JP5311668B2 - Axial gap type motor and rotor manufacturing method thereof - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an axial gap motor with a rotor, capable of securing rigidity which can withstand a centrifugal force generated by rotation and a magnetic suction force from a stator, even if a yoke is constituted of a stack formed by spirally wounding an electromagnetic steel plate, and capable of being easily assembled, and to provide a method of manufacturing the rotor. <P>SOLUTION: Each rotor 11, 11A and 11B of the axial gap motor 10 is constituted of a plurality of main magnets 41 which are magnetized in axial directions of rotation and arranged at prescribed intervals, and the stack 71 wound with the tape-shaped electromagnetic steel plate 60, wherein a plurality of the yokes 42 are arranged in at least one of the axial directions of rotation of the plurality of main magnets 41; an inside-diameter side pressing member is attached to the inside-diameter side of the stack 71; and an outside-diameter side pressing member is attached to the outside-diameter side of the stack 71. The rotor is configured such that a torque can be transmitted by allowing a compression force in the radial direction to act on the inside of the rotor with the inside-diameter side pressing member and the outside-diameter pressing member by attaching the outside-diameter side pressing member to the stack 71 so as to make the compression force act on the inside-diameter side of the stack after press-inserting the inside-diameter side pressing member to the inside-diameter side of the stack 71. <P>COPYRIGHT: (C)2011,JPO&amp;INPIT

Description

  The present invention relates to an axial gap type motor and a rotor manufacturing method thereof.

  Conventionally, for example, a rotor that can rotate around a rotation axis and a stator that is disposed to face the rotor from at least one side in the direction of the rotation axis are provided. An axial gap type motor that forms a loop is known.

  As a method of manufacturing a rotor constituting this axial gap type motor, various ones have been devised in which a yoke portion is constituted by a laminated body obtained by winding a tape-shaped electromagnetic steel sheet (see, for example, Patent Documents 1 to 3). . As shown in FIG. 14, in the axial gap type motor described in Patent Document 1, a yoke part 102 is formed by a laminated body in which a tape-shaped electromagnetic steel sheet is wound, and a magnet 104 is formed in an opening 103 formed in the laminated body. Is housed.

JP 2006-166635 A (FIG. 2) Japanese Patent Laying-Open No. 2005-168124 (FIG. 1) JP 2002-10537 A (FIG. 1)

  By the way, the laminated body which comprises a yoke part is attached to a shaft or a rotor frame inside the inside. When a shaft or a rotor frame is attached to this laminated body while ensuring rigidity, the assembly structure tends to be complicated as compared with a rotor structure in which the yoke portion is divided. In addition, the method for manufacturing a rotor described in Patent Documents 1 to 3 does not describe attachment to a specific shaft.

  The present invention has been made in view of the above-described circumstances, and the object thereof is to provide centrifugal force due to rotation and from the stator even when the yoke portion is constituted by a laminated body formed by winding a magnetic steel sheet. An object of the present invention is to provide an axial gap type motor including a rotor that can secure rigidity capable of withstanding a magnetic attractive force and can be easily assembled, and a method of manufacturing the rotor.

In order to achieve the above object, the invention described in claim 1
A rotor (for example, rotors 11, 11A, 11B in embodiments described later) that can rotate around a rotation axis;
An axial gap type motor (for example, an axial gap type motor 10 in an embodiment described later) including a stator (for example, a stator 12 in an embodiment described later) disposed opposite to the rotor from at least one of the rotation axis directions. And
The rotor is
A plurality of main magnet parts magnetized in the rotation axis direction and arranged at a predetermined interval in the circumferential direction (for example, a main magnet part 41 in an embodiment described later);
The rotary shafts of the plurality of main magnet portions are configured by a laminated body (for example, a laminated body 71 in an embodiment described later) wound by winding a tape-shaped electromagnetic steel sheet (e.g., an electromagnetic steel sheet 60 in an embodiment described later). A plurality of yoke portions (for example, yoke portions 42 in the embodiments described later) respectively disposed in at least one of the directions;
An inner diameter side pressing member (for example, inner plates 31A and 31B in the embodiments described later) attached to the inner diameter side of the laminate,
An outer diameter side pressing member attached to the outer diameter side of the laminate (for example, a die-cast string 33 and an outer ring 50 in an embodiment described later),
After the inner diameter side pressing member is press-fitted into the inner diameter side of the laminate, the outer diameter side pressing member is attached so that a compressive force to the inner diameter side is applied to the laminate, and the inner diameter side pressing member and the An axial gap type motor configured to transmit torque by applying a radial compressive force to the inside of the rotor by an outer diameter side pressing member.

In addition to the configuration of the invention described in claim 1, the invention described in claim 2
The laminate is configured by winding the electromagnetic steel sheet on an annular cored bar (for example, a cored bar 32 in an embodiment described later),
The inner diameter side pressing member is composed of an inner plate (for example, inner plates 31A and 31B in an embodiment described later) attached by press fitting to the inner peripheral portion of the core metal,
The outer diameter side pressing member is attached to the outer peripheral portion of the laminated body by die fitting (for example, a die cast string 33 in an embodiment described later) and a peripheral fitting portion of the die cast string by shrink fitting. It consists of an outer ring (for example, the outer ring 50 in embodiment mentioned later), It is characterized by the above-mentioned.

In addition to the structure of the invention described in claim 2, the invention described in claim 3
The required surface pressure P between the inner plate and the core metal, between the core metal and the laminated body, between the laminated body and the die cast ring, and between the die cast string and the outer ring is the maximum load torque T, fastening When the part radius is r, the fastening area A, and the friction coefficient μ,
P ≧ T / (r × A × μ)
It is characterized by satisfying.

In addition to the configuration of the invention described in claim 2 or 3, the invention described in claim 4
The inner plate is divided into two in the axial direction, and is press-fitted into the inner peripheral part of the cored bar from one axial side and the other axial side.

In addition to the structure of the invention described in any one of claims 1 to 4, the invention described in claim 5
The laminate is provided with a magnetic flux short-circuit suppression unit (for example, a magnetic flux short-circuit suppression unit 73 in an embodiment described later) between the main magnet units adjacent in the circumferential direction.
The cored bar is provided with a spoke through hole (for example, a spoke through hole 32a in an embodiment described later) at a position corresponding to the magnetic flux short-circuit suppressing portion,
The rotor is housed in the magnetic flux short-circuit suppressing portion through the spoke through-hole from the inside of the cored bar, and used as a positioning member when winding the tape-shaped electromagnetic steel sheet around the cored bar. And at least one spoke pin (for example, a spoke pin 35 in an embodiment described later).

In addition to the structure of the invention described in any one of claims 2 to 5, the invention described in claim 6
The die cast string is formed by casting a non-magnetic die cast alloy.

In addition to the structure of the invention according to any one of claims 1 to 6, the invention according to claim 7
The rotor further includes a shaft portion (for example, a shaft portion 55 in an embodiment described later) fixed to the inner plate,
The shaft portion, the inner diameter side pressing member, the laminate and the outer diameter side pressing member are provided with a cooling passage (for example, a cooling passage 90 in an embodiment described later),
The coolant supplied from the shaft portion is supplied to the stator through the cooling passage.

In addition to the configuration of the invention according to any one of claims 1 to 7, the invention according to claim 8
The rotor is magnetized in a direction orthogonal to the rotation axis direction and the radial direction, and is disposed between at least one side of the rotation axis direction between the main magnet portions adjacent to each other in the circumferential direction. (For example, it has the submagnet part 43 in embodiment mentioned later), It is characterized by the above-mentioned.

In order to achieve the above object, the invention according to claim 9 provides:
A plurality of main magnet portions magnetized in the rotation axis direction and arranged at predetermined intervals in the circumferential direction (for example, a main magnet portion 41 in an embodiment described later), and at least one of the plurality of main magnet portions in the rotation axis direction A plurality of yoke portions (for example, yoke portions 42 in the embodiments described later), and a rotor (for example, rotors 11, 11A, 11B in the embodiments described later) that can rotate around the rotation axis;
A rotor of an axial gap type motor (for example, an axial gap type motor 10 in an embodiment to be described later) provided with a stator (for example, a stator 12 in an embodiment to be described later) disposed opposite to the rotor from at least one of the rotation axis directions. A manufacturing method comprising:
A tape-shaped electromagnetic steel sheet (for example, an electromagnetic steel sheet 60 in an embodiment described later) is wound around an annular core metal (for example, a core metal 32 in an embodiment described later), and the plurality of yoke portions (for example, an implementation described later). Forming a laminated body (for example, a laminated body 71 in an embodiment described later) constituting the yoke portion 42) in the form;
Attaching the main magnet part to the laminate;
Attaching an inner plate (for example, inner plates 31A and 31B in an embodiment described later) to the inner periphery of the core by press-fitting;
A die cast string (for example, described later) is formed by casting a die casting alloy on the outer peripheral portion of the stacked body in a state where the stacked body in which the inner plate is attached is disposed on a mold (for example, molds 80 and 81 in the embodiments described later). Forming a die cast string 33) in the embodiment of
A step of attaching an outer ring (for example, an outer ring 50 in an embodiment described later) to the outer peripheral portion of the die cast ring by shrink fitting.

According to the first aspect of the present invention, after the inner diameter side pressing member is press-fitted into the inner diameter side of the laminated body containing the main magnet portion, the outer diameter side pressing member is applied with a compressive force on the inner diameter side of the laminated body. By mounting, surface pressure (radial compressive stress) can be generated inside the rotor. As a result, a frictional force is generated between the members, and torque can be transmitted by the frictional force, and rigidity that can withstand the magnetic attractive force can be ensured.
In addition, since the torque can be transmitted between each member with a frictional force, a rotor frame with a complicated structure is not required, the number of parts can be reduced, the assembly is improved, the increase in the weight of the rotor is suppressed, and the manufacturing cost is reduced. can do.

  According to the invention of claim 2, it is possible to manufacture a rotor that can be easily assembled with a simple configuration.

  According to the invention of claim 3, even if the maximum load torque acts on the rotor, it is possible to ensure the rigidity capable of withstanding the centrifugal force due to the rotation of the rotor and the magnetic attractive force from the stator.

  According to the invention of claim 4, the press-fitting load during press-fitting can be reduced, and the assembling work is facilitated.

  According to invention of Claim 5, the position shift at the time of laminating | stacking an electromagnetic steel sheet can be suppressed by using a spoke as a positioning member.

  According to the invention of claim 6, even if the outer ring is made of relatively inexpensive carbon steel, it is possible to suppress a short circuit of the magnet magnetic flux and suppress a decrease in induced voltage.

  According to the seventh aspect of the present invention, the stator can be cooled from the rotor side, and lubricating oil corresponding to the rotational speed of the rotor can be supplied to the stator by centrifugal force. Thereby, it is not necessary to provide a cooling structure on the stator side, and the apparatus can be reduced in size and weight.

  According to the eighth aspect of the present invention, the magnetic fluxes of the main magnet portion and the sub-magnet portion converge due to the so-called magnetic lens effect of the so-called permanent magnets, and the effective magnetic flux linked to the stator is relatively increased. it can.

According to the invention of claim 9, after the inner plate is attached to the inner peripheral portion of the core metal by press-fitting, a die cast string is formed by casting a die casting alloy on the outer peripheral portion of the laminated body, and the outer peripheral portion of the die cast string. By attaching the outer ring to the inner surface by shrink fitting, surface pressure (radial compressive stress) can be generated inside the rotor. As a result, a frictional force is generated between the members, and torque can be transmitted by the frictional force, and rigidity that can withstand the magnetic attractive force can be ensured.
In addition, since torque can be transmitted between each member by frictional force, a rotor frame with a complicated structure is not required, reducing the number of parts and the number of assembly steps, thereby suppressing the increase in rotor weight and manufacturing costs. Can be reduced.

1 is an overall perspective view of an axial gap type motor according to the present invention. It is a disassembled perspective view of the axial gap type motor of FIG. It is a disassembled perspective view of the rotor of 1st Embodiment. FIG. 4 is a sectional view taken along the line IV-IV in FIG. 2. It is the fragmentary perspective view which notched a part of rotor. It is a fragmentary perspective view of the laminated body which accommodated the main magnet part and the submagnet part. (A) is the figure which expand | deployed the main layer which consists of an innermost layer and an intermediate | middle layer in the circumferential direction, (b) is the figure which expand | deployed the outermost layer in the circumferential direction. It is explanatory drawing explaining the process of winding an electromagnetic steel plate and forming a laminated body. It is explanatory drawing explaining the process of forming a die-cast string. It is a fragmentary sectional view of the rotor of a 2nd embodiment. It is a disassembled perspective view of the rotor of 3rd Embodiment. It is a fragmentary sectional view of the rotor of FIG. (A) is a graph showing the relationship between the thickness of the die-cast string and the induced voltage constant (Ke), and (b) shows (a) as a ratio. 10 is an explanatory diagram of a rotor of an axial gap type motor disclosed in Patent Document 1. FIG.

Hereinafter, embodiments of an axial gap type motor according to the present invention will be described in detail with reference to the accompanying drawings. The drawings are viewed in the direction of the reference numerals.
<First Embodiment>
The axial gap type motor 10 according to the first embodiment of the present invention includes, for example, a substantially annular rotor 11 that is rotatably provided around a rotation axis O of the axial gap type motor 10 as shown in FIGS. And a pair of stators 12 that are opposed to each other so as to sandwich the rotor 11 from both sides in the direction of the rotation axis O and that have a plurality of phases of stator windings that generate a rotating magnetic field that rotates the rotor 11. ing.

  The axial gap type motor 10 is mounted as a drive source in a vehicle such as a hybrid vehicle or an electric vehicle, for example, and an output shaft is connected to an input shaft of a transmission (not shown), whereby the driving force of the axial gap type motor 10 is obtained. Is transmitted to drive wheels (not shown) of the vehicle via a transmission.

  Further, when the driving force is transmitted from the driving wheel side to the axial gap type motor 10 during deceleration of the vehicle, the axial gap type motor 10 functions as a generator to generate a so-called regenerative braking force, and the kinetic energy of the vehicle body is electrically converted. Recover as energy (regenerative energy). Further, for example, in a hybrid vehicle, when the rotary shaft O of the axial gap motor 10 is connected to a crankshaft of an internal combustion engine (not shown), the output of the internal combustion engine is transmitted to the axial gap motor 10 as well. The axial gap type motor 10 functions as a generator and generates power generation energy.

  Referring also to FIG. 2, each stator 12 has a substantially annular plate-shaped stator yoke portion 21 and a rotating shaft from a position spaced apart from the stator yoke 21 facing the rotor 11 at a predetermined interval in the circumferential direction. A plurality of teeth 22,..., 22 projecting toward the rotor 11 along the O direction and extending in the radial direction, and stator windings (not shown) mounted between the appropriate teeth 22, 22 are configured. Has been.

  Each stator 12 is, for example, a 6N type having six main poles (for example, U +, V +, W +, U−, V−, W−), and each U +, V +, W + pole of one stator 12. On the other hand, the U-, V-, and W-poles of the other stator 12 are set to face each other in the direction of the rotation axis O. For example, with respect to a pair of stators 12 and 12 opposed in the direction of the rotation axis O, three teeth 22 of one stator 12 corresponding to one of U +, V +, W + poles and one of U−, V−, W− poles, 22, 22 and the three teeth 22, 22, 22 of the other stator 12 corresponding to the other of the U +, V +, W + pole and the U−, V−, W− pole face each other in the direction of the rotation axis O. Thus, the energized state of the teeth 22 of one stator 12 and the teeth 22 of the other stator 12 facing each other in the direction of the rotation axis O is set so as to be reversed by an electrical angle.

  As shown in FIGS. 2 to 5, the rotor 11 includes a pair of inner plates 31 </ b> A and 31 </ b> B (inner diameter side pressing members), a cored bar 32, a plurality of main magnet portions 41,. , 43, a plurality of yoke portions 42,..., A die cast ring 33 (outer diameter side pressing member), and an outer ring 50 (outer diameter side pressing member).

  As shown in FIGS. 6 to 8, the plurality of yoke portions 42,..., 42 are configured by a laminated body 71 in which a tape-shaped electromagnetic steel sheet 60 is wound around a core metal 32. The tape-shaped electromagnetic steel sheet 60 is punched using, for example, a press molding machine, so that the innermost layer and the intermediate layer (hereinafter referred to as the main layer 71b) excluding the outermost layer 71a are shown in FIG. As shown to a), the notch 61 for main magnet parts, the notch 62 for submagnet parts, and the notch 63 for magnetic flux short circuit suppression parts are formed. As shown in FIG. 8, the tape-shaped electromagnetic steel sheet 60 is wound by winding the winding start part 64 on the core metal 32 and rotating the core metal 32 while applying tension to the electromagnetic steel sheet 60. The laminated body 71 is configured by cutting and welding at the end portion 65. The core metal 32 is an annular member made of a nonmagnetic material such as a stainless steel plate (for example, SUS304).

  Further, since the tape-shaped electromagnetic steel sheet 60 is wound on the annular cored bar 32, the length in the longitudinal direction is increased from the innermost layer to the first layer, the second layer, the third layer,. For this reason, in FIG. 7A, when the distance P between the centers of the magnetic flux short-circuit suppressing portion notches 63 is the pitch P, the pitch P of each layer is set so as to gradually increase radially outward.

  In the laminated body 71 wound in this manner, as shown in FIG. 6, a plurality of substantially magnet-shaped main magnet part insertion holes 72 formed by the main magnet part notches 61 are formed in the intermediate part in the rotation axis direction. , 72, and a plurality of substantially rectangular parallelepiped magnetic flux short-circuit suppression portions 73, ..., 73 formed by the magnetic flux short-circuit suppression portion notches 63 are alternately provided at predetermined intervals in the circumferential direction. On both sides in the rotation axis direction, a plurality of substantially magnet-shaped yoke portions 42,..., 42 and a plurality of sub-magnet-shaped housing portions 74 each having a substantially rectangular parallelepiped shape opened outward in the axial direction formed by the notch 62 for the sub-magnet portion. ,..., 74 are alternately provided at predetermined intervals in the circumferential direction (see FIG. 3).

  Further, the plurality of yoke portions 42,..., 42 are respectively disposed on both sides of the plurality of main magnet portion insertion holes 72,..., 72 in the rotation axis direction, and the plurality of sub magnet portion accommodating portions 74,. Are arranged on both sides of the rotation axis direction of the magnetic flux short-circuit suppressing portions 73,. The main magnet portion insertion hole 72 and the magnetic flux short-circuit suppressing portion 73 are partitioned by an axial connecting portion 75 that connects the yoke portions 42 on both sides in the axial direction, and the sub-magnet portion accommodating portion 74 and the magnetic flux short-circuit suppressing portion. 73 is partitioned by a circumferential connecting portion 76 that connects the yoke portions 42 on both sides in the circumferential direction.

In each of the main magnet part insertion holes 72, ..., 72 of the laminate 71 thus configured, a plurality of substantially sector-shaped main magnet parts 41, ... having substantially the same dimensions as the insertion holes 72, ..., 72 are provided. 41 is inserted into each of the secondary magnet portion accommodating portions 74,..., 74, and a plurality of substantially rectangular parallelepiped secondary magnet portions 43,. Is done.
In the present embodiment, the main layer 71b of the electromagnetic steel sheet 60 is wound and the main magnet portions 41,..., 41 and the sub magnet portions 43,. ,..., 72, the submagnet housing parts 74,..., 74 and the magnetic flux short-circuit suppressing parts 73,.

  Further, as shown in FIG. 6, the auxiliary magnet portion accommodating portion 74 is provided at the distal end portion of the inclined surface 77 formed at the circumferential connecting portion 76 between the adjacent yoke portions 42 and the circumferential end portion of the yoke portion 42. The sub-magnet portion 43 is positioned in the axial direction by the projection 78 formed, and is positioned in the circumferential direction between the circumferential side surfaces of the adjacent yoke portions 42.

  Thereby, the plurality of main magnet portions 41,..., 41 are arranged at predetermined intervals in the circumferential direction, and the rotation direction is different so that the magnetization direction is different for each of the adjacent main magnet portions 41, 41 in the circumferential direction. It is directed in the O direction. Further, the plurality of sub-magnet portions 43,..., 43 are disposed between the yoke portions 42 adjacent in the circumferential direction, and the magnetization directions thereof are directed in the direction orthogonal to the rotation axis direction and the radial direction. The secondary magnet portions 43 and 43 adjacent in the circumferential direction have different magnetization directions, and the secondary magnet portions 43 and 43 adjacent in the rotation axis direction also have different magnetization directions.

Further, the sub magnet portions 43 and 43 that sandwich the yoke portion 42 located on one side of the rotation axis O direction from both sides in the circumferential direction with respect to each main magnet portion 41 are magnetic poles on one side of the main magnet portion 41. The sub-magnet portions 43, 43, which are disposed so that the same-polarity magnetic poles face each other and sandwich the yoke portion 42 located on the other side in the rotation axis direction from both circumferential sides, are the same as the other-side magnetic poles of the main magnet portion 41. The magnetic poles of the poles are arranged to face each other. Thereby, due to the magnetic flux lens effect due to the so-called Halbach arrangement of so-called permanent magnets, the magnetic fluxes of the main magnet portion 41 and the sub-magnet portions 43 and 43 converge, and the effective magnetic flux linked to the stators 12 and 12 is relatively It is going to increase.
In addition, since each yoke portion 42,..., 42 is formed with an inclined surface 77 at its circumferential end, the polar arc angle is adjusted, and a sudden change in magnetic resistance between the stators 12 and 12 occurs. And the occurrence of torque ripple can be suppressed.

  Each of the inner plates 31A and 31B is made of a magnetic material such as carbon steel (for example, S45C), and is disposed on the inner peripheral side of the cored bar 32 to press the laminated body 71 to the outer diameter side via the cored bar 32. More specifically, each of the inner plates 31A and 31B is press-fitted into the inner peripheral portion of the cored bar 32 from one side and the other side in the direction of the rotation axis O to be brought into pressure contact with the cored bar 32. As a result, the diameter of the cored bar 32 is slightly increased, and a compressive force to the outer diameter side acts on the laminated body 71.

  In addition, a bolt fastening hole 36 used for fastening with a shaft portion 55 connected to an external drive shaft (for example, an input shaft of a vehicle transmission) is formed in the inner peripheral portion of the inner plates 31A and 31B. As shown in FIG. 4 (see FIGS. 2 and 3), the shaft portion 55 is fastened with bolts 45 (see FIG. 4).

  As shown in FIG. 9, the die-cast string 33 is in a state in which the main magnet portions 41,..., 41 and the sub magnet portions 43,. The laminate 71 is accommodated in the first and second molds 80 and 81, and is formed by melting a nonmagnetic die-cast alloy such as an aluminum alloy (for example, ADC12) and casting it while applying a predetermined die-cast pressure. The

  The first and second molds 80 and 81 are divided into two in the rotation axis direction, and the respective side surfaces respectively corresponding to the axial side surfaces of the inner plates 31A and 31B, the cored bar 32, the yoke portion 42, and the sub magnet portion 43. The first and second molds 80 and 81 have inner peripheral surfaces 80b, 81b, 80c, and 81c corresponding to the side surfaces and the outer peripheral surface of the die caster string 33, respectively.

  The first and second molds 80, 41, 41, submagnet parts 43,..., 43, the laminated body 71, the cored bar 32 and the inner plates 31 </ b> A and 31 </ b> B are accommodated. 81 is closed, and a die-cast alloy is poured into a space formed between the molds 80, 81 from a gate 84 provided in the second mold 81. The gate 84 is provided so as to open at a radial position corresponding to the die-cast string 33. For this reason, the die-cast alloy poured from the gate 84 flows into the space constituting the die-cast string 33, and the die-cast string 33 is formed by casting.

  In addition, at the time of casting, the outermost layer 71a of the laminated body 71 is pressed against the inner diameter side by the pressure, so that a compressive force to the inner diameter side acts on the laminated body 71. As a result, the die-cast string 33 is formed in pressure contact with the laminated body 71 from the outer diameter side.

  Since the die-cast alloy is prevented from coming into direct contact with the magnet parts 41, ..., 41, 43, ..., 43 by the outermost layer 71a, the magnet parts 41, ..., 41, 43, ..., 43 are prevented. It is possible to suppress the deterioration of the coercive force.

  An annular outer ring 50 made of a high-strength material such as a stainless steel plate (for example, SUS304) or carbon steel (for example, S45C) is attached to the outer peripheral portion of the die cast string 33. Since the outer ring 50 is attached to the outer peripheral portion of the die cast ring 33 by shrink fitting, the outer ring 50 also exerts a compressive force toward the inner diameter side on the laminated body 71 via the die cast string 33.

Therefore, the rotor 11 constituting the axial gap type motor 10 of the present embodiment is configured such that the core metal 32 is attached to the laminated body 71 in which the main magnet portions 41,..., 41 and the sub magnet portions 43,. The inner plates 31A and 31B are press-fitted from the inner diameter side, and the die cast ring 33 and the outer ring 50 are attached from the outer diameter side so as to exert a compressive force on the inner diameter side. ) Has occurred.
Here, the required surface pressures P between the inner plates 31A and 31B and the core metal 32, between the core metal 32 and the laminated body 71, between the laminated body 71 and the die-cast string 33, and between the die-cast string 33 and the outer ring 50 are maximum. When the load torque T, the fastening portion radius are r, the fastening area A, and the friction coefficient μ, the following equation (1) is satisfied.
P ≧ T / (r × A × μ) (1)
The required surface pressure P can be adjusted by the press-fitting allowance of the inner plates 31A and 31B to the cored bar 32, the die casting pressure at the time of forming the die cast string 33, and the shrinkage allowance of the outer ring 50.
Thereby, even if the maximum load torque acts on the rotor 11, it is possible to ensure the rigidity capable of withstanding the centrifugal force due to the rotation of the rotor 11 and the magnetic attractive force from the stator 12.

As described above, according to the present embodiment, after attaching the inner plates 31A and 31B as inner diameter side pressing members from the inner diameter side of the laminated body 71 constituting the plurality of yoke portions 42,. By attaching the die cast ring 33 as the pressing member and the outer ring 50 to the laminated body 71 so as to apply a compressive force to the inner diameter side, the laminated body 71 is tightened from both sides in the radial direction, and the surface pressure is increased inside the rotor. (Radial compressive stress) can be generated. As a result, a frictional force is generated between the members, and torque can be transmitted by the frictional force, and rigidity that can withstand the magnetic attractive force can be ensured.
In addition, since torque can be transmitted between each member with frictional force, a rotor frame with a complicated structure is not required, reducing the number of parts and the number of assembly steps, thereby suppressing the increase in the weight of the rotor and reducing the manufacturing cost. Can be reduced.

  In addition, according to the present embodiment, the electromagnetic steel plate 60 is wound around the annular cored bar 32 to form the laminated body 71, and the inner diameter side pressing member is attached to the inner peripheral surface of the cored bar 32 by press fitting. , 31B, and the outer diameter side pressing member is constituted by a die cast string 33 made of a die-cast alloy pressed against the outer peripheral surface of the laminate 71 and an outer ring 50 attached to the outer peripheral surface of the die cast string 33 by shrink fitting. Therefore, the rotor 11 which is easy to assemble with a simple configuration can be manufactured.

  Further, according to the present embodiment, the inner plates 31A and 31B are divided into two in the axial direction, and are press-fitted from one side and the other side of the cored bar 32, so that the press-fitting load at the time of press-fitting can be reduced and the assembling work is easy. become.

  Further, according to the present embodiment, the rotor 11 is magnetized in the direction of the rotation axis O and the direction orthogonal to the radial direction, and is at least in the direction of the rotation axis O between the main magnet portions 41 and 41 adjacent to each other in the circumferential direction. Since there are a plurality of sub-magnet portions 43 arranged on one side, the magnetic flux of the main magnet portion and the sub-magnet portion converge due to the magnetic flux lens effect due to the so-called Halbach arrangement of so-called permanent magnets. It can be increased relatively.

Second Embodiment
Next, an axial gap type motor 10 according to a second embodiment of the present invention will be described with reference to FIG. In the figure, the same or equivalent components as those in the first embodiment are denoted by the same or equivalent reference numerals, and description thereof is omitted.
The rotor 11 </ b> A of the present embodiment has a cooling passage 90 for supplying lubricating oil supplied from the shaft portion 55 to the pair of stators 12 in the rotor 11 of the first embodiment.

  In the shaft portion 55 of the present embodiment, an axial refrigerant path 91 formed concentrically with the rotation axis O, a radial refrigerant path 92 branched from the axial refrigerant path 91 and formed in a radial direction, Is formed. Here, the radial refrigerant path 92 is formed in at least one of a plurality of magnetic flux short circuit suppressing portions 73,..., 73 formed in the stacked body 71 (hereinafter referred to as a cooling magnetic flux short circuit suppressing portion 93). It is formed at the corresponding position. Further, a concave groove 94 communicating with the radial refrigerant path 92 is formed on the mating surface between the inner plate 31A and the inner plate 31B, and the concave groove 94 and the cooling magnetic flux short-circuit suppressing portion 93 are communicated with the cored bar 32. The inner diameter side through-hole 95 to be formed is formed, and the outermost layer 71a of the laminated body 71 and the die cast ring 33 are further formed with an outer diameter side through-hole 96 that is drilled from the cooling magnetic flux short-circuit suppressing portion 93 to the outer diameter side. The The outer diameter side through hole 96 communicates with a guide passage 97 formed between the inner peripheral surface of the outer ring 50 and the outer peripheral surface of the die casting string 33.

  As described above, the cooling passage 90 is constituted by the axial refrigerant passage 91, the radial refrigerant passage 92, the concave groove 94, the inner diameter side through hole 95, the cooling magnetic flux short-circuit suppressing portion 93, the outer diameter side through hole 96, and the guide passage 97. Then, the refrigerant supplied from the shaft portion 55 is supplied from the guide passage 97 to the stator 12 via the cooling passage 90 as shown by the arrows in FIG.

  The concave groove 94 formed in the inner plate 31B, the inner diameter side through hole 95 formed in the cored bar 32, and the guide passage 97 formed in the outer ring 50 are formed in advance before assembly. The outer diameter side through hole 96 formed in the outermost layer 71a of the laminated body 71 and the die cast ring 33 is formed by casting after the die cast string 33 is cast.

  According to this embodiment, the stator 12 can be cooled from the rotor 11 side, and lubricating oil corresponding to the rotational speed of the rotor 11 can be supplied to the stator 12 by centrifugal force. As a result, there is no need to provide a cooling structure on the stator 12 side, and the apparatus can be reduced in size and weight.

<Third Embodiment>
Next, an axial gap motor 10 according to a third embodiment of the present invention will be described with reference to FIGS. In the figure, the same or equivalent components as those in the first embodiment are denoted by the same or equivalent reference numerals, and description thereof is omitted.
The rotor 11B of this embodiment is provided with a plurality of spoke pins 35 that are arranged at predetermined intervals in the circumferential direction between the inner plates 31A and 31B and extend in the radial direction. Each spoke pin 35 is formed on a magnetic steel sheet 60 extending from the spoke base 35b to the outer diameter side with a spoke base 35b having a bolt through hole 35a communicating with a bolt fastening hole 36 formed in the inner plates 31A and 31B. And a spoke portion 35c having a cross-sectional shape substantially equal to the notch 63 for the magnetic flux short-circuit suppressing portion.

  Further, the core metal 32 is formed with a spoke through hole 32a through which the spoke portions 35c penetrate at predetermined intervals in the circumferential direction, and the spoke pin 35 spokes from the inner diameter side of the core metal 32 through the spoke through hole 32a. The part 35 c is accommodated in the magnetic flux short-circuit suppressing part 73 of the stacked body 71.

  The spoke pin 35 is used as a positioning member when the tape-shaped electromagnetic steel sheet 60 is wound on the cored bar 32, and when the electromagnetic steel sheet 60 is wound around the cored bar 32 while applying tension. Are inserted from the inner diameter side of the cored bar 32 and protruded from the notch 63 for the magnetic flux short-circuit suppressing portion to be cut out from the notch 61 for the main magnet portion, the notch 62 for the auxiliary magnet portion, and the notch 63 for the magnetic flux short-circuit suppressing portion of each layer. Is prevented from being laminated. In addition, although the 12 spoke pins 35 of this embodiment are provided so as to correspond to the magnetic flux short-circuit suppressing portions 73, ..., 73, it is not always necessary to provide them in all the magnetic flux short-circuit suppressing portions 73, ..., 73. It is preferable that at least two spoke pins 35 are equally arranged in the circumferential direction so as not to cause eccentricity in the rotor 11.

  In the manufacturing method of the rotor 11B, first, the main layer 71b of the electromagnetic steel plate 60 is wound on the core metal 32 while being positioned by the spoke pins 35, and the main magnet portions 41,..., 41 and the sub magnet portions 43,. , 43 after insertion, each magnetic magnet insertion hole 72,..., 72, each sub magnet portion accommodating portion 74,..., 74 and each magnetic flux short-circuit suppressing portion 73, which accommodates the spoke portion 35c of the spoke pin 35. The outermost layer 71a for sealing 73 is wound. Thereafter, the inner plates 31A and 31B are press-fitted into the inner diameter side of the core metal 32 so that the bolt through holes 35a of the spoke pins 35 and the bolt fastening holes 36 formed in the inner plates 31A and 31B communicate with each other. Similarly, the die cast ring 33 is cast on the outer diameter side of the laminated body 71, and the outer ring 50 is mounted from the outer diameter side by shrink fitting.

  According to the present embodiment configured as described above, a frictional force is generated between the members as in the axial gap motor 10 of the first embodiment, and the torque can be transmitted by the frictional force and the magnetic attraction is performed. Can receive power. In addition, since the spoke pin 35 is used as a positioning member when the tape-shaped electromagnetic steel sheet 60 is wound on the cored bar 32, it is possible to suppress the electromagnetic steel sheets 60 from being stacked with being shifted. it can. Furthermore, it is possible to easily perform the reference position at the time of fastening with the shaft portion 55.

  Subsequently, in order to examine the feasibility of the axial gap type motor configured as described above, a simulation was performed using the axial gap type motor of the first embodiment. In the simulation, the friction coefficient μ = 0.12, the maximum load torque in the circumferential direction is 300 Nm, and the thrust force is 5000 N (between the laminated body and the core metal, only between the core metal and the inner plate). The required surface pressure between the elements for satisfying was obtained from the above equation (1).

<Rotor specifications>
Inner plate (S45C) outer diameter: 74mm
Core metal (SUS304) outer diameter: 79mm
Laminate outer diameter: 117.2 mm
Die string (ADC12) outer diameter: 123.2mm
Rotor width: 20mm

<Required surface pressure P _OD between outer ring and die-cast ring>
P _OD = (torque) / (radius × fastening area × friction coefficient)
= (300 × 1000) / (123.2 × fastening area × 0.12)
Fastening area = 2 × π × 123.2 × 20 = 15482 mm ²
P _OD = (300 × 1000) / (123.2 × 15482 × 0.12)
= 1.31 MPa
≒ 1.4MPa

<Required surface pressure P _YD between laminate and die-cast _string >
Since the yoke portion has a surface area of 9177.6 mm ² and the main magnet portion has a surface area of 3964.4 mm ² ,
P _YD = (torque) / (radius × fastening area × friction coefficient)
= (300 × 1000) / (117.2 × fastening area × 0.12)
Fastening area = 9117.6 + 3984.4 = 13152 mm ²
P _YD = (300 × 1000) / (117.2 × 13152 × 0.12)
= 1.62 MPa
≒ 1.7MPa

<Required surface pressure P _{YC for} laminate and core>
Since the yoke surface area is 5827.6 mm ² and the main magnet surface area is 2539.2 mm ² ,
P _YC (circumferential direction) = (torque) / (radius × fastening area × friction coefficient)
= (300 × 1000) / (79.0 × fastening area × 0.12)
Fastening area = 5817.6 + 2539.2 = 8357.2 mm ²
P _YC (circumferential direction) = (300 × 1000) / (79.0 × 8357.2 × 0.12)
= 3.79 MPa
P _YC (Thrust direction) = (Thrust force) / (Fastening area × Friction coefficient)
= (5000) / (8357.2 × 0.12)
= 4.99 MPa
Required surface pressure of the laminated body and the core _{P YC} is _{P YC} P _YC as resultant force of (the circumferential direction) and _{P YC} (thrust direction) = √ _{(P YC} (circumferential ^direction) 2 _{+ P YC} (thrust ^direction) 2)
= √ (3.79 ² +4.99 ² )
= 6.27 MPa
≒ 6.3MPa

<Necessary surface pressure of the core and the inner plate _{P CI>}
P _CI (circumferential direction) = (torque) / (radius × fastening area × friction coefficient)
= (300 × 1000) / (74.0 × fastening area × 0.12)
Fastening area = 2 × π × 74.0 × 20 = 9299.1 mm ²
P _CI (circumferential direction) = (300 × 1000) / (74.0 × 9299.1 × 0.12)
= 3.64 MPa
P _CI (Thrust direction) = (Thrust force) / (Fastening area × Friction coefficient)
= (5000) / (9299.1 × 0.12)
= 4.48 MPa
The required surface pressure P _YC of the laminated body and the core metal is P _CI = √ (P _CI (circumferential direction) ² + P _CI (thrust direction) ² ) as a resultant force of P _YC (circumferential direction) and P _YC (thrust direction).
= √ (3.64 ² +4.48 ² )
= 5.77 MPa
≒ 5.8MPa

Next, for each required surface pressure, the inner plate press-fitting allowance is Φ0.05 mm, the die casting pressure is 65 MPa, and the outer ring shrinkage allowance is Φ0.3 mm. It was operated at the maximum number of revolutions while changing, and the surface pressure between each element at that time was measured. The results are shown in Table 1.

  From the above results, in any condition, the surface pressure between each element is larger than the calculated required surface pressure, and when the maximum load torque is applied and the temperature is displaced from the lowest temperature to the highest temperature, the rotor is It was confirmed that the required rigidity was satisfied.

  Subsequently, in the above simulation, the thickness of the die cast ring was set to 6.0 mm. The thickness of the die cast string can be arbitrarily set in relation to the induced voltage, and is preferably 1.5 mm or more. From FIG. 13 (a) and FIG. 13 (b), compared with the outer ring formed of SUS304, even when the outer ring made of S45C is used, a non-magnetic die-cast alloy ( Here, it can be confirmed that a decrease in induced voltage can be suppressed by providing a die cast string in which an aluminum die cast string (referred to as ADC in the figure) is cast. 13 (a) and 13 (b), the induced voltage decreases only about 3% when the thickness of the aluminum die-cast string is 3.3 mm, and decreases only about 1% when the thickness is 5.0 mm. In the case of 6.5 mm, an induced voltage of the same level is shown.

  As described above, according to the present embodiment, the outer ring is made of relatively inexpensive carbon steel by providing a die cast string formed by casting a non-magnetic die-cast alloy on the inner peripheral portion of the outer ring. Also, it is possible to suppress a short circuit of the magnetic flux and suppress a decrease in induced voltage.

In addition, this invention is not limited to what was illustrated to the said embodiment, In the range which does not deviate from the summary of this invention, it can change suitably.
For example, the inner plates 31A and 31B are not necessarily divided in the axial direction, and may be press-fitted from one side in the axial direction.

10 Axial gap type motor 11, 11A, 11B Rotor 12 Stator 31A Inner plate (inner diameter side pressing member)
31B Inner plate (inner diameter side pressing member)
32 Core metal 32a Spoke through hole 33 Die-cast string (outer diameter side pressing member)
35 Spoke Pin 41 Main Magnet Part 42 Yoke Part 43 Sub Magnet Part 50 Outer Ring (Outer Diameter Side Pressing Member)
55 Shaft portion 71 Laminate 72 Main magnet portion insertion hole 73 Magnetic flux short-circuit suppressing portion 74 Sub magnet portion accommodating portion O Rotating shaft

Claims (9)

A rotor rotatable around a rotation axis;
A stator disposed opposite to the rotor from at least one of the rotation axis directions, and an axial gap type motor,
The rotor is
A plurality of main magnet portions magnetized in the rotation axis direction and arranged at predetermined intervals in the circumferential direction;
A plurality of yoke portions, each of which is constituted by a laminate in which a tape-shaped electromagnetic steel sheet is wound, and is disposed on at least one of the plurality of main magnet portions in the rotation axis direction;
An inner diameter side pressing member attached to the inner diameter side of the laminate,
An outer diameter side pressing member attached to the outer diameter side of the laminate, and
After the inner diameter side pressing member is press-fitted into the inner diameter side of the laminate, the outer diameter side pressing member is attached so that a compressive force to the inner diameter side is applied to the laminate, and the inner diameter side pressing member and the An axial gap type motor configured to transmit torque by applying a radial compressive force to the inside of the rotor by an outer diameter side pressing member. The laminate is configured by winding the electromagnetic steel sheet on an annular cored bar,
The inner diameter side pressing member is composed of an inner plate attached by press fitting to the inner peripheral portion of the core metal,
2. The outer diameter side pressing member is composed of a die cast string made of a die cast alloy that is pressed against the outer peripheral portion of the laminate, and an outer ring attached to the outer peripheral portion of the die cast string by shrink fitting. An axial gap type motor described in 1. The required surface pressure P between the inner plate and the core metal, between the core metal and the laminated body, between the laminated body and the die cast ring, and between the die cast string and the outer ring is the maximum load torque T, fastening When the part radius is r, the fastening area A, and the friction coefficient μ,
P ≧ T / (r × A × μ)
The axial gap motor according to claim 2, wherein:   4. The axial gap motor according to claim 2, wherein the inner plate is divided into two in the axial direction, and is press-fitted into an inner peripheral portion of the cored bar from one axial side and the other axial side. The laminate is provided with a magnetic flux short-circuit suppressing portion between the main magnet portions adjacent in the circumferential direction,
The cored bar is provided with a spoke through hole at a position corresponding to the magnetic flux short-circuit suppressing portion,
The rotor is housed in the magnetic flux short-circuit suppressing portion through the spoke through-hole from the inside of the cored bar, and used as a positioning member when winding the tape-shaped electromagnetic steel sheet around the cored bar. The axial gap type motor according to claim 1, further comprising at least one spoke pin.   The axial gap type motor according to claim 2, wherein the die cast string is configured by casting a non-magnetic die cast alloy. The rotor further includes a shaft portion fixed to the inner plate,
The shaft portion, the inner diameter side pressing member, the laminate and the outer diameter side pressing member are provided with cooling passages,
The axial gap type motor according to claim 1, wherein the refrigerant supplied from the shaft portion is supplied to the stator through the cooling passage.   The rotor is magnetized in a direction orthogonal to the rotation axis direction and the radial direction, and is disposed between at least one side of the rotation axis direction between the main magnet portions adjacent to each other in the circumferential direction. The axial gap type motor according to claim 1, wherein the axial gap type motor is provided. A plurality of main magnet portions magnetized in the rotation axis direction and disposed at predetermined intervals in the circumferential direction; and a plurality of yoke portions respectively disposed in at least one of the plurality of main magnet portions in the rotation axis direction; A rotor rotatable around a rotation axis;
A stator that is disposed opposite to the rotor from at least one of the rotation axis directions, and a rotor manufacturing method for an axial gap motor,
Winding a tape-shaped electrical steel sheet around an annular cored bar to form a laminate that constitutes the plurality of yoke parts;
Attaching the main magnet part to the laminate;
Attaching the inner plate to the inner periphery of the core by press fitting;
Forming a die cast string by casting a die cast alloy on the outer periphery of the laminate in a state where the laminate having the inner plate attached to a mold is disposed;
Attaching the outer ring to the outer periphery of the die cast ring by shrink fitting, and manufacturing a rotor for an axial gap motor.

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