JP3252572B2 - Method for manufacturing rotor for electromagnetic clutch - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a rotor for an electromagnetic clutch which attracts an armature by a magnetic force.

[0002]

2. Description of the Related Art As a prior art of an electromagnetic clutch, there is one disclosed in, for example, Japanese Patent Application Laid-Open No. 56-55721. Here, this is shown in FIG. Armature 10
2 is a ring-shaped disk plate 10 made of a magnetic material.
3 and a ring-shaped disk plate 104 made of a magnetic material
And a ring-shaped coupling member 105 made of a non-magnetic material such as copper, which forms a magnetic cutoff. The armature 102 has an inner peripheral surface 109 of the disk plate 103 and an outer peripheral surface 110 of the disk plate 104.
Is manufactured by a method in which a coupling member 105 is inserted into a gap between the disk plates 103 and 104 and the coupling members 105 are mechanically coupled to each other.

[0003] Also, disk plates 103 and 10
4 (indicated by the symbol a in FIG. 17).
The thickness (indicated by reference numeral b in FIG. 17) of the connecting member 105 is reduced, and is thereby surrounded by the friction side end surface 113 of the coupling member 105, the inner peripheral surface 109 of the disk plate 103, and the outer peripheral surface 110 of the disk plate 104. A possible recess 108 is formed. By forming the recess 108, the friction surfaces 111 and 112 instantaneously function as an air damper when adsorbing to a rotor (not shown), thereby preventing generation of abnormal noise during adsorption.

[0004] Japanese Patent Application Laid-Open No. 56-55721, page 3, upper left column, line 16 to column 18, describes that a rotor is manufactured by the above manufacturing method. That is, the outer peripheral wall 114 made of a magnetic material as shown in FIG.
A rotor 1 having a U-shaped cross section having an inner peripheral wall 115 made of a magnetic material and a bottom part 116 made of a magnetic material connecting them.
13, the outer peripheral wall 114 and the bottom 11
Ring-shaped coupling member 11 made of a non-magnetic material
7, and a ring-shaped coupling member 118 made of a non-magnetic material is also inserted into the gap between the inner peripheral wall 115 and the bottom portion 116, and is mechanically coupled together. Also, the coupling members 117 and 118 are connected to the armature 1
02 to the friction surface 120 to be sucked,
1 and 122 are described.

In Japanese Patent Application Laid-Open No. 56-55721, page 14, lower right column, line 14 to page 2, upper left column, line 1,
Other prior art has been described. FIG. 19 shows a disk plate of this rotor. That is, the disk plate 126 of the rotor is punched out of a single steel plate by a press, and the disk plate 123, the disk plate 124, the disk plate 125, the disk plate 1
A connecting portion 127 for connecting 23 and 124; a connecting portion 128 for connecting the disk plates 124 and 125;
9 and the groove 130 are described.

[0006]

By the way, in the case of the rotor 113 shown in FIG. 18, the connecting members 117 and 118 are joined to the gap between the outer peripheral wall 114 and the bottom 116 and the gap between the inner peripheral wall 115 and the bottom 116, respectively. In this case, the positioning of the outer peripheral wall 114, the inner peripheral wall 115, and the bottom portion 116 is required in the same manner as described above, so that the assembling workability is poor and the number of parts is large, so that the manufacturing cost increases.

In the case of the rotor 123 shown in FIG.
There is no hassle of positioning as described above, but the connecting portion 12
7. Since the magnetic flux leaks from the connecting portion 128, the attraction force with the armature (not shown) is weakened. The present invention has been made in view of the above problems, and does not require positioning,
An object of the present invention is to provide a method of manufacturing a rotor for an electromagnetic clutch that does not leak magnetic flux.

[0008]

According to a first aspect of the present invention, there is provided a method of manufacturing a rotor for an electromagnetic clutch, comprising: forming an inner peripheral wall by plastically processing a ring-shaped plate of a magnetic material; Outer peripheral wall, and a ring-shaped member forming step of forming a ring-shaped member having a U-shaped cross section composed of a bottom connecting the inner peripheral wall and the outer peripheral wall, and after performing this step,
A groove forming step of forming a plurality of ring-shaped grooves at the bottom on the open side of the ring-shaped member over the entire circumference; and a non-magnetic material formed over the entire circumference of each of the plurality of ring-shaped grooves. A joining step of joining the joining members, a friction surface forming step of cutting a bottom surface of the bottom portion by an amount in a range where the joining members are not exposed, and a friction surface forming step of facing the groove to which the joining members are joined. Forming a concave surface by recessing a part of the friction surface, and exposing the coupling member to the friction surface side as a technical means.

According to a second aspect of the present invention, there is provided a method of manufacturing a rotor for an electromagnetic clutch, wherein an inner peripheral wall, an outer peripheral wall, and the inner peripheral wall and the outer peripheral wall are formed by plastically processing a magnetic ring-shaped plate. A ring-shaped member forming step for forming a ring-shaped member having a U-shaped cross-section comprising a bottom portion to be connected, and after performing this step, a plurality of ring-shaped members are formed on the bottom portion over the entire circumference on the open side of the ring-shaped member. A groove forming step of forming a groove, a bonding step of bonding a coupling member made of a non-magnetic material to each of the plurality of grooves, and cutting the bottom surface of the bottom until the coupling member is exposed. Forming a friction surface, and forming a concave surface by denting the coupling member exposed on the friction surface with a radial width substantially equal to a radial width of the exposed portion. Process and technical means It was.

[0010]

According to the first aspect of the present invention,
First, in the ring-shaped member forming step, the ring-shaped plate of the magnetic material is formed by cold working, plastic working such as press working, and the inner peripheral wall, the outer peripheral wall, and the bottom connecting the outer peripheral wall and the inner peripheral wall. A ring-shaped member having a U-shaped cross section is formed. After performing this processing, in the groove forming step, a plurality of ring-shaped grooves are formed in the bottom portion over the entire circumference on the open side of the ring-shaped member. In the joining step, a joining member made of a non-magnetic material is joined to each of the plurality of ring-shaped grooves over the entire circumference. Also,
In the friction surface forming step, the bottom surface of the bottom of the ring-shaped member is cut by an amount that does not expose the coupling member to form the friction surface of the rotor. Then, in the next concave surface forming step,
A part of the friction surface facing the groove to which the coupling member is joined is recessed to form a concave surface, and the coupling member is exposed to the friction surface side.

According to the second aspect of the present invention, first, in the ring-shaped member forming step, the inner peripheral wall and the outer peripheral wall are formed by subjecting the magnetic ring-shaped plate to plastic working such as cold casting or press working. A ring-shaped member having a U-shaped cross section comprising a wall and a bottom connecting the inner peripheral wall and the outer peripheral wall is formed. After performing this processing, in the groove forming step, a plurality of ring-shaped grooves are formed in the bottom portion over the entire circumference on the open side of the ring-shaped member. In the joining step, a coupling member made of a non-magnetic material is coupled to each of the plurality of ring-shaped grooves over the entire circumference. In the friction surface cutting step, a friction surface is formed by cutting the bottom surface of the bottom of the ring-shaped member until the coupling member is exposed.
Then, in the next concave surface forming step, the coupling member exposed on the friction surface is dented with a radial width substantially equal to the radial width of the exposed portion to form a concave surface.

[0012]

According to the method of manufacturing a rotor for an electromagnetic clutch of the present invention, since the inner peripheral wall, the outer peripheral wall, and the bottom are provided by processing one ring-shaped plate, there is no need for positioning.
For this reason, the assembling property is excellent, and the manufacturing cost can be suppressed. Also, there was no magnetic flux leakage, and the attraction force between the rotor and the armature could be increased.

[0013]

Next, a method of manufacturing a rotor for an electromagnetic clutch according to the present invention will be described based on a first embodiment shown in the drawings. FIG. 1 to FIG. 9 show a first embodiment of the present invention.

The electromagnetic clutch 1 shown in FIG. 1 is for interrupting transmission of rotational power from an engine (not shown) to a refrigerant compressor (not shown). This electromagnetic clutch 1
Are roughly divided into a rotor 3 having a pulley 2 which is rotationally driven by an engine, a rotating driven body 5 having an armature 4 which frictionally engages with the rotor 3, and a magnetic force generated when energized to generate the armature 4. And an electromagnetic coil 6 frictionally engaged with the rotor 3. The electromagnetic coil 6 is fixed to a stator 6b made of a magnetic material (for example, low-carbon steel such as SPCC or SPHC) via a resin winding frame 6a, and the stator 6b is further fixed via a disk-shaped stay 6c. And is fixed to the housing H of the compressor.

The pulley 2 is joined to the periphery of the rotor 3 by welding, and a multi-stage V-belt (not shown) is stretched over it. The rotor 3 is rotatably supported via an inner bearing 7.
It is supported by the housing H of the refrigerant compressor. This rotor 3
Is formed by processing a magnetic material such as soft iron, and is frictionally engaged with the inner peripheral wall 8 located on the inner peripheral side of the electromagnetic coil 6, the outer peripheral wall 9 located on the outer peripheral side of the electromagnetic coil 6, and the armature 4. A ring-shaped member having a U-shaped cross section is formed by the friction walls 10 that are formed. Here, the friction wall 10 has a bottom part 11 made of a magnetic material such as the above-mentioned soft iron, and a coupling member 22 provided on the inner peripheral side and the outer peripheral side of the bottom part 11. Bottom 11
The open side of the ring-shaped member, that is, the side on which the electromagnetic coil 6 is disposed is formed in an arc-shaped cross section. Also,
The coupling member 22 is made of a non-magnetic material such as copper that joins the inner peripheral wall 8 and the bottom 11 and the bottom 11 and the outer peripheral wall 9, and forms a magnetic path between the inner peripheral wall 8 and the bottom 11 and between the bottom 11 and the outer peripheral wall 9. It is to prevent being done. Also, the friction surface 1 of the friction wall 10
A friction material 13 made of a non-magnetic material for increasing the engaging force with the armature 4 is fitted on the outer peripheral side of the armature 4a.

The coupling member 22 is concave with respect to the friction surface 10a, and forms a concave surface 24. In the friction surface 10a, the width of the concave surface 24 in the vertical direction in the figure is sufficiently smaller than the width of the friction material 13 in the vertical direction in the figure. Since the bottom 11 on the side where the electromagnetic coil 6 is arranged is formed in an arc-shaped cross section, as shown in FIG.
The area (a1) of the portion of the inner connecting member 22 exposed to the friction surface 10a is set smaller than the open area (b1) of the ring-shaped member. Area (a) of the portion exposed to the friction surface 10a
2) is set smaller than the area (b2) on the open side of the ring-shaped member. That is, a1 <b1, a
2 <b2. Here, FIG. 8A is a diagram showing only the rotor 3 in FIG.

In FIG. 1, the armature 4 is opposed to a friction surface 10a of the rotor 3 with a gap therebetween, and has a friction surface 4a engaged with the rotor 3. The armature 4 has a ring shape made of a magnetic material such as iron, and has a ring-shaped magnetic blocking groove 1 formed by a slit at an intermediate portion.
4 are formed. In addition, the magnetic cutoff groove 14 is located substantially at the center of the bottom 11 of the rotor 3 opposed to the groove. The sectional area (Sn) of the bottom portion 11 of the rotor 3 starting from the magnetic blocking groove 14 of the armature 4 is shown in FIG.
As shown in FIG. 2B, the magnetic shielding groove 14 of the armature 4 is used.
The area (c1) on the inner peripheral side of the bottom 11 in the friction surface 10a starting from the bottom and the bottom 1 starting from the magnetic shielding groove 14
1 is larger than the area (c2) on the outer peripheral side.
That is, Sn> c1 and c2 are set. Thereby, the magnetic resistance at the bottom 11 can be reduced.
Here, FIG. 8B is a partially enlarged view of FIG.

The rotary driven member 5 in FIG. 1 rotates integrally with the rotation of the armature 4 to drive the input shaft of the refrigerant compressor, and includes an outer ring 16 fixed to the armature 4 with rivets 15; 4 includes a cushion rubber 17 that allows displacement in the rotation axis direction, and an inner hub 18 that is fitted to the input shaft. The outer ring 16 and the inner hub 18 are integrally connected via the cushion rubber 17.

Next, a method of manufacturing the rotor 3 in the first embodiment will be described with reference to FIGS. 1 and 6A to 6J. The manufacturing method according to the present embodiment is based on the manufacturing method described in claim 1. A magnetic metal plate (for example, low carbon steel such as SPCC or SPHC) having substantially the same thickness as the friction wall 10 of the rotor 3 is punched by press punching to form a circular disk material. Then, a punched hole 19c is formed in the center of the disk material by press punching, and FIG.
A ring-shaped plate member 19a as shown in FIG.

Next, the intermediate portion 191a of the ring-shaped plate 19a is depressed over the entire circumference by cold forging as plastic working, and the inner peripheral wall 8, the outer peripheral wall 9, and the inner peripheral wall 9 as shown in FIG. A ring-shaped member 19b having a U-shaped cross section and including a bottom 11 connecting the peripheral wall 8 and the outer peripheral wall 9 is formed (ring-shaped member forming step). Next, an intermediate portion of the bottom surface 11a of the bottom portion 11 is pressed down over the entire circumference, and a ring-shaped mold 30 provided with two ring-shaped protrusions 21c and 21d shown in FIG.
Is inserted into the space 12 formed by the inner peripheral wall 8, the outer peripheral wall 9, and the bottom portion 11, and this is pressed from the open side of the ring-shaped member 19b (the side on which an electromagnetic coil (not shown) is arranged). Thereby, as shown in FIG.
Two ring-shaped protrusions 20a and 20b are formed over the entire circumference on the inner and outer circumferences of a, and grooves 21a and 21b are formed over the entire circumference on the open side of the bottom 11 ( Groove forming step).

As described above, the inner peripheral wall 8, the outer peripheral wall 9, and the inner peripheral wall 8 and the outer peripheral wall 9 are connected to form the ring-shaped projection 2.
A ring-shaped member 19 comprising the bottom portion 11 having the grooves 0a and 20b and the grooves 21a and 21b is formed. Note that the cross-sectional shape of the two grooves 21a and 21b is such that the ring-shaped protrusions 21c and 21d provided on the ring-shaped mold 30 are widened to the open side of the ring-shaped member 19, so that the ring-shaped member 19 It has a shape that spreads out toward the open side. As a result, the bottom 1 on the open side of the ring-shaped member 19 is formed.
1 has an arc-shaped cross section. In addition, the ring-shaped mold 30
Of the ring-shaped protrusions provided on the outer peripheral side 21
The inner peripheral groove 21d protrudes higher than the inner peripheral groove 21c, so that the inner peripheral groove 21b is provided deeper than the outer peripheral groove 21a.

Next, metal balls, glass beads, or the like are sprayed on the entire surface of the ring-shaped member 19 so that the ring-shaped member 19 is formed.
The impurities attached to are removed (shot blast). Next, as shown in FIG. 4 (a), the grooves 21a and 21b shown in FIG.
A connecting member 2 having a ring-shaped wire made of a nonmagnetic material (for example, copper) having a lower melting point than the ring-shaped member 19.
2 and 22 are placed, and the joint members 22 and 22 are heated together with the ring-shaped member 19. Then, by heating the entire ring-shaped member 19, the coupling members 22, 22 are melted, and the coupling members 22, 22 are poured into the grooves 21a, 21b over the entire circumference (FIG. 4B). Thereafter, the coupling member 22 melted by cooling (radiating heat) the ring-shaped member 19.
Is cooled and solidified, and the ring-shaped member 19 (for example, iron) and the bonding member 22 (for example, copper) are diffused and bonded between molecules, so that the ring-shaped member 19 and the bonding member 22 are strongly bonded (the bonding step). ).

Here, as an example of the coupling member 22,
When bronze containing about 5% of tin in copper is used, it is necessary to heat the ring-shaped member 19 provided with the coupling member 22 at about 1080 ° C. In addition, during heating and cooling for joining the ring-shaped member 19 and the coupling member 22, in order to prevent oxidation of the ring-shaped member 19 and the coupling member 22, a vacuum or an inert gas (for example, nitrogen gas) atmosphere is used. Do inside.

Next, as shown by the two-dot chain line in FIG. 5, the inner peripheral side of the inner peripheral wall 8 of the ring-shaped member 19, the upper end of the outer peripheral wall 9 in the drawing, and the open side end face 31 of the bottom 11 are entirely The cutting is performed over the entire circumference, and the bottom surface 11a of the bottom 11 is cut over the entire circumference by an amount that does not expose the coupling member 22, thereby forming the friction surface 10a. (Friction Surface Forming Step) Next, as shown in FIG. 6A, the friction surface 10a facing the groove 21a is recessed by cutting over the entire circumference.
A recess 23 for fitting the friction material 13 is formed, and the coupling member 22 is exposed on the friction surface 10a side. The friction surface 10a facing the groove 21b is recessed by cutting over the entire circumference to form a concave surface 24, and the coupling member 22 is moved to the friction surface 10a.
(Step of forming concave surface). Here, FIG.
FIG. 9 shows an enlarged view of a portion A of FIG.

Next, as shown in FIG. 6B, the pulley 2 on which a multi-stage V-belt (not shown) is hung is connected to the ring-shaped member 19.
And press-fit from the outer periphery of it to fix it. Then, paint is sprayed on the entire surface of the ring-shaped member 19 to which the V-belt is fixed. Thereafter, as shown in FIG.
The friction material 13 is fitted into the recess 23 provided in the “a”.

Further, the friction surface 10a is cut from the state shown in FIG. 6C (shown by a two-dot chain line in FIG. 7).
By finishing a, the rotor 3 is completed. Next, the operation of the electromagnetic clutch 1 will be briefly described. When the electromagnetic coil 6 is energized, the electromagnetic coil 6 generates a magnetic force and causes the rotor 3 to attract the armature 4. Then, a magnetic path indicated by a dashed line α in FIG. 1 is formed. Here, a coupling member 22 made of a non-magnetic material is joined between the inner peripheral wall 8 and the bottom 11, and the bottom 11 and the outer peripheral wall 9 are joined.
Since the coupling member 22 and the friction material 13 made of a non-magnetic material are joined to each other, the space between the inner peripheral wall 8 and the bottom 11, between the bottom 11, and the bottom 11 in the rotor 3. Magnetic flux does not leak between the outer peripheral wall 9. Therefore,
The armature 4 is firmly attracted to the friction surface 10a of the rotor 3. As a result, the rotational power of the engine transmitted to the pulley 2 via the V-belt is reliably transmitted to the input shaft of the refrigerant compressor via the rotor 3, the armature 4, and the rotating driven member 5.

[Effects of the Embodiment] In the rotor 3 of the electromagnetic clutch 1 described in the present embodiment, the inner peripheral wall 8, the outer peripheral wall 9 and the bottom 11 are formed by plastically processing one ring-shaped plate member 19a. . Therefore, the number of parts can be reduced, the assemblability of the rotor 3 is excellent, and the manufacturing cost can be reduced.

The coupling member 22 made of a non-magnetic material is
Since one ring-shaped plate member 19a is joined to grooves 21a and 21b formed by plastic working over the entire circumference, the melted coupling member 22 does not leak to the outside of the bottom portion 11. For this reason, it is possible to prevent occurrence of defective products due to leakage of the melted coupling member 22 to the outside of the bottom 11. Also, in the mechanical coupling performed by the conventional technique shown in FIGS. 17 and 18, even if the disk plate 104 and the coupling member 105 are mechanically coupled, for example, the respective surfaces of the disk plate 104 and the coupling member 105 before coupling are formed. Has a surface roughness, and even if the disk plate 104 and the coupling member 105 are mechanically coupled to each other, there is a gap in the coupling surface, though it is fine.
Thereby, the disk plate 104 and the coupling member 105
Are not completely adhered to each other and the bonding strength is weak. As a result, in the present embodiment, since the coupling member 22 and the ring-shaped member 19 are diffusion-bonded, the coupling strength is higher than the mechanical coupling.

The bottom 11 has an arc-shaped cross section on the open side of the ring-shaped member 19. For this reason, as compared with a case where the thickness of the bottom 11 is the same as that of the present embodiment and the shape of the bottom 11 on the open side is a square cross section,
The distance between the bottom portion 11 and the stator 6b is increased (see the arrow β in FIG. 1), and it is possible to suppress a decrease in transmission torque due to direct leakage of magnetism from the stator 6b to the bottom portion 11.

Further, since the shape of the bottom 11 on the open side of the ring-shaped member 19 is provided in an arc-shaped cross section, the groove 21
b, the average distance between the inner peripheral wall 8 and the bottom 11 over the depth direction and the average distance between the bottom 11 and the outer peripheral wall 9 over the depth direction of the groove 21a are longer (see arrow γ in FIG. 1). Of the transmission torque due to magnetic leakage between the bottom 11 and the bottom 11 and between the bottom 11 and the outer peripheral wall 9 can be suppressed.

Since the open side of the ring-shaped member 19 of the bottom 11 is provided in an arc-shaped cross section, the ring-shaped protrusions 21c, 2 of the ring-shaped mold 30 for forming the grooves 21a, 21b are formed.
The thickness of 1d can be increased. For this reason, the ring-shaped mold 30
Can be reduced, the life of the mold can be extended, and as a result, the cost for manufacturing the rotor 3 can be suppressed. Further, in the present embodiment, the frictional surface 10a is formed by cutting the bottom surface 11a of the bottom portion 11 by an amount not to expose the coupling member 22, and the frictional surface 10a facing the groove 21b is further cut to form the coupling object 22. Is exposed, the height of the ring-shaped protrusions 21c and 21d provided on the ring-shaped mold 30 can be reduced, and furthermore, the ring-shaped mold 30 is formed.
Can be reduced, the life of the mold can be extended, and as a result, the cost for manufacturing the rotor 3 can be suppressed.

In the friction surface 10a, the width of the concave surface 24 in the vertical direction in FIG. 8 is sufficiently smaller than the width of the recess 23 in the vertical direction in FIG. Thereby, the armature 4 shown in FIG.
, The reduction of the area of the suction surface can be suppressed, and a strong suction force can be obtained. When the rotor 1 and the armature 4 are intermittently frictionally engaged with each other, frictional heat is generated due to slip between the rotor 1 and the armature 4. However, since the concave surface 24 is formed, the coupling member 22 is connected to the armature 4. Does not frictionally engage with Thereby, the coupling member 22 is not brought into a molten state or a softened state due to frictional heat.

[Second Embodiment] Next, a second embodiment in which the rotor 3 is manufactured by a manufacturing method different from that of the first embodiment will be described. Here, the manufacturing method of the second embodiment is described in claim 2
This is based on the manufacturing method described, and is specifically the same as the first embodiment except for the friction surface forming step and the concave surface forming step in the first embodiment. Therefore, the friction surface forming step and the concave surface forming step in the second embodiment will be described below.

As shown by a two-dot chain line in FIG. 10, the inner peripheral side of the inner peripheral wall 8 of the ring-shaped member 19, the upper end of the outer peripheral wall 9 in the drawing, and the open side end face 31 of the bottom 11 are respectively formed over the entire circumference. In addition to cutting, the friction surface 10a is formed by cutting the bottom surface 11a of the bottom portion 11 over the entire circumference until the coupling member 22 made of a non-magnetic material is exposed. Here, the groove 21b
Is deeper than the groove 21a, only the coupling member 22 joined to the groove 21b is exposed on the friction surface 10a (a friction surface forming step).

Next, as shown in FIG. 11, the friction surface 10a facing the groove 21a is cut by cutting the entire circumference to make the coupling member 22 exposed, and the recess 23 for fitting the friction material 13 is formed. To form In addition, the coupling member 22 joined to the groove 21a is formed by cutting over the entire circumference to form a concave surface 24 (a concave surface forming step). Here, the width of the concave surface 24 on the friction surface 10a is equal to the radial width of the portion of the coupling member 22 exposed on the friction surface 10a before performing the concave surface forming step. Here, B in FIG.
12 is shown in FIG.

As described above, in the second embodiment, the concave surface 24 and the exposed connecting member 2 are formed on the friction surface 10a.
2 have the same radial width, but this minimizes the reduction in the joint area between the coupling member 22 and the ring-shaped member 19. As a result, the magnet clutch is energized, and strong durability against stress generated by rotation of the rotor 3 is obtained.

[Third Embodiment] FIG. 13 is an explanatory view of a main part of a ring-shaped member forming step and a groove forming step in a manufacturing process of a rotor 3 according to a third embodiment. In the first embodiment,
Although the ring-shaped member 19 was formed by cold forging and the grooves 21a and 21b were formed by press working, the ring-shaped member 19 can be manufactured by the steps described below.

First, a magnetic metal plate (for example, bottom carbon steel such as SPCC and SPHC) having substantially the same thickness as the friction wall 10 of the rotor 3 is punched by press punching, as shown in FIG. A circular disk material 19d is formed. (Punching) Next, as shown in FIG. 13B, a hole 19e is formed in the center of the disk 19d by press punching to form a ring-shaped plate 19f. (Punching). Next, an intermediate portion 19 between the inner periphery and the outer periphery of the ring-shaped plate member 19f is formed by cold forging as plastic working.
1f is recessed to form a ring-shaped member 19f (ring-shaped member forming step).

Next, as shown in FIG. 13C, a ring-shaped projecting portion 20 projecting upward in the figure is formed by cold forging over the entire circumference of the intermediate portion 191f (groove forming step). ). Next, the inner peripheral portion and the outer peripheral portion of the ring-shaped member 19f are formed into a cylindrical shape by cold forging as shown in FIG.

As described above, a ring-shaped member 19 having a U-shaped cross section including the inner peripheral wall 8, the outer peripheral wall 9, and the bottom 11 connecting the inner peripheral wall 8 and the outer peripheral wall 8 is formed. The bottom 1 on the open side of the ring-shaped member 19, that is, on the upper side in the figure.
1, two grooves 21a and 21b are provided on the inner and outer circumferences of the protrusion 20.
However, the cross-sectional shape of the two grooves 21 a and 21 b is such that the end of the protruding portion 20 is provided in an arc of a cross-section, so that the shape widens toward the open side of the ring-shaped member 19. are doing. The depth of the groove 21b on the inner peripheral side is provided deeper than the groove 21a on the outer peripheral side.

In this embodiment, since the grooves 21a and 21b are formed by cold casting, which is a plastic working, the rotor 3 can be downsized as compared with the case where these grooves 21a and 21b are formed by punching. Can be. That is,
The grooves 129 and 130 shown in FIG. 19 are formed by pressing a die (not shown) having arc-shaped projections at positions facing the grooves 129 and 130, against the rotor 126, and punching. In order to reduce the size of the rotor 126, it is necessary to reduce the radial width of the grooves 129 and 130.

However, when the radial width of the grooves 129 and 130 is reduced, the radial width of the protrusion provided on the mold is reduced. As a result, the projecting portion of the mold cannot withstand the impact and stress at the time of punching, and the mold may be damaged. However, in this embodiment, the grooves 21a and 21b are formed by cold casting as plastic working. Accordingly, when the grooves 129 and 130 are formed by press punching, the interval between the grooves 129 and 130 is set to the bottom 11.
Although the minimum limit is 0.6 times the plate thickness, the present embodiment allows the thickness to be reduced to about 0.3 times, and the rotor 3 can be downsized.

[Fourth Embodiment] In this embodiment, an example of a friction surface forming step and a concave surface forming step will be described. In the first embodiment, the groove 2
1a, the groove 21b is deeper than the groove 21a.
b may have the same depth. In this case, the bottom surface 11a of the bottom 11 is removed by an amount that does not expose the coupling member 22 made of a non-magnetic material, and the friction surface 10a is formed (a friction surface forming step).

Next, a portion of the friction surface 10a facing the groove 21a on the outer peripheral side is cut by cutting, so that the friction material 13 is formed.
Is formed, and the coupling member 22 is exposed on the friction surface 10a side. Then, a portion of the friction surface 10a facing the groove 21b on the inner peripheral side is cut to be dented, thereby forming a concave surface 24 and exposing the coupling member (concave surface cutting step).

Alternatively, the friction surface 10a is formed by cutting the bottom surface 11a until the coupling member 22 made of a non-magnetic material is exposed, and the coupling member 22 joined to the grooves 21a and 21b is both exposed on the friction surface 10a ( Friction surface forming step). next,
By cutting the coupling member 22 joined to the groove 21a from the friction surface 10a side, the coupling member 22 is dented to expose the coupling member 22 and form a concave 23 for fitting the friction material 13. Further, the coupling member 22 joined to the groove 21a is connected to the friction surface 10a.
A concave surface 24 is formed by cutting from the side. Here, the width of the concave surface 24 on the friction surface 10a is equal to the radial width of the portion of the coupling member 22 exposed on the friction surface 10a before the concave surface 24 is formed (concave surface forming step).

Fifth Embodiment FIG. 14 is an explanatory view of a main part of a joining step in a rotor manufacturing process according to a fifth embodiment. This embodiment shows an example of a bonding step by induction heating. A powdery coupling member 22 made of a nonmagnetic material (for example, copper) having a lower melting point than that of the ring-shaped member 19 is placed in the two grooves 21 a and 21 b provided on the bottom 11 of the ring-shaped member 19. (For example, low-carbon steel) ring-shaped member 1
The bottom 11 of 9 is heated by an induction heating device 24.
The induction heating device 24 is provided at the bottom 11 of the ring-shaped member 19.
This is a device that is provided in a ring shape having a U-shaped cross section and that generates an induced current in the ring member 19 to heat the ring member 19. Then, the coupling member 22 is melted by the heat generated by the ring-shaped member 19 by the induction heating device 40, and then the ring-shaped member 19 is cooled to solidify the melted coupling member 22. At the time of this solidification, the bonding member 22 diffuses into the ring-shaped member 19, and the ring-shaped member 19 and the bonding member 2
2 solidifies and joins firmly.

When the bottom 11 of the ring-shaped member 19 is heated and cooled, the ring-shaped member 19 is held by the chuck 25 and driven to rotate. Due to the rotation of the ring-shaped member 19, the variation in the melting state and the solidification of the powder-like bonded object 22 is suppressed, and the occurrence of defective melting or the like is prevented. In this embodiment, the ring-shaped member 19 is used.
Is heated by the induction heating device 24, but a local heating device such as the induction heating device 24 is disposed so as to heat a part of the bottom portion 11, and the ring-shaped member 19 is rotated by the chuck 25 to rotate the bottom portion 11. You may provide so that the whole may be heated.

Further, by mixing a flux for preventing metal oxidation into the powdered joint body 22 or applying a flux in the grooves 21a and 21b, oxidation of the joint can be prevented. Accordingly, it is not necessary to perform the bonding step in a vacuum or in an inert gas atmosphere in order to keep the strength of the bonding portion high, and the manufacturing cost can be reduced.
Further, since oxidation of the ring-shaped member 19 cannot be prevented, an inert gas may be blown to the ring-shaped member 19 as necessary.

In this embodiment, a powdery material is used for the coupling member 22, but a ring-shaped wire or a granular material may be used. Sixth Embodiment FIG. 15 is an explanatory view of a main part of a joining process in a rotor manufacturing process according to a sixth embodiment.

In this embodiment, the coupling member 2 made of a non-magnetic material is used.
2 and two grooves 2 in the bottom 11 of the ring-shaped member 19.
An example of a joining step of pouring and joining into 1a and 21b will be described. In the present embodiment, an example is shown in which TIG welding (inert gas tungsten arc welding) is used as a technique for melting the coupling member 22 made of a non-magnetic material and pouring it into the two grooves 21a and 21b (the outer groove 21b in the figure). Shows an example of processing).

In this TIG welding, an inert gas (argon gas,
(Helium gas or the like) is sprayed, and a high voltage is applied to the tungsten electrode 27 and the ring-shaped member 19 to generate an arc between the tungsten electrode 27 and the ring-shaped member 19. Connecting member 22
Is melted by the heat of the arc. Then, the melted coupling member 22 is filled in the groove 21a or the groove 21b, and the coupling member 22 is joined in the groove 21a and the groove 21b.

Seventh Embodiment FIG. 16 is an explanatory view of a main part of a joining process in a rotor manufacturing process according to a seventh embodiment. In this embodiment, the joining member 2 made of a non-magnetic material is formed using MIG welding (inert gas metal arc welding).
2 is melted, and the melted connecting member 22 is inserted into the two grooves 21a, 2
1b shows an example of a joining step of pouring and joining in FIG.
3 shows a processing example of the outer groove 21b).

In the MIG welding, an inert gas is blown from the nozzle 26 to the grooves 21a and 21b, which are welding portions. At this time, a high voltage is applied to the coupling member 22 and the ring-shaped member 19, which are electrodes, to generate an arc between the coupling member 22 and the ring-shaped member 19, and the coupling member 22 is melted by the heat of the arc. Then, the melted connecting member 22 is inserted into the groove 21a or the groove 2a.
1b, and the joining member 22 is joined in the grooves 21a and 21b.

The coupling member 22 as an electrode is
During IG welding, it is performed while being continuously supplied. [Modification] In the above embodiments, cold forging is described as an example of plastic working in the step of forming a ring-shaped member. However, other working means such as press working may be used.

In each of the above embodiments, copper is shown as an example of the coupling member 22 made of a non-magnetic material. However, other non-magnetic metals such as aluminum, or a non-magnetic resin may be used depending on the application. . Further, the ring-shaped member 19 is heated to
1 shows an example in which the joining member 22 made of the nonmagnetic material in 1 is melted, or the melted joining member 22 is poured into the bottom portion 11. However, a nonmagnetic metal such as stainless steel is joined to the bottom portion 11 by a friction welding method. Is also good.

Although the shape of the bottom 11 on the open side of the ring-shaped member 19 is provided in an arcuate cross section, the bottom 11 may be provided in a tapered shape narrowing toward the open side or in a rectangular cross section. Also, the distance between the bottom 11 and the stator 6b is longer than when the shape of the bottom 11 is rectangular in cross section. Further, in the first embodiment, the concave surface forming step is performed after the friction surface forming step, but the order may be reversed as described below.

First, the bottom surface 11a of the bottom portion 11 facing the groove 21a is cut by cutting the entire circumference to form a recess 23 for fitting the friction material 13 therein.
2 is exposed on the bottom surface 11a side. Then, the bottom surface 11a of the bottom portion 11 facing the groove 21b is cut by being cut over the entire circumference to form a concave surface 24, and the coupling member 22 is exposed on the bottom surface 11a side of the bottom portion 11.

Next, the inner peripheral side of the inner peripheral wall 8 of the ring-shaped member 19, the end of the outer peripheral wall 9 corresponding to the portion shown by the two-dot chain line in FIG. While cutting over, the bottom surface 11a is cut over the entire circumference to form the friction surface 10a. Here, friction surface 1
The concave surface 24 is concave with respect to 0a.

In the second embodiment, the concave surface forming step is performed after the friction surface forming step. However, the order may be reversed as described below. First, the bottom 11 facing the groove 21a
By cutting the bottom surface 11a over the entire circumference, the coupling member 22 is exposed to form a recess 23 for fitting the friction material 13. In addition, the bottom surface 11a of the bottom portion 11 facing the groove 21a is formed by cutting over the entire circumference to form a concave surface 24.

Next, the inner peripheral side of the inner peripheral wall 8 of the ring-shaped member 19, the upper end of the outer peripheral wall 9, and the open end face 3 of the bottom 11.
1 along the entire circumference, and the bottom 11
Is cut over the entire circumference to form a friction surface 10a. Here, the concave surface 24 is concave with respect to the friction surface 10a. In the second embodiment and the second embodiment, the concave surface 24 is formed by a cutting process. However, the concave surface 24 is formed by pressing the bottom surface 11a from the friction surface 10a side with a ring-shaped mold provided with a ring-shaped protrusion. It may be formed.

In each of the above embodiments, two grooves are formed as a plurality of grooves. However, three or more grooves may be formed. Further, in each of the above embodiments, the electromagnetic clutch of the refrigerant compressor is described as an example, but the present invention can be applied to all electromagnetic clutches that transmit and cut off power, such as a supercharger and an automatic speed machine.

[Brief description of the drawings]

FIG. 1 is a sectional view of a rotor (first embodiment).

FIG. 2 is an explanatory diagram of a rotor manufacturing process (first embodiment).

FIG. 3 is an explanatory diagram of a rotor manufacturing process (first embodiment).

FIG. 4 is an explanatory diagram of a rotor manufacturing process (first embodiment).

FIG. 5 is an explanatory diagram of a rotor manufacturing process (first embodiment).

FIG. 6 is an explanatory diagram of a manufacturing process of the rotor. (First embodiment).

FIG. 7 is an explanatory diagram of a manufacturing process of the rotor. (First embodiment).

FIG. 8 is a sectional view of a rotor (first embodiment).

FIG. 9 is an enlarged view of a portion A of FIG.
Example).

FIG. 10 is an explanatory view of a main part of a rotor manufacturing process (second example).
Example).

FIG. 11 is an explanatory diagram of a main part of a rotor manufacturing process (second example).
Example).

FIG. 12 is an enlarged view of a portion B in FIG. 11 (second embodiment).

FIG. 13 is an explanatory diagram of a main part of a rotor manufacturing process (third embodiment).
Example).

FIG. 14 is an explanatory view of a main part of a rotor manufacturing process (fourth step).
Example).

FIG. 15 is an explanatory diagram of a main part of a manufacturing process of a rotor (fifth embodiment);
Example).

FIG. 16 is an explanatory diagram of a main part of a rotor manufacturing process (sixth step).
Example).

FIG. 17 is a sectional view of an armature (prior art).

FIG. 18 is a sectional view of an electromagnetic clutch (prior art).

FIG. 19 is a view showing a rotor (prior art).

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Electromagnetic clutch 3 Rotor 8 Inner peripheral wall 9 Outer peripheral wall 10a Friction surface 11 Bottom part 19 Ring-shaped member 22 Coupling member 21a Groove 21b Groove 24 Concave surface

──────────────────────────────────────────────────続 き Continuation of the front page (72) Inventor Masafumi Toba 1-1-1, Showa-cho, Kariya-shi, Aichi Japan Inside Denso Co., Ltd. (56) References JP-A-63-172025 (JP, A) JP-A-56 -55721 (JP, A) U.S.A. 63-45428 (JP, U) U.S. Pat. No. 3,712,439 (US, A) (58) Fields investigated (Int. Cl. ⁷ , DB name) F16D 27/10

Claims (1)

(57) [Claims] 1. A ring-shaped member having a U-shaped cross section composed of an inner peripheral wall, an outer peripheral wall, and a bottom connecting the inner peripheral wall and the outer peripheral wall by plastically processing a ring-shaped plate material of a magnetic material. A member forming step, and after performing this step, on the open side of the ring-shaped member,
A groove forming step of forming a plurality of ring-shaped grooves in the bottom portion over the entire circumference; and a joining step of bonding a coupling member made of a non-magnetic material to each of the plurality of ring-shaped grooves over the entire circumference. A friction surface forming step of forming a friction surface by cutting a bottom surface of the bottom portion by an amount that does not expose the coupling member; and a part of the friction surface facing the groove to which the coupling member is joined. A concave surface forming step of forming a concave surface by exposing the coupling member to the friction surface side.