JP2017192221A - Rotor, rotary electric machine, and method of manufacturing rotor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a rotor satisfying miniaturization, high-speed rotation, and high output, and capable of being formed at low cost, a rotary electric machine, and a method of manufacturing a rotor.SOLUTION: In a rotor 3 including a magnet 6 disposed in each of a plurality of insertion holes 7 formed at an interval in a circumferential direction Z of a circular iron core 30, each of the insertion holes 7 includes: each of external arc face portions 71A, 72A having a convex shape toward the center of the iron core 30 in a radial direction X and formed in a circumferential direction Z on the outside X2 in the radial direction X; each of internal arc face portions 71B, 72B formed in the circumferential direction Z on the inside X1 in the radial direction X; and each of end face portions 71C, 71D, 72C, 72D connecting between each of the external arc face portions 71A, 72A and each of the internal arc face portions 71B, 72B. A barrier wall 8 formed in close contact with the magnet 6 is provided between the magnet 6 and each of the end face portions 71C, 71D, 72C, 72D of each of the insertion holes 7, and the magnet 6 is in close contact with the external arc face portions 71A, 72A and the internal arc face portions 71B, 72B of each of the insertion holes 7.SELECTED DRAWING: Figure 5

Description

  The present invention relates to a rotor, a rotating electrical machine, and a method of manufacturing a rotor that can be formed at a low cost while satisfying miniaturization, high-speed rotation, and high output.

  In recent years, rotating machines used as electric motors and generators have been required to be reduced in cost while satisfying miniaturization, high-speed rotation, and high output. As one method for realizing small size, high speed rotation, and high output, there is a method of increasing a generated torque by embedding a rare earth sintered magnet as a permanent magnet (hereinafter simply referred to as a magnet) in a rotor. . However, rare earth sintered magnets are expensive and have to be inserted into the rotor after being molded, resulting in high costs.

  On the other hand, for example, Patent Document 1 and Patent Document 2 show that a rare earth sintered magnet, which is one of constituent elements of a rotor, is directly formed on an iron core. The cost of the rotating electrical machine is reduced and the generated torque is improved.

JP2015-104243A JP 2009-044795 A

  The conventional rotor is formed with magnets in close contact with the entire circumference of the insertion hole. Therefore, there is a problem that the generated torque may be reduced due to leakage of magnetic flux generated by the magnet.

  The present invention has been made in order to solve the above-described problems. A rotor, a rotating electrical machine, and a rotor that can be formed at a low cost while satisfying downsizing, high-speed rotation, and high output, and An object of the present invention is to provide a method for manufacturing a rotor.

The rotor of the present invention is
In a rotor in which magnets are respectively arranged in a plurality of insertion holes formed at intervals in the circumferential direction of a circular iron core,
The insertion hole has a convex shape toward the center in the radial direction of the iron core and an outer arc surface portion formed in the circumferential direction outside the radial direction, and has a convex shape toward the center in the radial direction of the iron core and a diameter. An inner arc surface portion formed in the circumferential direction inside the direction, and each end surface portion connecting the outer arc surface portion and the inner arc surface portion,
Between the magnet and each end surface portion of the insertion hole, provided with a partition wall formed in close contact with the magnet,
The magnet has a portion that is not in contact with the end surface portions of the insertion hole and is in close contact with the outer arc surface portion and the inner arc surface portion of the insertion hole.
The rotor of the present invention is
In a rotor in which magnets are respectively arranged in a plurality of insertion holes formed at intervals in the circumferential direction of a circular iron core,
The insertion hole has a convex shape toward the center in the radial direction of the iron core and an outer arc surface portion formed in the circumferential direction outside the radial direction, and has a convex shape toward the center in the radial direction of the iron core and a diameter. An inner arc surface portion formed in the circumferential direction inside the direction, and each end surface portion connecting the outer arc surface portion and the inner arc surface portion,
The magnet has a portion that is not in contact with the end surface portions of the insertion hole and is in close contact with the outer arc surface portion and the inner arc surface portion of the insertion hole.
The rotating electrical machine of the present invention is
The rotor shown above,
The rotor and a stator arranged coaxially are provided.
In addition, the method for manufacturing the rotor of the present invention includes:
In a rotor in which magnets are respectively arranged in a plurality of insertion holes formed at intervals in the circumferential direction of a circular iron core,
A first step of installing partition walls at two locations in the insertion hole;
A second step of filling the portion of the insertion hole sandwiched and separated by the two partition walls with unmagnetized magnetic powder;
A third step of applying a magnetic field to the iron core to align the direction of magnetization of the magnetic powder;
A fourth step of compressing the magnetic powder in the axial direction of the iron core;
A fifth step of sintering the magnetic powder;
And a sixth step of magnetizing the magnetic powder on the magnet.

According to the rotor of this invention, the rotating electrical machine, and the method of manufacturing the rotor,
It can be formed at low cost while satisfying miniaturization, high-speed rotation and high output.

It is a perspective view which shows the structure of the rotary electric machine provided with the rotor in Embodiment 1 of this invention. It is a top view which shows the structure of the rotary electric machine shown in FIG. It is a top view which shows the structure of the rotor of the rotary electric machine shown in FIG. FIG. 4 is an enlarged top view showing a part of the rotor shown in FIG. 3. FIG. 5 is an enlarged top view showing a part of the rotor shown in FIG. 4. FIG. 6 is an enlarged cross-sectional view taken along line QQ of the rotor illustrated in FIG. 5. It is process drawing which shows the manufacturing method of the magnet of the rotor in Embodiment 1 of this invention. It is sectional drawing which shows the structure of the manufacturing apparatus of the rotor in Embodiment 1 of this invention. It is a top view which expands and shows a part of rotor of the rotary electric machine in Embodiment 2 of this invention. FIG. 10 is an enlarged top view showing a part of the rotor shown in FIG. 9. It is process drawing which shows the manufacturing method of the magnet of the rotor in Embodiment 2 of this invention. It is sectional drawing which shows the structure of the manufacturing apparatus of the rotor in Embodiment 2 of this invention. It is a top view which expands and shows a part of rotor of the rotary electric machine in Embodiment 3 of this invention. It is sectional drawing which shows the structure of the manufacturing apparatus of the rotor in Embodiment 3 of this invention. It is a top view which expands and shows a part of rotor of the rotary electric machine in Embodiment 4 of this invention. It is sectional drawing which shows the structure of the manufacturing apparatus of the rotor in Embodiment 4 of this invention. It is sectional drawing which shows the structure of the manufacturing apparatus of the rotor of the other example in Embodiment 4 of this invention. It is process drawing which shows the manufacturing method of the magnet of the rotor of the other example in Embodiment 4 of this invention.

Embodiment 1 FIG.
Embodiments of the present invention will be described below.
1 is a perspective view showing a configuration of a rotating electrical machine including a rotor according to Embodiment 1 of the present invention.
FIG. 2 is a top view showing the configuration of the rotating electrical machine shown in FIG.
FIG. 3 is a top view showing the configuration of the rotor of the rotating electrical machine shown in FIG.
FIG. 4 is an enlarged top view of the 1/8 model (for one pole) of the rotor shown in FIG.

FIG. 5 is an enlarged top view showing a 1/16 model of the rotor shown in FIG. 3, that is, a half of the model shown in FIG.
FIG. 6 is an enlarged cross-sectional view of the RR line of the rotor shown in FIG.
FIG. 7 is a process diagram showing the method of manufacturing the rotor magnet in the first embodiment of the present invention.
FIG. 8 is a cross-sectional view showing the configuration of the rotor manufacturing apparatus according to Embodiment 1 of the present invention.

  In the first embodiment, an 8-pole 48-slot magnet type rotating electrical machine will be described. However, the present invention is not limited to this, and it is possible to configure similarly and achieve the same effect by appropriately dealing with the number of poles and the number of slots of the rotating electrical machine. Note that the number of poles and the number of slots of the rotating electrical machine are the same in the following embodiments, and therefore description thereof will be omitted as appropriate.

  1 and 2, the configuration of the rotary electric machine 1 will be described. The rotating electrical machine 1 includes a stator 2, a rotor 3, and a shaft 31. The rotating electrical machine 1 is arranged in the order of the stator 2, the rotor 3, and the shaft 31 from the outside in the radial direction X. Between the stator 2 and the rotor 3, there is an air gap 32 which is a gap. The air gap 32 is formed such that the gap G in the radial direction X is 0.1 mm to 2.5 mm.

The stator 2 includes a stator core 20 and a coil 21. The stator core 20 is configured in an annular shape. The stator core 20 is formed by punching a magnetic steel sheet. However, the present invention is not limited to punching electromagnetic steel sheets. The material used for the stator core 20 is not limited to the electromagnetic steel sheet. The stator core 20 is configured by laminating a plurality of electromagnetic steel plates in the axial direction Y.
The rotor 3 is a magnet type rotor. The rotor 3 includes a shaft 31, an iron core 30 fixed to the shaft 31, and a magnet 6 installed on the iron core 30.

  The magnet 6 is an aggregate of the magnetic powder 60 and is a compression-molded magnet formed by forming the magnetic powder 60. The shaft 31 is configured to be inserted into the axial center position of the rotor 3. The shaft 31 is fixed to the iron core 30 by, for example, shrink fitting or press fitting. Further, the rotating electrical machine 1 may be configured in either distributed winding or concentrated winding.

  The configuration of the rotor 3 will be described with reference to FIG. The rotor 3 includes an iron core 30, a magnet 6, an insertion hole 7, and a shaft 31. In addition to the magnet 6 and the insertion hole 7, the iron core 30 includes a partition wall 8, a gap 9, and a bridge 5. The magnet 6 is inserted and installed in the insertion hole 7. The iron core 30 is configured in an annular shape in which an opening is formed because the shaft 31 is inserted in the center. The iron core 30 is formed by punching out an electromagnetic steel sheet, and the thickness of the electromagnetic steel sheet is often configured between 0.1 mm and 1.0 mm. However, the present invention is not limited to punching electromagnetic steel sheets. The material used for the iron core 30 is not limited to the electromagnetic steel sheet. The iron core 30 is configured by laminating a plurality of electromagnetic steel plates in the axial direction Y.

  In the first embodiment, the magnet 6 and the insertion hole 7 are formed in two layers in the radial direction X with respect to one pole. In addition, two insertion holes 7 and two magnets 6 are formed in the circumferential direction Z via a bridge 5 described later for one layer. Here, the outer side X2 in the radial direction X will be described as the first layer, and the inner side X1 in the radial direction X will be described as the second layer.

  Details of the configuration of one pole of the rotor 3, that is, 1 / 8th, will be described with reference to FIG. The component which comprises the iron core 30 at this time is demonstrated. The insertion hole 7 includes a first insertion hole 71 in the first layer and a second insertion hole 72 in the second layer. The bridge 5 includes a first bridge 51 in the first layer and a second bridge 52 in the second layer. The first bridge 51 divides the first insertion hole 71 of the first layer into left and right. The second bridge 52 divides the second layer second insertion hole 72 into the left and right.

  The magnet 6 includes a first magnet 61 in the first layer and a second magnet 62 in the second layer. The partition walls 8 are installed at two locations in the insertion hole 7. The partition wall 8 is formed extending in the axial direction Y. The insertion hole 7 is separated by two partition walls 8. The partition 8 includes a first partition 81 in the first layer and a second partition 82 in the second layer. The partition wall 8 is formed of a nonmagnetic material plate. The partition wall 8 is not limited to a plate. The partition wall 8 is fixed in the insertion hole 7 when the magnet 6 is formed by press-fitting or gap fitting. In the present embodiment, the partition 8 is formed by a single plate. However, the present invention is not limited to this, and a plurality of plates may be installed as the partition 8.

  The air gap 9 functions as a flux barrier. The gap 9 includes a first gap 91 in the first layer and a second gap 92 in the second layer. In FIG. 4, one pole of the iron core 30 is configured to be mirror-symmetrical at the center in the circumferential direction Z, and similar parts formed symmetrically to the left and right of the circumferential direction Z are denoted by the same reference numerals. I will explain.

  Further, the details of the configuration of the half of FIG. 4 will be described with reference to FIG. 5 shows the configuration of the right half of the rotor 3 shown in FIG. Therefore, the configuration of the left half of the rotor 3 is configured mirror-symmetrically with the configuration of the right half of FIG. 5, and description thereof will be omitted as appropriate.

  The first magnet 61 has an outer peripheral portion 61A, an inner peripheral portion 61B, an outer end portion 61C, and an inner end portion 61D. The second magnet 62 has an outer peripheral portion 62A, an inner peripheral portion 62B, an outer end portion 62C, and an inner end portion 62D. The first insertion hole 71 is configured to have each of an outer arc surface portion 71A, an inner arc surface portion 71B, an outer end surface portion 71C, and an inner end surface portion 71D. The second insertion hole 72 includes each of the outer arc surface portion 72A, the inner arc surface portion 72B, the outer end surface portion 72C, and the inner end surface portion 72D.

  The outer arc surface portions 71 </ b> A and 72 </ b> A are surface portions that are convex toward the center in the radial direction X of the iron core 30 and are formed in the circumferential direction Z on the outer side X <b> 2 in the radial direction X. The inner arc surface portions 71 </ b> B and 72 </ b> B are surface portions that are convex toward the center in the radial direction X of the iron core 30 and are formed in the circumferential direction Z on the inner side X <b> 1 in the radial direction X. The outer end surface portions 71C and 72C are surface portions that connect the outer arc surface portions 71A and 72A and the inner arc surface portions 71B and 72B on the outer side X2 in the radial direction X. The inner end surface portions 71D and 72D are surface portions that connect the outer arc surface portions 71A and 72A and the inner arc surface portions 71B and 72B on the inner side X1 in the radial direction X. The outer end surface portions 71C and 72C and the inner end surface portions 71D and 72D are formed in an arc shape or a linear shape.

  The outer peripheral portion 61A and the inner peripheral portion 61B of the first magnet 61 are formed in close contact with the outer arc surface portion 71A and the inner arc surface portion 71B of the first insertion hole 71, respectively. The outer end 61C and the inner end 61D of the first magnet 61 are formed in close contact with the first partition 81, respectively. The outer peripheral portion 62A and the inner peripheral portion 62B of the second magnet 62 are formed in close contact with the outer arc surface portion 72A and the inner arc surface portion 72B of the second insertion hole 72, respectively. The outer end 62C and the inner end 62D of the second magnet 62 are formed in close contact with the second partition wall 82, respectively.

  A first gap 91 is formed between the first partition 81 and the outer end surface portion 71C, and between the first partition 81 and the inner end surface portion 71D. A second gap 92 is formed between the second partition wall 82 and the outer end surface portion 72C and between the second partition wall 82 and the inner end surface portion 72D. Therefore, the outer end portion 61C, the inner end portion 61D, the outer end surface portion 71C of the first insertion hole 71, and the inner end surface portion 71D are configured in a non-contact manner. In addition, the outer end portion 62C, the inner end portion 62D, the outer end surface portion 72C of the second insertion hole 72, and the inner end surface portion 72D are configured in a non-contact manner.

  6 is a cross-sectional view showing a cross section in the axial direction Y of the line RR in FIG. From the magnetic pole center Q toward the outer side X2 in the radial direction X, the first bridge 51 (a part of the iron core 30), the first gap 91, the first partition 81, the first magnet 61, the first partition 81, and the first gap 91. The first bridge 51 (part of the iron core 30) is used.

  In the following description, when the magnet 6, the insertion hole 7, the partition wall 8, the bridge 5, and the air gap 9 are indicated, all the same portions in the rotor 3 are indicated. In addition, since this is the same in the following embodiments, the description thereof will be omitted as appropriate. In addition, since each part is formed similarly in the following embodiments, the description thereof will be omitted as appropriate.

  Next, a method for manufacturing the rotor of the first embodiment configured as described above will be described. Here, a manufacturing process for forming the magnet 6 on the iron core 30 will be described with reference to FIGS. FIG. 8 is a diagram schematically showing a cross section in the axial direction Y shown in FIG.

  First, the rotor manufacturing apparatus 10 of FIG. 8 will be described. In the figure, the manufacturing apparatus 10 includes an electromagnet 13, a heater 12, a fixed plate 14, and a punch 15. A rotor iron core 30 is placed on the upper surface of the fixed plate 14 in the region sandwiched between the heaters 12. Therefore, the iron core 30 is arranged by the bridge 5, the gap 9, the partition wall 8, the magnetic powder 60 (magnet 6), the partition wall 8, the gap 9, and the bridge 5 from the right side.

  A punch 15 is disposed on the magnetic powder 60. The heater 12 is for heating the magnetic powder 60. Inevitably, the iron core 30 and the partition 8 are also heated. The electromagnet 13 generates a magnetic field in order to align the magnetization direction of the magnetic powder 60. The punch 15 moves to the fixed plate 14 side in the axial direction Y, and pressurizes and compresses the magnetic powder 60 from the upper surface.

  Next, the following steps are performed using the rotor manufacturing apparatus 10. First, the iron core 30 is placed on the upper surface of the fixed plate 14. And the insertion process as a 1st process which inserts the partition 8 in two places in the insertion hole 7 of the iron core 30 is performed (step ST101 of FIG. 7). By the partition walls 8 inserted in these two places, the inside of the insertion hole 7 is distinguished into a region of the gap 9 constituted by a gap and a region where the magnet 6 is formed.

  Next, a filling step is performed as a second step of filling the region where the magnet 6 is formed with unmagnetized magnetic powder 60 (step ST102 in FIG. 7). Next, a heating process is performed in which the filled magnetic powder 60 is heated by the heater 12 to rise to 150 ° C. (step ST103 in FIG. 7). Next, a magnetic easy axis preparation step is performed as a third step of applying a magnetic field from the outside of the heated magnetic powder 60 with the electromagnet 13 to align the magnetization direction of the magnetic powder 60 (step ST104 in FIG. 7). .

  Next, a pressurizing step is performed as a fourth step of compressing the magnetic powder 60 in the axial direction Y of the iron core 30 using the punch 15 (step ST105 in FIG. 7). Next, the cured magnetic powder 60 is heated by the heater 12 and cured at 250 ° C. or lower for 30 minutes or longer to perform a curing process as a fifth process for forming the magnet 6 (step ST106 in FIG. 7). Next, an unmagnetized magnet 6 is magnetized while being enclosed in the insertion hole 7, and a magnetizing process is performed as a sixth process for forming the magnet 6 (step ST107 in FIG. 7). Through the above steps, the magnet 6 is formed in the insertion hole 7.

  Thus, in this Embodiment 1, since the magnet 6 arrange | positioned at the insertion hole 7 is formed through the process shown above, after forming a magnet in the shape similar to an insertion hole, the said magnet This is different from the case where the adhesive material is applied to and inserted into the insertion hole. That is, in the first embodiment, the outer peripheral portion 61A and the inner peripheral portion 61B of the first magnet 61 are formed in close contact with the outer arc surface portion 71A and the inner arc surface portion 71B of the first insertion hole 71, respectively. The outer end 61C and the inner end 61D of the first magnet 61 are formed in close contact with the first partition 81, respectively. The outer peripheral portion 62A and the inner peripheral portion 62B of the second magnet 62 are formed in close contact with the outer arc surface portion 72A and the inner arc surface portion 72B of the second insertion hole 72, respectively. The outer end 62C and the inner end 62D of the second magnet 62 are formed in close contact with the second partition wall 82, respectively. The point that the insertion hole 7 and the magnet 6 are formed in close contact with each other is formed in the same manner in the following embodiments, and therefore this description is omitted as appropriate.

  Next, the manufacturing method of the rotary electric machine 1 using the rotor 3 shown above is demonstrated. It inserts in the coil 21 assembled in the annular | circular shape to the stator core 20 through insulating paper. And the shaft 31 is fixed to the rotor 3 of the iron core 30 in which the magnet 6 shown above was installed. Next, the stator 2 and the rotor 3 are assembled to manufacture the rotating electrical machine 1 (see FIGS. 1 and 2).

According to the rotor, the rotating electrical machine, and the method for manufacturing the rotor of Embodiment 1 configured as described above, leakage of magnetic flux generated by the magnet by forming a magnet smaller than the size of the insertion hole. Can be prevented.
Further, since the partition wall is inserted into the insertion hole and the magnet is formed, the positioning accuracy of the magnet in the insertion hole and the fixing force of the magnet are improved.

Moreover, the process of inserting a magnet can be reduced by directly forming a magnet in the insertion hole.
Further, when the magnet is formed, the insertion hole of the rotor iron core itself serves as a mold, and it is not necessary to create a new mold.
The outer peripheral surface and inner peripheral surface of the magnet are formed in close contact with the outer arc surface portion and inner arc surface portion of the insertion hole, respectively, and the outer end portion and inner end portion of the magnet are the outer end surface portion and inner end surface of the insertion hole. Since the portion is configured in a non-contact manner, the characteristics of the rotating electrical machine are improved and the torque is improved.

  Further, the outer peripheral surface and inner peripheral surface of the magnet and the outer arc surface portion and inner arc surface portion of the insertion hole are formed in a convex shape toward the inner side (to the center) in the radial direction of the iron core, so that reluctance torque is generated. Therefore, the difference between Ld (d-axis inductance) and Lq (q-axis inductance) can be increased.

In addition, since it can be formed at a temperature rise of 250 ° C. or less in the curing step, which is the sixth step of sintering formed by the magnet, the temperature rise temperature can be set lower than in the conventional case, and the temperature rise time Can be shortened.
Moreover, since the partition is formed of a nonmagnetic material, leakage of magnetic flux generated by the magnet can be prevented.
Moreover, since the magnet is formed of a compression molded magnet, the degree of freedom of the shape of the magnet is improved.

  In Embodiment 1, the insertion hole is divided into two layers in the radial direction per pole and divided into two pieces by a bridge in the circumferential direction. However, the present invention is not limited to this. If one or more insertion holes are formed in the radial direction and one or more insertion holes in the circumferential direction, they can be formed in the same manner as in the first embodiment, and the same effect can be obtained.

Embodiment 2. FIG.
In the second embodiment, unlike the first embodiment, an example in which the protrusion 4 is provided in the insertion hole 7 will be described.
FIG. 9 is an enlarged top view showing a 1/8 model (for one pole) of the rotor according to the second embodiment of the present invention.
FIG. 10 is an enlarged top view showing half of the rotor model shown in FIG.
FIG. 10 shows a configuration in the middle of manufacturing the rotor shown in FIG.
FIG. 11 is a process diagram showing a method of manufacturing a rotor magnet according to Embodiment 2 of the present invention.
FIG. 12 is a cross-sectional view showing a configuration of a rotor manufacturing apparatus according to Embodiment 2 of the present invention.

  In the figure, the same parts as those in the first embodiment are denoted by the same reference numerals and the description thereof is omitted. The iron core 30 has the protrusion 4 of the insertion hole 7. The protrusion 4 includes a first protrusion 41 in the first layer and a second protrusion 42 in the second layer. The first protrusions 41 are formed to protrude outwardly X2 in the radial direction X at two locations on the inner arc surface portion 71B of the first insertion hole 71. The first magnet 61 is formed in close contact with the first protrusion 41. The second protrusions 42 are formed so as to protrude outward X2 in the radial direction X at two locations on the inner arc surface portion 72B of the second insertion hole 72. The second magnet 62 is formed in close contact with the second protrusion 42.

  The partition 8 includes a first partition 83 in the first layer and a second partition 84 in the second layer. The first partition wall 83 is disposed between the first protrusion 41 and the outer arc surface portion 71 </ b> A of the first insertion hole 71. The second partition wall 84 is disposed between the second protrusion 42 and the outer arc surface portion 72 </ b> A of the second insertion hole 72.

  Next, a method for manufacturing the rotor according to the second embodiment configured as described above will be described. Here, a manufacturing process for forming the magnet 6 on the iron core 30 will be described with reference to FIGS. 11 and 12. FIG. 12 is a view schematically showing a cross section in the axial direction Y of the rotor 3 as in FIG. 8 of the first embodiment.

  First, the rotor manufacturing apparatus 10 of FIG. 12 will be described. In the figure, the same parts as those in the first embodiment are denoted by the same reference numerals and the description thereof is omitted. In the second embodiment, an example in which the partition 8 is divided into an upper partition 8A and a lower partition 8B in the axial direction Y will be described. The manufacturing apparatus 10 includes an upper punch 15A, a lower punch 15B, and a stopper 17.

  An upper partition wall 8A is installed on the upper punch 15A via a stopper 17, and is configured to be movable up and down in the axial direction Y. The upper punch 15A is moved downward in the axial direction Y by a moving mechanism different from the upper partition wall 8A, and compresses the magnetic powder 60 from the upper surface. A lower partition wall 8B is installed on the lower punch 15B via a stopper 17, and is configured to be movable up and down in the axial direction Y. The lower punch 15B is moved upward in the axial direction Y by a moving mechanism different from the lower partition wall 8B, and compresses the magnetic powder 60 from the lower surface.

  Next, the following steps are performed using the rotor manufacturing apparatus 10. First, the upper partition wall 8A is installed in the upper punch 15A, and the lower partition wall 8B is installed in the lower punch 15B by the stopper 17, and moved in the axial direction Y, and the partition wall 8 is inserted into two positions in the insertion hole 7 of the iron core 30. An insertion process is performed as a first process (step ST101 in FIG. 11). By the upper partition wall 8A and the lower partition wall 8B inserted in these two places, the inside of the insertion hole 7 is distinguished into a region of a void 9 constituted by a void and a region where the magnet 6 is formed.

  Next, a process similar to that of the first embodiment is performed, and a filling process is performed as a second process in which the region where the magnet 6 is to be formed is filled with the unmagnetized magnetic powder 60 (step ST102 in FIG. 11). Next, a heating step is performed in which the filled magnetic powder 60 is heated by the heater 12 to rise to 150 ° C. (step ST103 in FIG. 11). Next, a magnetic field easy axis preparation step is performed as a third step of applying a magnetic field from the outside of the heated magnetic powder 60 with the electromagnet 13 to align the magnetization direction of the magnetic powder 60 (step ST104 in FIG. 11). .

  Next, a pressing process is performed as a fourth process in which the magnetic powder 60 is compressed in the axial direction Y of the iron core 30 using the upper punch 15A and the lower punch 15B (step ST105 in FIG. 11). Next, the upper partition 15A is moved upward in the axial direction Y by the upper punch 15A, and the lower partition 8B is moved downward in the axial direction by the lower punch 15B. And the extraction process which extracts the partition 8 from the insertion hole 7 is performed (step ST109 of FIG. 11). Therefore, the removal step is performed between the fourth step and the fifth step.

  Hereinafter, a curing process is performed as a fifth process in which the same configuration as in the first embodiment is performed and the compressed magnetic powder 60 is heated by the heater 12 and cured at 250 ° C. or lower for 30 minutes or longer to form the magnet 6. This is performed (step ST106 in FIG. 11). Next, the unmagnetized magnet 6 is magnetized while being enclosed in the insertion hole 7, and a magnetizing process is performed as a sixth process for configuring the magnet 6 (step ST107 in FIG. 11). Through the above steps, the magnet 6 is formed in the insertion hole 7. Thus, the partition wall 8 extracted from the insertion hole 7 in the extraction process can be reused when other magnets 6 are formed.

According to the rotor, the rotating electrical machine, and the method of manufacturing the rotor according to the second embodiment configured as described above, the same effect as that of the first embodiment can be obtained, and the partition wall can be extracted and reused. Therefore, the partition wall can be used a plurality of times, and the manufacturing cost is reduced.
In addition, since the projection is provided in the insertion hole, even after the magnet is molded, the magnet is in close contact with the projection even if the partition is removed from the insertion hole, so that the magnet can be stably placed in the insertion hole. .
Further, since the magnet is in close contact with the protrusion, the positioning accuracy of the magnet is improved.

In the second embodiment, the example in which the partition wall 8 is extracted has been shown. However, the present invention is not limited to this example, and the partition wall 8 is formed as shown in FIG. It is also possible to configure the rotor 3 while remaining.
In the first embodiment, the example in which the partition wall 8 is left is shown. However, the present invention is not limited to this, and in the first embodiment, the partition wall 8 is extracted as in the second embodiment. It is also possible to configure.

Embodiment 3 FIG.
In the third embodiment, an example in which the insertion hole 7 of each layer is not divided by the bridge 5 will be described, unlike the above embodiments.
FIG. 13 is an enlarged top view showing a 1/8 model (for one pole) of the rotor according to the third embodiment of the present invention.
FIG. 14 is a cross-sectional view showing a configuration of a rotor manufacturing apparatus according to Embodiment 3 of the present invention.

  In the figure, the same parts as those in the above embodiments are denoted by the same reference numerals, and description thereof is omitted. The insertion hole 7 includes a first insertion hole 71 in the first layer and a second insertion hole 72 in the second layer, as in the above embodiments. However, in the third embodiment, one first insertion hole 71 and one second insertion hole 72 are formed for one pole and are not separated. Therefore, the third embodiment is configured with 8 poles and 48 slots.

  Next, the manufacturing method of the rotor of the third embodiment configured as described above is the same as that of the first embodiment. Therefore, the description is omitted as appropriate. FIG. 14 shows the rotor manufacturing apparatus 10 according to the third embodiment, and is a diagram schematically showing a cross section in the axial direction Y of the rotor 3 as in FIG. 8 of the first embodiment. As shown in FIG. 14, the rotor manufacturing apparatus 10 is formed in the same manner as in the above embodiments. Since the insertion hole 7 is not divided, the punch 15 for forming the magnet 6 is formed wide.

  According to the rotor, the rotating electrical machine, and the method for manufacturing a rotor of the third embodiment configured as described above, even if the insertion hole is not divided, it can be configured in the same manner as in the above-described embodiments. The same effects as those of the above embodiments are obtained.

Embodiment 4 FIG.
In the fourth embodiment, an example in which no gap is provided in the insertion hole, unlike the above embodiments, will be described.
FIG. 15 is an enlarged top view showing a 1/8 model (for one pole) of a rotor according to Embodiment 4 of the present invention.
FIG. 16 is a cross-sectional view showing a configuration of a rotor manufacturing apparatus according to Embodiment 4 of the present invention.

  In the figure, the same parts as those in the above embodiments are denoted by the same reference numerals, and description thereof is omitted. The partition 8 includes a first partition 85 in the first layer and a second partition 86 in the second layer. The first partition wall 85 is formed in all regions between the first magnet 61 and the end surface portions 71 </ b> C and 71 </ b> D of the first insertion hole 71. The second partition wall 86 is formed in all regions between the second magnet 62 and the end surface portions 72C and 72D of the second insertion hole 72. Therefore, in the fourth embodiment, there is no gap in the first insertion hole 71 and the second insertion hole 72, and the first partition 85 and the second partition 86 function as a flux barrier.

  Next, the method of manufacturing the rotor of the fourth embodiment configured as described above is the same as that of the first embodiment. Therefore, the description is omitted as appropriate. FIG. 16 shows the rotor manufacturing apparatus 10 according to the fourth embodiment, and is a diagram schematically showing a cross section in the axial direction Y of the rotor 3 as in FIG. 8 of the first embodiment. As shown in FIG. 16, the rotor manufacturing apparatus 10 is formed in the same manner as in each of the above embodiments. However, there are no voids.

  In the fourth embodiment, an example in which the partition wall 8 formed in a predetermined shape is inserted into the insertion hole 7 and installed is shown, but the present invention is not limited to this, and another example will be described. FIG. 17 shows another example of the rotor manufacturing apparatus 10 according to the fourth embodiment, and schematically shows a cross section in the axial direction Y of the rotor 3 as in FIG. 8 of the first embodiment. is there. FIG. 18 is a process diagram showing another example of the method for manufacturing a rotor according to the fourth embodiment of the present invention. In the figure, the same parts as those in the above embodiments are denoted by the same reference numerals, and description thereof is omitted. The temporary form frame 16 is installed at a place where the magnet 6 is disposed in the insertion hole 7.

  And the 1st process which installs the partition 8 in the insertion hole 7 is performed in the following processes. First, the temporary installation process which installs the temporary formwork 16 in the location which arrange | positions the magnet 6 in the insertion hole 7 is performed (step ST10 of FIG. 18). Therefore, the external shapes of the temporary mold frame 16 and the magnet 6 are formed in the same shape. Next, a forming step of forming a partition wall 8 by pouring and hardening a fluid material 80 made of a non-magnetic material into the portion of the insertion hole 7 isolated by the temporary mold frame 16 of the insertion hole 7 (FIG. 5). 18 step ST11). Next, a temporary removal step of extracting the temporary mold frame 16 from the insertion hole 7 is performed (step ST12 in FIG. 18). Subsequent steps are the same as those in the fourth embodiment, the magnet 6 is formed, and the rotor 3 is formed.

  According to the rotor, the rotating electrical machine, and the method of manufacturing the rotor of the fourth embodiment configured as described above, even if there is no gap in the insertion hole, it can be configured in the same manner as in each of the above embodiments. The same effects as those of the above embodiments are obtained.

  It should be noted that the present invention can be freely combined with each other within the scope of the invention, and each embodiment can be appropriately modified or omitted.

DESCRIPTION OF SYMBOLS 1 Rotating electric machine 10 Manufacturing apparatus 11 Magnetic pole center 12 Heater 13 Electromagnet
14 fixed plate, 15 punch, 15A upper punch, 15B lower punch, 16 temporary mold frame,
17 Stopper, 2 Stator, 20 Stator Core, 21 Coil, 3 Rotor,
30 iron core, 31 shaft, 32 air gap, 4 protrusions, 41 first protrusion,
42 second protrusion, 5 bridge, 51 first bridge, 52 second bridge,
6 magnets, 60 magnetic powder, 61 first magnet, 62 second magnet, 61A outer periphery,
61B inner peripheral part, 61C outer end part, 61D inner end part, 62A outer peripheral part, 62B inner peripheral part, 62C outer end part, 62D inner end part, 7 insertion hole, 71 first insertion hole, 71A outer arc surface part, 71B Inner arc surface portion, 71C outer end surface portion, 71D inner end surface portion, 72 second insertion hole,
72A outer arc surface portion, 72B inner arc surface portion, 72C outer end surface portion, 72D inner end surface portion,
8 partition wall, 80 fluidity material, 81 first partition wall, 82 second partition wall, 83 first partition wall,
84 2nd partition, 85 1st partition, 86 2nd partition, 9 space | gap, 91 1st space | gap,
92 2nd space | gap, X radial direction, X1 inner side, X2 outer side, Y axial direction, Z circumferential direction.

Claims (14)

In a rotor in which magnets are respectively arranged in a plurality of insertion holes formed at intervals in the circumferential direction of a circular iron core,
The insertion hole has a convex shape toward the center in the radial direction of the iron core and an outer arc surface portion formed in the circumferential direction outside the radial direction, and has a convex shape toward the center in the radial direction of the iron core and a diameter. An inner arc surface portion formed in the circumferential direction inside the direction, and each end surface portion connecting the outer arc surface portion and the inner arc surface portion,
Between the magnet and each end surface portion of the insertion hole, provided with a partition wall formed in close contact with the magnet,
The magnet is a rotor that has a portion that is not in contact with the end surface portions of the insertion hole and is in close contact with the outer arc surface portion and the inner arc surface portion of the insertion hole. In a rotor in which magnets are respectively arranged in a plurality of insertion holes formed at intervals in the circumferential direction of a circular iron core,
The insertion hole has a convex shape toward the center in the radial direction of the iron core and an outer arc surface portion formed in the circumferential direction outside the radial direction, and has a convex shape toward the center in the radial direction of the iron core and a diameter. An inner arc surface portion formed in the circumferential direction inside the direction, and each end surface portion connecting the outer arc surface portion and the inner arc surface portion,
The magnet is a rotor that has a portion that is not in contact with the end surface portions of the insertion hole and is in close contact with the outer arc surface portion and the inner arc surface portion of the insertion hole. The partition is formed of a non-magnetic plate.
The rotor according to claim 1, wherein a gap is formed between the partition wall and each end surface portion of the insertion hole. The rotor according to claim 3, wherein the partition is formed by a plurality of the plates. The rotor according to claim 1, wherein the partition wall is formed in all regions between the magnet and the end surface portions of the insertion hole. The inner arc surface portion of the insertion hole has a protrusion protruding outward in the radial direction,
The magnet is formed in close contact with the protrusion,
The rotor according to claim 1, wherein the partition is formed between the protrusion and the outer arc surface portion of the insertion hole. The inner arc surface portion of the insertion hole has a protrusion protruding outward in the radial direction,
The rotor according to claim 2, wherein the magnet is formed in close contact with the protrusion. The rotor according to any one of claims 1 to 7, wherein the magnet is formed of a compression-molded magnet. The rotor according to any one of claims 1 to 8,
A rotating electrical machine comprising the rotor and a stator arranged coaxially. In a rotor in which magnets are respectively arranged in a plurality of insertion holes formed at intervals in the circumferential direction of a circular iron core,
A first step of installing partition walls at two locations in the insertion hole;
A second step of filling the portion of the insertion hole sandwiched and separated by the two partition walls with unmagnetized magnetic powder;
A third step of applying a magnetic field to the iron core to align the direction of magnetization of the magnetic powder;
A fourth step of compressing the magnetic powder in the axial direction of the iron core;
A fifth step of sintering the magnetic powder;
And a sixth step of magnetizing the magnetic powder on the magnet. The method of manufacturing a rotor according to claim 10, wherein the partition wall is formed of a nonmagnetic material. The method for manufacturing a rotor according to claim 10 or 11, further comprising an extraction step of extracting each of the partition walls from the insertion hole between the fourth step and the fifth step. In the method of manufacturing a rotor, the partition is formed in all regions other than the location where the magnet and the magnet in the insertion hole are installed.
In the first step, a temporary installation step of installing a temporary formwork at a position where the magnet is disposed in the insertion hole;
A forming step in which a fluid material is poured into the portion of the insertion hole isolated by the temporary form frame of the insertion hole and cured to form the partition;
The method for manufacturing a rotor according to claim 10 or 11, further comprising a provisional extraction step of extracting the temporary form frame from the insertion hole after the formation step. The method for manufacturing a rotor according to any one of claims 10 to 13, wherein in the fifth step, the magnetic powder is sintered at 300 ° C or lower.

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