JP4972770B2 - Method for manufacturing rotor for axial gap type rotating electrical machine - Google Patents
Method for manufacturing rotor for axial gap type rotating electrical machine Download PDFInfo
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Description
本発明は、帯状に延在する薄板の電磁鋼板を巻き取って渦巻き状に成形したものを回転電機のロータコアとして用いる回転電機の構造に関するものである。 The present invention relates to a structure of a rotating electrical machine in which a thin electromagnetic steel sheet extending in a strip shape is wound and formed into a spiral shape as a rotor core of the rotating electrical machine.
回転電機のロータおよびステータをアキシャル（軸）方向に対向配置して、このアキシャル方向のギャップに磁界を発生することにより回転を生起させるアキシャルギャップ型の回転電機としては従来、例えば、特許文献１に記載のごときものが知られている。特許文献１に記載のロータは、帯状に延在する薄板の電磁鋼板を巻き取って形成された渦巻き鋼板からなる。
ところで、上記従来のようなロータにあっては、帯状の電磁鋼板同士を接着剤で貼り合わせることによりロータを形成する。あるいは、打ち抜き加工により、帯状の電磁鋼板に所定間隔で孔部を設け、巻き取りの際これら孔部を重ね合わせることによりこれら孔部がロータを径方向に貫通する貫通孔を形成し、当該貫通孔にリベットを挿入して、ロータの変形を防止する。 By the way, in the conventional rotor, the rotor is formed by bonding the strip-shaped electromagnetic steel sheets together with an adhesive. Alternatively, holes are provided at predetermined intervals in the strip-shaped electromagnetic steel sheet by punching, and these holes are overlapped during winding to form through holes that penetrate the rotor in the radial direction. Insert rivets into the holes to prevent rotor deformation.
また一方で、回転電機の高出力化の要求もあって、アキシャルギャップ型回転電機のロータに作用するステータ側への吸引力および遠心力も益々増大するという実情がある。 On the other hand, there is a demand for higher output of the rotating electrical machine, and there is a fact that the attractive force and centrifugal force to the stator side acting on the rotor of the axial gap type rotating electrical machine increase more and more.
しかしながら、このような貼り合わせにより接着したロータの場合、ステータ側への吸引力および遠心力が長期間に亘りロータに作用することによって、当該接着部分が剥がれて、ロータが変形するという経時劣化の懸念がある。
かといって、このような経時劣化の懸念を払拭するよう、上述したリベットによる補強を行うとすれば、多くの貫通孔およびリベットを設ける必要が新たに生じて、組み立てに要する工数が徒に増大する。
また、上述のような接着剤による貼り付けや、リベット留めに頼るのみでは、更なる回転電機の高出力化の要求に答えることが困難になる。
さらに回転電機の高出力化により、永久磁石がロータから剥がれてロータが破損する懸念もある。
However, in the case of a rotor bonded by such bonding, the time-dependent deterioration that the adhering part is peeled off and the rotor is deformed due to the suction force and centrifugal force acting on the stator side acting on the rotor for a long period of time. There are concerns.
However, if the above-described reinforcement with rivets is performed to eliminate the concern of deterioration over time, it becomes necessary to provide many through holes and rivets, and the number of man-hours required for assembly increases. To do.
Moreover, it becomes difficult to respond to the request | requirement of the further high output of a rotary electric machine only by depending on the sticking by the above adhesives or riveting.
Furthermore, there is a concern that the permanent magnet may be peeled off from the rotor and the rotor may be damaged due to the high output of the rotating electrical machine.
本発明は、上述の実情に鑑み、接着剤やリベットを用いることなく、積層鋼板で構成されるロータの強度および耐久性を向上することができるアキシャルギャップ型回転電機用ロータの製造方法を提案するものである。 The present invention is proposed in view of the circumstances described above, without using an adhesive or rivets, the manufacturing method of the low data Axial gap type rotating electric machine capable of improving the strength and durability of the rotor constituted by the laminated steel plates To do.
この目的のため本発明によるアキシャルギャップ型回転電機用ロータの製造方法は、請求項１に記載のごとく、
前記帯状の電磁鋼板に突起を延在方向所定間隔で複数設け、該帯状の電磁鋼板を巻き取ることにより、前記突起を重ね合わせて径方向と斜交して延在する突条を複数形成しつつ、前記ロータコアを形成し、
前記ロータコアを、前記ベースプレートの外縁部に設けられてロータの回転軸方向に突出するベースプレート突出部よりも内径側に位置させ、該ロータコアを巻き取り方向とは逆方向に解放することにより、該ロータコア外縁が該ベースプレート突出部に接触するまで該ロータコアを拡径し、
次に、前記ロータコア外縁を前記ベースプレートに固定し、該ロータコアの内縁を円周方向に相対回転させることにより前記突条の延在方向を径方向に整列させ、
次に、周方向で隣り合う突条同士の間に前記永久磁石を配置して、前記ロータコアの中央に形成したロータコア中央孔に係合部材を貫通させて該係合部材をベースプレートに結合し、該係合部材および前記ベースプレート突出部によって前記ロータコアおよび前記永久磁石を前記ベースプレートに固定する。
For this purpose, the manufacturing method of the rotor for an axial gap type rotating electrical machine according to the present invention is as described in claim 1,
A plurality of protrusions are provided on the belt-shaped electromagnetic steel sheet at predetermined intervals in the extending direction, and the belt-shaped electromagnetic steel sheet is wound to form a plurality of protrusions that overlap the protrusions and extend obliquely with the radial direction. While forming the rotor core,
The rotor core is positioned on the inner diameter side with respect to a base plate protruding portion that is provided at an outer edge portion of the base plate and protrudes in the rotation axis direction of the rotor, and the rotor core is released in a direction opposite to the winding direction. Expanding the rotor core until the outer edge contacts the base plate protrusion,
Next, the outer edge of the rotor core is fixed to the base plate, and the extending direction of the protrusions is aligned in the radial direction by relatively rotating the inner edge of the rotor core in the circumferential direction.
Next, the permanent magnet is disposed between the protrusions adjacent in the circumferential direction, the engagement member is passed through the rotor core central hole formed in the center of the rotor core, and the engagement member is coupled to the base plate. The rotor core and the permanent magnet are fixed to the base plate by the engaging member and the base plate protrusion.
かかる本発明のアキシャルギャップ型回転電機用ロータの製造方法によれば、ロータコアの内径側にある係合部材と、ロータコアの外径側にあるベースプレート突出部とが、ロータコアのみならず永久磁石をもベースプレートに固定するため、薄板の電磁鋼板を貼り合わせたり、リベット固定したりするまでもなく、渦巻き状のロータコアをそのままの形状でロータ内に保持することができる。
また、接着材を用いて永久磁石をロータコアに貼り付けるものではなく、永久磁石がロータコアから剥がれることを防止できる。
さらに、貼り合わせやリベット固定という工数を削減してロータの組み立てを省力化することができるばかりでなく、回転電機の高出力化の要求に答えることが可能となる。
According to the method of manufacturing a rotor for an axial gap type rotating electrical machine of the present invention, the engaging member on the inner diameter side of the rotor core and the base plate protrusion on the outer diameter side of the rotor core have not only the rotor core but also a permanent magnet. Since it is fixed to the base plate, it is possible to hold the spiral rotor core in the rotor as it is without needing to attach a thin electromagnetic steel plate or fix it with rivets.
Moreover, it is not what sticks a permanent magnet to a rotor core using an adhesive material, and can prevent that a permanent magnet peels from a rotor core.
Furthermore, not only can the man-hours of bonding and rivet fixing be reduced to save the labor of assembling the rotor, but it is also possible to meet the demand for higher output of the rotating electric machine.
また、ベースプレート突出部よりも内側にロータコアを配置することが可能になって、アキシャルギャップ型回転電機用ロータを効率的に組み立てることができる。 Also, it becomes possible to arrange the rotor core on the inner side of the base Supureto protrusion, it can be assembled rotor for A key interstitial gap rotary electric machine efficiently.
以下、本発明の実施の形態を、図面に示す実施例に基づき詳細に説明する。
図１は本発明の第１実施例になるアキシャルギャップ型回転電機用ロータを示す正面図である。また図２は、このロータを、回転軸Ｏを含む面で切断して見た状態を半分のみ示す縦断側面図である。
このロータ１の主要構成部材は、図示しないステータと対向するロータ前面に配設した永久磁石２と、このロータ前面とは反対側にあるロータ背面に配設したベースプレート３と、これら永久磁石２およびベースプレート３の間に介在するロータコア４と、回転軸Ｏが通るロータ１の中央部に配設した係合部材５と、である。
Hereinafter, embodiments of the present invention will be described in detail based on examples shown in the drawings.
FIG. 1 is a front view showing a rotor for an axial gap type rotating electrical machine according to a first embodiment of the present invention. FIG. 2 is a longitudinal sectional side view showing only half of the rotor as viewed by cutting along a plane including the rotation axis O. FIG.
The main constituent members of the rotor 1 are a permanent magnet 2 disposed on the rotor front surface facing a stator (not shown), a base plate 3 disposed on the rotor rear surface opposite to the rotor front surface, the permanent magnet 2 and A rotor core 4 interposed between the base plates 3, and an engagement member 5 disposed at the center of the rotor 1 through which the rotation axis O passes.
これら主要構成部材２〜５の特徴を、ロータ１の製造工程も交えて説明する。
ベースプレート３は、ロータ１の骨格となる円盤形状の部材であり、ロータ１および図示しないステータ間で形成される磁気回路が流れるためのバックヨークとしての役割を果す。ベースプレート３の中央には、図示しないシャフトを取り付けるための中央孔３ｈを設ける。ベースプレート３の最も外径側の部位、すなわちベースプレート外縁部には、回転軸Ｏ方向に、ロータ前面まで突出した突出部６を設ける。突出部６は図１に示すように、ベースプレート３の全周に亘り設けるが、この他にも円周方向に等間隔に複数設けるものであってもよい。突出部６の先端６ａは、径方向内方へ拡幅する。そして、先端６ａの内径側部にはテーパ面６ｔを形成する。先端６ａは径方向幅広であるのに対し、突出部６の中程部分（先端６ａ以外の突出部６の部分）は径方向の幅が狭いことから、テーパ面６ｔの法線は、ベースプレート３の前面３ｚに向かって内径方向と斜交する。
The characteristics of these main components 2 to 5 will be described together with the manufacturing process of the rotor 1.
The base plate 3 is a disk-shaped member that serves as a skeleton of the rotor 1 and serves as a back yoke for a magnetic circuit formed between the rotor 1 and a stator (not shown) to flow. In the center of the base plate 3, a central hole 3h for attaching a shaft (not shown) is provided. A protruding portion 6 that protrudes to the front surface of the rotor in the direction of the rotation axis O is provided at a portion on the outermost diameter side of the base plate 3, that is, an outer edge of the base plate. As shown in FIG. 1, the protrusions 6 are provided over the entire circumference of the base plate 3. Alternatively, a plurality of protrusions 6 may be provided at equal intervals in the circumferential direction. The tip 6a of the protrusion 6 is widened radially inward. And the taper surface 6t is formed in the internal diameter side part of the front-end | tip 6a. Since the tip 6a is wide in the radial direction, the middle portion of the protrusion 6 (the portion of the protrusion 6 other than the tip 6a) is narrow in the radial direction. Obliquely with the inner diameter direction toward the front surface 3z.
突出部６よりも内径側には、ロータコア４を配置する。ロータコア４は、図３に示すような帯状に延在する薄板の電磁鋼板７を、巻き取って渦巻き状に形成する。これにより、ローア１で渦電流が発生することを防止して、回転電機の運転効率を向上させる。 The rotor core 4 is disposed on the inner diameter side of the protruding portion 6. The rotor core 4 is formed by winding a thin electromagnetic steel sheet 7 extending in a strip shape as shown in FIG. 3 into a spiral shape. This prevents eddy currents from being generated in the lower 1 and improves the operating efficiency of the rotating electrical machine.
電磁鋼板７には打ち抜き加工により凹部区画８を設け、隣り合う凹部区画８、８間には突起９を残しておく。突起９は、所定間隔ｆ（ｄ）で複数設ける。突起９は図３に示すように、根元から先端に向けて先が細くなる形状とするが、平行であってもよいし、後述する第２実施例のように先端を拡幅してもよい。この電磁鋼板７を巻き取って、図４に示すようなロータコア４の原型を形成する。既に渦巻き状に巻かれた電磁鋼板７に、新たに１回転巻き付ける度に、既に巻かれた突起９に新たな突起９が重なり合って、突条１０が形成される。したがって前述した図３に示す突起９・９の所定間隔ｆ（ｄ）は、回転軸Ｏから電磁鋼板７までの距離ｄに基づき決まる。ロータコア４の最も内径側である内縁の巻き始め端７ｓ近辺で最も狭く、外径に向かうにつれて、所定間隔が徐々に大きくなり、ロータコア４の最も外径側である外縁の巻き終わり端７ｅ近辺で最も広くなる。
巻き取ったばかりのロータコア４の突条は、図４に示すように、径方向と斜交して延在する。またロータコア４の中央にはロータコア中央孔４ｈを形成する。
The electromagnetic steel sheet 7 is provided with a recessed section 8 by punching, and a protrusion 9 is left between the adjacent recessed sections 8 and 8. A plurality of protrusions 9 are provided at a predetermined interval f (d). As shown in FIG. 3, the protrusion 9 has a shape that tapers from the root toward the tip, but may be parallel, or the tip may be widened as in the second embodiment described later. The electromagnetic steel sheet 7 is wound up to form a prototype of the rotor core 4 as shown in FIG. Each time a new turn is wound around the magnetic steel sheet 7 which has already been wound in a spiral shape, the new protrusion 9 overlaps with the already-rolled protrusion 9 to form a protrusion 10. Therefore, the predetermined interval f (d) between the protrusions 9 and 9 shown in FIG. 3 is determined based on the distance d from the rotation axis O to the electromagnetic steel sheet 7. It is narrowest in the vicinity of the winding start end 7 s of the inner edge that is the innermost diameter side of the rotor core 4, and the predetermined interval gradually increases toward the outer diameter, and near the winding end end 7 e of the outer edge that is the outermost diameter side of the rotor core 4. Become the widest.
As shown in FIG. 4, the ridges of the rotor core 4 that has just been wound extend obliquely to the radial direction. A rotor core center hole 4 h is formed at the center of the rotor core 4.
ロータ１の製造方法は、まず図５の縦断側面図に示すように、円盤形状のベースプレート３の前面３ｚに、図４に示すロータコア４を位置させる。巻き取ったばかりのロータコア４は突出部６の内径側の寸法、即ち突出部６の先端６ａが形成する内径寸法、よりも小さく、突出部６の内径側に容易に位置させることができる。 In the manufacturing method of the rotor 1, first, as shown in the longitudinal side view of FIG. 5, the rotor core 4 shown in FIG. 4 is positioned on the front surface 3 z of the disk-shaped base plate 3. The rotor core 4 just wound up is smaller than the inner diameter side of the protrusion 6, that is, the inner diameter formed by the tip 6 a of the protrusion 6, and can be easily positioned on the inner diameter side of the protrusion 6.
そして、このロータコア４を、巻き取り方向とは逆方向に解放する。そうすると、渦巻きがほどけるようにロータコア４原型の径方向寸法が増大して、図５に矢印で示す向きに拡径し、図６の正面図に示すようにロータコア４の外縁が突出部６の内壁に接触する。
なお図６には、ロータコア４外縁が突出部６の中程部分の内壁６ｕに接触したことを示すため、突出部６のうち径方向に幅の狭い中程部分を断面にして示す。
Then, the rotor core 4 is released in the direction opposite to the winding direction. Then, the radial dimension of the rotor core 4 prototype increases so as to unwind the spiral, and the diameter increases in the direction indicated by the arrow in FIG. 5, and the outer edge of the rotor core 4 extends from the protrusion 6 as shown in the front view of FIG. 6. Contact the inner wall.
In FIG. 6, in order to show that the outer edge of the rotor core 4 is in contact with the inner wall 6 u of the middle portion of the protruding portion 6, the middle portion of the protruding portion 6 that is narrow in the radial direction is shown in cross section.
突出部６の中程部分のうち内壁６ｕには、位置決めピン１１を設けておく。そして、ロータコア４の巻き終わり端７ｅを、位置決めピン１１に係止させる。以上より、ロータコア４の外縁をベースプレート３に固定する。 A positioning pin 11 is provided on the inner wall 6 u of the middle portion of the protruding portion 6. Then, the winding end 7 e of the rotor core 4 is locked to the positioning pin 11. As described above, the outer edge of the rotor core 4 is fixed to the base plate 3.
次に、図６に示すロータコア４に、矢印の向きのトルクを加えて、ロータコア４の内径側を円周方向に回転させることにより、重なり合った電磁鋼板７，７同士で相対回転させて、突条１０の延在方向を径方向に整列させる。図７の正面図は整列した状態を示す。 Next, by applying torque in the direction of the arrow to the rotor core 4 shown in FIG. 6 and rotating the inner diameter side of the rotor core 4 in the circumferential direction, the overlapping electromagnetic steel plates 7 and 7 are rotated relative to each other, so that The extending direction of the strip 10 is aligned in the radial direction. The front view of FIG. 7 shows an aligned state.
この整列の作業には、図８の正面図に示すガイド部材１２を用いるのが効率的である。
ガイド部材１２は合わせ面１２ａを具える。このガイド部材１２を突出部６に仮固定して、合わせ面１２ａをロータ１の径方向に延在させる。
そして、ロータコア４外縁の巻き終わり端７ｅをベースプレートに固定し、ロータコア４の巻き始め端７ｓを円周方向に相対回転させて、斜交して延在する突条１０をガイド部材１２の合わせ面１２ａに係止させて、突条１０の延在方向を径方向に整列させる。
For this alignment work, it is efficient to use the guide member 12 shown in the front view of FIG.
The guide member 12 includes a mating surface 12a. The guide member 12 is temporarily fixed to the protruding portion 6, and the mating surface 12 a extends in the radial direction of the rotor 1.
Then, the winding end end 7e of the outer edge of the rotor core 4 is fixed to the base plate, the winding start end 7s of the rotor core 4 is relatively rotated in the circumferential direction, and the projecting ridges 10 extending obliquely are aligned with the mating surface of the guide member 12 The extending direction of the ridges 10 is aligned in the radial direction by engaging with 12a.
次に、径方向に整列した周方向に隣り合う突条１０、１０間に扇形の永久磁石２を配置する。永久磁石２の外径側稜線を面とり２ｋ、２ｍしておく、さらに内径側稜線を面取り２ｍしておく。そして、図９の縦断側面図に矢印で示すように永久磁石２を軸Ｏと斜交する方向から、永久磁石２の外径側端部を内壁６ｕへ差し込む。永久磁石２の背面２ｈの稜線には面取り２ｋを設けているため、差し込み作業が容易になる。
そして図１０の周方向展開図に示すように、永久磁石２全体を、矢印で示す軸Ｏの方向に押し込んで、永久磁石２の背面２ｈをロータコア４の前面４ｚに密着させる。これにより、外径側端部の面とり２ｍが、突出部６のテーパ面６ｔと密着する。そして円周方向で隣り合う突条１０，１０間に永久磁石２を介挿することから、突条１０が永久磁石の外径方向および円周方向の移動を規制する。
Next, the fan-shaped permanent magnet 2 is disposed between the protrusions 10 and 10 adjacent in the circumferential direction aligned in the radial direction. The outer diameter side ridge line of the permanent magnet 2 is chamfered 2k and 2m, and the inner diameter side ridge line is chamfered 2m. Then, as shown by an arrow in the longitudinal side view of FIG. 9, the outer diameter side end of the permanent magnet 2 is inserted into the inner wall 6u from a direction obliquely intersecting the axis O with the axis O. Since the chamfer 2k is provided on the ridge line of the back surface 2h of the permanent magnet 2, the insertion work is facilitated.
10, the entire permanent magnet 2 is pushed in the direction of the axis O indicated by the arrow so that the back surface 2h of the permanent magnet 2 is brought into close contact with the front surface 4z of the rotor core 4. As a result, the chamfer 2m of the outer diameter side end portion is in close contact with the tapered surface 6t of the protruding portion 6. And since the permanent magnet 2 is inserted between the protrusions 10 and 10 adjacent in the circumferential direction, the protrusion 10 regulates the movement of the permanent magnet in the outer diameter direction and the circumferential direction.
次に、ロータ１に係合部材５を、図２に矢印で示す方向に差し込む。係合部材５はロータコア中央孔４ｈを貫通して、ベースプレート３に達する。そしてボルト締めにより係合部材５をベースプレート３に結合して、ロータ１を完成させる。係合部材５は円環状の部材であり、外縁にはテーパ面５ｔを設けておく。テーパ面５ｔの法線は、ベースプレート３の表面３ｚに向かって外径方向と斜交する。係合部材５を結合すると、テーパ面５ｔが永久磁石２内径側端部の面とり２ｍと密着する。 Next, the engaging member 5 is inserted into the rotor 1 in the direction indicated by the arrow in FIG. The engaging member 5 passes through the rotor core central hole 4 h and reaches the base plate 3. Then, the engaging member 5 is coupled to the base plate 3 by bolting to complete the rotor 1. The engaging member 5 is an annular member, and a tapered surface 5t is provided on the outer edge. The normal line of the tapered surface 5t obliquely intersects with the outer diameter direction toward the surface 3z of the base plate 3. When the engaging member 5 is coupled, the taper surface 5t comes into close contact with the chamfer 2m at the inner diameter side end portion of the permanent magnet 2.
図２の縦断側面図に示すように、ロータコア中央孔４ｈに、係合部材５を貫通して、係合部材５をベースプレート３の回転軸中央部にボルトで結合した状態で、係合部材５および前記突出部６がロータコア４および永久磁石２をベースプレートに固定する。 As shown in the vertical sectional side view of FIG. 2, the engagement member 5 is inserted into the rotor core central hole 4h through the engagement member 5 and the engagement member 5 is coupled to the rotation shaft central portion of the base plate 3 with a bolt. And the said protrusion part 6 fixes the rotor core 4 and the permanent magnet 2 to a baseplate.
次に本発明の第２実施例について説明する。
なお、第２実施例も基本的な構造および製造方法は上述した第１実施例と同様であるため、共通する構成については同一符号を付して説明を省略し、異なる部分については新たに符号を付して説明する。
図１１は、第２実施例になるロータコア４を構成する電磁鋼板７を示す平面図であり、ロータコア４を周方向の円筒面で切断した切断面を展開した周方向展開図でもある。この実施例では、突起９の先端２１を拡幅する。そして、先端２１から突起９の中程に向かって、電磁鋼板７の延在方向とは斜めに走向する縁２１ｔを打ち抜き加工により形成する。
Next, a second embodiment of the present invention will be described.
Since the basic structure and manufacturing method of the second embodiment are the same as those of the first embodiment described above, the same reference numerals are given to common components and the description thereof is omitted, and different parts are newly denoted. Will be described.
FIG. 11 is a plan view showing the electromagnetic steel sheet 7 constituting the rotor core 4 according to the second embodiment, and is also a circumferential development view in which a cut surface obtained by cutting the rotor core 4 with a cylindrical surface in the circumferential direction is developed. In this embodiment, the tip 21 of the protrusion 9 is widened. Then, an edge 21t that runs obliquely from the extending direction of the electromagnetic steel sheet 7 from the tip 21 toward the middle of the protrusion 9 is formed by punching.
このような図１１に示す先端拡幅形状の電磁鋼板７を巻き取って渦巻き状に形成したロータコア４についても、突条１０の先端２１が周方向に拡幅する。そして、縁２１ｔは突条１０の先端２１から中程にかけてテーパ面２１ｔを構成する。テーパ面２１ｔの法線は、ロータコア前面４ｚに向かって周方向と斜交する。 Also in the rotor core 4 formed by winding the electromagnetic steel sheet 7 having the widened tip end shown in FIG. 11 to form a spiral shape, the tip 21 of the ridge 10 is widened in the circumferential direction. And the edge 21t comprises the taper surface 21t from the front-end | tip 21 of the protrusion 10 to the middle. The normal line of the taper surface 21t is oblique to the circumferential direction toward the rotor core front surface 4z.
図６および図７に沿って前述したようなトルクを、第２実施例のロータコア４の内径側に加え、重なり合った電磁鋼板７，７同士で相対回転させて、突条１０の延在方向を径方向に整列させるために、図１２に示すガイド治具２２を用いる。 The torque as described above with reference to FIGS. 6 and 7 is applied to the inner diameter side of the rotor core 4 of the second embodiment, and the overlapping electromagnetic steel plates 7 and 7 are rotated relative to each other so that the extending direction of the ridges 10 is changed. In order to align in the radial direction, a guide jig 22 shown in FIG. 12 is used.
ガイド治具２２は、左右１組から成り、一組のガイド治具２２，２２を１つにまとめた状態で、径方向と斜交して延在する突条１０、１０間にセットする。図１２はセットした状態を示す正面図である。１つにまとまったガイド治具２２，２２同士が相互に隣接することによりＶ字状の溝２２ｖを形成する。溝２２ｖから周方向に離れたそれぞれのガイド治具２２の端部には、直線状の合わせ面２２ａを設ける。 The guide jig 22 is composed of a pair of left and right, and is set between the protrusions 10 and 10 extending obliquely with the radial direction in a state where the pair of guide jigs 22 and 22 are combined into one. FIG. 12 is a front view showing a set state. The V-shaped groove 22v is formed by the guide jigs 22 and 22 that are combined into one adjacent to each other. A linear mating surface 22a is provided at the end of each guide jig 22 that is separated from the groove 22v in the circumferential direction.
次に、溝２２ｖに楔を打ち込む。楔が軸Ｏ方向に進行すると、図１３の周方向展開図に示すようにガイド治具２２は楔からの力Ｆを受けて、互いに周方向に離れる。これにより、一対のガイド治具２２が展開し、合わせ面２２ａが突条１０を図１４の周方向展開図に矢印で示すように周方向に押圧する。この結果、図１２に矢印で示すように、ロータコア４の内径側にトルクを加えて、重なり合った電磁鋼板７，７同士で相対回転させることとなる。 Next, a wedge is driven into the groove 22v. When the wedge advances in the direction of the axis O, the guide jig 22 receives the force F from the wedge as shown in the circumferential development view of FIG. Thereby, a pair of guide jig | tool 22 expand | deploys, and the mating surface 22a presses the protrusion 10 to the circumferential direction as shown by the arrow in the circumferential direction expanded view of FIG. As a result, as indicated by an arrow in FIG. 12, torque is applied to the inner diameter side of the rotor core 4 and the overlapping electromagnetic steel plates 7 and 7 are rotated relative to each other.
図１５の正面図に示すように、ガイド治具２２同士が、所定の距離Ｌまで周方向に離れると、合わせ面２２ａが径方向に沿って延在する位置に一致する。これにより突条１０は径方向に整列される。 As shown in the front view of FIG. 15, when the guide jigs 22 are separated from each other in the circumferential direction to a predetermined distance L, the mating surface 22a coincides with a position extending along the radial direction. Thereby, the protrusions 10 are aligned in the radial direction.
永久磁石２の配置は、上述した図９に代えて、図１６の周方向展開図に示すようにボンド磁石を成型する。つまり、係合部材５をベースプレート３に結合して、ロータコア４をロータ１に固定した後、周方向で隣り合う突条１０・１０間であって、かつ突出部６と係合部材５との間の凹部空間に塑性の磁性材料を充填し、樹脂で固結させたり、加熱および焼鈍しにより固結させたりして、永久磁石２を成型する。先端２１，２１、テーパ面６ｔおよび５ｔにより永久磁石２は四方から軸Ｏ方向の移動を規制される。これにより、永久磁石２がロータコア４から剥がれることを防止する。 The arrangement of the permanent magnets 2 is formed by bonding magnets as shown in the circumferential development view of FIG. 16 instead of FIG. 9 described above. That is, after the engaging member 5 is coupled to the base plate 3 and the rotor core 4 is fixed to the rotor 1, it is between the protrusions 10 and 10 adjacent to each other in the circumferential direction, and between the protruding portion 6 and the engaging member 5. The space between the recesses is filled with a plastic magnetic material and solidified with resin, or solidified by heating and annealing, and the permanent magnet 2 is molded. The permanent magnet 2 is restricted from moving in the direction of the axis O from four directions by the tips 21 and 21 and the tapered surfaces 6t and 5t. Thereby, it is prevented that the permanent magnet 2 is peeled off from the rotor core 4.
ところで、上記した本実施例によれば、ベースプレート３の外縁部にロータ１の回転軸Ｏ方向に突出する突出部６を設け、突出部６よりも内径側にロータコア４を配置し、ロータコア４の中央に形成した中央孔４ｈには、係合部材５を貫通して、係合部材５をベースプレート３の回転軸中央部にボルトで結合した状態で、係合部材５および突出部６がロータコア４および永久磁石２をベースプレート３に固定するよう構成したことから、
従来のように、接着剤による貼り付けや、リベット留めするまでもなく、ロータコア４をそのままの渦巻き形状でロータ１内に保持することができる。さらに、貼り合わせやリベット固定という工数を削減してロータ１の組み立てを省力化することができるばかりでなく、回転電機の高出力化の要求に答えることが可能となる。
By the way, according to the above-described embodiment, the protruding portion 6 that protrudes in the direction of the rotation axis O of the rotor 1 is provided on the outer edge portion of the base plate 3, and the rotor core 4 is disposed on the inner diameter side of the protruding portion 6. In the center hole 4h formed at the center, the engaging member 5 and the protruding portion 6 are connected to the rotor core 4 in a state where the engaging member 5 passes through the center hole 4h and the engaging member 5 is coupled to the central portion of the rotation shaft of the base plate 3 with a bolt. Since the permanent magnet 2 is fixed to the base plate 3,
The rotor core 4 can be held in the rotor 1 in a spiral shape as it is, without needing to be glued or riveted as in the prior art. Furthermore, not only can the man-hours of bonding and rivet fixing be reduced to save labor in assembling the rotor 1, but it is also possible to meet the demand for higher output of the rotating electrical machine.
また図１０に示すように、ロータコア４は径方向に延在し、軸Ｏ方向に突出する突条１０を複数具え、隣り合う突条１０，１０間に永久磁石２を配置した状態で突条１０が永久磁石の外径方向および円周方向の移動を規制することから、ロータ１の強度を一層高めることができる。 As shown in FIG. 10, the rotor core 4 extends in the radial direction, includes a plurality of ridges 10 protruding in the axis O direction, and the ridges in a state where the permanent magnet 2 is disposed between the adjacent ridges 10, 10. Since 10 regulates the movement of the permanent magnet in the outer diameter direction and the circumferential direction, the strength of the rotor 1 can be further increased.
具体的にはベースプレート突出部６の先端６ａを径方向内方に拡幅し、先端６ａの内径側部には、ロータコア４および永久磁石２の外径方向および回転軸Ｏ方向の移動を規制するテーパ面６ｔを設けて、ロータコア４および永久磁石２をベースプレート３に固定する。なお、図示はしなかったが、これらテーパ面５ｔ、６ｔおよび面とり２ｍに代えて、段差を設けて、永久磁石２を係止することにより外径方向および回転軸Ｏ方向の移動を規制してもよいこと勿論である。 Specifically, the tip 6a of the base plate protrusion 6 is expanded radially inward, and a taper that restricts movement of the rotor core 4 and the permanent magnet 2 in the outer diameter direction and the rotation axis O direction on the inner diameter side portion of the tip 6a. A surface 6 t is provided to fix the rotor core 4 and the permanent magnet 2 to the base plate 3. Although not shown, instead of these tapered surfaces 5t and 6t and the chamfer 2m, a step is provided and the permanent magnet 2 is locked to restrict movement in the outer diameter direction and the rotation axis O direction. Of course.
また第２実施例にあっては図１６に示すように、突条１０の先端２１を周方向に拡幅し、先端２１が永久磁石２の軸Ｏ方向の移動を規制することから、
突条１０が係合部材５および突出部６と相俟って、永久磁石２のロータ１からの脱落を防止することができ、ロータ１の強度を一層高めることができる。
Further, in the second embodiment, as shown in FIG. 16, the tip 21 of the ridge 10 is widened in the circumferential direction, and the tip 21 restricts the movement of the permanent magnet 2 in the axis O direction.
The protrusion 10 combined with the engaging member 5 and the protrusion 6 can prevent the permanent magnet 2 from falling off the rotor 1, and the strength of the rotor 1 can be further increased.
また図６に示すように、ベースプレート突出部６の内径側部である内壁６ｕには、ロータコア４外縁の回転を規制する位置決めピン１１を設けたことから、
ロータコア４全体がベースプレート３に対して相対回転することを防止でき、突条１０を径方向に整列する作業を、容易に行うことができる。
Further, as shown in FIG. 6, the inner wall 6 u that is the inner diameter side portion of the base plate protruding portion 6 is provided with a positioning pin 11 that restricts rotation of the outer edge of the rotor core 4.
The entire rotor core 4 can be prevented from rotating relative to the base plate 3, and the operation of aligning the protrusions 10 in the radial direction can be easily performed.
上記した本実施例の製造方法によれば、まず図３に示すように帯状の電磁鋼板７に突起９を延在方向所定間隔で複数設け、帯状の電磁鋼板７を巻き取ることにより、突起９を重ね合わせて径方向と斜交して延在する突条１０を複数形成しつつ、図４に示すような前記ロータコア４を形成し、
そして、このロータコア４を、図５に示すようにベースプレート突出部６よりも内径側に位置させ、該ロータコアを巻き取り方向とは逆方向に解放することにより、ロータコア外縁がベースプレート突出部に接触するまでロータコアを図５の矢の方向に拡径し、
次に、帯状の電磁鋼板７からなるロータコア４の外縁を図６に示すようにベースプレート３に固定し、ロータコア４の内縁を円周方向に相対回転させることにより突条１０の延在方向を径方向に整列させ、
次に、周方向で隣り合う突条１０，１０同士の間に永久磁石２を配置して、ロータコア中央孔４ｈに係合部材５を貫通して係合部材５をベースプレート３に結合することから、上述したアキシャルギャップ型回転電機のロータ１を効率的に組み立てることができる。
According to the manufacturing method of the present embodiment described above, first, as shown in FIG. 3, a plurality of protrusions 9 are provided on the belt-shaped electromagnetic steel sheet 7 at a predetermined interval in the extending direction, and the belt-shaped electromagnetic steel sheet 7 is wound up, whereby the protrusion 9 4 and forming the rotor core 4 as shown in FIG. 4 while forming a plurality of ridges 10 that obliquely extend in the radial direction.
Then, as shown in FIG. 5, the rotor core 4 is positioned closer to the inner diameter side than the base plate protruding portion 6 and the rotor core is released in the direction opposite to the winding direction, so that the outer edge of the rotor core contacts the base plate protruding portion. Until the rotor core is expanded in the direction of the arrow in FIG.
Next, the outer edge of the rotor core 4 made of the strip-shaped electromagnetic steel sheet 7 is fixed to the base plate 3 as shown in FIG. 6, and the inner edge of the rotor core 4 is relatively rotated in the circumferential direction so that the extending direction of the ridges 10 is reduced in diameter. Align in the direction,
Next, the permanent magnet 2 is disposed between the protrusions 10 adjacent to each other in the circumferential direction, and the engaging member 5 is passed through the rotor core central hole 4h to couple the engaging member 5 to the base plate 3. The rotor 1 of the axial gap type rotating electrical machine described above can be efficiently assembled.
この製造方法のうちロータコア４の外縁をベースプレート３に固定する工程では、図６に示すように、ベースプレート３の突出部６の内径側に位置決め構造たる位置決めピン１１を設け、帯状の電磁鋼板７からなるロータコア４の外縁の巻き終わり端７ｅを位置決めピン１１に係止することから、ベースプレート３にロータコア４の外縁を効率的に固定することができる。 In the manufacturing method, in the step of fixing the outer edge of the rotor core 4 to the base plate 3, as shown in FIG. 6, a positioning pin 11 as a positioning structure is provided on the inner diameter side of the protruding portion 6 of the base plate 3. Since the winding end 7 e of the outer edge of the rotor core 4 is locked to the positioning pin 11, the outer edge of the rotor core 4 can be efficiently fixed to the base plate 3.
この製造方法のうち突条１０を整列させる工程では、図８に示すようにガイド部材１２をベースプレート突出部６に仮固定し、ガイド部材１２の合わせ面１２ａをロータ１の径方向に延在させ、
ロータコア４内縁を相対回転させる際、斜交して延在する突条１０をガイド部材１２の合わせ面１２ａに係止させて、前記整列を行い、
その後、ガイド部材１２をベースプレート突出部６から取り外すことから、突条１０を効率的に整列させることができる。
In the step of aligning the protrusions 10 in this manufacturing method, the guide member 12 is temporarily fixed to the base plate protrusion 6 as shown in FIG. 8, and the mating surface 12 a of the guide member 12 extends in the radial direction of the rotor 1. ,
When the inner edge of the rotor core 4 is relatively rotated, the protrusion 10 extending obliquely is engaged with the mating surface 12a of the guide member 12, and the alignment is performed.
Then, since the guide member 12 is removed from the base plate protrusion part 6, the protrusion 10 can be aligned efficiently.
あるいは第２実施例では、突条１０を整列させる工程で図１２および図１３に示すように、周方向に並んだ１対のガイド治具２２を、周方向で隣り合う、斜交して延在する突条１０，１０同士の間に配置し、
次に、ガイド治具２２を図１４および図１５に示すように周方向に展開して、ガイド治具の合わせ面２２ａがこれら隣り合う突条１０，１０を周方向に押し広げることにより合わせ面２２ａがロータ１の径方向に一致して、前記整列を行うことから、突条１０を一層効率的に整列させることができる。
これらガイド部材１２およびガイド治具２２は、突条１０の先端２１が幅広に形成されてテーパ面２１ｔが設けている等の事情があっても、突条１０を正確に整列することができるという利点がある。
Alternatively, in the second embodiment, as shown in FIGS. 12 and 13 in the step of aligning the ridges 10, a pair of guide jigs 22 arranged in the circumferential direction are adjacent to each other in the circumferential direction and extend obliquely. Arranged between existing ridges 10, 10,
Next, as shown in FIGS. 14 and 15, the guide jig 22 is developed in the circumferential direction, and the mating surface 22 a of the guide jig pushes the adjacent protrusions 10, 10 in the circumferential direction to expand the mating surface. Since the alignment is performed by matching the radial direction of the rotor 1 with 22a, the protrusions 10 can be aligned more efficiently.
The guide member 12 and the guide jig 22 can accurately align the protrusions 10 even if the tip 21 of the protrusions 10 is formed wide and has a tapered surface 21t. There are advantages.
この製造方法のうち永久磁石２を配置する工程では、図１６に示すように周方向で隣り合う突条１０，１０同士の間を塑性の磁性材料で満たし、次に、この磁性材料を固結させることから、
永久磁石２の外径側にテーパ面６ｔを配置するのみならず、永久磁石２の周方向両端にもテーパ面２１ｔ、２１ｔを配置しているため、最終工程で永久磁石２を図９に示すように差し込み配置することができなくても、ロータ１に永久磁石２を成型配置することができる。
In the step of arranging the permanent magnet 2 in this manufacturing method, as shown in FIG. 16, the space between the adjacent ridges 10, 10 in the circumferential direction is filled with a plastic magnetic material, and then the magnetic material is consolidated. From
Since not only the tapered surface 6t is disposed on the outer diameter side of the permanent magnet 2 but also the tapered surfaces 21t and 21t are disposed at both circumferential ends of the permanent magnet 2, the permanent magnet 2 is shown in FIG. Thus, the permanent magnet 2 can be molded and arranged on the rotor 1 even if it cannot be inserted and arranged.
なお、上述したのはあくまでも本発明の一実施例であり、本発明はその主旨に逸脱しない範囲において種々変更が加えられうるものである。例えば、ロータ１の強度を一層確保する必要があれば、突条１０を整列させた後、図７の正面図に示すロータ１を樹脂で含浸する処理を追加する。これにより、隣接する電磁鋼板７，７同士が接着して、ロータコア４の強度を高めることができ、かつ、ベースプレート３およびロータコア４が接着されて、ロータ１の強度を高めることができる。 The above description is merely an example of the present invention, and the present invention can be variously modified without departing from the spirit of the present invention. For example, if it is necessary to further secure the strength of the rotor 1, a process of impregnating the rotor 1 shown in the front view of FIG. Thereby, the electromagnetic steel plates 7 and 7 adjacent to each other can be bonded to increase the strength of the rotor core 4, and the base plate 3 and the rotor core 4 can be bonded to increase the strength of the rotor 1.
１ ロータ
２ 永久磁石
３ ベースプレート
４ ロータコア
５ 係合部材
６ ベースプレート外縁の突出部
６ｔ テーパ面
７ 電磁鋼板
１０ 突条
１１ 位置決めピン
１２ ガイド部材
２２ ガイド治具
DESCRIPTION OF SYMBOLS 1 Rotor 2 Permanent magnet 3 Base plate 4 Rotor core 5 Engagement member 6 Projection part of base plate outer edge 6t Tapered surface 7 Electrical steel sheet 10 Projection 11 Positioning pin 12 Guide member 22 Guide jig
Claims (5)
前記帯状の電磁鋼板に突起を延在方向所定間隔で複数設け、該帯状の電磁鋼板を巻き取
ることにより、前記突起を重ね合わせて径方向と斜交して延在する突条を複数形成しつつ、前記ロータコアを形成し、
前記ロータコアを、前記ベースプレートの外縁部に設けられてロータの回転軸方向に突出するベースプレート突出部よりも内径側に位置させ、該ロータコアを巻き取り方向とは逆方向に解放することにより、該ロータコア外縁が該ベースプレート突出部に接触するまで該ロータコアを拡径し、
次に、前記ロータコア外縁を前記ベースプレートに固定し、該ロータコアの内縁を円周方向に相対回転させることにより前記突条の延在方向を径方向に整列させ、
次に、周方向で隣り合う突条同士の間に前記永久磁石を配置して、前記ロータコアの中央に形成したロータコア中央孔に係合部材を貫通させて該係合部材を前記ベースプレートに結合し、該係合部材および前記ベースプレート突出部によって前記ロータコアおよび前記永久磁石を前記ベースプレートに固定することを特徴とするアキシャルギャップ型回転電機用ロータの製造方法。 Manufacturing a rotor for an axial gap type rotating electrical machine in which a rotor core formed in a spiral shape is wound around a disk-shaped base plate by winding a thin electromagnetic steel plate extending in a strip shape, and a permanent magnet is provided on the rotor core. In the method
A plurality of protrusions are provided on the belt-shaped electromagnetic steel sheet at predetermined intervals in the extending direction, and the belt-shaped electromagnetic steel sheet is wound to form a plurality of protrusions that overlap the protrusions and extend obliquely with the radial direction. While forming the rotor core,
Said rotor core, said provided at the outer edge of the base plate is located on the inner diameter side than the base plate protrusion protruding in the direction of the rotation axis of the rotor, by the take-up direction the rotor core to release in the opposite direction, the rotor core outer edge is expanded the rotor core until contact with the base plate projecting portion,
Next, the rotor core outer edge fixed to the base plate, aligning the extending direction of the protrusions in the radial direction by relatively rotating the inner edge of the rotor core in the circumferential direction,
Next, said permanent magnet is disposed between the ridges adjacent to each other in the circumferential direction, by penetrating the engagement member in the rotor core center hole formed at the center of the rotor core attached to the engagement member to the base plate A method of manufacturing a rotor for an axial gap type rotating electrical machine , wherein the rotor core and the permanent magnet are fixed to the base plate by the engaging member and the base plate protrusion .
前記ロータコア外縁を前記ベースプレートに固定するため、前記ベースプレート突出部の内径側に位置決め構造を設け、前記帯状の電磁鋼板からなるロータコアの外縁の巻き終わり端を前記位置決め構造に係止することを特徴とするアキシャルギャップ型回転電機用ロータの製造方法。 In the manufacturing method of the rotor for axial gap type rotating electrical machines according to claim 1,
For securing the rotor core outer edge to the base plate, and wherein the positioning structure on the inner diameter side of the base plate projecting portion is provided to lock the winding end of the outer edge of the rotor core composed of a magnetic steel of the strip to said positioning structure A method for manufacturing a rotor for an axial gap type rotating electrical machine.
前記突条の整列のため、ガイド部材を前記ベースプレート突出部に仮固定し、該ガイド部材の合わせ面をロータの径方向に延在させ、
前記相対回転の際、前記斜交して延在する突条を前記ガイド部材の合わせ面に係止させて、前記整列を行い、
その後、前記ガイド部材を前記ベースプレート突出部から取り外すことを特徴とするアキシャルギャップ型回転電機用ロータの製造方法。 In the manufacturing method of the rotor for axial gap type rotating electrical machines according to claim 1 or 2,
Wherein for alignment ridges, temporarily fixing the guide member to the base plate protrusions, extend the mating surfaces of the guide member in the radial direction of the rotor,
Wherein upon relative rotation, with the ridge extending the oblique to to engage with the mating surfaces of the guide member, it performs the alignment,
Thereafter, the manufacturing method of the axial gap type rotating electric machine rotor, characterized in that removing the guide member from the base plate protruding portion.
前記突条の整列のため、周方向に並んだ１対のガイド治具を、周方向で隣り合う前記斜交して延在する突条同士の間に配置し、
次に、前記ガイド治具を周方向に展開して、該ガイド治具の合わせ面がこれら隣り合う突条を周方向に押し広げることにより前記合わせ面がロータの径方向に一致して、前記整列を行うことを特徴とするアキシャルギャップ型回転電機用ロータの製造方法。 In the manufacturing method of the rotor for axial gap type rotating electrical machines according to claim 1 or 2,
For alignment of the ridges, a pair of guide jigs arranged in the circumferential direction are disposed between the ridges extending obliquely adjacent to each other in the circumferential direction,
Next, the guide jig to expand in the circumferential direction, with the mating surfaces of the guide jig wherein the mating surface by pushing these adjacent protrusions in the circumferential direction coincides in the radial direction of the rotor, the A method for manufacturing a rotor for an axial gap type rotating electrical machine, wherein the alignment is performed.
前記永久磁石の配置のため、周方向で隣り合う突条同士の間を塑性の磁性材料で満たし、
次に、前記磁性材料を固結させることを特徴とするアキシャルギャップ型回転電機用ロータの製造方法。 In the manufacturing method of the rotor for axial gap type rotating electrical machines given in any 1 paragraph of Claims 1-4,
Because of the arrangement of the permanent magnets, the gap between adjacent ridges in the circumferential direction is filled with a plastic magnetic material,
Next, a method for manufacturing a rotor for an axial gap type rotating electrical machine, wherein the magnetic material is consolidated.
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| GB0821815D0 (en) * | 2008-11-28 | 2009-01-07 | Cummins Generator Technologies | Rotating electrical machine |
| ES2527783B1 (en) * | 2014-03-18 | 2015-11-12 | Innovació Electrònica I Mobilitat, S. L. | Electric machine |
| CN110401281B (en) * | 2019-07-22 | 2020-12-29 | 浙江大学 | Motor rotor and motor comprising same |
| IT201900015402A1 (en) * | 2019-09-02 | 2021-03-02 | Texa Dynamics S R L | "Electric motor rotor" |
| JP7364925B2 (en) * | 2020-09-29 | 2023-10-19 | 日亜化学工業株式会社 | Yoke for rotor of axial gap type motor |
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| JPS6260451A (en) * | 1985-09-06 | 1987-03-17 | Nissan Motor Co Ltd | Permanent-magnet field disk type synchronous machine |
| JPH0837766A (en) * | 1994-07-26 | 1996-02-06 | Tokyo Parts Ind Co Ltd | Spindle motor for disk drive |
| JPH09215251A (en) * | 1996-01-31 | 1997-08-15 | Tec Corp | Motor |
| JP2005094955A (en) * | 2003-09-18 | 2005-04-07 | Toyota Central Res & Dev Lab Inc | Axial permanent magnet motor |
| JP2006166635A (en) * | 2004-12-08 | 2006-06-22 | Nissan Motor Co Ltd | Dynamo-electric machine |
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