JP5929272B2 - Rotor for rotating electrical machine for vehicle and method for manufacturing the same - Google Patents

Description

The present invention relates to a rotor for a rotating electrical machine for a vehicle mounted on a passenger car, a truck or the like and a method for manufacturing the same .

  Conventionally, a magnet for reducing leakage magnetic flux has been mounted on both sides of the pole-shaped claw-shaped magnetic pole of the pole core, and the outer circumference of the magnet cage has been brought into contact with the collar provided on the outer circumference of the claw-shaped magnetic pole. An electric rotor is known (for example, see Patent Document 1). By adopting such a rotor structure, movement of the magnet in the centrifugal direction can be suppressed when the rotor is rotated.

Japanese Patent Laid-Open No. 10-201150 (6th page, FIGS. 11-13)

  By the way, in the rotor of the rotating electrical machine disclosed in Patent Document 1, the outer peripheral portion of the magnet holder is constrained by the flange portion provided on the claw-shaped magnetic pole. When it spreads to the outer peripheral side by centrifugal force, there is a problem that a stress corresponding to the spread acts on the magnet in the magnet cage, and the magnet breaks at a position where this stress is maximized. In particular, the two claw-shaped magnetic poles adjacent in the circumferential direction of the magnet holder have opposite directions on the tip side, and the tip sides having different directions spread separately, so that the magnet stored in the magnet holder Stress concentrates in the central part in the longitudinal direction, and cracks easily occur in this central part.

The present invention was created in view of the above points, and its purpose is to prevent movement of the magnet in the centrifugal direction and prevent cracking of the magnet by the collar provided on the claw-shaped magnetic pole. Another object of the present invention is to provide a rotor for a vehicular rotating electrical machine and a method for manufacturing the same.

  In order to solve the above-described problem, a rotor of a vehicular rotating electrical machine according to the present invention includes a pair of Randell iron cores each having a plurality of claw-shaped magnetic poles, and a pair of Randells magnetized in a direction to prevent leakage magnetic flux. In a rotor of a vehicular rotating electrical machine comprising a rotor having a plurality of magnets arranged between claw-shaped magnetic poles of a mold core and a plurality of magnet holders for holding each of the plurality of magnets, The magnetic pole has a collar portion that protrudes in the circumferential direction at the end portion on the outer diameter side and a part of the magnet holder contacts, and the magnet is divided into a plurality in the longitudinal direction. Since the magnet to be mounted between the claw-shaped magnetic poles is divided into a plurality of parts in the longitudinal direction, even when the tip side of the claw-shaped magnetic pole adjacent to the magnet spreads outward due to centrifugal force during rotation, Stress concentration can be reduced and magnet cracking can be prevented.

  Moreover, it is desirable that the magnet and the magnet holder described above correspond to each other on a one-to-one basis, and that a plurality of magnet segment pieces constituting the magnet are held by one magnet holder. By holding a plurality of magnet segment pieces with one magnet holder, the number of parts can be reduced, and the number of man-hours for assembling the rotor can be reduced.

  Moreover, as for the magnet holder mentioned above, it is desirable that each is independent in the axial direction. By making each magnet cage independent along the axial direction, there is no need to place a member that connects multiple magnet cages on the axial end face side of the Landel core, and a cooling fan is welded to this axial end face. In this case, a large area can be secured.

  Moreover, it is desirable that the above-described magnet splitting surface be inclined with respect to the longitudinal direction. Since the direction of the tip side of the two claw-shaped magnetic poles adjacent to the magnet cage is opposite, the maximum stress acts on the magnet in a direction inclined with respect to the longitudinal direction when each tip side spreads. However, it is possible to divide the magnet in the direction that intersects the maximum stress (for example, the direction perpendicular to it) by inclining the dividing surface of the magnet with respect to its longitudinal direction, effectively reducing the stress concentration on the magnet. Can be reduced.

In addition, the method for manufacturing a rotor of a rotating electrical machine for a vehicle according to the present invention includes a pair of Randell type iron cores each having a plurality of claw-shaped magnetic poles and a pair of Randel type iron cores magnetized in a direction to prevent leakage magnetic flux. A method of manufacturing a rotor of a rotating electrical machine for a vehicle comprising a rotor having a plurality of magnets arranged between the magnetic poles and a plurality of magnet holders for holding each of the plurality of magnets. Assembling a plurality of magnet holders each holding a plurality of unmagnetized magnets between the claw-shaped magnetic poles of the Landell type iron core, and a pair of Randells in a state where the plurality of magnet holders are assembled Cutting the outer peripheral surface of the mold core and the outer peripheral surface of the rotary shaft, and magnetizing a plurality of magnets after cutting the outer peripheral surface of the pair of Landel cores and the outer peripheral surface of the rotary shaft, The magnetic pole protrudes in the circumferential direction at the outer diameter side end. It has a flange portion part of the magnet retainer abuts with the magnet is divided into a plurality in the longitudinal direction. By using a non- magnetized magnet when assembling the magnet cage between the claw-shaped magnetic poles described above, the magnet can be magnetized after assembling the rotor and cutting the outer portion of the Landel iron core or the rotating shaft. This makes it possible to eliminate the need for a special process for removing the cutting powder adhering to the magnet, thereby reducing the manufacturing cost of the rotor.

  Moreover, it is desirable that the magnet holder described above is formed using a nonmagnetic material. Thereby, the magnetic flux reduction of a magnet can be suppressed compared with the case where the magnet holder formed with the magnetic material is used.

  In addition, it is preferable that a ring member that is in contact with the inner diameter surface of the claw-shaped magnetic pole and that is formed in an annular shape is further provided, and each of the plurality of magnet cages is fixed to the ring member. Thereby, it is possible to prevent the magnet holder from being displaced in the axial direction. In addition, by attaching each magnet cage after attaching the ring member to the Landel core, even if the relative circumferential position of the pair of Landel cores is deviated within an allowable range, it is possible to maintain the appropriate position. A magnet holder can be attached, and the assembly accuracy of the magnet holder can be improved.

  Further, it is desirable that a resin material is filled between the magnet holder and the magnet and between the magnet holder and the claw-shaped magnetic pole. Thereby, it can prevent that a magnet moves within a magnet holder, or a magnet holder moves between claw-shaped magnetic poles.

It is principal part sectional drawing of the alternating current generator for vehicles of one Embodiment. It is a perspective view of a rotor. It is a partial top view which shows the shape of a claw-shaped magnetic pole. It is a partial side view which shows the shape of a claw-shaped magnetic pole. It is explanatory drawing which shows the relationship between the adjacent claw-shaped magnetic pole, the magnet holder | retainer, and magnet which were arrange | positioned among them. It is explanatory drawing of a magnet and a magnet holder. It is a figure which shows the stress distribution which acts on a magnet at the time of rotation of a rotor, and the dividing position of the magnet. It is a fragmentary sectional view showing the state where a ring member was attached to a claw-like magnetic pole. It is a partial perspective view which shows the state which mounted | wore the ring member with each magnet holder.

  Hereinafter, an AC generator for a vehicle according to an embodiment to which the present invention is applied will be described with reference to the drawings. FIG. 1 is a cross-sectional view of a main part of an automotive alternator according to an embodiment. The vehicle alternator 1 according to this embodiment includes a stator 2 that serves as an armature, a rotor 3 that serves as a field, a housing 4 that supports the stator 2 and the rotor 3, and alternating current power to direct current power. The rectifier 5 to be converted is included.

  FIG. 2 is a perspective view of the rotor 3. In addition, although the cooling fan is being fixed to the axial direction end surface of the rotor 3, these cooling fans are abbreviate | omitted in FIG.

  The rotor 3 rotates integrally with the rotating shaft 6. The rotor 3 rotates integrally with the rotating shaft 6, a field coil 8 that magnetizes the Landel-type pole core 7, and the rear of the rotating shaft 6. Slip rings 9, 10 provided near the ends and connected to both ends of the field coil 8, cooling fans 11, 12 attached to axial end faces of the respective Landel pole cores 7, and a pair of Landel pole cores 7 and a magnet holder 31 that holds the magnet 30 that reduces the leakage magnetic flux between them.

  The rotating shaft 6 is connected to a pulley 20 and is rotationally driven by a traveling engine (not shown) mounted on the vehicle. One of the rundle type pole cores 7 on the pulley side includes a boss portion 711 assembled to the rotating shaft 6, a disk portion 721 extending in a radial direction from the pulley-side end portion of the boss portion 711, and an axial direction from the outer peripheral side of the disk portion 721. And a plurality of claw-shaped magnetic poles 731 extending in the direction. The other Landel-type pole core 7 on the non-pulley side includes a boss portion 712 assembled to the rotating shaft 6, a disk portion 722 that extends in a radial direction from the non-pulley side end of the boss portion 712, and an outer peripheral side of the disk portion 722. A plurality of claw-shaped magnetic poles 732 extending in the axial direction. These pole cores 7 are formed by forging. Each of the plurality of claw-shaped magnetic poles 731 and the plurality of claw-shaped magnetic poles 732 mesh with each other and the pair of Landel-type pole cores 7 are attached to the rotating shaft 6 in a state where the field coil 8 is disposed on the outer peripheral side of the boss portions 711 and 712. It is press-fitted and assembled.

  Although the number of poles of the claw-shaped magnetic poles 731 and 732 is generally 6 to 8, for example, in this embodiment, the number of poles is set to 8. When a field current flows from the regulator 13 to the field coil 8 via the slip rings 9 and 10, one claw-shaped magnetic pole 731 is magnetized to the N pole and the other claw-shaped magnetic pole 732 is magnetized to the S pole.

  FIG. 3 is a partial plan view showing the shape of the claw-shaped magnetic pole 731. FIG. 4 is a partial side view showing the shape of the claw-shaped magnetic pole. As shown in these drawings, the claw-shaped magnetic pole 731 is assembled with a flange portion 7311 projecting to both sides in the circumferential direction at the outer diameter side end portion, and a circumferential side surface 7312 facing the adjacent claw-shaped magnetic pole 732. And an inner diameter surface 7313 facing the field coil 8 disposed on the inner peripheral side. The same applies to the claw-shaped magnetic pole 732, which includes a collar portion 7321, a circumferential side surface 7322, and an inner diameter surface 7323. In addition, about the circumferential direction side surfaces 7312 and 7322, either the state which maintained the surface shape at the time of forging, or the state in which processes, such as cutting, are given may be sufficient.

  FIG. 5 is an explanatory diagram showing the relationship between the adjacent claw-shaped magnetic poles 731 and 732 and the magnet holder 31 and the magnet 30 arranged therebetween. FIG. 6 is an explanatory diagram of the magnet 30 and the magnet holder 31. The magnet 30 is a rare earth magnet such as a neodymium magnet and is divided into a plurality of pieces in the longitudinal direction. In the present embodiment, the magnet 30 is divided into two, and the magnet 30 is constituted by two magnet divided pieces 301 each having a divided surface 302 inclined with respect to the longitudinal direction. The magnet 30 is accommodated in the magnet holder 31 in a state where these two magnet segment pieces 301 are brought into contact with each other on the division surfaces 302. The magnet holder 31 is formed of a metal plate made of a nonmagnetic material such as stainless steel. In the example shown in FIG. 6, the magnet holder 31 has a rectangular parallelepiped shape, an opening into which the magnet 30 is inserted is formed on one surface, and the other five surfaces are wall surfaces that store and hold the magnet 30. ing. One facing surface 311 (FIG. 6) of the magnet holder 31 is sandwiched in the circumferential direction by the respective circumferential side surfaces 7312 and 7322 between the claw-shaped magnetic poles 731 and 732 facing in the circumferential direction. Further, a part 3121 on the outer diameter side of the other facing surface 312 (FIG. 6) of the magnet holder 31 is in contact with the flange portions 7311 and 7321 of the claw-shaped magnetic poles 731 and 732. Thus, the magnet holder 31 is arranged between the claw-shaped magnetic poles 731 and 732.

  Note that the magnet 30 and the magnet holder 31 correspond one to one. In addition, each magnet holder 31 is independent in the axial direction (direction along the rotation axis 6). By making each magnet holder 31 independent along the axial direction, there is no need to arrange a member connecting the plurality of magnet holders 31 on the end face side in the axial direction of the Landel pole core 7, and cooling is performed on this end face in the axial direction. A wide area for welding the fans 11 and 12 can be secured.

  Further, the magnet 30 (magnet divided piece 301) has one claw-shaped magnetic pole that becomes an N pole when a current is passed through the field coil 8, for example, a side surface that faces the circumferential side surface 7312 of the claw-shaped magnetic pole 731 has an N pole. Further, the other claw-shaped magnetic pole that becomes the S pole when a current is passed through the field coil 8, for example, the side surface facing the circumferential side surface 7322 of the claw-shaped magnetic pole 732 is magnetized so as to be the S pole. By magnetizing the magnet 30 in this manner, leakage of magnetic flux between the claw-shaped magnetic poles 731 and 732 is prevented.

  Magnetization of the magnet 30 is performed after cutting or the like of the rotor 3 is completed. That is, the unmagnetized magnet 30 is used when the magnet holder 31 is assembled between the claw-shaped magnetic poles 731 and 732. As the rotor 3, it is necessary to finally cut the outer peripheral surface of the Landel-type pole core 7, the outer peripheral surface of the rotating shaft 6, and the like to ensure the dimensional accuracy of these surfaces. Magnetization of the magnet 30 is performed. Since these cutting processes are performed before the magnet 30 is magnetized, the cutting powder generated in this process is not magnetic and can be easily washed away using a cleaning liquid. In addition, as a method of magnetizing the magnet 30 after the rotor 3 is assembled, a conventional method can be used. For example, the magnet 30 is magnetized using the magnetizing device disclosed in Japanese Patent Application Laid-Open No. 2009-050131.

  By the way, as described above, the split surface 302 that is the boundary between the two magnet split pieces 301 constituting the magnet 30 is inclined with respect to the longitudinal direction of the magnet 30. Next, the orientation of the split surface 302 will be described. FIG. 7 is a diagram illustrating a stress distribution acting on the magnet 30 when the rotor 3 rotates and a division position of the magnet 30. FIG. 7 shows the stress distribution when the magnet 30 is not divided. Further, a, b, c, and d are iso-stress lines, and the inside of the iso-stress line indicated by a is the highest stress portion, and the stress decreases in the order of b, c, and d toward the outside. ing. Moreover, the arrow f has shown the stress vector direction in the location where the maximum stress acts. When the integrated magnet 30 is used, the magnet 30 is easily cracked in a direction perpendicular to the arrow f at a position indicated by the arrow f. In the present embodiment, the dividing surface 302 is set in a direction orthogonal to the stress vector direction at the location where the maximum stress indicated by the arrow f acts.

  Since the direction of the tip side of the two claw-shaped magnetic poles 731 and 732 adjacent to the magnet holder 31 is opposite, when each tip side spreads by the centrifugal force during rotation, the magnet 30 has its longitudinal direction The maximum stress acts in the direction inclined with respect to. In the present embodiment, the magnet 30 is divided in a direction intersecting (orthogonal) with the maximum stress by inclining the dividing surface 302 of the magnet 30 with respect to the longitudinal direction.

  Thus, in the rotor 3 of the vehicle alternator 1 of the present embodiment, the magnet 30 to be mounted between the claw-shaped magnetic poles 731 and 732 is divided into two pieces in the longitudinal direction. Even when the tips of adjacent claw-shaped magnetic poles 731 and 732 spread outward due to centrifugal force, stress concentration in the central portion of the magnet 30 can be reduced and cracking of the magnet 30 can be prevented. In addition, by storing and holding the two divided magnet pieces 301 in one magnet holder 31, the number of parts can be reduced and the man-hour when the rotor 3 is assembled can be reduced. .

  In addition, by inclining the dividing surface 302 of the magnet 30 with respect to the longitudinal direction, specifically, the magnet 30 is divided in a direction orthogonal to the direction in which the maximum stress acts on the non-divided magnet 30 during rotation. Thus, stress concentration on the magnet 30 can be effectively reduced. Moreover, by forming the magnet holder 31 using a nonmagnetic material, it is possible to suppress a decrease in the magnetic flux of the magnet 30 as compared with the case where the magnet holder 31 formed of a magnetic material is used.

  In addition, this invention is not limited to the said embodiment, A various deformation | transformation implementation is possible within the range of the summary of this invention. For example, in the above-described embodiment, each magnet holder 31 is disposed between the adjacent claw-shaped magnetic poles 731 and 732, but in advance, an annular shape is provided so as to contact the inner diameter surfaces 7313 and 7323 of the claw-shaped magnetic poles 731 and 732. The ring member 74 may be assembled, and each magnet holder 31 may be attached and fixed to the ring member 74.

  FIG. 8 is a partial cross-sectional view showing a state in which the ring member 74 is attached to the claw-shaped magnetic poles 731 and 732. FIG. 9 is a partial perspective view showing a state in which each magnet holder 31 is mounted on the ring member 74. As shown in FIG. 8, a notch 7314 for fitting the ring member 74 is provided on the inner diameter surface 7313 of the claw-shaped magnetic pole 731. The same applies to the other claw-shaped magnetic poles 732, and the inner surface 7323 is provided with a notch 7324 for fitting the ring member 74. The pair of Landel-type pole cores 7 are assembled in a state in which the ring member 74 is fitted to these notches 7314 and 7324. At this time, the magnet holder 31 is not attached to the ring member 74. Thereafter, each magnet holder 31 is inserted into the space between the adjacent claw-shaped magnetic poles 731 and 732. At this time, each magnet holder 31 is locked and fixed to the ring member 74. As a specific method of locking, for example, the ring member 74 is sandwiched by folding back one surface of the magnet holder 31 (the surface that becomes the inner diameter side when inserted between the claw-shaped magnetic poles 731 and 732). It is conceivable to form a locking portion that can be formed, and lock the magnet holder 31 by locking the locking portion to the ring member 74.

  Thus, by fixing the magnet holder 31 using the ring member 74, the magnet holder 31 can be prevented from being displaced in the axial direction. Further, by attaching each magnet holder 31 after attaching the ring member 74 to the Landel pole core 7, even if the relative circumferential position of the pair of Landel pole cores 7 is deviated within an allowable range, The magnet holder 31 can be attached at an appropriate position, and the assembly accuracy of the magnet holder 31 can be improved.

  Further, at least one (preferably both) between the magnet holder 31 and the magnet 30 and between the magnet holder 31 and the claw-shaped magnetic poles 731 and 732 may be filled with a resin material. As the resin material, for example, a thermosetting liquid material such as epoxy is used. Thereby, it is possible to prevent the magnet 30 from moving in the magnet holder 31 and the magnet holder 31 from moving between the claw-shaped magnetic poles 731 and 732.

  In the above-described embodiment, the magnet holder 31 (FIG. 6) whose wall surfaces are the five surfaces other than the surface into which the magnet 30 is inserted is used, but opposed to the inner surface 7313, 7323 of the claw-shaped magnetic poles 731, 732 Including a first surface, a second surface facing the circumferential side surface 7312 of the claw-shaped magnetic pole 731, and a third surface facing the circumferential side surface 7322 of the claw-shaped magnetic pole 732, and omitting the other surfaces. A magnet holder may be used. By having the first surface, it is possible to restrict movement of the entire magnet 30 in the outer shape direction, and excessive stress concentration on the magnet 30 in the vicinity of the ends of the flange portions 7311 and 7321 of the claw-shaped magnetic poles 731 and 732. Can be prevented. Further, by having the second and third surfaces, excessive stress is applied to the magnet 30 due to partial unevenness on the circumferential side surfaces 7312 and 7322 of the claw-shaped magnetic poles 731 and 732 that maintain the surface shape during forging. Concentration can be prevented from occurring.

  In the above-described embodiment, the case where the magnet 30 is divided into two has been described. However, the magnet 30 may be divided into three or more. In addition, although the split surface 302 is set in a direction orthogonal to the stress vector direction at a location where the maximum stress is applied to the non-split magnet 30, the direction of the split surface 302 may be shifted from the orthogonal direction.

  In the above-described embodiment, the rotor of the vehicle alternator has been described. However, other rotating electrical machines, for example, a rotating electrical machine that performs an electric operation and a rotor of a rotating electrical machine that performs both a power generation operation and an electric operation. The present invention can also be applied.

  As described above, according to the present invention, since the magnet to be mounted between the claw-shaped magnetic poles is divided into a plurality of portions in the longitudinal direction, the tip side of the claw-shaped magnetic pole adjacent to the magnets is spread outward by centrifugal force during rotation. Even in this case, stress concentration in the central portion of the magnet can be reduced, and the magnet can be prevented from cracking.

DESCRIPTION OF SYMBOLS 1 Vehicle alternator 2 Stator 3 Rotor 4 Housing 5 Rectifier 6 Rotating shaft 7 Landel pole core 8 Field coil 11, 12 Cooling fan 30 Magnet 31 Magnet holder 74 Ring member 301 Magnet split piece 302 Split face 731 732 Claw-shaped magnetic poles 7311, 7321 collar portions 7312, 7322 circumferential side surfaces 7313, 7323 inner diameter surfaces

Claims (8)

A pair of Randell iron cores each having a plurality of claw-shaped magnetic poles, a plurality of magnets magnetized in a direction to prevent leakage magnetic flux and disposed between the claw-shaped magnetic poles of the pair of Randell iron cores, In a rotor of a vehicular rotating electrical machine comprising a rotor having a plurality of magnet holders that hold each of the magnets of
The claw-shaped magnetic pole has a collar portion that protrudes in the circumferential direction at an outer diameter side end portion and a part of the magnet holder comes into contact with,
The rotor of a vehicular rotating electrical machine, wherein the magnet is divided into a plurality in the longitudinal direction. In claim 1,
The magnet and the magnet holder correspond one-to-one,
A rotor for a vehicular rotating electrical machine, wherein a plurality of magnet segment pieces constituting the magnet are held by one magnet holder. In claim 2,
Each of the magnet holders is independent in the axial direction. In any one of Claims 1-3,
The rotor of a vehicular rotating electrical machine is characterized in that a split surface of the magnet is inclined with respect to the longitudinal direction. In any one of Claims 1-4,
The rotor of a vehicular rotating electrical machine, wherein the magnet holder is formed using a nonmagnetic material. In any one of Claims 1-5,
A ring member that is in contact with the inner diameter surface of the claw-shaped magnetic pole and formed in an annular shape;
The rotor of a vehicular rotary electric machine, characterized in Tei Rukoto respectively fixed in said plurality of magnet keeper to the ring member. In any one of Claims 1-6,
A rotor for a vehicular rotating electrical machine, wherein a resin material is filled between the magnet holder and the magnet and between the magnet holder and the claw-shaped magnetic pole.   A pair of Randell iron cores each having a plurality of claw-shaped magnetic poles, a plurality of magnets magnetized in a direction to prevent leakage magnetic flux and disposed between the claw-shaped magnetic poles of the pair of Randell iron cores, And a rotor having a plurality of magnet holders for holding each of the magnets.
  Assembling the plurality of magnet holders each holding the plurality of unmagnetized magnets between the claw-shaped magnetic poles of the pair of Landel type iron cores;
  Cutting the outer peripheral surface of the pair of Landel-type iron cores and the outer peripheral surface of the rotating shaft in a state where the plurality of magnet cages are assembled;
  Magnetizing the plurality of magnets after cutting the outer peripheral surface of the pair of Rundel-type iron cores and the outer peripheral surface of the rotating shaft;
  The claw-shaped magnetic pole has a flange portion that protrudes in the circumferential direction at an outer diameter side end portion and a part of the magnet holder contacts,
  The said magnet is divided | segmented into multiple in the longitudinal direction, The manufacturing method of the rotor of the rotary electric machine for vehicles characterized by the above-mentioned.

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