JP2018007528A - Manufacturing method of rotary electric machine - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a manufacturing method of rotary electric machine having plural permanent magnets embedded in a rotor core the outer surface of which is covered with adhesive in a wide range, capable of reducing stress acting on the permanent magnets at high speed rotation of the rotor core.SOLUTION: The manufacturing method includes: an insertion step S1 in which plural permanent magnets are inserted into magnet insertion holes in a stepped-portion; a lamination step S2 in which a stepped-portion of an upper step is laminated on a lower step portion while displacing the same in a circumferential direction; an injection step S3 in which an adhesive is injected into plural magnet insertion holes in the upper step portion and the adhesive is disposed in at least upper the periphery of the permanent magnets in the lower step disposed in the magnet insertion holes in the lower step portion; and a filling step S4 in which the permanent magnets in the upper step are pressed into the magnet insertion holes in the upper step portion to fill the adhesive over the outer surface of the permanent magnets in the lower step and the outer surface of the permanent magnets in the upper step.SELECTED DRAWING: Figure 3

Description

  The present invention relates to a method of manufacturing a rotating electrical machine.

  Conventionally, a permanent magnet type rotating electrical machine is known (see Patent Document 1 below). The permanent magnet type rotating electrical machine has a stator and a rotor arranged to face the stator via a gap. The stator includes a stator iron core and a stator winding attached to the stator iron core. The stator iron core is composed of an annular yoke iron core and a plurality of teeth iron cores protruding in the radial direction from the yoke iron core.

  The rotor includes a rotor core and a plurality of permanent magnets embedded in the rotor core. A pair of nonmagnetic portions are formed inside the rotor core and on both sides in the circumferential direction of the permanent magnet for one magnetic pole. A pair of magnetic path portions are formed on the stator core on the stator side of the pair of nonmagnetic portions by forming the pair of nonmagnetic portions.

  The circumferential pitch of the teeth core with respect to the center axis of the rotor is τs (degrees), and the opening angle formed by the circumferential width of the pair of magnetic path portions with respect to the center axis of the rotor is θ When (degrees), θ≈ (n + Y) × τs (n is an integer of 0 or more). When the winding method of the stator winding is distributed winding, Y is set to 0.5. When the winding method of the stator winding is concentrated winding, Y = 0.9 to 1.2 (see the same document, claim 1 and the like).

  According to this permanent magnet type rotating electrical machine, when the nonmagnetic portions are formed on both sides in the circumferential direction of the permanent magnet, the peak voltage of the induced electromotive voltage can be suppressed. Can be provided.

JP 2006-187189 A

  When the rotating electrical machine as described above is driven and the rotor rotates at a high speed, a large stress is applied by a centrifugal force between the permanent magnet embedded in the rotor core and the rotor core. In order to relieve such stress, it is required to cover a wider area of the outer surface of the permanent magnet with an adhesive filled between the permanent magnet and the stator core.

  The present invention has been made in view of the above problems, and can cover a wider range of the outer surface of the permanent magnet embedded in the rotor core with an adhesive, and acts on the permanent magnet when the rotor core rotates at high speed. It aims at providing the manufacturing method of the rotary electric machine which can relieve the stress which carries out.

  In order to achieve the above object, the present invention provides a method of manufacturing a rotating electrical machine having a rotor core having a plurality of step portions, an insertion step of inserting a permanent magnet into the magnet insertion hole of the step portion, and a lower step. A step of laminating the stepped portion of the upper step on the stepped portion in the circumferential direction, and injecting an adhesive into the magnet insertion hole of the stepped portion of the upper step and disposing it in the magnet insertion hole of the stepped portion of the lower step An injection step of disposing the adhesive around at least the upper end portion of the lower permanent magnet, and the upper permanent magnet is pushed into the magnet insertion hole of the upper step portion to put the adhesive into the lower permanent magnet. And a filling step for spreading the outer surface of the magnet and the outer surface of the upper permanent magnet.

  According to the method for manufacturing a rotating electrical machine of the present invention, a wider range of the outer surface of the permanent magnet embedded in the rotor core can be covered with the adhesive, and the stress acting on the permanent magnet when the rotor core rotates at high speed can be applied. Can be relaxed. Furthermore, by performing an injection step and a filling step after the insertion step and the lamination step, it is possible to reduce the time for the adhesive before solidification to contact the rotor core and to suppress the penetration of the adhesive into the rotor core. it can.

The exploded perspective view which shows an example of a rotary electric machine. The top view which shows an example of the stator and rotor of a rotary electric machine. The flowchart of the manufacturing method of the rotary electric machine which concerns on one Embodiment of this invention. Explanatory drawing of the insertion process shown in FIG. Explanatory drawing of the lamination process shown in FIG. Explanatory drawing of the injection | pouring process shown in FIG. Explanatory drawing of the filling process shown in FIG. Explanatory drawing of the 2nd lamination process after the lamination completion determination shown in FIG. Explanatory drawing of the 2nd injection | pouring process after the lamination completion determination shown in FIG. Explanatory drawing of the 2nd filling process after the lamination | stacking completion determination shown in FIG. Explanatory drawing of the hardening process and centrifugal filling process which are shown in FIG. The schematic block diagram of the vehicle carrying a rotary electric machine.

  Hereinafter, a method for manufacturing a rotating electrical machine according to an embodiment of the present invention will be described with reference to the drawings.

  Below, an example of the rotary electric machine manufactured by the manufacturing method of this invention is demonstrated first, and the manufacturing method of the rotary electric machine which concerns on one Embodiment of this invention is demonstrated in detail next.

(Rotating electric machine)
FIG. 1 is an exploded perspective view showing an example of a rotating electrical machine 100 manufactured by a manufacturing method according to the present invention. FIG. 2 is a plan view showing an example of the rotor 20 and the stator 30 used in the rotating electrical machine 100 shown in FIG.

  The rotating electrical machine 100 includes, for example, a shaft 10, a rotor 20 fixed to the shaft 10, and a stator 30 disposed around the rotor 20. The rotating electrical machine 100 is mounted on, for example, a vehicle such as a hybrid vehicle or an electric vehicle, and both functions as a motor that rotates the shaft 10 when electric power is supplied and functions as a generator that generates power by rotating the shaft 10. Each function can be switched and used according to the running state of the vehicle.

  The shaft 10 is a rod-like member that penetrates the center of the cylindrical rotor 20 in the direction of the axis L of the rotor 20, is fixed to the rotor 20, and is integrated with the rotor 20 around the axis L of the rotor 20. Rotate to. The rotor 20 includes a cylindrical rotor core 21 made of a magnetic material and end rings 22 made of a non-magnetic material fixed to both ends of the rotor core 21 in the axis L direction.

  The rotor core 21 is configured, for example, by laminating a plurality of electromagnetic steel plates in the axial direction. As the electromagnetic steel sheet constituting the rotor core 21, for example, an electromagnetic steel sheet having a thickness of about 0.05 mm to about 1 mm processed into a predetermined shape by punching or etching can be used.

  The rotor core 21 includes a plurality of magnet insertion holes 23 arranged at equal angular intervals in the circumferential direction and extending in the axis L direction, and a plurality of permanent magnets 24 inserted into the magnet insertion holes 23. The magnet insertion hole 23 has a shape corresponding to the permanent magnet 24, and the width of the magnet insertion hole 23 is larger than the width of the permanent magnet 24 in the circumferential direction of the rotor core 21, and both end portions of the magnet insertion hole 23 are arranged. Magnetic gaps are formed in the.

  An adhesive for fixing the permanent magnet 24 to the magnet insertion hole 23 is filled between the magnet insertion hole 23 and the permanent magnet 24. The adhesive covers the outer surface of the permanent magnet 24 and relieves stress acting between the permanent magnet 24 and the rotor core 21 by centrifugal force when the rotor core 21 rotates.

  In the illustrated example, the permanent magnet 24 has a long and narrow shape extending from one end to the other end of the rotor core 21 in the axis L direction of the rotor 20, and the cross-sectional shape perpendicular to the axis L direction is generally rectangular. It has a shape. The shape of the permanent magnet 24 is not particularly limited, and for example, the shape of the cross section perpendicular to the axis L direction may be a sector shape or an arc shape. As the permanent magnet 24, for example, a neodymium-based or samarium-based sintered magnet, a ferrite magnet, a neodymium-based bond magnet, or the like can be used.

  The permanent magnet 24 forms a field pole of the rotor 20. In the example shown in FIG. 2, the permanent magnet 24 has one magnetic pole formed by one permanent magnet 24. However, as in the example shown in FIG. 1, there may be a plurality of permanent magnets 24 constituting each magnetic pole. By using a plurality of permanent magnets 24 constituting one magnetic pole, the magnetic flux density of each magnetic pole can be increased and the magnet torque can be increased.

  The magnetization direction of the permanent magnet 24 faces the radial direction of the rotor 20, and the direction of the magnetization direction is reversed for each field pole. That is, the permanent magnets 24 are arranged at equal angular intervals in the circumferential direction of the rotor core 21 by alternately inverting the direction of the magnetization direction along the radial direction of the rotor core 21. Thereby, as for the surface of the radial direction outer side of the rotor core 21 of the two permanent magnets 24 adjacent to the circumferential direction of the rotor core 21, one is an S pole and the other is an N pole. In the example shown in FIG. 2, the rotor 20 includes 12 permanent magnets 24, and 12 magnetic poles are formed on the rotor core 21.

  In the rotor core 21, in the example shown in FIG. 2, auxiliary magnetic poles are formed between the permanent magnets 24 that form the magnetic poles. Here, the axis of the magnetic pole of the rotor 20 is defined as the d axis as the central axis of the permanent magnet in the direction of the magnetic flux generated by the magnetic pole, and the axis between the permanent magnet 24 electrically and magnetically orthogonal to the d axis is defined as q. Set to axis. The auxiliary magnetic pole acts so that the magnetic resistance of the q-axis magnetic flux generated by the coil 40 is reduced. With this auxiliary magnetic pole, the magnetic resistance of the q-axis magnetic flux is much smaller than that of the d-axis magnetic flux, so that a large reluctance torque can be generated.

  The rotor core 21 has, for example, a step skew configuration in which the position of the permanent magnet 24 is shifted stepwise in the circumferential direction. That is, the rotor core 21 is configured in multiple stages in the direction of the axis L, and the position of the permanent magnet 24 in each stage is shifted stepwise in the circumferential direction by a predetermined skew angle. The skew angle of the rotor core 21 is optimized, for example, to reduce cogging torque.

  The stator 30 mainly includes a cylindrical stator core 31, a plurality of slots 32 provided in the stator core 31, a plurality of coils 40 disposed in the slots 32, and a coil in the slot 32. And an insulator disposed around 40.

  For example, the stator core 31 is formed by punching or etching a magnetic steel sheet having a thickness of about 0.05 mm to 1 mm into a predetermined shape in a generally annular shape. It is configured by stacking. The stator core 31 has a hollow cylindrical shape and has a plurality of slots 32 provided at equiangular intervals in the circumferential direction. The stator core 31 can have 72 slots 32 in the circumferential direction, for example.

  The slot 32 is provided in a radial groove shape along the radial direction of the stator core 31 from the inner peripheral surface of the stator core 31, penetrates the stator core 31 in the axis L direction, and passes along the inner periphery along the axis L direction. The surface has an opening 33 continuous from one end surface 31a of the stator core 31 to the other end surface 31b.

  The stator core 31 includes a plurality of teeth 34 provided between the slots 32, and an annular core back 35 that is an outer peripheral portion of the stator core 31. The plurality of teeth 34 and the core back 35 are integrally provided, and the plurality of teeth 34 extend from the core back 35 along the radial direction of the stator core 31 toward the center C of the stator core 31. The rotor 20 shown in FIG. 1 has a small gap between the stator core 31 and the stator core 31 in the radial direction, that is, inside the cylindrical stator core 31. It is supported rotatably.

  For example, the coil 40 is a rectangular wire having a rectangular cross-sectional shape, has an insulating coating on the outer surface, and is arranged in a line along the radial direction of the stator core 31 in each slot 32. In the illustrated example, the coil 40 has a rectangular cross-sectional shape, and the long side of the cross-section is disposed in the slot 32 substantially parallel to the radial direction of the stator core 31. In the stator 30 of the rotating electrical machine 100 of the present embodiment, for example, a three-phase coil 40 is distributedly wound with 8 poles and 72 slots 32, and the coils 40 of each phase are connected by star connection.

(Manufacturing method of rotating electrical machine)
Next, the manufacturing method of the rotary electric machine which concerns on one Embodiment of this invention is demonstrated in detail. FIG. 3 is a flowchart showing each step included in the rotating electrical machine manufacturing method S100 according to the embodiment of the present invention.

  The rotating electrical machine manufacturing method S100 of the present embodiment mainly includes an insertion step S1, a stacking step S2, an injection step S3, and a filling step S4. Moreover, the manufacturing method S100 of the rotating electrical machine of the present embodiment can include, for example, an insertion completion determination S5, a lamination completion determination S6, a centrifugal filling step S7, a curing step S8, an adjustment step S9, and a magnetization step S10. . Hereafter, each process of manufacturing method S100 of the rotary electric machine of this embodiment is demonstrated in detail, referring FIGS. 4A to 4H.

(Insertion process)
4A is an explanatory diagram of the insertion step S1 shown in FIG. 3, and is a schematic cross-sectional view in the vicinity of the magnet insertion hole 23 of the rotor core 21 shown in FIGS. The insertion step S1 is a step of inserting the permanent magnet 24 into the magnet insertion hole 23 of one step portion 21a of the rotor core 21 constituted by a plurality of step portions 21a, 21b, 21c (see FIG. 4H).

  In the insertion step S <b> 1, first, the end ring 22 is fixed to one end of the rotor core 21 in the axis L direction, and one end of the magnet insertion hole 23 is closed by the end ring 22. Next, for example, using an automatic insertion machine, the permanent magnet 24 is gripped and inserted into the magnet insertion hole 23. Thereby, as shown in FIG. 4A, the permanent magnet 24 is disposed in the magnet insertion hole 23 of the step portion 21 a whose one end is closed by the end ring 22. In this state, a gap is formed between the outer peripheral surface of the permanent magnet 24 and the inner peripheral surface of the magnet insertion hole 23.

  The insertion step S1 can be sequentially performed on the plurality of magnet insertion holes 23. However, from the viewpoint of improving productivity, it is preferable to insert the plurality of permanent magnets 24 into the plurality of magnet insertion holes 23 in the insertion step S1. The permanent insertion of the permanent magnets 24 can be performed using, for example, an automatic insertion machine that holds a plurality of permanent magnets 24 and inserts them into the magnet insertion holes 23 at once. After the insertion step S1, the stacking step S2 is performed as shown in FIG.

(Lamination process)
FIG. 4B is an explanatory diagram of the stacking step S2 shown in FIG. In the stacking step S <b> 2, when the rotor core 21 has a multistage skew configuration in the direction of the axis L, the upper step 21 b is provided in the lower step 21 a in the circumferential direction of the rotor core 21. This is a step of laminating with the skew angle shifted. The lower opening of the magnet insertion hole 23 of the upper step portion 21b stacked in the stacking step S2 communicates with the upper opening of the magnet insertion hole 23 of the lower step portion 21a where the permanent magnet 24 is disposed. After the completion of the stacking step S2, an injection step S3 is performed as shown in FIG.

(Injection process)
FIG. 4C is an explanatory diagram of the implantation step S3 shown in FIG. In the injection step S3, the adhesive 25 is injected into the magnet insertion hole 23 of the upper step portion 21b, and around at least the upper end portion of the lower permanent magnet 24 arranged in the magnet insertion hole 23 of the lower step portion 21a. In this step, the adhesive 25 is disposed.

  In the injection step S3, the adhesive 25 is injected into the bottom of the magnet insertion hole 23 of the upper step portion 21b from the upper opening of the magnet insertion hole 23 of the upper step portion 21b laminated by the lamination step S2, for example, by a dispenser. To do. As the adhesive 25, for example, an epoxy adhesive can be used. Further, in order to prevent the adhesive 25 from leaking, an adhesive 25 mixed with a powder resin may be used.

  The viscosity of the adhesive 25 should be as high as possible within the range of 0.5 Pa · s to 80 Pa · s, for example, from the viewpoint of suppressing penetration into the electromagnetic steel sheet constituting the rotor core 21. Can do. The viscosity of the adhesive 25 is, for example, 15 Pa · s or more and 40 Pa · s or less when a ferrite magnet is used as the permanent magnet 24, and 20 Pa · s or more and 45 Pa when a neodymium magnet is used as the permanent magnet 24. -It is preferable that it is below s. That is, the viscosity of the adhesive 25 is preferably in the range of 15 Pa · s to 45 Pa · s.

  In the injection step S3, the injection amount of the adhesive 25 can be determined from the following viewpoints, for example. One is the viewpoint of the injection amount that can prevent the adhesive 25 from overflowing from the magnet insertion hole 23 after the filling step S4 described later. In addition, after the filling step S4 to be described later, the outer surface of the permanent magnet 24 arranged in the lower step portion 21a and the outer surface of the permanent magnet 24 arranged in the upper step portion 21b are as wide as possible. It is a viewpoint of the injection amount covered with.

  From the viewpoint of preventing overflow of the adhesive 25, the amount is adjusted such that at least the rear end surface 24b in the pushing direction of the permanent magnet 24 disposed in the upper step 21b is exposed from the adhesive 25 (see FIG. 4D). It is preferable. From the viewpoint of covering a wider area of the outer surface of the permanent magnet 24, the injection amount of the adhesive 25 can be determined as follows, for example. The volume from the lower end of the magnet insertion hole 23 of the lower step portion 21a to the volume of the permanent magnet 24 is subtracted from the volume from the lower end of the magnet insertion hole 23 of the upper step portion 21b to the upper end of the permanent magnet 24. The volume obtained by adding the volume obtained by subtracting the volume can be used as the injection amount of the adhesive 25.

  The permanent magnet 24 and the magnet insertion hole 23 have manufacturing tolerances. Therefore, the injection amount of the adhesive 25 is preferably adjusted based on the case where the permanent magnet 24 having the maximum dimension within the tolerance range is inserted into the magnet insertion hole 23 having the minimum dimension within the tolerance range. Thereby, it can prevent more reliably that the adhesive agent 25 overflows from the magnet insertion hole 23, and the usage-amount of the adhesive agent 25 can be optimized.

  The injection step S3 can be sequentially performed on the plurality of magnet insertion holes 23. However, from the viewpoint of improving productivity and preventing penetration of the adhesive 25, it is preferable to inject the adhesive 25 into the plurality of magnet insertion holes 23 in a single injection step S3. The batch injection of the adhesive 25 can be performed by, for example, a dispenser having a plurality of nozzles. After the completion of the injection step S3, a filling step S4 is performed as shown in FIG.

(Filling process)
FIG. 4D is an explanatory diagram of the filling step S4 shown in FIG. In the filling step S4, the upper permanent magnet 24 is pushed into the magnet insertion hole 23 of the upper step portion 21b, and the adhesive 25 is spread over the outer surface of the lower permanent magnet 24 and the outer surface of the upper permanent magnet 24. It is. In the filling step S4, first, the upper permanent magnet 24 is inserted into the magnet insertion hole 23 of the upper step portion 21b by, for example, an automatic insertion machine. Thereby, the upper permanent magnet 24 is arranged in the magnet insertion hole 23 of the upper step portion 21 b with the lower portion in contact with the adhesive 25.

  However, the adhesive 25 having a relatively high viscosity that can suppress the penetration of the adhesive 25 into the laminated electromagnetic steel plates constituting the rotor core 21 is used. Therefore, the adhesive 25 is not sufficiently spread around the permanent magnet 24 just by inserting the upper permanent magnet 24 into the magnet insertion hole 23 of the upper step portion 21b. In addition, a relatively high-viscosity adhesive 25 exists between the lower end of the upper permanent magnet 24 and the upper end of the lower permanent magnet 24, and a relatively large gap is formed.

  Therefore, in the filling step S4, as shown in FIG. 4D, the upper permanent magnet 24 is pushed into the magnet insertion hole 23 of the upper step portion 21b, and the adhesive 25 is put on the outer surface of the upper permanent magnet 24 and the lower permanent magnet. Spread to the outer surface of the magnet 24. The filling step S4 can be performed using, for example, a shaft S capable of controlling the force and distance for pushing the permanent magnet 24.

  In the filling step S4, the upper permanent magnet 24 is press-fitted into the magnet insertion hole 23 of the upper step portion 21b into which the adhesive 25 has been injected, so that the lower end of the upper permanent magnet 24 and the upper end of the lower permanent magnet 24 are In the meantime, the adhesive 25 is pressurized. As a result, the adhesive 25 is filled in the gaps between the side walls of the upper and lower step magnet portions 21 a and 21 b and the side surfaces of the upper and lower permanent magnets 24, and the upper and lower permanent magnets 24. A wider area of the outer surface can be covered by the adhesive 25.

  More specifically, the adhesive 25 reaches the outer surface of the upper permanent magnet 24 from the front end surface 24a in the pushing direction of the upper permanent magnet 24 to the vicinity of the rear end surface 24b in the pushing direction. Then, the outer periphery of the upper permanent magnet 24, except for the rear end surface 24 b and a very small area in the vicinity thereof, is covered with the adhesive 25 and fixed to the magnet insertion hole 23. Further, the adhesive 25 reaches the outer surface of the permanent magnet 24 from the upper end to the lower end of the lower permanent magnet 24. Then, the outer circumference of the lower permanent magnet 24, except for the lower end surface and a very small area in the vicinity thereof, is covered with the adhesive 25 and fixed to the magnet insertion hole 23. Thereby, the waste of the adhesive 25 can be eliminated and the usage amount of the adhesive 25 can be kept to a minimum.

  Further, in the filling step S4, by controlling the force for pushing the permanent magnet 24, the permanent magnet 24 can be prevented from being damaged, and the permanent magnet 24 can be pushed to an appropriate position. Further, in the filling step S4, by controlling the distance to push the permanent magnet 24, the permanent magnet 24 can be prevented from being damaged, and the permanent magnet 24 can be pushed to an appropriate position.

  The filling step S4 can be sequentially performed on the plurality of magnet insertion holes 23. However, from the viewpoint of improving productivity and preventing penetration of the adhesive 25, it is preferable to push the plurality of permanent magnets 24 into the plurality of magnet insertion holes 23 in the filling step S4. The permanent pressing of the permanent magnets 24 can be performed using, for example, an automatic press-fitting machine that press-fits a plurality of permanent magnets 24 into the magnet insertion holes 23 together by a plurality of shafts S.

  Note that the insertion step S1, the lamination step S2, the injection step S3, and the filling step S4 are the same as those shown in FIG. 2 even when a plurality of permanent magnets 24 are inserted into the magnet insertion holes 23, as in the example shown in FIG. As in the example shown, the same can be done when one permanent magnet 24 is inserted into the magnet insertion hole 23. After completion of the filling step S4, for example, an insertion completion determination S5 can be performed as shown in FIG.

(Insertion completion judgment)
In the insertion completion determination S5, it is determined whether or not the permanent magnets 24 have been inserted into all the magnet insertion holes 23. For example, when the injection step S3 and the filling step S4 are sequentially performed on the individual magnet insertion holes 23, it is determined whether or not the injection step S3 and the filling step S4 are performed a number of times equal to the number of the magnet insertion holes 23. judge.

  As a result of the determination, when the number of executions of each process has not reached the prescribed number (NO), the injection process S3 and the filling process S4 are performed again as shown in FIG. On the other hand, as a result of the determination, when the number of executions of each process has reached the specified number (YES), the stacking completion determination S6 is performed. In addition, when performing injection | pouring process S3 and filling process S4 collectively with respect to all the magnet insertion holes 23, insertion completion determination S5 can be abbreviate | omitted.

(Lamination completion judgment)
In the stacking completion determination S6, it is determined whether or not the stacking of the plurality of step portions 21a, 21b, 21c (see FIG. 4H) constituting the rotor core 21 is completed. That is, whether or not the stacking step S2 for stacking the step portions 21a, 21b, and 21c constituting the rotor core 21 is completed when the rotor core 21 has a multi-step skew configuration in the axis L direction. Determine whether.

  As a result of the determination, if the lamination step S2 is not completed (NO), the lamination step S2 is performed as shown in FIG. As a result of the determination, if the lamination step S2 is completed (YES), a curing step S8 and a centrifugal filling step S7 are performed as shown in FIG. When the rotor core 21 does not have a multi-stage configuration, the stacking completion determination S6 and the stacking step S2 can be omitted.

(Second lamination process)
FIG. 4E is an explanatory diagram of the second stacking step S2 after the stacking completion determination S6 illustrated in FIG. In the second stacking step S2, as in the first stacking step S2, the upper step 21c is stacked on the lower step 21b with a predetermined skew angle shifted in the circumferential direction of the rotor core 21. The lower opening of the magnet insertion hole 23 of the upper step portion 21c laminated in the lamination step S2 communicates with the upper opening of the magnet insertion hole 23 of the lower step portion 21b where the permanent magnet 24 is disposed. After the completion of the second stacking step S2, a second injection step S3 is performed as shown in FIG.

(Second injection process)
FIG. 4F is an explanatory diagram of the second injection step S3 after the stacking completion determination S6 shown in FIG. In the second injection step S3, the adhesive 25 is injected into the magnet insertion hole 23 of the upper step portion 21c stacked on the lower step portion 21b of the rotor core 21, and the magnet insertion hole 23 of the lower step portion 21b. An adhesive 25 is disposed around the upper end portion of the lower permanent magnet 24 disposed in FIG. As a result, the adhesive 25 is disposed on the upper portion of the magnet insertion hole 23 of the lower step portion 21b and the bottom portion of the magnet insertion hole 23 of the upper step portion 21c.

(Second filling process)
FIG. 4G is an explanatory diagram of the second filling step after the stacking completion determination S6 shown in FIG. In the second filling step S4, as in the first filling step S4, the permanent magnet 24 is inserted into the magnet insertion hole 23 into which the adhesive 25 of the upper step portion 21b has been injected. At this stage, as in the first filling step S4, the permanent magnet 24 is disposed around the magnet insertion hole 23 of the lower step portion 21b and the magnet insertion hole 23 of the upper step portion 21c. The adhesive 25 is not sufficiently spread around the permanent magnet 24. In addition, a relatively high-viscosity adhesive 25 exists between the lower end of the upper permanent magnet 24 and the upper end of the lower permanent magnet 24, and a relatively large gap is formed.

  Next, as in the first filling step S <b> 4, the permanent magnet 24 is pushed into the magnet insertion hole 23 of the upper step portion 21 c to spread the adhesive 25 on the outer surfaces of the upper and lower permanent magnets 24. After the completion of the second filling step S4, as shown in FIG. 3, the insertion completion determination S5 and the stacking completion determination S6 are performed again, and a predetermined number of steps 21c are stacked (see FIG. 4H). An injection step S3 and a filling step S4 are performed on the stepped portion 21c.

  Thus, in the manufacturing method S100 of the rotating electrical machine of the present embodiment, the stacking step S2, the injection step S3, and the filling step S4 can be repeated. Thereby, the rotor core 21 having the step portions 21a, 21b, and 21c having a desired number of steps can be manufactured. The injection amount of the adhesive 25 into the uppermost step portion 21c may be larger than the injection amount of the adhesive 25 into the other step portions 21a and 21b. Thereby, not only can a wider range of the outer surface of the uppermost permanent magnet 24 be covered, but also a wider range of the outer surface can be covered in the lowermost permanent magnet 24 by the centrifugal filling step S7 described later. It becomes possible.

  A predetermined number of stacking steps S2 are performed to stack a predetermined number of step portions 21a, 21b, and 21c, and an injection step S3 and a filling step S4 are performed on each of the step portions 21a, 21b, and 21c. If it is determined in S6 that the predetermined number of steps 21a, 21b, and 21c are stacked (YES), as shown in FIG. 3, a centrifugal filling step S7 and a curing step S8 are performed.

(Centrifugal filling process and curing process)
FIG. 4H is an explanatory diagram of the curing step S8 and the centrifugal filling step S7 shown in FIG. After the filling step S4 is completed, before the curing step S8 and the centrifugal filling step S7, the end ring 22 is joined to the rotor core 21 constituted by the plurality of step portions 21a, 21b, 21c, and the uppermost step portion 21c. The opening of the magnet insertion hole 23 is closed.

  Centrifugal filling step S7 is a step of rotating adhesive core 25 between permanent magnet 24 and rotor core 21 by rotating rotor iron core 21 around the axis after filling step S4. The curing step S8 is a step of curing the adhesive 25 by, for example, heating the adhesive 25 made of a thermosetting resin or irradiating the adhesive 25 made of an ultraviolet curable resin with ultraviolet rays.

  In addition, although hardening process S8 may be performed after completion | finish of centrifugal filling process S7, as shown in FIG. 3, centrifugal filling process S7 and hardening process S8 can be performed in parallel. As a result, the adhesive 25 can be cured while spreading between the permanent magnet 24 and the rotor core 21, and the unbalance amount can be minimized. Moreover, productivity can be improved by performing two processes in parallel. After completion of the centrifugal filling step S7 and the curing step S8, an adjustment step S9 is performed as shown in FIG.

(Adjustment process)
The adjustment step S9 is a step of adjusting the balance of the rotor 20 after the curing step S8 is completed. Specifically, the balance of the rotor 20 can be adjusted by adjusting a balance weight (not shown), for example. After completion of the adjustment step S9, a magnetization step S10 is performed as shown in FIG.

(Magnetization process)
The magnetizing step S <b> 10 is a step of magnetizing the permanent magnet 24. The magnetizing step S10 can be performed by an appropriate magnetizing device. In addition, when using the permanent magnet 24 magnetized in advance, the magnetizing step S10 shown in FIG. 3 can be omitted. Moreover, the manufacturing method S100 of the rotary electric machine of this embodiment can employ | adopt the process similar to the manufacturing method of a well-known rotary electric machine about processes other than each process shown in FIG.

  As described above, the rotating electrical machine manufacturing method S100 of the present embodiment includes the insertion step S1, the lamination step S2, the injection step S3, and the filling step S4. Therefore, the permanent magnet 24 is disposed in the magnet insertion hole 23 of the lowermost step portion 21a of the rotor core 21 in the insertion step S1, and the upper step is disposed above the magnet insertion hole 23 of the lower step portion 21a in the stacking step S2. A magnet insertion hole 23 of the stepped portion 21b is disposed.

  Then, in the injection step S3, the adhesive is injected from the opening above the magnet insertion hole 23 of the upper step portion 21b, and the periphery of the upper end portion of the permanent magnet 24 inserted into the magnet insertion hole 23 of the lower step portion 21a. An adhesive 25 can be disposed on the surface. As a result, even when a relatively high-viscosity adhesive capable of suppressing penetration of the rotor core 21 into the electromagnetic steel ribs is injected into the opening above the magnet insertion hole 23 of the lower step 21a, the upper step The overflow of the adhesive 25 can be prevented by the magnet insertion hole 23 of the stepped portion 21b.

  Further, in the filling step S4, the permanent magnet 24 is pushed into the magnet insertion hole 23 of the upper step portion 21b, and the adhesive 25 is applied to the outer surface of the permanent magnet 24 of the lower step portion 21a and the permanent portion of the upper step portion 21b. It can be distributed to the outer surface of the magnet 24.

  Therefore, according to the manufacturing method S100 of the rotating electrical machine of the present embodiment, a wider range of the outer surface of the permanent magnet 24 embedded in the rotor core 21 can be covered with the adhesive 25, and the rotor core 21 rotates at high speed. Sometimes the stress acting on the permanent magnet 24 can be relaxed. Therefore, for example, the rotating electrical machine 100 mounted on a vehicle such as a hybrid vehicle or an electric vehicle can be rotated at a high speed and output.

  Furthermore, according to the manufacturing method S100 of the rotating electrical machine of the present embodiment, the adhesive 25 before solidification is applied to the rotor core 21 by performing the injection step S3 and the filling step S4 after the insertion step S1 and the stacking step S2. The contact time can be shortened. Thereby, penetration of the adhesive 25 into the electromagnetic steel sheets constituting the rotor core 21 can be suppressed.

  Further, by injecting the adhesive 25 into the magnet insertion hole 23 of the lower step portion 21a (21b) into which the permanent magnet 24 has been inserted in advance via the magnet insertion hole 23 of the upper step portion 21b (21c), It is possible to prevent the adhesive 25 from overflowing. Therefore, the adhesive 25 having a relatively high viscosity can be used as described above, and the penetration of the adhesive 25 into the electromagnetic steel sheets constituting the rotor core 21 can be more effectively suppressed.

  FIG. 5 is a schematic configuration diagram of a power train of a hybrid vehicle on the premise of four-wheel drive on which the rotating electrical machine 100 manufactured by the rotating electrical machine manufacturing method S100 according to the above-described embodiment is mounted.

  The hybrid vehicle has an engine ENG and a rotating electric machine 100 as main power on the front wheel side. A rotating electrical machine 100 that is a power source on the front wheel side is arranged between the engine ENG and the transmission TR. The power of the engine ENG and the rotating electrical machine 100 is shifted by the transmission TR and transmitted to the front wheel drive wheels FW.

  The rotating electrical machine 100 that is the driving power source on the rear wheel side can be the same as the rotating electrical machine 100 that is the power source on the front wheel side, or a rotating electrical machine having another general configuration can be used. In driving the rear wheel, the rotating electrical machine 100 disposed on the rear wheel side and the rear wheel side driving wheel RW are mechanically connected, and the power of the rotating electrical machine 100 is transmitted to the rear wheel side driving wheel RW.

  The rotating electrical machine 100 starts the engine ENG, and switches between generation of driving force and generation of electric power for recovering energy at the time of vehicle deceleration as electric energy according to the traveling state of the vehicle. The drive and power generation operation of the rotating electrical machine 100 are controlled by the power converter INV so that the torque and the rotational speed are optimized in accordance with the driving situation of the vehicle.

  The electric power necessary for driving the rotating electrical machine 100 is supplied from the battery BAT via the power converter INV. Further, when the rotating electrical machine 100 performs a power generation operation, the battery BAT is charged with electric energy via the power converter INV.

  According to the rotating electrical machine manufacturing method S100 of this embodiment described above, in the rotating electrical machine 100 mounted on such a vehicle, eddy current can be reduced, motor efficiency can be improved, and high-speed rotation can be achieved. it can. Of course, the rotating electrical machine 100 can also be applied to a hybrid vehicle other than the four-wheel drive vehicle.

  The embodiment of the present invention has been described in detail with reference to the drawings, but the specific configuration is not limited to this embodiment, and there are design changes and the like without departing from the gist of the present invention. They are also included in the present invention.

  For example, in the method for manufacturing a rotating electrical machine according to the above-described embodiment, an example in which the stator coil of the rotating machine to be manufactured is a distributed winding of wave windings has been described. However, since the method for manufacturing a rotating electrical machine according to the present invention is characterized by the method for manufacturing a rotor, the configuration of the stator is not particularly limited. That is, the stator coil may be a lap winding method or a concentrated winding method. Moreover, although the example in which the rotary electric machine to be manufactured is an internal rotation type has been described, the manufacturing method of the rotary electric machine according to the present invention can also be applied when manufacturing an external rotation type rotary electric machine.

  In addition, as an application example of the rotating electrical machine manufactured by the manufacturing method of the rotating electrical machine according to the above-described embodiment, an electric vehicle or a hybrid electric vehicle has been described as an example. However, the rotating electrical machine manufactured by the method for manufacturing a rotating electrical machine according to the above-described embodiment is naturally an auxiliary motor for automobiles such as an alternator, a starter generator (including a motor generator), an electric compressor, and an electric pump. It can also be applied to industrial motors such as elevators and motors for home appliances such as air conditioner compressors.

DESCRIPTION OF SYMBOLS 21 ... Rotor core, 21a ... Step part, 21b ... Step part, 21c ... Step part, 22 ... End ring, 23 ... Magnet insertion hole, 24 ... Permanent magnet, 24b ... Rear end surface, 25 ... Adhesive, 25a ... Adhesion Agent layer, 100 ... rotating electric machine, S1 ... inserting process, S2 ... laminating process, S3 ... injection process, S4 ... filling process, S7 ... centrifugal filling process, S8 ... curing process, S100 ... manufacturing method of rotating electric machine

Claims (10)

A method of manufacturing a rotating electrical machine including a rotor core having a plurality of steps,
An insertion step of inserting a permanent magnet into the magnet insertion hole of the step portion;
A laminating step of laminating the upper step portion in the circumferential direction on the lower step portion;
An injection step of injecting an adhesive into the magnet insertion hole of the upper step and disposing the adhesive around at least the upper end of the lower permanent magnet arranged in the magnet insertion hole of the lower step When,
And a filling step of pushing the upper permanent magnet into the magnet insertion hole of the upper step to spread the adhesive over the outer surface of the lower permanent magnet and the outer surface of the upper permanent magnet. A method of manufacturing a rotating electrical machine.   The method for manufacturing a rotating electrical machine according to claim 1, wherein the stacking step, the injection step, and the filling step are repeated.   3. The method of manufacturing a rotating electrical machine according to claim 1, wherein in the filling step, a force for pushing the permanent magnet is controlled.   The method for manufacturing a rotating electrical machine according to any one of claims 1 to 3, wherein a distance for pushing the permanent magnet is controlled in the filling step. In the inserting step, the permanent magnets are collectively inserted into the plurality of magnet insertion holes,
In the injection step, the adhesive is injected into a plurality of the magnet insertion holes at once,
5. The method of manufacturing a rotating electrical machine according to claim 1, wherein, in the filling step, the plurality of permanent magnets are collectively pushed into the plurality of magnet insertion holes.   The injection amount of the adhesive in the injection step is adjusted to an amount at which a rear end surface in the pushing direction of the upper permanent magnet is exposed from the adhesive after the filling step. The manufacturing method of the rotary electric machine as described in any one of Claims 5-5.   The manufacturing method of the rotating electrical machine according to claim 6, wherein the injection amount of the adhesive to the uppermost step portion is larger than the injection amount of the adhesive to the other step portion in the injection step. Method.   2. The centrifugal filling step of rotating the rotor core around an axis after the filling step to spread the adhesive between the permanent magnet and the rotor core. The manufacturing method of the rotary electric machine as described in any one of Claims 7.   The method for manufacturing a rotating electrical machine according to claim 8, further comprising a curing step for curing the adhesive.   The method for manufacturing a rotating electrical machine according to claim 9, wherein the centrifugal filling step and the curing step are performed in parallel.

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