JP3849737B2 - Method of manufacturing rotor for reluctance motor - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a reluctance motor for an electric motor used in an air conditioner, an automobile, or the like, and more particularly to a method for manufacturing a rotor of a reluctance motor characterized by the manufacture of the rotor.
[0002]
[Prior art]
This reluctance motor has a structure shown in FIGS. 7 and 8, for example. 7 and 8, in the stator 1 that generates a rotating magnetic field, in order to generate reluctance torque, a plurality of magnetic steel plates having a bathtub-shaped cross section are stacked to form a magnetic steel plate portion 2 having a polygonal shape corresponding to the number of poles. A rotor 5 formed by fixing with a screw 4 is disposed on the boss portion 3 of the column. This magnetic steel plate 2 is formed with the bottom of the bathtub shape facing the center hole (for shaft) 6, and the magnetism due to the rotating magnetic field of the stator 1 is changed in the rotor 5, that is, the reluctance is made non-uniform. Form the pole.
[0003]
Specifically, a reluctance torque is generated according to a ratio (Xd / Xq; salient pole ratio) between the d-axis and the q-axis reluctance Xd, Xq, and a so-called rotor 5 is generated. In this case, the magnetic steel plate part 2 is interposed substantially perpendicularly in one (q-axis) magnetic path by the rotating magnetic field generated by the stator 1, and the magnetic steel plate part 2 is along the other (d-axis) magnetic path. Intervene. This d-axis magnetism forms a salient pole portion through the magnetic steel plate portion 2, and the reluctance ratio (Xd / Xq) increases.
[0004]
By the way, it is better for the reluctance motor to have a larger reluctance ratio (saliency ratio), that is, a larger generated torque. For this purpose, rotors of various configurations have been proposed, but the axial laminate type shown in FIG. 6 can increase the salient pole ratio. Therefore, in the present situation, it can be said that an axial laminate type rotor is very realistic.
[0005]
7 and 8, the case where the magnetic steel plate portion 2 having a four-layer structure is formed on the rotor 5 has been described, but the same applies to the case of a multilayer structure having two or more layers.
[0006]
[Problems to be solved by the invention]
However, in the reluctance motor, the magnetic steel plate is folded and overlapped, and the stacked magnetic steel plate portion 2 is fixed to the boss portion 3 of the polygonal column with the screw 4, but it takes time to process the boss portion 3, Not only is the cost high, but also the variation in the outer diameter of the magnetic steel plate part 2 for forming the salient pole part increases, resulting in a variation in the performance of the motor, leading to a reduction in quality. Become.
[0007]
The present invention has been made in view of the above-mentioned problems, and an object of the present invention is to reduce the manufacturing cost by making the rotor easy to manufacture and to suppress a variation in the performance of the motor. It is an object of the present invention to provide a method of manufacturing a rotor of a reluctance motor that can obtain the above.
[0008]
[Means for Solving the Problems]
In order to achieve the above object, the present invention provides a method for manufacturing an axially laminated rotor of a reluctance motor having a rotor in a stator that generates a rotating magnetic field. A cylindrical magnetic steel plate part is created, and a plurality of the magnetic steel plate parts are arranged on the same plane, and the boss part is integrated with a non-magnetic light metal so as to cover these magnetic steel plate parts, A central hole of the rotor is formed at a predetermined position of the integrated main body, and an outer shape is processed and cut into the shape of the rotor with reference to the central hole.
[0009]
The magnetic steel plate portion may be a cylinder having a predetermined inner diameter formed by using a magnetic steel plate, and the magnetic steel plate is wound around the cylinder to overlap the cylinder, and this may be repeated to form a cylinder having a predetermined inner and outer diameter.
[0010]
The reluctance motor is a quadrupole motor, and when the magnetic steel plate portions are arranged on the same plane, the magnetic steel plate portions may be arranged so that the center of the magnetic steel plate portion is at the apex of the square and the adjacent magnetic steel plate portions are in close contact with each other.
[0011]
The inner diameter d of the magnetic steel plate portion is preferably larger than (1-1 / (square root of 2)) × D and smaller than D.
[0012]
The magnetic steel plate portion is preferably made of a grain-oriented electrical steel plate, a non-oriented electrical steel plate, or those without an insulating film, and a cold-rolled steel plate.
[0013]
The non-magnetic light metal used as the boss is aluminum, zinc, magnesium or an alloy thereof, and the magnetic steel plate and the boss may be integrated by die casting or casting.
[0014]
When the integrated main body is processed and cut to obtain the rotor, wire electric discharge machining or laser machining may be performed, followed by cutting with a lathe and post-grinding with a grinder.
[0015]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, an embodiment of the present invention will be described in detail with reference to FIGS. In the figure, the same parts as those in FIG.
[0016]
The rotor manufacturing method of the reluctance motor according to the present invention has a magnetic path forming the salient pole portion close to an arc shape. For example, the magnetic steel plate is formed by winding a steel plate in a spiral shape. Magnetic steel plate part that forms salient pole parts by arranging the parts on a flat surface and casting the whole into a predetermined shape with a non-magnetic light metal and adding a part that becomes a boss part, then machining and cutting into the rotor shape It is noted that there is no variation in the outer diameter of the boss, and there is no need to process the boss portion for fixing the magnetic steel plate portion.
[0017]
Therefore, as shown in FIGS. 1 and 2, in the method of manufacturing a rotor of the reluctance motor, a cylindrical magnetic steel plate having an outer diameter D by winding a magnetic steel plate or a steel plate in a spiral shape around a column (diameter d). The parts 10 are created for the number of poles, arranged in a square shape on the same plane, and the main body 11 serving as the boss part is insert-casted by a die-casting method with a non-magnetic light metal so as to cover all of them.
[0018]
In this case, the inner diameter d of the magnetic steel plate portion 10 is determined so as to satisfy (1-1 / (2 square root)) × D <d <D, where D is the outer diameter.
In other words, the rotor diameter D0 described later needs to be smaller than D, and a flux barrier needs to be formed in the vicinity of the q axis.
[0019]
As shown in FIGS. 1 and 3, the magnetic steel plate portions 10 are arranged in a square shape, and the adjacent magnetic steel plate portions 10 are brought into close contact with each other, and insert casting is performed in a regular quadrangular prism mold.
[0020]
As shown in FIG. 3, as the magnetic steel plate portion 10, the steel plate is formed into a cylindrical shape with an inner diameter d, and the same steel plate is overlaid on the cylinder with the inner diameter d, and this is repeated until it becomes a cylindrical shape with an outer diameter D. May be obtained.
[0021]
Subsequently, the main body 11 is cut as shown by a solid line in FIG. In this case, after the center hole 6 for the shaft of the rotor 12 is formed at the center of the four magnetic steel plate portions 10, the wire is set so that the outer diameter D 0 (<D) of the rotor 12 becomes the reference with the center hole 6. Machining and cutting with an electric discharge machine. As another processing method, for example, a laser processing method may be used.
[0022]
As post-processing, the outer shape of the rotor 12 is cut by a lathe and post-grinding by a grinder.
Then, as shown in FIGS. 4 and 5, the rotor 12 has a laminated arcuate magnetic steel plate portion 10a arranged at equal intervals in the circumferential direction by the number of poles (four poles), that is, an axial laminate type. It becomes. Moreover, a non-magnetic light metal remains in the vicinity of the q-axis, a cross section of the arc-shaped magnetic steel plate portion 10a appears in the vicinity of the d-axis, and the whole becomes the boss portion 13.
[0023]
As shown in FIG. 6, when this rotor 12 is applied to the stator 1, both end portions (near the d-axis) of each arc-shaped magnetic steel plate portion 10 a become salient pole portions a, and near the q-axis becomes a flux barrier b. . Therefore, a reluctance torque having a large salient pole ratio (Xd / Xq) and a large generated torque can be obtained.
[0024]
This reluctance motor has three-phase (U-phase, V-phase, and W-phase) armature windings in a 24-slot stator 1, for example, an outer-side winding is a U-phase and an inner-side winding. Is the W phase and the intermediate winding is the V phase, but the number of slots and the number of armature windings may be different.
[0025]
Thus, in the manufacture of the rotor 12, a steel plate is wound in a coil shape, this is cast with a non-magnetic metal serving as a boss portion, and the outer shape is processed and cut into a rotor shape with a wire electric discharge machine or the like to finish. As a result, the machining cost of the boss portion 13 can be reduced, the variation in the outer dimension of the arc-shaped magnetic steel plate portion 10a forming the magnetic pole can be suppressed, and the arc-shaped magnetic steel plate portion 10a can be reduced. Since the accuracy of the outer dimensions can be improved, the quality of the reluctance motor can be improved.
[0026]
According to the manufacturing method described above, (1 + m) × (1 + n) rotors 12 can be obtained from (2 + m) × (2 + n) magnetic steel plate portions 10 most efficiently in the case of a four-pole motor.
Note that n and m are positive integers. If n and m are increased, the manufacturing efficiency of the rotor 12 can be increased.
[0027]
As the steel sheet of the magnetic steel sheet portion 10, a grain-oriented electrical steel sheet, a non-oriented electrical steel sheet, those without an insulating film thereof, and a cold-rolled steel sheet can be used. For example, if emphasis is placed on the torque characteristics of the reluctance motor, a grain-oriented electrical steel sheet is used, and if emphasis is placed on the cost of the reluctance motor, cold-rolled steel sheet is used. Therefore, the rotor 12 can be manufactured in accordance with the intended use of the reluctance motor.
[0028]
Moreover, as a material (nonmagnetic body) of the boss | hub part 13 which fixes each arc-shaped magnetic steel plate part 10a, light metals, such as aluminum, zinc, and magnesium, or those alloys are used.
[0029]
Furthermore, if the rotor 12 formed as described above is incorporated into a DC brushless motor, for example, as a compressor motor of an air conditioner, the performance of the air conditioner can be improved without increasing costs (increasing operating efficiency). , Vibration and noise reduction).
[0030]
【The invention's effect】
As described above, according to the first aspect of the method of manufacturing a rotor of a reluctance motor, in the method of manufacturing an axial laminate type rotor of a reluctance motor having a rotor in a stator that generates a rotating magnetic field, A steel plate is wound in a spiral shape to form a cylindrical magnetic steel plate portion having a predetermined inner and outer diameter, and a plurality of the magnetic steel plate portions are arranged on the same plane, and a boss portion is formed so as to cover these magnetic steel plate portions. The part is integrated with a non-magnetic light metal, the central hole of the rotor is formed at a predetermined position of the integrated main body, and the outer shape is processed and cut into the shape of the rotor based on the central hole Therefore, it is easy to manufacture the magnetic steel sheet that becomes the divided magnetic path, and the manufacturing cost can be reduced. Further, since there is no variation in the outer dimension of the magnetic steel plate part that forms the salient pole part, there is an effect that the precision of the outer dimension is increased and a highly efficient motor with less variation in motor performance can be obtained.
[0031]
According to the second aspect of the present invention, the magnetic steel plate portion according to the first aspect uses a magnetic steel plate to form a cylinder having a predetermined inner diameter, and the magnetic steel plate is wound around the cylinder to overlap the cylinder. In addition to the effect of the first aspect, the accuracy of the divided magnetic path forming the salient pole portion can be increased, and a motor with higher efficiency can be obtained.
[0032]
According to the invention of claim 3, the reluctance motor according to claim 1 or 2 is a four-pole motor, and when the magnetic steel plate portions are arranged on the same plane, the center of the magnetic steel plate portion is at the apex of the square. Since the adjacent magnetic steel plate portions are arranged in close contact with each other, in addition to the effect of claim 1 or 2, the ease of manufacturing the rotor is improved, and a highly efficient motor is obtained accurately and reliably. be able to.
[0033]
According to the invention of claim 4, in claim 3, the inner diameter d is larger than (1-1 / (square root of 2)) × D and smaller than D with respect to the outer diameter D of the magnetic steel plate portion. In addition to the effect of claim 3, when the rotor diameter D0 is smaller than D, a flux barrier can be formed in the vicinity of the q axis, that is, the salient pole ratio is increased, and a highly efficient motor can be obtained. There is an effect.
[0034]
According to the invention of claim 5, the magnetic steel plate portion according to claim 1, 2, 3 or 4 is a grain-oriented electrical steel sheet, a non-oriented electrical steel sheet, or those without an insulating film, and a cold-rolled steel sheet. In addition to the effect of claim 1, 2, 3 or 4, for example, if a directional electromagnetic steel sheet is used, the torque characteristics of the reluctance motor can be improved, and if a cold rolled steel sheet is used, The cost of the reluctance motor can be reduced. Therefore, there is an effect that the rotor 12 can be manufactured according to the purpose of use of the reluctance motor.
[0035]
According to the invention of claim 6, the light metal of the non-magnetic material that becomes the boss part in claim 1 or 2 is aluminum, zinc, magnesium or an alloy thereof, and the magnetic steel plate part and the boss part are die-cast, Since it is integrated by casting, in addition to the effect of claim 1 or 2, it can be realized by an easily available non-magnetic material, and a rotor can be easily manufactured by conventional insert casting and processing. Therefore, the manufacturing cost can be reduced.
[0036]
According to the seventh aspect of the present invention, when the integrated main body is processed and cut to obtain the rotor, wire electric discharge machining or laser machining is performed, then cutting with a lathe, post-grinding with a grinder Therefore, in addition to the effect of the first or second aspect, the outer shape of the rotor can be finished with high accuracy, and the performance of the motor can be improved.
[Brief description of the drawings]
FIG. 1 is a schematic plan view of a main body for explaining a method of manufacturing a rotor for a reluctance motor according to an embodiment of the present invention.
FIG. 2 is a schematic side view of the main body shown in FIG.
FIG. 3 is a schematic diagram for explaining a modified embodiment of the present invention.
FIG. 4 is a schematic plan view for explaining a rotor according to a method of manufacturing a rotor of a reluctance motor according to the present invention.
FIG. 5 is a schematic side view of the rotor shown in FIG. 3;
6 is a schematic plan view for explaining a reluctance motor having the rotor shown in FIGS. 3 and 4. FIG.
FIG. 7 is a schematic plan view showing a conventional reluctance motor.
8 is a schematic side view for explaining a rotor of the reluctance motor shown in FIG. 6;
[Explanation of symbols]
1 Stator 6 Center hole (for shaft)
DESCRIPTION OF SYMBOLS 10 Magnetic steel plate part 10a Arc-shaped magnetic steel plate part 11 Main body 12 Rotor 13 Boss part a Salient pole part b Flux barrier

Claims (7)

In a method for manufacturing an axial laminate type rotor of a reluctance motor having a rotor in a stator that generates a rotating magnetic field, a magnetic steel plate is wound in a spiral shape to form a cylindrical magnetic steel plate portion having a predetermined inner and outer diameter, and the magnetic A plurality of steel plate portions are arranged in a predetermined plane on the same plane, and a portion that becomes a boss portion is covered with a non-magnetic light metal so as to cover these magnetic steel plate portions, and the rotor is placed at a predetermined position of the integrated main body. And forming an outer shape into the shape of the rotor on the basis of the center hole, and manufacturing the rotor of the reluctance motor. 2. The reluctance according to claim 1, wherein the magnetic steel plate part is made of a magnetic steel plate to form a cylinder having a predetermined inner diameter, the magnetic steel plate is wound around the cylinder, the cylinders are stacked, and this is repeated to form a cylinder with a predetermined inner and outer diameter. A method for manufacturing a rotor of a motor. The reluctance motor is a quadrupole motor, and when the magnetic steel plate portions are arranged on the same plane, the magnetic steel plate portions are arranged so that the center of the magnetic steel plate portion is at the apex of the square and the adjacent magnetic steel plate portions are closely attached to each other. A method of manufacturing a rotor of a reluctance motor according to claim 1 or 2. 4. The method of manufacturing a rotor for a reluctance motor according to claim 3, wherein the inner diameter d of the magnetic steel plate portion is larger than (1-1 / (square root of 2)) × D and smaller than D. . 5. The rotation of a reluctance motor according to claim 1, 2, 3 or 4, wherein the magnetic steel plate portion is made of a directional electromagnetic steel plate, a non-oriented electromagnetic steel plate, or those without an insulating film thereof, and a cold rolled steel plate. Child manufacturing method. The reluctance according to claim 1 or 2, wherein the non-magnetic light metal to be the boss portion is aluminum, zinc, magnesium or an alloy thereof, and the magnetic steel plate portion and the boss portion are integrated by die casting or casting. A method for manufacturing a rotor of a motor. 2. When the integrated main body is processed and cut to obtain the rotor, wire electric discharge machining or laser machining is performed, and then cutting by a lathe and post-grinding by a grinding machine are performed. A method for manufacturing a rotor of a reluctance motor according to 2.

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