JP2018074754A - Rotor manufacturing method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a rotor manufacturing method that can easily form an outer periphery of an outer shaft in a polygonal shape and manufacture a rotor at a low cost.SOLUTION: The rotor manufacturing method comprises: a cylindrical material arranging step which is a step for installing a cylindrical material having a cylindrical part and a flange plate protruding inward from an inner peripheral surface of the cylindrical part in a polygonal mandrel whose outer peripheral shape is polygonal, and is the step for arranging the cylindrical material in the polygonal mandrel by holding both ends of the flange plate with a pair of polygonal mandrels, inside the cylindrical part; and an outer shaft forming step for forming an outer shaft which has a polygonal outer peripheral part and a flange part protruding inward from an inner peripheral surface of the outer peripheral part, by rotating the polygonal mandrel so that an axial center of the cylindrical material becomes a rotation center, pressing a forming roller against the cylindrical part from the outside, and moving the forming roller or the polygonal mandrel in an axial direction of the cylindrical material to form the cylindrical part in a polygonal shape.SELECTED DRAWING: Figure 7B

Description

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

  Patent Document 1 discloses a rotor for a rotating electrical machine including a rotor shaft configured so that a cylindrical outer shaft is fitted to the outer periphery of an inner shaft, and a rotor core disposed on the outer periphery of the outer shaft. Yes.

JP 2010-110100 A

  In a rotor such as Patent Document 1, key grooves are formed on the outer peripheral surface of the outer shaft and the inner peripheral surface of the rotor core, and the key member is inserted into the groove in a state where these key grooves face each other, so that the rotor core becomes a rotor. Prevents rotation around the shaft axis.

  Further, in order to prevent the rotor core from rotating around the axis of the rotor shaft, the shaft fitting hole of the rotor core has a polygonal shape, and the outer peripheral shape of the rotor shaft (outer shaft) has a shape corresponding to the shaft fitting hole. It is also possible. According to such a method, since the keyway and the key member can be omitted, the rotor structure can be simplified.

  However, when the outer peripheral shape of the outer shaft constituting the rotor shaft is a polygon, it takes time to manufacture the outer shaft, such as cutting the outer peripheral surface of the outer shaft, and the rotor cannot be manufactured easily. There is a problem.

  Accordingly, the present invention has been made in view of the above-described problems, and provides a rotor manufacturing method in which the outer peripheral shape of the outer shaft can be easily formed into a polygonal shape and the rotor can be manufactured at low cost. Objective.

  According to the present invention, there is provided a rotor manufacturing method for manufacturing a rotor for a rotating electrical machine by forming a rotor shaft using an inner shaft and an outer shaft having a polygonal outer shape and inserting and arranging a rotor core on the outer periphery of the outer shaft. Is done. The rotor manufacturing method is a step of installing a cylindrical material having a cylindrical portion and a flange plate protruding inward from an inner peripheral surface of the cylindrical portion on a polygonal mandrel having an outer peripheral shape, A cylindrical material placement step for placing the cylindrical material on the polygonal mandrel by sandwiching both ends of the flange plate with a pair of polygonal mandrels on the inside, and a polygonal mandrel so that the axis of the cylindrical material is the center of rotation , The molding roller is pressed against the cylindrical part from the outside, and the molding roller or polygonal mandrel is moved in the axial direction of the cylindrical material, so that the cylindrical part is shaped into a polygonal shape. An outer shaft forming step of forming an outer shaft having an outer peripheral portion and a flange portion protruding inward from an inner peripheral surface of the outer peripheral portion.

  According to the present invention, since the cylindrical portion of the cylindrical material is formed into a polygonal shape using the forming roller, the polygonal outer shaft is formed more easily than when the cylindrical material or the like is cut as in the prior art. be able to. As a result, a rotor using the polygonal outer shaft can be manufactured at low cost.

FIG. 1A is a longitudinal sectional view of a rotor manufactured by a rotor manufacturing method according to an embodiment of the present invention. FIG. 1B is a side view of the rotor of FIG. 1A. FIG. 2 is a process diagram illustrating the flow of the rotor manufacturing method. FIG. 3A is a perspective view of a disk-shaped material. FIG. 3B is a diagram for explaining a disk-shaped material arrangement step. FIG. 4 is a diagram for explaining the first half of the cylindrical material forming step. FIG. 5 is a diagram for explaining the latter half of the cylindrical material forming step. FIG. 6A is a longitudinal sectional view showing a state in which a cylindrical material is arranged on a polygonal mandrel in the cylindrical material arrangement step. FIG. 6B is a bottom view of the polygonal mandrel and the cylindrical material as viewed from below. FIG. 7A is a view for explaining an outer shaft forming step. FIG. 7B is a diagram for explaining an outer shaft forming step. FIG. 7C is a plan view showing the outer shaft. FIG. 8A is a view for explaining a finishing process, and is a longitudinal sectional view showing a state in which an outer shaft is arranged on a polygonal mandrel. FIG. 8B is a diagram illustrating the finishing process, and is a bottom view when the outer shaft and the polygonal mandrel are viewed from below. FIG. 9 is a diagram for explaining the rotor core arrangement step. FIG. 10 is a diagram for explaining the edge processing step.

  Embodiments of the present invention will be described below with reference to the drawings.

  FIG. 1A is a longitudinal sectional view of a rotor 100 manufactured using a manufacturing method according to an embodiment of the present invention. FIG. 1B is a side view of the rotor 100.

  A rotor 100 illustrated in FIGS. 1A and 1B is a member that constitutes a part of a rotating electrical machine that functions as an electric motor or a generator, and is a rotating member that is disposed inside an annular stator. The rotor 100 includes a rotor shaft 10 and a rotor core 20 provided on the outer periphery of the rotor shaft 10.

  The rotor shaft 10 includes an inner shaft 11 and an outer shaft 12 that fits on the outer periphery of the inner shaft 11.

  The inner shaft 11 is a cylindrical member and is formed using a technique such as forging. A projecting portion 11A having a larger outer diameter than other portions is formed at a substantially central portion in the axial direction of the inner shaft 11. The protruding portion 11 </ b> A of the inner shaft 11 functions as a connecting portion that is connected to the outer shaft 12. The protruding portion 11A may be formed at a predetermined position in the shaft axial direction, for example, at a position closer to the end, instead of the central portion of the inner shaft 11. Further, the protruding portion 11A may be omitted, and the inner shaft 11 may be directly connected to the outer shaft 12.

  The outer shaft 12 is a cylindrical member formed of a mild steel material. The outer shaft 12 includes an outer peripheral portion 12A formed as a rectangular tube whose outer peripheral shape is a hexagon, and a plate-like flange portion 12B protruding inward from the inner peripheral surface of the outer peripheral portion 12A. The outer peripheral portion 12 </ b> A functions as a support member that supports the rotor core 20 from the inside, and the flange portion 12 </ b> B functions as a connecting portion that is connected to the inner shaft 11.

  At the center of the flange portion 12B of the outer shaft 12, an insertion hole 12C into which the inner shaft 11 is inserted is formed. The outer shaft 12 is fixed to the outer periphery of the inner shaft 11 by welding the connecting portion between the insertion hole 12C and the protruding portion 11A in a state where the protruding portion 11A of the inner shaft 11 is inserted into the insertion hole 12C of the flange portion 12B. The

  The rotor core 20 is a laminate in which disc-shaped steel plates are laminated, and has an insertion hole 21 through which the outer peripheral portion 12A of the outer shaft 12 is inserted. A plurality of magnet insertion holes 22 are formed at positions near the outer edge of the rotor core 20, and these magnet insertion holes 22 are arranged at equal intervals along the circumferential direction of the rotor core 20. In each magnet insertion hole 22, a plurality of permanent magnets 23 are inserted in series. In the rotor 100, the number of the magnet insertion holes 22 is set to 12, but the number of the magnet insertion holes 22 can be arbitrarily set according to output characteristics required for the rotating electrical machine.

  The rotor core 20 is disposed so as to surround the outer peripheral portion 12 </ b> A of the outer shaft 12 through the insertion hole 21. Since the insertion hole 21 of the rotor core 20 is formed as a shape (hexagonal shape) corresponding to the shape of the outer peripheral portion 12A of the outer shaft 12, the outer periphery of the outer shaft 12 is in a state where the outer shaft 12 and the rotor core 20 are assembled. The shaft circumferential displacement of the rotor core 20 relative to the portion 12A is restricted. That is, in the rotor 100, the rotor core 20 does not rotate around the axis of the rotor shaft 10 (outer shaft 12).

  Next, a method for manufacturing the rotor 100 configured as described above will be described.

  FIG. 2 is a process diagram illustrating the flow of the method for manufacturing the rotor 100 according to the present embodiment.

  As shown in FIG. 2, in step 101 (S101), a material forming process for forming a cylindrical material from a disk-shaped material is executed.

  In S102, a cylindrical material placement step is performed in which the cylindrical material formed in the previous step is placed on a polygonal mandrel. Thereafter, in S103, an outer shaft forming step of forming the outer shaft 12 from the cylindrical material is performed by forming the outer peripheral shape of the cylindrical material into a polygon using a forming roller. In S104, a finishing process for adjusting the outer peripheral shape of the outer shaft 12 with a finishing roller is executed.

  In S105, the inner shaft 11 is connected to the finished outer shaft 12, and the rotor shaft assembling step for assembling the rotor shaft 10 is executed.

  In S106, the rotor core arrangement | positioning process which inserts and arranges the rotor core 20 in the outer peripheral part 12A of the outer shaft 12 which comprises the rotor shaft 10 is performed. Thereafter, in S107, an end machining step is performed in which the end of the outer peripheral portion 12A of the outer shaft 12 is bent outward in the rotor shaft 10 with the rotor core 20 mounted. In this way, the end portion of the outer shaft 12 is processed to prevent the rotor core 20 from coming off from the outer shaft 12.

  Through the steps S101 to S107 described above, the rotor 100 for a rotating electrical machine including the rotor shaft 10 having the inner shaft 11 and the outer shaft 12 and the rotor core 20 provided on the outer periphery of the rotor shaft 10 is manufactured. The

  Below, with reference to FIG. 3A-FIG. 8B, the raw material formation process (S101) which is a process of manufacturing the outer shaft 12, a cylindrical raw material arrangement | positioning process (S102), an outer shaft formation process (S103), and a finishing process ( S104) will be described in detail.

  The material forming step is a step of forming a cylindrical material that is a material of the outer shaft 12 using the disk-shaped material 200 as shown in FIG. 3A. The disc-shaped material 200 is a disc cut out from a plate material, and is a member provided with a through hole in the center portion.

  As shown in FIG. 2, the material forming step S101 includes a disk-shaped material arranging step S101A and a cylindrical material forming step S101B.

  As shown in FIG. 3B, in the disk-shaped material arrangement step, the disk-shaped material 200 is inserted into the columnar mandrels 301 and 302 by sandwiching the center portions of both ends of the disk-shaped material 200 between the pair of columnar mandrels 301 and 302. Arranged between. A pin 303 is provided at the center of the cylindrical mandrel 301 so as to protrude from the end face of the cylindrical mandrel 301. In a state where the disc-shaped material 200 is set, the pin 303 of the cylindrical mandrel 301 is inserted into the central hole 304 of the cylindrical mandrel 302 through the through-hole of the disc-shaped material 200. Thereby, centering of the disk-shaped material 200 arrange | positioned between the cylindrical mandrels 301 and 302 can be performed, and the axial center of the cylindrical mandrels 301 and 302 and the axial center of the disk-shaped material 200 are made to correspond. It becomes possible.

  The outer diameters of the cylindrical mandrels 301 and 302 are set to be smaller than the outer diameter of the disk-shaped material 200.

  Next, the cylindrical material forming step S101B in FIG. 2 will be described with reference to FIGS.

  As shown in FIG. 4, in the cylindrical material forming step, the cylindrical mandrels 301 and 302 are rotated so that the axis of the disk-shaped material 200 is the center of rotation, and the pair of processing rollers 311 and 312 are circularly moved from the outside. Press against the outer peripheral surface of the plate material 200. By bringing the processing rollers 311 and 312 closer to the center of rotation of the cylindrical mandrels 301 and 302, the outer peripheral portion of the disk-shaped material 200 positioned outside the cylindrical mandrels 301 and 302 is lined up and down in the figure. .

  In FIG. 4, two processing rollers are provided to line up the disk-shaped material 200, but the number of processing rollers may be one or more.

  After the processing rollers 311 and 312 are pressed against the disc-shaped material 200 to open the outer peripheral portion of the disc-shaped material 200, the processing rollers 311 and 312 are moved as shown in FIG. By moving the disk-shaped material 200 in the axial direction, the outer peripheral portion of the disk-shaped material 200 is ironed. At the time of ironing, the processing rollers 311 and 312 are adjusted in position so that the distance from the cylindrical mandrels 301 and 302 is constant, and reciprocate up and down in the drawing along the axial direction of the disk-shaped material 200. To be driven. By this ironing, the opened portions of the disk-shaped material 200 are formed into a cylindrical shape corresponding to the outer peripheral shape of the columnar mandrels 301 and 302.

  In the ironing, both the processing rollers 311 and 312 and the cylindrical mandrels 301 and 302 may be moved in the axial direction, or only the cylindrical mandrels 301 and 302 may be moved in the axial direction. Also good.

  Through the cylindrical material forming step described above, a cylindrical material 400 having a cylindrical portion 401 and a flange plate 402 protruding inward from the inner peripheral surface of the cylindrical portion 401 is formed. The flange plate 402 is a portion corresponding to the central portion of the disc-shaped material 200 and is a portion sandwiched between the cylindrical mandrels 301 and 302. Therefore, the flange plate 402 has a through hole 403 at the center thereof.

  In the cylindrical material forming process, the processing rollers 311 and 312 are rotated by the rotation of the disk-shaped material 200 by being pressed against the disk-shaped material 200. The processing rollers 311 and 312 may not be configured to rotate in a driven manner, but may be configured to be driven to rotate in synchronization with the rotation of the disk-shaped material 200. By rotating the processing rollers 311 and 312 in this manner, it becomes possible to perform a molding process with higher accuracy.

  Next, the cylindrical material arrangement step S102, the outer shaft formation step S103, and the finishing step S104 in FIG. 2 will be described in detail with reference to FIGS. 6A to 8B.

  FIG. 6A is a longitudinal sectional view showing a state in which the cylindrical material 400 is arranged on the polygonal mandrels 501 and 502 in the cylindrical material arrangement step. FIG. 6B is a bottom view when the polygonal mandrel 501 and the cylindrical material 400 are viewed from below.

  As shown to FIG. 6A, a cylindrical raw material arrangement | positioning process is a process of installing the cylindrical raw material 400 in the polygonal mandrels 501 and 502 whose outer peripheral shape is a hexagon. In this step, the cylindrical material 400 is arranged on the polygonal mandrels 501 and 502 by sandwiching both ends of the flange plate 402 between the pair of polygonal mandrels 501 and 502 inside the cylindrical portion 401.

  As shown in FIG. 6B, the polygonal mandrels 501 and 502 are configured such that the corners of the polygonal mandrels 501 and 502 are cylindrical portions of the cylindrical material 400 when the cylindrical material 400 is set on the polygonal mandrels 501 and 502. It is comprised so that the inner peripheral surface of 401 may be touched. As shown in FIG. 6A, the polygonal mandrels 501 and 502 are configured to protrude from the inside of the cylindrical portion 401 of the cylindrical material 400 outward in the axial direction.

  A pin 503 is provided at the center of the polygonal mandrel 501 so as to protrude from the end surface of the polygonal mandrel 501. In a state where the cylindrical material 400 is set, the pin 503 of the polygonal mandrel 501 is inserted into the central hole 504 of the polygonal mandrel 502 through the through hole 403 of the cylindrical material 400. Thereby, the cylindrical material 400 disposed between the polygonal mandrels 501 and 502 can be centered, and the axis of the polygonal mandrels 501 and 502 can be aligned with the axis of the cylindrical material 400. It becomes possible.

  With reference to FIG. 7A and 7B, the outer shaft formation process performed after a cylindrical raw material arrangement | positioning process is demonstrated.

  As shown in FIG. 7A, in the outer shaft forming step, the polygonal mandrels 501 and 502 are rotated so that the axial center of the cylindrical material 400 is the center of rotation, and the pair of forming rollers 511 and 512 is turned from the outside to the cylindrical material. The cylindrical portion 401 of the cylindrical material 400 is sequentially molded by being pressed against the cylindrical portion 401 of 400 and moving the forming rollers 511 and 512 in the axial direction of the cylindrical material 400. At the time of sequential forming, the forming rollers 511 and 512 are adjusted so that the distance between the forming rollers 511 and 512 and the polygonal mandrels 501 and 502 is a predetermined distance as shown in FIG. 7B and along the axial direction as shown in FIG. 7A. Are driven to reciprocate up and down in the figure. By this sequential forming, the cylindrical portion 401 of the cylindrical material 400 is formed into a hexagonal shape corresponding to the outer peripheral shape of the polygonal mandrels 501 and 502 as shown in FIG. 7B.

  In sequential molding, both the forming rollers 511 and 512 and the polygonal mandrels 501 and 502 may be moved in the axial direction, or only the polygonal mandrels 501 and 502 may be moved in the axial direction. Also good.

  Through the outer shaft formation step described above, as shown in FIG. 7C, the outer shaft 12 having a hexagonal outer peripheral portion 12A and a flange portion 12B protruding inward from the inner peripheral surface of the outer peripheral portion 12A is formed. The flange portion 12B is a portion corresponding to the flange plate 402 of the cylindrical material 400, and the insertion hole 12C of the flange portion 12B is a portion corresponding to the through hole 403 of the flange plate 402.

  In the outer shaft forming step, the forming rollers 511 and 512 are rotated by the rotation of the cylindrical material 400 by being pressed against the cylindrical material 400. The forming rollers 511 and 512 may be configured to be driven to rotate in synchronization with the rotation of the cylindrical material 400, instead of being configured to rotate in a driven manner. Thus, by rotating the forming rollers 511 and 512, it becomes possible to perform a more accurate forming process.

  In FIGS. 7A and 7B, two forming rollers are provided to perform sequential forming, but the number of forming rollers may be one or more.

  Next, the finishing process will be described with reference to FIGS. 8A and 8B. FIG. 8A is a longitudinal sectional view showing a state in which the outer shaft 12 is disposed on the polygonal mandrels 501 and 502. FIG. 8B is a bottom view of the polygonal mandrel 501 and the outer shaft 12 as viewed from below.

  A finishing process is a process performed after an outer shaft formation process, Comprising: It is a process for adjusting the shape (surface property) of the outer peripheral part 12A of the outer shaft 12. FIG.

  As shown in FIG. 8A, in the finishing process, the polygonal mandrels 501 and 502 on which the outer shaft 12 is arranged are rotated around the axis, and the finishing roller 513 is pressed against the outer peripheral portion 12A of the outer shaft 12 from the outside. Then, the finishing roller 513 is moved in the axial direction of the outer shaft 12 to perform finish molding so that the outer peripheral portion 12A of the outer shaft 12 has a flatter surface. The finishing roller 513 is a roller having a smaller diameter than the processing rollers 311 and 312 and the forming rollers 511 and 512, and the diameter of the finishing roller 513 is set smaller than the diameters of the processing rollers 311 and 312 and the forming rollers 511 and 512. Yes.

  As shown in FIG. 8A and FIG. 8B, the finishing roller 513 is adjusted so that the distance from the polygonal mandrels 501 and 502 is a predetermined distance, and reciprocates up and down in the figure along the axial direction. Driven by. However, in the finishing process, one end of the outer peripheral portion 12A in the axial direction of the outer shaft 12 (upper end in FIG. 8A) is a protruding portion 12D that protrudes radially outward from the other portion of the outer peripheral portion 12A. The moving range (reciprocating region) of the finishing roller 513 is adjusted so as to be formed.

  In finish molding, both the finishing roller 513 and the polygonal mandrels 501 and 502 may be moved in the axial direction, or only the polygonal mandrels 501 and 502 may be moved in the axial direction. . Further, the finishing roller 513 may be configured to be driven to rotate in synchronization with the rotation of the outer shaft 12 instead of being configured to rotate in a driven manner. By rotating the finishing roller 513 in this way, it is possible to perform finish molding with higher accuracy.

  Further, in FIG. 8A and FIG. 8B, one finishing roller is provided to perform finish molding, but the number of finishing rollers may be two or more.

  After the finishing process described above, the rotor shaft assembly process S105 shown in FIG. 2 is performed, and the outer shaft 12 and the inner shaft 11 are connected. In this assembly process, the outer shaft 12 is fixed to the outer periphery of the inner shaft 11 by welding a connection portion between the insertion hole 12 </ b> C of the outer shaft 12 and the protruding portion 11 </ b> A of the inner shaft 11.

  Subsequently, the rotor core arrangement step S106 in FIG. 2 will be described in detail with reference to FIG.

  In the rotor core arrangement step, the outer peripheral portion 12A of the outer shaft 12 is inserted into the cylindrical rotor core 20, and the rotor core 20 is brought into contact with the protruding portion 12D of the outer peripheral portion 12A from the other end portion side of the outer peripheral portion 12A toward one end portion. To move. Thereby, the rotor core 20 is inserted and arranged with respect to the outer peripheral portion 12 </ b> A of the outer shaft 12.

  The protrusion 12D formed at one end of the outer shaft 12 functions as a stopper that restricts the axial movement of the rotor core 20 disposed on the outer peripheral portion 12A of the outer shaft 12.

  In the state where the rotor core 20 is disposed on the rotor shaft 10, one end portion (tip portion) of the outer peripheral portion 12 </ b> A of the outer shaft 12 protrudes outward in the axial direction from the inside of the rotor core 20.

  Next, with reference to FIG. 10, the end portion processing step S107 in FIG. 2 will be described in detail.

  In the end portion machining step, the rotor shaft 10 with the rotor core 20 mounted thereon is rotated around the axis, and the caulking roller 514 is pressed against one end portion (tip portion) of the outer peripheral portion 12A of the outer shaft 12. By pressing the caulking roller 514, caulking is performed to bend the distal end portion of the outer peripheral portion 12A of the outer shaft 12 radially outward.

  In this way, the end portion of the outer shaft 12 is subjected to end processing, whereby the rotor core 20 is sandwiched between the end portion of the caulked outer shaft 12 and the protruding portion 12D located at the other end of the outer peripheral portion 12A. The rotor core 20 can be prevented from coming off from the outer shaft 12.

  Through the steps S101 to S107 described above, the rotor 100 for a rotating electrical machine as shown in FIGS. 1A and 1B is manufactured.

  According to the method for manufacturing the rotor 100 according to the above-described embodiment, the following effects can be obtained.

  In the method of manufacturing the rotor 100 according to the present embodiment, the rotor shaft 10 is formed using the inner shaft 11 and the outer shaft 12 having a polygonal outer periphery, and the rotor core 20 is inserted and disposed on the outer periphery of the outer shaft 12. This is a method for manufacturing a rotor for an automobile. The method for manufacturing the rotor 100 includes a cylindrical material arranging step and an outer shaft forming step. In the cylindrical material placement step, a cylindrical material 400 having a cylindrical portion 401 and a flange plate 402 protruding inward from the inner peripheral surface of the cylindrical portion 401 is placed on the polygonal mandrels 501 and 502 whose outer peripheral shapes are polygons. It is a process to do. In the cylindrical material placement step, the cylindrical material 400 is placed on the polygonal mandrels 501 and 502 by sandwiching both ends of the flange plate 402 between the pair of polygonal mandrels 501 and 502 inside the cylindrical portion 401. In the outer shaft forming step, the polygonal mandrels 501 and 502 are rotated so that the axial center of the cylindrical material 400 is the center of rotation, and the forming rollers 511 and 512 are pressed against the cylindrical portion 401 from the outside and the cylindrical material. By moving in the axial direction of 400, the cylindrical portion 401 is shaped so as to have a polygonal shape. Thereby, the outer shaft 12 having the polygonal outer peripheral portion 12A and the flange portion 12B protruding inward from the inner peripheral surface of the outer peripheral portion 12A is formed.

  According to the rotor manufacturing method described above, since the cylindrical portion 401 of the cylindrical material 400 is formed into a polygonal shape using the forming rollers 511 and 512 at the time of manufacturing the rotor, the cylindrical material or the like is cut as in the past. The polygonal outer shaft 12 can be formed more easily than the case. As a result, the rotor 100 using the polygonal outer shaft 12 can be manufactured at low cost.

  The rotor manufacturing method according to the present embodiment further includes a material forming step for forming the cylindrical material 400 before the above-described cylindrical material arranging step. The material forming process includes a disk-shaped material arranging process and a cylindrical material forming process.

  In the disk-shaped material arrangement step, the disk-shaped material 200 is arranged on the columnar mandrels 301 and 302 by sandwiching the center portions of both ends of the disk-shaped material 200 between the pair of columnar mandrels 301 and 302. In the cylindrical material forming step, the cylindrical mandrels 301 and 302 are rotated so that the axis of the disk-shaped material 200 is the center of rotation, and the processing rollers 311 and 312 are moved from the outside to the outer peripheral surface of the disk-shaped material 200. Then, the processing rollers 311 and 312 are moved in the axial direction of the disc-shaped material 200. Thereby, the outer peripheral part of the disc-shaped material 200 located outside the columnar mandrels 301 and 302 is formed into a cylindrical shape, and the cylindrical material 400 having the cylindrical portion 401 and the flange plate 402 is formed.

  As described above, in the rotor manufacturing method, the cylindrical material 400 is formed from the disk-shaped material 200, and the polygonal outer shaft 12 is formed from the cylindrical material 400. Therefore, it is only necessary to prepare a disk-shaped material 200 having a simple shape as a material on which the outer shaft 12 is based, and it is possible to reduce time and effort required for material preparation and to reduce manufacturing costs. . It is conceivable to form the tubular material 400 by forging, casting, or the like. However, when such a method is used, it is necessary to prepare a mold and the like, and it takes time to prepare the material, and the effect of reducing the manufacturing cost is low. Become.

  Further, the method for manufacturing the rotor 100 includes a finishing process in which finish molding is performed after the outer shaft forming process. In the finishing process, the polygonal mandrels 501 and 502 on which the outer shaft 12 is arranged are rotated, and the finishing roller 513 having a smaller diameter than the forming rollers 511 and 512 is pressed against the outer shaft 12 from the outside and moved in the axial direction. Then, finish molding of the outer peripheral shape of the outer shaft 12 is performed.

  As described above, by performing the finish molding using the small-diameter finishing roller 513, the dimensional accuracy regarding the outer shape of the outer shaft 12 can be increased. As a result, the productivity of the rotor 100 can be improved.

  Further, in the finishing step, finish molding is performed such that one end portion of the outer peripheral portion 12A in the axial direction of the outer shaft 12 is formed as a protruding portion 12D protruding outward in the radial direction from other portions of the outer peripheral portion 12A. The protruding portion 12D is integrally formed as a part of the outer peripheral portion 12A of the outer shaft 12, and functions as a stopper that restricts the axial movement of the rotor core 20 disposed on the outer peripheral portion 12A. By thus integrally forming the stopper for restricting the movement of the rotor core 20 on the outer shaft 12, it is not necessary to prepare a stopper member separately, and the manufacturing cost of the rotor 100 can be reduced.

  Furthermore, the manufacturing method of the rotor 100 has a rotor core arrangement | positioning process and an edge part manufacturing process. In the rotor core arrangement step, in the rotor shaft 10 configured by connecting the inner shaft 11 to the flange portion 12B of the outer shaft 12, the outer peripheral portion 12A of the outer shaft 12 extends from the other end portion toward the one end portion toward the outer peripheral portion 12A. The rotor core 20 is inserted and arranged. In the end portion machining step, the other end portion of the outer peripheral portion 12A where the rotor core 20 is disposed is deformed outward. In this way, by performing end processing on the outer shaft 12, the rotor core 20 is sandwiched between the bent end portion of the outer shaft 12 and the protruding portion 12D located at the other end of the outer peripheral portion 12A. It is possible to prevent the rotor core 20 from coming off from the outer shaft 12 more reliably. Further, it is not necessary to separately prepare a stopper member for preventing the rotor core 20 from coming off, and the manufacturing cost of the rotor 100 can be reduced.

  The present invention is not limited to the above-described embodiment, and it is obvious that various modifications can be made within the scope of the technical idea.

  In the present embodiment, the shape of the outer peripheral portion 12A of the outer shaft 12 and the shape of the insertion hole 21 of the rotor core 20 are formed in a hexagonal shape, but may be a polygonal shape such as a triangle, a quadrangle, or a pentagon. Accordingly, the mandrels having the shape required for the outer shaft 12 are used as the polygonal mandrels 501 and 502.

  In this embodiment, as shown in FIG. 2, the rotor shaft assembling process is executed after finishing. However, the inner shaft 11 may be assembled to the cylindrical material 400 immediately after the material forming process, or the inner shaft 11 may be assembled to the outer shaft 12 immediately after the outer shaft forming process. When the inner shaft 11 is assembled in this way, a polygonal mandrel having an insertion hole through which the inner shaft 11 is inserted is used in the tubular material arranging step, the outer shaft forming step, and the finishing step.

  In the present embodiment, the cylindrical material 400 is formed from the disk-shaped material 200 by the material forming step, but the cylindrical material 400 may be formed in advance by forging, casting, press molding, or the like.

  In this embodiment, the finishing process is performed after the outer shaft forming process, but the finishing process may be omitted. When the finishing process is omitted, by adjusting the axial movement of the forming rollers 511 and 512 in the outer shaft forming process, a protruding part 12D is formed at one end of the outer peripheral part 12A of the outer shaft 12. The

  In the present embodiment, the end portion machining step is performed after the rotor core arrangement step, but the end portion machining step can be omitted. When the end machining step is omitted, the rotor core 20 is prevented from coming off from the outer shaft 12 by arranging a stopper member or the like at the tip of the outer shaft 12.

  Further, in the end portion processing step, the end portion processing is performed by pressing the caulking roller 514 against the rotating outer shaft 12, but the die member is pressed against the outer shaft 12 in a stopped state. End processing may be performed.

DESCRIPTION OF SYMBOLS 100 Rotor 10 Rotor shaft 11 Inner shaft 12 Outer shaft 12A Outer peripheral part 12B Flange part 12C Insertion hole 12D Protrusion part 20 Rotor core 21 Insertion hole 200 Disc-shaped material 301 Columnar mandrel 302 Columnar mandrel 311 Processing roller 400 Cylindrical material 401 Cylinder Part 402 Flange plate 403 Through hole 501 Polygonal mandrel 502 Polygonal mandrel 511 Forming roller 513 Finishing roller 514 Caulking roller

Claims (5)

A rotor manufacturing method for manufacturing a rotor for a rotating electrical machine by forming a rotor shaft using an outer shaft having a polygonal outer shaft and an outer shaft, and inserting and arranging a rotor core on the outer periphery of the outer shaft,
A cylindrical material having a cylindrical portion and a flange plate projecting inward from the inner peripheral surface of the cylindrical portion is a step of installing a polygonal mandrel having an outer peripheral shape that is polygonal, and the inner side of the cylindrical portion By sandwiching both ends of the flange plate by a pair of the polygonal mandrels, a tubular material placement step of placing the tubular material on the polygonal mandrel;
The polygonal mandrel is rotated so that the axial center of the cylindrical material is the center of rotation, and the forming roller is pressed against the cylindrical portion from the outside, and the forming roller or the polygonal mandrel is fixed to the shaft of the cylindrical material. By moving in the direction, the cylindrical portion is shaped so as to be polygonal, and the outer shaft having a polygonal outer peripheral portion and a flange portion projecting inward from the inner peripheral surface of the outer peripheral portion is formed. An outer shaft forming step,
A rotor manufacturing method comprising: The rotor manufacturing method according to claim 1,
Prior to the tubular material placement step, further comprising a material forming step of forming the tubular material,
The material forming step includes
A disk-shaped material placement step of placing the disk-shaped material on the columnar mandrel by sandwiching the center portions of both ends of the disk-shaped material between a pair of columnar mandrels;
The cylindrical mandrel is rotated so that the axis of the disk-shaped material is the center of rotation, and the processing roller is pressed against the outer peripheral surface of the disk-shaped material from the outside, and then the processing roller or the cylindrical mandrel Is moved in the axial direction of the disk-shaped material, so that the outer peripheral portion of the disk-shaped material located outside the columnar mandrel is formed into a cylindrical shape, and the cylindrical portion and the flange plate are Including a cylindrical material forming step of forming the cylindrical material.
The rotor manufacturing method characterized by the above-mentioned. A rotor manufacturing method according to claim 1 or 2,
After the outer shaft forming step, the polygonal mandrel on which the outer shaft is arranged is rotated to press a finishing roller having a smaller diameter than the forming roller against the outer peripheral portion of the outer shaft from the outside, and the finishing roller Or, further comprising a finishing step of performing a finish molding of the outer peripheral shape of the outer shaft by moving the polygonal mandrel in the axial direction of the outer shaft,
The rotor manufacturing method characterized by the above-mentioned. The rotor manufacturing method according to claim 3,
In the finishing step, the finish molding is performed such that one end portion of the outer peripheral portion in the axial direction of the outer shaft is formed as a protruding portion that protrudes outward from other portions of the outer peripheral portion.
The rotor manufacturing method characterized by the above-mentioned. The rotor manufacturing method according to claim 4,
In the rotor shaft configured by connecting the inner shaft to the flange portion of the outer shaft, the rotor core is inserted and arranged in the outer peripheral portion from the other end portion side of the outer peripheral portion toward the one end portion of the outer shaft. A rotor core arranging step to perform,
An end portion processing step of deforming the other end portion of the outer peripheral portion where the rotor core is disposed toward the outside; and
The rotor manufacturing method characterized by the above-mentioned.

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