JP4966721B2 - Rotating electric machine rotor and method of manufacturing the rotating electric machine rotor - Google Patents

Description

  The present invention relates to a rotating electrical machine rotor including a rotor core in which a plurality of divided core plates are arranged in a ring shape and stacked, and a rotating shaft member disposed on the inner peripheral side of the rotor core, and a method for manufacturing the rotating electrical machine rotor .

  For example, the rotor core of an electric motor is configured in a ring shape (cylindrical shape) by laminating thin steel plates formed in a ring shape. For this reason, each thin steel plate is cut out in a ring shape from a plate member, and the inner peripheral part is not utilized.

  Therefore, in order to improve the utilization factor of the plate member, a rotor core composed of a divided core plate made of a plurality of fan-shaped thin steel plates divided in the circumferential direction has been adopted.

  In such a rotor core, the present applicant has proposed a method for manufacturing a rotor core (ring core) in which divided core plates are alternately laminated and molded (see Patent Document 1). According to this manufacturing method, the utilization factor of the plate member can be improved, and the stacking time of the split core plate can be shortened.

  Further, the present applicant has proposed a method of manufacturing a rotor core in which a plurality of divided core plates are arranged in a ring shape and stacked, and then the layers are coupled by inserting coupling members in the stacking direction (Patent Literature). 2). In this manufacturing method, after punching out the connecting portion of each split core plate, the rotor core is more easily and quickly connected by combining the layers while continuously discharging the punched portion returned to the split core plate again by the connecting member. The layers can be bonded together.

JP 2006-223022 A Japanese Patent Application No. 2006-269605

  By the way, in the manufacturing method of the said patent document 2, the process of laminating | stacking a rotor core and the process of inserting and inserting a coupling member are separate processes, and when using the shape | molded rotor core as a rotary electric machine rotor. In addition, it is necessary to assemble the rotating shaft member which is a boss | hub part in the inner peripheral side of this rotor core in another process. Therefore, in manufacturing such a rotating electrical machine rotor, it is desired to further reduce the number of processes and further improve productivity.

  The present invention has been made in relation to the above-described conventional technology, and can provide a rotating electrical machine rotor having a structure capable of further improving productivity, and more efficiently manufacturing the rotating electrical machine rotor. An object of the present invention is to provide a method for manufacturing a rotating electric machine rotor.

  A rotating electrical machine rotor according to the present invention includes a rotor core in which a plurality of divided core plates are arranged and stacked in a ring shape, and each layer is coupled by inserting coupling members along the stacking direction of the divided core plates. A rotary electric machine rotor including a rotary shaft member disposed on an inner peripheral side of the rotor core, wherein the rotary shaft member is inserted into the rotor core, and one end side in the axial direction of the cylindrical portion And a flange portion that is formed in a diametrical direction and has a recess that holds one end of the coupling member. The coupling between the rotor core and the flange portion corresponds to the recess. An end face plate having a through hole into which a member is inserted is interposed.

  According to such a configuration, the assembly of the state in which the coupling member is held in advance between the concave portion provided in the flange portion and the through hole provided in the end face plate is formed by stacking the split core plates. Incorporating into the process, in the laminating process, at the same time as the split core plate is laminated, the coupling member can be fitted into each layer of the rotor core, and the rotor core can be fitted into the cylindrical portion of the rotating shaft member. Can do. That is, the rotating electrical machine rotor according to the present invention can simultaneously perform the steps required for stacking the layers and inserting the coupling member and the rotating shaft member in the manufacturing process. Can be obtained.

  In this case, when a stepped portion having a reduced diameter of the cylindrical portion is provided on the other end side opposite to the one end side in the axial direction in which the flange portion is provided in the cylindrical portion, When holding the coupling member between the recessed portion provided in the portion and the through hole provided in the end plate, the end plate can be disposed in the stepped portion, so during the assembly work, There is no need to press-fit the end face plate into the cylindrical portion, and workability can be further improved.

  The split core plate is formed along the stacking direction, and is provided on a magnet mounting hole in which a magnet is mounted, and on an inner peripheral side of a central position in the circumferential direction of the magnet mounting hole, and the coupling member is inserted and inserted. And a groove corresponding to the convex portion is formed along the axial direction on the outer peripheral side of the cylindrical portion of the rotary shaft member, and the rotor core and the rotary shaft Positioning (phase determination) with the member can be performed more easily.

  Further, when the rotor cores are alternately laminated in such a manner that the phase of the end of each divided core plate between the overlapping layers is shifted from each other by the same phase as the phase difference between the adjacent coupling holes, Thus, the divided core plate can be held (fixed) more firmly, and the durability of the rotating electrical machine rotor according to the present invention in high-speed rotation operation can be improved.

  Furthermore, when the convex portion of the split core plate and the groove portion of the rotating shaft member are fitted, the rotor core and the rotating shaft member can be more firmly coupled, and the present invention It is possible to more reliably prevent the circumferential phase shift due to the rotational torque generated when the rotating electrical machine rotor rotates.

  In the method of manufacturing a rotating electrical machine rotor according to the present invention, a plurality of divided core plates are arranged and stacked in a ring shape, and each layer is bonded by inserting a connecting member along the stacking direction of the divided core plates. And a rotating shaft member having a cylindrical portion fitted on the inner peripheral side of the rotor core, the diameter of the rotating shaft member from one end side in the axial direction of the cylindrical portion. A ring-shaped end face plate is disposed in a stepped portion formed on the other end side in the axial direction of the cylindrical portion so as to face the flange extending in the direction, and a recess formed in the flange And a first step for holding the coupling member by a through hole formed at a position corresponding to the concave portion of the end face plate, and the split core plate is pushed in from one side, thereby The second step of arranging the rotary shaft member so that the end face plate corresponds to the other holding part where the plate is held and laminated, and the laminated core plate is laminated by being pushed into the holding part while being laminated. The end face plate is pressed by the split core plate, and is inserted into the cylindrical portion until the end face plate abuts on the flange portion, and is connected to the coupling hole formed in each split core plate of each layer. And a third step of joining the layers by inserting members.

  According to such a method, the assembly of the rotary shaft member and the end face plate holding the coupling member assembled in the first step is set in the apparatus for stacking the split core plates in the second step. As a result, in the third step, which is the lamination process of the divided core plates, the divided core plates can be laminated, and at the same time, the coupling member can be fitted into each layer of the rotor core, and the cylindrical portion of the rotating shaft member can be inserted into the rotor core. Can be inserted. That is, according to the method of manufacturing a rotating electrical machine rotor according to the present invention, the steps required for stacking the layers and inserting and inserting the coupling member and the rotating shaft member can be performed in parallel. The rotor can be manufactured, and the productivity can be increased.

  According to the present invention, the steps required for stacking the layers constituting the rotor core, inserting the coupling member for coupling the layers, and inserting the rotating shaft member into the rotor core can be performed in parallel. For this reason, it becomes possible to further improve the manufacturing efficiency of a rotating electrical machine rotor, and a rotating electrical machine rotor with high productivity is provided.

  DESCRIPTION OF EMBODIMENTS Hereinafter, a rotating electrical machine rotor according to the present invention will be described in detail with reference to the accompanying drawings by giving preferred embodiments in relation to a manufacturing method for manufacturing the rotating electrical machine rotor.

  FIG. 1 is a perspective view of a rotary electric machine rotor 10 manufactured by a method for manufacturing a rotary electric machine rotor according to an embodiment of the present invention, and FIG. 2 is a cross-sectional view taken along line II-II in FIG. . The rotating electrical machine rotor 10 according to the present embodiment constitutes a rotating electrical machine (electric motor) together with a stator (stator) and the like (not shown).

  The rotating electrical machine rotor 10 includes a rotor core 11 in which thin fan-shaped divided core plates are arranged in a ring shape and laminated, a rotating shaft member (boss portion) 13 disposed on the inner peripheral side of the rotor core 11, and the rotating shaft. It is composed of a flange portion 17 formed on the lower end side of the member 13 and an end face plate 15 interposed between the rotor core 11.

  As shown in FIG. 3, the rotor core 11 is a core plate formed in a ring shape by arranging a plurality of (three in the present embodiment) divided core plates (rotor core pieces) 12 made of thin-plate fan-shaped electromagnetic steel plates in the circumferential direction. A plurality of 14 (in this embodiment, 50) 14 are stacked.

  In such a rotor core 11, pins (coupling members) made of a nonmagnetic material (nonmagnetic material) are provided in four holes (coupling holes) 20 provided in each divided core plate 12, that is, twelve in each layer. ) 22 is inserted along the stacking direction (axial direction), and the respective layers are joined. It should be noted that the number of laminated rotor cores 11 can be appropriately changed according to the use conditions and the like.

  Examples of the nonmagnetic material constituting the pin 22 include aluminum, brass, and austenitic stainless steel. In the case of this embodiment, austenitic stainless steel is used in consideration of strength, availability, and the like. . In the case of aluminum, since the strength is low, the diameter of the pin 22 needs to be increased. In the case of brass, the strength is sufficient, but it is difficult to obtain and the cost may increase.

  In such a rotor core 11, between the overlapping layers, for example, the first layer which is the lowest layer and the second layer which is the upper layer, the end portions (abutment) where the divided core plates 12 constituting each layer abut against each other. The surface (the angular position in the circumferential direction) of the surface is laminated so as to be shifted from each other by the same phase as the phase difference between the adjacent holes 20.

  That is, when the contact position of the end portions of the predetermined two divided core plates 12 of the first layer core plate 14 is indicated by an arrow A1 in FIG. 3, the second layer core plate 14 The abutting position of the end portions of the two predetermined split core plates 12 is indicated by an arrow A2. Similarly, the third-layer core plate 14 is indicated by an arrow A3, the fourth-layer core plate 14 is indicated by an arrow A4, the fifth-layer core plate 14 is indicated by an arrow A1, and the same applies to the upper layer. Laminated in order. In this case, the phases of the arrows A1 to A4 are shifted by 60 °. On the other hand, the contact positions of the end portions in the respective layers, for example, the first layer, are located at a total of three positions in increments of 120 ° with respect to the position indicated by the arrow A1, and the contact positions of the end portions in the second layer. The positions are located at a total of three positions in increments of 120 ° with respect to the position indicated by the arrow A2, and the same applies to the other layers.

  Specifically, as shown in FIG. 4, for example, in the core plate 14 constituting the first layer (lowermost layer), the position A1 of the end portion (abutting surface) where the divided core plates 12 come into contact with each other is predetermined. They are arranged at a total of three locations in increments of angle θ1 (120 ° in this embodiment). And in the core plate 14 which comprises a 2nd layer, position A2 of the edge part which the division | segmentation core plates 12 contact | abut is made into the position which shifted | deviated predetermined angle (theta) 2 (30 degrees in this embodiment) from the said position A1. . Further, in the core plate 14 constituting the third layer, the position A3 of the end is further shifted from the position A2 by a predetermined angle θ2 (30 ° in the present embodiment), and the same applies to the upper layer. Thus, in the rotor core 11, each layer is laminated in a state shifted by the predetermined angle θ2 (30 °). And such a predetermined angle (theta) 2 is the same as the phase difference between the two adjacent hole parts 20 (refer FIG. 4).

  As shown in FIG. 4, the divided core plate 12 is formed with four substantially semicircular convex portions (projecting portions) 24 on the arcuate edge on the inner peripheral side thereof, and each convex portion 24 is divided into divided cores. It arrange | positions at equal intervals in the core plate 14 with which three plates 12 are arrange | positioned. A hole 20 into which the pin 22 is inserted is formed at a substantially central portion of the convex portion 24. Further, the magnetized core plate 12 is formed with four rectangular magnet holes (magnet mounting holes) 28 at substantially equal intervals along the arcuate edge on the outer peripheral side thereof. A magnet (not shown) is inserted into the magnet hole 28 in a state where the core plate 14 is laminated in layers. In this case, each convex portion 24 is in the same phase position as the center of each magnet hole 28.

  As shown in FIG. 5, the rotary shaft member 13 extends in the diametrical direction from a cylindrical portion 16 fitted on the inner peripheral side of the rotor core 11 and from one end side (lower end side) in the axial direction of the cylindrical portion 16. In the state where the rotor core 11 is inserted and formed as a rotary electric machine rotor 10, the rotor core 11 is arranged on the upper surface of the flange portion 17 with the end face plate 15 interposed therebetween ( (See FIG. 2).

  Twelve groove portions 16a extending in the axial direction corresponding to the convex portions 24 of the rotor core 11 are formed on the outer peripheral surface of the cylindrical portion 16 in the circumferential direction, and the flanges corresponding to the positions of the respective groove portions 16a are formed. A concave portion 17a in which the pin 22 is positioned and held is formed on the upper surface side of the portion 17 (see FIGS. 5, 6A, and 6B). Therefore, the rotor core 11 and the rotary shaft member 13 can be firmly coupled by providing a press-fitting allowance for fitting with the groove 16a in the convex portion 24 of the rotor core 11.

  In such a cylindrical portion 16, the cylindrical portion 16 is slightly reduced in diameter on the edge on the other end side (upper end side) opposite to the one end side in the axial direction where the flange portion 17 is provided. A portion 16b is formed. The stepped portion 16b may be formed in a tapered shape with a diameter decreasing toward the tip side.

  On the bottom surface side of the rotary shaft member 13, a cylindrical projection 18 having a smaller diameter and a lower height than the cylindrical portion 16 protrudes (see FIGS. 6B and 6C), and the axial direction of the cylindrical portion 16 and the cylindrical projection 18 The shaft holes 19a to 19c whose inner diameters are changed in three stages pass therethrough.

  As shown in FIG. 5, the end face plate 15 is a ring-shaped thin plate formed in substantially the same shape as the core plate 14, and can be inserted into a cylindrical portion 16 constituting the rotary shaft member 13. Accordingly, twelve convex portions 15a corresponding to the groove portions 16a are formed in the circumferential direction on the inner peripheral side of the end face plate 15, and in each convex portion 15a, the concave portion of the flange portion 17 is formed. A through hole 15b is formed in a substantially central portion corresponding to 17a. The through hole 15b functions to position and hold the pin 22 together with the concave portion 17a of the flange portion 17 during the molding process of the rotating electrical machine rotor 10 described later.

  Next, an example of a method for manufacturing the rotating electrical machine rotor 10 according to the present embodiment basically configured as described above will be described with reference to the drawings.

  FIG. 7 is a schematic plan view showing a configuration of a rotor production line 30 which is a production apparatus for producing the rotary electric machine rotor 10 according to the present embodiment.

  The rotor production line 30 includes a first molding device 31a and a second molding device 31b provided in parallel with the first molding device 31a. In this rotor production line 30, a plate member 32 made of a thin strip-shaped electromagnetic steel sheet straddling the first forming device 31a and the second forming device 31b is conveyed by one pitch in the arrow X direction (each arrow 1P in FIG. 7). The Then, the divided core plate 12 is continuously formed from the plate member 32 in parallel by the first forming device 31a and the second forming device 31b, and the two rotary electric machine rotors 10 are manufactured in parallel by being laminated. Is done.

  The first molding device 31a includes a pilot hole molding die 34, a hole portion molding die 36, and an outer shape extraction return die from the upstream side to which the plate member 32 is conveyed toward the downstream side (arrow X direction). 40, a magnet hole forming die 42, and a rotor forming die 46. Each of these molds includes, for example, an upper mold (not shown) provided with punches for punching holes and divided core plates, and a lower mold that is disposed opposite to the upper mold and on which the plate member 32 is conveyed. (Not shown).

  The second molding device 31b has substantially the same configuration as the first molding device 31a, and the pilot hole molding die 34 and the hole molding die 36 are configured integrally with those of the first molding device 31a. In addition, an outer shape extraction return mold 40, a magnet hole forming mold 42, and a rotor forming mold 46 are sequentially provided on the downstream side slightly spaced from the hole forming mold 36. In the second molding device 31b, the hole molding die 36, the outer shape withdrawal return die 40, the magnet hole molding die 42 and the rotor molding die 46 are respectively compared with those of the first molding device 31a. Are symmetrically configured in a direction orthogonal to the conveying direction (arrow X direction) of the plate member 32.

  FIG. 8 is a partially omitted plan view illustrating a first step of the method for manufacturing the rotating electrical machine rotor 10 by the rotor manufacturing line 30. In this manufacturing method, each step is performed every time the plate member 32 is conveyed by 1 pitch, and a symbol Op is shown in the drawing for a mold operated in each step. When a plurality of molds are operated simultaneously in a single process, the symbol Op is written on all the molds that are operated.

  As shown in FIG. 8, first, in the first step, a pilot hole 47 is formed in the pilot hole forming die 34 of the first molding device 31a and the second molding device 31b with respect to the plate member 32 conveyed by a conveying means (not shown). , 47 and 48, 48 are opened. The pilot holes 47 and 48 are engaged with pilot pins (not shown) provided on each mold and the rotor production line 30 for each process, and function to position the plate member 32 at a predetermined position. The pilot hole 47 is mainly used in the first molding device 31a, and the pilot hole 48 is mainly used in the second molding device 31b.

  In the rotor production line 30, the pilot hole forming die 34 is operated once every two processes, that is, in odd-numbered processes. However, the present invention is not limited to this. For example, the pilot hole forming mold 34 is set to operate in all processes. May be.

  After the pilot holes 47 and 48 are formed in the first step, the plate member 32 is conveyed by 2 pitches (in the direction of arrow X), and the pilot holes 47 and 48 are engaged with the pilot pins to position the plate member 32. To do. In addition, since the positioning operation by the pilot holes 47 and 48 and the pilot pin is usually performed in the same manner in each process, the description thereof will be omitted below.

  FIG. 9 is a partially omitted plan view for explaining a third step of the method for manufacturing the rotating electrical machine rotor 10 by the rotor manufacturing line 30.

  In the third step, new pilot holes 47 and 48 are formed in the pilot hole molding die 34 at a position 2 pitches (upstream side) behind the pilot holes 47 and 48 opened in the first step. At the same time, the hole 20 to be provided in the first split core plate 12 in each molding device 31a, 31b is opened by the hole molding die 36 of the first molding device 31a and the second molding device 31b.

  After the third step, the plate member 32 is conveyed by 1 pitch. Next, the hole forming mold 36 is operated in the same manner as in the third step, and the second divided core plate in each of the forming apparatuses 31a and 31b is located one pitch behind the hole 20 formed in the third step. 12 is opened (fourth step). Thereafter, the plate member 32 is conveyed by one pitch.

  FIG. 10 is a partially omitted plan view for explaining a fifth step of the method for manufacturing the rotating electrical machine rotor 10 by the rotor manufacturing line 30.

  In the fifth step, new pilot holes 47 and 48 are formed in the pilot hole forming die 34 behind the pilot holes 47 and 48 formed in the third step by two pitches. At the same time, by the hole forming mold 36 of the first forming device 31a and the second forming device 31b, the third sheet in each of the forming devices 31a and 31b is placed one pitch behind the hole 20 formed in the fourth step. A hole 20 to be provided in the split core plate 12 is opened.

  After the fifth step, the plate member 32 is conveyed by 3 pitches. Meanwhile, in the seventh step, new pilot holes 47 and 48 are opened by the pilot hole molding die 34. Further, in the sixth and seventh steps, the hole 20 to be provided in the fourth and fifth divided core plates 12 is opened by the hole molding die 36.

  FIG. 11 is a partially omitted plan view for explaining the eighth step of the method for manufacturing the rotating electrical machine rotor 10 by the rotor manufacturing line 30.

  In the eighth step, a new hole portion 20 is formed one pitch behind the hole portion 20 formed in the seventh step by the hole portion molding die 36. At the same time, the outer shape (contour) of the first split core plate 12 molded by the first molding device 31a is punched out by the outer shape extraction mold 40 of the first molding device 31a, and pushback is performed. This push back is a processing method in which when the workpiece (in this case, the divided core plate 12) is punched, the punched workpiece is pushed back to the original position.

  Here, with reference to FIGS. 12A to 12C, the pushback mechanism of the outer shape extraction return mold 40 will be described.

  Under the positioning action by the pilot hole 47 and the pilot pin, first, as shown in FIG. 12A, the plate member 32 is set in the outer shape extraction return mold 40. The outer shape extraction mold 40 is composed of an upper mold 50 and a lower mold 52, and the lower mold 52 includes a pushback mechanism 55.

  Next, as shown in FIG. 12B, the upper die 50 is lowered in the direction of the arrow Y1, and the split core plate 12 is punched out.

  Subsequently, the upper die 50 is raised, and the return portion 53 constituting the pushback mechanism 55 is raised in the arrow Y2 direction.

  That is, as shown in FIG. 12C, the split core plate 12 is pushed back by the pushback mechanism 55 into the hole 32a of the plate member 32 formed by punching the split core plate 12. Thereby, the divided core plate 12 punched out as described above is fitted back into the punched hole portion 32a of the plate member 32 formed by punching itself, and is conveyed to the subsequent steps.

  After such an eighth step, the plate member 32 is conveyed by 4 pitches. Meanwhile, in the ninth and eleventh steps, new pilot holes 47 and 48 are sequentially opened by the pilot hole molding die 34. Further, in the ninth to eleventh steps, new hole portions 20 are sequentially formed by the hole portion forming mold 36, and further, the second to fourth pieces are divided by the outer shape extraction die 40 of the first forming apparatus 31a. The core plate 12 is drawn back.

  FIG. 13 is a partially omitted plan view for explaining a twelfth step of the method of manufacturing the rotating electrical machine rotor 10 by the rotor manufacturing line 30.

  In the twelfth step, a new hole 20 is formed one pitch behind the hole 20 formed in the eleventh step by the hole molding die 36. At the same time, the fifth divided core plate 12 is placed one pitch behind the fourth divided core plate 12 that has been drawn back and formed in the eleventh step by the outer shape drawing / returning die 40 of the first molding device 31a. Draw back and mold. Further, in the twelfth step, the magnet hole 28 is opened in the first divided core plate 12 by the magnet hole forming die 42 of the first forming device 31a.

  After the twelfth step, the plate member 32 is conveyed by 11 pitches. Meanwhile, in the 13th to 22nd steps, the pilot hole forming mold 34 and the hole forming mold 36 of the first forming apparatus 31a and the second forming apparatus 31b, the outer shape extraction mold 40 of the first forming apparatus 31a, and The magnet hole forming mold 42 is appropriately operated, and predetermined processing is performed on the plate member 32.

  FIG. 14 is a partially omitted plan view for explaining the 23rd step of the method of manufacturing the rotating electrical machine rotor 10 by the rotor manufacturing line 30.

  In the 23rd step, new pilot holes 47 and 48 and the hole 20 are formed by the pilot hole forming die 34 and the hole forming die 36 of the first forming device 31a and the second forming device 31b. At the same time, a new split core plate 12 is extracted and molded by the outer shape extraction mold 40 of the first molding device 31 a, and a magnet hole 28 is opened in the new split core plate 12 by the magnet hole molding mold 42.

  In the 23rd step, the first divided core plate 12 reaches the drop-off position D (range surrounded by a dotted line in FIG. 15) of the rotor molding die 46. Accordingly, the rotor molding die 46 is operated, and after the punching with the outer shape withdrawal return die 40, the divided core plate 12 returned by the push back is pulled out. The rotor molding die 46 is sequentially operated in each subsequent process (the 24th process and thereafter), and the rotor core 11 is molded by stacking the divided core plates 12 while arranging them in a ring shape. And the rotating shaft member 13 are fitted together to form the rotary electric machine rotor 10.

  Therefore, a method for forming the rotary electric machine rotor 10 by extracting and stacking the divided core plate 12 from the plate member 32 using the rotor molding die 46 will be described with reference to the drawings.

  As shown in FIGS. 15 to 17, the rotor molding die 46 includes a substantially cylindrical upper frame 54 having a stepped portion 54 a having an annular groove 54 b on the inner peripheral side, and an upper frame 54. And a substantially cylindrical lower frame 60 that supports the lower surface. Furthermore, a substantially cylindrical movable frame 56 disposed on the step 54a of the upper frame 54 and having a step 56a and an annular groove 56b provided on the inner and outer peripheral sides, respectively, and the movable frame The outer guide member 57 includes a ring member (outer guide member, caulking ring) 58 fixed to the step portion 56a. The outer guide member 57 is configured to be rotatable by a rotational driving force of a servo motor (rotational drive source) 59. Note that the ring member 58 and the movable frame 56 may be configured integrally.

  As shown in FIG. 17, on the lower surface side of the upper frame 54 that comes into contact with the lower frame 60, a first passage 54c along the direction of the arrow Y perpendicular to the direction of the arrow X that is the conveying direction of the plate member 32 is provided. And a second passage 54d slightly larger than the first passage 54c communicates, and a carry-out member 63 that can advance and retreat in the arrow Y direction is disposed in the first passage 54c.

  Further, in the rotor molding die 46, the inner circumferential side of the ring member 58 is backed up at the tip side of a stepped cylindrical rod portion 62 constituting a hydraulic cylinder mechanism (back pressure applying mechanism) 61. An inner guide member (guide member) 64 held at a predetermined position (height) is disposed.

  The hydraulic cylinder mechanism 61 is configured such that the rod portion 62 inserted through the inner peripheral side of the movable frame body 56, the upper frame body 54, and the lower frame body 60 can be raised and lowered and stopped at a predetermined position. A flange portion 62a is provided on the lower end side. The flange portion 62a functions as a positioning portion for preventing the rod portion 62 from rising above a predetermined position (height) by contacting the flange portion 60a formed on the inner peripheral portion of the lower frame body 60. . Further, a stepped portion 62c is provided on the distal end side (upper end side) of the rod portion 62 to form a distal end rod 62b through which a bearing 66 and a table 68 are inserted in order. The bearing 66 has a lower surface secured to the bottom surface of the stepped portion 62c, and a table 68 secured to the upper surface. That is, the table 68 is rotatably supported by the bearing 66 around the tip rod 62b.

  As shown in FIGS. 16 and 17, the rotary shaft member 13 that positions and holds the pin 22 together with the end face plate 15 is attached to the distal end side of the rod portion 62.

  Here, FIG. 18 is an enlarged view of a main part along the line XVI-XVI in FIG. 15 for explaining the assembled state of the rotary shaft member 13, the end face plate 15 and the pin 22 when attached to the distal end side of the rod part 62. It is sectional drawing. As shown in FIG. 18, when the rotary shaft member 13 and the end face plate 15 are attached to the distal end side of the rod portion 62, the groove portion 16 a formed in the cylindrical portion 16 of the rotary shaft member 13 and the convexity of the end face plate 15. The end face plate 15 is positioned and placed on the stepped portion 16b of the cylindrical portion 16 in a state where the portions 15a are engaged with each other. At this time, one end (upper end) of the pin 22 is fitted into each through hole 15b of the end face plate 15, while the other end (lower end) of the pin 22 is inserted into each recess 17a of the flange portion 17 corresponding to each through hole 15b. Is fitted. Accordingly, the twelve pins 22 for connecting the rotor core 11 are securely held between the end face plate 15 and the flange portion 17.

  Therefore, when the assembled assembly of the rotary shaft member 13, the end face plate 15 and the pin 22 assembled as shown in FIG. 18 is attached to the distal end side of the rod portion 62, the second stage shaft hole of the rotary shaft member 13. The tip rod 62b constituting the rod portion 62 is inserted into 19b, and the cylindrical projection 18 on the bottom surface side of the rotary shaft member 13 is seated on the upper surface of the table 68 (see FIGS. 16 and 17). Then, the upper surface of the cylindrical portion 16 of the rotary shaft member 13 seated on the table 68 and the upper surface of the end surface plate 15 substantially constitute the tip surface of the rod portion 62. Further, the shaft hole 19 a of the rotating shaft member 13 functions as a relief portion of a convex portion (the head of a bolt 69 described later) provided on the lower surface of the inner guide member 64.

  On the other hand, the inner guide member 64 functions to support and guide an annular edge on the inner peripheral side of the core plates 14 that are sequentially stacked by the outer peripheral surface thereof. Such an inner guide member 64 includes a first guide member (piece member) 76 that abuts on the inner peripheral side of the core plate 14 and a second spring disposed inside the first guide member 76 via a leaf spring 78. A set of guide members (piece members) 80 is arranged on the inner peripheral side of the outer member 82 in which a plurality of sets (12 sets in the case of this embodiment) are arranged in a ring shape, and the outer member 82 And a central member 84.

  On the inner peripheral side of the second guide member 80, inclined surfaces 80a and 80b are formed which are inclined while increasing in diameter in the vertical direction from a substantially central portion in the height direction, and the central member 84 includes these inclined surfaces 80a. And a pair of wedge members 86a and 86b having a truncated cone shape corresponding to 80b. A screw hole 87 passes through the axial center of the wedge members 86a and 86b, and a bolt 69 is screwed into the screw hole 87. Further, a spacer (shim) 88 is inserted in a portion sandwiched between the wedge members 86a and 86b. The spacer 88 defines the position of the wedge members 86a and 86b in the axial direction (vertical direction) when the bolt 69 is screwed into the screw hole 87 and the wedge members 86a and 86b are fastened to each other. is there.

  Therefore, in the inner guide member 64, by changing the thickness of the spacer 88 inserted between the wedge members 86a and 86b, the position of the wedge members 86a and 86b in the axial direction when the bolt 69 is fastened (wedge member). 86a and 86b) can be set as appropriate. Thereby, the position of the second guide member 80 in the diametrical direction is appropriately adjusted by the sliding contact between the inclined surfaces 80a and 80b and the wedge members 86a and 86b. That is, when the plate thickness of the spacer 88 is reduced, the wedge member 86a and the wedge member 86b come close to each other. For this reason, when the second guide member 80 is pressed in a direction that expands in the diameter direction, the outer member 82 is expanded in the diameter direction (radial direction), and the gap between the first guide member 76 and the ring member 58 is increased. 89 dimension R1 (see FIG. 15) is shrunk. On the contrary, when the plate thickness of the spacer 88 is increased, the wedge member 86a and the wedge member 86b are separated from each other. For this reason, the outer member 82 is reduced in the diameter direction (radial direction), and the dimension R1 of the gap 89 between the first guide member 76 and the ring member 58 is increased.

  An annular groove 80c is provided around the outer periphery of the second guide member 80, and an annular protrusion 76b provided around the inner periphery of the first guide member 76 is engaged with the annular groove 80c. is doing. Accordingly, the first guide member 76 and the second guide member 80 are integrally formed with each other in the vertical direction.

  In the inner guide member 64 configured as described above, the outer peripheral surface of the outer member 82, that is, the outer peripheral surface formed by the first guide members 76 arranged in a ring shape, is the core plate 14 that is sequentially stacked. The shape corresponds to the inner peripheral annular edge. Accordingly, a plurality of groove portions 76 a extending in the axial direction are formed on the outer peripheral surface constituted by the first guide members 76 arranged in a ring shape, and these groove portions 76 a are formed on the inner peripheral side of the core plate 14. It is possible to engage with the formed convex portion 24.

  As shown in FIGS. 16 and 17, the servo motor 59 is fixed to the rotor 59 a fixed to the annular groove 54 b of the upper frame 54 and the annular groove 56 b of the movable frame 56 constituting the outer guide member 57. And a stator 59b. In this case, the rotor 59a is provided so as to surround the outer peripheral surface of the movable frame 56 in a band shape, and the stator 59b is disposed so as to face the rotor 59a. That is, the servo motor 59 is configured as a so-called direct drive motor in which the rotor 59a is directly disposed on the movable frame body 56 that constitutes the outer guide member 57 to be rotationally driven.

  Therefore, the rotor 59a can be rotated by a predetermined angle by passing a current through a coil (not shown) provided in the stator 59b under the control of the servo control unit 90, and together with the rotor 59a, the outer guide member 57 ( The movable frame 56 and the ring member 58) can be rotated at a predetermined angle with high accuracy and quickly. At this time, a sensor 91 may be disposed in the vicinity of the outer guide member 57, and rotation angle information and angular position (phase) information of the outer guide member 57 detected by the sensor 91 may be input to the servo control unit 90. . Then, the servo control unit 90 can perform feedback control of the servo motor 59 based on the rotation angle information and the angular position information, thereby enabling more accurate rotation control. Instead of the servo motor 59, for example, a rotary actuator driven by air pressure may be used.

  Three bearings 92 to 94 are disposed between the movable frame 56 constituting the outer guide member 57 and the upper frame 54, thereby ensuring a smooth rotation operation of the outer guide member 57. Has been. These bearings 92 to 94 also have a function as a receiving portion that receives a pressing force from the inner guide member 64 and the punch 96 described later with respect to the outer guide member 57.

  In the rotor mold 46 configured as described above, the outer peripheral surface of the first guide member 76 constituting the inner guide member 64 and the outer guide member 57 are adjusted under the position adjustment of the wedge members 86a and 86b by the bolt 69. The dimension R1 of the gap 89 formed between the inner peripheral surface of the ring member 58 that constitutes the ring member 58 (see FIG. 15) is the dimension R2 that is the radial width of the divided core plate 12 (see FIGS. 4, 15, and FIG. 16 (see FIG. 16) and so on (R1 <R2). Thereby, in the rotor molding die 46, the gap 89 can be functioned as a holding portion 89 for holding the divided core plate 12 that has been removed from the plate member 32.

  In this case, at the initial stage of operation of the rotor molding die 46, that is, at the start of lamination of the divided core plates 12, the rotor core 11 (FIG. 5) is a laminated body in which a predetermined number of core plates 14 are laminated (in the case of this embodiment, a total of 50). 3), the first and second dummy members 98a and 98b having substantially the same shape are fitted into the holding portion 89. Thereby, each component (the 1st guide member 76, the 2nd guide member 80, the center member 84, etc.) which constitutes inner guide member 64 can be united and can be certainly positioned and held in a desired position. It is possible to reliably prevent the guide member 76 and the like from falling off.

  Therefore, in the rotor molding die 46, the first split core first pulled back to the plate member 32 by the outer shape withdrawal die 40 under the positioning action of the pilot hole 47 and the pilot pin of the plate member 32. The plate 12 passes over the inner guide member 64 and is set on the holding portion 89 (see FIG. 16). That is, the first divided core plate 12 is set on the rotor molding die 46 at the drop-off position D in FIG.

  Next, as shown in FIG. 16, the punch 96 is lowered and the first divided core plate 12 is pulled out from the plate member 32.

  Then, the split core plate 12 that has been pulled out is slidably in contact with the outer peripheral surface of the inner guide member 64 and the inner pressure is applied to the outer peripheral arc-shaped edge at the holding portion 89. The portion is in sliding contact with the inner peripheral surface of the ring member 58 and a lateral pressure (external pressure) is applied. That is, the split core plate 12 that has been removed is press-fitted and held in the holding portion 89 (gap 89) under the positioning action of the convex portion 24 and the groove portion 76a. The same positioning effect can be obtained even if the convex portion 24 is formed as a concave portion and the groove portion 76a is formed as a convex portion.

  Here, the first guide member 76 of the inner guide member 64 is elastically supported in the diametrical direction via the leaf spring 78 with respect to the second guide member 80. For this reason, when the divided core plate 12 is press-fitted into the holding portion 89, variations in the width dimension R2 due to processing errors of the divided core plate 12 and differences in processing lots, wear of the inner guide member 64 and the outer guide member 57, and the like. The split core plate 12 can be stably held by the holding portion 89 without being substantially affected by the variation in the width dimension R1 of the holding portion 89. Furthermore, since the split core plate 12 can be prevented from being forced into the holding portion 89, it is possible to effectively prevent the split core plate 12, the first guide member 76, and the ring member 58 from being deformed or damaged. Thus, the smooth press-fitting of the split core plate 12 into the holding portion 89 is possible.

  Accordingly, as shown by a two-dot chain line in FIG. 16, the split core plate 12 is held by the holding portion 89 (see FIG. 19A), and at the same time, the first and second dummy members 98a and 98b are held on the lower surface side. Push downward by the thickness of the split core plate 12. For this reason, the first dummy member 98a held at the bottom presses the end face plate 15 positioned by the stepped portion 16b of the rotating shaft member 13 downward. Thus, the pin 22 is inserted into the through hole 15b of the end face plate 15 by the thickness of the split core plate 12, and the cylindrical portion is formed on the inner peripheral side of the end face plate 15 by the thickness of the split core plate 12. 16 is inserted. In other words, the end face plate 15 is pushed down by the thickness of the divided core plate 12 and is press-fitted into the cylindrical portion 16, and the pin 22 held between the through hole 15b and the concave portion 17a is also moved accordingly. The plate thickness is pressed into the through hole 15b. At the same time, the pin 22 is press-fitted by the thickness of the split core plate 12 into the hole 20 formed in the first dummy member 98 a in substantially the same manner as the hole 20 of the rotor core 11.

  Of course, it is not necessary to insert the pin 22 into the first and second dummy members 98a and 98b, so the rotation until the first laminated body (rotor core 11) is formed. The end face plate 15 and the pin 22 may not be assembled to the shaft member 13. In addition, a dummy rotating shaft member simulating the rotating shaft member 13 can be fitted into the first and second dummy members 98a and 98b, that is, the dummy rotating shaft member is set on the rod portion 62. You may keep it.

  Thus, when the first dummy member 98a is pushed down, the second guide member 80 and the central member 84 constituting the inner guide member 64 are given back pressure by the rod portion 62 via the table 68 and the bearing 66. Have been backed up. For this reason, it is not displaced by the downward pressing force by the punch 96 and is held at a predetermined position (original position). Furthermore, since the first guide member 76 has the annular convex portion 76b engaged with the annular groove portion 80c of the second guide member 80, the first guide member 76 also includes the split core plate 12 and the first and second core plates 12. The dummy members 98a and 98b are not pushed downward and are held in the original position.

  Further, when the divided core plate 12 is press-fitted into the holding portion 89, the inner guide member 64 (first guide member 76) and the outer guide member 57 (ring member 58) are pressed by the pressing force from the punch 96. A pressing force is applied in the diameter direction (radial direction) and the axial direction (vertically downward). Therefore, in the rotor molding die 46, the bearing 66 functions as a receiving portion for the pressing force in the axial direction of the inner guide member 64, and the bearings 92 to 94 are arranged in the diameter direction of the outer guide member 57 (movable frame body 56). It functions as a receiving part for the pressing force in the axial direction. For this reason, the inner guide member 64 and the outer guide member 57 (movable frame body 56) are extremely pressed against the rod portion 62 and the upper frame body 54, and smooth rotation operation in the subsequent steps is hindered. This can be effectively prevented. Further, the bearings 92 and 93 also function as receiving portions for the pressing force in the diametrical direction from the inner guide member 64 due to the urging force of the leaf spring 78.

  Although the 23rd step is completed as described above, the operation of the rotor molding die 46 after the 24th step will be described.

  In the 24th step, in the rotor molding die 46, first, the first split core plate 12 removed in the 23rd step is held by the holding portion 89 (see FIG. 19A), and then the servo motor 59 is used. And the movable frame 56 and the ring member 58 constituting the outer guide member 57 are turned by a predetermined angle θ1 (120 ° in the present embodiment) (see FIG. 19B).

  In this case, the split core plate 12 and the first and second dummy members 98a and 98b are press-fitted into the holding portion 89 based on the relationship of the dimension R1 <dimension R2 described above, and the split core plate The 12 convex portions 24 and the convex portions (not shown) of the first and second dummy members 98 a and 98 b are engaged with the groove portions 76 a of the inner guide member 64. For this reason, the rotation of the outer guide member 57 is transmitted to the inner guide member 64 via the split core plate 12 press-fitted into the holding portion 89. Therefore, the inner guide member 64 also turns by the predetermined angle θ1 in synchronization with the outer guide member 57 under the backup action by the hydraulic cylinder mechanism 61. In other words, the divided core plate 12 held by the holding portion 89 also turns with the outer guide member 57 by a predetermined angle θ1.

  When such a member rotates, the movable frame 56 constituting the outer guide member 57 is supported by bearings 92 and 93 on its side surface and supported by the bearing 94 on its lower surface. The inner guide member 64 is supported by bearings 66 on the lower surfaces of the first guide member 76 and the second guide member 80 via the rotary shaft member 13 and the table 68. Further, the lower surface of the first dummy member 98 a press-fitted into the holding portion 89 is also supported by the bearing 66 through the end face plate 15, the rotary shaft member 13 and the table 68. Therefore, in the case of this embodiment, in the rotor molding die 46, the rotational driving force from the servo motor 59 is hardly attenuated by friction between the members, and the outer guide member 57 rotates smoothly and reliably. Is transmitted to the split core plate 12 and the first and second dummy members 98a and 98b. For this reason, it is possible to turn and position the divided core plate 12 at a predetermined angle θ1 with high accuracy and speed.

  Next, the second divided core plate 12 is removed and press-fitted into the holding portion 89 in the same manner as the first divided core plate 12. Then, as shown in FIG. 19B, the second divided core plate 12 that has been removed is arranged side by side with respect to the first divided core plate 12 in the circumferential direction.

  In the 25th step, in the rotor molding die 46, similarly to the 24th step, after the outer guide member 57 is further turned by a predetermined angle θ1, the third divided core plate 12 is pulled out into the holding portion 89 and press-fitted. To do. Then, the removed third divided core plate 12 is arranged on the same plane side by side with the first and second divided core plates 12 to form a ring-shaped core plate 14. The core plate 14 thus formed constitutes the lowermost layer (first layer) of the rotor core 11.

  In the twenty-sixth step, in the rotor molding die 46, as shown in FIG. 19C, the outer guide member 57 is first moved to a predetermined angle θ2 (this embodiment) while the first-layer core plate 14 is held by the holding portion 89. In the embodiment, the core plate 14 of the first layer is turned by a predetermined angle θ2 by turning.

  Next, the fourth divided core plate 12 is removed and press-fitted so as to be laminated on the first core plate 14.

  In this case, since the first-layer core plate 14 has been turned by a predetermined angle θ2 in advance, the fourth divided core plate 12 that has been removed is replaced by two sheets of the first-layer core plate 14. The divided core plates 12 (here, the first and third divided core plates 12) are laminated in correspondence with each other on the end A1 in contact (see FIG. 19C). Further, the divided core plate 12 thus pulled out is fitted into the holding portion 89 by a punching load (pressing force) by the punch 96 as in the case of the divided core plate 12 constituting the first layer. At the same time, the laminated core plate 12 and the first and second dummy members 98a and 98b are laminated while being pushed down. At this time, since the predetermined angle θ2 is in phase with the phase difference between the adjacent hole portions 20 of the core plate 14, the hole portions 20 of the divided core plates 12 that are sequentially stacked are arranged in the stacking direction. It is formed as a matching through hole.

  20A and 20B are cross-sectional views of the rotor molding die 46, in which the divided core plates 12 are sequentially stacked while being held by the holding portion 89, and are developed 360 ° in the circumferential direction. 20A and 20B, numerals [1] to [9] attached in the vicinity of each divided core plate 12 indicate the order of molding in the rotor production line 30, for example, [1]. Indicates the first split core plate 12, and [4] indicates the fourth split core plate 12. 20A and 20B, a reference line C indicated by a broken line first punches the first to third divided core plates 12 (first-layer core plate 14), It is the held position (height).

  That is, in the 27th and 28th steps, first, the outer guide member 57 is turned by a predetermined angle θ1 (120 °) by the servo motor 59, and the core plate 14 and the fourth divided core plate 12 are turned by a predetermined angle θ1. Next, the fifth and sixth divided core plates 12 are removed. As a result, the core plate 14 serving as the second layer of the rotor core 11 is laminated on the first layer core plate 14 while being shifted from the first layer by a predetermined angle θ2 (30 °). At this time, the holes 20 of the first layer and the second layer core plates 14 are laminated to coincide with each other (see FIG. 20A).

  Similarly, in the 29th step, first, the outer guide member 57 is turned by a predetermined angle θ2 (30 °), and the core plates 14 of the first layer and the second layer are turned by a predetermined angle θ2, and then the seventh sheet is divided. The core plate 12 is pulled out on the second layer. Next, the first and second core plates 14 and the seventh divided core plate 12 are turned by a predetermined angle θ1 (120 °), and the eighth and ninth divided core plates 12 are pulled out (30th). And 31st process) (refer FIG. 20B). As a result, the core plate 14 serving as the third layer of the rotor core 11 is laminated on the second layer with a predetermined angle θ2 (30 °) shifted from the second layer.

  Since the method of removing and stacking the split core plate 12 by the rotor molding die 46 in the 32nd step and after is substantially the same as the case of the 29th step to the 31st step (see FIG. 20B), a detailed description will be given. Omitted. In addition, about each process after the said 24th process, although only operation | movement by the rotor shaping | molding metal mold | die 46 was demonstrated, it cannot be overemphasized that another metal mold | die is also operate | moved suitably and predetermined processing with respect to the plate member 32 is implemented.

  Also in the second molding apparatus 31b, when the plate member 32 is sequentially conveyed and reaches the predetermined machining positions of the outer shape extraction mold 40, the magnet hole molding mold 42, and the rotor molding mold 46, the second molding apparatus 31b As in the case of the first forming apparatus 31a, predetermined processing is performed on the plate member 32. For example, as shown in FIG. 21, in the 43rd step, the first split core plate 12 is removed by the rotor molding die 46 in the second molding apparatus 31b.

  After that, in the rotor molding die 46 of the first molding device 31a and the second molding device 31b, the stacking operation is continued until the number of stacked layers is a predetermined number of layers (in this embodiment, 50 layers). Then, when the core plate 14 is laminated up to a predetermined number of layers (50th layer), the laminated body 11a consisting of 50 layers in total is formed on the upper portion of the second dummy member 98b while being held by the holding portion 89. (See FIG. 22).

  When the laminated body 11a is formed in this way, the first dummy member 98a pushed down by the laminated body 11a is completely detached from the holding portion 89, and becomes the rotating shaft member 13 (or a dummy rotating shaft member). It will be in the state inserted completely (refer FIG. 22). Therefore, the combined body of the first dummy member 98a and the rotating shaft member 13 is carried out of the apparatus. In this case, the carrying-out method is carried out of the rotating electrical machine rotor 10 shown in FIGS. 24A to 24C described later. Since it is substantially the same as the method, detailed description is abbreviate | omitted.

  In the rotor molding die 46, when the first dummy member 98a is carried out, a new rotating shaft member 13 (see FIG. 18) or a dummy rotating shaft member is attached to the distal end side of the rod portion 62. Next, the first divided core plate 12 (151 from the first step) in the second round is laminated on the molded laminate 11a, and the divided core plates 12 are sequentially described above. Similar to the process, the layers are stacked up to a predetermined number.

  Then, a new laminate 11b is formed on the laminate 11a. In this state, the second dummy member 98b is completely detached from the holding portion 89 and completely inserted into the rotation shaft member 13 (or a dummy rotation shaft member). The combined body of 98b and the rotary shaft member 13 is carried out of the apparatus in the same manner as the first dummy member 98a.

  When the second dummy member 98b is carried out in this manner, as shown in FIG. 23A, an assembly of a new rotating shaft member 13, end face plate 15 and pin 22 (see FIG. 18).

  Next, the first divided core plate 12 in the third time (301st from the first step) is further laminated on the laminated body 11b, and the divided core plate 12 is sequentially applied to each step described above. Laminate in the same way. Then, as shown in FIG. 23B, the formation of a new laminated body 11c is started on the molded laminated body 11b, and at the same time, the first laminated body 11a positioned at the lowermost part is gradually detached from the holding portion 89. I will do it. That is, the laminated body 11 a is pushed down by the thickness of the core plate 14 by the laminated body 11 c that is gradually laminated and formed.

  Specifically, as in the case of the first dummy member 98a described above, first, the laminated body 11a is formed by the divided core plate 12 of the first laminated body 11c (the 301st sheet from the first step). The end plate 15 is pressed by being pushed down by the thickness of the divided core plate 12. As a result, the end face plate 15 is pushed down by the thickness of the split core plate 12 to be removed from the stepped portion 16b and press-fitted into the cylindrical portion 16, and accordingly, the pin held between the through hole 15b and the recessed portion 17a. 22 is press-fitted into the through hole 15b by the thickness of the divided core plate 12. At the same time, the pins 22 are press-fitted into the hole 20 of the laminated body 11a by the thickness of the divided core plate 12.

  Next, as the divided core plate 12 constituting the laminate 11c is sequentially press-fitted into the holding portion 89 by the punch 96, the laminate 11a gradually fits into the cylindrical portion 16 of the rotary shaft member 13 while pushing down the end face plate 15. The pins 22 are gradually inserted into the holes 20 of the laminate 11a (see FIG. 23B).

  And when the core plate 14 which comprises the laminated body 11c is laminated | stacked to the predetermined number of layers (50 layers), as shown to FIG. 23C, the new laminated body 11c will be formed on the laminated body 11b. . At the same time, the first laminate 11a is completely detached from the holding portion 89, and the pin 22 is completely inserted into the hole 20 of the core plate 14 of each layer to form the rotor core 11, and the inner peripheral side thereof is The rotary shaft member 13 is completely inserted and integrated. Further, the end face plate 15 pushed down by the laminated body 11a comes into contact with the flange portion 17 of the rotary shaft member 13, and is sandwiched between the flange portion 17 and the rotor core 11 (FIGS. 1 and 2). reference). Thereby, each layer of the rotor core 11 is firmly coupled by the pins 22, and the rotor core 11 and the rotating shaft member 13 are firmly coupled by the fitting operation of the convex portion 24 and the groove portion 16a. 10 is molded.

  Therefore, in the rotor molding die 46, the rod portion 62 of the hydraulic cylinder mechanism 61 is lowered from the state shown in FIG. 23C. Accordingly, when the flange portion 17 of the rotating shaft member 13 constituting the molded rotating electrical machine rotor 10 is caught on the upper end edge of the hole portion through which the rod portion 62 of the lower frame 60 is inserted, the rotating electrical machine rotor 10 is It will detach | leave from the rod part 62 and will be mounted on the upper surface of this lower frame 60 (refer FIG. 24A).

  In this case, since the laminated bodies 11b and 11c formed on the upper part of the rotating electrical machine rotor 10 are press-fitted between the holding portions 89, that is, the ring member 58 and the inner guide member 64, the rod portion 62 is lowered. In addition, the inner guide member 64 does not fall. In addition, since the first guide member 76, which is the outer peripheral portion of the inner guide member 64, is urged in the diameter direction (radial direction) by the leaf spring 78, the inner guide member 64 is more reliably prevented from falling.

  Therefore, as shown in FIG. 24B, the rotary electric machine rotor 10 can be easily carried out from the rotor molding die 46 by moving the carry-out member 63 on the upper surface of the lower frame 60 in the horizontal direction (arrow Y direction). Can do. At this time, the upper surface of the lower frame 60 corresponding to the second passage 54d of the upper frame 54 from which the rotating electrical machine rotor 10 is carried out has a diameter larger than the diameter of the cylindrical protrusion 18 protruding toward the bottom surface of the rotary shaft member 13. A rail-shaped groove 60b having a width that is larger than the diameter of the flange 17 and deeper than the height of the cylindrical protrusion 18 is provided. Then, when the rotating electrical machine rotor 10 is unloaded by the unloading member 63, the cylindrical protrusion 18 can be prevented from being caught by the upper end edge of the hole portion through which the rod portion 62 of the lower frame 60 is inserted, and the groove portion 60b is formed. Since it can be used as a rail for carrying out the rotary electric machine rotor 10, the rotary electric machine rotor 10 can be carried out from the rotor molding die 46 smoothly and reliably.

  Thereafter, in the rotor molding die 46, a new rotating electrical machine rotor is formed by the next laminate 11b, so that a new rotating shaft member 13, end face plate 15 and pins are formed on the upper surface of the lower frame 60 as shown in FIG. 24C. After the 22 assembled bodies (see FIG. 18) are placed, the rod portion 62 is raised, and the assembled body is moved to the distal end side of the rod portion 62 in the same manner as in the case of the first laminated body 11a shown in FIG. Set to. Thereby, in the rotor manufacturing line 30, a new laminated body is formed on the laminated body 11c, and such operations are continuously performed, so that the rotating electrical machine rotor 10 can be formed from one strip-shaped plate member 32. Can be continuously formed and automatically carried out.

  As described above, according to the present embodiment, as shown in FIG. 21, the divided core plate 12 can be cut out from the single plate member 32 with almost no gap, and the utilization factor of the plate member 32 can be further improved. Can do. Further, the divided core plate 12 can be formed while the plate member 32 is continuously conveyed, and these can be quickly stacked. Therefore, the rotating electrical machine rotor 10 can be formed with high efficiency and speed, and the manufacturing efficiency is extremely high.

  In this case, in the rotor molding die 46 in which the divided core plates 12 are arranged in a ring shape and stacked, from one end side (upper end side) to the other end side (lower end side) of the holding portion 89 into which the divided core plate 12 is press-fitted. Then, the assembly (see FIG. 18) composed of the rotary shaft member 13, the end surface plate 15, and the pin 22 is set on the distal end side of the rod portion 62 of the hydraulic cylinder mechanism 61 with the end surface plate 15 associated therewith. Thereby, in the rotor molding die 46, the rotor core 11 can be molded from each divided core plate 12, and at the same time, the layers of the rotor core 11 can be coupled by the pins 22, and the rotary shaft member 13 is fitted to the rotor core 11. Can be inserted.

  That is, in the rotor molding die 46, each process can be performed simultaneously and the rotating electrical machine rotor 10 can be molded from the divided core plate 12 at once. For this reason, according to this embodiment, there is no need to separately provide a step of inserting and inserting the pin 22 into the rotor core 11 and a step of inserting the rotating shaft member 13 into the rotor core 11, and an apparatus used for each of these insertion steps. There is no need to prepare it separately. Therefore, the rotating electrical machine rotor 10 according to this embodiment manufactured using the rotor molding die 46 and the assembly (see FIG. 18) composed of the rotating shaft member 13, the end face plate 15 and the pins 22 is produced. In addition, the method of manufacturing the rotating electrical machine rotor 10 according to the present embodiment makes it possible to manufacture the rotating electrical machine rotor 10 more efficiently. In addition, when the rotary shaft member 13, the end face plate 15 and the pin 22 are assembled (see FIG. 18), the end face plate 15 is disposed on the stepped portion 16b of the rotary shaft member 13, so that the end face plate 15 is cylindrical during the assembling operation. There is no need to press fit into the portion 16, and workability can be further improved.

  Moreover, in the rotary electric machine rotor 10 which concerns on this embodiment, each division | segmentation core plate 12 is laminated | stacked so that it may be brick-stacked alternately. For this reason, the shear load which acts on a pin at the time of the use can be disperse | distributed effectively. Further, in the rotor core 11 constituting the rotating electrical machine rotor 10, the divided core plates 12 constituting each layer are applied between the overlapping layers, for example, the first layer as the lowermost layer and the second layer as the upper layer. The layers are stacked in a state where the phases of the end portions in contact with each other are shifted from each other by the same phase as the phase difference between the adjacent hole portions 20. For this reason, the laminated core plates 12 can be held (fixed) more firmly, and the durability of the rotating electrical machine rotor 10 in high-speed rotation operation can be improved.

  Further, in the rotating electrical machine rotor 10, the rotor core 11 is provided with a convex portion 24, and the convex portion 24 is provided with a press-fitting allowance for fitting with the groove portion 16 a of the rotary shaft member 13. Thereby, positioning (phase determination) with the rotor core 11 and the rotating shaft member 13 becomes easy, and these can be combined more firmly. Therefore, the circumferential phase shift due to the rotational torque generated when the rotating electrical machine rotor 10 rotates can be effectively prevented. In this case, in the rotating electrical machine rotor 10, the end portions (abutting surfaces) of the respective divided core plates are formed in a straight shape. For this reason, even when a gap is generated on the abutting surface due to centrifugal force when the rotary electric machine rotor 10 is used, a uniform gap is ensured, which is caused by concentration of magnetic flux or magnetic saturation caused by partial contact. Since disturbance of the induced voltage output waveform can be effectively suppressed, the phase angle detection sensitivity can be improved.

  By the way, in the rotor molding die 46, the rotation mechanism for rotating the outer guide member 57 and changing the phase of the divided core plate 12 is constituted by a servo mechanism including a servo motor 59 and a servo control unit 90. ing. Therefore, the phase change can be executed with high accuracy and high responsiveness, and the setting can be easily changed even when the manufactured part changes. Moreover, in the servo motor 59, the rotor 59a is directly disposed on the movable frame 56 constituting the outer guide member 57, and the stator 59b is directly disposed on the upper frame 54 that supports the outer guide member 57. Yes. For this reason, for example, compared to a configuration in which the outer guide member 57 is rotationally driven from a motor via a belt, it is possible to improve the accuracy and speed of positioning of a desired removal position (index), and the rotating electrical machine rotor 10 manufacturing time can be shortened.

  Further, the rotor of the servo motor 59 in the movable frame 56 that supports the ring member 58 in order to counter the pressing force from the inner guide member 64 due to the urging force of the leaf spring 78 and the punch 96 that pulls out the divided core plate. Bearings 92 and 93 are arranged on both sides of 59a, and a bearing 94 is arranged on the lower surface of the movable frame 56. Thereby, distortion and a deformation | transformation of the ring member 58 and the movable frame 56 can be prevented effectively, and the outer peripheral side of a division | segmentation core plate can be supported stably. Further, by arranging the bearings 92 and 93, unnecessary stress can be prevented from being applied to the servo motor 59, and malfunction of the servo motor 59 can also be prevented.

  In the rotating electrical machine rotor 10 according to the present embodiment, a nonmagnetic material is used for the pin 22, and the hole 20 (projection 24) into which the pin 22 is inserted is laid out at the same phase position as the center of the magnet hole 28. Yes. At this time, the pin 22 is offset by the convex portion 24 to a position closer to the central axis of the rotor core 11 than the inner diameter of the rotor core 11. The same pitch as the inner diameter of the rotor core 11 may be used. Thereby, it can prevent effectively that the pin 22 obstruct | occludes the magnetic path by the magnet etc. which are engage | inserted by the said magnet hole.

  Specifically, since the pin 22 is formed of a non-magnetic material, the magnetic flux that is a magnetic flow passing through the rotor core 11 constituting the rotating electrical machine rotor 10 passes through the pin 22, so that eddy current is generated. Heat generation is suppressed, and it is possible to suppress a decrease in fuel consumption and output. This is because the magnetic flux does not pass through the non-magnetic material. In this case, if the pin 22 is a metal such as S50C, the magnetic flux passes through the pin 22 and generates heat, resulting in loss.

  In addition, the pin 22 is laid out in the above-described conditions (for example, at the same phase position as the center of the magnet hole 28 or at a position closer to the center axis of the rotor core 11), that is, at a position where the magnetic flux density is low. Can be further suppressed. That is, when the magnetic field analysis is performed under each of these conditions, the peak value of the induced voltage curve is that using the pin 22 (for example, the rotor core 11 constituting the rotating electrical machine rotor 10) and the pin 22 is not used. As a result, it was found that there was almost no difference in performance in output due to the presence or absence of the pin 22 between them.

  Although the number of divided core plates constituting each layer is three in each of the above embodiments, it is needless to say that the number of divided core plates is not limited to this, and when the number is changed, the angles θ1 and θ2 are also adjusted. You can change it. Similarly, the number of protrusions 24 and the number of pins 22 can be changed as appropriate.

  Moreover, the arrangement | positioning etc. of each metal mold | die which comprises the rotor manufacturing line 30 can be changed, and the structure of each metal mold | die can also be changed according to the shape etc. of the rotary electric machine rotor manufactured.

  The rotor production line 30 has been described as being capable of producing two rotating electrical machine rotors simultaneously from the plate member 32, but these may be only one or three or more.

  Furthermore, in each said embodiment, the division | segmentation core plate 12 can also be formed as what was formed with six magnet holes, for example.

  Note that the present invention is not limited to the above-described embodiments, and it is naturally possible to adopt various configurations without departing from the gist of the present invention.

It is a perspective view of the rotary electric machine rotor manufactured by the manufacturing method of the rotary electric machine rotor which concerns on one Embodiment of this invention. It is sectional drawing which follows the II-II line | wire shown in FIG. It is a perspective view of the rotor core which comprises the rotary electric machine rotor shown in FIG. It is the disassembled perspective view which decomposed | disassembled some rotor cores shown in FIG. It is a perspective view of the rotating shaft member and end surface plate which comprise the rotary electric machine rotor shown in FIG. 6A is a plan view of the rotating shaft member shown in FIG. 5, FIG. 6B is a cross-sectional view taken along line VIB-VIB in FIG. 6A, and FIG. 6C is a lower surface of the rotating shaft member shown in FIG. FIG. It is a schematic plan view which shows the structure of the rotor manufacturing line which is a manufacturing apparatus for manufacturing the rotary electric machine rotor which concerns on one Embodiment of this invention. FIG. 8 is a partially omitted plan view illustrating a first step of a method for manufacturing a rotating electrical machine rotor by the rotor manufacturing line shown in FIG. 7. FIG. 8 is a partially omitted plan view for explaining a third step of the method of manufacturing the rotating electrical machine rotor by the rotor manufacturing line shown in FIG. 7. FIG. 10 is a partially omitted plan view for explaining a fifth step of the method of manufacturing the rotating electrical machine rotor by the rotor manufacturing line shown in FIG. 7. FIG. 10 is a partially omitted plan view illustrating an eighth step of the method for manufacturing the rotating electrical machine rotor by the rotor manufacturing line shown in FIG. 7. FIG. 12A is a schematic cross-sectional view showing a state in which a plate member is set in the outer shape extraction return mold, and FIG. 12B shows a state in which the split core plate is punched by the upper die of the outer shape extraction return mold shown in FIG. 12A. 12C is a schematic cross-sectional view, and FIG. 12C is a schematic cross-sectional view showing a state where the split core plate punched out by the outer shape extraction return mold shown in FIG. 12B is pushed back. FIG. 10 is a partially omitted plan view for explaining a twelfth step of the method of manufacturing the rotating electrical machine rotor by the rotor manufacturing line shown in FIG. 7. FIG. 10 is a partially omitted plan view for explaining a twenty-third step of a method for manufacturing a rotating electrical machine rotor by the rotor manufacturing line shown in FIG. 7. FIG. 8 is a partially omitted plan view in which a rotor molding die of the rotor production line shown in FIG. 7 is enlarged. It is a schematic sectional drawing in alignment with the XVI-XVI line | wire in FIG. It is a schematic sectional drawing in alignment with the XVII-XVII line | wire in FIG. It is a principal part expanded sectional view which follows the XVI-XVI line | wire of FIG. 15 for demonstrating the assembly | attachment state of a rotating shaft member, an end surface plate, and a pin at the time of attaching to the front end side of the rod part of a rotor shaping die. FIG. 19A is a partially omitted plan view showing a state in which the first split core plate is pulled out by the rotor molding die, and FIG. 19B is a second split core by the rotor molding die shown in FIG. 19A. FIG. 19C is a partially omitted plan view showing a state in which the plate has been pulled out. FIG. 19C shows a state where the third split core plate is pulled out by the rotor molding die shown in FIG. It is a partially omitted plan view showing a state. FIG. 20A is a schematic cross-sectional view of the state in which the divided core plates are sequentially laminated by the rotor molding die, developed 360 ° in the circumferential direction. FIG. 20B is a diagram in which the divided core plates are further laminated from the state shown in FIG. It is the schematic sectional drawing which developed 360 degrees in the circumferential direction. FIG. 10 is a partially omitted plan view for explaining a forty-third step of a method for manufacturing a rotating electrical machine rotor by the rotor manufacturing line shown in FIG. 7. It is a schematic sectional drawing which shows the state which formed the laminated body with the rotor shaping | molding die. FIG. 23A is a partially omitted schematic cross-section along the line XVII-XVII in FIG. 15 showing a state in which an assembly of a rotating shaft member, an end face plate, and a pin is set on the distal end side of the rod portion constituting the rotor molding die. FIG. 23B is a partially omitted schematic cross-sectional view taken along line XVII-XVII in FIG. 15 showing a state in which a new laminate is formed from the state shown in FIG. 23A, and FIG. FIG. 16 is a partially omitted schematic cross-sectional view taken along line XVII-XVII in FIG. 15 showing a state in which the rotating electrical machine rotor is formed in the mold. 24A is a partially omitted schematic cross-sectional view taken along the line XVII-XVII in FIG. 15 showing a state where the molded rotating electrical machine rotor is placed on the upper surface of the lower frame, and FIG. 24B is a rotation shown in FIG. 24B. FIG. 24C is a partially omitted schematic cross-sectional view taken along line XVII-XVII in FIG. 15 showing a state in which the electric rotor is carried out, and FIG. 24C is a set of a new rotating shaft member, end plate and pin on the upper surface of the lower frame body. It is a partially-omission schematic sectional drawing which follows the XVII-XVII line of FIG. 15 which shows the state which mounted the appendage.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 ... Rotating electrical machine rotor 11 ... Rotor core 12 ... Divided core plate 13 ... Rotating shaft member 14 ... Core plate 15 ... End surface plate 15a, 24 ... Convex part 15b ... Through-hole 16 ... Cylindrical part 16a, 60b, 76a ... Groove part 16b ... Step Attached part 17 ... flange 17 a ... concave part 20 ... hole part 22 ... pin 28 ... magnet hole 30 ... rotor production line 32 ... plate member 46 ... rotor molding die 54 ... upper frame 57 ... outer guide member 59 ... servo motor 60 ... Lower frame 61 ... Hydraulic cylinder mechanism 62 ... Rod part 64 ... Inner guide member 89 ... Gap, holding part

Claims (6)

A plurality of split core plates are arranged in a ring shape and stacked, and a rotor core is formed by inserting coupling members along the stacking direction of the split core plates and the layers are connected to each other on the inner peripheral side of the rotor core. A rotating electrical machine rotor including a rotary shaft member provided,
The rotating shaft member includes a cylindrical portion that is fitted into the rotor core, and a flange portion that extends in a diametrical direction from one end side in the axial direction of the cylindrical portion and has a recess that holds one end of the coupling member. Have
The rotating electrical machine rotor, wherein an end plate having a through hole into which the coupling member is inserted is inserted at a position corresponding to the recess between the rotor core and the flange portion. The rotating electrical machine rotor according to claim 1,
The split core plate is formed along the laminating direction, and is provided with a magnet mounting hole in which a magnet is mounted, and a coupling in which the coupling member is inserted and provided on an inner peripheral side of a circumferential center position of the magnet mounting hole. And having a convex portion formed with a hole,
A rotating electrical machine rotor, wherein a groove portion corresponding to the convex portion is formed along an axial direction on an outer peripheral side of the cylindrical portion of the rotating shaft member. The rotating electrical machine rotor according to claim 2,
The rotor cores are alternately stacked in such a manner that the phase of the end of each divided core plate between overlapping layers is shifted from each other by the same phase as the phase difference between the adjacent coupling holes. Rotating electrical machine rotor. The rotating electrical machine rotor according to claim 2,
The rotating electrical machine rotor, wherein the convex portion of the split core plate and the groove portion of the rotating shaft member are fitted. The rotating electrical machine rotor according to claim 1,
Rotation characterized in that a stepped portion having a reduced diameter of the cylindrical portion is provided on the other end side opposite to the one end side in the axial direction in which the flange portion is provided in the cylindrical portion. Electric rotor. A plurality of divided core plates are arranged in a ring shape and stacked, and a rotor core in which the layers are combined by inserting coupling members along the stacking direction of the divided core plates, and a cylinder on the inner peripheral side of the rotor core A rotating electrical machine rotor comprising a rotating shaft member into which a portion is inserted,
The stepped portion formed on the other end side in the axial direction of the cylindrical portion so as to face the flange portion extending in the diametrical direction from one end side in the axial direction of the cylindrical portion in the rotating shaft member has a ring shape. A first step of disposing an end face plate, and holding the coupling member by a recess formed in the flange and a through hole formed at a position corresponding to the recess of the end face plate;
A second step of disposing the rotating shaft member so that the end face plate corresponds to the other of the holding parts where the divided core plate is held and stacked by being pushed from one side;
The end plate is pressed by the split core plate that is stacked by pushing into the holding portion while the split core plate is stacked, and is inserted into the cylindrical portion until the end plate abuts the flange. And a third step of coupling the respective layers by inserting the coupling member into coupling holes formed in the respective divided core plates of the respective layers;
The manufacturing method of the rotary electric machine rotor characterized by having.

Images