JP2019110680A - Method of manufacturing rotor of rotary electric machine and sleeve bonding apparatus - Google Patents

Abstract

To provide a method of manufacturing a rotor of a rotary electric machine and a sleeve bonding apparatus, capable of reliably bonding a sleeve of a workpiece to a magnet and each end cap.SOLUTION: The method of manufacturing a rotor of a rotary electric machine includes: a first magnet assembly manufacturing process of integrally molding a magnet on a shaft 10; a second magnet assembly manufacturing process in which a first end cap 22 and a second end cap 23 are fitted to a first magnet assembly 50A manufactured in the first magnet assembly manufacturing process; and a third magnet assembly manufacturing process having a sleeve bonding process for injecting an adhesive into a gap R formed at a second magnet assembly 50B manufactured in the second magnet assembly manufacturing process between an inner circumferential surface of a sleeve 40 of a workpiece W on which the sleeve 40 is mounted and an outer peripheral surface of the magnet 21 in a radial direction and between the inner circumferential surface of the sleeve 40 and an outer circumferential surface of at least a part of the second end cap 23 in the radial direction.SELECTED DRAWING: Figure 24

Description

  The present invention relates to a method of manufacturing a rotor of a rotating electrical machine and a sleeve bonding apparatus.

  The rotor of a rotating electrical machine generally has a magnet fixed to the shaft. When the rotor rotates, centrifugal force is generated and stress is generated on the magnet. Also, since magnets are generally fragile, they may crack if subjected to excessive tensile stress. As a countermeasure, it has been proposed to provide a sleeve for reinforcement on the outer periphery of the magnet (see, for example, Patent Document 1). In Patent Document 1, a magnet, a first end cap disposed at one end of the magnet, a second end cap disposed at the opposite end of the magnet, a magnet and an end cap are enclosed. Disclosed is an arrangement having a sleeve, which forms an interference fit with each of the end caps, and further having an adhesive disposed between the magnet and the sleeve.

  By this configuration, the adhesive can transmit tensile stress acting on the magnet to the sleeve, and excessive distortion or cracking of the magnet can be avoided. As a method of manufacturing this rotor, first, a magnet and each end cap are bonded to each other to manufacture a subassembly (first step). Next, the subassembly is placed on a sleeve placed in a container (adhesive bath) containing an adhesive, and the sleeve and each end cap are press-fit to form a rotor core assembly (second step). Next, the rotor core assembly is washed with water to remove residual adhesive (paragraph 0045, third step). The rotor core assembly is then placed in an oven to cure the adhesive placed between the magnet and the sleeve (fourth step). Finally, by bonding the rotor core assembly and the shaft, the rotor of the rotating electrical machine is manufactured (fifth step).

JP, 2012-50325, A (Paragraph 0045, FIGS. 3-5)

  However, in patent document 1, there are many manufacturing processes on the structure of a product, and the process which takes time and effort is needed, and the subject that manufacture of a product takes time takes an issue. In particular, in the bonding of the magnet and the sleeve, the step of washing with water after filling with the adhesive is time-consuming, and as a result there is a problem that the cost of the rotor of the rotating electric machine increases and productivity improvement is difficult. The

  The present invention has been made to solve the problems as described above, and an object of the present invention is to provide a method for manufacturing a rotor of a rotary electric machine with low cost and good productivity, and a sleeve bonding apparatus.

A method of manufacturing a rotor of a rotating electrical machine according to the present invention is
A shaft and a cylindrical magnet disposed on the outer peripheral surface of the shaft;
A cylindrical first end cap, which is disposed to be fitted to the shaft, on one of the first end faces in the axial direction of the magnet;
A second end cap disposed in engagement with the shaft on the other second end face side in the axial direction of the magnet;
A method of manufacturing a rotor of a rotating electrical machine, comprising: a sleeve surrounding the entire circumference of the magnet and at least a portion of the second end cap, wherein
A first magnet assembly manufacturing step of integrally molding the magnet on the shaft;
A second magnet assembly manufacturing process in which the first end cap and the second end cap are fitted to the first magnet assembly manufactured in the first magnet assembly manufacturing process;
Between the inner circumferential surface of the sleeve and the outer circumferential surface of the magnet of the work in which the sleeve is mounted on the second magnet assembly manufactured in the second magnet assembly manufacturing process, and the inner periphery of the sleeve And a third magnet assembly manufacturing process having a sleeve bonding process of injecting an adhesive into a gap formed between a surface and a radial direction of at least a part of the outer peripheral surface of the second end cap.

The sleeve bonding apparatus according to the present invention is
A shaft and a cylindrical magnet disposed on the outer peripheral surface of the shaft;
A cylindrical first end cap, which is disposed to be fitted to the shaft, on one of the first end faces in the axial direction of the magnet;
A second end cap disposed in engagement with the shaft on the other second end face side in the axial direction of the magnet;
A sleeve for bonding an inner circumferential surface of the sleeve and an outer circumferential surface of the magnet and the second end cap, of a work having a sleeve surrounding the entire circumference of the magnet and at least a part of the second end cap A bonding device,
With the rotation axis,
A work rotation unit comprising a sleeve guide connected to the rotation axis and holding an outer peripheral surface of the work so that the central axis of the work and the axis of the rotation axis coincide with each other;
From the nozzle,
It is formed between the inner peripheral surface of the sleeve and the outer peripheral surface of the magnet in the radial direction, and between the inner peripheral surface of the sleeve and the outer peripheral surface of at least a part of the second end cap. And an adhesive injection unit for injecting an adhesive into the gap;
The workpiece rotation unit is installed such that the central axis of the workpiece is inclined by θ degrees with respect to the central axis of the nozzle.

  According to the method of manufacturing the rotor of the rotary electric machine and the bonding device of the sleeve according to the present invention, since the sleeve of the work can be bonded to the magnet and the end cap more reliably, the rotor of the rotary electric machine with high reliability is provided inexpensively. be able to.

It is sectional drawing of the rotor of the rotary electric machine which concerns on Embodiment 1 of this invention. It is sectional drawing of the shaft which concerns on Embodiment 1 of this invention. It is sectional drawing of the modification of the shaft which concerns on Embodiment 1 of this invention. It is sectional drawing of the 1st magnet assembly which concerns on Embodiment 1 of this invention. It is a top view of the 1st magnet assembly concerning Embodiment 1 of the present invention. It is a perspective view of the 1st magnet assembly concerning Embodiment 1 of this invention. It is a sectional view of the 2nd magnet assembly concerning Embodiment 1 of the present invention. It is a perspective view of the 1st end cap concerning Embodiment 1 of the present invention. It is sectional drawing of the 2nd magnet assembly which covered the sleeve which concerns on Embodiment 1 of this invention. It is sectional drawing of the 3rd magnet assembly which concerns on Embodiment 1 of this invention. It is a principal part enlarged view of FIG. 7A. It is sectional drawing of the rotary electric machine which concerns on Embodiment 1 of this invention. It is sectional drawing of the air blower which concerns on Embodiment 1 of this invention. It is sectional drawing of the other example of the 3rd magnet assembly which concerns on Embodiment 1 of this invention. It is sectional drawing of the 3rd magnet assembly which concerns on Embodiment 2 of this invention. It is a principal part enlarged view of FIG. 11A. It is sectional drawing of the 3rd magnet assembly which concerns on Embodiment 3 of this invention. It is sectional drawing of the 3rd magnet assembly which concerns on Embodiment 4 of this invention. It is principal part sectional drawing of the 3rd magnet assembly which concerns on Embodiment 5 of this invention. It is a side view of the 1st magnet assembly concerning Embodiment 6 of this invention. It is a top view of the 1st magnet assembly concerning Embodiment 6 of this invention. It is a perspective view of the 1st magnet assembly concerning Embodiment 6 of this invention. It is sectional drawing of the 2nd magnet assembly which covered the sleeve which concerns on Embodiment 6 of this invention. It is a top view of the 2nd magnet assembly which covered the sleeve concerning Embodiment 6 of this invention. It is sectional drawing of the 3rd magnet assembly which concerns on Embodiment 6 of this invention. It is sectional drawing of the principal part of the 3rd magnet assembly which concerns on Embodiment 7 of this invention. It is sectional drawing in the BB line of FIG. 18A. 1 is a cross-sectional view of a sleeve bonding apparatus according to Embodiment 1 of the present invention. It is sectional drawing of the workpiece rotation unit which concerns on Embodiment 1 of this invention. It is a principal part cross-sectional schematic diagram of the sleeve bonding apparatus and the workpiece | work in which the adhesive agent which concerns on Embodiment 1 of this invention is inject | pouring. It is a modification of the sleeve bonding apparatus which concerns on Embodiment 1 of this invention. It is sectional drawing of the sleeve bonding apparatus which concerns on Embodiment 5 of this invention. It is a flowchart which shows each process of the manufacturing method of the air blower which concerns on Embodiment 1 of this invention.

Embodiment 1
Hereinafter, a method of manufacturing a rotor of a rotary electric machine and a sleeve bonding apparatus according to Embodiment 1 of the present invention will be described with reference to the drawings.

In the present specification, the terms “axial direction”, “radial direction”, and “circumferential direction” refer to the “axial direction”, “radial direction”, and “circumferential direction” of the shaft 10 and the rotor 100.
FIG. 24 is a flowchart showing the steps of the method for manufacturing a fan according to the present embodiment. As shown in the figure, the manufacturing process of the blower is roughly divided into a rotor manufacturing process, a rotary electric machine manufacturing process, and a blade mounting process.

  The rotor manufacturing process includes a first magnet assembly manufacturing process, a second magnet assembly manufacturing process, and a third magnet assembly manufacturing process. In the first magnet assembly manufacturing process, magnet magnets are formed on the shaft of the rotary electric machine, and in the second magnet assembly manufacturing process, the first and second end caps holding the magnets from the axial direction with respect to the first magnet assembly are fitted. Match. Then, in the third magnet assembly manufacturing process, a sleeve that encloses the outer peripheral surface of the magnet and the like with a gap is attached to the second magnet assembly, and an adhesive is injected into the gap to manufacture the third magnet assembly. Do. The respective steps will be described in detail below.

FIG. 1 is a cross-sectional view of a rotor 100 of a rotating electrical machine cut along a plane passing through its central axis.
The rotor 100 includes a shaft 10, a magnet unit 20 fixed to the shaft 10, and a bearing unit 30 rotatably supporting the shaft 10.

FIG. 2A is a cross-sectional view of the shaft 10.
FIG. 2B is a cross-sectional view of the shaft 10B. The shaft 10B is a modified example of the shaft 10. The shaft 10 has an axially stepped cylindrical shape, and has a center hole 11 coaxial with the central axis of the shaft 10 at the first axial end 10t1. A chamfered portion 12 is provided at the edge of the center hole 11, and a knurled portion 13 is provided at a portion on the outer peripheral surface where the magnet unit 20 is attached. In a certain range from the second end 10t2 side of the shaft 10, two step portions 10d1 and 10d2 in which the diameter on the end side of the shaft is reduced are provided. As shown to FIG. 2B, you may provide chamfer 12b in step 10d2.

  The center hole 11 is a cylindrical hole which is provided at the first axial end 10 t 1 of the shaft 10 and concentrically with the axial center of the shaft 10. The shaft 10 is manufactured by cutting or grinding an iron-based material (for example, carbon steel for machine structure or stainless steel). At the time of manufacturing, if the center hole 11 is first machined and the material is fixed using the center hole 11, there is an advantage that positional deviation between the center of the shaft 10 and the center of the outer periphery to be scraped can be easily suppressed. The small positional deviation of the center of the shaft 10 has an advantage that the vibration or sound at the time of rotation of the rotor 100 can be reduced.

  The knurled portion 13 is continuously formed on a part of the shaft 10 in the axial direction. In the knurled portion 13, minute unevenness is formed on the outer peripheral surface of the shaft 10, and the form thereof is an eye shape in which the unevenness is configured to intersect in two directions on the outer peripheral surface of the shaft 10 . Note that the knurled portion 13 may have a flat shape that makes asperities in a direction parallel to the axial direction.

FIG. 3A is a cross-sectional view of the first magnet assembly 50A.
FIG. 3B is a plan view of the first magnet assembly 50A.
FIG. 3C is a perspective view of the first magnet assembly 50A.
In FIG. 3C, the second end 10t2 side of the shaft 10 is omitted.
The first magnet assembly 50A has a structure in which a cylindrical magnet 21 is disposed on a part of the outer peripheral surface of the shaft 10. The magnet 21 is a plastic magnet and is manufactured by injection molding.

  Next, a first magnet assembly manufacturing process for manufacturing the first magnet assembly 50A will be described. First, the shaft 10 shown in FIG. 2 is manufactured by machining. Next, the shaft 10 is put into a mold for injection molding of a plastic magnet, and the plastic magnet is poured into a space in the mold around the knurled portion 13 of the shaft 10 and then cooled. Take out.

  Thus, it is possible to manufacture the first magnet assembly 50A having a structure in which the magnet 21 made of a cylindrical plastic magnet is provided around the knurled portion 13. At this time, the core between the center of the shaft 10 and the outer peripheral surface of the magnet 21 is made to come out. By forming a plastic magnet on the knurled portion 13 of the shaft 10, the adhesion between the shaft 10 and the magnet 21 can be easily enhanced. That is, the plastic magnet is engaged with the unevenness of the knurled portion 13, and an anchor effect can be obtained to enhance the mutual fixing force.

  Further, although the first magnet assembly 50A can also be configured by manufacturing only the magnet 21 alone and then pressing it into the shaft 10, it takes time and effort for press fitting, and the method described above is simpler than the first method. The magnet assembly 50A can be manufactured. In addition, it is conceivable that when the sintered magnet is made separately and then pressed into the shaft 10, the brittle sintered magnet may be cracked or cracked. Therefore, by forming the magnet 21 as a plastic magnet and integrally molding the shaft 10, the first magnet assembly 50A can be easily assembled.

  In addition, when manufacturing a single magnet and thereafter trying to couple it to the shaft by press-fitting or shrink-fitting, it is difficult to provide the shaft 10 with a knurled portion. This is because the knurled portion is likely to cause cracks and cracks in the magnet. Therefore, the coupling force between the magnet and the shaft is smaller than in the case where the knurled portion is provided. As a measure against this, it is conceivable to put an adhesive in the gap and bond the shaft and magnet as a clearance fit, but it takes time and effort for bonding.

  As shown in FIGS. 3A, 3B and 3C, four gate portions 21g are provided on the first end face 21t1 in the axial direction of the magnet 21. The gate is the name of a part of a mold for injecting a plastic magnet at the time of injection molding. The gate portion 21g is a cut surface of a portion to be the magnet 21 of the first magnet assembly 50A and the gate of the mold. When the magnet 21 is pulled away from the mold, a cut surface is generated. For this reason, the shape of the cut surface is difficult to stabilize. So, in the mold which manufactures the magnet 21, the gate is provided in the part which makes the outline of the magnet 21 so that it may protrude in convex shape to the magnet 21 side. As a result, the gate portion 21g remaining on the magnet 21 is formed in a concave shape so as to enter inside from the first end face 21t1 in the axial direction of the magnet 21. Thereby, the magnet 21 which can be assembled without interfering with the 1st end cap mentioned below can be obtained.

  In addition, when the gate having a small cross-sectional area increases in the mold for injection molding of the plastic magnet, the pressure loss increases at the time of injection molding, the gate may be clogged, and the mold may need to be repaired. Therefore, in the present embodiment, the gate portion 21g is provided on the side closer to the first end portion 10t1 in the axial direction of the shaft 10 in order to reduce the portion where the cross-sectional area of the gate of the mold is reduced. That is, as a position where the gate portion 21g can be provided in the axial direction in FIG. 3, the first end face 21t1 on the side where the gate portion 21g is actually disposed of the magnet 21 and the second side on the bearing unit 30 side opposite to that The end face 21t2 can be considered.

  Now, the dimension from the first end face 21t1 of the magnet 21 actually arranging the gate part 21g to the first end 10t1 of the shaft 10 is L1, and the second end face of the shaft 10 from the second end face 21t2 of the magnet 21. Assuming that the dimension up to the portion 10t2 is L2, L1 <L2, and if the gate is provided on the bearing unit 30 side of the mold, the portion where the mold gate and the shaft 10 interfere with each other becomes long. If it is attempted to reduce the cross sectional area of the gate, gate clogging is likely to occur. On the other hand, in the case of the present embodiment in which the gate of the mold is provided on the side close to the first end 10t1 of the shaft 10, the interference between the gate and the shaft 10 can be easily prevented, and the cross-sectional area of the gate can be enlarged. , You can control the gate clogging.

  Further, the number of magnetic poles of the magnet 21 of the present embodiment is four. Therefore, by making the number of gate portions 21g the same as the number of magnetic poles, it is possible to manufacture the magnets 21 having a substantially symmetrical shape centering on the shaft 10 with high accuracy, and to suppress the variation in product performance. .

FIG. 4 is a cross-sectional view of the second magnet assembly 50B.
Next, a second magnet assembly manufacturing process for manufacturing the second magnet assembly 50B will be described.
In FIG. 4, the gate portion 21 g shown in FIG. 3 is not shown because it shows a cross section cut at different planes passing through the axial center of the shaft 10. In the second magnet assembly manufacturing process, the first end cap 22 and the second end cap 23 are axially pressed into the first magnet assembly 50A as a radial interference fit.

FIG. 5 is a perspective view of the first end cap 22. FIG.
The first end cap 22 has a stepped cylindrical shape and has a centrally extending hole 22 h. The outer peripheral surface of the first end cap 22 is concentric with the outer peripheral surface 22outa (first outer peripheral surface) coextensive with the hole 22h and the hole 22h located closer to the magnet 21 than the outer peripheral surface 22outa. It is divided into an outer peripheral surface 22outb (second outer peripheral surface) whose diameter is smaller than 22outa. An annular sleeve contact surface 22s perpendicular to the axial direction is formed in the step between the outer peripheral surface 22outa and the outer peripheral surface 22outb.

  A chamfered portion 22m is formed at an edge on the outer peripheral surface 22outb side of the hole 22h. The chamfered portion 22m has a tapered shape. In the first end cap 22, in the axial direction, the end surface on the outer peripheral surface 22outa side is a first end surface 22t1, and in the axial direction, the end surface on the outer peripheral surface 22outb side is a second end surface 22t2. The second end face 22t2 abuts on the first end face 21t1 of the magnet 21.

  As shown in FIG. 4, the second end cap 23 has a cylindrical shape, and has a hole 23 h penetrating in the center, an outer peripheral surface 23 out concentric to the hole, and an axial end of the hole 23 h. The edge has a beveled portion 23m.

  The second magnet assembly 50B can be manufactured by axially pressing the first end cap 22 and the second end cap 23 into the first magnet assembly 50A. At this time, since the inner diameter of the hole 22 h of the first end cap 22 and the inner diameter of the hole 23 h of the second end cap 23 are made to be an interference fit with the outer diameter of the shaft 10, they are mutually press-fitted and fixed can do.

  Further, the first end cap 22 is press-fitted to the shaft 10 so that the second end face 22t2 having a smaller outer diameter is on the magnet 21 side. By providing the chamfered portion 22 m at the edge of the hole 22 h of the first end cap 22, the insertability of the first end cap 22 to the shaft 10 can be improved, and the working time can be shortened. Furthermore, since the chamfered portion 12out is also provided on the outer peripheral edge of the first end portion 10t1 in the axial direction of the shaft 10, the insertability is further improved, and the working time can be shortened.

  Further, by making the gate portion 21g of the magnet 21 concave so as not to protrude in the axial direction, interference between the magnet 21 and the first end cap 22 can be prevented. When the gate portion 21g is not formed in a concave shape, the first end cap 22 is fixed at a position axially distant from the magnet 21 in order to prevent the first end cap 22 and the magnet 21 from interfering with each other. Is considered. However, in such a configuration, there is a concern that the rotating electrical machine becomes axially long, the amount of use of various materials increases, and the weight becomes heavy. According to the gate portion 21g according to the present embodiment, since these concerns are eliminated, the magnet 21 and the first end cap 22 can be closely attached.

  FIG. 6 is a cross-sectional view of the second magnet assembly 50B covered with the sleeve 40, taken along a plane passing through the central axis of the shaft 10. As shown in FIG.

  The sleeve 40 is a hollow cylindrical part. The outer peripheral surface 41 and the inner peripheral surface 42 of the sleeve 40 are concentric. With respect to the outer peripheral surface 41 and the inner peripheral surface 42, surfaces in the direction perpendicular to the axial direction are a first end surface 40t1 and a second end surface 40t2. As shown in FIG. 6, between the sleeve 40 and the entire circumference of the magnet 21, a part of the outer peripheral surface of the first end cap 22, and a part of the outer peripheral surface of the second end cap 23. , And the communicating gap R is formed.

  Therefore, the axial dimension of the sleeve 40 is longer than the axial dimension of the magnet 21, and the axial total length of the outer peripheral surface 21 out of the magnet 21 and the axial total length of the outer peripheral surface 22 outb of the first end cap 22 , And a part of the outer peripheral surface 23out of the second end cap 23 on the magnet 21 side. Further, the first end surface 40 t 1 on the first end cap 22 side in the axial direction of the sleeve 40 is in contact with the sleeve contact surface 22 s of the first end cap 22.

FIG. 7 is a cross-sectional view of the third magnet assembly 50C taken along a plane passing through the central axis of the shaft 10.
Next, a third magnet assembly manufacturing process for manufacturing the third magnet assembly 50C shown in FIG. 7 will be described.
In the third magnet assembly manufacturing process, the sleeve 40 is covered on the outer peripheral surface of the second magnet assembly 50B via the gap R, and an adhesive is injected from the space between the second end cap 23 and the sleeve 40 into the gap R. The adhesive is injected from the upper side to the lower side as shown by the arrows in FIG. The adhesive is injected into the gap R and cured to form the adhesive layer 45 shown in FIG. 7, and the sleeve 40, the magnet 21, the first end cap 22, and the second end cap 23 are fixed.

  Since the adhesive is also injected into a portion of the gap R, around the first end cap 22 and a portion around the second end cap 23, the three parts and the sleeve 40 are firmly fixed. A third magnet assembly 50C can be obtained.

  By the way, since the first end cap 22 is provided with the sleeve contact surface 22s, the axial position of the sleeve 40 can be easily positioned by the sleeve contact surface 22s. Without the sleeve contact surface 22s, the cost of preparing the manufacturing apparatus, jigs, etc. would be required, and even if positioning was performed using the manufacturing apparatus or jigs, a slight error would occur, resulting in dimensional variation of the product. It causes it to occur.

  Moreover, generally, when rotating the rotor of the rotating electrical machine, if a force due to vibration or swinging is applied, the adhesive layer may be separated from the magnet assembly, and the sleeve may be separated in the axial direction. However, according to the third magnet assembly 50C according to the present embodiment, even if the sleeve 40 tries to come off on the first end cap 22 side in the axial direction, the sleeve contact surface 22s receives this force, so it comes off. A stopping effect can be obtained and a more rigid structure can be obtained. That is, the rotor 100 can be rotated at a higher speed.

  Furthermore, by providing a step between the second end face 22t2 of the first end cap 22 and the sleeve abutment surface 22s, the gap is also formed between the outer circumferential surface 22outb of the first end cap 22 and the inner circumferential surface 42 of the sleeve 40. A gap R can be formed and an adhesive can be injected here as well. Thereby, the sleeve 40 can be fixed more firmly. By manufacturing the third magnet assembly 50C in this manner, the magnet unit 20 of the rotor 100 can be formed.

Next, the third magnet assembly manufacturing process described above and the sleeve bonding apparatus 90 used in this process will be described in more detail with reference to the drawings.
First, in the sleeve attaching process, the workpiece W is assembled to the second magnet assembly 50B from the second end 10t2 side of the shaft 10 through the sleeve 40. In this state, centering of the sleeve 40 and the shaft 10 can not be performed.

Next, a work attaching step of fixing the work W to the sleeve bonding apparatus 90 is performed.
FIG. 19 is a cross-sectional view of the sleeve bonding apparatus 90. As shown in FIG.
FIG. 20 is a cross-sectional view of the workpiece rotation unit 91. As shown in FIG.
The sleeve bonding apparatus 90 includes a work rotation unit 91 for rotating the second magnet assembly 50B (work W) covered with the sleeve 40 in the circumferential direction, and an adhesive injection unit 92 for injecting an adhesive.

  The adhesive injection unit 92 consists of two syringes 92A, 92B for pushing out the adhesive, and a nozzle 92N for releasing the adhesive.

  The work rotation unit 91 includes a sleeve guide 91a, a screw 91b, and a rotation shaft 91c. The sleeve guide 91 a is used to install the sleeve 40 of the workpiece W on the workpiece rotation unit 91. The screw 91 b is used to fix the sleeve guide 91 a concentrically with the rotation shaft 91 c of the workpiece rotation unit 91.

  The rotating shaft 91c is pivoted in the H direction shown in FIG. 19 by a motor or the like (not shown). The sleeve guide 91a is also rotated by the rotation of the rotation shaft 91c. The rotary shaft 91c and the sleeve guide 91a are both cylindrical parts, and are fastened by a screw 91b in a state in which the respective central axes are concentric.

  The inner circumferential surface of the sleeve guide 91a is a centering portion 91s. The central axis of the centering portion 91s is concentric with the central axis of the sleeve guide 91a. That is, the central axis of the centering portion 91s and the rotation center of the workpiece rotation unit 91 coincide with each other. The outer peripheral surface 22outa of the first end cap 22 of the work W and the outer peripheral surface 41 of the sleeve 40 are inserted into the centering portion 91s so as to be a clearance fit. The workpiece W is inserted until the tip end of the first end cap 22 abuts on the axial positioning portion 91i of the sleeve guide 91a. Thus, first, by aligning the centering portion 91s of the sleeve guide 91a with the outer peripheral surface 22outa of the first end cap 22, the central axis W1 of the workpiece W (the central axis of the shaft 10) and the rotation of the workpiece rotation unit 91 The axis of the axis 91c coincides with that of the axis 91c.

  Further, by aligning the centering portion 91s of the sleeve guide 91a with the outer peripheral surface 41 of the sleeve 40, the axial center of the outer peripheral surface 41 of the sleeve 40 and the axial center of the work W coincide. As a result, even if the sleeve 40 and the magnet 21 themselves do not have a centering portion for centering each other, it is easy to use the work rotation unit 91 having the centering portion 91s, as a whole of the workpiece W and the workpiece The alignment with the rotation shaft 91 c of the rotation unit 91 can be performed. Since the centering portion 91s is a clearance fit, the work W rotates with the work rotation unit 91 even if the work W and the sleeve guide 91a are not positively fixed by a screw or the like.

Next, a sleeve bonding process is performed.
FIG. 21 is a schematic sectional view of an essential part of the sleeve bonding apparatus 90 and the work W during injection of the adhesive. FIG. 21 shows a state in which the adhesive is injected into the gap R.
As shown in FIGS. 19 and 21, the workpiece W is attached to the sleeve bonding apparatus 90 such that the second end cap 23 side is on the upper side (high position).

  Further, the nozzle 92N of the adhesive injection unit 92 is held downward in the vertical direction, and the workpiece rotation unit 91 is installed such that the central axis W1 of the workpiece W is inclined by θ degrees with respect to the central axis N1 of the nozzle N. By setting θ at 10 degrees to 80 degrees, interference between the nozzle 92N and the shaft 10 of the work W is prevented, and since there is no right angle such as 90 degrees, the adhesive is likely to enter the gap. .

  The adhesive used is one that is cured by mixing the two solutions. Even with one-component adhesive, it may be possible to obtain adhesion, but in that case it takes time to cure, or an additional step of shortening the time by heating etc. is required, so two-component curing type adhesion It is preferable to use an agent.

  One of the two-component adhesive is placed in the syringe 92A and the other in the syringe 92B. When the adhesive is injected, the adhesive is pushed out from the syringe 92A and the syringe 92B to the nozzle 92N, the two-component adhesive is mixed in the nozzle 92N, and the mixed liquid adhesive is injected into the gap R. At this time, the tip end on the workpiece W side of the nozzle 92N is injected while being in contact with the outer peripheral surface 23out of the second end cap 23.

  The adhesive is injected along the outer peripheral surface 23 out of the second end cap 23 by injecting the adhesive in a state where the tip of the nozzle 92 N is in contact with the outer peripheral surface 23 out of the second end cap 23. It flows into the gap R between the surface 42 and the outer circumferential surface 21 out of the magnet 21. Therefore, the adhesive can be reliably introduced into the gap R.

  When the inner diameter of the sleeve 40 is D1, the outer diameter of the outer peripheral surface 23out of the second end cap 23 is D2, and the outer diameter of the magnet 21 is D3, the dimensions of each member are set such that D1> D2 ≧ D3. Do. Thus, the adhesive is more reliably formed by the outer peripheral surface 22outb of the first end cap 22, the outer peripheral surface 21out of the magnet 21, the outer peripheral surface 23out of the second end cap 23, and the inner peripheral surface 42 of the sleeve 40. Can be injected into the gap R to be Thereby, the adhesive adheres to the outer peripheral surface 41 of the sleeve 40, and it is possible to suppress the work of removing the surplus in the later process.

  By the way, in order to use the adhesive agent hardened | cured by 2 liquid, in this Embodiment, syringe 92A, 92B for respectively putting A agent and B agent is used. As a result, the shaft 10 of the workpiece W and the syringes 92A and 92B, or the shaft 10 and components of the device (not shown) for gripping the syringes 92A and 92B easily interfere with each other. However, according to the sleeve bonding apparatus and the method of manufacturing the rotor of the rotary electric machine according to the present embodiment, the second end cap 23 is disposed above the first end cap 22 and the nozzle 92N is vertically formed. Since the workpiece rotation unit 91 can be installed so that the central axis W1 of the workpiece W is inclined by θ degrees with respect to the central axis N1 of the nozzle 92N while holding the direction downward, these can be injected. Interference can be easily avoided. In addition, as compared with the case of using a one-component curing adhesive, the curing time can be shortened, and the productivity of the sleeve bonding process can be improved. The direction of the nozzle 92N is not limited to the downward direction in the vertical direction. Further, even in the case of using a one-component curing adhesive, it is needless to say that interference between the nozzle 92N and the shaft 10 can be prevented by relative inclination of the nozzle 92N and the shaft 10.

Next, a specific adhesive injection method will be described.
In the state shown in FIGS. 19 and 21, first, the workpiece rotation unit 91 is rotated to rotate the workpiece W. Next, the adhesive is pushed out from the nozzle 92N applied to the outer peripheral surface 23out of the second end cap 23. At this time, the adhesive travels along the outer peripheral surface 23 out of the second end cap 23 and drops to the magnet 21 side. Since the work W is rotating, the adhesive adheres to the outer peripheral surface 21 out of the magnet 21 in a spiral shape as shown by the arrow L in FIG.

  Therefore, if the adhesive is not injected in an amount falling from the outer peripheral surface 23 out of the first end cap 22 into the gap R, the adhesive adheres to the outer peripheral surface 41 of the sleeve 40, and the amount of adhesive used increases. Removal work after bonding may be required. Therefore, by holding the amount of adhesive discharged from the nozzle 92N constant and injecting the adhesive while rotating the work W, the adhesive does not fall on the outer peripheral surface 41 of the sleeve 40, and the circumferential direction It is possible to inject the adhesive continuously. As a result, it is possible to improve the adhesive strength and the productivity of the sleeve bonding process.

  Although not employed in the present embodiment, the adhesive can be injected also by fixing the work W and rotating the nozzle 92N side. Since the central axis W1 of the work W is provided with an inclination of θ degrees with respect to the central axis N1 of the nozzle N, the nozzle 92N is rotated while being in contact with the outer peripheral surface 23out of the second end cap 23. This can be realized, for example, by attaching an actuator having a linear operation function of three axes (X, Y, Z axes). However, with the sleeve bonding apparatus 90 and the sleeve bonding method according to the present embodiment, only one actuator for rotating the workpiece W may be provided, and the inexpensive sleeve bonding apparatus 90 and the sleeve bonding method can be provided.

  As described above, interference between the nozzle 92N and the shaft 10 can be avoided by relatively inclining the central axis N1 of the nozzle 92N and the central axis W1 of the workpiece W using the sleeve bonding apparatus 90. On the other hand, particularly in the case of a rotor of a small-sized rotary electric machine, the diameter of the nozzle 92N may be larger than the diameter of the shaft.

  Generally, as the nozzle of the bonding apparatus, it is possible to make the bonding apparatus more inexpensive by using a commercially available one having a large number of circulation. On the other hand, changing the diameter of the shaft of the rotor of the rotary electric machine according to the bonding device may not be sufficient as strength. Alternatively, a dedicated nozzle may be manufactured, but the cost is high.

  However, according to the sleeve bonding apparatus 90 and the sleeve bonding method according to the present embodiment, the interference between the nozzle 92N and the shaft 10 can be easily avoided, and the central axis N1 of the nozzle 92N and the central axis W1 of the work W However, since there is no orthogonal relationship, there is an effect that the adhesive is likely to enter the gap R.

  Although it is possible to inject the adhesive while avoiding interference with the shaft 10 by bending the tip of the nozzle (for example, by making it L-shaped), it is difficult for the adhesive to be pushed out at the bent portion of the nozzle Become. And this causes the injection of a fixed amount of adhesive to be prevented, and the injection of the adhesive takes time. On the other hand, according to the sleeve bonding apparatus 90 and the sleeve bonding method according to the present embodiment, these problems do not occur.

  The sleeve bonding apparatus 90 was provided with a nozzle 92N (also called a static mixer) for mixing two adhesives, and had a function of delivering a mixture of two adhesives from the nozzle 92N at a constant speed. In general, when the adhesive is a two-component, the parts of the device supporting each of the two syringes may interfere with the shaft. However, according to the sleeve bonding apparatus 90, since the central axis W1 of the work W is inclined by θ degrees with respect to the central axis N1 of the nozzle 92N, mutual interference can be easily avoided. Moreover, the nonuniformity of mixing can be suppressed by providing the nozzle 92N which mixes two adhesive agents. In addition, since the amount of release of the adhesive can be made constant, it is possible to suppress the variation of the product.

  Further, since the workpiece rotation unit 91 has a function of centering the workpiece W and the workpiece rotation unit 91, the central axes of the sleeve bonding device 90 and the workpiece W can be easily aligned. As a result, when the workpiece rotation unit 91 is rotated, the workpiece W rotates without eccentricity, so the workpiece W can be rotated while the tip of the nozzle 92N is in contact with the outer peripheral surface 23out of the second end cap 23. The adhesive can be reliably injected into the gap R. As a result, adhesion of the adhesive to the outer peripheral surface 41 of the sleeve 40 can be suppressed, the wiping operation after the sleeve bonding step is not necessary, and the productivity of the sleeve bonding step can be improved.

  FIG. 22 is a cross-sectional view of a sleeve bonding apparatus 90B which is a modification of the sleeve bonding apparatus 90. As shown in FIG. The difference from the sleeve bonding apparatus 90 is that the first end cap 22B is provided with a through hole 22k which penetrates in the axial direction and is connected to the gap R, and the sleeve guide 91Ba has a suction hole 91Bak communicating with the through hole 22k. Point is provided. A suction machine (not shown) is attached to the suction hole 91Bak, and air in the gap R can be sucked out.

  While injecting the adhesive into the gap R from the second end cap 23 side as described above, the air in the gap R is sucked from the first end cap 22 side, whereby the adhesive to the gap R more quickly Can penetrate. Thereby, the productivity of the sleeve bonding process can be improved. Before the sleeve bonding step, a UV treatment step may be carried out in which one or both of the inner circumferential surface 42 of the sleeve 40 and the outer circumferential surface 21 out of the magnet 21 are subjected to UV treatment. As a result, the wettability of the surface on which the adhesive flows can be improved, the adhesive can be more rapidly penetrated into the gap R, and the productivity of the sleeve bonding process can be improved.

Next, the bearing unit 30 will be described.
As shown in FIG. 1, the bearing unit 30 is composed of a bearing 31a, a wave washer 32, a spacer 33, a washer 34, and a bearing 31b from the side of the magnet 21 in the axial direction. The bearings 31a and 31b use deep groove ball bearings, angular ball bearings, or the like. The wave washer 32 generates a force in the axial direction by a force of elastic deformation when the wave washer 32 is flexed in the axial direction, and is used as a preload to the bearing 31a, and pushes the outer ring of the bearing 31a.

  The spacer 33 uses a material having a linear expansion coefficient substantially the same as that of a frame described later. For example, the material of the frame is aluminum, and the material of the spacer 33 is also aluminum. Of course, if the main component of the material is aluminum, it will have substantially the same linear expansion coefficient, so it may be an aluminum-based material. The same is true for iron-based materials.

  The washer 34 is made of a material whose main component is rubber, and, for example, urethane rubber, chloroprene rubber, fluororubber, nitrile rubber, silicone rubber or the like is used. The washer 34 is not in contact with the inner ring of the bearing 31 b but in contact with the outer ring of the bearing 31 b and the spacer 33.

Next, a method of manufacturing the bearing unit 30 will be described.
After manufacturing the third magnet assembly 50C, the bearing 31a is pressed into the shaft 10. Next, the wave washer 32, the spacer 33, and the washer 34 are sequentially inserted into the shaft 10. The wave washer 32, the spacer 33, and the washer 34 have an inner diameter larger than the outer diameter of the shaft 10 and can be easily inserted. Finally, the bearing unit 30 is completed by press-fitting the bearing 31b to the shaft 10 to a predetermined position (bearing mounting step).

  At this time, the amount of deflection of the wave washer 32 and the washer 34 is managed by the axial pitch dimension of the bearings 31a and 31b. As a result, it is possible to easily manage the preload applied to the bearings 31a and 31b by the elastic force of the wave washer 32 and the elastic force of the washer 34.

  As shown in FIG. 1, the shaft 10 passes through the second end cap 23 and is interference fit to a position where the axial first end 10 t 1 is flush with the first end face 22 t 1 of the first end cap 22. It is inserted.

  In the case of Patent Document 1, the shaft is disposed at a position shorter than the axial end surface of one end cap (see FIG. 2 of Patent Document 1). In contrast to this, in the present embodiment, the shaft 10 penetrates the second end cap 23 and reaches the position where the end face position coincides with the first end cap 22. Thereby, the distance of the interference fit between the shaft 10 and the first end cap 22 and the second end cap 23 can be maximized, and the shaft 10 and the first end cap 22 and the second end cap 23 Can be easily and firmly fixed. That is, there is an advantage that even if there is a force applied in the axial direction as the rotor 100 swings during rotation, even a larger force can be tolerated. The number of bearings may be one.

  As described above, according to the rotor 100 of the rotary electric machine according to Embodiment 1 of the present invention, it is possible to provide the rotor 100 of the rotary electric machine with low cost and good productivity.

Next, the manufacturing process of the rotating electrical machine will be described.
FIG. 8 is a cross-sectional view of a rotary electric machine 100R using the rotor 100. As shown in FIG.
The rotary electric machine 100R is configured of a stator 60, a rotor 100, a frame 70, and a substrate 80. The central axes of the stator 60, the rotor 100, and the frame 70 are concentric. The substrate 80 is installed at a position distant in the axial direction. The substrate 80 has a control function for rotating the rotating electrical machine 100R. The rotor 100 of the rotary electric machine 100R rotates in the arrow Y direction about the central axis of the shaft 10.

  The stator 60 has a stator core 61, an insulator 62a, an insulator 62b, a coil 63, and a terminal 64. In the stator core 61 disposed on the outer peripheral side of the magnet 21 of the rotor 100 via the air gap G, an insulator 62a and an insulator 62b made of insulating resin are assembled on both end surfaces in the axial direction. Then, a conductive enameled wire is wound around the stator core 61 via the insulator 62a and the insulator 62b, thereby forming a coil 63. The end portion of the coil 63 is wound around a groove provided on the outer peripheral surface of the insulator 62 a and finally connected to the terminal 64. The joint portion 65 a is provided on a part of the terminal 64.

  The bonding portion 65 a electrically connects the coil 63 and the terminal 64 using, for example, a solder or a solder. Furthermore, the terminal 64 is electrically joined to the substrate 80 by the joint portion 65 b at a position separated in the axial direction. With this configuration, the rotational position of the rotor 100 of the rotary electric machine 100R is recognized by the substrate 80 having a control function, and the coil 63 of the stator 60 generates a desired current according to the position. 100R can be arbitrarily controlled and rotated.

  The substrate 80 is fixed to the female screw portion 66 of the insulator 62 a with a screw 67. By fixing in this manner, a contact portion is formed between the insulator 62a and the substrate 80, and in addition, mutual pressing can be performed with the screw 67. Therefore, the substrate 80 is fixed only by the bonding portion 65a and the bonding portion 65b. In contrast to the above, even if a force due to the vibration of the rotary electric machine 100R is applied, it is difficult to be removed, and a stronger fixation can be performed.

  The stator core 61 is fixed to the frame 70 by shrink fitting or press fitting. An axial end face 61t2 of the stator core 61 on the bearing unit 30 side is a stepped portion formed on the inner peripheral surface of the frame 70 and is brought into contact with an annular stator core abutting surface 71t2 perpendicular to the axial direction. Axial positioning within the frame 70 of the vehicle can be facilitated.

  In a general rotating electric machine (for example, FIG. 1 of JP-A-2013-90481), two bearings are often arranged so as to sandwich the magnet in the axial direction (hereinafter, this structure is called a double-supported structure) . In such a double-supported structure, it is necessary to center two bearings with a plurality of parts.

  On the other hand, according to the rotor 100 of the rotary electric machine 100R according to the present embodiment, the bearing 31a and the bearing 31b constituting the rotary electric machine 100R are not arranged in a structure sandwiching the magnet 21. That is, both are disposed on one side in the axial direction of the magnet 21 (hereinafter, this structure is referred to as a cantilever structure). Furthermore, the two bearings 31a, 31b are fitted to a part of the frame 70 which is one component. As described above, with the configuration according to the present embodiment, centering of the rotor 100 can be performed by the frame 70 of one component, and assembly of the rotating electrical machine 100R with high accuracy becomes possible.

  By the way, in the case of the rotor having this cantilever structure, the rotor may be displaced in the radial direction as it gets farther from the bearing unit in the axial direction. When the rotor rotates while swinging, an axial force is exerted on each component of the rotor. For example, with the structure disclosed in Patent Document 1, when the deflection of the rotor becomes large and the axial force becomes excessive, the adhesive layer peels off under shear force, causing the sleeve to be displaced in the axial direction. There is a concern that they will be out of In addition, even if the rotor is not damaged, there is a concern that the balance of the rotor may be deteriorated to increase the noise.

  However, according to the rotor 100 according to the present embodiment, the first end cap 22 is provided with the sleeve contact surface 22s, and even if the adhesive layer is subjected to a shearing force and the sleeve 40 tries to come off in the axial direction, The first end cap 22 receives this. The first end cap 22 is fixed by press fitting or shrink fitting with the shaft 10, and can hold up to the fixing force by the tight fitting. Since the fixing force by the narrow fit can be set arbitrarily to the force of the narrow fit, it can be set to a large force compared to the fixing force of the adhesive, and the material can be widely selected, so adjustment is possible. It has the advantage of being easy.

Next, a fan manufacturing process will be described.
FIG. 9 is a cross-sectional view of a blower 100F using the rotor 100. As shown in FIG.
In the fan 100F, a blade 85 is attached to the second end 10t2 side opposite to the first end cap 22 of the rotor 100 of the rotary electric machine 100R of the present embodiment in the axial direction. That is, in the fan 100F, the blade 85 is attached on the opposite side to the magnet 21 in the axial direction with the bearing unit 30 of the rotor 100 interposed therebetween.

  When the shaft 10 rotates in the arrow Y direction in FIG. 9, the blades 85 rotate to generate a wind. Generally, in a rotating electric machine or a blower, the heat source is often a coil wound on a stator. If the heat generation is large, measures may be taken to increase the heat dissipation part of the rotating electrical machine to cool it, but the amount of material used increases.

  However, according to fan 100F according to the present embodiment, cooling can be performed by applying wind to the vicinity of the heat generation source, and heat generation can be suppressed without increasing the volume of the rotating electrical machine. Furthermore, by notching a part of the frame 70 positioned in the axial direction with respect to the coil 63 and providing the through hole 72, the coil 63 can be directly winded, and the cooling efficiency can be further improved. .

  Generally, it is known that suppressing heat generation of a bearing in a rotating electrical machine or a blower will extend the life of the bearing. This is because the deterioration of the lubricating oil in the bearing can be suppressed. According to rotating electric machine 100R and fan 100F according to the present embodiment, holes 72b are opened also in the axial direction of frame 70 holding two bearings 31a and 31b, and on the side of vane 85, through which the wind by vane 85 is When introduced into the frame 70, the cooling of the two bearings 31a, 31b can be made more efficient and simple.

  On the other hand, in the double-supported structure, since the bearings are located at the positions sandwiching the magnet in the axial direction, even if wind can be applied to the frame holding one of the bearings, the other bearing or the other bearing It is difficult to wind the frame holding the

  As described above, according to the fan 100F according to the present embodiment, the cooling effect of the fan 100F can be easily increased by passing the wind around the two bearings 31a and 31b as a cantilever structure.

  Further, in the present embodiment, the inner circumferential surface 42 of the sleeve 40 and the outer circumferential surface 21 out of the magnet 21 are fixed by an adhesive, and the adhesive layer 45 is provided. The adhesive layer 45 can transmit tensile stress acting on the magnet 21 to the sleeve 40, and can avoid excessive distortion or cracking of the magnet 21.

  Furthermore, a gap R is also provided between the second end cap 23 and the sleeve 40 in the radial direction. As a result, after the sleeve 40 is put on the magnet 21, the adhesive can be introduced into the gap R in the axial direction from the side of the second end cap 23. By this, it is possible to suppress the time and effort of wiping off the residual adhesive, and in particular, it is possible to eliminate the process of washing with water after the sleeve bonding process, and to provide the inexpensive rotor 100 of the rotating electric machine, the rotating electric machine 100R, and the blower 100F. Can.

  Further, the first end cap 22 is in contact with the first end face 21 t 1 in the axial direction of the magnet 21 and the second end cap 23 is in contact with the second end face 21 t 2. Even if a force is applied, the force can be received by the first end cap 22 and the second end cap 23, so that the stress applied to the magnet 21 can be suppressed, and the crack or crack of the magnet 21 can be suppressed. it can.

FIG. 10 is a cross-sectional view of a rotor 100B which is a modification of the rotor 100. As shown in FIG.
As shown in FIG. 10, the outer peripheral surface of the first end cap 22B according to the present embodiment or the edge (a part of the contour) of the first end face 22t1 in the axial direction may be cut. The first end cap 22B is provided with a balance correction unit 22b in which a part of the contour is cut, so that the weight unbalance amount of the rotor 100B can be reduced. Similarly, the balance correction part 23b may be provided on the end face of the second end cap 23B on the bearing unit 30 side. By performing balance correction in both the first end cap 22B and the second end cap 23B, it is possible to adjust the amount of unbalance of the rotor 100B at axially distant positions. This makes it possible to manufacture with a smaller amount of imbalance than correcting the balance of the rotor 100 with one component, and has the effect of suppressing vibration and sound of the rotary electric machine 100R. The balance correction is performed after the sleeve bonding process.

  According to the method of manufacturing the rotor of the rotary electric machine and the bonding apparatus of the sleeve according to the first embodiment, the sleeve of the work can be bonded more reliably to the magnet and each end cap, so that the rotor of the rotary electric machine with high reliability is inexpensive. Can be manufactured.

Second Embodiment
Hereinafter, a method of manufacturing a rotor of a rotary electric machine and a sleeve bonding apparatus according to a second embodiment of the present invention will be described with reference to the drawings, focusing on differences from the first embodiment.
FIG. 11A is a cross-sectional view of the third magnet assembly 250C. 11A is a cross-sectional view of the whole, and FIG. 11B is an enlarged view of an essential part of FIG. 11A.
The difference between the third magnet assembly 50C according to the first embodiment and the third magnet assembly 250C according to the present embodiment is the shape of the first end cap 222. In the first embodiment, in the first end cap 22, the surface in contact with the magnet 21 and the surface in contact with the sleeve 40 at the axial end surface are not flush with each other. However, in the first end cap 222 of the present embodiment, the surface in contact with the magnet 21 and the surface in contact with the sleeve 240 are the same second end surface 222t2. Other than this is the same as the first embodiment.

  According to the first end cap 222 according to the second embodiment of the present invention, the shape of the first end cap 222 can be simplified, and the manufacturing cost of the rotor of the rotating electric machine, the rotating electric machine, and the blower can be suppressed. Further, although the configuration described in the first embodiment can inject a larger amount of adhesive for bonding the sleeve 40 and the first end cap 22 and can be more firmly fixed to each other, if this is surplus, By using the first end cap 222 according to the present embodiment, the amount of adhesive used can be suppressed. The sleeve bonding step of bonding the sleeve 240 and the magnet 21 is the same as that of the first embodiment.

Third Embodiment
Hereinafter, a method of manufacturing a rotor of a rotary electric machine and a sleeve bonding apparatus according to a third embodiment of the present invention will be described with reference to the drawings, focusing on differences from the first embodiment.
FIG. 12 is a cross-sectional view of the third magnet assembly 350C.
The difference between the third magnet assembly 50C according to the first embodiment and the third magnet assembly 350C according to the present embodiment is that there is an adhesive layer 45b between the first end cap 322 and the magnet 21 in the axial direction. There is an adhesive layer 45c between the second end cap 323 and the magnet 21 in the axial direction, and the adhesive layer 45, the adhesive layer 45b and the adhesive layer 45c are integrally formed.

  With the first end cap 322, the magnet 21, the second end cap 323, and the adhesive layers 45, 45b, 45c configured as such, the assembly of the first end cap 322, the second end cap 323 is performed. Even if the position varies, the variation can be absorbed by the adhesive layers 45b and 45c, and the productivity of the third magnet assembly 350C is improved.

  In the first embodiment, the first end cap 22 and the second end cap 23 are fixed only by the force of the narrowing fit, but in the third embodiment, the adhesive is added to the force of the narrowing fit. The axial direction can be fixed also by the adhesive force of Therefore, even if a load is applied in the axial direction as the rotor swings during rotation, even stronger forces can be tolerated. The sleeve bonding step of bonding the sleeve 40 and the magnet 21 is the same as that of the first embodiment.

Fourth Embodiment
Hereinafter, a method of manufacturing a rotor of a rotary electric machine and a sleeve bonding apparatus according to a fourth embodiment of the present invention will be described with reference to the drawings, focusing on differences from the first embodiment.
FIG. 13 is a cross-sectional view of a third magnet assembly 450C.
The difference between the third magnet assembly 50C according to the first embodiment and the third magnet assembly 450C according to the present embodiment is that the second end cap 23, the magnet and the second end cap are all as the magnet 421. , Being one part. Also in this embodiment, the magnet 421 is manufactured by a plastic magnet. For this reason, the shaft 10 is put in a mold for injection molding, and a plastic magnet is molded to obtain a magnet 421 corresponding to the three parts of the magnet 21 of the first embodiment, the first end cap 22 and the second end cap 23. It becomes possible to manufacture by integral molding at one time. As a result, the number of assembling steps of the third magnet assembly 450C can be reduced, and a method of manufacturing a rotor of a rotating electric machine and a sleeve bonding apparatus that can manufacture a cheaper rotor of a rotating electric machine can be provided. The magnet 421 may be manufactured by sintering.

  Also, the magnet and the first end cap may be made of a plastic magnet, and the second end cap may be separate members, or the magnet and the second end cap may be made of a plastic magnet, and the first end cap may be a separate member . In these cases, separate members are made of a material cheaper than the material of the plastic magnet. Depending on the manufacturing cost and the material cost, it may be selected whether there are merits as to whether the three parts are one part of the plastic magnet or two parts including another part. The sleeve bonding step of bonding the sleeve and the magnet 421 is the same as that of the first embodiment.

Embodiment 5
Hereinafter, a method of manufacturing a rotor of a rotary electric machine and a sleeve bonding apparatus according to a fifth embodiment of the present invention will be described with reference to the drawings, focusing on differences from the first embodiment.
FIG. 14 is a cross-sectional view of main parts of the third magnet assembly 550C.
The difference between the third magnet assembly 50C according to the first embodiment and the third magnet assembly 550C according to the present embodiment is the outer peripheral surface 522outb (second outer peripheral surface with a smaller outer diameter of the first end cap 522). Is processed so as to be concentric with the hole 522h, and the inner peripheral surface 542 of the sleeve 540 is fitted to the outer peripheral surface 522outb.

  As in the first embodiment, the shaft 10 and the inner peripheral surface of the hole 522 h of the first end cap 522 which is interference-fitted to the shaft 10 are processed coaxially. Further, the inner peripheral surface of the hole 522 h of the first end cap 522 and the outer peripheral surface 522 outb of the first end cap 522 are also processed coaxially. That is, the outer peripheral surface 522outb and the outer peripheral surface of the magnet 21 are concentric, and the outer peripheral surface 522outb and the inner peripheral surface 542 of the sleeve 540 are fitted to each other. Therefore, centering of the central axis of the shaft 10 and the outer peripheral surface 522outb of the first end cap 522 can be performed.

  Here, the inner peripheral surface 542 of the sleeve 540 and the outer peripheral surface 522outb of the first end cap 522 are center-fit as a clearance fit or a narrow fit. By this, it is possible to ensure uniform gaps in the circumferential direction in which the adhesive is inserted. As a result, the weight of the adhesive layer 545 is less uneven, and it is possible to provide a balanced rotor, a rotating electric machine, and a blower of the rotating electric machine.

FIG. 23 is a cross-sectional view of the sleeve bonding apparatus 590.
A different point from the sleeve bonding apparatus 90 of the first embodiment is the shape of the sleeve guide 591a of the work rotating unit 591. In the first embodiment, the sleeve guide 91a having a length substantially equal to the entire length of the sleeve 40 is employed. However, in the present embodiment, only the outer peripheral surface of the first end cap 522 and a part of the outer peripheral surface of the sleeve 40 on the first end cap 522 side are covered. In this embodiment, the first end cap 522 and the sleeve 540 are centered by the outer peripheral surface 522 outb of the first end cap 522 and the inner peripheral surface 542 of the sleeve 540. There is no need to center the first end cap 522 and the sleeve 540. Therefore, the sleeve guide 591a can be miniaturized.

  In addition, the output of an actuator (not shown) such as a motor attached to the workpiece rotation unit 591 can be reduced, and a cheaper sleeve bonding apparatus 590 can be provided. In addition, the sleeve guide 591a is provided with a centering portion 591s with the first end cap 522, and in a state in which the central axis W1 of the workpiece W and the axial center of the rotational shaft of the workpiece rotation unit 591 coincide with each other Since the function of rotating the unit 591 is left, the same effect as the sleeve bonding apparatus according to the first embodiment is obtained.

Sixth Embodiment
Hereinafter, a method of manufacturing a rotor of a rotary electric machine and a sleeve bonding apparatus according to a sixth embodiment of the present invention will be described with reference to the drawings, focusing on differences from the first embodiment.
FIG. 15A is a side view of a first magnet assembly 650A.
FIG. 15B is a plan view of the first magnet assembly 650A.
FIG. 15C is a perspective view of a first magnet assembly 650A.
FIG. 16A is a cross-sectional view of the second magnet assembly 650B with the sleeve 40 covered.
FIG. 16B is a plan view of the second magnet assembly 650B with the sleeve 40 covered.
FIG. 17 is a cross-sectional view of the third magnet assembly 650C.
The difference between each magnet assembly according to the first embodiment and the first magnet assembly 650A according to the present embodiment is that the magnet 621 is provided with a protrusion 621p for centering, and the magnet 621 and the sleeve 40 are concentrically provided. Are taking

  On the outer peripheral surface of the magnet 621, protrusions 621p that protrude in the radial direction and extend in the axial direction are provided at four places separated by 90 degrees in the circumferential direction. As shown in FIG. 15B, the protrusions 621p are provided at the pole center of the magnet 621 and are provided substantially at the midpoint between the four gate portions 621g provided in the circumferential direction.

  Further, all the protrusions 621 p are arranged to be rotationally symmetrical with respect to the central axis of the magnet 621. The magnet 621 and the sleeve 40 can be centered by fitting the outer peripheral portion of the protrusion 621p and the inner peripheral surface 42 of the sleeve 40 which is a hollow cylindrical part (gap fitting or light press-fitting).

  The protrusion 621 p extends in the axial direction of the magnet 621 from the side of the first end cap 22 in the axial direction to the vicinity of the central portion of the magnet 621 and does not exist over the entire length of the magnet 621. Thereby, even when the adhesive is injected from the second end cap 23 side when manufacturing the third magnet assembly 650C, it can be suppressed that the protrusion 621p becomes an obstacle and adhesion does not sufficiently enter the gap 600R. .

  Further, as shown in FIGS. 16A and 17, in the portion without the protrusion 621p, the adhesive layer 645 can be formed over the entire length in the axial direction of the gap 600R. An adhesive layer 645 can be formed at the extension of the direction. Thereby, it is possible to disperse the centrifugal force acting on the rotor via the adhesive layer 645, and it is possible to suppress the crack and the crack of the magnet 621.

  As described above, the protrusion 621p of the magnet 621 is provided at a portion to be the pole center of the magnet 621 and is provided approximately at the midpoint between the gate portions 621g in the circumferential direction. The magnet 621 is manufactured to generate a polar anisotropic magnetic field. The magnetic field at this time is indicated by a curved arrow in FIG. 15B. In general, when trying to manufacture a pole-anisotropic magnet, the direction of the magnetic powder differs between the pole and the pole center (position denoted as N, S). Due to this mismatch in orientation, a phenomenon occurs in which the diameter between the poles of the magnet is reduced and the magnet is recessed. Even if a projection is provided at this recessed position, there is a risk that it can not be fitted with the sleeve and centering can not be performed. Therefore, in the present embodiment, by arranging the centering protrusion 621p at the pole center, the phenomenon that the outer peripheral surface of the magnet 621 is recessed can be suppressed, and the centering of the sleeve 40 and the magnet 621 can be performed. It can be implemented reliably.

  Further, by arranging the projections 621p so as to be rotationally symmetrical with respect to the central axis of the magnet 621, adhesion between the projections 621p in the circumferential direction is made between the outer peripheral surface 621out of the magnet 621 and the inner peripheral surface 42 of the sleeve 40. The areas in which the layers are present can be arranged alternately. As a result, even if centrifugal force is applied to the magnet 621 while the rotor is rotating, a significant increase in stress can be suppressed. The step of bonding the sleeve and the magnet is the same as in the first embodiment or the first embodiment.

Embodiment 7
Hereinafter, a method of manufacturing a rotor of a rotary electric machine and a sleeve bonding apparatus according to a seventh embodiment of the present invention will be described with reference to the drawings, focusing on differences from the sixth embodiment.
FIG. 18A is a cross-sectional view of main parts of a third magnet assembly 750C.
FIG. 18B is a cross-sectional view taken along the line BB in FIG. 18A. In addition, the cross section in the AA line of FIG. 18B turns into FIG. 18A.
A great difference between the third magnet assembly 650C according to the sixth embodiment and the third magnet assembly 750C according to the present embodiment is that, on the sleeve 740 side, a plurality of centering sleeves 740 and magnets 21 are provided. The flat portion 742 p is provided to extend the core of both members, and the shape of the sleeve 740 is characterized.

  The sleeve 740 is provided on the inner circumferential surface 742 with a flat portion 742p which extends in the direction perpendicular to the radial direction of the sleeve 740 and in the axial direction, and the flat portion 742p and the outer circumferential surface 21out of the magnet 21 are engaged with each other. Centering of both members is realized. By doing so, centering of both members becomes easy, and further, compared to the sixth embodiment, the amount of use of the magnet can be suppressed because the magnet has no protrusion. Further, by fitting the flat portion 742p of the sleeve 740 to the magnet 21 with a light press-fit interference fit, the sleeve 740 can be temporarily fixed before the adhesive layer is formed. As a result, even if a force acts in a direction in which the sleeve 740 falls off the workpiece W in the manufacturing process of the rotor, the retaining effect can be obtained and the degree of freedom in the method of manufacturing the rotor can be advantageously increased. .

  The flat portions 742 p are provided at four locations so as to be rotationally symmetrical with respect to the central axis of the magnet 21. This is the same as the number of poles of the magnet 21. The magnet 21 is formed by molding a pole-anisotropic magnet with a plastic magnet, and thus each pole has the same shape (a center of the pole is convex and a gap between the poles is concave in the circumferential direction). repeat). For this reason, centering can be performed with good balance in the circumferential direction with respect to the convex portion of the magnet 21. In addition, since the adhesive is injected into the four gaps 700R that are rotationally symmetrical with respect to the central axis of the magnet 21 partitioned by the outer circumferential surface 21 out of the magnet 21 and the four flat portions 742p, the adhesive layer 745 is well balanced. It is possible to provide a method of manufacturing a rotor of a rotating electric machine and a sleeve bonding apparatus capable of forming a rotor of a rotating electric machine with less vibration. As in the case of the protrusion 621p of the sixth embodiment, the processing of the flat portion 742p may not be performed over the entire length of the sleeve 740, but may be part of the first end cap 22 side. The step of magnet bonding the sleeve is similar to that of the first embodiment or the fifth embodiment.

  In the present invention, within the scope of the invention, each embodiment can be freely combined, or each embodiment can be appropriately modified or omitted.

100, 100B rotor, 100R rotating electric machine, 100F blower,
10, 10B shaft, 10d1, 10d2 stepped portion, 10t1 first end,
10t2 second end, 11 center hole, 12, 12b, 12out chamfer,
13 knurled parts, 20 magnet units, 21,421,621 magnets,
21g, 621g gate part, 21out, 621out outer peripheral surface,
21t1 first end face, 21t2 second end face, 621p protrusion,
22, 22 B, 222, 322, 522 first end cap, 22 k through hole,
22b, 23b balance correction unit, 22h, 522h hole, 22m chamfer,
22outa, 22outb, 522outb outer peripheral surface, 22s sleeve contact surface,
22t1 first end face, 22t2, 222t2 second end face,
23, 23B, 323 second end cap, 23b balance correction part, 23h hole,
23m chamfer, 23out outer peripheral surface, 30 bearing units, 31a, 31b bearings,
32 wave washers, 33 spacers, 34 washers,
40, 240, 540, 740 sleeve, 40 t 1 first end face, 40 t 2 second end face, 41 outer peripheral surface, 42, 542 inner peripheral surface,
45, 45 b, 45 c, 545, 645, 745 adhesive layer,
50A, 650A first magnet assembly, 50B, 650B second magnet assembly,
50C to 750C third magnet assembly, 60 stators, 61 stator cores,
61t2 end face, 62a, 62b insulator, 63 coils, 64 terminals,
65a, 65b junction, 70 frame, 71t2 stator core contact surface,
72, 72b holes, 80 substrates, 85 blades, 742p flat parts,
90, 90 B sleeve bonding device, 91, 591 work rotating unit,
91Bak suction hole, 91a, 91Ba, 591a sleeve guide, 91c rotating shaft, 91s, 591s centering portion, 92 adhesive injection unit, 92A, 92B syringe, 92N nozzle, N1 central axis, W1 central axis, G air gap,
R, 600R, 700R Gap, Y arrow.

Claims (15)

A shaft and a cylindrical magnet disposed on the outer peripheral surface of the shaft;
A cylindrical first end cap, which is disposed to be fitted to the shaft, on one of the first end faces in the axial direction of the magnet;
A second end cap disposed in engagement with the shaft on the other second end face side in the axial direction of the magnet;
A method of manufacturing a rotor of a rotating electrical machine, comprising: a sleeve surrounding the entire circumference of the magnet and at least a portion of the second end cap, wherein
A first magnet assembly manufacturing step of integrally molding the magnet on the shaft;
A second magnet assembly manufacturing process in which the first end cap and the second end cap are fitted to the first magnet assembly manufactured in the first magnet assembly manufacturing process;
Between the inner circumferential surface of the sleeve and the outer circumferential surface of the magnet of the work in which the sleeve is mounted on the second magnet assembly manufactured in the second magnet assembly manufacturing process, and the inner periphery of the sleeve A third magnet assembly manufacturing process including a sleeve bonding process of injecting an adhesive into a gap formed between a surface and a radial direction of at least a part of the outer peripheral surface of the second end cap; Manufacturing method. In the manufacturing process of the third magnet assembly, the first end face on the first end cap side in the axial direction of the sleeve is brought into contact with an annular sleeve contact surface on the magnet side of the first end cap 2. The rotor according to claim 1, further comprising: a sleeve attaching step of forming an adhesive, and injecting the adhesive into the gap from the second end cap side in the sleeve attaching step after the sleeve attaching step. Manufacturing method. In the sleeve bonding step,
Using a sleeve bonding device with an adhesive injection unit that releases the adhesive from the tip of the nozzle;
The method for manufacturing a rotor of a rotary electric machine according to claim 1 or 2, wherein the adhesive is discharged in a state in which the tip end of the nozzle is in contact with the outer peripheral surface of the second end cap. The rotor according to claim 3, wherein the inner diameter of the sleeve is D1, the outer diameter of the second end cap is D2, and the outer diameter of the magnet is D3, the relationship of D1> D2 ≧ D3 is satisfied. Production method. In the sleeve bonding step,
The method for manufacturing a rotor of a rotary electric machine according to claim 3 or 4, wherein the adhesive is discharged in a state where the central axis of the work is inclined with respect to the central axis of the nozzle. The method for manufacturing a rotor of a rotary electric machine according to any one of claims 3 to 5, wherein in the sleeve bonding step, the nozzle is fixed, and the adhesive is discharged while rotating the work. The first end cap has a through hole axially penetrating and communicating with the gap;
The method for manufacturing a rotor of a rotating electrical machine according to any one of claims 1 to 6, wherein in the sleeve bonding step, air in the gap is sucked from the through hole while injecting the adhesive. The rotation according to any one of claims 1 to 7, further comprising a UV treatment step of performing a UV treatment on at least one of the inner circumferential surface of the sleeve or the outer circumferential surface of the magnet before the sleeve bonding step. Method of manufacturing a rotor of an electric machine. The magnet, the first end cap, and the second end cap are integrally formed on the shaft in the first magnet assembly manufacturing process;
The manufacturing method of the rotor of the rotary electric machine of any one of Claim 1 to 8 which abbreviate | omits a said 2nd magnet assembly manufacturing process. The manufacturing of the rotor of the rotary electric machine according to any one of claims 1 to 9, further comprising a bearing mounting step of assembling at least one or more bearings at an end of the shaft on the second end cap side. Method. A shaft and a cylindrical magnet disposed on the outer peripheral surface of the shaft;
A cylindrical first end cap, which is disposed to be fitted to the shaft, on one of the first end faces in the axial direction of the magnet;
A second end cap disposed in engagement with the shaft on the other second end face side in the axial direction of the magnet;
A sleeve for bonding an inner circumferential surface of the sleeve and an outer circumferential surface of the magnet and the second end cap, of a work having a sleeve surrounding the entire circumference of the magnet and at least a part of the second end cap A bonding device,
With the rotation axis,
A work rotation unit comprising a sleeve guide connected to the rotation axis and holding an outer peripheral surface of the work so that the central axis of the work and the axis of the rotation axis coincide with each other;
From the nozzle,
It is formed between the inner peripheral surface of the sleeve and the outer peripheral surface of the magnet in the radial direction, and between the inner peripheral surface of the sleeve and the outer peripheral surface of at least a part of the second end cap. And an adhesive injection unit for injecting an adhesive into the gap;
A sleeve bonding apparatus in which the work rotation unit is installed such that the central axis of the work is inclined by θ degrees with respect to the central axis of the nozzle. On the inner circumferential surface of the sleeve guide,
12. The sleeve bonding apparatus according to claim 11, further comprising: a centering portion for centering the workpiece and the workpiece rotation unit. The sleeve bonding apparatus according to claim 12, wherein the first end cap and the sleeve are fixed to the sleeve guide by a clearance fit. The said sleeve guide is a suction hole which attracts | sucks the air of the said clearance gap through the through-hole which penetrates axial direction to the said 1st end cap and is connected to the said clearance gap. Sleeve bonding device. The adhesive injection unit has two syringes each holding the adhesive and pushing it out to the nozzle,
The nozzle has a mixing function of adhesive ejected from two syringes, respectively.
The sleeve bonding device according to any one of claims 11 to 14, wherein the adhesive injection unit can keep the amount of the adhesive discharged constant.

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