JP4983430B2 - Rotor of rotating electrical machine and method for manufacturing the same - Google Patents

Description

  TECHNICAL FIELD The present invention relates to a rotor of a rotating electrical machine and a method for manufacturing the same, and particularly to a rotor of a rotating electrical machine suitable for a rotating electrical machine including a rotor core with a rotor core member paired, such as a vehicle AC generator. It relates to the manufacturing method.

[Conventional technology]
The conventional vehicle alternator has a Landel pole core as the rotor core of the rotor, and the Landel pole cores have the same shape and have one end faced opposite to each other and the shaft is press-fitted and fixed to the center thereof. It has a structure (see, for example, Patent Document 1). A conventional rotor core (pole core) has a cylindrical base, a large number of prismatic nail bases extending radially outward from the axially outer end of the base at predetermined intervals in the circumferential direction, and a nail base A claw portion extending so as to surround the field coil from the radial tip portion in the axial direction, and the claw portion is accommodated in the stator core.

  In addition, a large number of nail-raised shafts are press-fitted into the center of the pole cores facing each other, and staking caulking by press molding is processed in the annular groove attached to the pole core outer end surface position of the shaft Thus, a rotor is configured. The staking caulking is for maintaining mechanical strength even during high-speed rotation (see, for example, Patent Document 2). For this reason, a hole that penetrates the shaft, that is, a shaft through hole, is opened by cutting in the center of the base portion of the pole core.

  Generally, the rotor core that constitutes this pole core is manufactured by a forging facility using soft iron material, but the processing accuracy of the manufacturing facility is limited, and the opposing end faces do not necessarily have a geometric parallel or right angle. Rather, variations occur in the perpendicularity and flatness of the opposing one end face with respect to the shaft through hole.

  Accordingly, as shown in FIG. 10, the boss portion end surface 176 at one opposite end face is inclined with respect to the outer end surface 172, and the shaft through-hole 178 processed by cutting the pole core 107 is outside with respect to the outer end surface 172. In the case of a manufacturing method that is processed perpendicularly to the end surface 172, the angle α1 that intersects the outer end surface 172 is 90 °, but the angle α2 that intersects the boss end surface 176 is not 90 ° and does not intersect perpendicularly. It becomes. For this reason, when the opposing boss part end surfaces 176 are combined, they may not be brought into close contact with each other and may come into contact with each other to create a gap.

  The machining by the shaft through-hole 178 is not necessarily limited to the case of being machined perpendicularly to the outer end surface 172 with reference to the outer end surface 172, but the boss portion end surface 176 with reference to the inner end surface, that is, the boss portion end surface 176. There is a processing method in the case of being processed perpendicularly to the boss portion bottom end surface 177 or the boss portion bottom end surface 177 as a reference. Which machining method is adopted is selected in consideration of the machining accuracy and the degree of variation as well as the ease of machining the pole core. However, an inclination similarly occurs depending on the degree of variation.

  In the case of combining the opposing boss part end faces 176 of the pole core, the rotor manufacturing method in which the contact cannot be brought into close contact with each other and a gap is generated due to contact with each other is unavoidable in adopting the manufacturing process described below. A malfunction occurs. The problem will be described below together with the manufacturing process of the conventional example.

  11 to 14 show a pair of pole cores 107 (hereinafter referred to as a lower pole core 107a and an upper pole core 107b) having a shaft through hole (hereinafter referred to as an axial hole) 178 that is processed perpendicularly to the outer end surface 172 with reference to the outer end surface 172. The assembly process diagram of the conventional sequential assembly method in which the shaft 105 is press-fitted and the rotor 103 is assembled in order is shown in FIG.

  FIGS. 11A and 11B are schematic views of the main part of the shaft press-fitting device 130 showing the first step of assembly. As shown in FIG. 11A, the shaft press-fitting device 130 has a normal die set structure including a punch portion 131 and a die portion 132, and the die portion 132 is supported on a base 133 by a cradle 135 via a bearing 134. Has been. A guide hole is formed in the center of the cradle 135, and a center presser 136 is slidably disposed in the guide hole. The bearing 134 is for moving the cradle 135 in the horizontal direction when the center of the center presser 136 does not coincide with the center of the cradle 135. Further, at least two claw pressers 137 are fixed to the base 133, and hold and hold the claw portion 174 of the upper pole core 107b, which is a workpiece, in the axial direction or the centripetal direction. The lever 138 can be held and released freely. It has become a thing.

  The punch 131 is assembled in a die set so that the press-fitting punch 140 having a shaft holding punch 139 that holds the shaft 105 in the vertical direction is lowered or raised in the vertical direction.

  Next, shaft press-fitting by the shaft press-fitting device 130 will be described. First, as the first step, the upper pole core 107b sent out in the previous step is set on the receiving base 135. Since the upper pole core 107b set on the cradle 135 has a shaft hole 178 formed perpendicular to the outer end surface 172 which is a plane, the upper pole core 107b has an outer end surface 172 horizontally with respect to the cradle 135, and The shaft hole 178 is arranged vertically. Then, the center presser 136 rises from below and is inserted into the vertically oriented shaft hole 178 of the upper pole core 107b. At this time, even if the center of the press-fitting punch 140 and the center of the cradle 135 are misaligned, the misalignment is adjusted and concentric by the insertion of the center presser 136 into the upper pole core 107b. Then, the upper pole core 107 b is fixed to the cradle 135 by the lever operation of the claw presser 137.

  Next, as shown in FIG. 11 (b), the shaft 105 is vertically held by the shaft holding punch 139 of the press-fitting punch 140, and the non-holding side of the shaft 105 is inserted into the shaft hole 178 of the upper pole core 107b. The press-fitting punch 140 is lowered so as to be brought into contact with and guided by the upper end portion of the presser 136. Then, the shaft 105 is press-fitted into the upper pole core 107b while maintaining smoothness and verticality.

  When the press-fitting proceeds to a predetermined position, the press-fitting punch 140 releases the holding of the shaft holding punch 139 and the shaft 105, moves upward, returns to the original position, and stops. Then, the nail presser 137 is released by operating the lever 138, and the upper pole core 107b into which the shaft 105 is press-fitted is taken out.

  Next, the second process will be described. The second step is a combination step of the lower pole core 107a and the field coil 108 when the upper pole core 107b into which the shaft 105 is press-fitted in the first step is press-fitted into the lower pole core 107a. FIG. 12A is a schematic view of the main part of the shaft press-fitting device 130 showing the second step of assembly.

  The lower pole core 107a sent out in the previous process is mounted on the pallet with the field coil 108 attached. In this process, the lower pole core 107a to which the field coil 108 is attached is pulled out of the pallet by the gripping mechanism 160 provided in the punch portion 131, and the gripping mechanism 160 is lowered while being gripped. On the cradle 135, the lower pole core 107a on which the field coil 108 is mounted is set. And the holding | grip mechanism part 160 cancels | releases holding | grip of the lower pole core 107a, raises, and returns to an initial stop position. Similarly, the center presser 136 is raised and inserted into the shaft hole 178 of the lower pole core 107a. Then, the lower pole core 107 a is fixed to the cradle 135 by the lever operation of the claw presser 137.

  Subsequently, the third step will be described. The third step is a step of assembling the upper pole core 107b in which the shaft 105 is press-fitted in the first step into the lower pole core 107a to which the field coil 108 is attached. FIG. 12B is a schematic view of the main part of the shaft press-fitting device 130 showing the third step of assembly.

  The gripping mechanism section 160 that has returned to the initial position in the second step grips the upper pole core 107b into which the shaft 105 in the first step is press-fitted so that the shaft 105 is positioned vertically. Then, the shaft 105 is press-fitted into the shaft hole 178 of the lower pole core 107a by bringing the lower end portion of the shaft 105 into contact with the upper end portion of the center presser 136 and lowering the gripping mechanism portion 160. When the press-fitting proceeds to a predetermined position, the gripping mechanism section 160 releases the grip of the shaft 105 and the upper pole core 107b, rises upward, returns to the original position, and stops.

  Then, the pawl presser 137 is released to remove the shaft press-fitted pole core (which is in the form of a rotor, but before caulking, so this is hereinafter referred to as the pre-caulking rotor 103), and the process proceeds to the caulking step. .

  In the caulking step, concave indentations having a predetermined annular shape are formed on both outer end faces 172 of the pre-caulking rotor 103, and the indentations are similarly attached to the positions of both outer end faces 172 of the shaft 105. This is a step of forming a caulking formed by presenting a plastic flow in an annular groove. This caulking is generally called staking caulking, and the rotor 103 used at high speed for a vehicle AC generator or the like is pressed into the pole core 107 against centrifugal force or axial force during high speed rotation. It is intended to increase the mechanical strength so that it does not come out of the shaft 105 and the fastening force does not decrease.

  FIG. 13 is a schematic view of the main part of a caulking device 150 for explaining the caulking process. The difference from the shaft press-fitting device 130 used in the press-fitting process is that both the punch 151 and the die 152 are replaced with the caulking punch 153 and the caulking die 154. The pre-caulking rotor 103 taken out in the previous step is set on the cradle 155 as it is.

  A caulking die 154 that is guided by the lower center presser 156 at the center of the receiving base 155 is similarly arranged with the center aligned. Accordingly, since the center of the shaft 105 of the pre-caulking rotor 103 set on the cradle 155 coincides with the center of the caulking die 154, each of the upper and lower pole cores 107a and 107b formed at right angles (perpendicular) to the shaft 105. The outer end surface 172 also forms a right angle (vertical) with the center of the caulking die 154. That is, as the caulking die 154 or the caulking punch 153 moves up and down, an annular concave indentation is formed on each outer end surface 172, and the indentation is similarly provided on the positions of both outer end surfaces 172 of the shaft 105. Caulking is processed by exhibiting a plastic flow in the annular groove.

  After the above press-fitting process and caulking process, the rotor after caulking, that is, the rotor 103 of the Landel pole core is manufactured.

[Problems with conventional technology]
In this way, each pole core is opposed to each other in the rotor assembled through the assembly process in which the shafts are press-fitted with the respective pole cores having the shaft through holes cut perpendicularly to the outer end surface with the outer end face of the pole core as a reference. As a result, the end face of the boss part is slightly inclined with respect to the outer end face or the flatness is deteriorated. May occur.

  Even if the shaft can be press-fitted with such a gap, the axial thickness of the pole core exceeds the predetermined thickness, and the rotor comes into contact with the stator, generating abnormal noise. Or cause performance degradation. However, normally, the shaft and the shaft hole are coupled to each other by fitting coupling so that the shaft has a large press-fitting load. Therefore, as shown in FIG. 14A, the clearance is reduced by the press-fitting load. Due to the deformation, the deformation of the shaft hole and the shaft becomes large, and the press-fitting does not proceed any more.

  If the press-fitting load is further increased, the press-fitting of the shaft proceeds due to the balance with the shaft galling, but the load is applied until the end faces of the boss portions where the gaps are formed so that a large bending moment acts on the shaft 105. become. When the load increases and the bending moment further increases and exceeds the allowable elastic deformation limit, the shaft 105 of the rotor 103 taken out from the press-fitting device or the caulking device is bent as shown in FIG. It happens. When the shaft 105 bends, the outer diameter swing increases with respect to the rotation shaft reference of the rotor 103, interference with the stator core, an increase in vibration and rotational fluctuation, a reduction in bearing life and power generation in an AC generator for a vehicle. There arises a problem that fluctuations and variations become large.

  Similarly, in the staking caulking process, if each boss end face hits at one place and press fitting does not proceed any more, the axial thickness of the pole core exceeds the predetermined thickness and caulking is performed. (Refer to FIG. 14 (a)), the annular groove depth is uneven and uneven, resulting in variations in the fastening force of the shaft, which may cause problems such as the shaft of the pole core coming off during high-speed rotation. . In addition, since the staking caulking has a larger punching pressure than the shaft press-fitting, both bosses of the pole core in the caulking process are pressed from a single contact state to a close contact state, and the shaft is bent at this time, The end face of each boss part of the pole core may come into contact with the surface. In this case as well, the shaft 105 of the extracted rotor 103 is bent as described above. As a result, the same problem as described above occurs.

In addition, in order to reduce this shaft runout, the boss end face of the pole core before assembly is finished and cut at right angles to the shaft hole, the pole core and shaft are finished in a perpendicular or parallel process in the front and rear processes, and corrected based on the rotation axis. There are cutting removal methods, straightening bending methods, etc., but all of these require additional steps, and there is a concern that the cutting cost must be estimated, resulting in waste of materials and an increase in cost.
JP-A-11-220845 JP 56-98349 A

  SUMMARY OF THE INVENTION The present invention has been made in view of the above problems, and a rotor for a rotating electrical machine capable of suppressing an increase in cost, reducing a swing of the rotor pole core with respect to both bearing portion standards, and suppressing a decrease in performance, and a method for manufacturing the same. The purpose is to provide.

[Means of Claim 1]
According to the means of claim 1, a plurality of rotor cores composed of a hollow core member having claw portions extending in the axial direction from the radial tip portions of a large number of claw base portions extending in the radially outward direction are provided. A rotor of a rotating electrical machine having a shaft mounted in a hollow portion formed opposite to each other, and having a shaft press-fitted and fixed to a shaft shaft hole of each of the rotor cores, the shaft being penetrated and fixed in position. Each rotor core is formed with a plane portion in the axial direction, the plane portion is inclined with respect to the rotation center axis of the shaft, and the plane portions of each rotor core are in contact with each other in parallel. Before and after the axial direction of the part, the shaft is straight, and the axis perpendicular to the inclined surface of the flat part on the axial projection of each rotor core is a radial imaginary connecting the center of the claw part and the center of the shaft shaft hole Radial temporary connecting the line, the center between the claws, and the shaft shaft hole center It is characterized in that on the line in the line.

  As a result, the planar portions of the rotor cores that are in contact with each other can be in close contact with each other in parallel, so that the magnetic resistance between the iron cores can be reduced and the shaft is straight, so that it rotates with respect to both ends of the shaft. In this case, the vibration becomes smaller with respect to the rotation reference, and vibration and rotation fluctuation can be reduced without causing interference with the stator core. In addition, in a vehicle AC generator, the bearing life is improved, and fluctuations and variations in power generation are suppressed.

[Means of claim 2]
According to the means described in claim 2, each rotor core includes an outer end plane on the outer side in the axial direction of each rotor core and a boss end face on the inner side in the axial direction, and the outer end portion of each rotor core. The planes are characterized by being parallel to each other and the outer end planes of the other rotor cores facing each other.
This minimizes the thickness between the axially outer end faces of the plurality of rotor cores, and further suppresses dynamic imbalance associated with rotation without causing interference with the stator core, thereby reducing vibration.

[Means of claim 3]
According to the third aspect of the present invention, each rotor core is a Landel pole core. As a result, since only a pair of rotor cores are assembled to face each other, a rotor with very little shaft runout can be obtained more easily and accurately.

[Means of claim 4]
According to a fourth aspect of the present invention, each of the rotor cores is caulked and fitted into an annular groove provided in the outer peripheral region of the shaft on the outer end plane of each rotor core.
As a result, the fixing strength between the rotor core and the press-fitted shaft becomes stronger, and even if the rotor is used at high speed rotation, the shaft into which the rotor core is pressed against the centrifugal force and axial force at high speed rotation It is possible to prevent the slipping off or the fastening force from being reduced.

[Means of claim 5]
A method of manufacturing a rotor of a rotating electrical machine that employs the means of claim 5 includes: a hollow core member having claw portions extending in the axial direction from radial tip portions of a plurality of claw base portions extending radially outward. In the method of manufacturing a rotor of a rotating electrical machine, a plurality of rotor iron cores that are opposed to each other and having a shaft that is press-fitted and fixed in a shaft shaft hole of each rotor iron core, in which a coil is mounted in the formed hollow portion, Each rotor core to be fixed is formed with a plane portion in the axial direction, the plane portion is inclined with respect to the rotation center axis of the shaft, the plane portions of each rotor core are in contact with each other in parallel, and each rotor core Matching process of rotating and combining the rotor cores so that the shaft is in a straight line before and after the flat part of the flat part of the flat part, and after the matching process, press the shafts into the rotor cores that have been rotationally adjusted Adopting press-fitting process And wherein the Rukoto.

  According to this method, the minimum thickness in the axial direction can be easily combined by simply rotating a plurality of rotor cores relative to each other about the center of the shaft shaft hole without additional machining or correction processes. Moreover, it is possible to easily press-fit the shaft so as to maintain a predetermined press-fitting fitting holding force without difficulty in the shaft holes of the plurality of rotor cores arranged in a straight line. That is, it is possible to suppress an increase in cost, reduce the runout of the rotor, and suppress performance deterioration of the rotating electrical machine.

[Means of claim 6]
The method for manufacturing a rotor of a rotating electrical machine according to claim 6 is characterized in that the opposing surfaces of the rotor cores are flat. According to this method, it is possible to easily detect the inclination of the plane and the direction of the inclination, and when the planes are opposed to each other, they are in close contact with each other, so that a gap is not easily formed, that is, a minimum thickness is easily secured. .

[Means of Claim 7]
According to a seventh aspect of the present invention, there is provided a method for manufacturing a rotor of a rotating electrical machine, wherein the opposing flat surfaces of the rotor cores are in close contact with each other. According to this method, when the flat surfaces face each other and come into contact with each other, they are in close contact with each other, so that a gap is hardly formed, that is, it is easy to ensure a minimum thickness.

[Means of Claim 8]
The method for manufacturing a rotor of a rotating electrical machine according to claim 8 is a staking in which each rotor core is caulked and fitted in an annular groove provided in a shaft outer peripheral region of an outer end plane of each rotor core. The caulking process is performed after the shaft is assembled.
According to this method, it is possible to easily further improve the rotational strength of the rotor with reduced shaft runout, and to adjust the rotational strength by increasing the shaft press-fitting load of the rotor with relatively large shaft runout. It is much easier than securing it, and can suppress the increase in cost and improve reliability.

[Means of Claim 9]
The method for manufacturing a rotor of a rotating electrical machine according to claim 9 is characterized in that each rotor core is assembled by abutting in the axial direction after positioning in the circumferential direction of each rotor core.
According to this method, even when the claw portions of the rotor core interfere with each other to restrict the rotation in the circumferential direction, the circumferential positioning can be easily performed, and the inclined plane portions can be assembled so as to be in close contact with each other.

  The best mode of the present invention will be described together with Example 1 shown in the drawings.

[Configuration of Example 1]
(Overall Configuration of Vehicle Alternator) A first embodiment of the present invention will be described as applied to a vehicle AC generator as a rotor of a rotating electrical machine.

  FIG. 1 is a half sectional view in the axial direction showing an AC generator for a vehicle. The vehicle alternator 1 includes a stator 2 that works as an armature and a rotor 3 that works as a field element. The stator 2 includes a stator core 21 that is fixed to the housing 4 and a stator coil 22 that is wound around the stator core 21. The rotor 3 includes a shaft 5 rotatably supported on the housing 4, a pole core (rotor core of the present invention) 7 on which the shaft 5 is press-fitted and fixed, and a field coil 8.

  In addition, a pair of slip rings 9 and 10, a pair of brushes 11, a regulator 12, an end cover 13, an output terminal 14, and a pair of cooling fans 15 are provided at the rear portion (right portion in the drawing) of the shaft 5. Have. Further detailed description of the structure and operation other than the rotor 3 of the vehicle alternator 1 will be omitted.

  (Overall Configuration of Rotor) Next, the rotor 3 will be described with reference to FIG. FIG. 2 is an axial sectional view of the rotor. The rotor 3 is press-fitted into the shaft through-hole 78 of the pole core 7 which is in the same shape and opposite to each other in close contact with each other, so that the shaft 5 which is knurled or a plurality of raised portions is not relatively rotatable, and the pole core 7 is fixed in a predetermined position. And it is a rotary body by which the circumference of the front-and-rear end of the press-fitted shaft 5 is supported by a bearing. In addition, a field coil 8 for power generation is sandwiched and fixed inside the opposing pole core 7 (hollow part), and a cooling fan 15 is disposed on the outer end surface 72 of the opposing pole core 7.

  (Landel type pole core) Next, the Randel type pole core will be described with reference to FIG. FIG. 3A is a front cross-sectional view of one Landell-type pole core, and FIG. 3B is a plan view thereof. The Landel-type pole core is a combination of opposing pole cores 7 having the structure described below and facing each other.

  As shown in FIG. 3 (a), each pole core 7 has a cylindrical base 71, which extends from the outer end in the axial direction of the base 71 in the radially outward direction, and has a predetermined interval in the circumferential direction. A plurality of nail base portions 73 having a prismatic shape are provided. And the nail | claw part 74 extended | stretched so that a hollow part may be formed toward the axial direction from the radial direction front-end | tip part of each nail | claw base 73 is provided. In this embodiment, the pawl core 7 is provided with eight claw portions 74, and these claw portions 74 are arranged concentrically so as to be accommodated in the stator core 21.

  In addition, an outer end surface 72 constituted by a plane is provided at one end of the cylindrical base 71 of the pole core 7, and a boss 75 is provided at the other end of the cylindrical base 71. An end face (boss part end face) 76 is provided. A boss bottom end face 77 is formed at a substantially intermediate part between the boss 75 and the base 71, and the pole core 7 has a structure in which three end faces are geometrically parallel to each other.

  A shaft through hole (hereinafter referred to as a shaft hole) 78 is opened at the center of the base of the pole core 7 by cutting. In this embodiment, the shaft hole 78 is formed by drilling a hole perpendicular to the outer end surface 72 with the outer end surface 72 as a reference.

  At this time, since the shaft hole 78 is cut perpendicularly to the outer end face 72 (see angle α1 = 90 ° in the drawing), the other end face, that is, the boss end face 76 and the boss bottom end face 77 are also machined perpendicularly. It is. However, when the pole core 7 is manufactured with a soft iron forging facility with high productivity, the boss end face 76 and the boss bottom end face 77 are not necessarily vertically processed. The flatness and parallelism are deteriorated depending on the processing accuracy of the forging equipment or the size of the variation, and between the two end faces, that is, between the outer end face 72 and the boss end face 76, or between the outer end face 72 and the boss bottom end face 77. This is because a relative inclination (see the angle α2 ≠ 90 ° in the figure) occurs between them.

  FIG. 4 is a schematic view showing a state in which the boss end surfaces 76 of a pair of pole cores 7 (hereinafter referred to as the lower pole core 7a and the upper pole core 7b) that are inclined at least between both end faces are combined to face each other. (A) is a top view, (b) is front sectional drawing. As shown in FIG. 4B, when the axial centers are aligned, a gap is formed between the opposing end faces 76 of the boss portions (see the solid line figure in the figure), and the axial thickness of the combined pole core 7 increases. . Further, if the boss end faces 76 are aligned, the shaft center is displaced or the shaft core is broken, so that the shaft hole 78 does not become straight (see the two-dot chain line in the figure), and it is difficult to press-fit the shaft 5. It becomes.

  Accordingly, the shaft 5 is first press-fitted into the lower pole core 7a, and a field coil (not shown) is attached, and then the upper pole core 7b is press-fitted into the shaft 5 and sequentially assembled. In both of the simultaneous assembly methods in which the lower pole core 7a and the upper pole core 7b are combined to face each other with the coil interposed therebetween and the shaft 5 is press-fitted into the shaft hole 78, the press-fitting load is remarkably increased. In addition, it has already been described that there is a problem in that the shaft 5 is bent and the shaft run-out increases if the press-fit is forced by the increased press-fit load.

  However, if the maximum area and the minimum area of the boss part height due to the inclination of the boss part end faces 76 of the pair of upper and lower pole cores 7a and 7b are known at this time, for example, the maximum area of the boss part height of the lower pole core 7a If the upper and lower pole cores 7a and 7b are relatively rotated and combined so that the minimum area of the boss portion height of the upper pole core 7b substantially matches, the gap between the boss portion end faces 76 can be reduced without causing a single contact, It is possible to abut against each other in parallel. Hereinafter, such a combination is referred to as a per-surface combination.

  A pair of upper and lower pole cores 7a and 7b in the case of combination per surface is schematically shown in FIG. FIG. 5A is a plan view, and FIG. 5B is a front sectional view. As shown in FIG. 5B, the end surfaces 76 of the boss portions are inclined surfaces, but are in contact with each other in parallel and closely contact each other with no gap, and the combined axial thickness of the upper and lower pole cores 7a and 7b is minimized. . 5A (or FIG. 4), the direction of the inclination of the inclined surfaces that are formed in contact with each other in parallel and in contact with each other in parallel is considered as an axis perpendicular to the inclined surface of the boss portion end surface 76. As shown in (a)), the axis perpendicular to the inclined plane is on the midline between the radial imaginary line connecting the center of the claw and the shaft shaft hole center, and the radial imaginary line connecting the center between the claw part and the shaft shaft hole center. It becomes possible to specify by existing.

  In other words, if the axes perpendicular to each other's inclined surfaces rotate relative to each other until they reach the middle line, the inclined surfaces abut on each other in parallel and move up and down. The pole cores 7a and 7b are at positions where the combined axial thickness is minimum. In the pole core 7 of this embodiment, the upper and lower pole cores 7a and 7b forming a pair having the same number of claws as the eight claws are opposed to each other, and the claws of the upper pole core 7b are combined between the claws of the lower pole core 7a. Therefore, after combination, it is not possible to freely rotate and adjust the inclined surfaces of each other, and the boss portion height of the upper pole core 7b and the boss portion height of the lower pole core 7a are not necessarily adjusted. In some cases, it is not possible to make a combination that completely matches the minimum position. However, at least between the center of the claw part of the upper pole core 7b and the center of the claw part of the lower pole core 7a, that is, only between the center of the claw part of the upper and lower pole cores 7a and 7b and the center of the claw part, Although a deviation occurs, the circumferential positional deviation between the center of the claw part and the center between the claw parts hardly affects the gap in the axial direction.

  If the inclinations of the boss part end faces 76 are substantially the same, the axial holes 78 of the two pole cores 7 can be formed with respect to each other by setting the positions of the pole cores 7 to be symmetrical with respect to the center of the axial hole on the boss end face 76. Positioned in parallel and on the same axis, that is, the shaft hole 78 for penetrating the shaft is straight, so that the shaft press-fitting is facilitated, and of course, the press-fitted shaft is not bent. Such point-symmetric rotation of the pole cores 7 between the shaft hole centers, that is, relative rotation is referred to as rotation adjustment. Further, in order to appropriately perform point-symmetric rotation about the center of the shaft hole, it is necessary to determine the position of the height of the boss portion of the pole core 7 before that.

  The position indexing is automatically or manually performed by a boss height indexing / aligning device or jig of the pole core 7. The difference between automatic and manual is that the setting of the combination position of the pole core 7 that makes a pair with the measurement of the boss height of the pole core 7 and the indexing of the position is mechanically detected and electrically controlled as described later. The basic process is the same, depending on whether the work is set. Accordingly, the mechanical position determination process will be described as an example below.

  The boss height indexing / aligning device (not shown) of the pole core 7 includes rotating means for indexing and rotating position detecting means. These rotating means and rotational position detecting means are mounted on the elevating means and are moved up and down (up and down). The tip (lower end) of the rotational position detecting means is provided with a pole core height measuring contact, a pole core rotation transmission claw, and a pole core floating prevention presser. The pole core 7 as a workpiece moves in a horizontal direction perpendicular to the axis of ascending / descending of the rotational position detection means, and the pole core 7 that is directly below the rotational position detection means is disposed to face the rotational position detection means. It is sandwiched from above and below by a pole core receiving jig with lifting means. Since the pole core receiving jig with lifting means is provided with a guide shaft that can be inserted into the shaft hole of the pole core 7 at the shaft center, the pole core 7 is arranged to be allowed to rotate with respect to the shaft center by the guide shaft. Become.

  When the boss part height indexing / aligning device of the pole core 7 is operated, the rotating means and the rotational position detecting means are lowered, and the pole core lifting prevention presser pushes the pole core downward with no looseness by the lowering. The axis is rotated. The pole core height measuring contact set at the position of the boss portion of the pole core 7 traces the boss portion height of one rotation of the pole core 7, that is, one round. Then, the maximum area and the minimum area of the boss height are detected, the position index is set, and the pole core 7 is sent out on the pallet or table in the next assembly process (assembly machine).

  The mechanical position indexing process described above is shown as an example in which the mechanical rotation means and the electrical detection means are implemented. However, the position indexing process is not limited to this, and the rotation means is manually operated as described above. Even if it exists, a detection means may be mechanical. In short, in the position indexing process of the height of the boss portion of the pole core 7, a matching process can be adopted in which the indexed pole core 7 is assembled by adjusting the rotation by the point-symmetric relative rotation of the shaft hole center. Anything is acceptable. Here, the matching process is a combination of the position indexing process and the rotation adjusting process.

  An example of the assembly | attachment process of the rotor 3 of a present Example is shown in FIGS. 6 to 8 are process diagrams of a press-fitting process and a caulking process when the pole core 7 and the shaft 5 are sequentially press-fitted.

  FIG. 6 is a schematic view of the main part of the press-fitting device showing the first step of the press-fitting step of the sequential press-fitting method. The press-fitting device 30 has a normal die set structure including a punch portion 31 and a die portion 32, and the die portion 32 is supported by a base 33 through a bearing 34. A guide hole is formed in the center of the cradle 35, and the guide hole 35 is disposed with a gap sufficient for the center presser 36 to slide. The bearing 34 is for moving the cradle 35 in the horizontal direction when the center of the center presser 36 and the center of the cradle 35 do not coincide. Also, at least two claw pressers 37 are fixed to the base 33, and the claw portions 74 of the lower pole core 7a as a work are pressed and held in the axial direction or the centripetal direction, and can be held and released freely by the lever 38. It has become.

  The punch portion 31 is assembled in a die set so that the press-fitting punch 40 having a shaft holding punch 39 that holds the shaft 5 in the vertical direction is lowered or raised in the vertical direction.

  Next, shaft press-fitting by the press-fitting device 30 will be described. First, the lower pole core 7a for which the indexing in the tilt direction of the boss end surface 76 has already been obtained in the matching process of the previous process is set on the cradle 35. The lower pole core 7a set on the cradle 35 has a flat outer surface 72 and a shaft hole 78 formed perpendicular to the flat surface. Therefore, the lower pole core 7a has an outer end surface with respect to the cradle 35. 72 is placed horizontally and the shaft hole 78 is placed vertically. Then, the center presser 36 rises from below and is inserted into the shaft hole 78 of the lower pole core 7a. At this time, even if the center of the press-fitting punch 40 and the center of the cradle 35 are misaligned, the misalignment is adjusted and concentric by insertion into the lower pole core 7a of the center presser 36. And the nail | claw part 74 of the lower pole core 7a is hold | maintained by the lever operation of the nail | claw presser 37 at an axial direction.

  Next, the shaft 5 is vertically held by the shaft holding punch 39 of the press-fitting punch 40, and the non-holding side of the shaft 5 is brought into contact with the upper end portion of the center presser 36 inserted in the shaft hole 78 of the lower pole core 7a. The press-fitting punch 40 is lowered so as to guide. Then, the shaft 5 is press-fitted into the lower pole core 7a while maintaining smoothness and verticality.

  When the press-fitting proceeds to a predetermined position, the press-fitting punch 40 releases the holding of the shaft holding punch 39 and the shaft 5, rises upward, returns to the original position, and stops (see the two-dot chain line in FIG. Display position).

Next, the second step of the press-fitting step will be described. FIG. 7 is a schematic view of the main part of the press-fitting device showing the second step of the press-fitting step. A field coil 8 is mounted inside the lower pole core 7a into which the shaft 5 is press-fitted, and the upper pole core 7b is press-fitted so as to sandwich the field coil 8.
Similar to the lower pole core 7a, the upper pole core 7b is a pair of pole cores 7 whose boss heights have already been indexed in the matching process. These indexing positions are rotationally adjusted to be point-symmetrical (circumferential direction) about the center of the shaft hole so as to be in close contact with each other and press-fitted.

  A press-fitting punch 40 having a pressing surface that presses the outer end surface 72 of the upper pole core 7b in the vertical direction to press-fit the shaft 5 is provided. Similar to the die portion 32, the press-fit punch 40 is provided with an upper center presser 41 for aligning the centers of the shaft 5 and the press-fit punch 40, and the lower end of the upper center presser 41 is at the upper end of the shaft 5. It is in contact. As the press-in punch 40 descends, the upper pole core 7b is smoothly inserted in the vertical direction and guided by the upper center presser 41 so that the shaft 5 is press-fitted straight without tilting.

  When press-fitting proceeds to a predetermined position, the upper and lower pole cores 7a and 7b are brought into close contact with each other and the axial end thickness of the pole core 7 is minimized, so that the press-fitting is stopped at this position. Then, the press-fitting punch 40 is raised upward, the claw presser 37 is released, the shaft press-fitted pole core 7 is taken out, and the caulking process is started.

  In the caulking process, concave indentations having a predetermined annular shape are formed on both outer end faces 72 of the pole core 7 into which the shaft 5 is press-fitted, and the indentations are similarly provided at the positions of both outer end faces 72 of the shaft 5. This refers to a step of forming a staking caulking formed by exhibiting a plastic flow in an annular groove.

  FIG. 8 is a schematic view of the main part of a caulking apparatus for explaining the caulking process. The caulking device 50 that performs the caulking process is different from the press-fitting device 30 that describes the above-described press-fitting process in that the caulking punch 53 and the caulking die 54 are replaced in both the punch portion 51 and the die portion 52. The pre-caulking rotor 3 in which the shaft 5 is press-fitted in a straight line to the opposing pole core 7 in the previous step is set on the pedestal 55 as it is. A caulking die 54 guided by the lower center presser 56 is arranged at the center of the cradle 55 in the same manner so as to coincide with the center. Accordingly, since the center of the shaft 5 press-fitted into the pole core 7 set on the pedestal 55 coincides with the center of the caulking die 54, the outer end surface of the pole core 7 formed at a right angle (perpendicular) to the press-fitted shaft 5 72 forms a right angle (vertical) with the center of the caulking die 54. In other words, as the caulking die 54 or the caulking punch 53 is raised or lowered, the annular concave indentation depth formed on the outer end surface 72 of the pole core 7 has a condition that it is processed uniformly without deviation. Become.

  Similarly, since the caulking punch 53 is also provided with a guide hole for guiding the shaft 5 at the center thereof, the caulking punch 53 is guided by the straight shaft 5 as the caulking punch 53 descends and is formed on the outer end surface 72 of the pole core 7. The annular concave indentation depth is provided with a condition of being uniformly processed without being biased. The lowering of the caulking punch 53 and the raising of the caulking die 54 are relative, and the caulking of both outer end faces 72 is performed simultaneously by either one of the operations. At this time, both the outer end surfaces 72 of the pole core 7 are parallel to each other and form a right angle (vertical) with the press-fitted shaft 5, so that the caulking is performed smoothly and uniformly.

  As described above, the rotor 3 can be manufactured by the matching process, the shaft press-fitting process, and the caulking process.

[Effect of Example 1]
In the manufacturing method of this embodiment, a pair of pole cores 7 composed of upper and lower pole cores 7a and 7b obtained by machining a shaft hole 78 perpendicular to the outer end face 72 with reference to the outer end face 72 of the pole core 7 is formed on the end face of the boss portion. A matching step for indexing the height of the boss portion 76 and adjusting the rotation so that the height directions are in close contact with each other, and a shaft 5 is press-fitted into the indexed lower pole core 7a. 8, the upper pole core 7 b adjusted in rotation is combined therewith, and a press-fitting process of sequentially press-fitting into the shaft 5, and an annular concave shape is formed on both outer end faces 72 of the pair of pole cores 7 fitted with the shaft. A caulking process for forming the indentation at a predetermined depth in the axial direction is employed.

  According to this method, after adjusting the rotation so that the height direction of the boss portion end surfaces 76 of the pair of pole cores 7 are in close contact with each other, the shaft is press-fitted, so that the magnetic resistance between the iron cores is reduced. And the axial thickness of the paired pole cores 7 is the minimum. Further, the shaft 5 can be smoothly press-fitted in a straight line without bending. Thereby, when rotating with reference to both ends of the outer periphery of the shaft, the vibration is reduced with respect to the rotation reference, and vibration and rotational fluctuation can be reduced without causing interference with the stator core 21. As a result, in the vehicle alternator 1, the bearing life can be improved, and the power generation performance can be improved by suppressing fluctuations and variations in power generation.

  Further, in this manufacturing method, each pole core 7 is assembled by abutting in the axial direction after positioning the respective pole cores 7 in the circumferential direction, so that the claw portions 74 of the pole cores 7 interfere with each other and restrict rotation in the circumferential direction. Even in the case of a Landell-type pole core, positioning in the circumferential direction can be easily performed, and it is possible to easily assemble the end surfaces of the inclined boss portions so as to be in close contact with each other. Therefore, an increase in cost can be suppressed and reliability can be improved.

[Configuration of Example 2]
The assembly of the rotor 3 in the first embodiment relates to a method of manufacturing a rotor by a sequential assembly method in which individual pole cores 7 and shafts 5 are sequentially press-fitted and assembled. In the present embodiment, the rotor 3 is assembled. This assembly is for a method of manufacturing a rotor by a simultaneous assembly method in which a pair of pole cores 7 each having a field coil 8 mounted therein are combined to face each other and a shaft 5 is simultaneously press-fitted. Below, the manufacturing method of the rotor by this simultaneous assembly system is demonstrated.

  FIG. 9 is a schematic diagram of a main part of the press-fitting device 30 for explaining a press-fitting process in the case of the simultaneous press-fitting method. The press-fitting device 30 in the case of simultaneous press-fitting is basically the same as the press-fitting device 30 in the case of sequential press-fitting. The difference is that the combination of the upper and lower pole cores 7a and 7b already adjusted in the matching process due to the difference on the workpiece side and the matching (completed) pole core in which the field coil 8 is mounted are prepared in the next process ( It is the case that flows out). At this time, the upper and lower pole cores 7a and 7b face each other at the boss portion 75, the outer end faces 72 of the pair of pole cores 7 are parallel to each other, and the shaft holes 78 processed perpendicularly to the outer end faces 72 form a straight line. Therefore, this is a process of simply press-fitting the straight shaft 5 into the shaft hole 78.

  In FIG. 9, the pair of pole cores 7 which are rotationally adjusted in the matching process and in which the field coil 8 is mounted are set on a cradle 35. The pedestal 35 is provided with a center presser 36. The center presser 36 moves concentrically with the pedestal 35, and the upper end of the center presser 36 is inserted into the shaft hole 78 of the pole core 7 that makes a pair. As a result, both outer end surfaces 72 of the pole core 7 that forms a perpendicular to the shaft shaft hole 78 are held horizontally by the cradle 35. The nail retainer 37 is fixed to the cradle 35 by being held by the lever 38.

  Next, the shaft 5 is vertically held by the shaft holding punch 39 of the press-fitting punch 40, and the non-holding side of the shaft 5 is brought into contact with the upper end portion of the center presser 36 inserted in the shaft hole 78 of the lower pole core 7a. The press-fitting punch 40 is lowered so as to guide. Then, the shaft 5 is press-fitted into the upper and lower pole cores 7a and 7b while maintaining smoothness and verticality.

  When press-fitting proceeds to a predetermined position, the press-fitting punch 40 releases the holding of the shaft holding punch 39 and the shaft 5, rises upward, returns to the original position (dotted line position in FIG. 9), and stops. The shaft 5 that has been press-fitted is press-fitted perpendicularly to both outer end surfaces 72 without being inclined or bent. Therefore, a straight shaft structure is formed, and shaft runout does not occur.

Next, the claw presser 37 is released, the shaft press-fitted pole core is taken out, and the caulking process is started.
The caulking process can use the same process and apparatus as the above-described sequential assembling caulking process, and its operation and effect are not changed.
Thereby, the rotor 3 can be manufactured.

[Effect of Example 2]
The difference between the present embodiment and the first embodiment is whether the press-fitting process of the shaft 5 is sequential or simultaneous, and the structure and function of the assembled rotor 3 are not changed. Therefore, the same operation and effect as Example 1 are produced. Further, in the simultaneous press-fitting method, the press-fitting of the shaft 5 can be completed only once, so that the manufacturing method is an assembly process with one less process, and productivity is improved and an increase in cost can be suppressed.

[Modification]
In both of the embodiments of the present invention described above, the Landel-type pole core in which the shaft 5 is inserted through the center with the one end surfaces of the pole cores 7 having the same shape and a pair facing each other is used, but the present invention is not limited thereto. Two paired pole cores 7 may be employed in a tandem pole core that is press-fitted into a skewer by a shaft 5, or may be employed in a rotor that forms a plurality of contact surfaces facing each other. .

(Example 1) which is an axial direction half sectional view which shows the AC generator for vehicles. (Example 1) which is an axial sectional view showing a rotor. The structure of a pole core is shown, (a) is front sectional drawing, (b) is a top view (Example 1). It is a schematic diagram which shows the state (at the time of one piece contact | abutting) combined with the boss | hub part end surface of a pair of pole cores facing each other, (a) is a top view, (b) is front sectional drawing (Example 1) ). It is a schematic diagram which shows the state (at the time of contact | abutting per surface) which combined and made the boss | hub part end surface of a pair of pole cores oppose, (a) is a top view, (b) is front sectional drawing (Example 1) ). It is a principal part schematic diagram of the press-fitting apparatus which shows the 1st process of the press-fitting process of a sequential press-fitting system (Example 1). (Example 1) which is the principal part schematic of the press injection apparatus which shows the 2nd process of a press injection process. It is a principal part schematic of the caulking apparatus which shows a caulking process (Example 1). (Example 2) which is the principal part schematic of the press-fitting apparatus which shows the press-fitting process of a simultaneous press-fitting system. It is sectional drawing of the pole core which has the vertical shaft hole processed on the basis of the outer side end surface (conventional example). (A), (b) is the principal part schematic of the press-fit apparatus which shows the 1st process of a press-fit process (conventional example). (A) is the principal part schematic of the press injection apparatus which shows the 2nd process of a press injection process, (b) is the principal part schematic of the press injection apparatus which shows the 3rd process of a press injection process (conventional example). It is a principal part schematic diagram of the caulking apparatus which shows the caulking process (conventional example). (A) is a principal part schematic diagram of the press-fitting device when a shaft is bent in the third step, and (b) is a schematic diagram of a main part of the press-fitting device showing a rotor taking-out process after assembly. (Conventional example).

Explanation of symbols

1 Vehicle alternator (rotary electric machine)
3 Rotor 5 Shaft 7 Pole core (Rotor iron core, Landell-type pole core)
7a Lower pole core 7b Upper pole core 8 Field coil (coil)
72 Outer end face (outer end plane)
73 Claw base portion 74 Claw portion 75 Boss portion 76 Inner end surface (end surface of boss portion, flat portion)
78 Shaft hole (shaft through hole, shaft shaft hole)

Claims (9)

A plurality of rotor cores composed of hollow core members each having a claw portion extending in the axial direction from a radial tip portion of a large number of claw base portions extending in the radially outward direction are opposed to each other to form a hollow portion A rotor of a rotating electrical machine equipped with a coil and having a shaft press-fitted and fixed to the shaft shaft hole of each of the rotor cores,
Each rotor core that is penetrated by the shaft and fixed in position is formed with a plane portion in the axial direction,
The plane portion is inclined with respect to the rotation center axis of the shaft,
The planar portions of the rotor cores are in contact with each other in parallel.
Before and after the flat portion of each rotor core in the axial direction, the shaft is straight,
And the axis perpendicular to the inclined surface of the plane portion on the axial projection of each rotor core is:
A radial imaginary line connecting the claw center and the shaft shaft hole center;
A rotor of a rotating electrical machine, wherein the rotor is on the middle line of a radial imaginary line connecting the center between the claw parts and the center of the shaft shaft hole. In the rotor of the rotating electrical machine according to claim 1,
Each rotor core is an outer end plane on the outside in the axial direction of each rotor core;
Boss end face is provided on the inner side in the axial direction,
The rotor of a rotating electrical machine, wherein the outer end planes of the respective rotor cores are parallel to the outer end planes of the opposing other rotor cores. In the rotor of the rotary electric machine according to claim 1 or 2,
Each of the rotor cores is a Landel pole core. In the rotor of the rotary electric machine according to any one of claims 1 to 3,
The rotor of a rotating electrical machine, wherein each of the rotor cores is caulked and fitted into an annular groove provided in a shaft outer peripheral region of an outer end plane of each of the rotor cores. A plurality of rotor cores composed of hollow core members each having a claw portion extending in the axial direction from a radial tip portion of a large number of claw base portions extending in the radially outward direction are opposed to each other to form a hollow portion In a method for manufacturing a rotor of a rotating electrical machine, including a shaft that is fitted with a coil and press-fitted and fixed to a shaft shaft hole of each of the rotor cores,
Each rotor core to be fixed in position has a flat portion in the axial direction,
The plane portion is inclined with respect to the rotation center axis of the shaft,
The plane portions of the rotor cores are in contact with each other in parallel,
And a matching step of rotating and combining the rotor cores so that the shaft is in a straight line before and after the flat portion of each rotor core in the axial direction;
A method of manufacturing a rotor of a rotating electrical machine, wherein a press-fitting step of press-fitting the shaft into each of the rotor cores whose rotation has been adjusted is employed after the matching step. In the manufacturing method of the rotor of the rotating electrical machine according to claim 5,
The method of manufacturing a rotor of a rotating electrical machine, wherein the opposing surfaces of the rotor cores are flat. In the manufacturing method of the rotor of the rotating electrical machine according to claim 5 or 6,
A method of manufacturing a rotor of a rotating electrical machine, wherein the opposing flat surfaces of the rotor cores are in close contact with each other. In the manufacturing method of the rotor of the rotating electrical machine according to any one of claims 5 to 7,
A rotating electric machine characterized in that a staking caulking process for caulking and fitting each of the rotor cores into an annular groove provided in the outer peripheral region of the shaft on the outer end plane of each rotor core is performed after the shaft is assembled. Method of manufacturing the rotor. In the manufacturing method of the rotor of the rotating electrical machine according to any one of claims 5 to 8,
The method of manufacturing a rotor of a rotating electrical machine, wherein the rotor cores are assembled by abutting in the axial direction after positioning the rotor cores in the circumferential direction.

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