. Therefore, the shafts of the hollow rotor core portion and the first and second rotation support members can be reliably aligned.

  According to a second aspect of the present invention, in the rotor of the rotating electrical machine according to the first aspect, the first hole for the tubular pin and the permanent magnet embedded hole are alternately formed in the circumferential direction in the hollow rotor core portion. It is good to apply when it is.

  In the invention according to claim 3, a hollow rotor core part which is formed by laminating electromagnetic steel sheets, has a cylindrical shape, and has an inner peripheral surface and an outer peripheral surface as a gap surface, and has a first hole for a tubular pin; The second rotation support member having the second hole for the tubular pin and the third rotation member having the third hole for the tubular pin and sandwiching the hollow rotor core portion with the first rotation support member In a method of manufacturing a rotor of a rotating electrical machine including a support member, a tubular pin having a flange portion formed at one end is connected to a second hole of the first rotation support member, and a first hole of the hollow rotor core portion. A first step of inserting the fitting portion into the third hole of the second rotation support member so that the fitting portion is fitted to the second hole, and expanding the tube by plastic deformation by press-fitting the tubular expansion member. The second hole to be in close contact with the first hole, the second hole, and the third hole And extent, and summarized in that comprises a.

  According to the third aspect of the present invention, in the first step, the tubular pin having the flange portion formed at one end includes the second hole of the first rotation support member, the first hole of the hollow rotor core portion, The fitting portion is inserted into the third hole of the second rotation support member so as to fit the second hole. In the second step, the tubular pin is expanded by plastic deformation by press-fitting the expanded member, and is brought into close contact with the first hole, the second hole, and the third hole. As a result, the rotor of the rotating electrical machine according to claim 1 can be manufactured.

  According to the present invention, the shafts of the hollow rotor core portion and the first and second rotation support members can be reliably aligned.

The perspective view of the magnet rotor in embodiment. The exploded perspective view of a magnet rotor. (A) is a longitudinal cross-sectional view of a rotary electric machine, (b) is a longitudinal cross-sectional view in the AA line of (a). The partially expanded longitudinal cross-sectional view of a rotary electric machine. The partially expanded front view of a rotary electric machine. (A) is a longitudinal cross-sectional view of a rotary electric machine, (b) is a longitudinal cross-sectional view in the AA line of (a). The partially expanded longitudinal cross-sectional view of a rotary electric machine. Explanatory drawing of the tubular pin arrangement | positioning part of a rotary electric machine. Explanatory drawing of the tubular pin arrangement | positioning part of the rotary electric machine of another example. (A) is a longitudinal cross-sectional view of the rotary electric machine for a comparison, (b) is a longitudinal cross-sectional view in the AA line of (a). The disassembled perspective view of the magnet rotor for a comparison.

DESCRIPTION OF EXEMPLARY EMBODIMENTS Hereinafter, an embodiment of the invention will be described with reference to the drawings.
As shown in FIG. 3, the rotating electrical machine 1 includes a magnet rotor 10 as a rotor, a winding stator 100, and a winding rotor 110. The magnet rotor 10 has a cylindrical shape, and a cylindrical winding stator 100 is disposed on the outer side of the magnet rotor 10 via a gap (magnetic gap). Further, a cylindrical winding rotor 110 is disposed inside the magnet rotor 10 with a gap (magnetic gap) interposed therebetween. The magnet rotor 10, the winding stator 100, and the winding rotor 110 are arranged coaxially. The magnet rotor 10 is connected to the output shaft (or input shaft) of the vehicle, and the winding rotor 110 is connected to the input shaft (output shaft).

  A plurality of slots 102 are formed in the core portion 101 of the winding stator 100 side by side in the circumferential direction, and each slot 102 opens on the inner peripheral surface of the cylindrical core portion 101. A coil 103 is inserted into the slot 102. A plurality of slots 112 are arranged in the circumferential direction in the core portion 111 of the winding rotor 110, and each slot 112 is open to the outer peripheral surface of the cylindrical core portion 111. A coil 113 is inserted into the slot 112.

  As shown in FIGS. 1 and 2, the magnet rotor 10 includes a hollow rotor core part (magnet rotor core part) 20, a first rotation support member 30, a second rotation support member 40, and a first end plate 50. The second end plate 60 and a plurality (specifically, eight) tubular pins 70 are provided. The hollow rotor core portion 20 is configured by laminating electromagnetic steel plates in the axial direction, and has a cylindrical shape. As for the hollow rotor core part 20, an inner peripheral surface and an outer peripheral surface become a gap surface. The hollow rotor core portion 20 has eight first holes 21 and eight permanent magnet embedded holes 22 for tubular pins. The first hole 21 and the permanent magnet embedded hole 22 extend (penetrate) in the axial direction. The eight first holes 21 are formed at an equal angle in the circumferential direction. In the hollow rotor core portion 20, first holes 21 for tubular pins and permanent magnet embedded holes 22 are alternately formed in the circumferential direction. Further, a permanent magnet 25 having a rectangular cross section is fitted into the permanent magnet embedded hole 22 having a rectangular cross section, thereby constituting a permanent magnet embedded rotor.

  The first rotation support member 30 has a bowl shape and has a shaft portion 30a at the center. In the opening in the bowl-shaped first rotation support member 30, the circumferential portion 30b has eight second holes 31 for tubular pins. The second rotation support member 40 has a bowl shape, and the central portion has a through hole 40a. In the opening portion of the bowl-shaped second rotation support member 40, the circumferential portion 40b has eight third holes 41 for tubular pins. The hollow rotor core portion 20 is sandwiched between the first rotation support member 30 and the second rotation support member 40.

  The first end plate 50 has a disk shape and has eight through holes 51 for tubular pins. The first end plate 50 is disposed between the first rotation support member 30 and the hollow rotor core portion 20. The second end plate 60 has a disk shape and has eight through holes 61 for tubular pins. The second end plate 60 is disposed between the second rotation support member 40 and the hollow rotor core portion 20.

  The tubular pin 70 is made of stainless steel (for example, SUS304). As shown in FIGS. 2 and 4, the main body 71 of the tubular pin 70 includes the second hole 31 of the first rotation support member 30, the through hole 51 of the first end plate 50, and the first of the hollow rotor core part 20. Of the second end plate 60, and the third hole 41 of the second rotation support member 40. The tubular pin 70 includes a flange portion 72, a fitting portion 73 (see FIG. 8), a pipe expanding portion 74, and a caulking portion 76. A flange portion 72 having a diameter larger than that of the main body portion 71 is formed at one end of the main body portion 71, and the flange portion 72 is formed at one end protruding from the second hole 31 of the first rotation support member 30. The fitting portion 73 is formed on one end side of the main body portion 71 and is fitted in the second hole 31 of the first rotation support member 30. Thereby, the positions of the tubular pin 70 and the second hole 31 of the first rotation support member 30 are aligned.

  The pipe expansion part 74 is a pipe expansion member so as to be in close contact with the first hole 21 of the hollow rotor core part 20, the second hole 31 of the first rotation support member 30, and the third hole 41 of the second rotation support member 40. It is plastically deformed by press-fitting (reference numeral 150 in FIG. 7). Thereby, the position of the 1st hole 21 of the tubular pin 70, the hollow rotor core part 20, and the 3rd hole 41 of the 2nd rotation support member 40 is in alignment. A caulking portion 76 having a diameter larger than that of the main body portion 71 is formed at the other end of the main body portion 71, and the caulking portion 76 is formed by folding back at an end portion protruding from the third hole 41 of the second rotation support member 40. And has a flange shape. Thereby, it is fastened in the axial direction.

  As shown in FIG. 5, each width (bridge width) of a portion (bridge portion) between the first hole 21 through which the tubular pin 70 in the hollow rotor core portion 20 passes and the inner peripheral surface and the outer peripheral surface of the hollow rotor core portion 20. ) D1 and D1 are smaller than structures (FIGS. 10 and 11) that are fastened with bolts and nuts described later.

Next, the operation of the rotor (magnet rotor 10) of the rotating electrical machine configured as described above will be described.
In the manufacturing process, as shown in FIGS. 6 and 7, the tubular pin 70 having the flange portion 72 formed at one end is connected to the second hole 31 of the first rotation support member 30 and the through hole of the first end plate 50. 51, the first hole 21 of the hollow rotor core portion 20, the through hole 61 of the second end plate 60, and the third hole 41 of the second rotation support member 40. At this time, the fitting portion 73 of the tubular pin 70 is inserted so as to fit into the second hole 31 of the first rotation support member 30.

  In other words, a pipe-shaped tubular pin 70 is prepared, and one end of the tubular pin 70 has a flange shape, and contacts the surface around the opening of the second hole 31 of the first rotation support member 30. Moreover, as shown in FIG. 8, the base part of the flange part 72 in the tubular pin 70 is the fitting part 73, and can be assembled to the second hole 31 of the first rotation support member 30 with a clearance fit. Thus, a stepped portion (tapered portion) 75 is provided. The right part of the stepped portion 75 is fitted into the right part of the second hole 31. As a result, the positions of the tubular pin 70 and the second hole 31 of the first rotation support member 30 are aligned. Further, in the pin insertion state (before caulking) shown in FIG. Exists.

  After that, the tubular expansion member 150 shown in FIG. 7 is axially pressed into the tubular pin 70 from the side where the flange portion 72 of the tubular pin 70 is formed, and the tubular pin 70 is plastically deformed by press-fitting the tubular expansion member 150. The pipe is expanded from the inner diameter side of 70. As a result, the outer peripheral surface of the tubular pin 70, the second hole 31 of the first rotation support member 30, the first hole 21 of the hollow rotor core portion 20, and the third hole 41 of the second rotation support member 40 are formed. Adhere closely.

  More specifically, in the state in which the pipe-shaped tubular pin 70 is inserted, the outer diameter D of the tube expansion member (tube expansion jig) 150 is smaller than the d value with respect to the inner diameter d of the tubular pin 70 as shown in FIG. (D> d). The tube expansion member 150 can be inserted into the tubular pin 70. The tubular pin 70 can be expanded by press-fitting the tubular expansion member 150 into the tubular pin 70. At this time, it is preferable to expand the tube at the same time for all eight tubular pins 70.

  By this expansion, the positions of the tubular pin 70, the first hole 21 of the hollow rotor core portion 20, and the third hole 41 of the second rotation support member 40 are aligned. Therefore, the rotation support members 30 and 40 on both sides of the hollow rotor core portion 20 and the inner and outer diameters of the hollow rotor core portion 20 can be secured coaxially. That is, the axis of the hollow rotor core portion 20 when viewed from the winding rotor 110 and the axis of the hollow rotor core portion 20 when viewed from the winding stator 100 are coaxial.

  After the end of the pipe expansion, as shown in FIG. 4, the end portion of the tubular pin 70 on the second rotation support member 40 side is molded and deformed into a flange shape to form a caulking portion 76. That is, the other end of the tubular pin 70 is formed into a flange shape by caulking a portion protruding from the second rotation support member 40 after the tube expansion.

As a result, as shown in FIG. 1, the assembly of the magnet rotor is completed.
In this manner, the hollow rotor core portion 20 and the tubular pin 70 can be brought into an interference fit state by the expansion of the tubular pin 70 by the press-fitting of the tube expansion member 150, and the cylindricity of the hollow rotor core portion 20 can be ensured. Moreover, rotational torque can also be received by all the tubular pins 70.

  10 and 11 are diagrams for comparison, and show a structure when a magnetic steel sheet is fastened using bolts and nuts. Bolt through-holes 201 are formed in the hollow rotor core portion 200, and bolts 250 are passed through the through-holes 201 and fastened using nuts 251 and 252 from both sides. In this case, it was necessary to maintain a large bridge width (d1 value and D1 value in FIG. 5) in order to ensure the rotational strength.

  That is, when positioning the rotor assembly, if all the bolts are made to be reamer bolts, the bolts cannot be inserted into the bolt through holes of the core part due to the processing accuracy of the core part. For this reason, a method is adopted in which only two bolts on the diagonal are positioned as reamer bolts. Since this structure has a large number of points even with only the fastening parts, it requires a lot of assembly man-hours and costs. Moreover, in order to ensure the seat surface of a nut, it is necessary to enlarge the inner-outer diameter difference of a core part, or to make small the screw size of a nut. Furthermore, it is desirable to reduce the width (bridge width) of each portion (bridge portion) between the bolt through hole and the inner and outer peripheral surfaces of the core portion in order to increase the magnetic characteristics of the motor. From the viewpoint of securing the above-mentioned seating surface, it becomes wider.

  On the other hand, in this embodiment, the three-part configuration of the bolt 250 and the nuts 251 and 252 in the comparative example is one part. Therefore, the cost can be reduced. Further, the diameter of the pin flange portion 72 in this embodiment can be set to the minimum necessary, and can be made smaller than the bearing surface diameter of the nuts 251 and 252 in the comparative example. Therefore, the width of the hollow rotor core portion 20, that is, the inner / outer diameter difference ΔW in FIG. 5 can also be reduced. Thereby, the hollow rotor core part 20 can be reduced in size in the radial direction. In addition, the loose fit can be eliminated by expanding the tubular pin 70 so as to achieve an accurate positioning.

  Furthermore, residual stress is applied to the hollow rotor core portion 20 formed by laminating electromagnetic steel sheets by pipe expansion, so that the magnetic resistance can be increased, and as a result, the same effect as that of reducing the bridge width can be exhibited. Can do. In other words, in order to increase the magnetic characteristics of the motor, it is possible to ensure the motor characteristics by increasing the magnetic resistance by giving the electromagnetic steel sheet a residual stress by adopting a tube expansion structure.

  For example, the magnetic steel sheet is compared with the case where there is no residual stress and the bridge width (d1 value, D1 value in FIG. 5) is 2 mm. By applying residual stress to the electromagnetic steel sheet as in this embodiment, the substantial bridge width (path width through which the short-circuit magnetic flux passes) can be set to 0.5 mm. In this way, the residual stress due to the interference fit due to the expansion of the electromagnetic steel sheet makes it possible to utilize the characteristic deterioration to make the area not to function as an electromagnetic steel sheet, so that the actual stress width is 1.5 mm even if the measured bridge width is 2 mm. In terms of performance, it is only 0.5 mm. Therefore, it is possible to realize a dimension that cannot be produced by manufacturing, thereby making it difficult for the short-circuit magnetic flux to pass.

According to the above embodiment, the following effects can be obtained.
(1) As a configuration of the magnet rotor 10 as a rotor of the rotating electrical machine, the tubular pin 70 includes a first hole 21 of the hollow rotor core portion 20, a second hole 31 of the first rotation support member 30, a second It is inserted into the third hole 41 of the rotation support member 40. In the tubular pin 70, a flange portion 72 is formed at one end protruding from the second hole 31. The fitting portion 73 of the tubular pin 70 is fitted into the second hole 31, and the tube expansion portion 74 is plastically deformed so as to be in close contact with the first hole 21, the second hole 31, and the third hole 41. Thereby, the axis | shaft of the hollow rotor core part 20 and the 1st and 2nd rotation support members 30 and 40 can be match | combined reliably. That is, the accuracy of the axial centers of the first and second rotation support members 30 and 40 and the axial center of the hollow rotor core portion 20 is high. Also, the hollow rotor core portion 20 can be downsized in the radial direction without being fastened with bolts and nuts.

  (2) Residual stress is applied to the hollow rotor core portion 20 (laminate of electromagnetic steel sheets) by expanding the tubular pin 70. Thereby, the substantial bridge width (path width through which the short-circuit magnetic flux passes) in the magnetic circuit can be reduced, and a structure in which the short-circuit magnetic flux is difficult to pass can be obtained.

  (3) As a method for manufacturing a rotor (magnet rotor) of a rotating electrical machine, a first step and a second step are included. In the first step, the tubular pin 70 having the flange portion 72 formed at one end is connected to the second hole 31 of the first rotation support member 30, the first hole 21 of the hollow rotor core portion 20, and the second rotation support member. The fitting part 73 is inserted into the third hole 41 of the 40 so as to fit the second hole 31. In the second step, the tubular pin 70 is expanded by plastic deformation by press-fitting the expanded member 150 and is brought into close contact with the first hole 21, the second hole 31, and the third hole 41. Thereby, the magnet rotor 10 of the rotating electrical machine of the above (1) can be manufactured.

The embodiment is not limited to the above, and may be embodied as follows, for example.
As shown in FIG. 9, an enlarged diameter portion 32 (processed surface) is formed in the vicinity of the opening in the second hole 31 of the first rotation support member 30, and the tubular pin 70 is formed on the inner wall of the enlarged diameter portion 32. You may fit the fitting part 73 (processed surface). If the fit on the processed surface of the pin processed surface and the first rotary support member 30 is an intermediate fit, the shaft is more likely to come out.

Although the rotor (110) is provided inside the magnet rotor 10, a stator may be used.
-The area where the residual stress is applied by the expansion of the hollow rotor core (magnetic steel sheet) is arbitrary.

  DESCRIPTION OF SYMBOLS 10 ... Magnet rotor, 20 ... Hollow rotor core part, 21 ... 1st hole, 22 ... Permanent magnet embedding hole, 30 ... 1st rotation support member, 31 ... 2nd hole, 40 ... 2nd rotation support member , 41 ... third hole, 70 ... tubular pin, 72 ... flange portion, 73 ... fitting portion, 74 ... tube expanding portion.

Claims (3)

A hollow rotor core portion that is configured by laminating electromagnetic steel plates, has a cylindrical shape, and has an inner peripheral surface and an outer peripheral surface as a gap surface, and has a first hole for a tubular pin;
A first rotation support member having a second hole for a tubular pin;
A second rotation support member having a third hole for a tubular pin and sandwiching the hollow rotor core portion with the first rotation support member;
A flange portion is formed at one end that is inserted into the first hole, the second hole, and the third hole and protrudes from the second hole, and a fitting portion that fits into the second hole, and A tubular pin having an expanded portion plastically deformed so as to be in close contact with the first hole, the second hole, and the third hole;
A rotor for a rotating electrical machine comprising:   2. The rotor of a rotating electrical machine according to claim 1, wherein the first hole for the tubular pin and the permanent magnet embedded hole are alternately formed in the circumferential direction in the hollow rotor core portion. A hollow rotor core portion that is configured by laminating electromagnetic steel plates, has a cylindrical shape, and has an inner peripheral surface and an outer peripheral surface as a gap surface, and has a first hole for a tubular pin;
A first rotation support member having a second hole for a tubular pin;
A second rotation support member having a third hole for a tubular pin and sandwiching the hollow rotor core portion with the first rotation support member;
In a method for manufacturing a rotor of a rotating electrical machine comprising:
A tubular pin having a flange portion formed at one end is fitted into the second hole of the first rotation support member, the first hole of the hollow rotor core portion, and the third hole of the second rotation support member. A first step of inserting the part so as to fit the second hole;
A second step in which the tubular pin is expanded by plastic deformation by press-fitting a tube expansion member and is brought into close contact with the first hole, the second hole, and the third hole;
The manufacturing method of the rotor of the rotary electric machine characterized by including this.