JP2022061064A - Rotary electric machine, and method for manufacturing the same - Google Patents

Abstract

To provide a rotary electric machine capable of accurately positioning magnets in an output shaft direction and a circumferential direction, and holding the magnets while suppressing backlash of the magnets in a radial direction.SOLUTION: A rotary electric machine is provided with: a rotor core 12 fixed to an output shaft 2; a plurality of magnets 13 arranged in a circumferential direction of the rotor core 12; and a magnet holder 14 for holding the magnets 13. The magnet holder 14 has a plurality of arm parts 16 extending from a disk-shaped base part 17 along the output shaft 2 and arranged between the magnets 13. The arm parts 16 have outer circumferential end face holding parts 21 for holding both radial end faces of outer circumferences of the magnets 13 in a radial direction, and circumferential side surface pressing parts 22 for holding both circumferential side surfaces. The magnet holder 14 is fixed to the rotor core 12, and the magnets 13 are held between the rotor core 12, the outer circumferential end face holding parts 21 and the circumferential side surface pressing parts 22 of the magnet holder 14.SELECTED DRAWING: Figure 3

Description

The present application relates to a rotary electric machine and a method for manufacturing the same.

Conventionally, for rotary electric machines used for motors, generators, etc., a magnet holder equipped with a comb-shaped arm is fitted and fixed in a holder mounting groove provided along the output axis direction on the outer periphery of the rotor core. There is a structure in which a magnet, which is a permanent magnet, is inserted between each arm of the magnet holder with a slight press-fitting from the output axis direction to fix the magnet to the outer periphery of the rotor core.

In particular, in the following Patent Document 1, a bridge portion smaller than the arm is formed between the arm of the magnet holder and the base holding the arm, and the bridge portion is deformed when the magnet is inserted, whereby the magnet is formed. It is held by elasticity.

International Publication No. 2007/080888

However, in the prior art described in Patent Document 1, since the arm is deformed starting from the arm base, it is difficult to completely suppress the degree of opening of the arm end. Further, since the magnet is positioned and fixed in the circumferential direction by the arm having the deformable bridge portion, the positioning accuracy in the circumferential direction is poor, and there is a concern that the performance as a rotary electric machine such as cogging torque and torque ripple is deteriorated. Further, the magnet holder is fitted and fixed to the fitting portion provided on the rotor core, but the fitting portion also has a required play or deformation when the magnet is inserted, so that the positioning accuracy in the circumferential direction of the magnet is deteriorated. There is a concern that it will cause.

The present application discloses a technique for solving the above-mentioned problems, and enables highly accurate positioning and holding of a magnet in the output axis direction and the circumferential direction while suppressing rattling in the radial direction of the magnet. It is an object of the present invention to provide a rotary electric machine and a method for manufacturing the same.

The rotary electric machine disclosed in the present application is
It is provided with a rotor core fixed to an output shaft, a plurality of magnets arranged along the circumferential direction of the rotor core, and a magnet holder for holding the magnets.
The magnet holder has a disk-shaped base portion having an insertion hole for the output shaft formed in the center, and a plurality of magnet holders extending from the base portion along the output shaft and arranged between the magnets. It has an arm part and
An outer peripheral beam portion is formed on the base portion along the outer circumference thereof, and the arm portion includes an outer peripheral end face holding portion for holding both end faces in the radial direction of the outer circumference of the magnet and both sides in the circumferential direction of the magnet. A circumferential side holding portion for holding the surface is formed inward in the radial direction from the outer peripheral beam portion.
The magnet holder is fixed to the rotor core, and the magnet is held between the rotor core, the outer peripheral end surface holding portion of the magnet holder, and the circumferential side surface holding portion.

Further, the method for manufacturing a rotary electric machine disclosed in the present application is as follows.
The rotor core is fixed to the output shaft, a plurality of magnets arranged along the circumferential direction of the rotor core, and a magnet holder for holding the magnets. The magnet holder has an insertion hole for the output shaft in the center. A rotary electric machine having a disk-shaped base portion on which a magnet is formed, and a plurality of arm portions extending from the base portion along the output shaft and arranged between the magnets. It ’s a manufacturing method,
The arm portion is formed with an outer peripheral end face holding portion that holds both end faces in the radial direction of the outer circumference of the magnet and a circumferential side holding portion that holds both side surfaces in the circumferential direction of the magnet.
The rotor core is formed with a position-regulating protrusion that regulates the position of the magnet in the output axis direction at one end in the output axis direction.
After fixing the magnet to the rotor core, the magnet holder is inserted from the direction opposite to the position restricting protrusion of the rotor core to fix the magnet holder to the rotor core, and the magnet is fixed to the rotor core and the magnet holder. It is held between the outer peripheral end surface holding portion and the circumferential side surface pressing portion.

According to the rotary electric machine and the manufacturing method thereof disclosed in the present application, it is possible to perform highly accurate positioning in the output shaft direction and the circumferential direction and hold the magnet while suppressing rattling in the radial direction of the magnet.

It is sectional drawing of the rotary electric machine in Embodiment 1. FIG. It is an exploded perspective view of the rotor of the rotary electric machine of Embodiment 1. FIG. It is a perspective view which shows the appearance of the magnet holder of the rotary electric machine of Embodiment 1. FIG. FIG. 5 is a partially enlarged plan view of the magnet holder of the rotary electric machine of the first embodiment as viewed from the output axis direction. It is a perspective view which shows the appearance of the rotor core of the rotary electric machine of Embodiment 1. FIG. It is a top view of the core plate which constitutes the rotor core of the rotary electric machine of Embodiment 1. FIG. It is a top view of the core plate which constitutes the rotor core of the rotary electric machine of Embodiment 1. FIG. It is a top view which shows the state which attached the magnet holder to the rotor core of the rotary electric machine of Embodiment 1. FIG. It is a perspective view which shows the state which attached the rotor core and the magnet holder, and held the magnet in the rotary electric machine of Embodiment 1. FIG. FIG. 8 is a plan view of the rotor core 12 as viewed from one end surface side. It is explanatory drawing which shows the assembly procedure of the rotor of the rotary electric machine of Embodiment 1. FIG. It is explanatory drawing which shows the assembly procedure of the rotor of the rotary electric machine of Embodiment 1. FIG. It is explanatory drawing which shows the assembly procedure of the rotor of the rotary electric machine of Embodiment 1. FIG. It is explanatory drawing which shows the assembly procedure of the rotor of the rotary electric machine of Embodiment 1. FIG. It is explanatory drawing which shows the assembly procedure of the rotor of the rotary electric machine of Embodiment 1. FIG. It is a perspective view which shows the appearance of the magnet holder of the rotary electric machine in Embodiment 2. FIG. FIG. 11 is a plan view of the magnet holder of FIG. 11 as viewed from the output axis direction. It is a perspective view which shows the appearance of the magnet holder of the rotary electric machine in Embodiment 3. FIG. FIG. 3 is a plan view of the magnet holder of FIG. 13 as viewed from the output axis direction.

Embodiment 1.
FIG. 1 is a cross-sectional view showing the configuration of the rotary electric machine 100 according to the first embodiment of the present application. In addition, in order to avoid unnecessary redundancy of the following explanations and to facilitate the understanding of the parties concerned, detailed explanations of already well-known matters and duplicate explanations for substantially the same configuration may be omitted. be.

This rotary electric machine has an output shaft 2 built in a cylindrical motor case 1, a rotor 3 fixed to the output shaft 2, and an inner peripheral surface facing the outer peripheral surface of the rotor 3 via an air gap. It is mainly composed of the stator 4 having the above.

Further, a frame 8 is provided on one end side (upper end side in the drawing) of the motor case 1, and the frame 8 serves as a lid for closing the inside of the rotary electric machine 100. Further, the structure 10 is integrally attached to the other end side (lower end side in the figure) of the motor case 1.

The armature winding 5 is wound around the stator 4, and is press-fitted and fixed to the inner surface of the motor case 1. The armature winding 5 has three conductors connected to the winding end of the U-phase winding, the winding end of the V-phase winding, and the winding end of the W-phase winding, respectively. It is organized together. An annular wiring portion 6 is arranged near the upper part of the figure with respect to the armature winding 5, and the annular wiring portion 6 is connected to the end of the armature winding 5 by TIG welding or the like. A winding end portion 7 is provided in a direction extending from the annular wiring portion 6 to the axis of the rotary electric machine. One end of the winding end 7 penetrates the frame 8 described later and extends to the outside, and the other end is connected to one end of the armature winding 5 via the annular wiring portion 6. ..

A plurality of pairs of magnets (not shown in FIG. 1), which are permanent magnets constituting field poles, are arranged on the peripheral surface of the rotor 3. Further, it includes a pair of bearings 9a and bearings 9b that rotatably support the output shaft 2. The bearing 9a provided on the output side (lower side in the figure) of the rotor 3 is fixed to the structure 10, and the bearing 9b provided on the non-output side (upper side in the figure) is in the motor case 1. It is arranged close to the frame 8.

A sensor rotor 11 that rotates with the rotation of the output shaft 2 is attached to the end on the opposite side of the output shaft 2, and the sensor rotor 11 includes a pair or a plurality of pairs of permanent magnets. A rotation sensor (not shown) is arranged on the axial end surface of the sensor rotor 11 via a gap, and detects a change in the magnetic field from the permanent magnet of the sensor rotor 11 and converts it into an electric signal.

Although the sensor rotor 11 and the rotation sensor have been described here as being of the magnetic sensor type, they may be other than the magnetic sensor type, for example, may be a resolver, or may be a hall sensor.

FIG. 2 is an exploded perspective view of the rotor 3 of the rotary electric machine 100 according to the first embodiment.
The rotor 3 in the first embodiment adopts a step skew structure, two rotor cores 12 are provided in the front and rear along the output shaft 2, and a segment type magnet 13 is placed on the outer periphery of each rotor core 12 in the circumferential direction. Eight are arranged along. Each magnet 13 is held by a magnet holder 14 individually provided for each rotor core 12. In this case, the magnets 13 having the same polarity in the adjacent row are attached at positions shifted by a predetermined step angle in the circumferential direction.

Further, a cylindrical cover 15 is attached to the outside of the magnet 13, and this cover 15 prevents the magnet 13 from scattering and locking the rotary electric machine in the unlikely event that the magnet 13 is damaged. Has the function of magnetizing.

FIG. 3 is a perspective view showing the appearance of the magnet holder 14, and FIG. 4 is a partially enlarged plan view of the magnet holder 14 as viewed from the axial direction of the output shaft.
The magnet holder 14 is made of synthetic resin and includes a disk-shaped base portion 17. An insertion hole 26 for the output shaft 2 is formed in the base portion 17 at the center position thereof. Further, a groove portion 18 is integrally formed on the outer peripheral portion of the base portion 17, and an outer peripheral beam portion 19 is integrally formed on the outer diameter side of the groove portion 18 in a ring shape.

Further, the magnet holder 14 is provided with an arm portion 16 for holding the magnet 13 along the circumferential direction of the base portion 17, corresponding to the number of magnets 13. Each arm portion 16 has the same shape and extends from the base portion 17 along the output shaft direction, and is oriented in the output shaft direction so as to straddle the groove portion 18 at the base end portion thereof. A slit portion 20 extending is formed. The length of the slit portion 20 in the output axis direction can be arbitrarily set. Further, on the anti-arm portion side of the outer peripheral beam portion 19, the tip portion is reduced in diameter in a tapered shape in order to facilitate the insertion of the cover 15.

Further, as shown in FIG. 4, the arm portion 16 has an outer peripheral end face holding portion 21 having a substantially arcuate cross section extending in the output axis direction from the outer peripheral beam portion 19, and a cross section protruding inward in the radial direction from the outer peripheral end face holding portion 21. A substantially trapezoidal peripheral side pressing portion 22 and a substantially hook-shaped cross-section substantially hook-shaped protrusion 25 protruding inward in the radial direction from the circumferential side pressing portion 22 are integrally formed. In this case, the retaining protrusion 25 includes an extending portion 25a extending inward from the peripheral side holding portion 22 and a bending portion 25b bent at a right angle from the extending portion 25a.

Here, the outer peripheral end surface holding portion 21 serves to hold both end faces in the radial direction of the outer circumference of the magnet 13, and the circumferential side holding portion 22 holds both side surfaces in the circumferential direction of the magnet 13. Play a role. Therefore, the circumferential side surface pressing portion 22 is formed with a first pressing surface 22a that presses one side surface of the magnet 13 in the circumferential direction and a second pressing surface 22b that presses the other side surface of the magnet 13 in the circumferential direction. There is. Further, the protrusion 25 for preventing disconnection serves to prevent the arm portion 16 from ejecting to the outer peripheral side of the rotor core 12 when the magnet holder 14 is assembled to the rotor core 12.

5 is a perspective view showing the appearance of the rotor core 12 of the rotary electric machine according to the first embodiment, FIG. 6A is a sectional view taken along the line AA of the rotor core 12 of FIG. 5, and FIG. 6B is taken along the line BB of FIG. It is a cross-sectional view.

As shown in FIGS. 6A and 6B, the rotor core 12 is formed by laminating two types of core plates 30a and 30b having a substantially octagonal shape having a thickness of about 0.5 mm and made of, for example, an electromagnetic steel plate for a required number of laminated side surfaces. It is composed of welding.

The rotor core 12 is formed with an insertion hole 31 for the output shaft 2 at the center position thereof. Further, on the outer periphery of the rotor core 12, a rectangular planar magnet mounting surface 27 to which each magnet 13 is in contact is formed in a number corresponding to the number of magnets 13 along the circumferential direction. Further, a position regulating protrusion 28 for regulating the position of the magnet 13 in the output shaft direction is provided at one end of each magnet mounting surface 27 in the output shaft direction. Further, when the rotor core 12 is assembled to the magnet holder 14, the above-mentioned protrusion 25 for preventing the magnet holder 14 is fitted between the magnet mounting surfaces 27 on the outer peripheral portion of the rotor core 12. A groove 29 is formed.

Here, for convenience of explanation, among the both end faces in the output axis direction of the rotor core 12, the end face side on which the position restricting protrusion 28 is formed is formed on the protrusion forming side, and the opposite end face side is formed on the anti-projection portion. Called the side.

FIG. 7 is a plan view of the rotor core 12 with the magnet holder 14 assembled from the projection forming side in the output axial direction, and FIG. 8 shows the state of the rotor core 12 and the magnet holder 14 assembled with the magnet 13 held. FIG. 9 is a perspective view showing a plan view of FIG. 8 as viewed from the protrusion forming side of the rotor core 12.

When the magnet holder 14 is assembled to the rotor core 12, a part of the first pressing surface 22a on the side of the peripheral side pressing portion 22 of the magnet holder 14 on the side of the protruding portion 25 for preventing disconnection, and all of the protruding portion 25 for preventing disconnection. Is press-fitted and fixed in the fitting groove 29. In this case, the dimensions are set so that a slight gap 32 is formed between the bent portion 25b of the protrusion preventing protrusion 25 and the fitting groove 29. Reference numeral 33 is a space formed between the magnet mounting surface 27 of the rotor core 12 and the outer peripheral beam portion 19 of the magnet holder 14.

Next, the procedure for assembling the rotor 3 of the rotary electric machine according to the first embodiment will be described with reference to FIGS. 10A to 10E.
After arranging the magnets 13 on the magnet mounting surface 27 of the rotor core 12, the rotor core 12 and the magnet 13 are fixed to an assembly jig (not shown) (FIG. 10A). Next, the magnet holder 14 is inserted in the output axial direction from the counter-projection forming side of the rotor core 12 (FIG. 10B).

At that time, the protrusion 25 for preventing the magnet holder 14 from coming off is press-fitted and fixed in the fitting groove 29 of the rotor core 12. As a result, the magnet holder 14 is positioned and fixed with respect to the rotor core 12. Further, the magnet 13 is narrowly fitted between the magnet mounting surface 27 of the rotor core 12 and the outer peripheral end surface holding portion 21 of the magnet holder 14 due to the elasticity of the arm portion 16 and the outer peripheral beam portion 19 of the magnet holder 14.

The outer peripheral end face holding portion 21 of the magnet holder 14 has a dimensional relationship so that the magnet 13 is securely press-fitted, and a gap 32 is provided between the bent portion 25b of the protrusion 25 for preventing disconnection and the fitting groove 29. By providing the magnet holder 14, the bent portion 25b of the protrusion 25 for preventing disconnection is displaced toward the outer peripheral side when the magnet holder 14 is inserted (direction of arrow in FIG. 9). In this case, the first pressing surface 22a of the magnet holder 14 is perpendicular to the magnet mounting surface 27 of the rotor core 12, and a part of the first pressing surface 22a and the entire protrusion 25 for preventing disconnection are formed. It is press-fitted and fixed in the fitting groove 29. As a result, both side surfaces of the magnet 13 along the circumferential direction are assembled to the rotor core 12 with reference to the first pressing surface 22a of the magnet holder 14.

Then, the output shaft 2 is press-fitted into a set of two rotor cores 12 into which the magnet holder 14 is inserted (FIG. 10C). Next, the shatterproof cover 15 of the magnet 13 is inserted from the output axial direction (FIG. 10D), and then the output axial end portion of the cover 15 is bent inward in the radial direction to provide the bent portion 34. Is completed (Fig. 10E).

According to the rotary electric machine according to the first embodiment configured as described above, the following effects can be obtained.

In the first embodiment, the outer peripheral beam portion 19 is easily deformed to the outer peripheral side when the magnet holder 14 is inserted, and the protrusion 25 for preventing disconnection is fitted into the fitting groove 29 of the rotor core 12. It is possible to prevent the tips of the arm portions 16 from opening excessively with each other in the circumferential direction, and it is possible to perform highly accurate positioning that suppresses rattling with the magnet 13.

Further, since the slit portion 20 is provided in the arm portion 16 to reduce the rigidity of the arm portion 16, the likelihood of the dimensional variation of the magnet 13 is increased, and the durability of the magnet holder 14 itself is improved while the outer peripheral beam portion is improved. The elasticity of 19 makes it possible to hold the magnet 13 with a high holding force.

Further, the outer peripheral end face holding portion 21 of the magnet holder 14 has a dimensional relationship so that the magnet 13 is securely press-fitted, and there is a gap between the bent portion 25b of the protrusion 25 for preventing disconnection and the fitting groove 29. By providing 32, the bent portion 25b of the protrusion 25 for preventing disconnection is displaced toward the outer peripheral side when the magnet holder 14 is inserted. In this case, the first pressing surface 22a of the magnet holder 14 is perpendicular to the magnet mounting surface 27 of the rotor core 12, and a part of the first pressing surface 22a and the entire protrusion 25 for preventing disconnection are formed. It is press-fitted and fixed in the fitting groove 29. From this, both side surfaces of the magnet 13 along the circumferential direction can be assembled to the rotor core 12 with the first pressing surface 22a of the magnet holder 14 as a reference, and the magnet 13 can be positioned and fixed to the rotor core 12 with high accuracy. It becomes possible to do.

If the first pressing surface 22a of the magnet holder 14 is perpendicular to the magnet mounting surface 27 of the rotor core 12, it is preferable for positioning the circumferential direction of the magnet 13 with high accuracy, but it is not vertical. However, since the tip of the arm portion 16 can be prevented from opening, highly accurate positioning that suppresses rattling with the magnet 13 becomes possible.

Further, in the state where the magnet holder 14 is assembled to the rotor core 12, both end faces in the output axial direction of the magnet 13 are end faces on the arm portion forming side of the position restricting protrusion 28 of the rotor core 12 and the outer peripheral beam portion 19 of the magnet holder 14. It is held narrowly between and. As a result, the magnet 13 is held by absorbing the size variation in the output axial direction of the magnet 13 due to the deformation and elasticity of the outer peripheral beam portion 19, so that the output axial direction of the magnet 13 is positioned with high accuracy and high holding force. It becomes possible to hold it. Further, as compared with the case where the output axial direction of the magnet 13 is held only by the holding force of the bent portion 34 of the cover 15, the magnet holder 14 and the pressure input of the rotor core 12 are also held, so that the magnet is stronger. It is possible to hold the output axis direction of 13.

Further, by fixing the rotor core 12 and the magnet 13 to the assembly jig and then inserting the magnet holder 14 into the rotor core 12, the eight magnets 13 can be positioned and fixed at once, and the work efficiency is improved. Further, since the tip portion of the magnet holder 14 on the anti-arm portion side of the outer peripheral beam portion 19 is reduced in diameter in a tapered shape, the insertability of the cover 15 is improved.

As described above, the rotary electric machine of the first embodiment can perform positioning in the output shaft direction and the circumferential direction with high accuracy while suppressing rattling in the radial direction of the magnet, so that cogging torque, torque ripple, etc. can be performed. It is possible to eliminate the occurrence of problems and maintain good performance as a rotary electric machine.

Embodiment 2.
11 is a perspective view showing the appearance of the magnet holder of the rotary electric machine according to the second embodiment, and FIG. 12 is a plan view of the magnet holder of FIG. 11 as viewed from the output axis direction. In addition, the same sign is attached to the component corresponding to or corresponding to the first embodiment.

The second embodiment is a modification of the first embodiment, in which the reliability of the magnet holder 14 itself is improved and the opening of the tip portion of the arm portion 16 on the anti-base portion side is further suppressed to further suppress the opening of the magnet 13. Make positioning even more accurate. Further, it is intended to improve the assemblability by reducing the insertion load of the magnet holder 14 and to increase the likelihood of the size variation of the magnet 13 to reduce the processing cost of the magnet 13.

Therefore, in the first embodiment, the outer peripheral beam portion 19 is provided on the entire circumference of the base portion 17 of the magnet holder 14, whereas in the second embodiment, the base portion 17 of the magnet holder 14 is provided with the outer peripheral beam portion 19. The formation of the groove portion 18 is omitted, and a cut portion 19a is provided in which the portion between the arm portions 16 in the outer peripheral beam portion 19 is locally cut off. Therefore, the remaining portion of the outer peripheral beam portion 19 excluding the cut portion 19a protrudes left and right along the circumferential direction from the base end portion of each arm portion 16, and this protruding portion is the position in the output axis direction of the magnet 13. It is formed as a position regulation unit 19b that regulates.

The other configurations of each arm portion 16 in the magnet holder 14, the configuration of the base portion 17, the slit portion 20, and the shape of the rotor core 12 are the same as those in the first embodiment. Further, since the assembly procedure of the rotor 3 is the same as that of the first embodiment, detailed description thereof will be omitted here.

According to the rotary electric machine according to the second embodiment configured as described above, the following effects can be obtained.
That is, in the second embodiment, as in the first embodiment, the positioning in the output axis direction and the circumferential direction can be made highly accurate while suppressing the rattling in the radial direction of the magnet 13. In addition to this, in the second embodiment, the cutting portion 19a is provided on the outer peripheral beam portion 19 of the magnet holder 14 to reduce the rigidity of the arm portion 16, so that when the magnet holder 14 is inserted, the arm portion 16 is moved to the outer peripheral side. Is easier to transform.

Since the outer peripheral beam portion 19 is easily deformed in the outer peripheral direction in this way, it is possible to further suppress the opening of the tip portion of the arm portion 16 when the magnet holder 14 is inserted, and the magnet 13 can be more accurately performed. It becomes possible to regulate the position of. Further, by lowering the rigidity of the arm portion 16, the insertion load at the time of inserting the magnet holder 14 can be reduced, and the assembling property is improved.

Further, since the likelihood of size variation in the circumferential direction and the output shaft direction of the magnet 13 is further increased, the reliability of the magnet holder 14 itself is improved, and the processing accuracy of the magnet 13 can be lowered, resulting in a low product. It is possible to reduce the cost.

Embodiment 3.
13 is a perspective view showing the appearance of the magnet holder in the third embodiment, and FIG. 14 is a plan view of the magnet holder of FIG. 13 as viewed from the output axis direction. In addition, the same sign is attached to the component corresponding to or corresponding to the first embodiment.

This third embodiment is a modification of the first embodiment, and in addition to making the positioning of the magnet 13 more accurate by further suppressing the opening of the tip of the arm portion 16, the holding force of the magnet 13 is further increased. The purpose is to improve.

Therefore, in the third embodiment, in the bent portion 25b of the protrusion 25 for preventing the magnet holder 14 from coming off, the press-fitting rib 25c protruding toward the gap 32 formed between the fitting groove 29 of the rotor core 12 is the arm portion. 16 is provided from the base end side to the tip end side.

In this case, the press-fitting rib 25c may be formed in a tapered shape so that the radial dimension gradually decreases from the proximal end side to the distal end side of the arm portion 16 in the output shaft direction. Further, the length of the press-fitting rib 25c in the output shaft direction can be appropriately changed. Further, the thickness of the press-fitting rib 25c is preferably set so that the press-fitting rib 25c is always press-fitted into the fitting groove 29 in anticipation of deformation of the arm portion 16 when the size of the magnet 13 is minimized.

The other configurations of each arm portion 16 in the magnet holder 14, the configuration of the base portion 17, the slit portion 20, and the shape of the rotor core 12 are the same as those in the first embodiment. Further, since the assembly procedure of the rotor 3 is the same as that of the first embodiment, detailed description thereof will be omitted here. Further, in the third embodiment, the case where the press-fitting rib 25c is provided is described on the premise of the configuration of the first embodiment, but in the configuration of the second embodiment, the bent portion 25b of the protrusion 25 for preventing disconnection is provided. Of course, it is possible to provide the press-fit rib 25c.

According to the rotary electric machine according to the third embodiment configured as described above, the following effects can be obtained.
That is, in the third embodiment, as in the case of the first embodiment, the positioning in the output shaft direction and the circumferential direction can be made highly accurate while suppressing the rattling in the radial direction of the magnet 13. In addition to this, in the bent portion 25b of the protrusion 25 for preventing disconnection, a press-fit rib 25c is provided so as to project toward the gap 32 formed between the rotor core 12 and the fitting groove 29, and the press-fit rib 25c is fitted into the fitting groove. Since it is press-fitted and fixed to 29, it is possible to suppress the opening of the tip portions of the arm portions 16 and to improve the holding force of the magnet 13.

It should be noted that the above-mentioned description is not intended to limit the subject matter described in the claims. For example, in the above description, an example of applying the present application to a rotary electric machine having a step skew structure has been shown, but it is also possible to apply the present application to a rotary electric machine having no step skew structure. The present application is also applicable to a magnet holder that is not divided in the axial direction (for example, the magnet holder described in Patent Document 1). Furthermore, the number of magnets is not limited.

Further, although the present application describes various exemplary embodiments, the various features, embodiments, and functions described in one or more embodiments may be applied to the particular embodiment. It is not limited, and can be applied to embodiments alone or in various combinations.

Therefore, innumerable variations not exemplified are envisioned within the scope of the art disclosed in the present application. For example, it may include the case of transforming, adding, or omitting at least one component, and further, the case of extracting at least one component and combining it with the components of other embodiments. ..

1 motor case, 2 output shaft, 3 rotor, 4 stator, 5 armature winding,
9a, 9b bearings, 12 rotor cores, 13 magnets, 14 magnet holders,
15 cover, 16 arm, 17 base, 18 groove, 19 outer beam,
19a cutting part, 19b position restricting part, 20 slit part, 21 outer peripheral end face holding part,
22 Circumferential side presser foot, 22a 1st presser foot, 22b 2nd presser foot,
25 Detachment prevention protrusion, 25a extension, 25b bend, 25c press-fit rib,
26 Insertion hole, 27 Magnet mounting surface, 28 Position regulation protrusion, 29 Fitting groove,
31 insertion holes, 32 gaps.

Claims (10)

It is provided with a rotor core fixed to an output shaft, a plurality of magnets arranged along the circumferential direction of the rotor core, and a magnet holder for holding the magnets.
The magnet holder has a disk-shaped base portion having an insertion hole for the output shaft formed in the center, and a plurality of magnet holders extending from the base portion along the output shaft and arranged between the magnets. It has an arm part and
An outer peripheral beam portion is formed on the base portion along the outer circumference thereof, and the arm portion includes an outer peripheral end face holding portion for holding both end faces in the radial direction of the outer circumference of the magnet and both sides in the circumferential direction of the magnet. A circumferential side holding portion for holding the surface is formed inward in the radial direction from the outer peripheral beam portion.
A rotary electric machine in which the magnet holder is fixed to the rotor core, and the magnet is held between the rotor core, the outer peripheral end surface holding portion of the magnet holder, and the peripheral side holding portion. The rotary electric machine according to claim 1, wherein a cut portion is formed in a portion of the outer peripheral beam portion located between the arm portions. A magnet mounting surface on which a magnet is mounted is provided on the outer peripheral portion of the rotor core according to the number of magnets, and the magnet is provided on one end of the magnet mounting surface in the output axial direction. A position-regulating protrusion that regulates the position of the magnet in the output axis direction is formed, and both ends of the magnet in the output axis direction are narrowed by the position-regulating protrusion and the outer peripheral beam portion of the magnet holder. The rotary electric machine according to claim 1 or 2. The arm portion is provided with a protrusion for preventing disconnection, and a fitting groove into which the protrusion for preventing disconnection is fitted is formed between the magnet mounting surfaces of the outer peripheral portion of the rotor core. The rotary electric machine according to claim 3. The rotary electric machine according to claim 4, wherein the protrusion for preventing disconnection is press-fitted and fixed in the fitting groove of the rotor core. The circumferential side pressing portion has a first pressing surface that holds one side surface of the magnet in the circumferential direction and a second pressing surface that holds the other side surface, and the first pressing surface is the magnet of the rotor core. The protrusion for preventing the withdrawal is formed perpendicular to the mounting surface, and the protrusion for preventing the withdrawal is bent inward from the circumferential side holding portion in the radial direction and at a right angle from the extending portion. The rotary electric machine according to claim 4 or 5, which comprises a bent portion. The sixth aspect of claim 6 in which a gap is formed between the bent portion of the detachment prevention protrusion and the fitting groove in the fitting state of the disconnection prevention protrusion into the fitting groove. Rotating electric machine. The rotation according to claim 7, wherein a press-fitting rib that protrudes toward the gap formed between the rotor core and the fitting groove of the rotor core is formed in the bent portion of the protrusion for preventing the magnet holder from coming off. Electric. The rotary electric machine according to any one of claims 1 to 8, wherein the rotor core has a stage skew structure provided in a plurality of stages along the output shaft. The rotor core is fixed to the output shaft, a plurality of magnets arranged along the circumferential direction of the rotor core, and a magnet holder for holding the magnets. The magnet holder has an insertion hole for the output shaft in the center. A rotary electric machine having a disk-shaped base portion on which a magnet is formed, and a plurality of arm portions extending from the base portion along the output shaft and arranged between the magnets. It ’s a manufacturing method,
The arm portion is formed with an outer peripheral end face holding portion that holds both end faces in the radial direction of the outer circumference of the magnet and a circumferential side holding portion that holds both side surfaces in the circumferential direction of the magnet.
The rotor core is formed with a position-regulating protrusion that regulates the position of the magnet in the output axis direction at one end in the output axis direction.
After fixing the magnet to the rotor core, the magnet holder is inserted from the direction opposite to the position restricting protrusion of the rotor core to fix the magnet holder to the rotor core, and the magnet is fixed to the rotor core and the magnet holder. A method for manufacturing a rotary electric machine that is held between the outer peripheral end surface holding portion and the circumferential side surface pressing portion.

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