JP2019033618A - Rotor and manufacturing method thereof - Google Patents

Abstract

To provide a rotor and a manufacturing method thereof capable of preventing a part of a rotor member from scattering to the outside of the rotor from a magnet disposition hole portion while preventing the increase of the number of components and the complication of a manufacturing facility.SOLUTION: A rotor 100 includes a permanent magnet 1 and a rotor core 2 having a magnet disposition hole portion 3a in which a permanent magnet 1 is disposed. The permanent magnet 1 is fixed to the magnet disposition hole portion 3a by an adhesive material 5. The rotor core 2 includes a through electromagnetic steel sheet 3 having the magnet disposition hole portion 3a and a lid electromagnetic steel sheet 4 laminated on end portions 2a and 2b in the lamination direction of the rotor core 2 and configured to close the magnet disposition hole portion 3a.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a rotor and a method for manufacturing the rotor.

  Conventionally, a rotor including a rotor core formed by laminating a plurality of electromagnetic steel plates is known (see, for example, Patent Document 1).

  Patent Document 1 discloses a rotor including a permanent magnet and a rotor core formed by laminating a plurality of electromagnetic steel plates. In this rotor, a permanent magnet is inserted into the magnet insertion hole of the rotor core, and the permanent magnet is fixed to the magnet insertion hole by filling a resin member into the magnet insertion hole where the permanent magnet is disposed and curing. Has been. Among the plurality of electromagnetic steel sheets, the electromagnetic steel sheets constituting both ends in the rotational axis direction of the rotor (hereinafter referred to as “axial direction”) have a remaining amount in a range that does not overlap with the permanent magnet in the radial direction and the axial direction of the rotor. Convex portions that protrude from the electromagnetic steel sheet into the magnet insertion hole (in the radial direction) are provided. Thus, the rotor is configured such that the permanent magnet can be inserted into the magnet insertion hole via a portion where the convex portion and the permanent magnet do not overlap (a hole portion exposed in the axial direction). The resin member can be filled into the magnet insertion hole via a portion that does not overlap the magnet (a hole portion exposed in the axial direction).

Japanese Patent Laying-Open No. 2015-136245

  However, in the rotor of the motor described in Patent Document 1, a hole exposed in the axial direction is formed in the electromagnetic steel sheet constituting both ends in the axial direction among the plurality of electromagnetic steel sheets. Here, the magnetic steel sheet, the permanent magnet, and the resin member have different linear expansion coefficients (thermal expansion coefficients). For this reason, when the temperature changes, the permanent magnet and the resin member are damaged due to the difference in the linear expansion coefficient. While the rotor is rotating, the broken permanent magnet fragments and the resin member It is considered that the portion (a part of the rotor member) may be scattered (dropped) outside the rotor through the hole portion exposed in the axial direction. Here, it is conceivable to provide end plates at both ends of the rotor core in the axial direction in order to prevent the fragments of the permanent magnets and part of the resin member from scattering. However, when the end plate is provided, the number of parts increases, and it becomes necessary to prepare a manufacturing facility for the end plate separately from the manufacturing facility for the rotor core, which increases the number of parts for the rotor and makes the manufacturing facility complicated. Therefore, in the rotor described in Patent Document 1, a part of the rotor member scatters from the magnet insertion hole (magnet arrangement hole) to the outside of the rotor while preventing an increase in the number of parts and complication of manufacturing equipment. It is thought that there is a problem that it is difficult to prevent this.

  The present invention has been made to solve the above-described problems, and one object of the present invention is to prevent the increase in the number of parts and the complexity of the manufacturing equipment from the magnet arrangement hole to the rotor. It is an object of the present invention to provide a rotor and a method of manufacturing the rotor that can prevent a part of the members from being scattered outside the rotor.

  To achieve the above object, a rotor according to a first aspect of the present invention includes a permanent magnet, a rotor core that is formed by laminating a plurality of electromagnetic steel plates, and has a magnet arrangement hole in which the permanent magnet is arranged. The permanent magnet is fixed to the magnet arrangement hole by a resin magnet fixing member, and the plurality of electromagnetic steel plates are in the stacking direction of the first electromagnetic steel plate having the magnet arrangement hole and the plurality of electromagnetic steel plates. And a second electromagnetic steel plate arranged at both ends and configured to close the magnet arrangement hole.

  In the rotor according to the first aspect of the present invention, as described above, the plurality of electromagnetic steel sheets constituting the rotor core are arranged at both ends in the stacking direction of the first electromagnetic steel sheet having the magnet arrangement hole and the plurality of electromagnetic steel sheets. And a second electromagnetic steel plate configured to close the magnet arrangement hole. Thereby, since the both ends of the lamination direction of the magnet arrangement | positioning hole part of a 1st electromagnetic steel plate are obstruct | occluded by the 2nd electromagnetic steel plate comprised so that a magnet arrangement | positioning hole part may be obstruct | occluded, it arrange | positions inside a magnet arrangement | positioning hole part. It is possible to prevent the permanent magnet fragments and a part of the magnet fixing member from being scattered outside the rotor. Moreover, since the magnet arrangement | positioning hole part of a 1st electromagnetic steel plate can be block | closed with the 2nd electromagnetic steel plate which comprises a part of rotor core, it is not necessary to provide an end plate separately from a rotor core. As a result, it is possible to prevent an increase in the number of parts, and it is not necessary to prepare a manufacturing facility for the end plate. Therefore, it is possible to prevent an increase in the number of parts of the rotor and a complicated manufacturing facility of the rotor. it can. As a result, it is possible to prevent a part of the rotor member from being scattered from the magnet arrangement hole to the outside of the rotor while preventing an increase in the number of parts and a complicated manufacturing facility.

  A rotor manufacturing method according to a second aspect of the present invention is a rotor manufacturing method including a permanent magnet and a rotor core that is formed by laminating a plurality of electromagnetic steel plates and has a magnet arrangement hole in which the permanent magnet is arranged. The method includes: forming a first electromagnetic steel plate that is an electromagnetic steel plate having a magnet arrangement hole portion; forming a plurality of second electromagnetic steel plates that are electromagnetic steel plates configured to close the magnet arrangement hole portion; By placing the second electromagnetic steel sheet at one end in the stacking direction of the electromagnetic steel sheets, after the step of forming a part of the rotor core and the step of forming a part of the rotor core, the permanent magnet or the magnet arrangement hole is made of resin. After the step of arranging the magnet fixing member, the step of forming a part of the rotor core, the step of arranging the permanent magnet in the magnet arrangement hole, the step of arranging the magnet fixing member, and the permanent magnet Engineer to place After, the magnet fixing member is cured after the step of completing the rotor core and the step of completing the rotor core by disposing the electromagnetic steel plate including the second electromagnetic steel plate at the other end in the stacking direction of the plurality of electromagnetic steel plates. And a step of fixing the permanent magnet to the magnet arrangement hole.

  In the rotor manufacturing method according to the second aspect of the present invention, by configuring as described above, a part of the rotor member can be removed from the magnet arrangement hole while preventing an increase in the number of parts and complication of the manufacturing equipment. It is possible to provide a method for manufacturing a rotor capable of preventing scattering to the outside of the rotor.

  According to the present invention, as described above, it is possible to prevent a part of the rotor member from being scattered from the rotor to the outside of the rotor while preventing an increase in the number of parts and a complicated manufacturing facility. it can.

It is sectional drawing which shows the structure of the rotor (rotary electric machine) by one Embodiment of this invention. It is a perspective view which shows the structure of the rotor by one Embodiment of this invention. It is a side view which shows the permanent magnet by which the adhesive material by one Embodiment of this invention is arrange | positioned. It is a disassembled perspective view which shows the structure of the rotor by one Embodiment of this invention. It is the figure which looked at the block core with a lower end lid and penetration block core by one embodiment of the present invention in the direction of an axis. It is the figure which looked at the block core with an upper end lid by one Embodiment of this invention to the axial direction. It is a figure for demonstrating before (a) of expansion | swelling of the foaming agent of the adhesive material by one Embodiment of this invention, and (b) after expansion | swelling. It is a figure for demonstrating before (a) and after drying (b) of the dilution solvent of the adhesive agent by one Embodiment of this invention. It is a figure for demonstrating the structure of the rotor core by one Embodiment of this invention. It is sectional drawing (a) along the 800-800 line of FIG. 6, and sectional drawing (b) and (c) along the 700-700 line of FIG. It is a figure for demonstrating the press work apparatus by one Embodiment of this invention. It is a figure for demonstrating the process of comprising a part of rotor core by one Embodiment of this invention. It is a figure for demonstrating the structure of the cam mechanism for magnet holes by one Embodiment of this invention. It is a figure for demonstrating the process of forming the fitting through-hole by one Embodiment of this invention. It is a figure for demonstrating the process of forming the convex part and recessed part by one Embodiment of this invention. It is a figure for demonstrating the process of arrange | positioning the adhesive material by one Embodiment of this invention to a permanent magnet. It is a figure for demonstrating the process of drying the adhesive material by one Embodiment of this invention. It is a figure for demonstrating the process of fixing the permanent magnet by one Embodiment of this invention to a magnet arrangement | positioning hole. 3 is a flowchart for explaining a method of manufacturing a rotor according to an embodiment of the present invention. It is a flowchart for demonstrating the process of forming a part of rotor by one Embodiment of this invention. It is a figure which shows the structure of the rotor by the 1st modification of one Embodiment of this invention. It is a figure which shows the structure of the rotor by the 2nd modification of one Embodiment of this invention. It is a figure which shows the structure of the block core by the 3rd modification of one Embodiment of this invention. It is a figure which shows the structure of the rotor by the 3rd modification of one Embodiment of this invention.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

[Rotor structure]
With reference to FIGS. 1-10, the structure of the rotor 100 by one Embodiment of this invention is demonstrated.

  In this specification, the “stacking direction” means the stacking direction of the electromagnetic steel plates (penetrating electromagnetic steel plate 3 and lid electromagnetic steel plate 4) of the rotor 100, and means the arrow Z direction in FIG. Further, the “axial direction” means a direction along the rotation axis C of the rotor 100 as shown in FIG. 2, and means an arrow Z direction. Further, “radial direction” means the radial direction of the rotor 100 (arrow R1 direction or arrow R2 direction), and “circumferential direction” means the circumferential direction of the rotor 100 (arrow A1 direction or arrow A2 direction).

  The rotor 100 constitutes a part of the rotating electrical machine 101. The rotating electrical machine 101 is configured as, for example, a motor, a generator, or a motor / generator. The rotor 100 is disposed on the radially inner side of the stator 102 so as to face the stator 102 in the radial direction. That is, the rotating electrical machine 101 is configured as an inner rotor type rotating electrical machine.

  The rotor 100 constitutes a part of an embedded permanent magnet motor (IPM motor) in which a plurality of permanent magnets 1 are arranged inside the rotor 100 (rotor core 2). The rotor 100 is fixed to a hub member 103 connected to a shaft, and is configured to transmit rotational motion to the outside of the rotating electrical machine 101 via the hub member 103 and the shaft. The stator 102 is fixed to a case (not shown) of the rotating electrical machine 101. In the present embodiment, the rotor 100 is connected to the shaft via the hub member 103, but the shaft may be directly connected to the rotor 100.

  The permanent magnet 1 is formed of, for example, a neodymium magnet. As shown in FIG. 3, the permanent magnet 1 is formed to have a rectangular shape when viewed in the radial direction, for example. And the permanent magnet 1 is arrange | positioned 1 each at the magnet arrangement | positioning hole part 3a, as shown in FIG.

  As shown in FIG. 1, the rotor core 2 includes a plurality of penetrating electromagnetic steel plates 3 (hereinafter referred to as “penetrating steel plates 3”) and a plurality of lid electromagnetic steel plates 4 (hereinafter referred to as “lid steel plates 4”). Are stacked. The penetration steel plate 3 is an example of the “first electromagnetic steel plate” in the claims. The lid steel plate 4 is an example of the “second electromagnetic steel plate” in the claims.

  The penetrating steel plate 3 is provided with a magnet arrangement hole 3a in which the permanent magnet 1 is arranged. Moreover, in 1st Embodiment, the steel plate 4 for a lid | cover (closed part 4a) is comprised so that the steel plate 4 for lid | covers may be laminated | stacked with the penetration steel plate 3, and the magnet arrangement | positioning hole 3a of the penetration steel plate 3 is closed. ing. In other words, the lid steel plate 4 is closed at the portion corresponding to the magnet arrangement hole 3a by the closing portion 4a. And the steel plate 4 for lid | covers is each arrange | positioned at the both ends of the lamination direction. Thereby, the both ends of the lamination direction of the magnet arrangement | positioning hole part 3a are closed. In addition, the part corresponding to the magnet arrangement | positioning hole part 3a is a part of the area | region where the steel plate 4 for lids and the magnet arrangement | positioning hole part 3a overlap in the steel plate 4 for lids seeing from an axial direction. In addition, the permanent magnet 1 is arrange | positioned in the space formed when the magnet arrangement | positioning hole part 3a of the some penetration steel plate 3 continues in a lamination direction.

  The rotor 100 includes an adhesive material 5. The adhesive 5 is arranged between the permanent magnet 1 and the magnet arrangement hole 3a, and is configured to fix the permanent magnet 1 to the magnet arrangement hole 3a. For example, as shown in FIG. 3, the adhesive 5 is formed on the radially inner side surface 11 of the permanent magnet 1 from the vicinity of one end portion in the axial direction of the permanent magnet 1 to the vicinity of the other end portion. It arrange | positions so that it may have a rectangular shape. Further, the adhesive 5 is disposed on the side surface 11 of the permanent magnet 1 in the vicinity of both sides in the circumferential direction. The adhesive 5 is an example of the “resin magnet fixing member” in the claims.

  As shown in FIG. 7, the adhesive 5 includes a foaming agent 51, a main agent 52 and a curing agent 53. In this embodiment, the permanent magnet 1 is being fixed to the magnet arrangement | positioning hole 3a by the main agent 52 and the hardening | curing agent 53 being hardened in the state (FIG.7 (b)) which the foaming agent 51 expanded. The foaming agent 51 is an expansion agent that foams (expands) when heated to an expansion temperature or higher. The main agent 52 and the curing agent 53 are thermosetting resins that react and cure when heated to a temperature equal to or higher than the curing temperature that is equal to or higher than the expansion temperature. The foaming agent 51 is an example of the “expansion agent” in the claims.

  The foaming agent 51 is configured as a capsule body, and is configured such that, when heated to a temperature equal to or higher than the expansion temperature, the capsule body expands to increase its volume. For example, the foaming agent 51 contains isopentane. In other words, the expansion temperature is a foaming temperature at which the capsule body is foam-molded. When the foaming agent 51 expands and expands, the thickness of the adhesive 5 changes from the thickness t1 (FIG. 7A) to the thickness t2 (FIG. 7B). Here, the thickness t2 is substantially the same size as the distance d1 between the side surface 11 of the permanent magnet 1 and the magnet arrangement hole 3a.

  The main agent 52 includes, for example, an epoxy-based resin (for example, bisphenol A liquid epoxy and epoxy resin polymer). The curing agent 53 includes, for example, dicyandiamide. The permanent magnet 1 and the rotor core 2 are fixed to each other by curing the main agent 52 and the curing agent 53 of the adhesive 5 by heating the adhesive 5 to the curing temperature. Moreover, the curing temperature is higher than the drying temperature described later.

  As shown in FIG. 8A, the adhesive 5 is volatilized before the permanent magnet 1 is bonded to the magnet arrangement hole 3a by the adhesive 5 and before the adhesive 5 is dried. A diluting solvent 54 as a volatile agent having a property is included. For example, ketones such as methyl ethyl ketone, and volatile organic solvents such as alcohols and ethers can be used as the dilution solvent 54. In the present embodiment, the dilution solvent 54 includes both methyl ethyl ketone and ethyl acetate. The dilution solvent 54 has a lower viscosity than at least one of the main agent 52, the foaming agent 51, and the curing agent 53. Thereby, the dilution solvent 54 has a function of decreasing the viscosity of the adhesive 5 and increasing the fluidity (function of increasing the ease of application) by being contained in the adhesive 5.

  And the dilution solvent 54 volatilizes by making it the temperature more than drying temperature. Here, as the drying temperature, for example, the boiling point temperature of the dilution solvent 54 or a temperature in the vicinity of the boiling point temperature can be set. The drying temperature is lower than the expansion temperature and lower than the curing temperature. Thereby, by setting the temperature of the adhesive 5 to a temperature lower than the expansion temperature and higher than the drying temperature, the foaming agent 51 is not expanded, and the main agent 52 and the curing agent 53 are not cured. The diluted solvent 54 can be volatilized. Then, when the diluted solvent 54 is volatilized (dried), the thickness of the adhesive 5 is reduced from t3 (FIG. 8A) to t1 (FIG. 8B). That is, after the adhesive 5 is dried, the amount of the diluted solvent 54 in the adhesive 5 is decreased or the diluted solvent 54 in the adhesive 5 is not substantially contained.

  As shown in FIG. 9, in this embodiment, the rotor core 2 includes a block core 21 with a lower end lid (hereinafter referred to as “core 21 with a lower end lid”) and a block core 22 with an upper end lid (hereinafter referred to as “with an upper end lid”). And a plurality of (for example, two) penetrating block cores 23 (hereinafter referred to as “penetrating cores 23”). The core 21 with the lower end lid is an example of the “first block core” in the claims. The core 22 with an upper end lid is an example of the “second block core” in the claims.

  Moreover, in this embodiment, the core 21 with a lower end lid | cover is arrange | positioned at the one end 2a of the lamination direction of the rotor core 2, and the steel plate 4 for lid | covers is arrange | positioned at the one end part 21a (lower end) of the lamination direction of the core 21 with a lower end lid. Has been. And the core 21 with a lower end lid has the steel plate 4 for lid | covers arrange | positioned at a lower end, and several (for example, dozens) penetration steel plates 3 are laminated | stacked on the upper part (arrow Z1 direction) of the steel plate 4 for lids. That is, the core 21 with a lower end lid is configured as a block core having a closing portion 4a (lid) on the lower end side (arrow Z2 direction side). The number of penetrating steel plates 3 and the number of penetrating cores 23 are not limited to the example of FIG.

  Moreover, the core 22 with an upper end lid is arrange | positioned at the other end 2b of the lamination direction of the rotor core 2, and the steel plate 4 for lid | covers is arrange | positioned at the other end part 22a (upper end) of the lamination direction of the core 22 with an upper end lid. The upper cover-covered core 22 has a cover steel plate 4 disposed at the upper end, and a plurality of (for example, several tens) through steel plates 3 are laminated below the cover steel plate 4 (in the direction of the arrow Z2). That is, the core 22 with an upper end lid is configured as a block core having a closing portion 4a (lid) on the upper end side (arrow Z1 direction side).

  The plurality of penetrating cores 23 are stacked and disposed between the core 21 with the lower end lid and the core 22 with the upper end lid. The through core 23 is formed by laminating a plurality of through steel plates 3. That is, the penetration core 23 is formed so that the magnet arrangement hole 3a penetrates from the upper end to the lower end. And the magnet arrangement | positioning hole part 3a of the core 21 with a lower end lid | cover, the magnet arrangement | positioning hole part 3a of the core 22 with an upper end lid | cover, and the magnet arrangement | positioning hole part 3a of the penetration core 23 are connected.

  As shown in FIG. 5, in the penetration steel plate 3, a magnet arrangement hole 3a in which the permanent magnet 1 is arranged, a shaft hole 3b in which the hub member 103 (see FIG. 1) is arranged, and a connecting projection 3d. And are provided. And as shown in FIG. 10, the penetration steel plate 3 is provided with the recessed part 3e currently formed in the back side (arrow Z2 direction side) of the convex part 3d. Further, as shown in FIGS. 10B and 10C, the lower end penetrating steel plate 30, which is the penetrating steel plate 3 constituting the lower end of the core 22 with the upper end lid and the penetrating core 23, has another penetrating steel plate 3. Unlike the above, the fitting through-hole 3c is provided at a position corresponding to the protrusion 3d and the protrusion 3d. The protrusion 3d protrudes on one side in the stacking direction (arrow Z2 direction side). The recess 3e is recessed on one side in the stacking direction. The fitting through-hole 3c is an example of the “concave portion” in the claims.

  As shown in FIG. 6, the lid steel plate 4 provided on the core 22 with the top lid of the lid steel plate 4 has a position where the radial position and the circumferential position coincide with those of the magnet arrangement hole 3 a (over). A closing portion 4a formed at a position for wrapping is provided. That is, the lid steel plate 4 is configured to close the magnet arrangement hole 3a. The lid steel plate 4 is provided with a shaft hole 3b in which the hub member 103 is disposed and a connecting projection 3d. And as shown in FIG. 10, the steel plate 4 for lid | covers is provided with the recessed part 3e currently formed in the back side (arrow Z2 direction side) of the convex part 3d. Further, as shown in FIG. 10 (a), the lower end lid steel plate 40 provided in the core 21 with the lower end lid of the lid steel plate 4 is different from the other lid steel plates 4 in that the convex portion 3d and the convex portion. A fitting through hole 3c is provided at a position corresponding to 3d. In the penetrating steel plate 3 and the lid steel plate 4, portions having the same function / structure are denoted by the same reference numerals and description thereof is omitted.

  Then, by fitting the convex portion 3d and the concave portion 3e (fitting through hole 3c), the penetration steel plate 3 or the lid steel plate 4 having the fitted convex portion 3d and the fitted concave portion 3e (fitting penetration) A penetration steel plate 3 or a lid steel plate 4 having a hole 3c) is connected.

[Configuration of rotor manufacturing equipment]
Next, with reference to FIGS. 11-18, the manufacturing apparatus 200 of the rotor 100 by this embodiment is demonstrated.

  As shown in FIG. 11, the manufacturing apparatus 200 includes a press working apparatus 210. The press working apparatus 210 is configured as a progressive press working apparatus that performs press working while sequentially moving the belt-shaped electromagnetic steel sheet 300.

  Specifically, the press working apparatus 210 includes an upper die set 70 and a lower die set 80. In the press working apparatus 210, a strip-shaped electromagnetic steel sheet 300 is disposed between the upper die set 70 and the lower die set 80. Further, in the press working apparatus 210, the belt-shaped electromagnetic steel sheet 300 is sequentially fed from the X1 direction side to the X2 direction side by a feeding mechanism (not shown).

  The press working apparatus 210 includes a pilot hole machining part 220, a magnet hole machining part 230, a shaft hole machining part 240, a fitting through hole machining part 250, a convex part machining part 260, and an outer shape machining part 270. I have. In the press working apparatus 210, the pilot hole machining part 220 and the magnet hole machining part 230, the shaft hole machining part 240, the fitting through hole machining part 250, the convex part machining part 260, and the outer shape machining part 270 are X1. They are arranged in this order from the direction side to the X2 direction side.

  The pilot hole machining unit 220 includes a pilot hole punch 221 and a pilot hole die 222. The pilot hole punch 221 is provided in the upper die set 70, and the pilot hole die 222 is provided in the lower die set 80. The pilot hole machining section 220 is configured to form a pilot hole 300a for positioning (see FIG. 12) in the belt-shaped electromagnetic steel sheet 300 by the pilot hole punch 221 and the pilot hole die 222. The pilot hole 300a is provided for positioning the belt-shaped electromagnetic steel sheet 300 at a predetermined position in the press working apparatus 210.

  The magnet hole machining section 230 includes a magnet hole punch 231, a magnet hole die 232, and a magnet hole cam mechanism 233. The magnet hole punch 231 and the magnet hole cam mechanism 233 are provided in the upper die set 70, and the magnet hole die 232 is provided in the lower die set 80. The magnet hole processing portion 230 is configured to form the magnet arrangement hole portion 3 a in the belt-shaped electromagnetic steel sheet 300 by the magnet hole punch 231 and the magnet hole die 232. The magnet hole cam mechanism 233 raises and lowers the magnet hole punch 231 between a lowered position where the magnet arrangement hole 3a can be punched and an elevated position where the magnet arrangement hole 3a cannot be punched. It is configured.

  Specifically, as shown in FIG. 13, the magnet hole cam mechanism 233 includes a cam mechanism main body 233a and a cam groove 233b provided in the cam mechanism main body 233a. The cam mechanism main body 233a is configured to be movable in the horizontal direction by a driving unit 234 such as a cylinder. The cam mechanism main body 233a is connected to an end (Z1 direction side) opposite to the end of the magnet hole punch 231 on the punch side (Z2 direction side). The magnet hole cam mechanism 233 moves the cam mechanism main body portion 233a in the horizontal direction by the drive portion 234, and fits the magnet hole punch 231 into the cam groove 233b of the cam mechanism main body portion 233a, thereby The punch 231 is configured to be raised to the raised position. Further, the magnet hole cam mechanism 233 moves the cam mechanism main body portion 233a in the horizontal direction by the driving portion 234 to release the fitting between the cam groove 233b of the cam mechanism main body portion 233a and the magnet hole punch 231. Thus, the magnet hole punch 231 is lowered to the lowered position.

  As shown in FIG. 11, the shaft hole processing portion 240 has a shaft hole punch 241 and a shaft hole die 242. The shaft hole punch 241 is provided in the upper die set 70, and the shaft hole die 242 is provided in the lower die set 80. The shaft hole machining section 240 uses the shaft hole punch 241 and the shaft hole die 242 to convert the shaft hole 3b (see FIG. 12) for the hub member 103 (shaft) inserted into the rotor core 2 into the belt-shaped electromagnetic steel sheet 300. It is configured to form.

  The fitting through-hole processing unit 250 includes a fitting through-hole punch 251, a fitting through-hole die 252, and a fitting through-hole cam mechanism 253. The fitting through-hole punch 251 and the fitting through-hole cam mechanism 253 are provided in the upper die set 70, and the fitting through-hole die 252 is provided in the lower die set 80. The fitting through hole processing portion 250 is configured to form the fitting through hole 3c (see FIG. 12) in the belt-shaped electromagnetic steel sheet 300 by the fitting through hole punch 251 and the fitting through hole die 252. ing. Similar to the magnet hole cam mechanism 233, the fitting through hole cam mechanism 253 includes a lowered position where the fitting through hole punch 251 can be punched, and the fitting through hole 3c. It is comprised so that it may raise / lower between the raising positions which cannot be punched out. As shown in FIG. 14, the punch width L1 of the fitting through hole punch 251 and the hole width D1 of the fitting through hole 3c are larger than the punch width L2 of the convex punch 261 described later.

  As shown in FIG. 11, the convex portion processing portion 260 includes a convex portion punch 261, a convex portion die 262, and a convex portion ejector pin 263. The convex punch 261 is provided in the upper die set 70, and the convex die 262 and the convex ejector pin 263 are provided in the lower die set 80. As shown in FIG. 15, the convex portion processing portion 260 is configured to form the connecting convex portion 3 d and the concave portion 3 e in the belt-shaped electromagnetic steel sheet 300 by the convex portion punch 261 and the convex portion die 262. ing. As shown in FIG. 11, the convex ejector pin 263 is configured to discharge the convex portion 3 d formed on the belt-shaped electromagnetic steel sheet 300 from the opening 262 a of the convex die 262.

  The outer shape processing unit 270 includes an outer shape punch 271 and an outer shape die 272. The outer shape punch 271 is provided in the upper die set 70, and the outer shape die 272 is provided in the lower die set 80. The outer shape processing portion 270 is configured to form the penetrating steel plate 3 or the lid steel plate 4 by punching the belt-shaped electromagnetic steel plate 300 with the outer shape punch 271 and the outer shape die 272.

  Further, the press working apparatus 210 is provided with a stripper 280 and three stripper urging portions 281. The stripper 280 is configured to hold the belt-shaped electromagnetic steel sheet 300 from above (Z1 direction) during press working. Specifically, the stripper 280 is configured to be lowered together with the upper die set 70 by being pushed from above by the three stripper urging portions 281 as the upper die set 70 is lowered. . Then, after the stripper 280 comes into contact with the upper surface of the strip-shaped electromagnetic steel sheet 300, the upper die set 70 is further lowered, so that the stripper 280 is stripped by the weight of the stripper 280 and the biasing force of the three stripper biasing portions 281. The electromagnetic steel sheet 300 is configured to be pressed from above.

  The press working apparatus 210 is configured to perform press working with each punch by further lowering only the upper die set 70 while the strip-shaped electromagnetic steel sheet 300 is pressed from above by the stripper 280.

  Further, the stripper 280 is configured to peel the strip-shaped electrical steel sheet 300 from each punch by continuously pressing the strip-shaped electrical steel sheet 300 from above when only the upper die set 70 is lifted after press working. .

  As shown in FIG. 16, the manufacturing apparatus 200 includes a coating apparatus 290 that applies the adhesive 5. The coating device 290 is configured to apply the adhesive 5 containing the diluted solvent 54 to the side surface 11 of the permanent magnet 1 disposed on the pallet 291.

  As shown in FIG. 17, the manufacturing apparatus 200 includes a heater 292 that dries the adhesive material 5. The heater 292 is configured to volatilize the diluted solvent 54 of the adhesive 5 applied to the permanent magnet 1 by heating the adhesive 5 (permanent magnet 1) to a drying temperature.

  As shown in FIG. 18, the manufacturing apparatus 200 includes a heating furnace 293 that cures the adhesive material 5. The heating furnace 293 is configured to cure the adhesive 5 by reacting the main agent 52 of the adhesive 5 applied to the permanent magnet 1 and the curing agent 53 by heating the adhesive 5 to the curing temperature. ing.

[Method of manufacturing rotor]
Next, a method for manufacturing the rotor 100 will be described with reference to FIGS. 1, 2, and 7 to 20. In the present embodiment, a rotor 100 including a permanent magnet 1 and a rotor core 2 that is formed by laminating a penetration steel plate 3 and a lid steel plate 4 and has a magnet arrangement hole 3a in which the permanent magnet 1 is arranged is provided. A method will be described. FIG. 19 shows a flowchart for explaining the entire manufacturing process of the rotor 100. FIG. 20 shows a flowchart for explaining a process of forming a part of the rotor core.

(Process for forming part of the rotor core)
In the present embodiment, a part of the rotor core 2 is formed in step S1 (see FIG. 19). Specifically, a plurality of penetration steel plates 3 having magnet arrangement holes 3a are formed, a plurality of lid steel plates 4 configured to close the magnet arrangement holes 3a are formed, and one of the rotor cores 2 in the stacking direction is formed. The lid steel plate 4 is disposed at the end 21a (one end 2a). Here, the penetration steel plate 3 and the lid steel plate 4 are formed continuously in, for example, one belt-shaped electromagnetic steel plate 300.

<Formation of pilot holes>
In step S11 (see FIG. 20), pilot holes are formed in the belt-shaped electromagnetic steel sheet 300. First, as shown in FIGS. 11 and 12, the belt-shaped electromagnetic steel sheet 300 is fed from the X1 direction side to the X2 direction side, whereby the belt-shaped electromagnetic steel sheet 300 is supplied to the press working apparatus 210. Then, the pilot hole machining portion 220 punches out the belt-shaped electromagnetic steel sheet 300, thereby forming a pilot hole 300a having a substantially circular shape in plan view in the band-shaped electromagnetic steel sheet 300.

<Formation of magnet placement hole or closed part>
In step S12, the magnet arrangement hole 3a or the closing part 4a is formed in the belt-shaped electromagnetic steel sheet 300. Specifically, when forming the penetration steel plate 3 (magnet arrangement hole portion 3a), the band-shaped electromagnetic steel plate 300 is punched out by the magnet hole punch 231 and the magnet hole die 232 of the magnet hole processing portion 230, Magnet arrangement hole 3a having a substantially rectangular shape in a plan view is formed in belt-shaped electromagnetic steel sheet 300. Moreover, in this embodiment, when forming the lid steel plate 4 (closed portion 4a), by not forming the magnet arrangement hole portion 3a by the magnet hole punch 231 and the magnet hole die 232 of the magnet hole processing portion 230, A portion corresponding to the magnet arrangement hole 3a remains and becomes the closed portion 4a.

  Specifically, when the through steel plate 3 is formed, the magnet hole punch 231 is arranged at a lowered position where the magnet arrangement hole 3a can be punched out by the magnet hole cam mechanism 233 (see FIG. 13). When the lid steel plate 4 is formed, the magnet hole punch 231 is arranged by the magnet hole cam mechanism 233 at a raised position where the magnet arrangement hole 3a cannot be punched.

<Formation of shaft hole>
In step S <b> 13, the shaft hole 3 b is formed in the belt-shaped electromagnetic steel sheet 300. Specifically, the shaft-shaped hole 3b is punched out by the shaft hole processing portion 240, whereby a shaft hole 3b having a substantially circular shape in a plan view is formed in the band-shaped electromagnetic steel plate 300. And the strip | belt-shaped electromagnetic steel plate 300 in which the axial hole 3b was formed is sent to the X2 direction side from the X1 direction side.

<Formation of fitting through hole>
In step S14, the fitting through hole 3c is formed in the belt-shaped electromagnetic steel sheet 300 corresponding to the lower end penetrating steel sheet 30 or the lower end cover steel sheet 40. Specifically, as shown in FIG. 14, the band-shaped electromagnetic steel sheet 300 is punched out by the fitting through-hole processing section 250, so that the band-shaped electromagnetic steel sheet 300 has a substantially circular shape in plan view. 3c is formed. That is, when the lower end through steel plate 30 or the lower end lid steel plate 40 is formed, the fitting through hole punch 251 is lowered to a position where the fitting through hole 3c can be punched out by the fitting through hole cam mechanism 253. Is formed and the fitting through hole 3c is punched out by the fitting through hole cam mechanism 253 when the through steel plate 3 other than the lower end through steel plate 30 and the lid steel plate 4 other than the lower end lid steel plate 40 are formed. The fitting through-hole punch 251 is disposed at a raised position where the punch cannot be performed. And the strip | belt-shaped electromagnetic steel plate 300 in which the fitting through-hole 3c was formed or the fitting through-hole 3c was not formed is sent to the X2 direction side from the X1 direction side.

<Formation of convex part and concave part>
In step S <b> 15, the convex portion 3 d and the concave portion 3 e are formed on the belt-shaped electromagnetic steel sheet 300. Specifically, as shown in FIG. 15, the belt-shaped electromagnetic steel sheet 300 is deformed by the protrusion processing unit 260, so that the belt-shaped electromagnetic steel sheet 300 has a convex portion 3 d and a concave portion having a substantially circular shape in plan view. 3e is formed. When forming the lower end through steel plate 30 or the lower end lid steel plate 40, the fitting through hole 3c (see FIG. 14) having a hole width D1 larger than the punch width L2 of the convex punch 261 in the previous step. Since it is formed, the convex punch 261 is swung with respect to the fitting through hole 3c so as to pass through the fitting through hole 3c. Then, the belt-shaped electromagnetic steel sheet 300 in which the fitting through hole 3c is crushed or the fitting through hole 3c is not crushed is sent from the X1 direction side to the X2 direction side.

<Outline processing>
In step S <b> 16, an outer shape process is performed on the belt-shaped electromagnetic steel sheet 300. Specifically, when the magnet arrangement hole 3 a is formed in the belt-shaped electromagnetic steel plate 300, the magnet arrangement hole 3 a is formed by punching the band-shaped electromagnetic steel plate 300 by the outer shape processing portion 270. The penetrated steel plate 3 is formed in the hole 270a. Further, when the magnet arrangement hole 3a is not formed in the belt-shaped electromagnetic steel sheet 300 but the closing portion 4a is formed, the belt-shaped electromagnetic steel sheet 300 is punched out by the outer shape processing portion 270, so that A steel plate 4 is formed in the hole 270a. In FIG. 12, as an example, the penetrating steel plate 3 is illustrated at a position corresponding to steps S11 to S15, and the lid steel plate 4 is illustrated at a position corresponding to step S16. However, the present invention is not limited to this example.

  Further, when the fitting through hole 3 c is formed in the belt-shaped electromagnetic steel plate 300, the through steel plate 3 is formed as the lower end through steel plate 30, and the lid steel plate 4 is formed as the lower end lid steel plate 40. The punched through steel plate 3 and the lid steel plate 4 are laminated on the opening 80 a formed in the outer die 272 and the lower die set 80.

<Lamination and rollover of block cores>
In step S17, as shown in FIG. 10 (a), when forming the core 21 with the lower end lid, the convex portion 3d of the penetration steel plate 3 is press-fitted into the fitting through hole 3c of the lower end lid steel plate 40. As a result, the lower end lid steel plate 40 and the penetrating steel plate 3 are connected. And when the convex part 3d of the penetration steel plate 3 is press-fit in the recessed part 3e of the penetration steel plate 3, the laminated penetration steel plates 3 are connected. As a result, the core 21 with the lower end lid is formed on the lower end lid steel plate 40 disposed at the one end 21a (lower end) in the stacking direction and the predetermined number of through steel plates 3 are stacked and connected.

  As shown in FIG. 10 (b), when the core 22 with the upper end lid is formed, the convex portion 3 d of the penetrating steel plate 3 is press-fitted into the fitting through hole 3 c of the lower end penetrating steel plate 30, thereby allowing the lower end penetration. The steel plate 30 and the penetration steel plate 3 are connected. And when the convex part 3d of the penetration steel plate 3 is press-fit in the recessed part 3e of the penetration steel plate 3, the laminated penetration steel plates 3 are connected. And the penetration part 3d of the lid steel plate 4 laminated | stacked on the other end part 22a (upper end) of the lamination direction is press-fitted in the recessed part 3e of the penetration steel plate 3, and the penetration steel plate laminated | stacked with the upper lid steel plate 4 is carried out. 3 are laminated to form a core 21 with a lower end lid.

  As shown in FIG. 10 (c), when forming the through core 23, the lower end penetrating steel plate 30 is formed by press-fitting the protrusion 3 d of the penetrating steel plate 3 into the fitting through hole 3 c of the lower end penetrating steel plate 30. And the penetration steel plate 3 are connected. And when the convex part 3d of the penetration steel plate 3 is press-fit in the recessed part 3e of the penetration steel plate 3, the laminated penetration steel plates 3 are connected. Thereby, the penetration core 23 is formed.

  Then, as shown in FIG. 9, a plurality of through cores 23 are respectively rolled and stacked on the upper part of the core 21 with the lower end lid. That is, a portion of the rotor core 2 excluding the core 22 with the upper end lid (a part of the rotor core 2) is formed. Here, “rolling” means that the penetrating cores 23 are laminated in a state rotated by a predetermined angle in the circumferential direction with respect to other cores, or are laminated in a state reversed in the axial direction. To do.

(Process of placing adhesive)
In the present embodiment, the adhesive 5 is disposed on the permanent magnet 1 in step S2. Specifically, as shown in FIG. 16, a plurality of permanent magnets 1 are arranged on the pallet 291. Then, the adhesive 5 including the foaming agent 51, the main agent 52, the curing agent 53, and the dilution solvent 54 is applied to the side surface 11 of the permanent magnet 1 by the coating device 290.

(Process to dry the adhesive)
In step S3, the applied adhesive 5 is dried before the permanent magnet 1 is placed in the magnet placement hole 3a. That is, in this embodiment, after at least a part of the dilution solvent 54 of the adhesive 5 is volatilized, the permanent magnet 1 is arranged in the magnet arrangement hole 3a. Specifically, as shown in FIG. 17, when the adhesive 5 (permanent magnet 1) is heated to the drying temperature by the heater 292, the diluted solvent 54 in the adhesive 5 is volatilized, and as shown in FIG. Further, the thickness t3 is changed to t1 (thinning).

(Process of arranging a permanent magnet in the magnet arrangement part)
Thereafter, in step S4, the permanent magnet 1 is arranged in the magnet arrangement hole 3a. Specifically, as shown in FIG. 9, the permanent magnet 1 in which the dried adhesive material 5 is disposed in a state where the core 21 with the lower end lid is disposed at one end 2 a (lower end) of a part of the rotor core 2, It inserts in the magnet arrangement | positioning hole part 3a of the penetration core 23 and the core 21 with a lower end lid. That is, the permanent magnet 1 is inserted into the magnet arrangement hole 3 a in the axial direction (stacking direction) through the opening on the upper end side of the through core 23. Here, since the adhesive material 5 is thinned by being dried, the permanent magnet 1 is mounted in a state where a gap is formed between the adhesive material 5 and the magnet arrangement hole 3a (a state in which no interference occurs). It can be inserted into the magnet arrangement hole 3a. And the permanent magnet 1 with which the adhesive material 5 is arrange | positioned is inserted in each of the some magnet arrangement | positioning hole 3a.

(Process to complete the rotor core)
Thereafter, in step S5, after the adhesive material 5 is arranged on the permanent magnet 1 and after the permanent magnet 1 is arranged in the magnet arrangement hole portion 3a, the penetrating core 23 and the upper end of the core 21 with a lower end lid are arranged. A core 22 with an upper end lid is laminated. Thereby, it will be in the state where the steel plate 4 for lid | covers is arrange | positioned at the other end part 22a of the rotor core 2, and will be in the state where the steel plate 4 for lid | covers is each arrange | positioned at the both ends of the lamination direction of the rotor core 2. And the both ends of the lamination direction of the magnet arrangement | positioning hole part 3a are closed by the closing part 4a. As a result, the rotor core 2 is completed.

(Step of fixing the permanent magnet to the magnet arrangement part)
After the rotor core 2 is completed, the permanent magnet 1 is fixed to the magnet arrangement hole 3a by curing the adhesive 5 in step S6. Specifically, as shown in FIG. 18, the rotor core 2 is disposed inside the heating furnace 293, and the rotor core 2 (adhesive material 5) is heated to the foaming temperature. Thereby, the foaming agent 51 of the adhesive 5 foams, and the thickness of the adhesive 5 is changed from t1 to t2 (see FIG. 7). As a result, the permanent magnet 1 is pressed radially outward by the adhesive 5 in the magnet arrangement hole 3a.

  Then, in the heating furnace 293, the rotor core 2 (adhesive 5) is heated to the curing temperature. As a result, the main agent 52 and the curing agent 53 of the adhesive 5 react to cure the adhesive 5. As a result, the permanent magnet 1 is fixed (adhered) to the magnet arrangement hole 3a. Then, the rotor 100 according to the present embodiment is completed.

[Effect of structure of this embodiment]
With the structure of this embodiment, the following effects can be obtained.

  In the said embodiment, the 1st electromagnetic steel plate (3) which has a magnet arrangement | positioning hole part (3a) in several electromagnetic steel plates (3, 4) which comprise a rotor core (2), and several electromagnetic steel plates (3, 4). And a second electromagnetic steel plate (4) arranged at both ends (2a, 2b) in the laminating direction and configured to close the magnet arrangement hole (3a). Thereby, since the both ends (2a, 2b) in the stacking direction of the magnet arrangement hole (3a) are blocked by the second electromagnetic steel plate (4) configured to close the magnet arrangement hole (3a), It is possible to prevent the fragments of the permanent magnet (1) and a part of the magnet fixing member (5) arranged inside the magnet arrangement hole (3a) from being scattered outside the rotor (100). Moreover, since the magnet arrangement | positioning hole part (3a) can be block | closed with the 2nd electromagnetic steel plate (4) which comprises a part of rotor core (2), it is not necessary to provide an end plate separately from a rotor core (2). . As a result, it is possible to prevent an increase in the number of parts, and it is not necessary to prepare a production facility for the end plate. Therefore, an increase in the number of components of the rotor (100) and a production facility for the rotor (100) (200 ) Can be prevented from becoming complicated. As a result, while preventing an increase in the number of parts of the rotor (100) and complication of the manufacturing facility (200), some of the members of the rotor (100) from the magnet arrangement hole (3a) are part of the rotor (100). It is possible to prevent scattering to the outside.

  In the above embodiment, the rotor core (2) includes a plurality of block cores (21, 22, 23) in which a plurality of electromagnetic steel plates (3, 4) are stacked, and the plurality of block cores (21, 22, 23). ) Is disposed at one end (21a) in the stacking direction of the plurality of block cores (21, 22, 23), and the first block in which the second electromagnetic steel sheet (4) is disposed at one end (2a) in the stacking direction. The core (21) and the plurality of block cores (21, 22, 23) are disposed at the other end (22a) in the stacking direction, and the second electromagnetic steel sheet (4) is disposed at the other end (2b) in the stacking direction. A second block core (22). If comprised in this way, when manufacturing the rotor (100), the permanent magnet (1) was arrange | positioned in the magnet arrangement | positioning hole part (3a) of the block core (21, 23) containing the 1st block core (21). Later, since the second block core (22) can be arranged on the block core (21, 23), both ends of the magnet arrangement hole (3a) can be easily closed. Further, by forming the rotor core (2) by laminating a plurality of block cores (21, 22, 23), when manufacturing the rotor core (2), compared with the case where the magnetic steel sheets are handled individually one by one. Thus, the manufacturing process of the rotor core (2) such as the transshipment process can be easily performed.

  Moreover, in the said embodiment, a magnet fixing member (5) contains an expansion agent (51), and a permanent magnet (1) is a magnet arrangement | positioning hole by a magnet fixing member (5) in the state which the expansion agent (51) expanded. It is fixed to the part (3a). If comprised in this way, a magnet fixing member (5) will be arrange | positioned by arrange | positioning a magnet fixing member (5) in a permanent magnet (1) or a magnet arrangement | positioning hole (3a) in the state which does not expand an expansion agent (51). The permanent magnet (1) can be easily inserted into the magnet arrangement hole while preventing the permanent magnet (1) and the magnet arrangement hole (3a) from interfering with the magnet fixing member (5). (3a). And even if the magnet arrangement | positioning hole (3a) is obstruct | occluded with the 2nd electromagnetic steel plate (4), a magnet fixing member is newly made to a magnet arrangement | positioning hole (3a) by expanding an expansion agent (51). The magnet fixing member (5) including the expansion agent (51) that has expanded the inside of the magnet arrangement hole (3a) can be filled without filling. As a result, the permanent magnet (1) can be reliably bonded (fixed) to the magnet arrangement hole (3a) while allowing the permanent magnet (1) to be easily arranged in the magnet arrangement hole (3a). it can. In addition, by using the expansion agent (51), unlike the case of using a resin mold, it is not necessary to fill (inject) after the permanent magnet (1) is arranged in the magnet arrangement hole (3a). ) For the rotor core (2). As a result, even if the magnet arrangement hole (3a) is closed by the second electromagnetic steel plate (4), the fragments of the permanent magnet (1) and the magnet fixing member (5) are effectively provided without providing holes in other portions. Can be prevented from being scattered outside the rotor (100).

  Moreover, in the said embodiment, the convex part (3d) which protrudes in one side of a lamination direction is provided in one side of a 1st electromagnetic steel plate (3) or a 2nd electromagnetic steel plate (4), and a lamination direction is provided in the other. A concave portion (3e) that is depressed on one side of the first electromagnetic steel plate is provided, and the first electromagnetic steel plate (3) and the second electromagnetic steel plate (4) are provided by arranging the convex portion (3d) in the concave portion (3e). It is connected. If comprised in this way, a convex part (3d) will be arrange | positioned in a recessed part (3e) by laminating | stacking a 1st electromagnetic steel plate (3) and a 2nd electromagnetic steel plate (4), and the 1st electromagnetic steel plate (3 ) And the second electrical steel sheet (4) can be easily coupled. For example, unlike the case of providing an end plate that needs to be joined to the rotor core (2) by welding or the like, no new joining work such as welding is required to close the magnet arrangement hole (3a), so the rotor (100) The manufacturing process can be prevented from becoming complicated.

[Effect of manufacturing method of this embodiment]
In the manufacturing method of the present embodiment, the following effects can be obtained.

  In the above embodiment, while preventing an increase in the number of parts of the rotor (100) and complication of the manufacturing facility (200), part of the members of the rotor (100) from the magnet arrangement hole (3a) is formed in the rotor (100). It is possible to provide a method of manufacturing the rotor (100) capable of preventing the outside of the rotor from being scattered.

  Moreover, in the said embodiment, the process (S1) of forming a part of rotor core (2) forms a magnet arrangement | positioning hole part (3a) in a strip | belt-shaped electromagnetic steel plate (300) with the magnet arrangement | positioning hole punch (231). Then, the first electromagnetic steel plate (3) is formed by punching the belt-shaped electromagnetic steel plate (300), and the magnet arrangement hole (3a) is formed by the magnet arrangement hole punch (231). The second electromagnetic steel sheet (4) is formed by punching the belt-shaped electromagnetic steel sheet (300) without forming the rotor, and the second electromagnetic steel sheet (4) is disposed at one end (2a) in the stacking direction, thereby forming the rotor core. This is a step of forming a part of (2). If comprised in this way, since both the 1st electromagnetic steel plate (3) and the 2nd electromagnetic steel plate (4) can be formed with the same manufacturing equipment (press processing machine (210)), the 1st electromagnetic steel plate There is no need to prepare separate molds for (3) and the second electromagnetic steel sheet (4), and the manufacturing facility (200) for the rotor (100) can be further simplified.

  Moreover, in the said embodiment, the process (S1) which forms a part of rotor core (2) is a convex part (one side of the lamination direction) which protrudes in a strip | belt-shaped electromagnetic steel plate (300) by the convex punch (261). 3d) and a concave portion (3e) that is recessed on one side in the stacking direction is formed on the back side of the convex portion (3d), and the first electromagnetic steel plate (3) and the first electromagnetic steel plate (3) This is a step of laminating the first electromagnetic steel plate (3) and the second electromagnetic steel plate (4) in a state where the two electromagnetic steel plates (4) are formed and the convex portions (3d) are arranged in the concave portions (3e). . If comprised in this way, when forming a 1st electromagnetic steel plate (3) and a 2nd electromagnetic steel plate (4), it is for connecting a 1st electromagnetic steel plate (3) and a 2nd electromagnetic steel plate (4). Since a convex part (3d) and a recessed part (3e) can be formed, it is not necessary to provide the process for connecting a 1st electromagnetic steel plate (3) and a 2nd electromagnetic steel plate (4) separately. As a result, it is possible to prevent the manufacturing process of the rotor (100) from becoming complicated. Moreover, laminating | stacking the 1st electromagnetic steel plate (3) which has one of a convex part (3d) or a recessed part (3e), and the 2nd electromagnetic steel plate (4) which has the other of a convex part (3d) or a recessed part (3e). Thus, since the convex portion (3d) is disposed in the concave portion (3e), the first electromagnetic steel plate (3) and the second electromagnetic steel plate (4) can be easily connected. Thus, unlike the case of providing an end plate that needs to be joined to the rotor core (2) by welding or the like, no new joining work such as welding is required to close the magnet arrangement hole (3a). ) Can be further prevented from becoming complicated.

  Moreover, in the said embodiment, the process (S1) which forms a part of rotor core (2) forms several 1st electromagnetic steel plates (3) and several 2nd electromagnetic steel plates (4), and is 2nd electromagnetic steel plates. A 1st block core (21) is formed by laminating | stacking a 1st electromagnetic steel plate (3) and a 2nd electromagnetic steel plate (4) so that (4) may be arrange | positioned at the one end (2a) of a lamination direction. A second block core is formed by laminating the first electromagnetic steel plate (3) and the second electromagnetic steel plate (4) so that the second electromagnetic steel plate (4) is disposed at the other end (2b) in the lamination direction. (22) is a step of forming a plurality of block cores (21, 22, 23), and the step (S4) of disposing the permanent magnet (1) is to form the first block core (21) into a plurality of blocks. In a state of being arranged at one end (21a) of the core (21, 22, 23) The step of arranging the permanent magnet (1) in the magnet arrangement part (5) of the first block core (21), and the step of completing the rotor core (2) (S5) is the step of arranging the permanent magnet (1). In this step, the second block core (22) is laminated on the other end (22a) of the plurality of block cores (21, 22, 23) including the one block core (21). If comprised in this way, after arrange | positioning a permanent magnet (1) in the magnet arrangement | positioning hole (3a) of a block core containing a 1st block core (21), a 2nd block core (22) will be arrange | positioned to a block core. In this case, both ends of the magnet arrangement hole (3a) can be easily closed. Also, by forming a rotor core (2) by laminating a plurality of block cores (21, 22, 23), the rotor core (2) in the rolling step, etc., compared to the case where the individual electromagnetic steel sheets are handled individually. The manufacturing process can be easily performed.

  Moreover, in the said embodiment, the process (S2) which arrange | positions a magnet fixing member (5) is a process of arrange | positioning a magnet fixing member (5) to a permanent magnet (1), and the process of arrange | positioning a permanent magnet (1). (S4) is a state in which the first block core (21) is arranged at one end (21a) of the plurality of block cores (21, 22, 23), and the magnet arrangement hole (3a) of the first block core (21). ) Is a step of inserting the permanent magnet (1) in which the magnet fixing member (5) is disposed. If comprised in this way, compared with the case where a magnet fixing member (5) is separately arrange | positioned to a some block core (21, 22, 23), a magnet fixing member (5) will be arrange | positioned to a permanent magnet (1). Thereby, it can prevent that the process of arrange | positioning a magnet fixing member (5) becomes complicated.

  In the above embodiment, the magnet fixing member (5) includes the expansion agent (51), and the step of fixing the permanent magnet (1) to the magnet arrangement hole (3a) expands the expansion agent (51). The magnet fixing member (5) is cured during at least one of the period during which the expansion agent (51) is expanded and the magnet fixing member (5) is cured. This is a step of fixing to (3a). If comprised in this way, a permanent magnet (1) can be easily arrange | positioned in a magnet arrangement | positioning hole (3a) in the state where the volume of the magnet fixing member (5) before expanding an expansion agent (51) is comparatively small ( In the state where the volume of the magnet fixing member (5) is increased by expanding the expansion agent (51) after arranging the permanent magnet (1) in the magnet arrangement hole (3a). The permanent magnet (1) can be fixed to the magnet arrangement hole (3a). As a result, the permanent magnet (1) is more reliably inserted into the magnet arrangement hole (3a) by the expanded magnet fixing member (5) while improving the insertion property of the permanent magnet (1) into the magnet arrangement hole (3a). Can be fixed (adhered).

  Moreover, in the said embodiment, a magnet fixing member (5) contains a volatile agent (64), and the process (S2) of arrange | positioning a magnet fixing member (5) adds a volatile agent (64) to a permanent magnet (1). The step (S4) of arranging the permanent magnet (1) in the magnet arrangement hole (3a) is a step of arranging the magnet fixing member (5) including at least the volatilizing agent (64) of the magnet fixing member (5). This is a step of disposing the permanent magnet (1) in the magnet disposition hole (3a) after a part has been volatilized. If comprised in this way, while being able to arrange | position the magnet fixing member (5) of the state to which the viscosity fell and the applicability | paintability was improved by the amount in which a volatile agent (64) is contained, it can arrange | position to a permanent magnet (1). After the magnet fixing member (5) is arranged on the permanent magnet (1), the volume (thickness) of the magnet fixing member (5) can be reduced by the amount of volatilization of the volatilizing agent (64). ) Can be inserted into the magnet arrangement hole (3a).

[Modification]
The embodiment disclosed this time should be considered as illustrative in all points and not restrictive. The scope of the present invention is shown not by the above description of the embodiment but by the scope of claims for patent, and further includes all modifications (modifications) within the meaning and scope equivalent to the scope of claims for patent.

  For example, in the above embodiment, an example in which the rotor is configured as an inner rotor has been described, but the present invention is not limited to this. For example, the rotor may be configured as an outer rotor.

  In the above embodiment, an example in which the rotor core is configured by stacking a plurality of block cores (the core 21 with the lower end lid, the core 22 with the upper end lid, and the through core 23) is shown, but the present invention is limited to this. Absent. For example, the rotor core may be formed by laminating a plurality of through-cores and laminating lid steel plates at both ends in the laminating direction without forming a block core. In this case, for example, a lid steel plate is arranged at one end in the laminating direction, a through core is laminated, a permanent magnet coated with an adhesive is arranged in the magnet arrangement portion, and then the other end in the laminating direction is arranged. If the lid steel plate is arranged, it is possible to manufacture a rotor capable of preventing a part of the rotor member from being scattered from the magnet arrangement portion to the outside of the rotor.

  Moreover, although the example which provides a penetration core in a rotor core was shown in the said embodiment, this invention is not limited to this. For example, like the rotor 400 of the first modified example shown in FIG. 21, the core 21 with the lower end lid and the core 22 with the upper end lid are laminated to form the rotor core 402 without providing the through core. In this case, after the permanent magnet 401 is arranged on the core 21 with the lower end lid, the core 22 with the upper end lid is laminated.

  Moreover, in the said embodiment, although the example which inserts the permanent magnet by which the adhesive material was arrange | positioned in the magnet arrangement | positioning part was shown, this invention is not limited to this. For example, like the rotor 500 of the second modified example shown in FIG. 22, the permanent magnet 1 may be arranged in the magnet arrangement hole 503a of the rotor core 502 with the adhesive 505 applied to the inner wall surface.

  Moreover, in the said embodiment, although the example which provides a foaming agent (expansion agent) and a dilution solvent (volatile agent) in the adhesive material was shown, this invention is not limited to this. For example, if there is no problem in the applicability of the adhesive to the permanent magnet and the insertability of the permanent magnet into the magnet arrangement part, and the rotor structure does not require expansion of the adhesive, only the thermosetting resin is used as the adhesive. You may comprise.

  Moreover, in the said embodiment, although the example which provides the steel plate for lid | covers 1 each in the both ends of the lamination direction of a rotor core was shown, this invention is not limited to this. For example, a plurality of lid steel plates may be provided at both ends of the rotor core in the stacking direction.

  In the above embodiment, the magnet arrangement hole has a substantially rectangular shape when viewed from the axial direction, and the fitting through hole, the convex portion, and the concave portion have a substantially circular shape when viewed from the axial direction. The present invention is not limited to this. For example, the magnet arrangement hole may have a shape other than a substantially rectangular shape when viewed from the axial direction, and the fitting through hole, the convex portion, and the concave portion have a shape other than a substantially circular shape when viewed from the axial direction. You may do it.

  Moreover, in the said embodiment, although the example which provides the steel plate for lid | covers at the one end (most end) and the other end (most end) of the lamination direction of a rotor core was shown, this invention is not limited to this. That is, the lid steel plate may be disposed at one end (in the vicinity of one end) and the other end (in the vicinity of the other end) of the rotor core in the stacking direction.

  Moreover, in the said embodiment, as shown in FIG.9 and FIG.10, although the example which forms a block core with a lower end lid and a block core with an upper end lid in a mutually different structure was shown, this invention is not limited to this. . For example, as in the rotor 600 of the third modification shown in FIGS. 23 and 24, one of the two block cores 620 formed in the same manner is the block core 621 with a lower end lid, and the other (reversed). It is good also as block core 622 with an upper end lid.

  Here, as shown in FIG. 23 (a), in the method of manufacturing the rotor 600 according to the third modification of the above embodiment, a plurality of penetration steel plates 3 are laminated on the steel plate 4 for the lid (the steel plate 40 for the lower end lid). Two block cores 620 are formed. Specifically, as shown in FIG. 23 (b), the lower end lid steel plate 40 (lid steel plate 4) having the fitting through hole 3c, the convex portion 3d protruding downward (in the direction of arrow Z2), and A plurality of through-steel plates 3 having recesses 3e recessed downward are laminated.

  Then, as shown in FIG. 24 (a), the adhesive 5 is provided in the magnet arrangement hole 603a of the block core 621 with the lower end lid, which is one block core 620 arranged on the lower side of the two block cores 620. Is inserted into the permanent magnet 601.

  A block core 622 with an upper end lid that is obtained by inverting the other block core 620 of the two block cores 630 is disposed above the block core 621 with a lower end lid. That is, as shown in FIG. 24 (b), in the block core 622 with the upper end lid, the lid steel plate 4 having the fitting through hole 3c is arranged at the upper end, and the convex portion 3d protruding upward (in the direction of the arrow Z1), And the some penetration steel plate 3 which has the recessed part 3e recessed upwards is arrange | positioned under the steel plate 4 for lid | covers. And this block core 622 with an upper end cover is arrange | positioned above the block core 621 with a lower end cover in which the permanent magnet 601 is arrange | positioned. Thereby, the rotor core 602 is completed. Thereafter, the adhesive 5 is cured, whereby the rotor 600 according to the third modification is completed.

  If it is configured like the rotor (600) according to the third modification, the structure of the plurality of block cores (630) constituting the rotor (600) can be made common, so that the types of components increase. This makes it possible to prevent the manufacturing equipment from becoming complicated.

  Moreover, although the example which arrange | positions an adhesive material to a rotor by apply | coating an adhesive material to a permanent magnet was shown in the said embodiment, this invention is not limited to this. For example, the adhesive may be arranged on the rotor by filling the gap between the permanent magnet and the magnet arrangement portion with an adhesive (resin).

1, 401, 601 Permanent magnet 2, 402, 502, 602 Rotor core 2a One end (one end in the stacking direction) 2b The other end (the other end in the stacking direction)
DESCRIPTION OF SYMBOLS 3 Through electromagnetic steel plate (1st electromagnetic steel plate) 3a, 503a, 603a Magnet arrangement | positioning hole part 3c Fitting through hole (recessed part) 3d Convex part 3e Recessed part 4 Electrical steel sheet for lids (2nd electromagnetic steel sheet)
4a Closure part (part corresponding to magnet arrangement hole part) 5,505 Adhesive (magnet fixing member)
21, 621 Block core with lower end lid (first block core)
21a One end (one end of block core)
22, 622 Block core with upper end lid (second block core)
22a The other end (the other end of the block core)
51 Foaming agent (swelling agent) 54 Diluent solvent (volatile agent)
DESCRIPTION OF SYMBOLS 100, 400, 500, 600 Rotor 231 Magnet arrangement | positioning hole punch 261 Protrusion punch 300 Strip | belt-shaped electromagnetic steel plate

Claims (11)

With permanent magnets,
A plurality of electromagnetic steel sheets are laminated and formed, and a rotor core having a magnet arrangement hole in which the permanent magnet is arranged,
The permanent magnet is fixed to the magnet arrangement hole by a resin magnet fixing member,
The plurality of electromagnetic steel plates are arranged at both ends of the first electromagnetic steel plate having the magnet arrangement hole and the stacking direction of the plurality of electromagnetic steel plates, and are configured to close the magnet arrangement hole. Including the rotor. The rotor core includes a plurality of block cores in which the plurality of electromagnetic steel plates are laminated,
The plurality of block cores are disposed at one end in the stacking direction of the plurality of block cores, and the first block core is disposed at one end in the stacking direction, and the plurality of block cores The rotor according to claim 1, further comprising: a second block core disposed at the other end in the laminating direction, and the second electromagnetic steel sheet disposed at the other end in the laminating direction. The magnet fixing member includes an expansion agent,
The rotor according to claim 1 or 2, wherein the permanent magnet is fixed to the magnet arrangement hole by the magnet fixing member in a state where the expansion agent is expanded.   One of the first electromagnetic steel plate or the second electromagnetic steel plate is provided with a convex portion protruding on one side in the stacking direction, and the other is provided with a concave portion recessed on one side in the stacking direction. The rotor according to any one of claims 1 to 3, wherein the first electromagnetic steel plate and the second electromagnetic steel plate are connected by arranging the convex portion in the concave portion. A rotor manufacturing method comprising: a permanent magnet; and a rotor core that is formed by laminating a plurality of electromagnetic steel plates and has a magnet arrangement hole in which the permanent magnet is arranged.
Forming a first electromagnetic steel plate that is the electromagnetic steel plate having the magnet arrangement hole, forming a plurality of second electromagnetic steel plates that are the electromagnetic steel plate configured to close the magnet arrangement hole, and A step of forming a part of the rotor core by disposing the second electromagnetic steel sheet at one end in the stacking direction of the electromagnetic steel sheets;
Arranging a resin magnet fixing member in the permanent magnet or the magnet arrangement hole;
After the step of forming a part of the rotor core, the step of arranging the permanent magnet in the magnet arrangement hole,
After the step of arranging the magnet fixing member and after the step of arranging the permanent magnet, the electromagnetic steel plate including the second electromagnetic steel plate is arranged at the other end in the stacking direction of the plurality of electromagnetic steel plates. A step of completing the rotor core,
And a step of fixing the permanent magnet to the magnet arrangement hole by curing the magnet fixing member after the step of completing the rotor core.   The step of forming a part of the rotor core includes forming the first electromagnetic steel sheet by punching the belt-shaped electromagnetic steel sheet by forming the magnet arrangement hole into a belt-shaped electromagnetic steel sheet using a magnet arrangement hole punch. The second electromagnetic steel plate is formed by punching the belt-like electromagnetic steel plate without forming the magnet arrangement hole portion in the belt-like electromagnetic steel plate by the magnet arrangement hole punch, and at one end in the stacking direction. The method for manufacturing a rotor according to claim 5, which is a step of forming a part of the rotor core by disposing the second electromagnetic steel sheet.   The step of forming a part of the rotor core includes a convex portion protruding on one side in the stacking direction on the belt-shaped electromagnetic steel sheet by a punch for convex portions and a recess on one side in the stacking direction on the back side of the convex portion. The first electromagnetic steel sheet is formed in a state where the first electromagnetic steel sheet and the second electromagnetic steel sheet are respectively formed by forming a recess and punching the strip-shaped electromagnetic steel sheet, and the protrusion is disposed in the recess. The method of manufacturing a rotor according to claim 5, wherein the rotor is a step of laminating the second electromagnetic steel sheet. The step of forming a part of the rotor core forms a plurality of the first electromagnetic steel plates and a plurality of the second electromagnetic steel plates, so that the second electromagnetic steel plates are arranged at one end in the stacking direction. The first electromagnetic steel plate and the second electromagnetic steel plate are formed by laminating the first electromagnetic steel plate and the second electromagnetic steel plate so that the second electromagnetic steel plate is disposed at the other end in the stacking direction. Forming a second block core by laminating the second electromagnetic steel sheet, forming a plurality of block cores;
The step of arranging the permanent magnet is a step of arranging the permanent magnet in the magnet arrangement hole of the first block core in a state where the first block core is arranged at one end of the plurality of block cores. ,
The step of completing the rotor core is a step of laminating the second block core on the other end of the plurality of block cores including the first block core on which the permanent magnet is disposed. The method for manufacturing a rotor according to any one of the preceding claims. The step of arranging the magnet fixing member is a step of arranging the magnet fixing member on the permanent magnet,
In the step of arranging the permanent magnet, the magnet fixing member is arranged in the magnet arrangement hole of the first block core in a state where the first block core is arranged at one end of the plurality of block cores. The method for manufacturing a rotor according to claim 8, which is a step of inserting a permanent magnet. The magnet fixing member includes an expansion agent,
The step of fixing the permanent magnet to the magnet arrangement hole includes fixing the magnet during at least one of a period during which the expansion agent is expanded or a period after the expansion agent is expanded. The method of manufacturing a rotor according to any one of claims 5 to 9, which is a step of fixing the permanent magnet to the magnet arrangement hole by curing a member. The magnet fixing member includes a volatile agent,
The step of arranging the magnet fixing member is a step of arranging the magnet fixing member containing the volatilizing agent in the permanent magnet,
The step of arranging the permanent magnet in the magnet arrangement hole is a step of arranging the permanent magnet in the magnet arrangement hole after at least a part of the volatilizing agent of the magnet fixing member is volatilized. Item 11. The method for manufacturing a rotor according to any one of Items 5 to 10.

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