JP4969064B2 - Electric motor rotor and electric motor - Google Patents

Electric motor rotor and electric motor Download PDF

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JP4969064B2
JP4969064B2 JP2005173828A JP2005173828A JP4969064B2 JP 4969064 B2 JP4969064 B2 JP 4969064B2 JP 2005173828 A JP2005173828 A JP 2005173828A JP 2005173828 A JP2005173828 A JP 2005173828A JP 4969064 B2 JP4969064 B2 JP 4969064B2
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rotor core
rotor
electric motor
synthetic resin
pole piece
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JP2006352973A (en
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博文 成田
友弘 大川
栄治 豊田
春雄 小原木
裕治 榎本
俊一 石川
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Hitachi Appliances Inc
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Description

本発明は、洗濯機等に使用される電動機の回転子及びこの回転子を備えた電動機に関する。   The present invention relates to a rotor of an electric motor used for a washing machine or the like and an electric motor including the rotor.

一般に洗濯機等に使用される電動機として、ブラシレス電動機がある。このブラシレス電動機は、電磁コイルを有する固定子(ステータ)と、鉄心及び永久磁石を内蔵した回転子(ロータ)と、を備えて構成される。   As an electric motor generally used in a washing machine or the like, there is a brushless electric motor. This brushless electric motor includes a stator (stator) having an electromagnetic coil, and a rotor (rotor) incorporating an iron core and a permanent magnet.

この種の電動機において用いられる回転子は、回転子鉄心と、この回転子鉄心の周方向に沿って配置される希土類で作られた複数の永久磁石と、回転子鉄心と永久磁石を埋め込むように一体にモールド成形された合成樹脂部と、を有して構成されている。ここで回転子鉄心は多数枚の電磁鋼板を積層して構成され、その周方向に沿って形成された複数の穴部に永久磁石を埋め込むように配置したものがある（例えば下記の特許文献１参照）。そしてこの永久磁石が埋め込まれた回転子鉄心は、永久磁石より固定子側に凸となる磁極片部が固定子側の電磁コイルと対向し、その間の電磁作用によって固定子に対し回転子が回転駆動されるようになっている。
特開２００４−１４７４５１号公報 The rotor used in this type of electric motor is embedded with a rotor core, a plurality of permanent magnets made of rare earth arranged along the circumferential direction of the rotor core, and the rotor core and permanent magnets embedded therein. And a synthetic resin portion molded integrally. Here, the rotor core is configured by laminating a large number of electromagnetic steel sheets, and is arranged so that permanent magnets are embedded in a plurality of holes formed along the circumferential direction (for example, Patent Document 1 below). reference). In the rotor core embedded with the permanent magnet, the magnetic pole piece protruding from the permanent magnet toward the stator faces the electromagnetic coil on the stator side, and the rotor rotates relative to the stator by electromagnetic action between them. It is designed to be driven.
JP 2004-147451 A

このように構成される従来の回転子において、その内部に埋め込まれる回転子鉄心の構造を見ると、ここで回転子鉄心は、永久磁石より固定子側に凸となる磁極片部が、永久磁石の両側の脚部で回転子鉄心の本体に接続された構造となっている。このような回転子鉄心の構造では、永久磁石の両側の脚部の部分から磁束の漏れが生じ易く、そのため固定子側の誘起電圧が低下して、大きな回転駆動力を必要とする場合に充分な回転駆動力が得られなくなるという問題がある。   When the structure of the rotor core embedded in the conventional rotor configured as described above is seen, the rotor core has a magnetic pole piece projecting toward the stator side from the permanent magnet. It has a structure that is connected to the main body of the rotor core at the leg portions on both sides. In such a rotor core structure, leakage of magnetic flux is likely to occur from the leg portions on both sides of the permanent magnet, so that the induced voltage on the stator side is reduced, which is sufficient when a large rotational driving force is required. There is a problem that a large rotational driving force cannot be obtained.

本発明は斯かる点に鑑みてなされたもので、回転子に内蔵される回転子鉄心の構造を改良し、大きな回転駆動力が得られる電動機を提供することを目的とする。   The present invention has been made in view of such points, and an object of the present invention is to provide an electric motor capable of improving the structure of a rotor core built in a rotor and obtaining a large rotational driving force.

前記の目的を達成するため本発明は、
電動機の固定子に対向して設けられる回転子において、
電磁鋼板を積層してなり、内周側に凹部と凸部が交互に設けられた穴を有する回転子鉄心と、この回転子鉄心の周方向に沿って配置される希土類で作られた複数の永久磁石と、前記回転子鉄心の内周側に形成された前記穴に配置されて前記電動機の回転軸と結合する回転軸支持板と、前記回転子鉄心、前記永久磁石及び前記回転軸支持板を埋め込むように一体にモールド成形された合成樹脂部と、を有して構成され、
ここで前記回転子鉄心は、前記永久磁石より前記固定子側に凸となるように配置される
磁極片を有し、この磁極片を、全て回転子鉄心の本体から分離し、
前記磁極片の一部が前記合成樹脂部の周面から露出され、
前記磁極片の露出面より前記合成樹脂部の周面が突き出ており、
前記磁極片は、その露出面側の両端部分に切り欠き状の段部が形成され、この段部に前
記合成樹脂部が食い込む構造とし、
前記電磁鋼板は、前記回転子鉄心の本体と、前記磁極片からなり、前記回転子鉄心の本体と前記磁極片それぞれに、積層したときに互いに結合し合う結合ポンチ部が形成されており、
前記回転子鉄心の本体と前記磁極片は、それぞれ前記結合ポンチ部によって複数の前記電磁鋼板を結合することで一体に形成され、
前記回転軸支持板は、前記回転子鉄心の前記穴に設けた前記凹部に入り込む凸部を有し、
前記回転子鉄心の前記凹部に前記回転軸支持板の凸部が入り込む状態で、前記回転子鉄心の本体と前記回転軸支持板とが組み合わされ、前記回転子鉄心の前記凹部に前記回転軸支持板の凸部の間に前記合成樹脂部が充填される
ことを特徴とするものである。 In order to achieve the above object, the present invention provides:
In the rotor provided facing the stator of the electric motor,
Ri Na laminated electromagnetic steel plates, a plurality of concave portions and convex portions on the inner peripheral side is made with a rotor core having a hole provided alternately, in the rare earth which is arranged along the circumferential direction of the rotor core Permanent magnet, a rotary shaft support plate that is disposed in the hole formed on the inner peripheral side of the rotor core and is coupled to the rotary shaft of the electric motor, the rotor core, the permanent magnet, and the rotary shaft support And a synthetic resin part molded integrally so as to embed a plate ,
Here, the rotor core has a pole piece arranged so as to protrude from the permanent magnet to the stator side, and all the pole pieces are separated from the main body of the rotor core,
A part of the magnetic pole piece is exposed from the peripheral surface of the synthetic resin portion,
The peripheral surface of the synthetic resin portion protrudes from the exposed surface of the pole piece,
The pole piece has a structure in which notched step portions are formed at both end portions on the exposed surface side, and the synthetic resin portion bites into the step portions ,
The electromagnetic steel sheet is composed of a main body of the rotor core and the magnetic pole piece, and a coupling punch portion is formed on each of the main body of the rotor core and the magnetic pole piece to be coupled to each other when stacked.
The main body of the rotor core and the magnetic pole piece are integrally formed by combining the plurality of electromagnetic steel sheets by the coupling punch part,
The rotating shaft support plate has a convex portion that enters the concave portion provided in the hole of the rotor core,
The main body of the rotor core and the rotary shaft support plate are combined in a state where the convex portion of the rotary shaft support plate enters the concave portion of the rotor core, and the rotary shaft support is supported by the concave portion of the rotor core. The synthetic resin portion is filled between the convex portions of the plate .

このように構成される本発明の電動機の回転子は、永久磁石より固定子側に凸となるように配置される磁極片を、全て回転子鉄心の本体から分離し、磁極片の一部が合成樹脂部の周面から露出され、磁極片の露出面より合成樹脂部の周面が突き出ており、磁極片は、その露出面側の両端部分に切り欠き状の段部が形成され、この段部に合成樹脂部が食い込む構造としたことにより、永久磁石からの磁束の漏れが抑えられるので、固定子側の誘起電圧が増加し、大きな回転駆動力を得ることができると共に、合成樹脂部と磁極片の結合がより強固なものとなり、このため磁極片は、回転子の高速回転による遠心力が加わっても合成樹脂部から脱落することがなく、合成樹脂部内で磁極片と永久磁石がしっかりと保持されるので、回転子は常に安定した状態で確実に回転駆動される。 In the rotor of the electric motor of the present invention configured as described above, all the pole pieces arranged so as to protrude toward the stator side from the permanent magnet are separated from the main body of the rotor core, and a part of the pole piece is It is exposed from the peripheral surface of the synthetic resin portion, the peripheral surface of the synthetic resin portion protrudes from the exposed surface of the magnetic pole piece, and the magnetic pole piece is formed with notched step portions at both end portions on the exposed surface side. By adopting a structure in which the synthetic resin part bites into the step part, leakage of magnetic flux from the permanent magnet is suppressed, so that the induced voltage on the stator side increases and a large rotational driving force can be obtained , and the synthetic resin part And the magnetic pole pieces are more firmly coupled, so that the magnetic pole pieces do not fall out of the synthetic resin portion even when centrifugal force is applied due to the high-speed rotation of the rotor. Since the rotor is held firmly, the rotor is always safe. It is reliably rotated at the state.

以下、図面を参照しながら本発明の実施例について詳細に説明する。
先ず、本発明が適用される電動機の構成を図１７で簡単に説明する。この電動機３０は、回転軸３４に結合される回転子１と、この回転子１の外周面に対向して固定配置される固定子３２と、を有して構成される。この電動機は、固定子３２を外側に配置し、回転子１を内側に配置した内転型の電動機である。この電動機において回転子１には、その回転方向に沿って複数の永久磁石３を組み込んだ回転子鉄心２が内蔵され、一方固定子３２には電磁コイル３２ａが備えられており、この電磁コイル３２ａと回転子鉄心２との間の電磁作用によって固定子３２に対し回転子１が回転し、これと一体に回転軸３４が回転駆動される。
本発明は、このような電動機３０に用いられる回転子１の構造に係るものである。 Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.
First, the configuration of an electric motor to which the present invention is applied will be briefly described with reference to FIG. The electric motor 30 includes a rotor 1 coupled to a rotating shaft 34 and a stator 32 fixedly disposed so as to face the outer peripheral surface of the rotor 1. This electric motor is an add-on type electric motor in which the stator 32 is disposed outside and the rotor 1 is disposed inside. In this electric motor, the rotor 1 has a built-in rotor core 2 incorporating a plurality of permanent magnets 3 along the direction of rotation, while the stator 32 is provided with an electromagnetic coil 32a, and this electromagnetic coil 32a. The rotor 1 is rotated relative to the stator 32 by electromagnetic action between the rotor core 2 and the rotor core 2, and the rotary shaft 34 is rotationally driven integrally therewith.
The present invention relates to the structure of the rotor 1 used for such an electric motor 30.

図１〜図３に示すように、本例の回転子１は、回転子鉄心２、永久磁石３、回転軸支持板４、合成樹脂部５を有して構成される。ここで回転子鉄心２、永久磁石３、回転軸支持板４は、合成樹脂部５に埋め込まれるように合成樹脂部５と一体にモールド成形されて回転子１を構成する。またこの回転子１は、合成樹脂部５の端面から回転軸心線方向に突き出る複数の冷却ファン用の突起部７を有する。さらにこの回転子１の合成樹脂部５には、回転子１を電動機に組み付ける際に治具を挿入するための作業用の孔８を有すると共に、合成樹脂部５の内周面には、電動機から回転子１を取り外す際に治具で挟んで引き出すためのリブ９が形成されている。   As shown in FIGS. 1 to 3, the rotor 1 of this example includes a rotor core 2, a permanent magnet 3, a rotating shaft support plate 4, and a synthetic resin portion 5. Here, the rotor iron core 2, the permanent magnet 3, and the rotating shaft support plate 4 are molded integrally with the synthetic resin portion 5 so as to be embedded in the synthetic resin portion 5 to constitute the rotor 1. The rotor 1 has a plurality of cooling fan protrusions 7 protruding from the end surface of the synthetic resin portion 5 in the direction of the rotation axis. Furthermore, the synthetic resin portion 5 of the rotor 1 has a working hole 8 for inserting a jig when the rotor 1 is assembled to the electric motor, and the inner peripheral surface of the synthetic resin portion 5 has an electric motor. Ribs 9 are formed to be pulled out with a jig when the rotor 1 is removed from.

回転子鉄心２は、図５〜図７に示すように多数枚の電磁鋼板を積層して形成される。ここで回転子鉄心２を構成する電磁鋼板としては、図８、図９、図１０に示すような３種類の電磁鋼板が用いられる。すなわち、回転子１内で回転軸支持板４と対応する第１の電磁鋼板１０(図８)と、回転子鉄心２の大部分を占める主部としての第２の電磁鋼板１１(図９)と、永久磁石の押さえ部材としての第３の電磁鋼板１２(図１０)と、を積層して回転子鉄心２が構成される。   The rotor core 2 is formed by laminating a plurality of electromagnetic steel plates as shown in FIGS. Here, three types of electromagnetic steel plates as shown in FIGS. 8, 9, and 10 are used as the electromagnetic steel plates constituting the rotor core 2. That is, the 1st electromagnetic steel plate 10 (FIG. 8) corresponding to the rotating shaft support plate 4 in the rotor 1, and the 2nd electromagnetic steel plate 11 as a main part which occupies most of the rotor core 2 (FIG. 9). The rotor core 2 is configured by laminating the third electromagnetic steel plate 12 (FIG. 10) as a pressing member for the permanent magnet.

押さえ部材としての第３の電磁鋼板１２は、一枚で足りるが複数枚にすることも可能である。回転軸支持板４と対応する第１の電磁鋼板１０は、回転軸支持板４との連結で大きな力がかかるので、複数枚を必要とする。回転軸鉄心２におけるその他の部分は、多数枚の第２の電磁鋼板１１で占められる。   One sheet is sufficient for the third electromagnetic steel sheet 12 as the pressing member, but a plurality of sheets may be used. Since the first electromagnetic steel plate 10 corresponding to the rotating shaft support plate 4 is applied with a large force when connected to the rotating shaft support plate 4, a plurality of sheets are required. Other portions of the rotary shaft core 2 are occupied by a large number of second electromagnetic steel plates 11.

このように多数枚の電磁鋼板を積層して構成される回転子鉄心２の外周に沿って、複数(本例では１０個)の永久磁石３が配置される。この永久磁石３は、図４に示すように平板の形状を有し、その板厚を半分に分けるようにＮ極とＳ極の着磁が施されており、このＮ極とＳ極が回転子鉄心２の回転軸心を通る放射方向線に沿って内外方向に並ぶように永久磁石３を配置する。ここで複数の永久磁石３は、隣接間では磁極の並びが逆になるように配置される。   A plurality (10 in this example) of permanent magnets 3 are arranged along the outer periphery of the rotor core 2 configured by laminating a large number of electromagnetic steel plates in this way. The permanent magnet 3 has a flat plate shape as shown in FIG. 4, and is magnetized with N and S poles so that the plate thickness is divided in half, and the N and S poles rotate. The permanent magnets 3 are arranged so as to be lined up inward and outward along a radial line passing through the rotational axis of the core 2. Here, the plurality of permanent magnets 3 are arranged so that the arrangement of magnetic poles is reversed between adjacent magnets 3.

この構成において回転子鉄心２を構成する各電磁鋼板１０，１１，１２は、永久磁石３より固定子側(外周側)に凸となるように配置される複数の磁極片１４を有し、ここでこの磁極片１４は、全て各電磁鋼板１０，１１，１２の本体から分離した構造となっている。すなわち、従来の回転子鉄心の構成では図１１(Ａ)に示す如く、磁極片１４の内側に永久磁石を埋め込むための穴部１５を有し、この穴部１５の両側の脚部１６ａ，１６ｂによって磁極片１４が回転子鉄心２の本体に接続された構造となっていたが、本例ではこの両側の脚部１６ａ，１６ｂを打ち抜いて除去することで、同図(Ｂ)に示すように磁極片１４を回転子鉄心２の本体から完全に切り離したものである。   In this configuration, each of the electromagnetic steel plates 10, 11, 12 constituting the rotor core 2 has a plurality of magnetic pole pieces 14 arranged so as to protrude from the permanent magnet 3 toward the stator (outer peripheral side). The pole pieces 14 are all separated from the main bodies of the electromagnetic steel plates 10, 11, and 12. That is, in the configuration of the conventional rotor core, as shown in FIG. 11 (A), there is a hole 15 for embedding a permanent magnet inside the pole piece 14, and leg portions 16a, 16b on both sides of the hole 15 are provided. In this example, the pole pieces 14 are connected to the main body of the rotor core 2 by punching and removing the leg portions 16a and 16b on both sides, as shown in FIG. The pole piece 14 is completely separated from the main body of the rotor core 2.

このように本例の回転子１は、磁極片１４を全て回転子鉄心２の本体から分離させた構造としたことにより、永久磁石３の両側での磁束の漏れを抑えることができるので、固定子側の誘起電圧(起磁力)が増加し、大きな回転駆動力が得られることになる。ここで本発明者らが実際に試作実験を行った結果、図１１(Ａ)のように磁極片１４を接続する脚部１６ａ，１６ｂを有する構成から、同図(Ｂ)のように脚部を除去して磁極片１４を分離した構成とすることで、誘起電圧が約１０％増加することが確認された。   As described above, the rotor 1 of this example has a structure in which the magnetic pole pieces 14 are all separated from the main body of the rotor core 2, so that leakage of magnetic flux on both sides of the permanent magnet 3 can be suppressed. The induced voltage (magnetomotive force) on the child side increases, and a large rotational driving force can be obtained. Here, as a result of the actual experiment conducted by the inventors, the leg portions 16a and 16b for connecting the magnetic pole pieces 14 as shown in FIG. It was confirmed that the induced voltage increased by about 10% by removing the magnetic pole piece 14 and separating the pole piece 14.

本例の回転子鉄心２において第１の電磁鋼板１０と第２の電磁鋼板１１とは、磁極片１４を含む外周側が同じ形状に形成されている。第１の電磁鋼板１０の内周側には、凹凸を有する穴が形成され、第２の電磁鋼板１１の内周側には、第１の電磁鋼板１０の穴より径大な円形穴が形成されている。一方、押さえ部材としての第３の電磁鋼板１２は、磁極片１４の部分は他の電磁鋼板と同じであるが、本体部の外周が他の電磁鋼板よりもやや径大に形成されている。またこの第３の電磁鋼板１２の内周側には、第２の電磁鋼板１１の円形穴と同径の円形穴が形成されている。   In the rotor core 2 of this example, the first electromagnetic steel sheet 10 and the second electromagnetic steel sheet 11 are formed in the same shape on the outer peripheral side including the pole piece 14. A hole having irregularities is formed on the inner peripheral side of the first electromagnetic steel plate 10, and a circular hole having a diameter larger than that of the first electromagnetic steel plate 10 is formed on the inner peripheral side of the second electromagnetic steel plate 11. Has been. On the other hand, the third electromagnetic steel plate 12 as a pressing member is the same as the other electromagnetic steel plates in the part of the pole piece 14, but the outer periphery of the main body is formed to be slightly larger in diameter than the other electromagnetic steel plates. Further, a circular hole having the same diameter as the circular hole of the second electromagnetic steel plate 11 is formed on the inner peripheral side of the third electromagnetic steel plate 12.

さらに各電磁鋼板１０，１１，１２には、これを積層したときに互いに結合し合う結合ポンチ部１８が形成されている。この結合ポンチ部１８は、永久磁石３と対応する位置に打ち出し形成されるもので、各電磁鋼板１０，１１，１２の本体部と磁極片１４とに夫々設けられている。そして各電磁鋼板１０，１１，１２を積層した状態では、この結合ポンチ部１８が互いに結合し合って一体の回転子鉄心２になる。ここで特に本例の結合ポンチ部１８は、図１２に示すようなＶ字形の断面形状に打ち出し形成されているため、互いに強く食い込むように結合されて充分な結合強度が得られるものである。このように各電磁鋼板１０，１１，１２が結合ポンチ部１８で結合されて一体の回転子鉄心２となることで、各電磁鋼板がバラバラになることはなく、取り扱い易い。また、この回転子鉄心２は、合成樹脂部５に埋め込まれるようにモールド成形されるが、予め一体になっているので成形金型への組み込みが容易である。   Further, each electromagnetic steel sheet 10, 11, 12 is formed with a coupling punch portion 18 that couples to each other when they are laminated. The coupling punch 18 is formed at a position corresponding to the permanent magnet 3, and is provided on the main body and the magnetic pole piece 14 of each of the electromagnetic steel plates 10, 11, 12. And in the state which laminated | stacked each electromagnetic steel plate 10,11,12, this coupling punch part 18 mutually couple | bonds together, and it becomes the integral rotor core 2. FIG. Here, in particular, the coupling punch portion 18 of this example is formed so as to have a V-shaped cross-sectional shape as shown in FIG. 12, and therefore, the coupling punch portion 18 is coupled so as to bite into each other to obtain a sufficient coupling strength. Thus, each electromagnetic steel plate 10,11,12 is couple | bonded by the coupling punch part 18, and becomes the integral rotor core 2, Each electromagnetic steel plate does not fall apart and it is easy to handle. Further, the rotor core 2 is molded so as to be embedded in the synthetic resin portion 5, but since it is integrated in advance, it can be easily incorporated into a molding die.

回転子鉄心２の外周に沿って配置された永久磁石３は、図５及び図７に示すように、押さえ部材である第３の電磁鋼板１２に一端面が当接し、この第３の電磁鋼板１２によって押さえられる状態で回転子鉄心２に組み込まれる。ここで第３の電磁鋼板１２は、Ｎ極またはＳ極の一方(内周側となる方)にのみ当接して永久磁石３を押さえるようにしてあり、すなわちＮ極とＳ極に跨って第３の電磁鋼板１２が当接されることはない。このため、永久磁石３の端面では、磁気の流れ易い電磁鋼板を介して磁束が短絡してしまうことはなく、電動機としての性能が損なわれることはない。   As shown in FIGS. 5 and 7, the permanent magnet 3 arranged along the outer periphery of the rotor core 2 has one end surface in contact with a third electromagnetic steel plate 12 that is a pressing member, and this third electromagnetic steel plate. Incorporated into the rotor core 2 while being pressed by the rotor 12. Here, the third electrical steel sheet 12 is in contact with only one of the N and S poles (the one on the inner peripheral side) to hold down the permanent magnet 3, that is, the third straddling the N and S poles. No. 3 magnetic steel sheet 12 is not contacted. For this reason, at the end face of the permanent magnet 3, the magnetic flux is not short-circuited through the electromagnetic steel plate that easily flows, and the performance as an electric motor is not impaired.

永久磁石３は、希土類の素材を用いて作られるもので、ここでは表面がメッキ等の防錆処理を施されていない防錆未処理の永久磁石を用いる。回転子鉄心２に組み込まれた永久磁石３は隙間のない状態で合成樹脂部５にて完全に被覆されるので、防錆未処理でも発錆が起き難く、防錆未処理のものを好適に使用できる。防錆未処理の永久磁石３を使用することにより、コスト低減を図ることができる。   The permanent magnet 3 is made of a rare earth material, and here, a rust-proof untreated permanent magnet whose surface is not subjected to a rust-proof treatment such as plating is used. Since the permanent magnet 3 incorporated in the rotor core 2 is completely covered with the synthetic resin part 5 without any gaps, rusting is not likely to occur even if the rust prevention treatment is not performed. Can be used. Cost reduction can be achieved by using the permanent magnet 3 that has not been subjected to rust prevention.

またこの回転子１では、回転子鉄心２と永久磁石３が隙間なく配置されているので、回転子１の外径精度は永久磁石３の厚み精度で決まることになるが、永久磁石３は研磨等で厚み精度を出し易く、かつメッキ等による防錆被膜がないため、回転子の外径精度のバラツキを極めて少なく抑えることができる。この場合、永久磁石にメッキによる防錆被膜があると精度のバラツキを抑えるのは±０．０５ｍｍ程度が限界であったが、メッキによる防錆被膜をなくした永久磁石を用いることで、回転子の外径精度のバラツキを±０．０１ｍｍ程度に抑えることができる。   In this rotor 1, the rotor core 2 and the permanent magnet 3 are arranged without a gap, so that the outer diameter accuracy of the rotor 1 is determined by the thickness accuracy of the permanent magnet 3, but the permanent magnet 3 is polished. Since the thickness accuracy can be easily obtained by such as and there is no rust preventive film by plating or the like, variation in the outer diameter accuracy of the rotor can be suppressed to an extremely low level. In this case, if the permanent magnet has a rust preventive coating by plating, the limit of accuracy variation is limited to about ± 0.05 mm. However, by using a permanent magnet without the plating rust preventive coating, the rotor The variation in the outer diameter accuracy of can be suppressed to about ± 0.01 mm.

図２に示すように、回転軸支持板４は、合成樹脂部５により回転子鉄心２と一体にモールド成形されて結合される。この回転軸支持板４は鋼板で形成され、図１３に示す如く中心部には電動機の回転軸と結合する結合孔４ｄを有し、外周には凹部４ａと凸部４ｂ，４ｃが形成されている。ここで凸部４ｂ，４ｃはそれぞれ対称的に突出形成されており、凸部４ｂが凸部４ｃよりも大きく突出して形成されている。   As shown in FIG. 2, the rotating shaft support plate 4 is molded and joined integrally with the rotor core 2 by the synthetic resin portion 5. The rotating shaft support plate 4 is formed of a steel plate, and has a coupling hole 4d for coupling with the rotating shaft of the electric motor at the center as shown in FIG. 13, and a recess 4a and protrusions 4b and 4c are formed on the outer periphery. Yes. Here, the convex portions 4b and 4c are formed so as to project symmetrically, and the convex portion 4b is formed so as to project larger than the convex portion 4c.

一方、回転子鉄心２において回転軸支持板４と対応する第１の電磁鋼板１０は、内周側に凹部１０ａと凸部１０ｂが交互に設けられた穴を有する。そして、合成樹脂部５内において回転軸支持板４と回転子鉄心２とは、図１４に示すように組み合わされる。すなわち、第１の電磁鋼板１０の凹部１０ａに回転軸支持板４の凸部４ｂが入り込む状態で回転軸支持板４と回転子鉄心２とが組み合わされる。   On the other hand, the 1st electromagnetic steel plate 10 corresponding to the rotating shaft support plate 4 in the rotor core 2 has the hole by which the recessed part 10a and the convex part 10b were provided alternately by the inner peripheral side. And in the synthetic resin part 5, the rotating shaft support plate 4 and the rotor core 2 are combined as shown in FIG. That is, the rotary shaft support plate 4 and the rotor core 2 are combined with the convex portion 4 b of the rotary shaft support plate 4 entering the concave portion 10 a of the first electromagnetic steel plate 10.

合成樹脂部５により一体にモールド成形された回転子１は、回転子鉄心２の凹部１０ａと回転軸支持板４の凸部４ｂ、４ｃとの間に合成樹脂が充填されて、強い結合構造になる。特に回転子鉄心２の凹部１０ａと回転軸支持板４の凸部４ｂとの間に充填された合成樹脂層の部分には、圧縮力の作用しか働かないので、丈夫な結合構造を提供できる。また回転軸支持板４と回転子鉄心２とは合成樹脂部５を介して電気的に絶縁されているので、回転軸から回転子鉄心２を電気的に分離させることができる。   The rotor 1 molded integrally by the synthetic resin portion 5 is filled with the synthetic resin between the concave portion 10a of the rotor core 2 and the convex portions 4b and 4c of the rotating shaft support plate 4 to form a strong coupling structure. Become. In particular, since the portion of the synthetic resin layer filled between the concave portion 10a of the rotor core 2 and the convex portion 4b of the rotating shaft support plate 4 only acts by a compressive force, a strong bonding structure can be provided. Moreover, since the rotating shaft support plate 4 and the rotor core 2 are electrically insulated via the synthetic resin part 5, the rotor core 2 can be electrically separated from the rotating shaft.

合成樹脂による回転子のモールド成形は、図示しない成形用金型内で行なわれる。このモールド成形では、永久磁石３を組み込んだ回転子鉄心２を金型内にセットし、その状態で金型内に合成樹脂材を注入して成形を行う。この場合、回転子鉄心２が所定の位置で保持されるように、金型内に複数の支持ピンを設け、この支持ピンで回転子鉄心２を押さえた状態で金型内に合成樹脂材を注入するようにしている。この支持ピンは、モールド成形後には抜き外すので、図２及び図３に示すように、回転子１の合成樹脂部５にはこの支持ピンの抜き跡である複数の抜き穴２０が形成される。   Molding of the rotor with synthetic resin is performed in a molding die (not shown). In this molding, the rotor core 2 incorporating the permanent magnet 3 is set in a mold, and in this state, a synthetic resin material is injected into the mold to perform molding. In this case, a plurality of support pins are provided in the mold so that the rotor core 2 is held at a predetermined position, and the synthetic resin material is placed in the mold in a state where the rotor core 2 is pressed by the support pins. I try to inject. Since this support pin is removed after molding, as shown in FIGS. 2 and 3, a plurality of punch holes 20 which are traces of this support pin are formed in the synthetic resin portion 5 of the rotor 1. .

成形用金型にセットされた回転子鉄心２は、支持ピンが押さえ部材としての第３の電磁鋼板１２に突き当てられた状態に置かれ、第３の電磁鋼板１２の反対側（第１の電磁鋼板１０側）に設けられた合成樹脂注入ゲートより樹脂の注入が行われる。ここで回転子鉄心２は樹脂の強い注入圧により第３の電磁鋼板１２側に押されるが、その注入圧に抗して第３の電磁鋼板１２が支持ピンで押さえられることで回転子鉄心２は所定位置で確実に保持され、これによって合成樹脂で一体にモールド成形される回転子１は所定寸法・所定形状に形成される。   The rotor core 2 set in the molding die is placed in a state where the support pin is abutted against the third electromagnetic steel sheet 12 as a pressing member, and the opposite side of the third electromagnetic steel sheet 12 (first Resin is injected from a synthetic resin injection gate provided on the electromagnetic steel sheet 10 side. Here, the rotor core 2 is pushed toward the third electromagnetic steel plate 12 side by the strong injection pressure of the resin, but the rotor core 2 is pressed against the injection pressure by the third electromagnetic steel plate 12 being held by the support pins. Is securely held at a predetermined position, whereby the rotor 1 molded integrally with synthetic resin is formed in a predetermined size and shape.

こうして成形される回転子１において押さえ部材としての第３の電磁鋼板１２は、支持ピンの跡である抜き穴２０の部分に樹脂の被覆がないので、外部に露出する。しかし、永久磁石３の端面は、第３の電磁鋼板１２により外部とは閉ざされているので、防錆未処理の永久磁石３でも錆が発生することはない。その結果、電動機の性能を損ねることはなく、長寿命の電動機を提供することができるものである。   In the rotor 1 formed in this way, the third electromagnetic steel plate 12 as a pressing member is exposed to the outside because there is no resin coating in the portion of the punched hole 20 that is the trace of the support pin. However, since the end face of the permanent magnet 3 is closed from the outside by the third electromagnetic steel plate 12, no rust is generated even in the permanent magnet 3 that has not been subjected to rust prevention. As a result, it is possible to provide a motor having a long life without impairing the performance of the motor.

さらに本例の回転子１では、図１５に示すように、合成樹脂部５の外周面から磁極片１４の一部を露出させてあり、ここでは合成樹脂部５の外周面が磁極片１４の露出面より外側に突き出た構造となっている。この場合、合成樹脂部５の外周面と磁極片１４の露出面との間の段差ａは０．５ｍｍ程度とされる。   Furthermore, in the rotor 1 of this example, as shown in FIG. 15, a part of the magnetic pole piece 14 is exposed from the outer peripheral surface of the synthetic resin portion 5, and here the outer peripheral surface of the synthetic resin portion 5 is the magnetic pole piece 14. The structure protrudes outward from the exposed surface. In this case, the step a between the outer peripheral surface of the synthetic resin portion 5 and the exposed surface of the pole piece 14 is about 0.5 mm.

このように本例の回転子１は、合成樹脂部５の外周面が磁極片１４の露出面より外側に突き出た構造となっていることにより、この回転子１を電動機に組み込む際には、磁極片１４が固定子に接触して完全に磁気吸着されてしまうようなことがなく、固定子との間にギャップを持たせながらスムーズに組み込むことができる。   As described above, the rotor 1 of this example has a structure in which the outer peripheral surface of the synthetic resin portion 5 protrudes outward from the exposed surface of the magnetic pole piece 14, so that when the rotor 1 is incorporated into an electric motor, The pole piece 14 does not come into contact with the stator and is not completely magnetically attracted, and can be smoothly assembled with a gap between the pole piece 14 and the stator.

さらに本例の回転子１では、磁極片１４の露出面側の両端部分に切り欠き状の段部１４ａ，１４ｂが形成されており、この段部１４ａ，１４ｂに合成樹脂部５が食い込む構造となっている。このような構造としたことで合成樹脂部５と磁極片１４の結合がより強固なものとなり、このため磁極片１４は、回転子１の高速回転による遠心力が加わっても合成樹脂部５から脱落することがなく、合成樹脂部５内で磁極片１４と永久磁石３がしっかりと保持されるので、回転子１は常に安定した状態で確実に回転駆動される。さらに図１６に示す如く磁極片１４の形状を、その両側端縁１４ｃ，１４ｄが回転子１の内側に向って大きく傾斜した扇型形状に形成することにより、回転子１の遠心力に対して一段と脱落しにくい構造とすることができる。   Further, in the rotor 1 of this example, notched step portions 14a and 14b are formed at both end portions on the exposed surface side of the pole piece 14, and the synthetic resin portion 5 bites into the step portions 14a and 14b. It has become. With such a structure, the coupling between the synthetic resin portion 5 and the magnetic pole piece 14 becomes stronger, so that the magnetic pole piece 14 is separated from the synthetic resin portion 5 even if a centrifugal force is applied due to the high-speed rotation of the rotor 1. Since the magnetic pole piece 14 and the permanent magnet 3 are firmly held in the synthetic resin portion 5 without falling off, the rotor 1 is always driven to rotate reliably in a stable state. Further, as shown in FIG. 16, the pole piece 14 is formed in a fan shape in which both side edges 14 c and 14 d are inclined greatly toward the inner side of the rotor 1, so that the centrifugal force of the rotor 1 can be prevented. The structure can be made more difficult to drop off.

なお、以上の如く構成される回転子１は、上述したように磁極片１４の一部が合成樹脂部５の外周面から露出する構造となっているが、本例の回転子１は内転型(インナーロータ)であるため、磁極片１４の露出面に水滴が付着しても、この水滴は回転子１の高速回転による遠心力で外側に弾かれるので、磁極片１４の露出面から回転子１の内部に水が侵入するおそれはない。   Note that the rotor 1 configured as described above has a structure in which a part of the pole piece 14 is exposed from the outer peripheral surface of the synthetic resin portion 5 as described above. Since it is a mold (inner rotor), even if water droplets adhere to the exposed surface of the pole piece 14, the water droplet is bounced outward by the centrifugal force due to the high-speed rotation of the rotor 1. There is no risk of water intruding into the child 1.

図１７は本発明による回転子が組み込まれる電動機の構成例を示す。この電動機３０は例えば洗濯機に用いられるもので、減速機構３１と一体にユニット化されている。ここで電動機３０は、上述した回転子１、固定子３２、ハウジング３３、回転軸３４、エンドブラケット３５、軸受部３６を有して構成される。ハウジング３３は固定子３２を内側に固定し、回転軸３４はエンドブラケット３５に設けた軸受部３６に回転自在に支持され、回転子１の回転軸支持板４に結合される。固定子３２は、回転子１の外周面に対向して配置され、この固定子３２に巻装される電磁コイル３２ａと回転子１の回転子鉄心２との間の電磁作用によって固定子３２に対し回転子１が回転し、これと一体に回転軸３４が回転駆動される。   FIG. 17 shows a configuration example of an electric motor in which a rotor according to the present invention is incorporated. The electric motor 30 is used for a washing machine, for example, and is unitized with the speed reduction mechanism 31. Here, the electric motor 30 includes the rotor 1, the stator 32, the housing 33, the rotating shaft 34, the end bracket 35, and the bearing portion 36 described above. The housing 33 fixes the stator 32 on the inner side, and the rotation shaft 34 is rotatably supported by a bearing portion 36 provided on the end bracket 35, and is coupled to the rotation shaft support plate 4 of the rotor 1. The stator 32 is disposed so as to face the outer peripheral surface of the rotor 1, and the stator 32 is attached to the stator 32 by electromagnetic action between the electromagnetic coil 32 a wound around the stator 32 and the rotor core 2 of the rotor 1. On the other hand, the rotor 1 rotates, and the rotating shaft 34 is rotationally driven integrally therewith.

電動機の回転軸３４は、減速機構３１の入力側に噛み合わされる。減速機構３１の入力側は遊星歯車を有し、回転軸３４に形成したピニオンが噛み合わされる。減速機構３１の出力側には、洗濯機駆動軸３８が設けられる。この洗濯機駆動軸３８は減速機構３１の内側軸受部３９に回転自在に支持され、回転子１の回転がこの洗濯機駆動軸３８から減速して出力される。さらに洗濯機駆動軸３８の外側には中空回転軸４０が設けられる。この中空回転軸４０は減速機構３１のケース４１に結合され、回転軸３４と一体に回転して回転子１の回転を減速せずに出力するものである。   The rotating shaft 34 of the electric motor is meshed with the input side of the speed reduction mechanism 31. The input side of the speed reduction mechanism 31 has a planetary gear, and a pinion formed on the rotating shaft 34 is engaged. A washing machine drive shaft 38 is provided on the output side of the speed reduction mechanism 31. The washing machine drive shaft 38 is rotatably supported by the inner bearing 39 of the speed reduction mechanism 31, and the rotation of the rotor 1 is decelerated from the washing machine drive shaft 38 and output. Further, a hollow rotary shaft 40 is provided outside the washing machine drive shaft 38. The hollow rotary shaft 40 is coupled to the case 41 of the speed reduction mechanism 31 and rotates integrally with the rotary shaft 34 to output the rotation of the rotor 1 without decelerating.

このような電動機を備えた洗濯機の構成例を図１８に示す。この洗濯機は、筐体５０の内部にサスペンション５１を介して懸架支持される水槽５２と、この水槽５２の内部に回転可能に配置され、洗濯物が投入される洗濯槽５３と、この洗濯槽５３内の底部に配置され、洗濯槽５３内の洗濯物を攪拌する回転翼５４と、を有して構成されており、この洗濯機において水槽５２の底部に設けられた固定板５５に、図１７に示した電動機３０が取り付けられている。   A configuration example of a washing machine including such an electric motor is shown in FIG. The washing machine includes a water tank 52 suspended and supported in a housing 50 via a suspension 51, a washing tank 53 that is rotatably arranged in the water tank 52 and into which laundry is put, and the washing tank. 53, and a rotating blade 54 that stirs the laundry in the washing tub 53. In this washing machine, a fixed plate 55 provided at the bottom of the water tub 52 An electric motor 30 shown in FIG. 17 is attached.

そしてこの電動機３０の出力軸である洗濯機回転軸３８が回転翼５４に連結されると共に、中空回転軸４０が洗濯槽５３に連結されている。従ってこの洗濯機では、洗濯時には電動機３０の回転子１の回転が減速機構３１を介して減速されて回転翼５４に伝達され、これによって回転翼５４が回転して洗濯槽５３内の洗濯物を攪拌する洗濯動作が行われると共に、脱水時には電動機３０の回転子１の回転が減速されずに洗濯槽５３に伝達されて洗濯槽５３が高速回転して脱水動作が行われる。この動作の切り換えは、電動機に備えられるクラッチ機構によって行われる。   The washing machine rotating shaft 38 that is the output shaft of the electric motor 30 is connected to the rotary blade 54, and the hollow rotating shaft 40 is connected to the washing tub 53. Therefore, in this washing machine, at the time of washing, the rotation of the rotor 1 of the electric motor 30 is decelerated via the speed reduction mechanism 31 and transmitted to the rotary blade 54, whereby the rotary blade 54 rotates and the laundry in the washing tub 53 is removed. A washing operation for stirring is performed, and at the time of dehydration, the rotation of the rotor 1 of the electric motor 30 is transmitted to the washing tub 53 without being decelerated, and the washing tub 53 is rotated at a high speed to perform the dehydration operation. This switching of operation is performed by a clutch mechanism provided in the electric motor.

本発明による電動機の回転子の実施例を示す平面図である。It is a top view which shows the Example of the rotor of the electric motor by this invention. 図１のＡ−Ａ線断面図である。It is the sectional view on the AA line of FIG. 本発明による電動機の回転子の実施例を示す底面図である。It is a bottom view which shows the Example of the rotor of the electric motor by this invention. 実施例の回転子に用いられる永久磁石片の斜視図である。It is a perspective view of the permanent magnet piece used for the rotor of an Example. 実施例の回転子における回転子鉄心の断面図である。It is sectional drawing of the rotor core in the rotor of an Example. 図５の回転子鉄心を矢印Ｂ方向から見た図である。It is the figure which looked at the rotor core of FIG. 5 from the arrow B direction. 図５の回転子鉄心を矢印Ｃ方向から見た図である。It is the figure which looked at the rotor core of FIG. 5 from the arrow C direction. 実施例の回転子において回転子鉄心を構成する第１の電磁鋼板の平面図である。It is a top view of the 1st electromagnetic steel plate which comprises a rotor core in the rotor of an Example. 実施例の回転子において回転子鉄心を構成する第２の電磁鋼板の平面図である。It is a top view of the 2nd electromagnetic steel plate which comprises a rotor core in the rotor of an Example. 実施例の回転子において回転子鉄心を構成する第３の電磁鋼板の平面図である。It is a top view of the 3rd electromagnetic steel plate which comprises a rotor core in the rotor of an Example. 回転子鉄心における磁極片の分離構造の説明図である。It is explanatory drawing of the separation structure of the pole piece in a rotor core. 実施例の回転子において積層した電磁鋼板を結合する結合ポンチ部の拡大断面図である。It is an expanded sectional view of the coupling punch part which couple | bonds the magnetic steel plate laminated | stacked in the rotor of an Example. 実施例の回転子における回転軸支持板の平面図である。It is a top view of the rotating shaft support plate in the rotor of an Example. 実施例の回転子における回転軸支持板と回転子鉄心の組み合わせ構造を示す図である。It is a figure which shows the combined structure of the rotating shaft support plate and rotor core in the rotor of an Example. 実施例の回転子における磁極片の露出部の構造を示す断面図である。It is sectional drawing which shows the structure of the exposed part of the pole piece in the rotor of an Example. 磁極片の他の形状例を示す図である。It is a figure which shows the other example of a shape of a pole piece. 本発明による回転子が組み込まれる電動機の構成例を示す断面図である。It is sectional drawing which shows the structural example of the electric motor in which the rotor by this invention is integrated. 本発明による回転子が組み込まれ電動機を備えた洗濯機の例を示す構成図である。It is a block diagram which shows the example of the washing machine with which the rotor by this invention was integrated and was equipped with the electric motor.

符号の説明Explanation of symbols

１…回転子、２…回転子鉄心、３…永久磁石、５…合成樹脂部、１０…第１の電磁鋼板、１１…第２の電磁鋼板、１２…第３の電磁鋼板。１４…磁極片、１４ａ，１４ｂ…段部、１８…結合ポンチ部   DESCRIPTION OF SYMBOLS 1 ... Rotor, 2 ... Rotor core, 3 ... Permanent magnet, 5 ... Synthetic resin part, 10 ... 1st electromagnetic steel plate, 11 ... 2nd electromagnetic steel plate, 12 ... 3rd electromagnetic steel plate. 14 ... Magnetic pole piece, 14a, 14b ... Step part, 18 ... Coupling punch part

Claims (2)

電動機の固定子に対向して設けられる回転子において、
電磁鋼板を積層してなり、内周側に凹部と凸部が交互に設けられた穴を有する回転子鉄心と、この回転子鉄心の周方向に沿って配置される希土類で作られた複数の永久磁石と、前記回転子鉄心の内周側に形成された前記穴に配置されて前記電動機の回転軸と結合する回転軸支持板と、前記回転子鉄心、前記永久磁石及び前記回転軸支持板を埋め込むように一体にモールド成形された合成樹脂部と、を有して構成され、
前記回転子鉄心は、前記永久磁石より前記固定子側に凸となるように配置される磁極片を有し、この磁極片が、全て回転子鉄心の本体から分離し、
前記磁極片の一部が前記合成樹脂部の周面から露出され、
前記磁極片の露出面より前記合成樹脂部の周面が突き出ており、
前記磁極片は、その露出面側の両端部分に切り欠き状の段部が形成され、この段部に前記合成樹脂部が食い込む構造とし、
前記電磁鋼板は、前記回転子鉄心の本体と、前記磁極片からなり、前記回転子鉄心の本体と前記磁極片それぞれに、積層したときに互いに結合し合う結合ポンチ部が形成されており、
前記回転子鉄心の本体と前記磁極片は、それぞれ前記結合ポンチ部によって複数の前記電磁鋼板を結合することで一体に形成され、
前記回転軸支持板は、前記回転子鉄心の前記穴に設けた前記凹部に入り込む凸部を有し、
前記回転子鉄心の前記凹部に前記回転軸支持板の凸部が入り込む状態で、前記回転子鉄心の本体と前記回転軸支持板とが組み合わされ、前記回転子鉄心の前記凹部に前記回転軸支持板の凸部の間に前記合成樹脂部が充填される
ことを特徴とする電動機の回転子。 In the rotor provided facing the stator of the electric motor,
Ri Na laminated electromagnetic steel plates, a plurality of concave portions and convex portions on the inner peripheral side is made with a rotor core having a hole provided alternately, in the rare earth which is arranged along the circumferential direction of the rotor core Permanent magnet, a rotary shaft support plate that is disposed in the hole formed on the inner peripheral side of the rotor core and is coupled to the rotary shaft of the electric motor, the rotor core , the permanent magnet, and the rotary shaft support And a synthetic resin part molded integrally so as to embed a plate ,
The rotor core has magnetic pole pieces arranged so as to protrude from the permanent magnet to the stator side, and all the magnetic pole pieces are separated from the main body of the rotor core;
A part of the magnetic pole piece is exposed from the peripheral surface of the synthetic resin portion,
The peripheral surface of the synthetic resin portion protrudes from the exposed surface of the pole piece,
The pole piece has a structure in which notched step portions are formed at both end portions on the exposed surface side, and the synthetic resin portion bites into the step portions ,
The electromagnetic steel sheet is composed of a main body of the rotor core and the magnetic pole piece, and a coupling punch portion is formed on each of the main body of the rotor core and the magnetic pole piece to be coupled to each other when stacked.
The main body of the rotor core and the magnetic pole piece are integrally formed by combining the plurality of electromagnetic steel sheets by the coupling punch part,
The rotating shaft support plate has a convex portion that enters the concave portion provided in the hole of the rotor core,
The main body of the rotor core and the rotary shaft support plate are combined in a state where the convex portion of the rotary shaft support plate enters the concave portion of the rotor core, and the rotary shaft support is supported by the concave portion of the rotor core. A rotor for an electric motor , wherein the synthetic resin portion is filled between convex portions of a plate . 請求項１に記載の電動機の回転子において、
前記永久磁石は、表面が防錆未処理である
ことを特徴とする電動機の回転子。 In the rotor of the electric motor according to claim 1,
The permanent magnet has a rust-proof untreated surface. An electric motor rotor.
JP2005173828A 2005-06-14 2005-06-14 Electric motor rotor and electric motor Expired - Fee Related JP4969064B2 (en)

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