JP2018121503A - Rotor laminated core and manufacturing method of the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To more increase efficiency of a motor by suppressing a loss of an electric energy due to an eddy current.SOLUTION: A rotor laminated core 1 comprises: a laminate body 10 to which six block bodies B and two block bodies C are laminated; and a permanent magnet 12. In each block body B, a penetration hole Bb larger than an outer shape of the permanent magnet 12 in view from a laminate direction, penetrating to the laminate body 10 in a laminate direction is provided. In each block body C, a penetration hole Cb larger than the outer shape of the permanent magnet 12 in view from the laminate direction, penetrating in the laminate direction, and an insulation holding tool 18 that coats all of an inner peripheral surface while being extended along an inner peripheral surface of the penetration hole Cb are provided. In the laminate body 10, a magnet insertion hole 10b constructed so that the penetration holes Bb and Cb are communicated in the laminate direction is provided. The permanent magnet 12 is inserted into the magnet insertion hole 10b in a state of being held by the insulation holding tool 18.SELECTED DRAWING: Figure 2

Description

  The present disclosure relates to a rotor laminated core and a method for manufacturing the same.

  The rotor laminated iron core is usually inserted into a laminated body in which a plurality of punched members obtained by punching a metal plate (for example, a magnetic steel sheet) into a predetermined shape and a magnet insertion hole extending in the laminating direction of the laminated body. And a resin material filled in a gap between the magnet insertion hole and the permanent magnet. When the permanent magnet and the metal plate are in contact with each other, an eddy current is generated at the contact point, and the eddy current flows through the metal plate, so that electric energy can be lost.

  Therefore, Patent Document 1 discloses a plurality of first metal plates provided with first through holes that form magnet insertion holes, and at least one second metal plate provided with second through holes that form magnet insertion holes. It discloses that a laminated body of rotor laminated iron cores is formed using a metal plate. The size of the first through hole is larger than the outer shape of the permanent magnet. A plurality of protrusions for holding the outer peripheral surface of the permanent magnet are provided on the periphery of the second through hole. When permanent magnets are inserted into the magnet insertion holes of such a laminate, the permanent magnets are held by the projections of the second through holes in a small number of second metal plates and come into contact with a large number of first metal plates. It becomes difficult. Therefore, the contact area between the metal plate and the permanent magnet is minimized, and the loss of electrical energy due to eddy current is greatly reduced.

JP 2013-110827 A

  The present disclosure describes a rotor laminated iron core capable of suppressing loss of electric energy due to eddy currents and further improving the efficiency of a motor, and a method for manufacturing the same.

  A rotor laminated core according to one aspect of the present disclosure includes a laminated body in which a plurality of first iron core members and at least one second iron core member are laminated, and a permanent magnet. The first iron core member is provided with a first through hole that penetrates in the stacking direction of the stacked body and is larger than the outer shape of the permanent magnet when viewed from the stacking direction. The second iron core member includes a second through hole that penetrates in the stacking direction and is larger than the outer shape of the permanent magnet when viewed from the stacking direction, and extends along the inner peripheral surface of the second through hole. An insulating holder that covers the entire surface is provided. The laminated body is provided with a magnet insertion hole configured such that the first and second through holes communicate with each other in the lamination direction. The permanent magnet is inserted into the magnet insertion hole while being held by the insulating holder.

  A method for manufacturing a rotor laminated core according to another aspect of the present disclosure includes a first core member provided with a first through hole larger than the outer shape of the permanent magnet, and a second larger than the outer shape of the permanent magnet. A first step of preparing a second core member provided with a through hole, and a second step of disposing a core in the second through hole so as not to contact the inner peripheral surface of the second through hole. And after filling the insulating material between the inner peripheral surface of the second through hole and the core, the core is removed, and the inner periphery extends along the inner peripheral surface of the second through hole. Laminating the first core member and the second core member so that the third step of forming an insulating holder covering the entire surface and the first and second through holes communicate with each other to form a magnet insertion hole And the 4th process which constitutes a layered product, and the 5th process of inserting a permanent magnet in a magnet insertion hole and holding a permanent magnet in an insulating holder

  According to the rotor laminated core and the method for manufacturing the same according to the present disclosure, it is possible to suppress loss of electric energy due to eddy current and further increase the efficiency of the motor.

FIG. 1 is a perspective view showing an example of a rotor laminated iron core. 2 is a cross-sectional view taken along line II-II in FIG. FIG. 3 is an enlarged view of a portion III surrounded by a one-dot chain line circle in FIG. FIG. 4 is an exploded perspective view of the laminate. Fig.5 (a) is a top view which shows the block body provided with the insulation holder, FIG.5 (b) is a top view which expands and shows a through-hole (magnet insertion hole) among the said block bodies. FIG. 6 is a schematic view showing an example of a manufacturing apparatus for a rotor laminated core. FIG. 7 is a flowchart for explaining an example of a method for producing a rotor laminated core. FIG. 8 is a diagram for explaining a manufacturing process of the rotor laminated core. FIG. 9 is a cross-sectional view of another example of the rotor laminated core cut in the same manner as in FIG. FIG. 10 is a cross-sectional view of another example of the rotor laminated iron core cut in the same manner as in FIG.

  Since the embodiment according to the present disclosure described below is an example for explaining the present invention, the present invention should not be limited to the following contents.

<< Summary of Embodiment >>
[1] A rotor laminated core according to an example of the present embodiment includes a laminated body in which a plurality of first iron core members and at least one second iron core member are laminated, and a permanent magnet. The first iron core member is provided with a first through hole that penetrates in the stacking direction of the stacked body and is larger than the outer shape of the permanent magnet when viewed from the stacking direction. The second iron core member includes a second through hole that penetrates in the stacking direction and is larger than the outer shape of the permanent magnet when viewed from the stacking direction, and extends along the inner peripheral surface of the second through hole. An insulating holder that covers the entire surface is provided. The laminated body is provided with a magnet insertion hole configured such that the first and second through holes communicate with each other in the lamination direction. The permanent magnet is inserted into the magnet insertion hole while being held by the insulating holder.

  In the rotor laminated iron core according to one example of this embodiment, an insulating holder is provided that extends along the inner peripheral surface of the second through hole and covers the entire inner peripheral surface. The permanent magnet is inserted into the magnet insertion hole while being held by the insulating holder. Therefore, even if the permanent magnet swings in the magnet insertion hole (in the second through hole), the permanent magnet does not contact the first and second core members. Therefore, since no eddy current is generated between the permanent magnet and the first and second iron core members, loss of electrical energy due to the eddy current is suppressed. As a result, when the motor is configured using the rotor laminated core according to one example of the present embodiment, it is possible to further increase the efficiency of the motor. Moreover, the magnitude | size of a 1st through-hole should just be larger than the external shape of a permanent magnet to such an extent that a permanent magnet does not contact a 1st through-hole. For this reason, the gap generated between the first through hole and the permanent magnet can be set to a minimum. Therefore, since the decrease in the volume of the first iron core member can be suppressed, the motor performance can be improved.

  [2] In the rotor laminated iron core according to the first item, the second iron core member may be a block body in which a plurality of punching members obtained by punching a metal plate along a predetermined shape are stacked. . In this case, the area of the inner peripheral surface of the second through hole is increased as compared with the case where the second iron core member is constituted by a single punching member. Therefore, the insulating holder can be firmly fixed to the inner peripheral surface of the second through hole.

  [3] In the rotor laminated iron core according to item 1 or 2, the insulating holder has a tapered shape that protrudes inwardly from one end face of the laminate to the other end face in the laminating direction. May be. In this case, when the permanent magnet is inserted into the magnet insertion hole, the permanent magnet is inserted in the forward direction (the direction from one end face of the laminate to the other end face) with respect to the insulating holder having a tapered shape. Thus, the permanent magnet can be smoothly attached to the insulating holder.

  [4] In the rotor laminated core according to any one of items 1 to 3, the laminated body is configured such that the second iron core member is sandwiched between the first iron core members, The outer shape of the second through hole is larger than the outer shape of the first through hole, and at least a part of the inner peripheral surface of the insulating holder protrudes inward from the inner peripheral surface of the first through hole. Good. In this case, the outer peripheral surface of the insulating holder is located outward from the inner peripheral surface of the first through hole. Therefore, the base end portion of the insulating holder (the portion of the insulating holder that is in contact with the inner peripheral surface of the second through hole) is sandwiched between the pair of first iron core members. Therefore, since the insulating holder is held by the pair of first iron core members, the insulating holder is more difficult to drop off from the second through hole. Further, since at least a part of the inner peripheral surface of the insulating holder is located inward of the inner peripheral surface of the first through hole, the permanent magnet can be held by the part.

  [5] In the rotor laminated iron core according to any one of [1] to [4], a recess recessed toward the outside of the second through hole is formed on the periphery of the second through hole. The insulating holder may be fitted in the recess. In this case, due to the anchor effect generated between the insulating holder and the recess, the insulating holder is more difficult to drop out of the second through hole.

  [6] In the rotor laminated core according to item 5, the recess may be recessed in a direction intersecting with the radial direction of the laminate as viewed from the lamination direction. In this case, even if a centrifugal force acts on the insulating holder in the radial direction of the laminated body during the rotation of the rotor laminated core, the insulating holder is held in the second through hole against the centrifugal force. . Therefore, it becomes difficult for the insulating holder to fall out of the second through hole.

  [7] In the rotor laminated core according to any one of [1] to [6], the permanent magnet and the insulating holder may be partially separated. In this case, a gap is partially generated between the permanent magnet and the insulating holder. Therefore, after the permanent magnet is inserted into the magnet insertion hole and held by the insulating holder, the gap is used when the molten resin is filled in the magnet insertion hole and the permanent magnet is resin-sealed in the magnet insertion hole. Functions as a flow path for the molten resin. Therefore, the molten resin can be efficiently filled into the magnet insertion hole.

  [8] A method for manufacturing a rotor laminated core according to another example of the present embodiment includes a first core member provided with a first through hole larger than the outer shape of the permanent magnet, and an outer shape of the permanent magnet. A first step of preparing a second core member provided with a large second through hole, and a core in the second through hole so as not to contact the inner peripheral surface of the second through hole The second step of disposing, and after filling the insulating material between the inner peripheral surface of the second through hole and the core, the core is removed and extends along the inner peripheral surface of the second through hole And the 3rd process of forming the insulating holder which covers the whole inner peripheral surface, and the 1st iron core member and the 2nd iron core so that the 1st and 2nd penetration hole may be connected and it may constitute a magnet insertion hole A fourth step of laminating the members to constitute the laminated body, and a fifth step of inserting the permanent magnet into the magnet insertion hole and holding the permanent magnet on the insulating holder Including the. In this case, the same effects as those of the first item are obtained.

  [9] In the method according to the above item 8, the peripheral side surface of the core is a tapered surface because the core has a tapered shape, and in the second step, the peripheral side surface of the core and the second side A core may be arranged in the second through hole so that the inner peripheral surface of the through hole faces the other. In this case, the same effects as those of the third item are achieved.

≪Example of embodiment≫
Hereinafter, an example of an embodiment according to the present disclosure will be described in more detail with reference to the drawings. In the following description, the same reference numerals are used for the same elements or elements having the same function, and redundant description is omitted.

[Configuration of rotor laminated core]
First, the structure of the rotor laminated core 1 will be described with reference to FIGS. The rotor laminated core 1 is a part of a rotor (rotor). A rotor is constituted by attaching an end face plate and a shaft to the rotor laminated core 1. An electric motor (motor) is configured by combining the rotor with the stator (stator). As shown in FIG. 1, the rotor laminated core 1 includes a laminated body 10, a plurality of permanent magnets 12, and a plurality of resin materials 14.

  The laminate 10 includes a plurality of block bodies B (first iron core members) and a plurality of block bodies C (second iron core members; holding blocks). In the example illustrated in FIGS. 1 to 4, the stacked body 10 includes six block bodies B1 to B6 and two block bodies C1 and C2. Specifically, the block bodies B1, C1, B2 to B5, C2, and B6 are stacked in this order from the upper side to the lower side in FIGS. In other words, in this embodiment, the pair of block bodies B sandwich the block body C. In the stacking direction of the stacked body 10 (hereinafter simply referred to as “stacking direction”), the stacked body 10 may have a plurality of block bodies B and at least one block body C.

  The block body B is a laminated body in which a plurality of punching members 30A are stacked as shown in FIGS. In the present embodiment, the number of stacked punching members 30A is six as shown in FIGS. 2 to 4, but may be two or more. As shown in FIG. 4, a through hole Ba extending in the stacking direction (thickness direction) is provided in the central portion of the block body B. Therefore, the block body B has a cylindrical shape extending along the central axis Ax. The punching member 30A is a plate-like body (punching member) obtained by punching a magnetic steel sheet W (described later) that is a metal plate into a predetermined shape.

  As shown in FIGS. 2 and 4, the block body C is a stacked body in which a plurality of punching members 30 </ b> B are stacked. In this embodiment, the number of the punching members 30B stacked is three as shown in FIGS. 2 to 4, but may be two or more. As shown in FIG. 4, a through-hole Ca extending in the stacking direction (thickness direction) is provided in the central portion of the block body C. Therefore, the block body C has a cylindrical shape extending along the central axis Ax. The punching member 30B is a plate-like body (punching member) obtained by punching a magnetic steel sheet W (described later) that is a metal plate into a predetermined shape.

  In the state of the laminated body 10 in which the block bodies B and C are laminated, the through hole Ba of the block body B and the through hole Ca of the block body C communicate with each other in the laminating direction, and the laminating direction in the central portion of the laminated body 10 A shaft hole 10a extending in the direction is configured. A shaft (not shown) is inserted into the shaft hole 10a.

  The punching members 30 </ b> A adjacent in the stacking direction are fastened by the crimping portion 16. The punching members 30 </ b> B adjacent in the stacking direction are fastened by the crimping portion 16. The block bodies B and C adjacent in the stacking direction are not fastened by the crimping portion 16. Specifically, as shown in FIG. 2, the caulking portion 16 includes the caulking 16a formed on the punching members 30A and 30B other than the lowermost layer of the block bodies B and C, and the upper ends of the block bodies B and C. And through-holes 16b formed in the punching members 30A and 30B forming the lower layer. The caulking 16a includes a concave portion formed on the front surface side of the punching members 30A and 30B and a convex portion formed on the back surface side of the punching members 30A and 30B.

  The concave portion of the caulking 16a of one punching member 30A, 30B is joined to the convex portion of the caulking 16a of another punching member 30A, 30B adjacent to the surface side of the one punching member 30A, 30B. The convex portion of the caulking 16a of one punching member 30A, 30B is joined to the concave portion of the caulking 16a of another punching member 30A, 30B adjacent on the back side of the one punching member 30A, 30B. The convex portions of the caulking 16a of the punching members 30A and 30B adjacent to the lowermost layers of the block bodies B and C are joined to the through hole 16b. The through-hole 16b has a function of preventing the block bodies B and C to be manufactured next from being fastened by the caulking 16a with respect to the block bodies B and C that have already been manufactured when the block bodies B and C are continuously manufactured. And the function of preventing the adjacent block bodies B and C from being fastened by the caulking 16a.

  A plurality of through holes Bb and Cb are formed in the block bodies B and C, respectively. In this embodiment, as shown in FIGS. 4 and 5A, the block body B has 16 through holes Bb (first through holes), and the block body C has 16 holes. Through-hole Cb (second through-hole) is formed. As shown in FIG. 4, these through holes Bb and Cb are arranged at predetermined intervals along the outer peripheral edges of the block bodies B and C. Specifically, in the block body B, a pair is formed such that the two through holes Bb have a V shape extending toward the outer peripheral edge side of the block body B, and the eight through holes Bb are formed on the central axis Ax. It is arrange | positioned every 45 degrees around. Similarly, in the block body C, a pair is formed so that two through holes Cb have a V shape extending toward the outer peripheral edge of the block body C, and eight sets of through holes Cb are arranged around the central axis Ax. They are arranged approximately every 45 °.

  As shown in FIG. 4, the through holes Bb and Cb extend along the central axis Ax (stacking direction) and penetrate the block bodies B and C. As shown in FIGS. 1 to 3, the through holes Bb and Cb are larger than the outer shape of the permanent magnet 12 when viewed from the direction of the central axis Ax. As shown in FIGS. 2 to 4, the outer shape of the through hole Cb is larger than the outer shape of the through hole Bb when viewed from the direction of the central axis Ax.

  As shown in FIG. 1, the shape of the through hole Bb has a rectangular shape in this embodiment, but other shapes (for example, a circular shape, an elliptical shape, an oval shape (a square shape with rounded corners), Polygonal shape). The position, shape, and number of the through holes Bb may be changed according to the use of the motor, required performance, and the like.

  As shown in FIGS. 4 and 5, the shape of the through hole Cb has a rectangular shape as a whole in the present embodiment, but other shapes (for example, a circular shape, an elliptical shape, an oval shape (the corner is Round quadrangular shape, polygonal shape, etc.). The position, shape, and number of the through holes Cb may be changed according to the use of the motor, required performance, and the like. At the periphery of the through hole Cb, at least one recess Cc that is recessed toward the outside of the through hole Cb is provided. In the present embodiment, as shown in FIGS. 4 and 5A, two recesses Cc are arranged on each of the pair of long sides of the through hole Cb. That is, the recess Cc is recessed in a direction intersecting with the radial direction of the stacked body 10 (block body C) when viewed from the stacking direction. The shape of the recess Cc may be a semicircular shape as shown in FIGS. 4 and 5A, or may be various shapes such as a rectangular shape, a triangular shape, and a trapezoidal shape.

  In the state of the laminated body 10 in which the block bodies B and C are laminated, each through hole Bb of the block body B and each through hole Cb of the block body C correspond to each other. Thereby, each through-hole Bb and each through-hole Cb are connected in the lamination direction, and respectively comprise the magnet insertion hole 10b extended in a lamination direction. That is, the laminated body 10 is provided with a plurality of magnet insertion holes 10b arranged at predetermined intervals along the outer peripheral edge thereof.

  As shown in FIGS. 2 to 5, an insulating holder 18 is provided on the inner peripheral surface of the through hole Cb. The insulating holder 18 extends along the inner peripheral surface of the through hole Cb and covers the entire inner peripheral surface. Therefore, the insulation holder 18 has an annular shape in the present embodiment. That is, as shown in FIGS. 4 and 5, a through hole 18 a extending in the stacking direction is provided in the central portion of the insulating holder 18.

  The through hole 18a has a function of holding the permanent magnet 12 inserted into the through hole 18a. At least a part of the inner peripheral surface of the through hole 18 a is in contact with the outer peripheral surface of the permanent magnet 12. In the present embodiment, as shown in FIG. 5, the through hole 18 a and the permanent magnet 12 are partially separated. A gap V is provided between the through hole 18 a and the permanent magnet 12.

  As shown in FIGS. 4 and 5, the base end portion of the insulating holder 18 (the portion of the insulating holder 18 on the side in contact with the inner peripheral surface of the through hole Cb) is filled in the recess Cc. . The insulating holder 18 is fitted in the recess Cc. In the present embodiment, since the pair of block bodies B sandwich the block body C, the inner peripheral surface of the through hole Cb is recessed with respect to the inner peripheral surface of the through hole Bb. The base end portion of the insulating holder 18 that is in contact with the inner peripheral surface of the through hole Cb is sandwiched between a pair of block bodies B as shown in FIGS.

  As shown in FIGS. 2 and 3, the distal end portion of the insulating holder 18 (the portion inside the through hole Cb of the insulating holder 18) is the lower surface from the upper surface (one end surface) of the stacked body 10 in the stacking direction. It has a tapered shape that protrudes inward toward the other end surface. The inner peripheral surface of the insulating holder 18 (through hole 18a) is a tapered surface that narrows downward. At least a part (lower part of the tapered surface) of the inner peripheral surface of the insulating holder 18 (through hole 18a) protrudes inward from the inner peripheral surface of the through hole Bb. As shown in FIGS. 2 and 3, when viewed from the direction of the central axis Ax, the outer shape of the through hole 18a is smaller than the outer shape of the through hole Bb.

  The insulating holder 18 may be made of an insulator. Examples of the insulator include a thermosetting resin, a thermoplastic resin, and glass. Specific examples of the thermosetting resin include a resin composition containing a main agent and an additive. Examples of the main agent include an epoxy resin, a curing initiator, and a filler. Examples of the additive include a flame retardant, a stress reducing agent, and a colorant. The insulating holder 18 may be made of a metal material having a higher electrical resistivity than the metal plate (electromagnetic steel plate W) forming the punching members 30A and 30B. Examples of the metal material having a higher electrical resistivity than the electromagnetic steel sheet W include stainless steel.

  As shown in FIGS. 1 and 2, the permanent magnet 12 is disposed in the magnet insertion hole 10b. In the present embodiment, one permanent magnet 12 is inserted into one magnet insertion hole 10b. As shown in FIGS. 2 and 3, the permanent magnet 12 is held by an insulating holder 18 in the magnet insertion hole 10 b. More specifically, the outer peripheral surface of the permanent magnet 12 is in contact with a part of the inner peripheral surface of the through hole 18a of the insulating holder 18 (the lower portion of the tapered surface). The permanent magnet 12 may be held by an insulating holder 18 of at least two block bodies C that are separated in the stacking direction. In this case, the permanent magnet 12 is difficult to tilt in the magnet insertion hole 10b. The type of the permanent magnet 12 may be determined according to the use of the motor, required performance, and the like. For example, the permanent magnet 12 may be a sintered magnet or a bonded magnet.

  The resin material 14 is filled in the magnet insertion hole 10b after the permanent magnet 12 is inserted. The resin material 14 has a function of fixing the permanent magnet 12 in the magnet insertion hole 10b and a function of joining the punching members 30A and 30B adjacent in the vertical direction. Examples of the resin material 14 include a thermosetting resin or a thermoplastic resin. When the insulating holder 18 is made of resin, the components of the resin material 14 may be the same as or different from those of the insulating holder 18.

[Production equipment for rotor cores]
Then, with reference to FIG. 6, the manufacturing apparatus 100 of the rotor lamination | stacking iron core 1 is demonstrated.

  The manufacturing apparatus 100 is an apparatus for manufacturing the rotor lamination | stacking iron core 1 from the electromagnetic steel plate W (working board) which is a strip | belt-shaped metal plate. The manufacturing apparatus 100 includes an uncoiler 110, a delivery device 120, a punching device 130, a processing device 140, a laminating device 150, a magnet mounting device 160, and a controller 170 (control unit).

  The uncoiler 110 rotatably holds the coil material 111 in a state in which the coil material 111 that is a strip-shaped electromagnetic steel sheet W wound in a coil shape is mounted. The feeding device 120 includes a pair of rollers 121 and 122 that sandwich the electromagnetic steel sheet W from above and below. The pair of rollers 121, 122 rotate and stop based on an instruction signal from the controller 170, and intermittently sequentially feed the electromagnetic steel sheet W toward the punching device 130.

  The length of the electromagnetic steel plate W constituting the coil material 111 may be, for example, about 500 m to 10000 m. The thickness of the electromagnetic steel sheet W may be, for example, about 0.1 mm to 0.5 mm. From the viewpoint of obtaining the rotor laminated core 1 having more excellent magnetic characteristics, the thickness of the electromagnetic steel sheet W may be, for example, about 0.1 mm to 0.3 mm. The width of the electromagnetic steel sheet W may be, for example, about 50 mm to 500 mm.

  The punching device 130 operates based on an instruction signal from the controller 170. The punching device 130 sequentially forms the punching members 30A and 30B by punching the electromagnetic steel sheets W intermittently delivered by the delivery device 120 and the punching members 30A and 30B obtained by punching. It has a function of manufacturing a plurality of block bodies B and C by stacking them while being stacked, and a function of temporarily stacking a plurality of block bodies B and C to form a temporary stack 11.

  When the temporary laminate 11 is discharged from the punching device 130, it is placed on a conveyor Cv1 provided so as to extend between the punching device 130 and the processing device 140. The conveyor Cv1 operates based on an instruction from the controller 170, and sends the temporary laminate 11 to the processing device 140.

  The processing device 140 has a function of taking out the block body C from the temporary laminate 11 and providing the insulating holder 18 in each through hole Cb of the block body C. The processing device 140 restacks the block body C provided with the insulating holder 18 on the block body B again to reconfigure the temporary laminate 11. The temporary laminate 11 discharged from the processing apparatus 140 is placed on a conveyor Cv2 provided so as to extend between the processing apparatus 140 and the lamination apparatus 150. The conveyor Cv2 operates based on an instruction from the controller 170, and sends the temporary laminate 11 to the laminating apparatus 150.

  The laminating apparatus 150 has a function of laminating the block bodies B and C of the temporary laminated body 11 sent from the conveyor Cv2 based on a predetermined order to form the laminated body 10. The laminated body 10 discharged from the laminating apparatus 150 is placed on a conveyor Cv3 provided so as to extend between the laminating apparatus 150 and the magnet mounting apparatus 160. The conveyor Cv3 operates based on an instruction from the controller 170, and sends the laminated body 10 to the magnet attachment device 160.

  The magnet mounting device 160 operates based on an instruction signal from the controller 170. The magnet mounting device 160 has a function of performing the work of inserting at least one permanent magnet 12 into each magnet insertion hole 10b and the work of filling the resin material 14 into each magnet insertion hole 10b through which the permanent magnet 12 is inserted. And a function to perform.

  The controller 170 is, for example, based on a program recorded in a recording medium (not shown) or an operation input from an operator, etc. An instruction signal for operating each of 160 is generated, and the instruction signals are transmitted to the feeding device 120, the punching device 130, the processing device 140, the laminating device 150, and the magnet mounting device 160, respectively.

[Method of manufacturing rotor core]
Then, with reference to FIG.7 and FIG.8, the manufacturing method of the rotor laminated core 1 is demonstrated.

  First, the temporary laminate 11 is formed (see step S1 in FIG. 7). Specifically, based on an instruction from the controller 170, the electromagnetic steel plate W is sent out to the punching device 130 by the feeding device 120, and the processed portion of the electromagnetic steel plate W is punched into a predetermined shape by the punching device 130. Thereby, the punching member 30A is formed. By repeating this punching process, a predetermined number of the punching members 30A are stacked while being fastened together by the crimping portion 16, and one block body B is manufactured (first step). Similarly, a punching member 30B is formed from the electromagnetic steel sheet W, and a plurality of punching members 30B are stacked while being fastened to each other by the caulking portion 16 to produce one block body C (first step). ). The punching device 130 repeats this process to stack a plurality of block bodies B1 to B6, C1, and C2 to form the temporary laminate 11 (see FIG. 7). At this time, the block bodies B <b> 1 to B <b> 6, C <b> 1, and C <b> 2 constituting the temporary laminate 11 are not fastened to each other and can be freely moved and removed.

  Subsequently, based on an instruction from the controller 170, the conveyor Cv <b> 1 conveys the temporary laminate 11 discharged from the punching device 130 to the processing device 140. The processing apparatus 140 first takes out the block body C from the temporary laminate 11 as shown in FIG. Next, the processing apparatus 140 arrange | positions the core 40 in each through-hole Cb of the block body C, as FIG.8 (b) shows (2nd process). At this time, the core 40 does not contact the inner peripheral surface of the through hole Cb. In the present embodiment, the core 40 has a tapered shape as shown in FIG. More specifically, the peripheral side surface of the core 40 has a tapered surface. The peripheral side surface of the core 40 disposed in the through hole Cb is opposed to the inner peripheral surface of the through hole Cb.

  Next, as shown in FIG. 8C, the processing apparatus 140 fills an insulating material between the core 40 and the through hole Cb. Next, the processing apparatus 140 takes out the core 40 from the insulating holder 18 as shown in FIG. Thereby, the insulation holder 18 is provided in the through hole Cb (third step; see step S2 in FIG. 7). Next, the processing apparatus 140 reconstructs the temporary laminated body 11 by stacking the block body C provided with the insulating holder 18 on the block body B again.

  Subsequently, based on an instruction from the controller 170, the conveyor Cv2 conveys the temporary laminate 11 discharged from the processing apparatus 140 to the lamination apparatus 150. The laminating apparatus 150 transships the block bodies B1 to B6, C1, and C2 constituting the temporary laminated body 11 in a predetermined order. Specifically, the block bodies B and C are restacked in the order of the block bodies B1, C1, B2 to B5, C2, and B6 to form the stacked body 10 (fourth step; see step S3 in FIG. 7). .

  Next, based on an instruction from the controller 170, the conveyer Cv3 conveys the obtained laminate 10 to the magnet mounting device 160. When the laminated body 10 reaches the magnet attaching device 160, the controller 170 instructs the magnet attaching device 160 to insert the permanent magnets 12 one by one into each magnet insertion hole 10b of the laminated body 10 (fifth step; Step S4 in FIG. As a result, the permanent magnet 12 is held in the through hole 18 a of the insulating holder 18.

  Next, the controller 170 instructs the magnet mounting device 160 to fill and solidify the molten resin material 14 in each magnet insertion hole 10b (see step S5 in FIG. 7). At this time, since the gap V is provided between the through hole 18a and the permanent magnet 12, the molten resin flows through the gap V and fills the entire magnet insertion hole 10b. Thus, the permanent resin 12 is fixed in the magnet insertion holes 10b by the solidified resin material 14, and the block bodies B1 to B6, C1, and C2 are integrated. Thus, the rotor laminated iron core 1 is obtained.

  Thereafter, the shaft is inserted into the shaft hole 10a, and the shaft is fixed to the rotor laminated core 1 with a key or the like (see step S6 in FIG. 7). Next, an end face plate is respectively arrange | positioned with respect to the both end surfaces of the rotor laminated core 1 (refer step S6 of FIG. 7). For example, the end face plate may be fixed to the end face of the rotor laminated core 1 by caulking, or may be fixed to the rotor laminated iron core 1 by screwing a nut onto the shaft, or by a key or the like. It may be fixed with respect to the shaft. In this way, a rotor including the rotor laminated core 1, the shaft, and the end face plate is obtained.

[Action]
In the present embodiment as described above, the insulating holder 18 is provided so as to extend along the inner peripheral surface of the through hole Cb. The permanent magnet 12 is inserted into the magnet insertion hole 10 b while being held by the insulating holder 18. Therefore, even if the permanent magnet 12 swings in the magnet insertion hole 10b (in the through hole Cb), the permanent magnet 12 does not contact the block bodies B and C. Therefore, since no eddy current is generated between the permanent magnet 12 and the block bodies B and C, the loss of electric energy due to the eddy current is suppressed. As a result, when the motor is configured using the rotor laminated core 1, it is possible to further increase the efficiency of the motor. The size of the through hole Bb only needs to be larger than the outer shape of the permanent magnet 12 so that the permanent magnet 12 does not contact the through hole Bb. Therefore, the gap generated between the through hole Bb and the permanent magnet 12 can be set to a minimum. Therefore, since the reduction in the volume of the block body B can be suppressed, it is possible to improve the motor performance.

  In the present embodiment, the block body C is configured by laminating a plurality of punching members 30B in which the electromagnetic steel sheet W is punched along a predetermined shape. Therefore, the area of the inner peripheral surface of the through hole Cb is larger than that of the single punching member 30B. Therefore, the insulating holder 18 can be firmly fixed to the inner peripheral surface of the through hole Cb.

  In the present embodiment, the insulating holder 18 has a tapered shape that protrudes inwardly from the upper surface (one end surface) to the lower surface (the other end surface) of the stacked body 10 in the stacking direction. Therefore, when the permanent magnet 12 is inserted into the magnet insertion hole 10b, the permanent magnet 12 is inserted in the forward direction (the direction from the upper surface to the lower surface of the laminate 10) with respect to the insulating holder 18 having a tapered shape. Thus, the permanent magnet 12 can be smoothly attached to the insulating holder 18.

  In the present embodiment, the stacked body 10 is configured such that the block body C is sandwiched between the pair of block bodies B, and the outer shape of the through hole Cb is larger than the outer shape of the through hole Bb. Therefore, the outer peripheral surface of the insulating holder 18 is located outward from the inner peripheral surface of the through hole Bb. Therefore, the base end portion of the insulating holder 18 (the portion of the insulating holder 18 on the side in contact with the inner peripheral surface of the through hole Cb) is sandwiched between the pair of block bodies B. As a result, the base end portion of the insulating holder 18 is held by the pair of block bodies B, so that the insulating holder 18 is less likely to drop out of the through hole Cb. At this time, since at least a part of the inner peripheral surface of the insulating holder 18 is located inward of the inner peripheral surface of the through hole Bb, the permanent magnet 12 can be held by the part.

  In the present embodiment, a recess Cc that is recessed outward from the through hole Cb is provided at the periphery of the through hole Cb, and the insulating holder 18 is fitted with the recess Cc. Therefore, the insulating holder 18 is more difficult to drop out of the through hole Cb due to the anchor effect generated between the insulating holder 18 and the recess Cc.

  In the present embodiment, the recess Cc is recessed in a direction intersecting the radial direction of the stacked body 10 when viewed from the stacking direction. Therefore, even if a centrifugal force acts on the insulating holder 18 in the radial direction of the laminated body 10 when the rotor laminated core 1 rotates, the insulating holder 18 is held in the through hole Cb against the centrifugal force. The Therefore, it is difficult for the insulating holder 18 to fall off from the through hole Cb.

[Other Embodiments]
As mentioned above, although embodiment concerning this indication was described in detail, you may add various deformation | transformation to said embodiment within the range of the summary of this invention. For example, as shown in FIG. 9, the laminated body 10 includes block bodies B1, ¹ C1, B2, ¹ C2, B3, B4, ² C1, B5, ² C2, and B6 from the upper side to the lower side. The layers may be laminated in order. In this case, two permanent magnets 12A and 12B are inserted into one magnet insertion hole 10b so as to be aligned in the stacking direction. Specifically, the permanent magnets 12A, the two block bodies ^{1 C1,} 1 C2 of the through-holes are inserted into the Cb, two insulating holder 18A provided in the respective through holes Cb block body ^{1 C1,} 1 C2 Is held by. Permanent magnets 12B, the two block bodies ^{2 C1,} 2 C2 are inserted into the through hole Cb of, held by two insulating holder 18B provided in the respective through holes Cb of the block body ^{2 C1,} 2 C2 ing. Since the shape of the through hole 18a of the block body ^{1 C1,} 1 C2 and the block body ^{2 C1,} 2 C2 and an insulating retainer 18 is different, the permanent magnet 12A and permanent magnet 12B, in the same magnet insertion holes 10b Held in different positions. In this case, it is possible to adjust the weight imbalance of the laminate 10 by the permanent magnets 12A and 12B.

  As shown in FIG. 9, the insulating holder 18A that holds the permanent magnet 12A may have a tapered shape that narrows toward the insulating holder 18B that holds the permanent magnet 12B. Similarly, the insulating holder 18B that holds the permanent magnet 12B may have a tapered shape that narrows toward the insulating holder 18A that holds the permanent magnet 12A. In this case, the permanent magnet 12A is inserted into the through hole 18a of the insulating holder 18A from the upper side of FIG. 9, and the permanent magnet 12B is inserted into the through hole 18a of the insulating holder 18B from the lower side of FIG. The two permanent magnets 12A and 12B can be attached to the laminate 10 more smoothly.

  The number of permanent magnets 12 inserted into the magnet insertion hole 10b may be one or plural. A plurality of permanent magnets 12 may be arranged in the lamination direction in the magnet insertion hole 10b, or may be arranged in the longitudinal direction of the magnet insertion hole 10b when viewed from the lamination direction, as shown in FIG. As seen from the stacking direction, a plurality of magnet insertion holes 10b may be arranged in the short direction, or a plurality of the magnet insertion holes 10b may be arranged in a predetermined direction as viewed from the stacking direction. Alternatively, three or more permanent magnets 12 may be arranged in the magnet insertion hole 10b so as to form an annular shape when viewed from the stacking direction.

  As shown in FIGS. 9 and 10, an insulator 20 may be interposed between adjacent permanent magnets 12. In this case, a decrease in magnetism due to contact between adjacent permanent magnets 12 can be prevented. The plurality of permanent magnets 12 and the insulator 20 may be individually inserted into the through hole 18a. Alternatively, an insulator 20 (for example, an insulating tape, a foam sheet, etc.) is joined between adjacent permanent magnets 12 to form a block body, and the block body is inserted into the through hole 18a. Also good. Instead of the insulator 20, the resin material 14 may be filled between adjacent permanent magnets 12. In this case, after inserting into the through-hole 18a so that the several permanent magnet 12 may not contact, what is necessary is just to fill with molten resin between the adjacent permanent magnets 12. FIG.

  In the above embodiment, the permanent magnet 12 is inserted into the magnet insertion hole 10b and the resin material 14 is filled. However, the resin material 14 is not filled into each magnet insertion hole 10b. Good.

  As long as the permanent magnet 12 can be held by the through hole 18a of the insulating holder 18 provided in the block body C, the stacking position of the block body C in the stacked body 10 is not particularly limited.

  Instead of the block body C, a single punching member 30B (second iron core member) may be used.

  The inner peripheral surface of the through hole 18a of the insulating holder 18 may be narrowed from the both end sides of the through hole 18a toward the center. That is, the cross-sectional shape of the inner peripheral surface of the through hole 18a may have a mountain shape that protrudes inward at the center in the extending direction of the through hole 18a. In this case, each inclined surface is a taper surface among the inner peripheral surfaces of the through hole 18a having a mountain shape.

  The inner peripheral surface of the through hole 18a of the insulating holder 18 may not be a tapered surface. For example, the inner peripheral surface may extend straight along the stacking direction, may be an uneven surface in which unevenness repeatedly appears in the stacking direction or the circumferential direction, or exhibits a wave shape in the stacking direction or the circumferential direction. It may be a wavy surface.

  The entire inner peripheral surface (the entire tapered surface) of the through hole 18a of the insulating holder 18 may protrude inward from the inner peripheral surface of the through hole Bb.

  The recess Cc may be provided at any position on the periphery of the through hole Cb.

  Instead of the recess Cc, the inner peripheral surface of the through hole Cb may be roughened. Also in this case, an anchor effect is generated between the insulating holder 18 and the inner peripheral surface of the through hole Cb, and the insulating holder 18 is difficult to drop off from the through hole Cb. Note that since the rough surface is an uneven surface when viewed microscopically, it can be said that the concave portion constituting the rough surface corresponds to the concave portion Cc of the above embodiment.

  The through hole Cb may not have the recess Cc.

  The gap V may not be provided between the through hole 18a and the permanent magnet 12.

  The present invention may be applied not only to the rotor laminated core 1 but also to the stator laminated core.

  DESCRIPTION OF SYMBOLS 1 ... Rotor laminated iron core, 10 ... Laminated body, 10b ... Magnet insertion hole, 12 ... Permanent magnet, 14 ... Resin material, 18 ... Insulation holder, 40 ... Core, B ... Block body (1st iron core member) , Bb ... through hole (first through hole), C ... block body (second core member), Cb ... through hole (second through hole), Cc ... recess, V ... gap.

Claims (9)

A laminate in which a plurality of first iron core members and at least one second iron core member are laminated;
With a permanent magnet,
The first iron core member is provided with a first through hole that penetrates in the stacking direction of the laminate and is larger than the outer shape of the permanent magnet when viewed from the stacking direction,
The second iron core member has a second through hole that penetrates in the laminating direction and is larger than the outer shape of the permanent magnet when viewed from the laminating direction, and along an inner peripheral surface of the second through hole. An insulating holder that extends and covers the entire inner peripheral surface,
The laminated body is provided with a magnet insertion hole configured such that the first and second through holes communicate with each other in the laminating direction,
The permanent magnet is a rotor laminated iron core that is inserted into the magnet insertion hole while being held by the insulating holder.   2. The rotor laminated core according to claim 1, wherein the second iron core member is a block body in which a plurality of punched members obtained by punching a metal plate along a predetermined shape are stacked.   3. The rotor laminated core according to claim 1, wherein the insulating holder has a tapered shape that protrudes inwardly from one end face of the laminated body toward the other end face in the laminating direction. The laminate is configured such that the second iron core member is sandwiched between the first iron core members,
The outer shape of the second through hole is larger than the outer shape of the first through hole,
The rotor laminated core according to any one of claims 1 to 3, wherein at least a part of the inner peripheral surface of the insulating holder protrudes inward from the inner peripheral surface of the first through hole. . A recess recessed toward the outside of the second through hole is provided on the periphery of the second through hole,
The rotor laminated iron core according to any one of claims 1 to 4, wherein the insulating holder is fitted with the recess.   The rotor laminated core according to claim 5, wherein the concave portion is recessed in a direction intersecting with a radial direction of the laminated body as seen from the lamination direction.   The rotor laminated core according to any one of claims 1 to 6, wherein the permanent magnet and the insulating holder are partially separated from each other. A first iron core member provided with a first through hole larger than the outer shape of the permanent magnet and a second iron core member provided with a second through hole larger than the outer shape of the permanent magnet are prepared. 1 process,
A second step of disposing a core in the second through hole so as not to contact the inner peripheral surface of the second through hole;
After filling the insulating material between the inner peripheral surface of the second through hole and the core, the core is removed, and the inner periphery extends along the inner peripheral surface of the second through hole. A third step of forming an insulating holder covering the entire surface;
A fourth step of laminating the first iron core member and the second iron core member so that the first and second through holes communicate with each other to form a magnet insertion hole, thereby constituting a laminated body; ,
And a fifth step of inserting the permanent magnet into the magnet insertion hole and holding the permanent magnet on the insulating holder. When the core has a tapered shape, the peripheral side surface of the core is a tapered surface;
The said 2nd process WHEREIN: A core is arrange | positioned in a said 2nd through-hole so that the surrounding side surface of the said core and the internal peripheral surface of a said 2nd through-hole may oppose. the method of.

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