JP3752946B2 - Manufacturing method of rotor of rotating machine - Google Patents

Manufacturing method of rotor of rotating machine Download PDF

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JP3752946B2
JP3752946B2 JP2000048254A JP2000048254A JP3752946B2 JP 3752946 B2 JP3752946 B2 JP 3752946B2 JP 2000048254 A JP2000048254 A JP 2000048254A JP 2000048254 A JP2000048254 A JP 2000048254A JP 3752946 B2 JP3752946 B2 JP 3752946B2
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JP2001238380A (en
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徹 桑原
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Isuzu Motors Ltd
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Description

【０００１】
【発明の属する技術分野】
本発明は、発電機又は電動機である回転機のロータ、更に詳しくは、回転軸が装着された内側磁性板積層体と、少なくとも内側磁性板積層体と外側磁性板積層体との間に挿入された複数の永久磁石と、非磁性材が収容されうる複数の隙間とを備えている形態の回転機のロータの製作方法に関する。
【０００２】
【従来の技術】
一般にＩＰＭ（Ｉｎｔｅｒｒｉｒ Ｐｅｒｍａｎｅｎｔ Ｍａｇｎｅｔ）と称されている上記形態のロータの第１の典型例は、電磁鋼板を積層して形成された磁性板積層体を有している。磁性板積層体はほぼ円柱形状をなし、その中心部には貫通孔が形成されている。磁性板積層体には、周方向に間隔をおいてほぼ６角形をなすように配列された、断面が細長い矩形状をなす６個の同形の貫通孔が形成されている。磁性板積層体の、６個の貫通孔の各々間に対応する周方向位置には、磁性板積層体の外周面から半径方向内側に向かって、６個の貫通孔の各々間の肉部を周方向に２分するように延在する切欠きが形成されている（切欠きは総計６個である）。中心部の貫通孔には回転軸が一体的に装着され、６個の貫通孔の各々内には、永久磁石が挿入されている。
【０００３】
上記形態のロータの第２の典型例は、電磁鋼板を積層して形成された磁性板積層体を有している。磁性板積層体はほぼ円柱形状をなし、その中心部には貫通孔が形成されている。磁性板積層体には、周方向に間隔をおいてほぼ正方形をなすように配列された、断面が細長い矩形状をなす４個の同形の貫通孔が形成されている。磁性板積層体の、４個の貫通孔の各々間に対応する周方向位置には、それぞれ、４個の貫通孔の各々の相互に隣接する端から周方向に間隔をおいて半径方向外側に、磁性板積層体の半径方向外側端の近傍まで延在する一対の貫通孔が形成されている（一対の貫通孔は総計で４対形成されている）。中心部の貫通孔には回転軸が一体的に装着され、４個の貫通孔の各々内には永久磁石が挿入されている。また、４対の貫通孔の各々内には、オーステナイト系のステンレス等からなる非磁性部材が挿入されている。
【０００４】
上記形態のロータの第３の典型例は、電磁鋼板を積層して形成された内側磁性板積層体を有している。内側磁性板積層体は、軸方向に見てほぼ正方形をなす４個の辺を有すると共に４つの角部には面取が形成されている。内側磁性板積層体の中心部には貫通孔が形成されている。内側磁性板積層体の半径方向外側には、４個の外側磁性板積層体が配置されている。外側磁性板積層体の各々は、内側磁性板積層体の辺の各々の半径方向外側に半径方向隙間をおいて配置された半径方向内側端を有しかつ相互に周方向隙間をおいて配置されている。該半径方向隙間の各々には周方向隙間をおいて４個の永久磁石が挿入されている。永久磁石の各々間及び外側磁性板積層体の各々間の該周方向隙間の各々は、内側磁性板積層体の対応する角部において相互に整合するよう配置されて角部隙間を形成している。該角部隙間の各々には半径方向内側に隙間を残して永久磁石が挿入されている。そして残された該隙間の各々には、オーステナイト系のステンレス等からなる非磁性部材が挿入されている。
【０００５】
【発明が解決しようとする課題】
上記のように構成された従来のロータのうち、第１及び第２の典型例は、一般には、電磁鋼板を、一枚一枚回転軸に嵌合させながらかつ相互に接着しながら積層し、次いで外周部をかしめるか、又は溶接することによって、回転軸と一体の磁性板積層体を形成した後、永久磁石を対応する貫通孔に接着剤を介して挿入することにより形成していた。このため組付作業が煩雑で、多くの組付作業時間と多大の労力を要し、生産性に乏しい。また生産コストが高くなる。
【０００６】
また、磁気ショート（磁気洩れ）を可能な限り少なくするため、上記のとおり、第１の典型例においては、永久磁石の各々間に対応する、電磁鋼板の外周部、したがって磁性板積層体の外周部に６個の切欠きを形成することにより異極間の磁気の遮断を図っていた。しかしながら、これらの切欠きが過剰に小さいと、電磁鋼板の、したがって磁性板積層体の当該部分の余肉（切欠きの各々と、周方向に隣接する永久磁石の周方向端との間に形成される周方向の厚さ）が過剰に大きくなり、磁気ショートが多くなって性能の低下を招く。また切欠きが過剰に大きいと、電磁鋼板の、したがって磁性板積層体の当該部分の余肉が過剰に小さくなり、高速回転時における強度が不足するおそれがある。したがって両者を満足するための設計が困難であった。第２の典型例においてはまた、４対の非磁性部材を挿入することに起因して、第１の典型例に比べて部品点数が増大し、生産性が更に低下し、また生産コストが一層高くなる。
【０００７】
他方、第３の典型例においても、第１及び第２の典型例と同様な理由によって、組付作業が煩雑で、多くの組付作業時間と多大の労力を要し、生産性に乏しい。第３の典型例においてはまた、第１の典型例に比べて、永久磁石の数が増加しかつ非磁性部材が付加されることに起因して、部品点数が増大し、生産性が更に低下すると共に、生産コストが高くなる。更に、電磁鋼板が当初から４つに分割されていることに起因して、組付作業が一層煩雑となり、生産性が一層低下させられると共に生産コストが一層高くなる。
【０００８】
本発明は上記事実に基づいてなされたものであり、その目的は、従来に比べて組付作業が簡単となり、そして組付作業時間が短縮されると共に労力の負担が軽減され、その結果、生産性の向上及び製造コストの低減を可能にする、新規な回転機のロータの製作方法を提供することである。
【０００９】
本発明の他の目的は、異極間の磁気ショートを軽減すると共に高速回転時における強度を確保することを容易に可能にする、新規な回転機のロータの製作方法を提供することである。
【００１０】
本発明の更に他の目的は、部品点数を著しく低減し、その結果、生産性の向上及び製造コストの低減を可能にする、新規な回転機のロータの製作方法を提供することである。
【００１１】
本発明の更に他の目的は、回転機の所要の性能及び耐久性を長期にわたって十分に確保することを容易に可能にする、新規な回転機のロータの製作方法を提供することである。
【００１２】
本発明のその他の目的及び特徴は、本発明に従って構成された回転機のロータの製作方法の実施形態について添付図面を参照して詳細に説明する後の記載から明らかになるであろう。
【００１６】
【課題を解決するための手段】
本発明の局面によれば、円筒部を有する成形型の軸心に合わせて回転軸をセットし、軸心部に取付孔が形成されかつ偶数個の辺を有した実質上多角形状の内側磁性板を取付孔を介して回転軸に挿入しながら積層し、かつ円形外周端と、該辺と同数の半径方向内側端及び該内側端の各々の周方向端の間に形成されて一端が半径方向内側に開放され他端が該外周端との間に橋絡部を残して閉じられた溝を有する貫通孔とからなる外側磁性板本体を、該円筒部に嵌合しながら積層することにより、該内側端の各々と、対応する該辺との間に半径方向隙間を、また該溝の各々と内側磁性板の対応する角部との間に角部隙間を形成して、該円筒部内に内側磁性板積層体及び外側磁性板本体積層体を形成し、該半径方向隙間の各々に永久磁石を挿入した後、溶融された非磁性材を鋳込んで、内側磁性板積層体、永久磁石の各々、外側磁性板本体積層体、及び該角部隙間の各々の軸方向両端面を該非磁性材の層で覆うと共に、該角部隙間の各々を該層の各々と一体となるよう充填し、離型後、外側磁性板本体積層体及び非磁性材の外周端を切削して橋絡部の各々を切除する、ことを特徴とする回転機のロータの制作方法、が提供される。
【００１７】
本発明の更に他の局面によれば、円筒部を有する成形型の軸心に合わせて回転軸をセットし、軸心部に取付孔が形成されかつ偶数個の辺を有した実質上多角形状の内側磁性板を取付孔を介して回転軸に挿入しながら積層し、かつ円形外周端と、該辺と同数の半径方向内側端及び該内側端の各々の周方向端の間に形成されて一端が半径方向内側に開放され他端が該外周端との間に橋絡部を残して閉じられた溝を有する貫通孔とからなる外側磁性板本体を、該円筒部に嵌合しながら積層することにより、該内側端の各々と対応する該辺との間に半径方向隙間を、また該溝の各々と内側磁性板の対応する角部との間に角部隙間を形成して、該円筒部内に内側磁性板積層体及び外側磁性板本体積層体を形成し、該半径方向隙間の各々に永久磁石を挿入しかつ該角部隙間の各々にそれぞれ半径方向内側に該隙間の一部を残して永久磁石を挿入した後、溶融された非磁性材を鋳込んで、内側磁性板積層体、永久磁石の各々、外側磁性板本体積層体、及び該隙間の一部の各々の軸方向両端面を該非磁性材の層で覆うと共に、該隙間の一部の各々を該層の各々と一体となるよう充填し、離型後、外側磁性板本体積層体及び非磁性材の外周端を切削して橋絡部の各々を切除する、
ことを特徴とする回転機のロータの制作方法、が提供される。
【００１８】
本発明の更に他の局面によれば、円筒部を有する成形型の軸心に合わせて回転軸をセットし、軸心部に形成された取付孔と、円形外周端と、偶数個の実質上正多角形をなすよう形成された半径方向隙間と、半径方向隙間の各々の角部において半径方向に延在するよう形成された半径方向橋絡部を周方向に挟んでそれに沿って半径方向に延在するよう形成されて円形外周端との間に周方向橋絡部を形成する一対の周方向隙間とを備えている磁性板を、取付孔を介して回転軸に挿入しながらかつ円形外周端を該円筒部に嵌合しながら積層することにより磁性板積層体を形成し、該半径方向隙間の各々に永久磁石を挿入した後、溶融された非磁性材を鋳込んで、磁性板積層体、永久磁石の各々、及び周方向隙間の各々の軸方向両端面を該非磁性材の層で覆うと共に、周方向隙間の対の各々を該層の各々と一体となるよう充填し、離型後、磁性板積層体及び非磁性材の外周端を切削して周方向橋絡部の各々を切除する、
ことを特徴とする回転機のロータの制作方法、が提供される。
【００１９】
【発明の実施の形態】
以下、本発明の好適実施形態を添付図面を参照して更に詳細に説明する。図１〜図３を参照して、発電機又は電動機である回転機に適用されるロータ１００は、回転軸２が装着された内側磁性板積層体１０と、複数の（実施形態においては６個の）外側磁性板積層体２０と、複数の（実施形態においては６個の）永久磁石３０と、溶融可能な非磁性材４０とから構成されている。
【００２０】
以下、本発明によるロータ１００の構成（完成された構成）について具体的に説明する。内側磁性板積層体１０は、相互に実質上同一の構成を有する複数の内側磁性板１１を積層することにより構成されている。内側磁性板１１は、電磁鋼板、実施形態においては珪素鋼板からなり、それぞれ直線状に延在する偶数個の辺１２を有しかつ実質上、正多角形状をなすよう形成されている。実施形態においては、内側磁性板１１は６個の辺１２を有しかつ実質上、正６角形状をなすよう形成されている。内側磁性板１１の６個の角部には、それぞれ半径方向外側に延び出す突起１３が形成されている。内側磁性板１１の軸心部には、回転軸２が装着される取付穴１４が形成されている。以上のように構成された内側磁性板１１を複数枚積層することにより内側磁性板積層体１０が構成され、内側磁性板積層体１０の取付穴１４には回転軸２が嵌合・装着されている。
【００２１】
相互に実質上同一の構成を有する偶数個の（実施形態においては６個の）外側磁性板積層体２０の各々は、相互に実質上同一の構成を有する複数の外側磁性板２１を積層することにより構成されている。外側磁性板２１は、電磁鋼板、実施形態においては珪素鋼板からなり、円弧形状をなす半径方向外側端２２と、直線状に延在する半径方向内側端２３と、周方向両側端２４とを有している。以上のように構成された外側磁性板２１を複数枚積層することにより外側磁性板積層体２０が構成される。外側磁性板積層体２０の各々は、内側磁性板積層体１０の、実質上、半径方向外側に半径方向隙間をおいてかつ周方向に周方向隙間をおいて配置されている。すなわち、外側磁性板積層体２０の各々の半径方向内側端２３は、内側磁性板積層体１０の対応する辺１２に対し半径方向隙間をおいて平行に対向するよう配置されると共に周方向に周方向隙間をおいて対向するよう配置される。半径方向外側端２２の各々は、回転軸２と共通の軸心を有する仮想円周上に位置付けられ、内側磁性板積層体１０の各々の周方向隙間は、各々の周方向端２４の間に形成されかつ内側磁性板積層体１０の角部の各々、したがって突起１３の各々に整合した周方向位置に配置される。
【００２２】
外側磁性板積層体２０の各々の半径方向内側端２３と、内側磁性板積層体１０の対応する辺１２との間の半径方向隙間の各々には、例えばＮｄ−Ｆｅ−Ｂ系の永久磁石３０が挿入されている。永久磁石３０の各々は、細長いほぼ直方体形状に形成されている。永久磁石３０の各々間に形成される周方向隙間の各々及び外側磁性板積層体２０の各々間に形成される周方向隙間の各々は、内側磁性板積層体１０の対応する角部において相互に整合するよう配置されて、角部隙間を形成する。この角部隙間の総計は６個である。該角部隙間の各々には内側磁性板積層体１０の突起１３が位置付けられる。突起１３の半径方向外側端は、相互に周方向に対向する永久磁石３０の周方向端における半径方向外側端よりも半径方向内側に位置付けられている。なお、永久磁石３０の各々は、各々の磁極が半径方向に向けられるよう形成され、かつ周方向に隣接する永久磁石３０の各々間において半径方向外側の磁極同士が互いに異極をなし、したがって半径方向内側の磁極同士が互いに異極をなすよう配置される。
【００２３】
内側磁性板積層体１０、永久磁石３０の各々、外側磁性板積層体２０の各々、及び該角部隙間の各々の軸方向両端面は、溶融可能な非磁性材４０の層により覆われ、そして該角部隙間の各々は、該非磁性材４０により該層の各々と一体となるよう充填されている。非磁性材４０は、アルミニウム、アルミニウム合金あるいは亜鉛合金等の非磁性材からなる。非磁性材４０は、後述するようにしてダイキャストにより、回転軸２、内側磁性板積層体１０、永久磁石３０の各々及び外側磁性板積層体２０の各々を、外側磁性板積層体２０の各々の半径方向外側端面を除き、実質上一体に鋳ぐるむことができる。内側磁性板積層体１０及び永久磁石３０の各々は、外側磁性板積層体２０の各々及び非磁性材４０の内部に完全に埋設される。内側磁性板積層体１０、永久磁石３０の各々、外側磁性板積層体２０の各々、及び該角部隙間の各々の軸方向両端面を覆う非磁性材４０の層の各々と、該角部隙間の各々を充填した非磁性材４０の各々とは、ほぼ円柱形状をなす、ロータ１００の本体部１０２を構成する。本体部１０２の軸方向両端面は非磁性材４０により形成され、外周面は、外側磁性板積層体２０の各々の半径方向外側端面と、該角部隙間に充填された非磁性材４０の各々の半径方向外側端面とにより形成される。
【００２４】
本発明による回転機のロータ１００は、上記したように、内側磁性板積層体１０、永久磁石３０の各々、外側磁性板積層体２０の各々及び該角部隙間の各々の軸方向両端面が溶融可能な非磁性材４０の層により覆われかつ該角部隙間の各々が該非磁性材４０により該層の各々と一体となるよう充填されているので、内側磁性板積層体１０、永久磁石３０の各々及び外側磁性板積層体２０の各々を非磁性材４０によって、外側磁性板積層体２０の各々の外周面を除き、一体的に鋳ぐるむことを可能にする。非磁性材４０は鋳造により一体に成形することが可能である。このため、従来におけるような、かしめ、溶接、接着等の煩雑な作業が不要となり、従来に比べて組付作業が簡単となり、そして組付作業時間が短縮されると共に労力の負担が軽減され、その結果、生産性の向上及び製造コストの低減を可能にする。また従来のロータにおけるような切欠きが不要となり、切欠きの部分には非磁性材４０が充填されるので、異極間の磁気ショートを軽減すると共に高速回転時における強度を確保することを容易に可能にするものである。更にはまた、永久磁石３０の各々は、外側磁性板積層体２０の各々及び非磁性材４０によって完全に覆われるので（埋設されるので）、発電機又は電動機である回転機に適用した場合、回転機のケースに通風孔を設け、回転軸に配設したファンによりケース内にエアを供給することにより強制冷却を行っても、鉄粉等のダストあるいは水等から永久磁石３０の各々を完全に保護することが可能になる。その結果、回転機の所要の性能及び耐久性を長期にわたって十分に確保することを容易に可能にする。
【００２５】
上記ロータ１００においてはまた、内側磁性板積層体１０の角部の各々には、半径方向外側に対応する該角部隙間に向かって延び出す突起１３が形成され、突起１３の各々は、対応する角部において相互に周方向に対向する永久磁石３０の周方向端の間に位置付けられているので、高速回転時における強度を向上させることができる。なお、実用上、高速回転時における強度が確保できるのであれば、突起１３の各々を形成しない他の実施形態もありうる。
【００２６】
次に上記ロータ１００の制作方法について説明する。図４を参照して、先に述べた内側磁性板１１は、図示しないプレス機械によって珪素鋼板（平板）を打ち抜き加工することにより形成することができる。突起１３の各々の周方向両端は、内側磁性板１１を軸方向に見て、取付孔１４の軸心Ｏ及び正６角形の図示しない角を通って半径方向に延在する仮想直線Ｌを等角度で挟んで、軸心Ｏを通り半径方向に延在する２本の仮想直線Ｌ１上に延在するよう形成される。したがって、突起１３の各々の周方向両端は、仮想直線Ｌに対し周方向の対称位置において、半径方向外側に向かってその周方向幅が末広がりとなるよう傾斜している。また突起１３の各々の半径方向外側端は、上記仮想直線Ｌに直交するよう（すなわち接線方向に延在するよう）形成されている。
【００２７】
先に述べた外側磁性板積層体２０の各々は、成型後のロータ１００として完成された状態においては、先に説明したように、相互に周方向に分離された不連続の独立部材として配列されているが、成形前においては、溶融可能な非磁性材４０が充填される上記角部隙間の各々の半径方向外側端が円弧状の細い橋絡部２１２によって連結されることにより、外周端部全体が連続した円形状をなすよう一体に形成された１枚の外側磁性板本体２１０を積層することにより形成される外側磁性板本体積層体２２０（図７及び図８参照）から構成される。そして後述する、成形後の切削加工により、上記のように外側磁性板積層体２０の各々に分離される。
【００２８】
図５を参照して、図示しないプレス機械によって珪素鋼板（平板）を打ち抜き加工することにより形成される外側磁性板本体２１０は、円形外周端２１１を有しかつ内側磁性板１１の辺１２と同数である偶数個の（実施形態においては６個の）半径方向内側端２３と、内側端２３の各々の周方向端の間に形成されて一端が半径方向内側に開放され他端が上記外周端２１１との間に橋絡部２１２を残して閉じられた溝２１３とからなる貫通孔２１４を有している。内側端２３の各々は、それぞれ直線状に延在し、実質上、正６角形の辺を構成するよう配置され、この正６角形の角部の各々に溝２１３が配置されている。この正６角形の中心、したがって貫通孔２１４の中心は、外側磁性板本体２１０の軸心Ｏと一致するよう位置付けられている。溝２１３の各々の周方向両端は、外側磁性板本体２１０を軸方向に見て、外側磁性板本体２１０の軸心Ｏ及び上記正６角形の図示しない角を通って半径方向に延在する仮想直線Ｌを等角度で挟んで、軸心Ｏを通り半径方向に延在する２本の仮想直線Ｌ１上に延在するよう形成され、また溝２１３の各々の半径方向外側端は、円形外周端２１１に平行な円弧形状に形成されている。これらの直線Ｌ及びＬ１の各々は、外側磁性板本体２１０の軸心Ｏが、内側磁性板１１の軸心上に位置付けられた状態で、内側磁性板１１における上記直線Ｌ及びＬ１の各々と一致するよう規定されている。２点鎖線２２で示される円形状部は、後述する切削加工によって切削される切削予定面（切削予定ライン）を表している。この切削代は、少なくとも外側磁性板本体２１０の橋絡部２１２の各々が完全に切除される程度に規定される。
【００２９】
図６には、ロータ１００の組付及び成形用型３００の構成が概略的に示されている。組付及び成形用型３００は、下端に底壁３０１を有する円筒部３０２と、円筒部３０２の開口端を離脱自在に閉塞しうる蓋型３０３とを有している。円筒部３０２内の底壁３０１の上面には、キャップ形状の隙間設定部材３０４が挿入されている。底壁３０１の軸心部には、回転軸２が嵌合される図示しない貫通孔、及び溶融された非磁性材４０を注入するための注湯口が形成されている。蓋型３０３の軸心部には、回転軸２が嵌合される貫通孔３０５が形成されている。隙間設定部材３０４は、後述するとおりにして鋳込まれる溶融可能な上記非磁性材４０と同じ材料から形成され、その天壁部には、６個の貫通孔３０６が周方向に間隔をおいて形成されている。
【００３０】
図６〜図８を参照して、以上のように構成された組付及び成形用型３００において、ロータ１００の一部である回転軸２を、底壁３０１の図示しない貫通孔に嵌合することにより、組付及び成形用型３００の軸心に合わせてセットする。回転軸２の上端部は円筒部３０２の開口端を越えて上方に突出させられ、また下端部は底壁３０１から下方に突出させられる。次いで、上記内側磁性板１１をその取付孔１４を介して回転軸２に挿入しながら円筒部３０２内に挿入して、隙間設定部材３０４の上面に適宜の枚数、積層する。この積層作業は、内側磁性板１１を単に回転軸２に挿入して積み重ねてゆくだけであり、容易かつ確実に行なうことができる。その後、上記外側磁性板本体２１０を、円筒部３０２の内周面に嵌合しながら、隙間設定部材３０４の上面に適宜の枚数、積層する。この積層作業も、外側磁性板本体２１０を円筒部３０２の内周面に沿って挿入して積み重ねてゆくだけであり、容易かつ確実に行なうことができる。外側磁性板本体２１０は、貫通孔２１４が内側磁性板１１の半径方向外側全体を半径方向外側から覆うよう配置され、そして内側端２３の各々が内側磁性板１１の対応する辺１２に対し半径方向外側に半径方向隙間をおいて平行に対向し、かつ溝２１３の各々の周方向位置と内側磁性板１１の対応する角部（突起１３）とが整合してそれぞれ角部の半径方向外側に角部隙間２３０が形成されるように配置される。内側磁性板１１及び外側磁性板本体２１０は、予め上記配置を可能にするような形状及び大きさに、それぞれ形成されることはいうまでもない。外側磁性板本体２１０の外径を円筒部３０２の内径とほぼ同じ（若干小さめ）に形成しておくことは、ガタ防止上好ましい。なお、この実施形態においては、内側磁性板１１を複数枚積層した後に、内側磁性板１１の半径方向外側に外側磁性板本体２１０を複数枚積層するようその順序が規定されているが、もちろん逆の順序であっても成立する。内側磁性板１１の積層及び外側磁性板本体２１０の積層を複数回繰り返すことにより、円筒部３０２内に所定の軸方向厚さを有する内側磁性板積層体１０及び外側磁性板本体積層体２２０を形成する。
【００３１】
次に、内側磁性板積層体１０の辺１２の各々と外側磁性板本体積層体２２０の対応する内側端２３との間の半径方向隙間にそれぞれ永久磁石３０を挿入する（図８参照）。永久磁石３０の各々は対応する隙間に実質上密着して挿入される。先に述べたように、内側磁性板１１の各々における突起１３の周方向両端は、半径方向外側に向かってその周方向幅が末広がりとなるよう傾斜しており、永久磁石３０の各々の周方向両端は、対応する突起１３の周方向端の傾斜面に実質上密着させられるよう位置付けられるので、該傾斜に対応した傾斜を有するよう形成されている。したがって永久磁石３０の各々の横断面はほぼ台形状をなす。また永久磁石３０の各々の軸方向長さは、内側磁性板積層体１０及び外側磁性板本体積層体２２０の軸方向の厚さとほぼ一致するよう形成されている。内側磁性板積層体１０の辺１２の各々と外側磁性板本体積層体２２０の対応する内側端２３との間の半径方向隙間にはそれぞれ永久磁石３０が挿入されるので、内側磁性板積層体１０の角部に存在する突起１３の各々の半径方向外側端面と、永久磁石３０の各々の周方向に対向する端面の各々と、外側磁性板本体積層体２２０の対応する溝２１３との間には、それぞれ最終的に角部隙間２３０（図８参照）が形成される。この角部隙間２３０の数は総計６個である。角部隙間２３０の各々は軸方向に見てほぼ台形状をなしている。内側磁性板１１の各々における突起１３の各々の半径方向外側端は、相互に周方向に対向する永久磁石３０の周方向端の半径方向外側端よりも半径方向内側に位置付けられる。なお、角部隙間２３０の各々は、組付及び成形用型３００の底壁３０１の上面にセットされた、上記隙間設定部材３０４の天壁部に形成された６個の貫通孔３０６の各々に対応した位置に位置付けられる。
【００３２】
以上のとおりにして、内側磁性板積層体１０、外側磁性板本体積層体２２０及び永久磁石３０の各々が、組付及び成形用型３００の円筒部３０２内にセットされた後、円筒部３０２の開口端を蓋型３０３により閉塞する。蓋型３０３と、内側磁性板積層体１０、永久磁石３０の各々及び外側磁性板本体積層体２２０の軸方向上端面（実質上同一面上にある）との間には、所定の軸方向隙間が設けられる。この軸方向隙間は、内側磁性板積層体１０、永久磁石３０の各々及び外側磁性板本体積層体２２０の軸方向下端面（実質上同一面上にある）と底壁３０１との間に、隙間設定部材３０４によって設定される軸方向隙間と実質上同一に規定される。次いで、溶融された非磁性材４０を、内側磁性板積層体１０、永久磁石３０の各々、外側磁性板本体積層体２２０、及び角部隙間２３０の各々の軸方向両端面を非磁性材４０の層で覆うと共に、角部隙間２３０の各々を該層の各々と一体となるよう充填することにより（鋳込むことにより）、回転軸２、内側磁性板積層体１０、永久磁石３０の各々及び外側磁性板本体積層体２２０を、外側磁性板本体積層体２２０の外周面の一部を除き、一体に鋳ぐるむ。
【００３３】
更に具体的には、組付及び成形用型３００の底壁３０１に形成された図示しない注湯口から溶融された非磁性材４０を注湯する。溶融された非磁性材４０は、底壁３０１と隙間設定部材３０４との間の軸方向隙間、隙間設定部材３０４の貫通孔３０６の各々、上記角部隙間２３０の各々及び、蓋型３０３と、内側磁性板積層体１０、永久磁石３０の各々及び外側磁性板本体積層体２２０の軸方向上端面との間の上記軸方向隙間を上記記載順に流動させられ、それらの各々を充填する。なお、蓋型３０３には適宜のエア抜き手段が設けられているが詳細は省略する。組付及び成形用型３００内に充填された溶融非磁性材４０を、周知の加圧手段により加圧して、ダイキャスト鋳造を遂行する。上記隙間設定部材３０４は、溶融された非磁性材４０によって一体に実質上鋳ぐるまれる。隙間設定部材３０４は溶融された非磁性材４０と同じ材料からなるので、問題はない。このようにして溶融された非磁性材４０により一体に実質上鋳ぐるむことによって成形されたロータ１００の中間品を、所定時間経過後、組付及び成形用型３００から取り出し（離型し）、冷却した後、外側磁性板本体積層体２２０及び軸方向両側の非磁性材４０の層の外周面を回転軸２の軸心まわりに切削加工を施して、外側磁性板本体積層体２２０の橋絡部２１２の各々を切除する。
【００３４】
上記切削加工によって、橋絡部２１２の各々の半径方向内側の上記角部隙間２３０の各々に充填されかつ成形当初は橋絡部２１２の各々によって半径方向外側が覆われていた非磁性材４０の各々は、外周面に露呈されることになる。また上記切削加工によって、外側磁性板本体２１０の積層体から構成された外側磁性板本体積層体２２０を、相互に周方向に分離された６個の外側磁性板積層体２０とする。外側磁性板積層体２０の各々、角部隙間２３０の各々に充填された非磁性材４０及び軸方向両側の非磁性材４０の層の各々、の半径方向外側端面は、実質上共通の円形外周面２２上に位置付けられ、該円形外周面２２は切削面から形成されることになる。この切削面は、図２に示される、不連続の独立した外側磁性板積層体２０の各々の半径方向外側端（外側端面）２２を規定する。次に、必要であれば、上記ロータ１００の中間品の軸方向両側面を切削加工する。次いでロータ１００の回転バランス取り（バランシング）を行なうことにより、ロータ１００は完成品となる。
【００３５】
本発明によるロータ１００の製作方法によれば、組付及び成形用型３００の円筒部３０２にセットされた回転軸２に、内側磁性板１１をその取付孔１４を介して挿入しながら積層し、また外側磁性板本体２１０を円筒部３０２に嵌合しながら積層して、外側磁性板本体２１０の内側端２３の各々と内側磁性板１１の対応する辺１２との間に半径方向隙間を、また外側磁性板本体２１０の溝２１３の各々と内側磁性板１１の対応する角部との間に角部隙間２３０を形成して、円筒部３０２内に内側磁性板積層体２０及び外側磁性板本体積層体２２０を形成し、複数の永久磁石３０を半径方向隙間の各々に挿入した後、溶融された非磁性材４０を、内側磁性板積層体２０、永久磁石３０の各々、外側磁性板本体積層体２２０、及び角部隙間２３０の各々の軸方向両端面を非磁性材４０の層で覆うと共に、角部隙間２３０の各々を該層の各々と一体となるよう充填することにより（鋳込むことにより）、回転軸２、内側磁性板積層体１０、永久磁石３０の各々及び外側磁性板本体積層体２２０を、外側磁性板本体積層体２２０の外周面の一部を除き、一体に鋳ぐるみ、離型後、外側磁性板本体積層体２２０及び非磁性材４０の外周端を切削して外側磁性板本体２１０の橋絡部２１２の各々を切除することによって、ロータ１００を製作することができる。その結果、従来におけるような、かしめ、溶接、接着等の煩雑な作業が不要となり、従来に比べて組付作業が簡単となり、そして組付作業時間が短縮されると共に労力の負担が軽減され、その結果、生産性の向上及び製造コストの低減を可能にする。
【００３６】
回転軸２に、内側磁性板１１をその取付孔を介して挿入しながら積層し、また外側磁性板本体２１０を円筒部３０２の内周面に嵌合しながら積層することにより、円筒部３０２内に内側磁性板積層体２０及び外側磁性板本体積層体２２０を形成することができるので、組付作業が容易化され、組付作業時間が短縮されると共に労力の負担が軽減される。特にロータ１００の完成時には相互に分離されている外側磁性板２１の各々は、組付時には外側磁性板本体２１０として一体に形成されているので、部品点数が低減され、上記のとおりに組付作業が容易化される。また円筒部３０２内に内側磁性板積層体１０及び外側磁性板本体積層体２２０を形成し、永久磁石３０の各々を組み付けた後、非磁性材４０による鋳造によって各部材を鋳ぐるむことによりロータ１００の中間品を形成することができるので、トータル的に製作が容易化され、製作時間が短縮されると共に労力の負担が軽減される。
【００３７】
また従来のロータにおけるような切欠きが不要となり、切欠きの部分には非磁性材４０が充填されるので、異極間の磁気ショートを軽減すると共に高速回転時における強度を確保できるロータ１００を製作することができる。更にはまた、永久磁石３０の各々が外側磁性板積層体２０の各々及び非磁性材４０によって完全に覆われたロータ１００を製作することができるので、このロータ１００を発電機又は電動機である回転機に適用した場合、回転機のケースに通風孔を設け、回転軸に配設したファンによりケース内にエアを供給することにより強制冷却を行っても、鉄粉等のダストあるいは水から永久磁石３０の各々を完全に保護することが可能になる。その結果、回転機の所要の性能及び耐久性を長期にわたって十分に確保することを容易に可能にする。
【００３８】
図９には、本発明による回転機のロータ１００の他の実施形態を構成する、内側磁性板１１及び内側磁性板積層体１０、外側磁性板本体２１０及び外側磁性板本体積層体２２０、及び、永久磁石３０の各々の他の実施形態が、組付及び成形用型３００の円筒部３０２内に挿入された状態で示されている。内側磁性板１１における突起１３の各々の周方向両端は、内側磁性板１１を軸方向に見て、取付孔１４の軸心Ｏ及び正６角形の図示しない角を通って半径方向に延在する仮想直線Ｌを等間隔に挟みかつ半径方向に平行に延在する２本の仮想直線Ｌ２上に延在するよう形成される。したがって、突起１３の各々の周方向両端は、仮想直線Ｌに対し周方向の対称位置において、半径方向外側に向かって平行に直線状に延在している。内側磁性板１１及び内側磁性板積層体１０のその他の構成は図１〜図８を参照して説明した先の実施形態における内側磁性板１１及び内側磁性板積層体１０と実質上同じである。また図９に示される外側磁性板本体２１０における溝２１３の各々の周方向両端は、外側磁性板本体２１０を軸方向に見て、外側磁性板本体２１０の軸心Ｏ及び上記正６角形の図示しない角を通って半径方向に延在する仮想直線Ｌを等間隔に挟んで、軸心Ｏを通り半径方向に平行に延在する２本の仮想直線Ｌ２上に延在するよう形成される。これらの直線Ｌ及びＬ２の各々は、外側磁性板本体２１０の軸心Ｏが、内側磁性板１１の軸心上に位置付けられた状態で、内側磁性板１１における上記直線Ｌ及びＬ２の各々と一致するよう規定されている。外側磁性板本体２１０及び外側磁性板本体積層体２２０のその他の構成は、図５〜図８を参照して説明した先の実施形態における外側磁性板本体２１０及び外側磁性板本体積層体２２０と実質上同じである。なお永久磁石３０の各々は、各々の周方向両端の傾斜が若干相違するのみで、横断面はほぼ台形をなす基本構成は先の実施形態とほぼ同じである。角部隙間２３０の各々は軸方向に見てほぼ矩形状をなしている。
【００３９】
上記各部材を含むロータ１００において、内側磁性板１１及び内側磁性板積層体１０、及び、外側磁性板本体２１０及び外側磁性板本体積層体２２０の構成は、図１〜図８を参照して説明した先の実施形態におけるそれらの構成よりも若干簡略化されているが、本質的な特徴に相違はない。したがって、図９に示される、上記各部材を含むロータ１００及びそれを製作する方法、の作用効果は、図１〜図８を参照して説明した先の実施形態におけると実質上同一であり、説明は省略する。
【００４０】
図１０には、本発明による回転機のロータ１００の更に他の実施形態を構成する、内側磁性板１１及び内側磁性板積層体１０、外側磁性板本体２１０及び外側磁性板本体積層体２２０、及び、永久磁石３０の各々の、更に他の実施形態が、組付及び成形用型３００の円筒部３０２内に挿入された状態で示されている。内側磁性板１１における突起１３の各々の周方向両端は、内側磁性板１１を軸方向に見て、対応する辺１２の周方向端から直角に半径方向外側に向かって延び出すよう形成されている。内側磁性板１１及び内側磁性板積層体１０のその他の構成は図１〜図８を参照して説明した先の実施形態における内側磁性板１１及び内側磁性板積層体１０と実質上同じである。図１０に示される外側磁性板本体２１０及び外側磁性板本体積層体２２０は、図９に示された外側磁性板本体２１０及び外側磁性板本体積層体２２０と実質上同じ構成を有している。また永久磁石３０の各々の周方向両端は、対応する突起１３の周方向端に実質上密着させられるので、永久磁石３０の各々の横断面は実質上矩形状に形成されている。永久磁石３０の各々の周方向両端の半径方向外側端は、外側磁性板本体２１０の対応する溝２１３の半径方向内側端に位置付けられている。上記各部材を含むロータ１００において、永久磁石３０の各々の構成は、図１〜図８を参照して説明した先の実施形態における永久磁石３０の各々の構成よりも単純化され、したがって比較的低コストで製造することができるが、全体の構成における本質的な特徴に相違はない。したがって、図１０に示される、上記各部材を含むロータ１００及びそれを製作する方法、の作用効果は、図１〜図８を参照して説明した先の実施形態におけると実質上同一であり、説明は省略する。
【００４１】
図１１には、本発明による回転機のロータ１００の更に他の実施形態を構成する、内側磁性板１１及び内側磁性板積層体１０、外側磁性板本体２１０及び外側磁性板本体積層体２２０、及び、永久磁石３０の各々の、更に他の実施形態が、組付及び成形用型３００の円筒部３０２内に挿入された状態で示されている。内側磁性板１１、したがって内側磁性板積層体１０における突起１３の各々は、対応する角部隙間２３０の半径方向中央を、角部隙間２３０の半径方向外側端、すなわち橋絡部２１２の半径方向内側端まで延在して、角部隙間２３０を周方向に２分割するよう位置付けられている。内側磁性板１１及び内側磁性板積層体１０のその他の構成は、図１〜図８を参照して説明した先の実施形態における内側磁性板１１及び内側磁性板積層体１０と実質上同一である。また外側磁性板本体２１０及び外側磁性板本体積層体２２０の構成、及び、永久磁石３０の各々の構成は、図１０に示されたそれらの構成と実質上同一である。上記各部材を含むロータ１００においては、内側磁性板１１、したがって内側磁性板積層体１０における突起１３の各々が、対応する角部隙間２３０の半径方向中央を、橋絡部２１２の半径方向内側端まで延在して、角部隙間２３０を周方向に２分割するよう位置付けられているので、先の実施形態のいずれよりも、高速回転時における強度を一層向上させることができる。また周方向に２分割された角部隙間２３０の各々には、先の実施形態と同じとおりにして非磁性材４０が充填されるので、周方向に２分割された角部隙間２３０の各々に非磁性部材を挿入する形態の、従来のロータに比べて部品点数を著しく低減することができ、その結果、生産性の向上及び製造コストの低減を可能にする。図１１に示される、上記各部材を含むロータ１００の全体の構成における本質的な特徴は、先の実施形態と実質上同じである。したがって、図１１に示される、上記各部材を含むロータ１００及びそれを製作する方法、の作用効果は、図１〜図８を参照して説明した先の実施形態におけると実質上同一であり、説明は省略する。
【００４２】
なお、図１〜図１１を参照して説明した先に実施形態の各々において、内側磁性板１１及び内側磁性板積層体１０の辺１２の数は、それぞれ６個であるが、各実施形態において、偶数個であれば、４個、あるいは８個以上であっても成立する。内側磁性板１１及び内側磁性板積層体１０の辺１２の数に応じて、外側磁性板本体２１０及び外側磁性板本体積層体２２０の構成、及び、永久磁石３０の数等が規定されることはいうまでもない。
【００４３】
図１２には、本発明による回転機のロータ１００の更に他の実施形態が示されている。このロータ１００は、回転軸２が装着された内側磁性板積層体１０と、４個の外側磁性板積層体２０と、４個の永久磁石３０と、４個の他の永久磁石５０と、溶融可能な非磁性材４０とから構成されている。内側磁性板積層体１０は、相互に実質上同一の構成を有する複数の内側磁性板１１を積層することにより構成されている。内側磁性板１１は、電磁鋼板、実施形態においては珪素鋼板からなり、それぞれ直線状に延在する４個の辺１２を有しかつ実質上、正４角形状をなすよう形成されている。内側磁性板１１の４個の角部には、それぞれ面取１５が形成されている。内側磁性板１１の軸心部には、回転軸２が装着される取付孔１４が形成されている。以上のように構成された内側磁性板１１を複数枚積層することにより内側磁性板積層体１０が構成され、内側磁性板積層体１０の取付孔１４には回転軸２が嵌合・装着されている。
【００４４】
相互に実質上同一の構成を有する４個の外側磁性板積層体２０の各々は、相互に実質上同一の構成を有する複数の外側磁性板２１を積層することにより構成されている。外側磁性板２１は、電磁鋼板、実施形態においては珪素鋼板からなり、円弧形状をなす半径方向外側端２２と、直線状に延在する半径方向内側端２３と、周方向両側端２４とを有している。以上のように構成された外側磁性板２１を複数枚積層することにより外側磁性板積層体２０が構成される。外側磁性板積層体２０の各々は、内側磁性板積層体１０の、実質上、半径方向外側に半径方向隙間をおいてかつ周方向に周方向隙間をおいて配置されている。すなわち、外側磁性板積層体２０の各々の半径方向内側端２３は、内側磁性板積層体１０の対応する辺１２に対し半径方向隙間をおいて平行に対向するよう配置されると共に周方向に周方向隙間をおいて対向するよう配置される。外側磁性板積層体２０の各々の周方向間に形成される周方向隙間の各々は、半径方向に一定の周方向幅で延在するよう形成されている。半径方向外側端２２の各々は、回転軸２と共通の軸心を有する仮想円周上に位置付けられ、内側磁性板積層体１０の各々の周方向隙間は、内側磁性板積層体１０の角部の各々、したがって面取１５の各々に整合した周方向位置に配置される。
【００４５】
外側磁性板積層体２０の各々の半径方向内側端２３と、内側磁性板積層体１０の対応する辺１２との間の半径方向隙間の各々には、例えばＮｄ−Ｆｅ−Ｂ系の永久磁石３０が挿入されている。永久磁石３０の各々は、細長いほぼ直方体形状に形成されている。永久磁石３０の各々間に形成される周方向隙間の各々及び外側磁性板積層体２０の各々間に形成される周方向隙間の各々は、内側磁性板積層体１０の対応する角部において相互に整合するよう配置されて、角部隙間を形成する。この角部隙間の総計は４個である。該角部隙間の各々には内側磁性板積層体１０の面取１５が対向して位置付けられる。該角部隙間の各々にはまた、半径方向内側に隙間の一部を残して他の永久磁石５０が挿入されている。例えばＮｄ−Ｆｅ−Ｂ系の永久磁石５０は、細長いほぼ直方体形状に形成されている。
【００４６】
内側磁性板積層体１０、永久磁石３０の各々、外側磁性板積層体２０の各々、及び該隙間の一部の各々の軸方向両端面は、溶融可能な非磁性材４０の層により覆われ、そして該隙間の一部の各々は、該非磁性材４０により該層の各々と一体となるよう充填されている。非磁性材４０は、先の実施形態におけると同様にして、回転軸２、内側磁性板積層体１０、永久磁石３０の各々、永久磁石５０の各々及び外側磁性板積層体２０の各々を、外側磁性板積層体２０の各々の半径方向外側端面を除き、実質上一体に鋳ぐるむことができる。内側磁性板積層体１０及び永久磁石３０の各々は、外側磁性板積層体２０の各々及び非磁性材４０の内部に完全に埋設される。内側磁性板積層体１０、永久磁石３０の各々、永久磁石５０の各々、外側磁性板積層体２０の各々、及び該隙間の一部の各々の軸方向両端面を覆う非磁性材４０の層の各々と、該隙間の一部の各々を充填した非磁性材４０の各々とは、ほぼ円柱形状をなす、ロータ１００の本体部１０２を構成する。本体部１０２の軸方向両端面は非磁性材４０により形成され、外周面は、外側磁性板積層体２０の各々の半径方向外側端面２２と、永久磁石５０の各々の半径方向外側端面とにより形成される。
【００４７】
本発明による回転機のロータ１００は、上記したように、内側磁性板積層体１０、永久磁石３０の各々、永久磁石５０の各々、外側磁性板積層体２０の各々及び該隙間の一部の各々の軸方向両端面が、溶融可能な非磁性材４０の層により覆われかつ該隙間の一部の各々は該非磁性材４０により該層の各々と一体となるよう充填されているので、内側磁性板積層体１０、永久磁石３０の各々、永久磁石５０の各々及び外側磁性板積層体２０の各々を非磁性材４０によって、永久磁石５０の各々の半径方向外側端面及び外側磁性板積層体２０の各々の外周面を除き、一体的に鋳ぐるむことを可能にする。非磁性材４０は鋳造により一体に成形することが可能である。このため、従来におけるような、かしめ、溶接、接着等の煩雑な作業が不要となり、従来に比べて組付作業が簡単となり、そして組付作業時間が短縮されると共に労力の負担が軽減され、その結果、生産性の向上及び製造コストの低減を可能にする。更にはまた、従来において軸方向の両端面が外部に露呈されていた永久磁石３０及び５０の各々を含む軸方向の両端面は、非磁性材４０によって完全に覆われるので、発電機又は電動機である回転機に適用した場合、回転機のケースに通風孔を設け、回転軸に配設したファンによりケース内にエアを供給することにより強制冷却を行っても、鉄粉等のダストあるいは水等から永久磁石３０の各々を完全に保護することが可能になる。また永久磁石５０の各々の軸方向両端面側は完全に保護することが可能になる。その結果、回転機の所要の性能及び耐久性を長期にわたって確保することを容易に可能にする。
【００４８】
次に図１２に示された上記ロータ１００の制作方法について説明する。図１２に示された上記ロータ１００の制作方法は、先に述べた制作方法と本質的には同じであり、したがって以下、その概要を説明する。図１３には、図１２を参照して説明したロータ１００を構成する、内側磁性板１１及び内側磁性板積層体１０と、外側磁性板本体２１０及び外側磁性板本体積層体２２０とが、組付及び成形用型３００の円筒部３０２内に挿入された状態で示され、また図１４には、図１２を参照して説明したロータ１００を構成する、内側磁性板１１及び内側磁性板積層体１０、外側磁性板本体２１０及び外側磁性板本体積層体２２０、永久磁石３０の各々、及び永久磁石５０の各々が、組付及び成形用型３００の円筒部３０２内に挿入された状態で示されている。
【００４９】
図１３を参照して、先に述べた、実質上正方形をなす内側磁性板１１は、図示しないプレス機械によって珪素鋼板（平板）を打ち抜き加工することにより形成することができる。先に述べた外側磁性板積層体２０の各々は、成型後のロータ１００として完成された状態においては、先に説明したように、相互に周方向に分離された不連続の独立部材として配列されているが、成形前においては、溶融可能な非磁性材４０が充填される上記隙間の各々の半径方向外端が円弧状の細い橋絡部２１２によって連結されることにより、外周端部全体が連続した円形状をなすよう一体に形成された１枚の外側磁性板本体２１０を積層することにより形成される外側磁性板本体積層体２２０から構成される。そして後述する、成形後の切削加工により、上記のように外側磁性板積層体２０の各々に分離される。
【００５０】
図示しないプレス機械によって珪素鋼板（平板）を打ち抜き加工することにより形成される外側磁性板本体２１０は、円形外周端２１１を有しかつ内側磁性板１１の辺１２と同数である４個の半径方向内側端２３と、内側端２３の各々の周方向端の間に形成されて一端が半径方向内側に開放され他端が上記外周端２１１との間に橋絡部２１２を残して閉じられた溝２１３とからなる貫通孔２１４を有している。内側端２３の各々は、それぞれ直線状に延在し、実質上、正４角形の辺を構成するよう配置され、この正４角形の角部の各々に溝２１３が配置されている。この正４角形の中心、したがって貫通孔２１４の中心は、外側磁性板本体２１０の軸心Ｏと一致するよう位置付けられている。溝２１３の各々の周方向両端は、外側磁性板本体２１０を軸方向に見て、外側磁性板本体２１０の軸心Ｏ及び上記正４角形の図示しない角を通って半径方向に延在する仮想直線Ｌを等間隔に挟んで、軸心Ｏを通り半径方向に平行に延在する２本の仮想直線Ｌ３上に延在するよう形成され、また溝２１３の各々の半径方向外側端は、円形外周端２１１に平行な円弧形状に形成されている。２点鎖線２２で示される円形状部は、先に述べたと同様な切削予定面を表している。永久磁石３０及び５０の各々は直方体形状に形成されている。
【００５１】
上記組付及び成形用型３００の円筒部３０２にセットされた回転軸２に、内側磁性板１１をその取付孔１４を介して挿入しながら積層し、また外側磁性板本体２１０を円筒部３０２に嵌合しながら積層する。これらの積層によって、外側磁性板本体２１０の内側端２３の各々と、内側磁性板１１の対応する辺１２との間に半径方向隙間を、また外側磁性板本体２１０の溝２１３の各々と内側磁性板１１の対応する角部との間に角部隙間２３０を形成して、円筒部３０２内に内側磁性板積層体１０及び外側磁性板本体積層体２２０を形成する。図１３と共に図１４をも参照して、上記半径方向隙間の各々に永久磁石３０を挿入する。永久磁石３０の各々の横断面における長手方向の長さは、内側磁性板１１の対応する辺１２の長さとほぼ同一に規定されている。また角部隙間２３０の各々にそれぞれ半径方向内側に隙間の一部（角部隙間２３０の一部）２３０ａを残して永久磁石５０を挿入する。永久磁石５０の各々の横断面における長手方向の長さは、外側磁性板本体２１０の対応する溝２１３の半径方向長さとほぼ同一に規定されている。以上のとおりにして、内側磁性板積層体１０、外側磁性板本体積層体２２０、永久磁石３０の各々及び永久磁石５０の各々が、組付及び成形用型３００の円筒部３０２内にセットされた後、円筒部３０２の開口端を先の実施形態と同様にして蓋型３０３により閉塞する。次いで、溶融された非磁性材４０を、内側磁性板積層体１０、永久磁石３０の各々、永久磁石５０の各々、外側磁性板本体積層体２２０、及び隙間の一部２３０ａの各々の軸方向両端面を非磁性材４０の層で覆うと共に、隙間の一部２３０ａの各々を該層の各々と一体となるよう充填することにより（鋳込むことにより）、回転軸２、内側磁性板積層体１０、永久磁石３０の各々、永久磁石５０の各々及び外側磁性板本体積層体２２０を、外側磁性板本体積層体２２０の外周面の一部を除き、一体に鋳ぐるむ。離型後、外側磁性板本体積層体２２０及び非磁性材４０の外周端を切削して橋絡部２１２の各々を切除する。以上の方法によって、図１２に示されたロータ１００を製作することができる。その結果、従来におけるような、かしめ、溶接、接着等の煩雑な作業が不要となり、従来に比べて組付作業が簡単となり、そして組付作業時間が短縮されると共に労力の負担が軽減され、その結果、生産性の向上及び製造コストの低減を可能にする。
【００５２】
なお、図１２〜図１４を参照して説明した先に実施形態の各々において、内側磁性板１１及び内側磁性板積層体１０の辺１２の数は、それぞれ４個であるが、各実施形態において、偶数個であれば、４個、あるいは８個以上であっても成立する。内側磁性板１１及び内側磁性板積層体１０の辺１２の数に応じて、外側磁性板本体２１０及び外側磁性板本体積層体２２０の構成、及び、永久磁石３０及び５０の数等が規定されることはいうまでもない。
【００５３】
図１５には、本発明による回転機のロータ１００の他の実施形態を構成する、内側磁性板１１及び外側磁性板本体２１０の更に他の実施形態が示されている。先の実施形態におけると同じ材料から形成されている内側磁性板１１は、それぞれ直線状に延在する８個の辺１２を有しかつ実質上、正８角形状をなすよう形成されている。内側磁性板１１の８個の角部には、それぞれ半径方向内側に延び出す溝１１Ａが形成されている。溝１１Ａの各々における半径方向内側端部の周方向幅は該内側端部よりも半径方向外側領域の周方向幅より広く形成されている。すなわち溝１１Ａの各々は、対応する角部から一定の周方向幅で軸心に向かって延びた後、半径方向内側端部において周方向両側に延び出すよう形成されている。内側磁性板１１の軸心部には、回転軸２が装着される取付穴１４が形成されている。先の実施形態におけると同じ材料から形成されている外側磁性板本体２１０は、円形外周端２１１を有しかつ内側磁性板１１の辺１２と同数である８個の半径方向内側端２３と、内側端２３の各々の周方向端の間に形成されて一端が半径方向内側に開放され他端が上記外周端２１１との間に橋絡部２１２を残して閉じられた溝２１３とからなる貫通孔２１４を有している。内側端２３の各々は、それぞれ直線状に延在し、実質上、正８角形の辺を構成するよう配置され、この正８角形の角部の各々に溝２１３が配置されている。この正８角形の中心、したがって貫通孔２１４の中心は、外側磁性板本体２１０の軸心Ｏと一致するよう位置付けられている。溝２１３の各々における半径方向外側端部の周方向幅は該外側端部よりも半径方向内側領域の周方向幅より広く形成されている。すなわち溝２１３の各々は、対応する角部から一定の周方向幅で半径方向外側に向かって延びた後、半径方向外側端部において周方向両側に延び出すよう形成されている。溝２１３の各々の半径方向外側端は、円形外周端２１１に平行な円弧形状に形成されている。２点鎖線２２で示される円形状部は、先の実施形態におけると同様な切削加工によって切削される切削予定面（切削予定ライン）を表している。この切削代は、少なくとも外側磁性板本体２１０の橋絡部２１２の各々が完全に切除される程度に規定される。
【００５４】
図１６には、図１５に示す内側磁性板１１及び内側磁性板積層体１０、外側磁性板本体２１０及び外側磁性板本体積層体２２０、及び、永久磁石３０の各々が、組付及び成形用型３００の円筒部３０２内に挿入された状態で示されている。永久磁石３０の各々は、内側磁性板積層体１０の辺１２の各々と外側磁性板本体積層体２２０の対応する内側端２３との間の半径方向隙間に挿入される。内側磁性板積層体１０の溝１１Ａの各々と外側磁性板本体積層体２２０の溝２１３の各々とは周方向に整合されて位置付けられ、先の実施形態におけると実質上同じとおりにしてロータ１００が製作される。
【００５５】
図１５及び図１６に示す上記各部材を含むロータ１００において、内側磁性板積層体１０の角部の各々には、半径方向内側に向かって延びる溝１１Ａが形成され、溝１１Ａの各々における半径方向内側端部の周方向幅は該内側端部よりも半径方向外側領域の周方向幅より広く形成され、永久磁石３０の各々間及び外側磁性板積層体２１０の各々間の周方向隙間の各々により形成される角部隙間の各々における半径方向外側端部の周方向幅は該外側端部よりも半径方向内側領域の周方向幅より広く形成され、溝１１Ａの各々により形成される隙間の各々は該角部隙間の各々に整合して該角部隙間の各々の一部を構成する。これらの角部隙間の各々には、先に述べた溶融非磁性材４０が充填されるが、角部隙間の各々に充填された非磁性材４０の半径方向内側端部及び半径方向外側端部は、その間に存在する他の部分よりも周方向幅が広いため、ロータ１００の高速回転時において、先の実施形態におけるよりも、半径方向外側へ飛び出しにくくなり、一層確実に該飛び出しが防止される、とのメリットが得られる。図１５及び図１６に示す上記各部材を含むロータ１００は、図１〜図８を参照して説明した先の実施形態における特徴ある基本的構成を共有するものであり、また製作方法も実質上同じであり、したがって該実施形態におけると実質上同じ作用効果が得られることはいうまでもない。
【００５６】
以上、本発明による回転機のロータの製作方法を、実施形態に基づいて添付図面を参照しながら詳細に説明したが、本発明は上記実施形態に限定されるものではなく、本発明の範囲を逸脱することなく、更に他の種々の変形あるいは修正が可能である。例えば、ＩＰＭと称されているロータには、上記実施形態の他に、種々の形態が存在するが、本発明は、回転軸に装着された内側磁性板積層体と、内側磁性板積層体の実質上半径方向外側に配置された外側磁性板積層体と、少なくとも内側磁性板積層体と外側磁性板積層体との間に挿入された複数の永久磁石と、非磁性材が収容されうる複数の隙間とを備えている形態の回転機のロータであれば、上記実施形態以外の他の形態のロータにも適用することができる。該隙間の各々の一端は、ロータ本体部の軸方向の一端面に開口し、また他端はロータ本体部の軸方向の他端面に開口するよう形成される。該隙間の各々に非磁性材を収容することによって、異極間の磁気ショートを防止する隔壁として機能させられ、種々の配列形態がある。そして本発明の特徴は、内側磁性板積層体、永久磁石の各々、外側磁性板積層体の各々及び該隙間の各々の軸方向両端面が溶融可能な非磁性材の層により覆われかつ該隙間の各々が該非磁性材により該層の各々と一体となるよう充填されている、ことにある。この特徴ある構成により、先に述べた鋳ぐるみを可能にし、したがって、先に述べた種々の作用効果を達成することができるのである。
【００５７】
磁性板４００は、軸心部に形成されかつ軸心Ｏを有する取付孔１４と、軸心Ｏと共通の軸心を有する円形外周端４０２と、軸心Ｏを中心に偶数個の実質上正多角形（実施形態では正８角形）をなすよう形成された半径方向隙間４０４と、半径方向隙間４０４の各々の角部において半径方向に延在するよう形成された半径方向橋絡部（ブリッジ）４０６を周方向に挟んでそれに沿って半径方向に延在するよう形成された一対の周方向隙間４０８とを備えている。半径方向隙間４０４及び周方向隙間４０８の各々は貫通孔から形成される。半径方向隙間４０４の各々は一定の半径方向幅をもって直線状に延在するよう形成されている。周方向隙間４０８の各々は、半径方向隙間４０４の各々よりも半径方向内側から半径方向外側に向かって延在し、各々の半径方向外側端は、円形外周端４０２に平行な円弧形状をなしている。周方向隙間４０８の各々の半径方向外側端と磁性板４００の円形外周端４０２との間には、円弧状に延在する周方向橋絡部４１０が形成される。半径方向橋絡部４０６の各々は一定の周方向幅をもって半径方向に直線状に延在するよう形成され、各々の半径方向外側端は対応する周方向橋絡部４１０に接続される。半径方向橋絡部４０６の各々を周方向に挟むよう配置された周方向隙間４０８の各々の半径方向内側端部の周方向幅及び半径方向外側端部の周方向幅は、半径方向内側端部と半径方向外側端部との間の全中間領域の周方向幅よりも広く形成されている。周方向隙間４０８の各対は、半径方向隙間４０４の各々の角部における角部隙間を構成するので、角部隙間の各々の半径方向内側端部の周方向幅及び半径方向外側端部の周方向幅は、半径方向内側端部と半径方向外側端部との間の全中間領域の周方向幅よりも広く形成されている、といえる。２点鎖線２２で示される円形状部は、先に述べたと実質上同じとおりにして行なわれる切削加工によって切削される切削予定面（切削予定ライン）を表している。この切削代は、少なくとも上記周方向橋絡部４１０の各々が完全に切除される程度に規定される。
【００５８】
【発明の効果】
本発明による回転機の製作方法によれば、従来に比べて組付作業が簡単となり、そして組付作業時間が短縮されると共に労力の負担が軽減され、その結果、生産性の向上及び製造コストの低減を可能にする。また、異極間の磁気ショートを軽減すると共に高速回転時における強度を確保することを容易に可能にする。更にはまた、部品点数を著しく低減し、その結果、生産性の向上及び製造コストの低減を可能にする。更にはまた、回転機の所要の性能及び耐久性を長期にわたって十分に確保することを容易に可能にする。
【００５９】
以上、本発明による回転機のロータ及びその製作方法を、実施形態に基づいて添付図面を参照しながら詳細に説明したが、本発明は上記実施形態に限定されるものではなく、本発明の範囲を逸脱することなく、更に他の種々の変形あるいは修正が可能である。例えば、ＩＰＭと称されているロータには、上記実施形態の他に、種々の形態が存在するが、本発明は、回転軸に装着された内側磁性板積層体と、内側磁性板積層体の実質上半径方向外側に配置された外側磁性板積層体と、少なくとも内側磁性板積層体と外側磁性板積層体との間に挿入された複数の永久磁石と、非磁性材が収容されうる複数の隙間とを備えている形態の回転機のロータであれば、上記実施形態以外の他の形態のロータにも適用することができる。該隙間の各々の一端は、ロータ本体部の軸方向の一端面に開口し、また他端はロータ本体部の軸方向の他端面に開口するよう形成される。該隙間の各々に非磁性材を収容することによって、異極間の磁気ショートを防止する隔壁として機能させられ、種々の配列形態がある。そして本発明の特徴は、内側磁性板積層体、永久磁石の各々、外側磁性板積層体の各々及び該隙間の各々の軸方向両端面が溶融可能な非磁性材の層により覆われかつ該隙間の各々が該非磁性材により該層の各々と一体となるよう充填されている、ことにある。この特徴ある構成により、先に述べた鋳ぐるみを可能にし、したがって、先に述べた種々の作用効果を達成することができるのである。
【００６０】
また、上記実施形態において、内側磁性板１１及び外側磁性板２１、磁性板４００は、電磁鋼板の一実施形態である珪素鋼板から構成されているが、他の軟磁性鋼板（電磁鋼板に対し、保磁力が比較的弱い鋼板）、例えば、ＳＰＣＣ、ＳＰＨＣ、ＳＳ４１Ｐ等の軟磁性鋼板から構成される他の実施形態ももちろん成立する。要するに非磁性材料ではなく、磁性材料（強磁性材料あるいは軟磁性材料のいずれでもよい）から形成された鋼板であれば成立する。更にはまた、上記実施形態においては、非磁性材４０を、アルミニウム、アルミニウム合金、亜鉛合金等の非磁性金属材料により形成しているが、耐熱性を有する高強度合成樹脂等の非金属材料により形成してもよい。なお、非磁性材４０としてアルミニウムを使用する場合には、冷却時の収縮が比較的大きいために、電磁鋼板との間に若干の隙間ができる可能性があるので、含浸剤（接着剤との共用も可）を注入することが好ましい。また溶融可能な非磁性材４０をアルミニウム等、電気抵抗の比較的少ない材料とすることが好ましい。
【００６１】
【発明の効果】
本発明による回転機のロータ及びその製作方法によれば、従来に比べて組付作業が簡単となり、そして組付作業時間が短縮されると共に労力の負担が軽減され、その結果、生産性の向上及び製造コストの低減を可能にする。また、異極間の磁気ショートを軽減すると共に高速回転時における強度を確保することを容易に可能にする。更にはまた、部品点数を著しく低減し、その結果、生産性の向上及び製造コストの低減を可能にする。更にはまた、回転機の所要の性能及び耐久性を長期にわたって十分に確保することを容易に可能にする。
【図面の簡単な説明】
【図１】本発明によるロータの実施形態を半径方向外側から見た図。
【図２】図１に示されるロータを、その軸方向の一端部を覆う非磁性材を除去した状態で示す斜視図。
【図３】図２に示されるロータを軸方向に見た図。
【図４】内側磁性板の平面図。
【図５】外側磁性板の平面図。
【図６】図１に示すロータのための組付及び成形用型及びロータを構成する部材を分解して示す斜視概略図。
【図７】内側磁性板及び外側磁性板が、図６に示される組付及び成形用型の円筒部内に挿入された状態を軸方向に見た図。
【図８】図７において、永久磁石が更に挿入された状態を示す図。
【図９】本発明によるロータの他の実施形態を構成する部材を示す図であって、図８と同様な図。
【図１０】本発明によるロータの更に他の実施形態を構成する部材を示す図であって、図８と同様な図。
【図１１】本発明によるロータの更に他の実施形態を構成する部材を示す図であって、図８と同様な図。
【図１２】本発明によるロータの更に他の実施形態を示す斜視図であって、図２と同様な斜視図。
【図１３】図１２に示すロータに含まれる内側磁性板及び外側磁性板が、図６に示される組付及び成形用型の円筒部内に挿入された状態を軸方向に見た図。
【図１４】図１３において、永久磁石が更に挿入された状態を示す図。
【図１５】本発明によるロータの更に他の実施形態を構成する内側磁性板及び外側磁性板を同軸上に配置して軸方向に見た図。
【図１６】図１５に示す内側磁性板及び外側磁性板が、図６に示される組付及び成形用型の円筒部内に挿入された状態を軸方向に見た図。
【図１７】本発明によるロータの更に他の実施形態を構成する一体構造の磁性板を軸方向に見た図。
【図１８】図１７に示す磁性板が、図６に示される組付及び成形用型の円筒部内に挿入された状態を軸方向に見た図。
【符号の説明】
２ 回転軸
１０ 内側磁性板積層体
１１ 内側磁性板
１２ 辺
１３ 突起
２０ 外側磁性板積層体
２２ 切削予定面
２１ 外側磁性板
３０、５０ 永久磁石
４０ 非磁性材
１００ ロータ
２１０ 外側磁性板本体
２１２ 橋絡部
２２０ 外側磁性板本体積層体
２３０ 角部隙間
２３０ａ 残された隙間の一部
４００ 磁性板
４０４ 半径方向隙間
４０６ 半径方向橋絡部
４０８ 周方向隙間
４１０ 周方向橋絡部
４２０ 磁性板積層体[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a rotor of a rotating machine that is a generator or an electric motor. More specifically, the rotor is inserted between an inner magnetic plate laminate on which a rotating shaft is mounted, and at least the inner magnetic plate laminate and the outer magnetic plate laminate. A plurality of permanent magnets and a plurality of gaps in which a nonmagnetic material can be accommodated. Manufacturing method of rotor of rotating machine About.
[0002]
[Prior art]
A first typical example of the rotor of the above form, which is generally called IPM (Interrer Permanent Magnet), has a magnetic plate laminate formed by laminating electromagnetic steel plates. The magnetic plate laminate has a substantially cylindrical shape, and a through hole is formed at the center thereof. The magnetic plate laminate is formed with six identical through-holes having a rectangular cross-section and arranged in a substantially hexagonal shape at intervals in the circumferential direction. In a circumferential position corresponding to each of the six through holes of the magnetic plate laminate, a meat portion between each of the six through holes is formed radially inward from the outer peripheral surface of the magnetic plate laminate. Notches extending so as to divide into two in the circumferential direction are formed (the total number of notches is six). A rotation shaft is integrally attached to the central through hole, and a permanent magnet is inserted into each of the six through holes.
[0003]
The 2nd typical example of the rotor of the said form has a magnetic board laminated body formed by laminating | stacking an electromagnetic steel plate. The magnetic plate laminate has a substantially cylindrical shape, and a through hole is formed at the center thereof. In the magnetic plate laminate, four identical through-holes having a rectangular shape with a long cross section are formed so as to form a substantially square shape at intervals in the circumferential direction. In the circumferential position corresponding to each of the four through-holes of the magnetic plate laminate, each of the four through-holes is spaced radially outward from the mutually adjacent ends. A pair of through-holes extending to the vicinity of the radially outer end of the magnetic plate laminate is formed (a total of four pairs of through-holes are formed). A rotation shaft is integrally attached to the central through hole, and a permanent magnet is inserted into each of the four through holes. A nonmagnetic member made of austenitic stainless steel or the like is inserted into each of the four pairs of through holes.
[0004]
The 3rd typical example of the rotor of the said form has an inner side magnetic board laminated body formed by laminating | stacking an electromagnetic steel plate. The inner magnetic plate laminate has four sides that are substantially square when viewed in the axial direction, and chamfers are formed at the four corners. A through hole is formed at the center of the inner magnetic plate laminate. Four outer magnetic plate laminates are arranged on the outer side in the radial direction of the inner magnetic plate laminate. Each of the outer magnetic plate laminates has a radially inner end arranged with a radial gap on the radially outer side of each of the sides of the inner magnetic plate laminate, and is arranged with a circumferential gap therebetween. ing. Four permanent magnets are inserted into each of the radial gaps with a circumferential gap. Each of the circumferential gaps between each of the permanent magnets and each of the outer magnetic plate laminates is arranged to be aligned with each other at the corresponding corners of the inner magnetic plate laminate to form a corner gap. . A permanent magnet is inserted into each of the corner gaps leaving a gap on the radially inner side. A nonmagnetic member made of austenitic stainless steel or the like is inserted into each of the remaining gaps.
[0005]
[Problems to be solved by the invention]
Of the conventional rotors configured as described above, the first and second typical examples are generally laminated with electromagnetic steel sheets being fitted to the rotating shaft one by one and bonded to each other, Next, the outer peripheral portion is caulked or welded to form a magnetic plate laminate integrated with the rotating shaft, and then the permanent magnet is inserted into the corresponding through hole via an adhesive. Therefore, the assembling work is complicated, requiring a lot of assembling work time and a lot of labor, and the productivity is poor. Also, the production cost becomes high.
[0006]
In order to minimize magnetic short-circuits (magnetic leakage), as described above, in the first typical example, the outer peripheral portion of the electromagnetic steel plate corresponding to each of the permanent magnets, and hence the outer periphery of the magnetic plate laminate. By forming six notches in the part, the magnetism between the different poles was cut off. However, if these notches are excessively small, the surplus of the part of the magnetic steel sheet, and thus the magnetic plate laminate (formed between each notch and the circumferential end of the permanent magnet adjacent in the circumferential direction) (Circumferential thickness) becomes excessively large, resulting in an increase in magnetic shorts and a decrease in performance. If the notch is excessively large, the surplus portion of the magnetic steel sheet, and therefore the portion of the magnetic plate laminate, becomes excessively small, and the strength at the time of high-speed rotation may be insufficient. Therefore, it was difficult to design to satisfy both. In the second typical example, due to the insertion of four pairs of non-magnetic members, the number of parts is increased as compared to the first typical example, the productivity is further reduced, and the production cost is further increased. Get higher.
[0007]
On the other hand, in the third typical example, for the same reason as in the first and second typical examples, the assembling work is complicated, requires a lot of assembling work time and much labor, and is poor in productivity. In the third typical example, as compared with the first typical example, the number of permanent magnets is increased and a nonmagnetic member is added, resulting in an increase in the number of parts and a further decrease in productivity. In addition, the production cost increases. Furthermore, due to the fact that the electromagnetic steel sheet is divided into four parts from the beginning, the assembling work becomes more complicated, the productivity is further reduced, and the production cost is further increased.
[0008]
The present invention has been made on the basis of the above facts, and its purpose is to make assembly work easier than in the past, and to reduce the burden of labor while reducing the assembly work time, resulting in production. New, enabling improved productivity and reduced manufacturing costs Manufacturing method of rotor of rotating machine Is to provide.
[0009]
Another object of the present invention is to reduce the magnetic short between different poles and to make it easy to ensure the strength at high speed rotation. Manufacturing method of rotor of rotating machine Is to provide.
[0010]
Yet another object of the present invention is to provide a novel device that significantly reduces the number of parts, thereby improving productivity and reducing manufacturing costs. Manufacturing method of rotor of rotating machine Is to provide.
[0011]
Still another object of the present invention is to provide a novel machine that can easily ensure sufficient performance and durability of a rotating machine over a long period of time. Manufacturing method of rotor of rotating machine Is to provide.
[0012]
Other objects and features of the invention were constructed in accordance with the invention. Manufacturing method of rotor of rotating machine These embodiments will be apparent from the following description with reference to the accompanying drawings.
[0016]
[Means for Solving the Problems]
Aspects of the invention In accordance with the present invention, the rotation shaft is set in accordance with the axis of the mold having the cylindrical portion, the mounting hole is formed in the axial center portion, and the substantially inner polygonal magnetic plate having an even number of sides is attached to the mounting hole. And is laminated between the circular outer peripheral end, the same number of radial inner ends as the sides, and the circumferential end of each of the inner ends, and one end is opened radially inward. And laminating an outer magnetic plate body comprising a through hole having a closed groove with the other end being closed with a bridging portion between the outer end and the inner end. A radial gap between each of the grooves and the corresponding side, and a corner gap between each of the grooves and the corresponding corner of the inner magnetic plate, thereby forming an inner magnetic plate in the cylindrical portion. A laminated body and an outer magnetic plate main body laminated body were formed, a permanent magnet was inserted into each of the radial gaps, and then melted A magnetic material is cast, and both end surfaces in the axial direction of each of the inner magnetic plate laminate, the permanent magnet, the outer magnetic plate main body laminate, and the corner gap are covered with the nonmagnetic material layer, and the corner portions are covered. Each of the gaps is filled so as to be integrated with each of the layers, and after release, the outer magnetic plate main body laminate and the outer peripheral edge of the nonmagnetic material are cut to cut off each of the bridging portions. A method for producing a rotor of a rotating machine is provided.
[0017]
According to still another aspect of the present invention, a rotating shaft is set in accordance with the axis of a mold having a cylindrical part, a mounting hole is formed in the axis and a substantially polygonal shape having an even number of sides. The inner magnetic plate is laminated while being inserted into the rotation shaft through the mounting hole, and is formed between the circular outer peripheral end, the same number of radially inner ends as the sides, and the circumferential ends of the inner ends. Laminating an outer magnetic plate body having a through hole having a groove with one end opened radially inward and the other end closed with a bridging portion between the outer peripheral end and fitting to the cylindrical portion Forming a radial gap between each of the inner ends and the corresponding side, and forming a corner gap between each of the grooves and a corresponding corner of the inner magnetic plate, An inner magnetic plate laminate and an outer magnetic plate body laminate are formed in the cylindrical portion, and permanent magnets are inserted into each of the radial gaps. And after inserting a permanent magnet leaving a part of the gap radially inside each of the corner gaps, casting a molten nonmagnetic material, each of the inner magnetic plate laminate and the permanent magnets, The outer magnetic plate main body laminate, and both axial ends of each part of the gap are covered with the nonmagnetic material layer, and each part of the gap is filled with each of the layers, After mold release, the outer peripheral edge of the outer magnetic plate main body laminate and the non-magnetic material are cut to cut off each of the bridging portions.
A method for producing a rotor of a rotating machine is provided.
[0018]
According to still another aspect of the present invention, the rotation shaft is set in accordance with the axis of the molding die having the cylindrical portion, the mounting hole formed in the shaft center, the circular outer peripheral end, and the even number of substantially A radial gap formed so as to form a regular polygon, and a radial bridge formed so as to extend in the radial direction at each corner of the radial gap in the circumferential direction along the circumferential direction. A magnetic plate having a pair of circumferential gaps formed so as to extend and forming a circumferential bridging portion between the circular outer circumferential end and the circular outer circumference while being inserted into the rotating shaft through the mounting hole A magnetic plate laminate is formed by laminating while fitting the end to the cylindrical portion, and after inserting a permanent magnet into each of the radial gaps, a molten nonmagnetic material is cast, The body, the permanent magnet, and the circumferential end of each axial end surface of the non-magnetic material Each of the circumferential bridges is filled with each of the circumferential gap pairs so as to be integrated with each of the layers, and after release, each of the circumferential bridge portions is cut by cutting the outer peripheral ends of the magnetic plate laminate and the nonmagnetic material. Excise the,
A method for producing a rotor of a rotating machine is provided.
[0019]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, preferred embodiments of the present invention will be described in more detail with reference to the accompanying drawings. Referring to FIGS. 1 to 3, a rotor 100 applied to a rotating machine that is a generator or an electric motor includes an inner magnetic plate laminate 10 on which a rotating shaft 2 is mounted, and a plurality of (in the embodiment, six). The outer magnetic plate laminate 20, a plurality of (six in the embodiment) permanent magnets 30, and a nonmagnetic material 40 that can be melted.
[0020]
Hereinafter, the configuration (completed configuration) of the rotor 100 according to the present invention will be specifically described. The inner magnetic plate laminate 10 is configured by laminating a plurality of inner magnetic plates 11 having substantially the same configuration. The inner magnetic plate 11 is made of an electromagnetic steel plate, in the embodiment, a silicon steel plate, and has an even number of sides 12 each extending in a straight line shape and is substantially formed in a regular polygonal shape. In the embodiment, the inner magnetic plate 11 has six sides 12 and is substantially formed in a regular hexagonal shape. Protrusions 13 extending outward in the radial direction are formed at the six corners of the inner magnetic plate 11. A mounting hole 14 in which the rotary shaft 2 is mounted is formed in the axial center portion of the inner magnetic plate 11. The inner magnetic plate laminate 10 is configured by laminating a plurality of inner magnetic plates 11 configured as described above, and the rotating shaft 2 is fitted and mounted in the mounting hole 14 of the inner magnetic plate laminate 10. Yes.
[0021]
Each of the even number (six in the embodiment) of outer magnetic plate laminates 20 having substantially the same configuration is formed by stacking a plurality of outer magnetic plates 21 having substantially the same configuration. It is comprised by. The outer magnetic plate 21 is made of an electromagnetic steel plate, in the embodiment, a silicon steel plate, and has a radially outer end 22 having an arc shape, a radially inner end 23 extending linearly, and both circumferential ends 24. is doing. The outer magnetic plate laminate 20 is formed by laminating a plurality of outer magnetic plates 21 configured as described above. Each of the outer magnetic plate laminates 20 is disposed with a radial gap substantially radially outward of the inner magnetic laminate 10 and with a circumferential gap in the circumferential direction. That is, the radially inner end 23 of each of the outer magnetic plate laminates 20 is disposed so as to face the corresponding side 12 of the inner magnetic plate laminate 10 in parallel with a radial gap and is circumferentially circumferential. They are arranged to face each other with a directional gap. Each of the radially outer ends 22 is positioned on a virtual circumference having a common axis with the rotary shaft 2, and each circumferential gap of the inner magnetic plate laminate 10 is between each circumferential end 24. It is formed and arranged at a circumferential position aligned with each of the corners of the inner magnetic plate laminate 10 and thus with each of the protrusions 13.
[0022]
In each of the radial gaps between the radially inner end 23 of each of the outer magnetic plate laminates 20 and the corresponding side 12 of the inner magnetic plate laminate 10, for example, an Nd—Fe—B permanent magnet 30 is provided. Has been inserted. Each of the permanent magnets 30 is formed in an elongated and substantially rectangular parallelepiped shape. Each of the circumferential gaps formed between each of the permanent magnets 30 and each of the circumferential gaps formed between each of the outer magnetic plate laminates 20 are mutually connected at corresponding corners of the inner magnetic plate laminate 10. Arranged to align to form a corner gap. The total number of corner clearances is six. A protrusion 13 of the inner magnetic plate laminate 10 is positioned in each of the corner gaps. The radially outer end of the protrusion 13 is positioned radially inward from the radially outer end at the circumferential end of the permanent magnet 30 that faces each other in the circumferential direction. Each of the permanent magnets 30 is formed such that the magnetic poles are directed in the radial direction, and the magnetic poles on the outer side in the radial direction are different from each other between the permanent magnets 30 adjacent to each other in the circumferential direction. The magnetic poles on the inner side in the direction are arranged so as to have different polarities.
[0023]
Each of the inner magnetic plate laminate 10, the permanent magnet 30, each of the outer magnetic plate laminate 20, and each axial end face of each of the corner gaps is covered with a layer of meltable nonmagnetic material 40, and Each of the corner gaps is filled with the nonmagnetic material 40 so as to be integrated with each of the layers. The nonmagnetic material 40 is made of a nonmagnetic material such as aluminum, an aluminum alloy, or a zinc alloy. As will be described later, the nonmagnetic material 40 is formed by die-casting the rotary shaft 2, the inner magnetic plate laminate 10, each of the permanent magnets 30, and each of the outer magnetic plate laminate 20 and each of the outer magnetic plate laminate 20. Except for the radially outer end face, it can be cast in one piece. Each of the inner magnetic plate laminate 10 and the permanent magnet 30 is completely embedded in each of the outer magnetic plate laminate 20 and the nonmagnetic material 40. Each of the inner magnetic plate laminate 10, the permanent magnet 30, each of the outer magnetic plate laminate 20, each of the layers of the non-magnetic material 40 covering each axial end surface of each of the corner gaps, and each of the corner gaps Each of the nonmagnetic materials 40 filled with each of the first and second non-magnetic members 40 constitutes a main body 102 of the rotor 100 having a substantially cylindrical shape. Both end surfaces in the axial direction of the main body portion 102 are formed of the nonmagnetic material 40, and the outer peripheral surfaces thereof are the outer end surfaces in the radial direction of the outer magnetic plate laminate 20 and the nonmagnetic materials 40 filled in the corner gaps. And an outer end surface in the radial direction.
[0024]
As described above, the rotor 100 of the rotating machine according to the present invention melts the axial end surfaces of each of the inner magnetic plate laminate 10, the permanent magnet 30, each of the outer magnetic plate laminate 20, and each of the corner gaps. Since each of the corner gaps is covered with the nonmagnetic material 40 so as to be integrated with each of the layers, the inner magnetic plate laminate 10 and the permanent magnet 30 are covered with a possible nonmagnetic material 40 layer. Each of the outer magnetic plate laminate 20 and the outer magnetic plate laminate 20 can be integrally cast with the nonmagnetic material 40 except for the outer peripheral surface of each of the outer magnetic plate laminates 20. The nonmagnetic material 40 can be integrally formed by casting. This eliminates the need for troublesome work such as caulking, welding, and bonding as in the prior art, makes the assembly work easier than before, reduces the work time and reduces the burden of labor, As a result, productivity can be improved and manufacturing costs can be reduced. Further, the notch is not required as in the conventional rotor, and the notch portion is filled with the nonmagnetic material 40, so it is easy to reduce the magnetic short between the different poles and ensure the strength at high speed rotation. Is what makes it possible. Furthermore, since each of the permanent magnets 30 is completely covered (embedded) with each of the outer magnetic plate laminate 20 and the non-magnetic material 40, when applied to a rotating machine that is a generator or an electric motor, Ventilation holes are provided in the case of the rotating machine, and even if forced cooling is performed by supplying air into the case by a fan arranged on the rotating shaft, each of the permanent magnets 30 is completely removed from dust such as iron powder or water. It becomes possible to protect. As a result, the required performance and durability of the rotating machine can be easily ensured over a long period of time.
[0025]
In the rotor 100, the corners of the inner magnetic plate laminate 10 are formed with projections 13 extending toward the corner gaps corresponding to the radially outer sides, and each of the projections 13 corresponds. Since the corner portions are positioned between the circumferential ends of the permanent magnets 30 facing each other in the circumferential direction, the strength at the time of high-speed rotation can be improved. In practice, there may be other embodiments in which each of the protrusions 13 is not formed as long as the strength during high-speed rotation can be ensured.
[0026]
Next, a method for producing the rotor 100 will be described. Referring to FIG. 4, the inner magnetic plate 11 described above can be formed by punching a silicon steel plate (flat plate) with a press machine (not shown). The circumferential ends of each of the protrusions 13 are, for example, an imaginary straight line L extending in the radial direction through the axial center O of the mounting hole 14 and a corner (not shown) of the regular hexagon when the inner magnetic plate 11 is viewed in the axial direction. It is formed so as to extend on two imaginary straight lines L1 extending in the radial direction through the axis O and sandwiched at an angle. Accordingly, both ends in the circumferential direction of the protrusion 13 are inclined so that the circumferential width is widened toward the outer side in the radial direction at a symmetrical position in the circumferential direction with respect to the virtual straight line L. Further, the radially outer end of each of the protrusions 13 is formed so as to be orthogonal to the virtual straight line L (that is, to extend in the tangential direction).
[0027]
Each of the outer magnetic plate laminates 20 described above is arranged as discontinuous independent members separated from each other in the circumferential direction, as described above, in a state where the rotor 100 is completed as a molded rotor 100. However, before molding, the outer peripheral end portions of the corner gaps filled with the meltable non-magnetic material 40 are connected to each other by the arc-shaped thin bridging portions 212. The outer magnetic plate main body laminate 220 (see FIGS. 7 and 8) formed by laminating one outer magnetic plate main body 210 integrally formed so as to form a continuous circular shape as a whole. And it isolate | separates into each of the outer side magnetic board laminated body 20 as mentioned above by the cutting process after shaping | molding mentioned later.
[0028]
Referring to FIG. 5, outer magnetic plate main body 210 formed by punching a silicon steel plate (flat plate) by a press machine (not shown) has circular outer peripheral end 211 and the same number as side 12 of inner magnetic plate 11. Is formed between an even number (six in the embodiment) of radial inner ends 23 and the circumferential ends of each of the inner ends 23, one end being opened radially inward and the other end being the outer circumferential end. A through hole 214 including a groove 213 which is closed while leaving a bridging portion 212 is provided. Each of the inner ends 23 extends linearly and is arranged so as to substantially form a regular hexagonal side, and a groove 213 is disposed in each of the regular hexagonal corners. The center of this regular hexagon, and hence the center of the through hole 214 is positioned so as to coincide with the axis O of the outer magnetic plate main body 210. Both ends in the circumferential direction of the groove 213 are virtual extending in the radial direction through the axial center O of the outer magnetic plate main body 210 and the regular hexagon (not shown) when the outer magnetic plate main body 210 is viewed in the axial direction. The straight line L is formed at an equal angle so as to extend on two virtual straight lines L1 extending in the radial direction through the axis O, and each radial outer end of the groove 213 has a circular outer peripheral end. It is formed in an arc shape parallel to 211. Each of these straight lines L and L1 coincides with each of the straight lines L and L1 in the inner magnetic plate 11 in a state where the axis O of the outer magnetic plate main body 210 is positioned on the axial center of the inner magnetic plate 11. It is prescribed to do. A circular portion indicated by a two-dot chain line 22 represents a planned cutting surface (scheduled cutting line) to be cut by a cutting process described later. This cutting allowance is defined such that at least each of the bridging portions 212 of the outer magnetic plate main body 210 is completely removed.
[0029]
FIG. 6 schematically shows the structure of the assembly of the rotor 100 and the molding die 300. The assembly and molding die 300 includes a cylindrical portion 302 having a bottom wall 301 at the lower end, and a lid die 303 that can detachably close the opening end of the cylindrical portion 302. A cap-shaped gap setting member 304 is inserted into the upper surface of the bottom wall 301 in the cylindrical portion 302. A through hole (not shown) into which the rotary shaft 2 is fitted and a pouring port for pouring the molten nonmagnetic material 40 are formed in the shaft center portion of the bottom wall 301. A through hole 305 into which the rotary shaft 2 is fitted is formed in the axial center portion of the lid mold 303. The gap setting member 304 is made of the same material as the meltable nonmagnetic material 40 to be cast as described later, and six through holes 306 are spaced apart in the circumferential direction on the top wall portion. Is formed.
[0030]
6 to 8, in the assembly and molding die 300 configured as described above, the rotary shaft 2 that is a part of the rotor 100 is fitted into a through hole (not shown) of the bottom wall 301. As a result, it is set according to the axis of the assembly and molding die 300. The upper end portion of the rotary shaft 2 protrudes upward beyond the opening end of the cylindrical portion 302, and the lower end portion protrudes downward from the bottom wall 301. Next, the inner magnetic plate 11 is inserted into the cylindrical portion 302 while being inserted into the rotating shaft 2 through the mounting hole 14, and an appropriate number of layers are stacked on the upper surface of the gap setting member 304. This stacking operation can be performed easily and reliably by simply inserting the inner magnetic plate 11 into the rotating shaft 2 and stacking them. Thereafter, an appropriate number of the outer magnetic plate main bodies 210 are stacked on the upper surface of the gap setting member 304 while being fitted to the inner peripheral surface of the cylindrical portion 302. This stacking operation can be easily and reliably performed simply by inserting the outer magnetic plate main body 210 along the inner peripheral surface of the cylindrical portion 302 and stacking them. The outer magnetic plate main body 210 is arranged such that the through-hole 214 covers the entire radially outer side of the inner magnetic plate 11 from the radially outer side, and each of the inner ends 23 is radial with respect to the corresponding side 12 of the inner magnetic plate 11. Oppositely in parallel with a radial gap on the outside, the circumferential position of each of the grooves 213 and the corresponding corner (projection 13) of the inner magnetic plate 11 are aligned, and the corner is radially outward of the corner. It arrange | positions so that the part gap 230 may be formed. Needless to say, the inner magnetic plate 11 and the outer magnetic plate main body 210 are formed in advance in shapes and sizes that enable the above arrangement. Forming the outer diameter of the outer magnetic plate main body 210 to be substantially the same (slightly smaller) as the inner diameter of the cylindrical portion 302 is preferable for preventing backlash. In this embodiment, the order is defined so that a plurality of outer magnetic plate bodies 210 are stacked radially outside the inner magnetic plate 11 after a plurality of inner magnetic plates 11 are stacked. Even in the order of By laminating the inner magnetic plate 11 and the outer magnetic plate body 210 a plurality of times, the inner magnetic plate laminate 10 and the outer magnetic plate body laminate 220 having a predetermined axial thickness are formed in the cylindrical portion 302. To do.
[0031]
Next, the permanent magnets 30 are inserted into the radial gaps between each of the sides 12 of the inner magnetic plate laminate 10 and the corresponding inner end 23 of the outer magnetic plate main body laminate 220 (see FIG. 8). Each of the permanent magnets 30 is inserted in close contact with the corresponding gap. As described above, both ends in the circumferential direction of the protrusion 13 in each of the inner magnetic plates 11 are inclined so that the circumferential width is widened toward the outer side in the radial direction. Since both ends are positioned so as to be substantially in close contact with the inclined surface at the circumferential end of the corresponding protrusion 13, the both ends are formed to have an inclination corresponding to the inclination. Therefore, each transverse section of the permanent magnet 30 has a substantially trapezoidal shape. The axial lengths of the permanent magnets 30 are formed so as to substantially match the axial thicknesses of the inner magnetic plate laminate 10 and the outer magnetic plate body laminate 220. Since the permanent magnets 30 are respectively inserted into the radial gaps between the sides 12 of the inner magnetic plate laminate 10 and the corresponding inner ends 23 of the outer magnetic plate main body laminate 220, the inner magnetic plate laminate 10 Between each of the radially outer end faces of the projections 13 present at the corners of each of the protrusions 13, each of the end faces facing each other in the circumferential direction of the permanent magnet 30, and the corresponding groove 213 of the outer magnetic plate main body laminate 220. Finally, each corner gap 230 (see FIG. 8) is formed. The total number of corner gaps 230 is six. Each of the corner gaps 230 has a substantially trapezoidal shape when viewed in the axial direction. The radially outer end of each of the protrusions 13 in each of the inner magnetic plates 11 is positioned radially inward from the radially outer end of the circumferential ends of the permanent magnets 30 facing each other in the circumferential direction. Each of the corner gaps 230 is inserted into each of the six through holes 306 formed on the top wall of the gap setting member 304 set on the upper surface of the bottom wall 301 of the assembly and molding die 300. It is positioned at the corresponding position.
[0032]
As described above, after each of the inner magnetic plate laminate 10, the outer magnetic plate main body laminate 220, and the permanent magnet 30 is set in the cylindrical portion 302 of the assembly and molding die 300, the cylindrical portion 302 The open end is closed by the lid mold 303. Between the lid mold 303 and each of the inner magnetic plate laminate 10, the permanent magnet 30, and the axial upper end surface (substantially on the same surface) of the outer magnetic plate main body laminate 220, a predetermined axial gap is provided. Is provided. This axial gap is a gap between each of the inner magnetic plate laminate 10, the permanent magnet 30, and the lower end surface (substantially on the same plane) of the outer magnetic plate main body laminate 220 and the bottom wall 301. It is defined to be substantially the same as the axial clearance set by the setting member 304. Next, the axially opposite end surfaces of the melted nonmagnetic material 40 of each of the inner magnetic plate laminate 10, the permanent magnet 30, the outer magnetic plate main body laminate 220, and the corner gap 230 are attached to the nonmagnetic material 40. By covering each of the corner gaps 230 so as to be integrated with each of the layers (by casting), the rotating shaft 2, the inner magnetic plate laminate 10, each of the permanent magnets 30, and the outer side are covered. The magnetic plate main body laminate 220 is cast integrally except for a part of the outer peripheral surface of the outer magnetic plate main body laminate 220.
[0033]
More specifically, the molten nonmagnetic material 40 is poured from a pouring port (not shown) formed on the bottom wall 301 of the assembly and molding die 300. The melted nonmagnetic material 40 includes an axial gap between the bottom wall 301 and the gap setting member 304, each of the through holes 306 of the gap setting member 304, each of the corner gaps 230, and the lid mold 303. The axial gaps between the inner magnetic plate laminate 10, the permanent magnets 30, and the axial upper end surface of the outer magnetic plate main body laminate 220 are caused to flow in the order described above, and each of them is filled. The lid mold 303 is provided with appropriate air venting means, but the details are omitted. The molten nonmagnetic material 40 filled in the assembly and molding die 300 is pressed by a known pressurizing means to perform die casting. The gap setting member 304 is substantially cast integrally with the melted nonmagnetic material 40. Since the gap setting member 304 is made of the same material as the melted nonmagnetic material 40, there is no problem. The intermediate product of the rotor 100 molded by substantially casting with the nonmagnetic material 40 thus melted is taken out from the assembly and molding die 300 after a predetermined time (released). After cooling, the outer peripheral surfaces of the outer magnetic plate main body laminate 220 and the nonmagnetic material 40 layers on both sides in the axial direction are cut around the axis of the rotary shaft 2 to bridge the outer magnetic plate main body laminate 220. Each tangle 212 is excised.
[0034]
By the cutting process, the nonmagnetic material 40 filled in each of the corner gaps 230 on the radially inner side of each bridging portion 212 and covered at the outer side in the radial direction by each bridging portion 212 at the beginning of molding. Each will be exposed to the outer peripheral surface. Further, the outer magnetic plate main body laminate 220 constituted by the outer magnetic plate main body 210 laminate is formed into six outer magnetic plate laminates 20 separated from each other in the circumferential direction by the cutting process. The radially outer end surfaces of the outer magnetic plate laminate 20, the nonmagnetic material 40 filled in each of the corner gaps 230, and the layers of the nonmagnetic material 40 on both axial sides are substantially circular outer circumferences. Positioned on the surface 22, the circular outer peripheral surface 22 will be formed from a cutting surface. This cutting surface defines the radially outer end (outer end surface) 22 of each of the discontinuous independent outer magnetic plate laminates 20 shown in FIG. Next, if necessary, both axial side surfaces of the intermediate product of the rotor 100 are cut. Next, the rotor 100 becomes a finished product by balancing the rotation of the rotor 100.
[0035]
According to the method for manufacturing the rotor 100 according to the present invention, the inner magnetic plate 11 is laminated on the rotating shaft 2 set in the cylindrical portion 302 of the assembly and molding die 300 while being inserted through the mounting hole 14. Further, the outer magnetic plate main body 210 is laminated while being fitted to the cylindrical portion 302, and a radial gap is formed between each of the inner ends 23 of the outer magnetic plate main body 210 and the corresponding side 12 of the inner magnetic plate 11, or A corner gap 230 is formed between each of the grooves 213 of the outer magnetic plate main body 210 and a corresponding corner of the inner magnetic plate 11, and the inner magnetic plate laminate 20 and the outer magnetic plate main body laminate are formed in the cylindrical portion 302. After forming the body 220 and inserting the plurality of permanent magnets 30 into each of the radial gaps, the melted non-magnetic material 40 is replaced with the inner magnetic plate laminate 20, the permanent magnet 30, and the outer magnetic plate body laminate. 220 and corner gap 230 By covering each end face in the axial direction with a layer of nonmagnetic material 40 and filling each corner gap 230 so as to be integral with each of the layers (by casting), the rotary shaft 2 and the inner magnetism Each of the plate laminate 10, the permanent magnets 30, and the outer magnetic plate main body laminate 220 is integrally cast except for a part of the outer peripheral surface of the outer magnetic plate main body laminate 220, and after release, the outer magnetic plate main body laminate is laminated. The rotor 100 can be manufactured by cutting the outer peripheral ends of the body 220 and the nonmagnetic material 40 and cutting each of the bridging portions 212 of the outer magnetic plate main body 210. As a result, troublesome work such as caulking, welding, and bonding as in the past is unnecessary, the assembling work is simpler than before, the assembling work time is shortened and the burden of labor is reduced, As a result, productivity can be improved and manufacturing costs can be reduced.
[0036]
The inner magnetic plate 11 is stacked on the rotating shaft 2 while being inserted through the mounting hole, and the outer magnetic plate main body 210 is stacked while being fitted to the inner peripheral surface of the cylindrical portion 302. Since the inner magnetic plate laminate 20 and the outer magnetic plate main body laminate 220 can be formed, the assembling work is facilitated, the assembling work time is shortened, and the burden of labor is reduced. In particular, each of the outer magnetic plates 21 separated from each other when the rotor 100 is completed is integrally formed as the outer magnetic plate body 210 at the time of assembly, so that the number of parts is reduced and the assembly work is performed as described above. Is facilitated. Further, the inner magnetic plate laminate 10 and the outer magnetic plate main body laminate 220 are formed in the cylindrical portion 302, each of the permanent magnets 30 is assembled, and then each member is cast by non-magnetic material 40 to form a rotor. Since 100 intermediate products can be formed, the manufacturing is totally facilitated, the manufacturing time is shortened, and the burden of labor is reduced.
[0037]
Further, the notch is not required as in the conventional rotor, and the notch portion is filled with the nonmagnetic material 40. Therefore, the rotor 100 that can reduce the magnetic short between the different poles and can ensure the strength at the time of high speed rotation. Can be produced. Furthermore, since the rotor 100 in which each of the permanent magnets 30 is completely covered with each of the outer magnetic plate laminates 20 and the nonmagnetic material 40 can be manufactured, the rotor 100 can be a generator or a motor. Even if forcible cooling is performed by supplying air into the case by a fan provided on the rotating shaft and supplying air into the case, the permanent magnet can be made from dust such as iron powder or water. Each of 30 can be fully protected. As a result, it is possible to easily ensure the required performance and durability of the rotating machine for a long period of time.
[0038]
In FIG. 9, the inner magnetic plate 11 and the inner magnetic plate laminate 10, the outer magnetic plate main body 210 and the outer magnetic plate main laminate 220, which constitute another embodiment of the rotor 100 of the rotating machine according to the present invention, Other embodiments of each of the permanent magnets 30 are shown inserted into the cylindrical portion 302 of the assembly and molding die 300. The circumferential ends of each of the protrusions 13 on the inner magnetic plate 11 extend in the radial direction through the axial center O of the mounting hole 14 and corners (not shown) of the regular hexagon when the inner magnetic plate 11 is viewed in the axial direction. The virtual straight lines L are formed so as to extend on two virtual straight lines L2 sandwiching the virtual straight lines L at equal intervals and extending parallel to the radial direction. Accordingly, both circumferential ends of the protrusions 13 extend linearly in parallel to the outer side in the radial direction at symmetrical positions in the circumferential direction with respect to the virtual straight line L. Other configurations of the inner magnetic plate 11 and the inner magnetic plate laminate 10 are substantially the same as the inner magnetic plate 11 and the inner magnetic plate laminate 10 in the previous embodiment described with reference to FIGS. Further, the circumferential ends of each of the grooves 213 in the outer magnetic plate main body 210 shown in FIG. 9 show the axial center O of the outer magnetic plate main body 210 and the regular hexagon when the outer magnetic plate main body 210 is viewed in the axial direction. It is formed so as to extend on two virtual straight lines L2 extending in parallel to the radial direction through the axis O with the virtual straight lines L extending in the radial direction passing through the corners at equal intervals. Each of these straight lines L and L2 coincides with each of the straight lines L and L2 in the inner magnetic plate 11 in a state where the axial center O of the outer magnetic plate main body 210 is positioned on the axial center of the inner magnetic plate 11. It is prescribed to do. Other configurations of the outer magnetic plate main body 210 and the outer magnetic plate main body laminate 220 are substantially the same as those of the outer magnetic plate main body 210 and the outer magnetic plate main body laminate 220 in the previous embodiment described with reference to FIGS. Same as above. Each of the permanent magnets 30 has a slightly different inclination at both ends in the circumferential direction, and the basic configuration having a substantially trapezoidal cross section is substantially the same as the previous embodiment. Each of the corner gaps 230 has a substantially rectangular shape when viewed in the axial direction.
[0039]
In the rotor 100 including the above members, the configurations of the inner magnetic plate 11 and the inner magnetic plate stack 10, and the outer magnetic plate main body 210 and the outer magnetic plate main body stack 220 will be described with reference to FIGS. Although slightly simplified from those of the previous embodiment, there is no difference in essential features. Therefore, the operation and effects of the rotor 100 including the above-described members and the method of manufacturing the same shown in FIG. 9 are substantially the same as those in the previous embodiment described with reference to FIGS. Description is omitted.
[0040]
FIG. 10 shows an inner magnetic plate 11 and an inner magnetic plate laminate 10, an outer magnetic plate main body 210 and an outer magnetic plate main body laminate 220, which constitute still another embodiment of the rotor 100 of the rotating machine according to the present invention. Still another embodiment of each of the permanent magnets 30 is shown inserted into the cylindrical portion 302 of the assembly and molding die 300. Both ends in the circumferential direction of the protrusions 13 on the inner magnetic plate 11 are formed so as to extend outward in the radial direction at right angles from the circumferential ends of the corresponding sides 12 when the inner magnetic plate 11 is viewed in the axial direction. . Other configurations of the inner magnetic plate 11 and the inner magnetic plate laminate 10 are substantially the same as the inner magnetic plate 11 and the inner magnetic plate laminate 10 in the previous embodiment described with reference to FIGS. The outer magnetic plate main body 210 and the outer magnetic plate main body laminate 220 shown in FIG. 10 have substantially the same configuration as the outer magnetic plate main body 210 and the outer magnetic plate main body laminate 220 shown in FIG. In addition, since both ends in the circumferential direction of the permanent magnet 30 are substantially brought into close contact with the circumferential ends of the corresponding protrusions 13, each transverse section of the permanent magnet 30 is formed in a substantially rectangular shape. The outer end in the radial direction at each circumferential end of each permanent magnet 30 is positioned at the inner end in the radial direction of the corresponding groove 213 of the outer magnetic plate main body 210. In the rotor 100 including the above-described members, the configuration of each permanent magnet 30 is simpler than the configuration of each permanent magnet 30 in the previous embodiment described with reference to FIGS. Although it can be manufactured at a low cost, there is no difference in essential characteristics in the overall configuration. Therefore, the operation and effects of the rotor 100 including the above-described members and the method of manufacturing the same shown in FIG. 10 are substantially the same as those in the previous embodiment described with reference to FIGS. Description is omitted.
[0041]
FIG. 11 shows an inner magnetic plate 11 and an inner magnetic plate laminate 10, an outer magnetic plate main body 210 and an outer magnetic plate main body laminate 220, which constitute still another embodiment of the rotor 100 of the rotating machine according to the present invention. Still another embodiment of each of the permanent magnets 30 is shown inserted into the cylindrical portion 302 of the assembly and molding die 300. Each of the protrusions 13 on the inner magnetic plate 11, and thus the inner magnetic plate laminate 10, has a corresponding radial center of the corner gap 230, a radially outer end of the corner gap 230, that is, a radially inner side of the bridging portion 212. It extends to the end and is positioned so as to divide the corner gap 230 into two in the circumferential direction. Other configurations of the inner magnetic plate 11 and the inner magnetic plate laminate 10 are substantially the same as those of the inner magnetic plate 11 and the inner magnetic plate laminate 10 in the previous embodiment described with reference to FIGS. . The configuration of the outer magnetic plate main body 210 and the outer magnetic plate main body laminate 220 and the configuration of each of the permanent magnets 30 are substantially the same as those shown in FIG. In the rotor 100 including the above-described members, the inner magnetic plate 11, and thus each of the protrusions 13 in the inner magnetic plate laminate 10, has a corresponding radial center of the corner gap 230 and a radially inner end of the bridging portion 212. Since the corner gap 230 is positioned so as to be divided into two in the circumferential direction, the strength during high-speed rotation can be further improved as compared with any of the previous embodiments. Further, since each of the corner gaps 230 divided into two in the circumferential direction is filled with the nonmagnetic material 40 in the same manner as in the previous embodiment, each corner gap 230 divided into two in the circumferential direction is filled in. Compared to a conventional rotor in which a nonmagnetic member is inserted, the number of parts can be significantly reduced, and as a result, productivity can be improved and manufacturing costs can be reduced. The essential features in the overall configuration of the rotor 100 including the above-described members shown in FIG. 11 are substantially the same as those in the previous embodiment. Therefore, the operation and effect of the rotor 100 including the above-described members and the method of manufacturing the same shown in FIG. 11 are substantially the same as those in the previous embodiment described with reference to FIGS. Description is omitted.
[0042]
In each of the embodiments described above with reference to FIGS. 1 to 11, the number of sides 12 of the inner magnetic plate 11 and the inner magnetic plate laminate 10 is six. If it is an even number, even if it is 4, or 8 or more, it is established. Depending on the number of sides 12 of the inner magnetic plate 11 and the inner magnetic plate laminate 10, the configurations of the outer magnetic plate main body 210 and the outer magnetic plate main body laminate 220, the number of permanent magnets 30 and the like are defined. Needless to say.
[0043]
FIG. 12 shows still another embodiment of the rotor 100 of the rotating machine according to the present invention. The rotor 100 includes an inner magnetic plate laminate 10 to which the rotating shaft 2 is attached, four outer magnetic plate laminates 20, four permanent magnets 30, four other permanent magnets 50, It consists of possible nonmagnetic material 40. The inner magnetic plate laminate 10 is configured by laminating a plurality of inner magnetic plates 11 having substantially the same configuration. The inner magnetic plate 11 is made of an electromagnetic steel plate, in the embodiment, a silicon steel plate, and has four sides 12 extending in a straight line, and is formed to have a substantially square shape. Chamfers 15 are formed at the four corners of the inner magnetic plate 11 respectively. A mounting hole 14 in which the rotary shaft 2 is mounted is formed in the axial center portion of the inner magnetic plate 11. By laminating a plurality of inner magnetic plates 11 configured as described above, an inner magnetic plate laminate 10 is formed, and the rotating shaft 2 is fitted and mounted in the mounting hole 14 of the inner magnetic plate laminate 10. Yes.
[0044]
Each of the four outer magnetic plate laminates 20 having substantially the same configuration is configured by stacking a plurality of outer magnetic plates 21 having substantially the same configuration. The outer magnetic plate 21 is made of an electromagnetic steel plate, in the embodiment, a silicon steel plate, and has a radially outer end 22 having an arc shape, a radially inner end 23 extending linearly, and both circumferential ends 24. is doing. The outer magnetic plate laminate 20 is formed by laminating a plurality of outer magnetic plates 21 configured as described above. Each of the outer magnetic plate laminates 20 is disposed with a radial gap substantially radially outward of the inner magnetic laminate 10 and with a circumferential gap in the circumferential direction. That is, the radially inner end 23 of each of the outer magnetic plate laminates 20 is disposed so as to face the corresponding side 12 of the inner magnetic plate laminate 10 in parallel with a radial gap and is circumferentially circumferential. They are arranged to face each other with a directional gap. Each of the circumferential gaps formed between the circumferential directions of the outer magnetic plate laminate 20 is formed to extend in the radial direction with a constant circumferential width. Each of the radially outer ends 22 is positioned on a virtual circumference having a common axis with the rotary shaft 2, and each circumferential clearance of the inner magnetic plate laminate 10 is a corner of the inner magnetic plate laminate 10. Are arranged in circumferential positions aligned with each of the chamfers 15 and thus each of the chamfers 15.
[0045]
In each of the radial gaps between the radially inner end 23 of each of the outer magnetic plate laminates 20 and the corresponding side 12 of the inner magnetic plate laminate 10, for example, an Nd—Fe—B permanent magnet 30 is provided. Has been inserted. Each of the permanent magnets 30 is formed in an elongated and substantially rectangular parallelepiped shape. Each of the circumferential gaps formed between each of the permanent magnets 30 and each of the circumferential gaps formed between each of the outer magnetic plate laminates 20 are mutually connected at corresponding corners of the inner magnetic plate laminate 10. Arranged to align to form a corner gap. The total number of corner clearances is four. The chamfers 15 of the inner magnetic plate laminate 10 are positioned to face each of the corner gaps. Another permanent magnet 50 is inserted into each of the corner gaps leaving a part of the gap radially inward. For example, the Nd—Fe—B permanent magnet 50 is formed in an elongated and substantially rectangular parallelepiped shape.
[0046]
Each of the inner magnetic plate laminate 10, the permanent magnet 30, each of the outer magnetic plate laminate 20, and each axial end surface of each part of the gap is covered with a layer of non-magnetic material 40 that can be melted, Each part of the gap is filled with the nonmagnetic material 40 so as to be integrated with each of the layers. In the same manner as in the previous embodiment, the non-magnetic material 40 is formed so that the rotating shaft 2, the inner magnetic plate laminate 10, each of the permanent magnets 30, each of the permanent magnets 50, and each of the outer magnetic plate laminates 20 are outside. Except for the radially outer end face of each of the magnetic plate laminates 20, it can be cast substantially integrally. Each of the inner magnetic plate laminate 10 and the permanent magnet 30 is completely embedded in each of the outer magnetic plate laminate 20 and the nonmagnetic material 40. Each of the inner magnetic plate laminate 10, the permanent magnets 30, each of the permanent magnets 50, each of the outer magnetic plate laminates 20, and a layer of the nonmagnetic material 40 that covers both axial end faces of each of the gaps. Each and each of the nonmagnetic materials 40 filling each part of the gap constitute a main body 102 of the rotor 100 having a substantially cylindrical shape. Both end surfaces in the axial direction of the main body 102 are formed by the nonmagnetic material 40, and the outer peripheral surface is formed by each radial outer end surface 22 of the outer magnetic plate laminate 20 and each radial outer end surface of the permanent magnet 50. Is done.
[0047]
As described above, the rotor 100 of the rotating machine according to the present invention includes the inner magnetic plate laminate 10, the permanent magnets 30, the permanent magnets 50, the outer magnetic plate laminate 20, and a part of the gap. Since both end surfaces in the axial direction are covered with a layer of meltable nonmagnetic material 40 and a part of the gap is filled with the nonmagnetic material 40 so as to be integrated with each of the layers. Each of the plate laminate 10, each of the permanent magnets 30, each of the permanent magnets 50, and each of the outer magnetic plate laminates 20 is made of a nonmagnetic material 40, and each of the radial outer end surfaces of the permanent magnets 50 and each of the outer magnetic plate laminates 20. Except for each outer peripheral surface, it is possible to cast integrally. The nonmagnetic material 40 can be integrally formed by casting. This eliminates the need for troublesome work such as caulking, welding, and bonding as in the prior art, makes the assembly work easier than before, reduces the work time and reduces the burden of labor, As a result, productivity can be improved and manufacturing costs can be reduced. Furthermore, since both end surfaces in the axial direction including each of the permanent magnets 30 and 50 in which both end surfaces in the axial direction are exposed to the outside in the past are completely covered with the non-magnetic material 40, a generator or an electric motor is used. When applied to a rotating machine, even if forcible cooling is provided by supplying air into the case with a fan provided in the rotating shaft and a fan arranged on the rotating shaft, dust or water such as iron powder Thus, it becomes possible to completely protect each of the permanent magnets 30. Further, both end surfaces in the axial direction of the permanent magnet 50 can be completely protected. As a result, the required performance and durability of the rotating machine can be easily ensured over a long period of time.
[0048]
Next, a method for producing the rotor 100 shown in FIG. 12 will be described. The production method of the rotor 100 shown in FIG. 12 is essentially the same as the production method described above, and therefore the outline thereof will be described below. In FIG. 13, the inner magnetic plate 11 and the inner magnetic plate laminate 10, the outer magnetic plate main body 210 and the outer magnetic plate main body laminate 220 constituting the rotor 100 described with reference to FIG. 12 are assembled. The inner magnetic plate 11 and the inner magnetic plate laminate 10 are shown in a state where they are inserted into the cylindrical portion 302 of the mold 300, and in FIG. 14, the rotor 100 described with reference to FIG. The outer magnetic plate main body 210 and the outer magnetic plate main body laminate 220, each of the permanent magnets 30, and each of the permanent magnets 50 are shown inserted into the cylindrical portion 302 of the assembly and molding die 300. Yes.
[0049]
Referring to FIG. 13, inner magnetic plate 11 having a substantially square shape described above can be formed by punching a silicon steel plate (flat plate) with a press machine (not shown). Each of the outer magnetic plate laminates 20 described above is arranged as discontinuous independent members separated from each other in the circumferential direction, as described above, in a state where the rotor 100 is completed as a molded rotor 100. However, before molding, the outer peripheral end of each of the gaps filled with the meltable nonmagnetic material 40 is connected by a thin arcuate bridge 212 so that the entire outer peripheral end is The outer magnetic plate main body laminate 220 is formed by laminating one outer magnetic plate main body 210 integrally formed so as to form a continuous circular shape. And it isolate | separates into each of the outer side magnetic board laminated body 20 as mentioned above by the cutting process after shaping | molding mentioned later.
[0050]
The outer magnetic plate main body 210 formed by punching a silicon steel plate (flat plate) by a press machine (not shown) has four radial directions having a circular outer peripheral end 211 and the same number as the sides 12 of the inner magnetic plate 11. A groove formed between the inner end 23 and each circumferential end of the inner end 23 and having one end opened radially inward and the other end closed between the outer end 211 and the bridge portion 212. And a through hole 214 formed of 213. Each of the inner ends 23 extends linearly and is arranged so as to substantially form a regular quadrangular side, and a groove 213 is disposed in each of the regular quadrangular corners. The center of this regular quadrangle, and thus the center of the through hole 214 is positioned so as to coincide with the axis O of the outer magnetic plate main body 210. Both ends in the circumferential direction of the groove 213 are virtual extending in the radial direction through the axial center O of the outer magnetic plate main body 210 and corners (not shown) of the regular quadrangle when the outer magnetic plate main body 210 is viewed in the axial direction. The straight line L is formed so as to extend on two imaginary straight lines L3 extending in parallel to the radial direction through the axis O with the straight line L being equally spaced, and the radially outer end of each of the grooves 213 is circular. It is formed in an arc shape parallel to the outer peripheral end 211. A circular portion indicated by a two-dot chain line 22 represents a cutting scheduled surface similar to that described above. Each of the permanent magnets 30 and 50 is formed in a rectangular parallelepiped shape.
[0051]
The inner magnetic plate 11 is stacked on the rotary shaft 2 set in the cylindrical portion 302 of the assembly and molding die 300 while being inserted through the mounting hole 14, and the outer magnetic plate main body 210 is stacked on the cylindrical portion 302. Laminate while fitting. These laminations cause a radial gap between each of the inner ends 23 of the outer magnetic plate body 210 and the corresponding side 12 of the inner magnetic plate 11, and each of the grooves 213 of the outer magnetic plate body 210 and the inner magnetic plate. A corner gap 230 is formed between corresponding corners of the plate 11 to form the inner magnetic plate laminate 10 and the outer magnetic plate main body laminate 220 in the cylindrical portion 302. Referring to FIG. 14 together with FIG. 13, the permanent magnet 30 is inserted into each of the radial gaps. The length of each permanent magnet 30 in the cross section in the longitudinal direction is defined to be substantially the same as the length of the corresponding side 12 of the inner magnetic plate 11. Further, the permanent magnet 50 is inserted into each of the corner gaps 230 while leaving a part of the gap (a part of the corner gap 230) 230a on the radially inner side. The length in the longitudinal direction of each permanent magnet 50 in the cross section is defined to be substantially the same as the radial length of the corresponding groove 213 of the outer magnetic plate main body 210. As described above, the inner magnetic plate laminate 10, the outer magnetic plate main body laminate 220, each of the permanent magnets 30 and each of the permanent magnets 50 are set in the cylindrical portion 302 of the assembly and molding die 300. Thereafter, the open end of the cylindrical portion 302 is closed by the lid mold 303 in the same manner as in the previous embodiment. Next, the melted nonmagnetic material 40 is subjected to axial ends of each of the inner magnetic plate laminate 10, the permanent magnet 30, each of the permanent magnets 50, the outer magnetic plate main body laminate 220, and a part 230a of the gap. The surface is covered with a layer of the nonmagnetic material 40, and each of the gap portions 230a is filled so as to be integrated with each of the layers (by casting), whereby the rotary shaft 2 and the inner magnetic plate laminate 10 are filled. Each of the permanent magnets 30, each of the permanent magnets 50, and the outer magnetic plate main body laminate 220 are integrally cast except for a part of the outer peripheral surface of the outer magnetic plate main body laminate 220. After mold release, the outer peripheral edge of the outer magnetic plate main body laminate 220 and the nonmagnetic material 40 is cut to cut off each of the bridging portions 212. The rotor 100 shown in FIG. 12 can be manufactured by the above method. As a result, troublesome work such as caulking, welding, and bonding as in the past is unnecessary, the assembling work is simpler than before, the assembling work time is shortened and the burden of labor is reduced, As a result, productivity can be improved and manufacturing costs can be reduced.
[0052]
In each of the embodiments described with reference to FIGS. 12 to 14, the number of sides 12 of the inner magnetic plate 11 and the inner magnetic plate laminate 10 is four. If it is an even number, even if it is 4, or 8 or more, it is established. Depending on the number of sides 12 of the inner magnetic plate 11 and the inner magnetic plate laminate 10, the configuration of the outer magnetic plate main body 210 and the outer magnetic plate main body laminate 220, the number of permanent magnets 30 and 50, and the like are defined. Needless to say.
[0053]
FIG. 15 shows still another embodiment of the inner magnetic plate 11 and the outer magnetic plate main body 210 constituting another embodiment of the rotor 100 of the rotating machine according to the present invention. The inner magnetic plate 11 made of the same material as in the previous embodiment has eight sides 12 extending in a straight line and is substantially formed in a regular octagonal shape. Grooves 11A extending inward in the radial direction are formed at the eight corners of the inner magnetic plate 11. The circumferential width of the radially inner end in each of the grooves 11A is formed wider than the circumferential width of the radially outer region than the inner edge. That is, each of the grooves 11A is formed so as to extend from the corresponding corner portion toward the axial center with a constant circumferential width, and then to extend to both sides in the circumferential direction at the radially inner end portion. A mounting hole 14 in which the rotary shaft 2 is mounted is formed in the axial center portion of the inner magnetic plate 11. The outer magnetic plate body 210 formed of the same material as in the previous embodiment has eight radially inner ends 23 having a circular outer peripheral end 211 and the same number as the sides 12 of the inner magnetic plate 11, and the inner side. A through-hole formed between each circumferential end of the end 23 and a groove 213 having one end opened inward in the radial direction and the other end closed with the bridging portion 212 between the outer peripheral end 211. 214. Each of the inner ends 23 extends linearly and is arranged so as to substantially form a regular octagonal side, and a groove 213 is disposed in each of the regular octagonal corners. The center of the regular octagon, that is, the center of the through hole 214 is positioned so as to coincide with the axis O of the outer magnetic plate main body 210. The circumferential width of the radially outer end of each of the grooves 213 is formed wider than the circumferential width of the radially inner region than the outer end. That is, each of the grooves 213 is formed so as to extend radially outward from a corresponding corner portion with a constant circumferential width, and then extend to both sides in the circumferential direction at the radially outer end portion. Each radially outer end of the groove 213 is formed in an arc shape parallel to the circular outer peripheral end 211. A circular portion indicated by a two-dot chain line 22 represents a scheduled cutting surface (scheduled cutting line) to be cut by the same cutting process as in the previous embodiment. This cutting allowance is defined such that at least each of the bridging portions 212 of the outer magnetic plate main body 210 is completely removed.
[0054]
In FIG. 16, the inner magnetic plate 11 and the inner magnetic plate laminate 10, the outer magnetic plate main body 210 and the outer magnetic plate main body laminate 220, and the permanent magnet 30 shown in FIG. It is shown inserted into the cylindrical portion 302 of 300. Each of the permanent magnets 30 is inserted into a radial gap between each of the sides 12 of the inner magnetic plate laminate 10 and the corresponding inner end 23 of the outer magnetic plate main body laminate 220. Each of the grooves 11A of the inner magnetic plate laminated body 10 and each of the grooves 213 of the outer magnetic plate main body laminated body 220 are positioned in alignment with each other in the circumferential direction, and the rotor 100 is substantially the same as in the previous embodiment. Produced.
[0055]
In the rotor 100 including the above-described members shown in FIGS. 15 and 16, a groove 11A extending inward in the radial direction is formed in each corner of the inner magnetic plate laminate 10, and the radial direction in each of the grooves 11A The circumferential width of the inner end is formed wider than the circumferential width of the radially outer region than the inner end, and is defined by the circumferential gap between each of the permanent magnets 30 and each of the outer magnetic plate laminate 210. The circumferential width of the radially outer end in each of the corner gaps formed is wider than the circumferential width of the radially inner region than the outer end, and each of the gaps formed by each of the grooves 11A A part of each of the corner gaps is formed in alignment with each of the corner gaps. Each of the corner gaps is filled with the molten nonmagnetic material 40 described above, and the radially inner end and the radially outer end of the nonmagnetic material 40 filled in each of the corner gaps. Is wider in the circumferential direction than the other portions existing between them, and therefore, when the rotor 100 is rotated at a high speed, it is less likely to jump outward in the radial direction than in the previous embodiment, and the jumping is prevented more reliably. The benefits of The rotor 100 including the above-described members shown in FIGS. 15 and 16 shares the characteristic basic configuration in the previous embodiment described with reference to FIGS. 1 to 8, and the manufacturing method is substantially also. Therefore, it is needless to say that substantially the same operational effects as those in the embodiment can be obtained.
[0056]
As described above, according to the present invention. Manufacturing method of rotor of rotating machine Although the present invention has been described in detail with reference to the accompanying drawings based on the embodiments, the present invention is not limited to the above-described embodiments, and various other modifications or changes can be made without departing from the scope of the present invention. Correction is possible. For example, there are various types of rotors called IPMs in addition to the above-described embodiment. The present invention includes an inner magnetic plate laminate mounted on a rotating shaft, and an inner magnetic plate laminate. An outer magnetic plate laminate disposed substantially radially outward, a plurality of permanent magnets inserted between at least the inner magnetic plate laminate and the outer magnetic plate laminate, and a plurality of nonmagnetic materials can be accommodated If it is a rotor of the rotary machine of the form provided with a clearance gap, it can apply also to the rotor of other forms other than the said embodiment. One end of each of the gaps is formed so as to open to one end surface in the axial direction of the rotor main body, and the other end is opened to the other end surface in the axial direction of the rotor main body. By accommodating a non-magnetic material in each of the gaps, it functions as a partition that prevents magnetic shorts between different poles, and there are various arrangement forms. A feature of the present invention is that each of the inner magnetic plate laminate, the permanent magnet, each of the outer magnetic plate laminate, and each axial end face of each of the gaps is covered with a meltable nonmagnetic material layer and the gap Each of the layers is filled with the nonmagnetic material so as to be integrated with each of the layers. With this characteristic configuration, the above-described cast-in can be achieved, and thus the various functions and effects described above can be achieved.
[0057]
The magnetic plate 400 includes a mounting hole 14 formed in an axial center portion and having an axial center O, a circular outer peripheral end 402 having an axial center common to the axial center O, and an even number of substantially positive holes centered on the axial center O. A radial gap 404 formed to form a polygon (in the embodiment, a regular octagon), and a radial bridge (bridge) formed to extend in the radial direction at each corner of the radial gap 404 And a pair of circumferential gaps 408 formed so as to extend radially along the circumferential direction. Each of the radial gap 404 and the circumferential gap 408 is formed from a through hole. Each of the radial gaps 404 is formed to extend linearly with a certain radial width. Each of the circumferential gaps 408 extends from the radially inner side to the radially outer side than each of the radial gaps 404, and each radially outer end has an arc shape parallel to the circular outer circumferential edge 402. Yes. A circumferential bridging portion 410 extending in an arc shape is formed between each radial outer end of the circumferential gap 408 and the circular outer circumferential end 402 of the magnetic plate 400. Each of the radial bridges 406 is formed to extend linearly in the radial direction with a constant circumferential width, and each radially outer end is connected to a corresponding circumferential bridge 410. The circumferential width of the radially inner end and the circumferential width of the radially outer end of each of the circumferential gaps 408 arranged so as to sandwich each of the radial bridge portions 406 in the circumferential direction are the radially inner end portions. And the width in the circumferential direction of the entire intermediate region between the outer end portion in the radial direction. Each pair of circumferential gaps 408 constitutes a corner gap at each corner of the radial gap 404, so the circumferential width of each radially inner end and the circumference of the radially outer end of each corner gap. It can be said that the direction width is formed wider than the circumferential width of the entire intermediate region between the radially inner end and the radially outer end. A circular portion indicated by a two-dot chain line 22 represents a planned cutting surface (scheduled cutting line) to be cut by cutting performed in substantially the same manner as described above. This cutting allowance is defined so that at least each of the circumferential bridge portions 410 is completely cut off.
[0058]
【The invention's effect】
According to the invention How to make a rotating machine According to the present invention, assembling work becomes simpler than before, the assembling work time is shortened, and the burden of labor is reduced. As a result, productivity can be improved and manufacturing cost can be reduced. In addition, it is possible to reduce magnetic shorts between different poles and to easily ensure strength at high speed rotation. Furthermore, the number of parts is significantly reduced, and as a result, productivity can be improved and manufacturing costs can be reduced. Furthermore, the required performance and durability of the rotating machine can be easily ensured sufficiently for a long period of time.
[0059]
As mentioned above, although the rotor of the rotary machine by this invention and its manufacturing method were demonstrated in detail, referring an accompanying drawing based on embodiment, this invention is not limited to the said embodiment, The range of this invention Various other variations or modifications can be made without departing from the above. For example, there are various types of rotors called IPMs in addition to the above-described embodiment. The present invention includes an inner magnetic plate laminate mounted on a rotating shaft, and an inner magnetic plate laminate. An outer magnetic plate laminate disposed substantially radially outward, a plurality of permanent magnets inserted between at least the inner magnetic plate laminate and the outer magnetic plate laminate, and a plurality of nonmagnetic materials can be accommodated If it is a rotor of the rotary machine of the form provided with a clearance gap, it can apply also to the rotor of other forms other than the said embodiment. One end of each of the gaps is formed so as to open to one end surface in the axial direction of the rotor main body, and the other end is opened to the other end surface in the axial direction of the rotor main body. By accommodating a non-magnetic material in each of the gaps, it functions as a partition that prevents magnetic shorts between different poles, and there are various arrangement forms. A feature of the present invention is that each of the inner magnetic plate laminate, the permanent magnet, each of the outer magnetic plate laminate, and each axial end face of each of the gaps is covered with a meltable nonmagnetic material layer and the gap Each of the layers is filled with the nonmagnetic material so as to be integrated with each of the layers. With this characteristic configuration, the above-described cast-in can be achieved, and thus the various functions and effects described above can be achieved.
[0060]
Moreover, in the said embodiment, although the inner side magnetic plate 11, the outer side magnetic plate 21, and the magnetic plate 400 are comprised from the silicon steel plate which is one Embodiment of an electromagnetic steel plate, other soft magnetic steel plates (relative to an electromagnetic steel plate, Other embodiments composed of soft magnetic steel plates such as SPCC, SPHC, SS41P, etc., of course, are also possible. In short, any steel plate made of a magnetic material (either a ferromagnetic material or a soft magnetic material), not a non-magnetic material, can be established. Furthermore, in the above embodiment, the nonmagnetic material 40 is formed of a nonmagnetic metal material such as aluminum, aluminum alloy, or zinc alloy. However, the nonmagnetic material 40 is formed of a nonmetallic material such as a high-strength synthetic resin having heat resistance. It may be formed. In addition, when using aluminum as the nonmagnetic material 40, since the shrinkage at the time of cooling is relatively large, there is a possibility that a slight gap may be formed between the magnetic steel sheet and the impregnating agent (adhesive and adhesive). It is preferable to inject it. The meltable nonmagnetic material 40 is preferably made of a material having a relatively low electrical resistance, such as aluminum.
[0061]
【The invention's effect】
According to the rotor of the rotating machine and the manufacturing method thereof according to the present invention, the assembling work becomes simpler than before, the assembling work time is shortened and the burden of labor is reduced, and as a result, the productivity is improved. In addition, the manufacturing cost can be reduced. In addition, it is possible to reduce magnetic shorts between different poles and to easily ensure strength at high speed rotation. Furthermore, the number of parts is significantly reduced, and as a result, productivity can be improved and manufacturing costs can be reduced. Furthermore, the required performance and durability of the rotating machine can be easily ensured sufficiently for a long period of time.
[Brief description of the drawings]
FIG. 1 is a view of an embodiment of a rotor according to the present invention viewed from the outside in the radial direction.
FIG. 2 is a perspective view showing the rotor shown in FIG. 1 with a nonmagnetic material covering one end in the axial direction removed.
FIG. 3 is a view of the rotor shown in FIG. 2 as viewed in the axial direction.
FIG. 4 is a plan view of an inner magnetic plate.
FIG. 5 is a plan view of an outer magnetic plate.
6 is an exploded perspective view schematically showing an assembly and molding die for the rotor shown in FIG. 1 and members constituting the rotor. FIG.
7 is a view of the state in which the inner magnetic plate and the outer magnetic plate are inserted into the cylindrical portion of the assembly and molding die shown in FIG. 6 as viewed in the axial direction.
FIG. 8 is a view showing a state where a permanent magnet is further inserted in FIG. 7;
FIG. 9 is a view showing members constituting another embodiment of a rotor according to the present invention, similar to FIG. 8;
FIG. 10 is a view showing members constituting still another embodiment of the rotor according to the present invention, similar to FIG.
FIG. 11 is a view showing members constituting still another embodiment of the rotor according to the present invention, similar to FIG.
12 is a perspective view showing still another embodiment of the rotor according to the present invention, and is a perspective view similar to FIG. 2. FIG.
13 is a view of the state in which the inner magnetic plate and the outer magnetic plate included in the rotor shown in FIG. 12 are inserted into the cylindrical portion of the assembly and molding die shown in FIG. 6 when viewed in the axial direction.
FIG. 14 is a view showing a state where a permanent magnet is further inserted in FIG. 13;
FIG. 15 is a view in which an inner magnetic plate and an outer magnetic plate constituting still another embodiment of the rotor according to the present invention are coaxially arranged and viewed in the axial direction.
16 is a view of the state in which the inner magnetic plate and the outer magnetic plate shown in FIG. 15 are inserted into the cylindrical portion of the assembly and molding die shown in FIG. 6 as viewed in the axial direction.
FIG. 17 is an axial view of a monolithic magnetic plate constituting still another embodiment of the rotor according to the present invention.
18 is a view of the state in which the magnetic plate shown in FIG. 17 is inserted into the cylindrical portion of the assembly and molding die shown in FIG. 6 as viewed in the axial direction.
[Explanation of symbols]
2 Rotating shaft
10 Inner magnetic laminate
11 Inside magnetic plate
12 sides
13 Protrusion
20 Outer magnetic plate laminate
22 Planned cutting surface
21 Outside magnetic plate
30, 50 Permanent magnet
40 Non-magnetic material
100 rotor
210 Outside magnetic plate body
212 Bridge
220 Outer magnetic plate body laminate
230 Corner gap
230a Part of the remaining gap
400 Magnetic plate
404 radial clearance
406 Radial bridge
408 circumferential clearance
410 Circumferential bridge
420 Magnetic plate laminate

Claims (3)

円筒部を有する成形型の軸心に合わせて回転軸をセットし、軸心部に取付孔が形成されかつ偶数個の辺を有した実質上多角形状の内側磁性板を取付孔を介して回転軸に挿入しながら積層し、かつ円形外周端と、該辺と同数の半径方向内側端及び該内側端の各々の周方向端の間に形成されて一端が半径方向内側に開放され他端が該外周端との間に橋絡部を残して閉じられた溝を有する貫通孔とからなる外側磁性板本体を、該円筒部に嵌合しながら積層することにより、該内側端の各々と、対応する該辺との間に半径方向隙間を、また該溝の各々と内側磁性板の対応する角部との間に角部隙間を形成して、該円筒部内に内側磁性板積層体及び外側磁性板本体積層体を形成し、該半径方向隙間の各々に永久磁石を挿入した後、溶融された非磁性材を鋳込んで、内側磁性板積層体、永久磁石の各々、外側磁性板本体積層体、及び該角部隙間の各々の軸方向両端面を該非磁性材の層で覆うと共に、該角部隙間の各々を該層の各々と一体となるよう充填し、離型後、外側磁性板本体積層体及び非磁性材の外周端を切削して橋絡部の各々を切除する、ことを特徴とする回転機のロータの制作方法。  A rotating shaft is set in accordance with the axis of the mold having a cylindrical portion, and a substantially polygonal inner magnetic plate having an even number of sides and having an even number of sides is rotated through the mounting hole. Laminated while being inserted into the shaft, and formed between a circular outer peripheral end, the same number of radially inner ends as the sides, and a circumferential end of each of the inner ends, one end being opened radially inward and the other end being By laminating an outer magnetic plate main body composed of a through hole having a closed groove leaving a bridging portion between the outer peripheral end and fitting to the cylindrical portion, A radial gap is formed between the corresponding sides, and a corner gap is formed between each of the grooves and a corresponding corner of the inner magnetic plate, and the inner magnetic plate laminate and the outer side are formed in the cylindrical portion. After forming a magnetic plate body laminate and inserting a permanent magnet into each of the radial gaps, the molten non-magnetic material The inner magnetic plate laminate, the permanent magnet, the outer magnetic plate main body laminate, and the axial end surfaces of each of the corner gaps are covered with the nonmagnetic material layer, and each of the corner gaps is covered. A rotating machine comprising: filling with each of the layers so as to be integral with each other; and cutting the outer peripheral edge of the outer magnetic plate main body laminate and the nonmagnetic material after cutting to cut off each of the bridging portions. How to make a rotor. 円筒部を有する成形型の軸心に合わせて回転軸をセットし、軸心部に取付孔が形成されかつ偶数個の辺を有した実質上多角形状の内側磁性板を取付孔を介して回転軸に挿入しながら積層し、かつ円形外周端と、該辺と同数の半径方向内側端及び該内側端の各々の周方向端の間に形成されて一端が半径方向内側に開放され他端が該外周端との間に橋絡部を残して閉じられた溝を有する貫通孔とからなる外側磁性板本体を、該円筒部に嵌合しながら積層することにより、該内側端の各々と、対応する該辺との間に半径方向隙間を、また該溝の各々と内側磁性板の対応する角部との間に角部隙間を形成して、該円筒部内に内側磁性板積層体及び外側磁性板本体積層体を形成し、該半径方向隙間の各々に永久磁石を挿入しかつ該角部隙間の各々にそれぞれ半径方向内側に該隙間の一部を残して永久磁石を挿入した後、溶融された非磁性材を鋳込んで、内側磁性板積層体、永久磁石の各々、外側磁性板本体積層体、及び該隙間の一部の各々の軸方向両端面を該非磁性材の層で覆うと共に、該隙間の一部の各々を該層の各々と一体となるよう充填し、離型後、外側磁性板本体積層体及び非磁性材の外周端を切削して橋絡部の各々を切除する、ことを特徴とする回転機のロータの制作方法。  A rotating shaft is set in accordance with the axis of the mold having a cylindrical portion, and a substantially polygonal inner magnetic plate having an even number of sides and having an even number of sides is rotated through the mounting hole. Laminated while being inserted into the shaft, and formed between a circular outer peripheral end, the same number of radially inner ends as the sides, and a circumferential end of each of the inner ends, one end being opened radially inward and the other end being By laminating an outer magnetic plate main body composed of a through hole having a closed groove leaving a bridging portion between the outer peripheral end and fitting to the cylindrical portion, A radial gap is formed between the corresponding sides, and a corner gap is formed between each of the grooves and a corresponding corner of the inner magnetic plate, and the inner magnetic plate laminate and the outer side are formed in the cylindrical portion. A magnetic plate body laminate is formed, a permanent magnet is inserted into each of the radial gaps, and each of the corner gaps is inserted therein. After inserting a permanent magnet leaving a part of the gap on the radially inner side, casting a molten nonmagnetic material, each of an inner magnetic plate laminate, a permanent magnet, an outer magnetic plate body laminate, and The both end surfaces in the axial direction of a part of the gap are covered with the layer of the nonmagnetic material, and each part of the gap is filled so as to be integrated with each of the layers. A method for producing a rotor of a rotating machine, wherein the outer peripheral ends of the laminate and the nonmagnetic material are cut to cut off each of the bridging portions. 円筒部を有する成形型の軸心に合わせて回転軸をセットし、軸心部に形成された取付孔と、円形外周端と、偶数個の実質上正多角形をなすよう形成された半径方向隙間と、半径方向隙間の各々の角部において半径方向に延在するよう形成された半径方向橋絡部を周方向に挟んでそれに沿って半径方向に延在するよう形成されて円形外周端との間に周方向橋絡部を形成する一対の周方向隙間とを備えている磁性板を、取付孔を介して回転軸に挿入しながらかつ円形外周端を該円筒部に嵌合しながら積層することにより磁性板積層体を形成し、該半径方向隙間の各々に永久磁石を挿入した後、溶融された非磁性材を鋳込んで、磁性板積層体、永久磁石の各々、及び周方向隙間の各々の軸方向両端面を該非磁性材の層で覆うと共に、周方向隙間の対の各々を該層の各々と一体となるよう充填し、離型後、磁性板積層体及び非磁性材の外周端を切削して周方向橋絡部の各々を切除する、ことを特徴とする回転機のロータの制作方法。  A rotating shaft is set in accordance with the axial center of a mold having a cylindrical portion, a mounting hole formed in the axial center portion, a circular outer peripheral end, and a radial direction formed so as to form an even number of substantially regular polygons. A gap and a circular outer circumferential edge formed so as to extend in the radial direction along a radial bridge portion that is formed to extend in the radial direction at each corner of the radial gap. A magnetic plate having a pair of circumferential gaps forming a circumferential bridging portion between the two is inserted into the rotating shaft through the mounting hole and laminated while fitting the circular outer peripheral end to the cylindrical portion. After forming a magnetic plate laminate and inserting a permanent magnet into each of the radial gaps, a molten nonmagnetic material is cast into the magnetic plate laminate, each of the permanent magnets, and the circumferential gap. Each axial end surface of each of the non-magnetic material is covered with a layer of the non-magnetic material, and a pair of circumferential gaps Each of the layers is filled so as to be integrated with each of the layers, and after release, the outer peripheral ends of the magnetic plate laminate and the nonmagnetic material are cut to cut off each of the circumferential bridge portions. How to make a machine rotor.
JP2000048254A 2000-02-24 2000-02-24 Manufacturing method of rotor of rotating machine Expired - Fee Related JP3752946B2 (en)

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