JP2018113755A - Method for manufacturing rotor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a manufacturing method capable of fixing an outer rotor core onto a shaft so that a central axis of the outer rotor core and that of the shaft become high precision concentricity with a rotor having an inner rotor core and the outer rotor core.SOLUTION: A manufacturing method of a rotor 1 having an inner rotor core 11 and an outer rotor core 13 includes: a temporarily fixing step for temporarily fixing the outer rotor core 13 onto an end plate 12 in a non fastening state; a positioning step for positioning a central axis of a shaft 10 with that of the outer rotor core 13 by a positioning jig 30; and a fastening process for fastening the outer rotor core 13 onto the end plate 12 in a positioning state by the positioning jig 30. The positioning jig 30 includes an engaging unit 31 that engages with the shaft 10 so that a central axis of the jig becomes coaxial with that of the shaft 10, and a contact units 32 that extend for the same length at an opposite side from each other from the central axis of the jig in a radial direction of the rotor to come into contract with an inner peripheral surface of the outer rotor core 13.SELECTED DRAWING: Figure 3

Description

  The present invention relates to a method for manufacturing a rotor, and more particularly, to a method for manufacturing a rotor including an inner rotor core and an outer rotor core.

  A rotor used in a rotating electrical machine or the like includes a shaft and a rotor core fixed to the shaft. Such a rotor is manufactured by inserting and fixing a shaft in a shaft hole provided in the center of the rotor core.

  In order to fix the shaft and the rotor core with high accuracy, after inserting a normal temperature shaft into the shaft hole of the heated rotor core, the rotor core is cooled, and the shaft is fixed to the rotor core by reducing the shaft hole accompanying cooling. There is a fitting technique. In addition, there is a technique in which a shaft hole having a non-circular portion is expanded outward, the shaft is inserted into the expanded shaft hole, the expanded state is released, and the shaft is fixed to the rotor core (for example, Patent Document) 1).

JP 2010-166735 A

  As the motor, there is a multi-face gap motor having gaps on both the inner peripheral face and the outer peripheral face of the stator core. A rotor used for a multi-face gap motor includes an inner rotor core fixed to a shaft and an outer rotor core fixed to the shaft via an end plate or the like. In this rotor, the shaft and the inner rotor core can be fixed with high accuracy by applying the above-described warm fitting technique and the technique of expanding the shaft hole to the shaft and the inner rotor core.

  However, since the shaft and the outer rotor core are not directly fixed, that is, fixed via an end plate or the like, the above-described warm-fitting technique and the technique of expanding the shaft hole cannot be applied. For this reason, the mounting position accuracy between the shaft and the outer rotor core may be low. If the mounting position accuracy between the shaft and the outer rotor core is low, rotation of the rotor becomes unbalanced, and uneven wear, noise, and vibration of the bearing may occur.

  Therefore, in the present invention, in a rotor including an inner rotor core and an outer rotor core, the outer rotor core can be fixed to the shaft so that the center axis of the outer rotor core and the center axis of the shaft have a highly accurate coaxiality. It aims to provide a method.

  The rotor manufacturing method of the present invention is a rotor manufacturing method comprising a shaft, an inner rotor core fixed to the shaft, and an outer rotor core fastened to an end plate fixed to the shaft, and the outer rotor core. Is temporarily fixed to the end plate in an unfastened state, a positioning step is performed to align the central axis of the shaft and the central axis of the outer rotor core with a positioning jig, and an alignment state is performed with the positioning jig. And a fastening step of fastening the outer rotor core to the end plate, and the positioning jig engages with the shaft such that the central axis of the jig is coaxial with the central axis of the shaft. And the outer rotor extending from the central axis of the jig to the opposite sides in the rotor radial direction by the same length And having a contact portion that contacts the inner peripheral surface of A.

  According to the present invention, in a rotor including an inner rotor core and an outer rotor core, the outer rotor core can be fixed to the shaft so that the central axis of the outer rotor core and the central axis of the shaft have a highly accurate coaxiality. As a result, the rotational balance of the rotor can be improved and the occurrence of uneven wear, noise and vibration of the bearing can be suppressed.

It is a schematic block diagram of the rotor which concerns on 1st Embodiment, (A) shows a top view, (B) shows BB sectional drawing of (A). It is a block diagram which shows the manufacturing process of the rotor which concerns on 1st Embodiment. It is explanatory drawing of the positioning process of the outer side rotor core which concerns on 1st Embodiment, (A) shows the state which attaches a positioning jig to a shaft and positions an outer side rotor, (B) fastens an outer side rotor core to an end plate. Indicates the state. It is explanatory drawing of the positioning process of the outer side rotor core which concerns on 2nd Embodiment, (A) shows the state which attaches a positioning jig to a shaft and positions an outer rotor, (B) fastens an outer side rotor core to an end plate. Indicates the state.

  The rotor 1 of 1st Embodiment is demonstrated with reference to FIGS. The rotor 1 in the first embodiment is used for, for example, a multi-sided gap motor mounted on a hybrid vehicle, an electric vehicle, or the like.

  As shown in FIG. 1, the rotor 1 includes a hollow shaft 10, an inner rotor core 11 fixed to the outer periphery of the shaft 10, and an outer rotor core 13 fastened to an end plate 12 fixed to the shaft 10.

  A disc-shaped flange 10 a is provided at one end of the shaft 10. A disc-shaped end plate 12 is placed on the flange 10 a, and the end plate 12 is fixed to the shaft 10. A screw thread 10 b is formed on the peripheral surface of the other end of the shaft 10.

  The inner rotor core 11 is configured by laminating a plurality of electromagnetic steel plates punched into a substantially annular shape in the axial direction and integrally connecting them by welding or caulking. The inner rotor core 11 is mounted on the end plate 12, and is fixed to the shaft 10 by screwing a nut 14 into a screw thread 10 b at the other end of the shaft 10.

  Six screw holes 12 a for fixing the outer rotor core 13 are provided on the outer peripheral portion of the end plate 12. Then, the outer rotor core 13 is fastened and fixed to the end plate 12 by inserting the bolt 15 into the mounting hole 13a (see FIG. 3) of the outer rotor core 13 and screwing the bolt 15 into the screw hole 12a. Similar to the inner rotor core 11, the outer rotor core 13 is configured by laminating a plurality of electromagnetic steel sheets each punched into a substantially annular shape in the axial direction and integrally connecting them by welding or caulking.

  A space is formed between the outer peripheral surface of the inner rotor core 11 and the inner peripheral surface of the outer rotor core 13. In this space, an annular stator 20 is disposed between each of the circumferential surfaces with a gap therebetween. Thus, the rotor 1 has a multifaceted gap with respect to the stator 20, that is, a gap between the outer peripheral surface of the inner rotor core 11 and the inner peripheral surface of the stator 20, and a gap between the inner peripheral surface of the outer rotor core 13 and the outer peripheral surface of the stator 20. have.

  Next, the manufacturing process of the rotor 1 will be described with reference to FIG. First, in the end plate fixing step of step S10, the room temperature shaft 10 is inserted into the shaft hole of the heated end plate 12, and the end plate 12 is placed on the flange 10a of the shaft 10. Then, the end plate 12 is fixed to the shaft 10 by reducing the shaft hole of the end plate 12 accompanying cooling. In other words, the end plate 12 is fixed to the shaft 10 by shrink fitting.

  In the inner rotor core fixing step of step S <b> 11, the inner rotor core 11 is mounted on the shaft 10 and the inner rotor core 11 is placed on the end plate 12. Then, the inner rotor core 11 is fastened and fixed to the shaft 10 by screwing the nut 14 into the thread 10 b of the shaft 10.

  In the outer rotor core temporary fixing step of step S12, the outer rotor core 13 in which a large number of electromagnetic steel plates are laminated in the axial direction and connected in advance is temporarily fixed to the end plate 12. This temporary fixing means that the outer rotor core 13 is not placed on the end plate 12 in a state where the mounting holes 13a (see FIG. 3) of the outer rotor core 13 and the screw holes 12a of the end plate 12 are aligned. This is a fastened state where the position of the outer rotor core 13 can be corrected.

  In the positioning jig attaching step in step S13, the positioning jig 30 is lowered toward the shaft 10 from above the rotor 1, as shown in FIG. Here, the positioning jig 30 will be described. As shown in FIG. 3A, the positioning jig 30 serves as an engaging portion that engages with the hollow hole 10c of the shaft 10 so that the central axis of the positioning jig 30 is coaxial with the central axis of the shaft 10. The protrusion 31 and the contact portion 32 that extends from the central axis of the protrusion 31 in a cross shape in the rotor radial direction and contacts the inner peripheral surface of the outer rotor core 13 are provided.

  The convex portion 31 has a substantially conical shape that tapers toward the tip. The abutting portion 32 includes a first arm 33 extending the same length from the central axis of the convex portion 31 in the rotor radial direction, and bent by approximately 90 degrees from the tip of the first arm 33 to the rotor axial direction. And a second arm 34 extending toward the end. A tapered surface 34a and a positioning surface 34b continuous with the tapered surface 34a are formed on the outer surface of the distal end portion of the second arm 34. The length R1 from the central axis of the convex portion 31 to the positioning surface 34b is the same length as the length (inner diameter) from the central axis of the outer rotor core 13 to the inner peripheral surface.

  In the positioning jig attaching step of step S <b> 13, as shown in FIG. 3A, the convex portion 31 of the positioning jig 30 is inserted into the hollow hole 10 c at one end of the shaft 10 to attach the positioning jig 30 to the shaft 10. At this time, since the conical surface of the convex portion 31 of the positioning jig 30 is attached to the shaft 10 along the hollow hole 10c of the shaft 10, the positioning jig 30 is attached to the central axis of the convex portion 31 of the positioning jig 30 and the center of the shaft 10. The axis is located on the same axis.

  In the outer rotor core positioning step of step S14, as shown in FIG. 3B, when the positioning jig 30 is lowered, the tapered surface 34a of the second arm 34 of the positioning jig 30 is formed on the inner peripheral surface of the outer rotor core 13. In contact, the position of the outer rotor core 13 is corrected. When the positioning jig 30 is further lowered, the positioning surface 34b of the second arm 34 of the positioning jig 30 comes into contact with the inner peripheral surface of the outer rotor core 13 to move the outer rotor core 13 to a normal position. That is, since the outer rotor core 13 is temporarily fixed to the end plate 12 (unfastened state), the outer rotor core 13 is moved and positioned along the positioning surface 34 b of the positioning jig 30.

  In the outer rotor core fastening step of step S15, as shown in FIG. 3B, in a state where the position of the outer rotor core 13 is maintained, the bolt 15 is inserted into the mounting hole 13a of the outer rotor core 13, and the screw hole of the end plate 12 is inserted. 12a. By this screwing, the outer rotor core 13 is fastened and fixed at a precise position with respect to the shaft 10 with high accuracy. After the fixing of the outer rotor core 13 is completed, the positioning jig 30 is removed.

  Thus, the outer rotor core 13 is fixed to the end plate 12 in a state where the outer rotor core 13 is accurately positioned with respect to the shaft 10 by the positioning jig 30, so that the outer rotor core 13 can be fixed with high accuracy. it can. As a result, the rotation balance of the rotor 1 can be improved and the occurrence of uneven wear, noise and vibration of the bearing can be suppressed.

  Next, a modification of the first embodiment will be described. In the above description, in the outer rotor core temporary fixing step in step S12, the outer rotor core 13 in which a large number of electromagnetic steel plates are stacked in the axial direction and connected in advance is temporarily fixed to the end plate 12, but the outer rotor core in step S15 is temporarily fixed. A number of electromagnetic steel sheets may be connected in the axial direction by fastening in the fastening process.

  That is, in the outer rotor core temporary fixing step in step S12, a large number of electromagnetic steel sheets are stacked and placed on the end plate 12 in the axial direction. In this state, for example, a bolt 15 is inserted into one place of the mounting hole 13 a to temporarily fix the laminated electromagnetic steel plates to the end plate 12.

  In the positioning jig attaching step in step S13, the positioning jig 30 is attached to the shaft 10. Subsequently, in the outer rotor core positioning step of step S14, the positioning jig 30 is lowered, and a plurality of electromagnetic steel sheets are positioned by the positioning surface 34b of the second arm 34 of the positioning jig 30.

  In the outer rotor core fastening process in step S15, six bolts 15 are screwed into the screw holes 12a of the end plate 12 in a state where a large number of electromagnetic steel sheets are positioned. By this screwing, a large number of electromagnetic steel plates are connected in a state of being laminated in the rotor axial direction, thereby forming the outer rotor core 13. Further, the outer rotor core 13 is fastened and fixed to the shaft 10 at an accurate position with high accuracy.

  As described above, the connection of the multiple electromagnetic steel plates constituting the outer rotor core 13 in the rotor axial direction and the positioning of the outer rotor core 13 with respect to the shaft 10 can be performed simultaneously. In this case, when the positioning jig 30 is lowered, the second arm 34 of the positioning jig 30 is extended so that the positioning surface 34b comes into contact with all the electromagnetic steel plates. The end plate 12 is provided with a clearance hole that avoids interference with the second arm 34 of the positioning jig 30.

  Next, a second embodiment will be described with reference to FIG. In the second embodiment, the configuration of the positioning jig 40 is different from the configuration of the positioning jig 30 of the first embodiment. For this reason, the same components as those described in the first embodiment are denoted by the same reference numerals, and redundant description is omitted.

  As shown in FIG. 4, the positioning jig 40 extends in a cross shape in the rotor radial direction from the screw hole 41 as an engaging portion that engages with the thread 10 b of the shaft 10, and the central axis of the screw hole 41, And a contact portion 42 that contacts the inner peripheral surface of the outer rotor core 13. The contact portion 42 includes a first arm 43 and a second arm 44 corresponding to the first arm 33 and the second arm 34 in the first embodiment.

  The correction of the mounting position of the outer rotor core 13 will be described using the positioning jig 40. FIG. The steps S10 to S12 in FIG. 2 are the same, and the steps S13 to S15 are different, so these steps will be described.

  In the positioning jig attaching step in step S13, the screw hole 41 of the positioning jig 40 is screwed into the thread 10b at one end of the shaft 10. Then, the positioning jig 40 is moved down along the shaft 10 by rotating the positioning jig 40. At this time, the central axis of the screw hole 41 of the positioning jig 40 and the central axis of the shaft 10 are located on the same axis.

  In the outer rotor core positioning step of step S14, as shown in FIG. 4B, when the positioning jig 40 is further lowered, the tapered surface 44a of the second arm 44 of the positioning jig 40 becomes the inner peripheral surface of the outer rotor core 13. To correct the position of the outer rotor core 13. When the positioning jig 40 is further lowered, the positioning surface 44b of the second arm 44 of the positioning jig 40 comes into contact with the inner peripheral surface of the outer rotor core 13 and moves the outer rotor core 13 to a normal position. That is, since the outer rotor core 13 is temporarily fixed to the end plate 12 (unfastened state), the outer rotor core 13 is moved and positioned along the positioning surface 44b of the positioning jig 40.

  Thereafter, in the outer rotor core fastening step of step S15, as shown in FIG. 4B, in a state where the position of the outer rotor core 13 is maintained, the bolt 15 is inserted into the mounting hole 13a of the outer rotor core 13, and the end plate 12 is inserted. Screwed into the screw hole 12a. By this screwing, the outer rotor core 13 is fastened and fixed to the shaft 10 at an accurate position with high accuracy. After the outer rotor core 13 is fixed, the positioning jig 40 is removed.

  As described above, also in the second embodiment, the outer rotor core 13 is fixed to the end plate 12 in a state where the outer rotor core 13 is adjusted to an accurate fixing position with respect to the shaft 10 by the positioning jig 40. 13 can be fixed with high accuracy. As a result, the rotation balance of the rotor 1 can be improved and the occurrence of uneven wear, noise and vibration of the bearing can be suppressed.

  In addition, although the shape of the contact part 32 of the positioning jig 30 and the shape of the contact part 42 of the positioning jig 40 has been described as a cross shape, the shape is not limited to this, and may be, for example, a disk shape or a bar shape. That is, it is only necessary to have a shape in which the contact portion is formed at a position extending from the central axis of the engaging portion to the opposite side in the radial direction of the rotor by the same length.

  Further, in the above-described embodiment, the positioning surface 34 b of the positioning jig 30 and the positioning surface 44 b of the positioning jig 40 are brought into contact with the inner peripheral surface of the outer rotor core 13 to position the outer rotor core 13. The outer rotor core 13 may be positioned by contacting the tapered surface 34 a and the tapered surface 44 a of the positioning jig 40 with the inner peripheral edge of the outer rotor core 13.

  DESCRIPTION OF SYMBOLS 1 Rotor, 10 shaft, 10a flange, 10b thread, 10c hollow hole, 11 inner rotor core, 12 end plate, 12a, 41 screw hole, 13 outer rotor core, 13a mounting hole, 14 nut, 15 bolt, 20 stator, 30, 40 positioning jig, 31 convex part, 32, 42 contact part, 33, 43 first arm, 34, 44 second arm, 34a, 44a taper surface, 34b, 44b positioning surface.

Claims (1)

A rotor manufacturing method comprising: a shaft; an inner rotor core fixed to the shaft; and an outer rotor core fastened to an end plate fixed to the shaft,
A temporary fixing step of temporarily fixing the outer rotor core to the end plate in an unfastened state;
An alignment step of aligning the central axis of the shaft and the central axis of the outer rotor core with a positioning jig;
A fastening step of fastening the outer rotor core to the end plate in an alignment state by the positioning jig;
Including
The positioning jig includes an engaging portion that engages with the shaft such that a central axis of the jig is coaxial with the central axis of the shaft, and the same length on opposite sides in the rotor radial direction from the central axis of the jig. And a contact portion that extends and contacts the inner peripheral surface of the outer rotor core.