JP6115448B2 - Manufacturing method of rotor for rotating electrical machine and rotor for rotating electrical machine - Google Patents

Description

  The present invention relates to a rotor for a rotating electrical machine and a method for manufacturing a rotor for a rotating electrical machine.

  In a rotating electrical machine such as an electric motor or a generator, a permanent magnet embedded rotor is used. The permanent magnet embedded rotor is also referred to as an IPM (Interior Permanent Magnet) rotor. In the IPM type rotor, a magnet insertion hole is formed in the vicinity of the outer peripheral surface of a rotor core made of a cylindrical magnetic body so as to extend in the axial direction. Then, a permanent magnet is inserted into the magnet insertion hole, and is bonded and fixed with a resin material.

  For example, Patent Document 1 discloses a rotor in which one surface of a magnet is fixed in contact with an inner wall of a hole when a magnet is fixed to a hole (magnet insertion hole) using a resin. According to this rotor, a rotor using a solid fixing resin composition having excellent filling characteristics is provided.

  Patent Document 2 discloses a rotor for a rotating electrical machine in which a permanent magnet is inclined and fixed in the axial direction of a rotor core in a magnet insertion hole. In this example, the permanent magnet is inserted into the magnet insertion hole with the rotor core inclined. Then, by filling the filler while maintaining this state, the permanent magnet is inclined and fixed with respect to the magnet insertion hole. Thus, it is described that the contact area between the magnet insertion hole and the permanent magnet can be reduced, and the eddy current generated in the permanent magnet can be suppressed.

JP2013-136725A International Publication No. 2012/169043

  However, the inventors have found that the above-described method has the following problems. In the method described in Patent Document 1, the contact area between the hole and the magnet increases, and the electrical resistance between the hole and the magnet decreases. As a result, the eddy current generated in the magnet is increased and the eddy current loss is large. Although it is conceivable to cover the magnet with an insulating film in order to reduce the electrical resistance, an increase in cost due to the addition of processes is inevitable.

  In Patent Document 2, although the eddy current can be suppressed, a special process for tilting the rotor core is required when the rotor core is manufactured. Therefore, a separate device for holding the rotor core in an inclined manner is required. Further, unless the rotor core is stably tilted in the intended direction, the tilt angle of the permanent magnet will vary.

  In the method for manufacturing a rotor for a rotating electrical machine according to one aspect of the present invention, a permanent magnet is inserted into a magnet housing portion of the magnet insertion hole of a rotor core formed by extending a magnet insertion hole in the axial direction, and the magnet Filler is injected into filler injection portions provided at both ends in the circumferential direction of the rotor core of the magnet housing portion on both end surfaces in the axial direction of the rotor core of the housing portion, and the circumferential direction of the magnet housing portion The filler filled in the filler injection part is guided to the filler introduction means provided in contact with the filler injection part at both ends of the magnet, and the circumferential direction of the magnet insertion hole is guided by the filler introduction means. The filler is guided to a first surface of the permanent magnet facing the radial direction of the rotor core at one end of the permanent magnet, and the other end of the permanent magnet opposed to the permanent magnet at the other end in the circumferential direction of the magnet insertion hole. By guiding the filler to the surface of 2 The permanent magnet is inclined with respect to the magnet insertion hole with the axial direction as the rotation axis, or at both ends of the magnet insertion hole on the first end surface which is one end surface in the axial direction of the rotor core. The filler is guided to the first surface of the permanent magnet, and the second surface of the permanent magnet is disposed at both ends in the circumferential direction of the magnet insertion hole of the second end surface that is the other end surface of the rotor core in the axial direction. The permanent magnet is inclined with respect to the magnet insertion hole with the circumferential direction as a rotation axis, and the permanent magnet is inclined with respect to the magnet insertion hole. It is to be cured.

  In the above method for manufacturing a rotor for a rotating electrical machine, the filler introduction means are guide grooves provided at both ends in the circumferential direction of the magnet insertion hole, and are provided at one end in the circumferential direction of the magnet insertion hole. The guide groove is provided at a position where the filler is brought into contact with the first surface of the permanent magnet, and the guide groove provided at the other circumferential end of the magnet insertion hole is the filler. Is preferably provided at a position in contact with the second surface of the permanent magnet.

  In the above method for manufacturing a rotor for a rotating electrical machine, it is preferable that the guide groove is provided so as to penetrate the rotor core in the axial direction of the rotor core.

  In the above method for manufacturing a rotor for a rotating electrical machine, the filler introduction means are protrusions provided at both ends in the circumferential direction of the magnet insertion hole and projecting from inner walls of the magnet insertion hole, and the magnet insertion hole The protrusion provided at one end in the circumferential direction is provided at a position that prevents the filler from contacting the second surface of the permanent magnet, and is provided at the other end in the circumferential direction of the magnet insertion hole. It is preferable that the provided protrusion is provided at a position that prevents the filler from coming into contact with the first surface of the permanent magnet.

  In the above method for manufacturing a rotor for a rotating electrical machine, the filler introduction means are guide grooves provided at both ends in the circumferential direction of the magnet insertion hole, and the magnet insertion hole in the first end surface of the rotor core. The guide grooves provided at both ends in the circumferential direction are provided at positions where the filler is brought into contact with the first surface of the permanent magnet, and the magnet insertion holes in the second end surface of the rotor core It is desirable that the guide grooves provided at both ends in the circumferential direction are provided at positions where the filler is brought into contact with the second surface of the permanent magnet.

  In the above method for manufacturing a rotor for a rotating electrical machine, the filler introduction means are protrusions provided at both ends in the circumferential direction of the magnet insertion hole and projecting from inner walls of the magnet insertion hole, The protrusions provided at both ends in the circumferential direction of the magnet insertion hole of the first end surface are provided at positions where the filler is prevented from contacting the second surface of the permanent magnet, and the rotor core The protrusions provided at both ends in the circumferential direction of the magnet insertion hole of the second end surface of the second end surface of the second end surface are provided at positions where the filler is prevented from contacting the first surface of the permanent magnet. Is desirable.

  In the above method for manufacturing a rotor for a rotating electrical machine, a rotor core, a magnet insertion hole having a magnet housing portion formed by extending in the axial direction of the rotor core, and being inserted into the magnet insertion hole, A permanent magnet that is fixed while being inclined, a filler that fixes the permanent magnet, and a filler injection portion that is provided at both ends of the magnet housing portion in the circumferential direction of the rotor core and into which the filler is injected. A filler introduction means provided on both ends of the magnet housing portion in the circumferential direction so as to be in contact with the filler injection portion and guiding the filler filled in the filler injection portion. The means guides the filler to a first surface of the permanent magnet facing the radial direction of the rotor core at one end in the circumferential direction of the magnet insertion hole, and the permanent at the other end in the circumferential direction of the magnet insertion hole. Opposite across the magnet By guiding the filler to the second surface of the permanent magnet, the permanent magnet is inclined with respect to the magnet insertion hole with the axial direction as a rotation axis, or one end surface of the rotor core in the axial direction At both ends of the magnet insertion hole, the filler is guided to the first surface of the permanent magnet, and at both ends in the circumferential direction of the magnet insertion hole on the other end surface of the rotor core in the axial direction, It is desirable that the permanent magnet be inclined with respect to the magnet insertion hole with the circumferential direction as a rotation axis by guiding the filler to the second surface.

  According to the present invention, the permanent magnet can be tilted and fixed inside the magnet insertion hole of the rotor for a rotating electrical machine only by filling the filler.

1 is a cross-sectional view showing an axial cross section of a rotor 10 for a rotating electrical machine according to a first embodiment; FIG. 3 is a diagram showing an end surface of the rotor core 12 in the axial direction. It is the figure which expanded and showed one of the magnetic poles 24 shown in FIG. It is a top view which shows the permanent magnet 26 at the time of overlooking the magnet insertion hole 32. FIG. 3 is a flowchart showing a method for manufacturing the rotor for a rotating electrical machine according to the first embodiment. It is a top view which shows the magnet insertion hole 32 after inserting the permanent magnet 26. FIG. It is a top view which shows the magnet insertion hole 32 after filling the filler 34. FIG. It is a top view which shows the magnet insertion hole 32 after progress for a fixed time since the filler 34 was filled. It is a top view which shows the permanent magnet 26 at the time of overlooking the magnet insertion hole 35. FIG. 6 is a flowchart showing a method for manufacturing a rotor for a rotating electrical machine according to a second embodiment. It is a top view which shows the magnet insertion hole 35 after inserting the permanent magnet 26. FIG. It is a top view which shows the magnet insertion hole 35 after filling the filler 34. FIG. It is a top view which shows the magnet insertion hole 35 after progress for a fixed time since the filling material 34 was filled. It is a top view which shows the permanent magnet 26 at the time of bird's-eye view of the magnet insertion hole 36. FIG. It is a top view which shows the permanent magnet 26 at the time of overlooking the magnet insertion hole 41. FIG. It is sectional drawing of the magnet insertion hole 41 and permanent magnet in the AA cross section of FIG. 6 is a flowchart showing a method for manufacturing a rotor for a rotating electrical machine according to a fourth embodiment. It is a figure which shows the cross section of the magnet insertion hole 41 and the permanent magnet 26 in the AA cross section of FIG. 15 after inserting the permanent magnet 26 in the magnet insertion hole 41. FIG. It is a figure which shows the cross section of the magnet insertion hole 41 and the permanent magnet 26 in the AA cross section of FIG. 15 after filling the filler 34 in the magnet insertion hole 41. FIG. It is a figure which shows the cross section of the magnet insertion hole 41 and the permanent magnet 26 in the AA cross section of FIG. 15 after progress for a fixed time since the filler 34 was filled in the magnet insertion hole 41. FIG.

Embodiment 1
A method for manufacturing the rotor for a rotating electrical machine according to the first embodiment will be described. In this manufacturing method, a permanent magnet is fixed to a magnet insertion hole provided in the rotor core. First, the rotor core will be described.

  FIG. 1 is a sectional view showing an axial section of a rotor for a rotating electrical machine (hereinafter simply referred to as a rotor) 10 according to a first embodiment. The cylindrical stator 11 is provided around the rotor 10 with a predetermined gap therebetween, whereby a rotating electrical machine is configured. On the inner periphery of the stator 11, a plurality of teeth protrudes radially inward at equal intervals in the circumferential direction. Between the adjacent teeth, the same number of slots as the teeth are formed so as to open on the inner peripheral side and both axial ends. A stator coil (not shown) wound around the teeth is inserted and disposed in the slot. Thereby, when the stator coil is energized, a rotating magnetic field for rotating the rotor 10 is formed inside the stator 11.

  The rotor 10 includes a columnar or cylindrical rotor core 12 having a shaft hole 23 in the central portion in the radial direction, a shaft 14 fixed through the shaft hole 23 of the rotor core 12, and a shaft 14 indicated by an arrow X (and the rotor core). 12) an end plate 16 disposed on both sides of the rotor core 12 with respect to the axial direction, and a fixing member 18 that fixes the rotor core 12 and the end plate 16 on the shaft 14.

  The rotor core 12 is configured by, for example, laminating a number of electromagnetic steel plates formed in an annular shape by punching a silicon steel plate having a thickness of 0.3 mm into an annular shape in the axial direction. Each electromagnetic steel plate constituting the rotor core 12 is integrally connected by a method such as caulking, bonding, welding or the like for each block obtained by dividing the rotor core 12 in the axial direction or all together. The electromagnetic steel sheets constituting the rotor core 12 are electrically insulated from each other by an insulating film formed on the surface.

  The rotor core 12 is provided with a plurality of magnetic poles 24 (see FIG. 2) at equal intervals in the circumferential direction. Each magnetic pole 24 includes a pair of permanent magnets, details of which will be described later. Further, the rotor core 12 has a circumferential position on the shaft 14 fixed by an interference fit or key fitting.

  In addition, the rotor core 12 is not limited to a form in which electromagnetic steel sheets are laminated, but iron, iron-silicon alloy, iron-nitrogen alloy, iron-nickel alloy, iron-carbon alloy, iron-boron alloy, iron- Soft magnetic metal powder such as cobalt alloy, iron-phosphorus alloy, iron-nickel-cobalt alloy and iron-aluminum-silicon alloy, or soft magnetic metal oxide powder is a resin binder such as silicone resin. It may be formed of a powder magnetic core made of coated magnetic powder or the like.

  The shaft 14 is made of, for example, a round steel bar, and a flange portion 15 that protrudes radially outward is formed on the outer periphery of the shaft 14. The flange portion 15 functions as a contact portion that contacts the end plate 16 when the rotor 10 is assembled and determines the axial position of the rotor core 12 on the shaft 14.

  The end plate 16 is constituted by a disk having an outer shape substantially the same as the axial end surface of the rotor core 12. The end plate 16 is preferably formed of a nonmagnetic metal material such as aluminum or copper. Here, the nonmagnetic metal material is used in order to suppress a short circuit of the magnetic flux at the axial end of the permanent magnet constituting the magnetic pole. However, the material is not limited to a metal material as long as it is a nonmagnetic material, and may be formed of a resin material. Further, the end plate 16 may have a smaller diameter than the rotor core 12 or may be omitted to reduce costs.

  The fixing member 18 includes a cylindrical fixing portion 20 that is fixed to the shaft 14 and an annular pressing portion 22 that protrudes radially outward from one end portion of the fixing portion 20. The fixing member 18 is fixed to the shaft 14 by, for example, caulking, welding, screwing, or the like in a state where the rotor core 12 and the two end plates 16 are pressed toward the flange portion 15 by the holding portion 22. It is fixed on the shaft 14 by being fixed by the method. Thereby, the rotor core 12 is fixed to the shaft 14 together with the end plate 16.

  Next, the rotor core 12 will be described. FIG. 2 is a view showing an end face of the rotor core 12 in the axial direction. The configuration of the rotor core 12 having a cross section perpendicular to the axial direction is the same as that in FIG.

  A shaft hole 23 for inserting and fixing the shaft 14 is formed through the central portion of the rotor core 12 having a cylindrical outer shape. When the rotor core 12 is fixed to the shaft 14 by an interference fit, the shaft hole 23 is circular as shown in FIG. 2, and no key is formed at the edge thereof. However, when the rotor core 12 is attached to the shaft 14 through key fitting, a key (or key groove) is projected (or recessed) at the edge of the shaft hole 23.

  A plurality of magnetic poles 24 are provided at equal intervals in the circumferential direction on the outer peripheral portion of the rotor core 12. In the present embodiment, an example is shown in which eight magnetic poles 24 are provided at 45 ° intervals in the circumferential direction. Since each magnetic pole 24 has the same configuration except for the magnetization direction of the permanent magnet 26, only one magnetic pole 24 will be described below.

  FIG. 3 is an enlarged view of one of the magnetic poles 24 shown in FIG. A pair of permanent magnets 26 is disposed on the magnetic pole 24. The pair of permanent magnets 26 is embedded in the vicinity of the outer peripheral surface 13 of the rotor core 12. As shown in FIG. 3, the two permanent magnets 26 included in the magnetic pole 24 have the same shape and size. That is, the permanent magnet 26 has a flat rectangular axial end surface (and a cross section) having two short side surfaces and long side surfaces, and is formed to have substantially the same axial length as the rotor core 12. However, the present invention is not limited to this, and the pair of permanent magnets 26 may have different shapes or sizes.

  In the magnetic pole 24, the pair of permanent magnets 26 are respectively inserted into the magnet insertion holes 32 and fixed. As a result, the two permanent magnets 26 are arranged in a substantially V shape so that the distance between the two permanent magnets 26 increases toward the outer peripheral surface 13 of the rotor core 12. The pair of permanent magnets 26 are arranged symmetrically on both sides with respect to the magnetic pole center line C, which is a radial line passing through the circumferential magnetic pole center position. However, the present invention is not limited to this, and the pair of permanent magnets 26 may be disposed asymmetrically with respect to the magnetic pole center line C.

  Next, the positional relationship between the magnet insertion hole 32 and the permanent magnet 26 will be described. FIG. 4 is a top view showing the permanent magnet 26 when the magnet insertion hole 32 is looked down on. As described above, the configuration of the cross section perpendicular to the axial direction of the rotor core 12 is the same. Therefore, the shape of the magnet insertion hole 32 in the cross section perpendicular to the axial direction of the rotor core 12 is the same in any cross section.

  The magnet insertion hole 32 includes a magnet housing portion 321, a first filler injection portion 322, a second filler injection portion 323, a first invitation groove 324, and a second invitation groove 325. The magnet housing portion 321 is formed in a rectangular shape that is substantially similar to the transverse section of the permanent magnet 26 and is slightly larger. The long side of the magnet housing part 321 extends in the circumferential direction. Thereby, the magnet accommodating part 321 can accommodate the permanent magnet 26 inside.

  A first filler injection part 322 is connected to one end of the magnet housing part 321 in the circumferential direction. A first guide groove 324 is provided at the radially outer end of the connecting portion between the magnet housing portion 321 and the first filler injection portion 322. The first guiding groove 324 is formed so as to run over a part of the magnet housing portion 321 in the circumferential direction. In other words, the first guiding groove 324 is provided on the radially outer side of the magnet housing portion 321 and the first filler injection portion 322 so as to contact the magnet housing portion 321 and the first filler injection portion 322.

  A second filler injection part 323 is connected and provided at the other circumferential end of the magnet housing part 321. A second guide groove 325 is provided at the radially inner end of the connecting portion between the magnet housing portion 321 and the second filler injection portion 323. The second guide groove 325 is formed so as to run over a part of the magnet housing portion 321 in the circumferential direction. In other words, the second guide groove 325 is provided on the inner side in the radial direction of the magnet housing part 321 and the second filler injection part 323 so as to be in contact with the magnet housing part 321 and the second filler injection part 323.

  That is, the first guiding groove 324 and the second guiding groove 325 are provided at diagonal positions outside the magnet housing portion 321. The guide groove is provided as a filler insertion means for guiding the flow of the filler when the filler is injected into the filler injection portion.

  The permanent magnet 26 is arranged in the magnet housing portion 321 so as to rotate clockwise with respect to the magnet housing portion 321. That is, the permanent magnet 26 is disposed so that the gap between the first guiding groove 324 and the second guiding groove 325 becomes large. Thereby, a tapered gap is formed between the inner wall 326 of the magnet insertion hole 32 on the radially outer side and the long side surface 261 of the permanent magnet 26. A tapered gap is formed between the inner wall 327 of the magnet insertion hole 32 on the radially inner side and the long side surface 262 of the permanent magnet 26.

  An insulating filler 34 is filled between the permanent magnet 26 and the magnet insertion hole 32. Thereby, the permanent magnet 26 is fixed inside the magnet insertion hole 32. The filler 34 is preferably filled in a tapered gap between the inner wall 326 of the radially outer magnet insertion hole 32 and the long side surface 261 of the permanent magnet 26 without a gap. The filler 34 is preferably filled in a tapered gap between the inner wall 327 of the magnet insertion hole 32 on the radially inner side and the long side surface 262 of the permanent magnet 26 without a gap. However, as long as the adhesive strength of the permanent magnet 26 to the rotor core 12 is ensured, the filler 34 may be filled in a state where a gap is left in the tapered gap.

  The permanent magnet 26 is magnetized with the first polarity on the outer side in the radial direction of the two long side surfaces, and the second polarity on the other inner side in the radial direction is different from the first polarity. Is magnetized. Specifically, a pair of permanent magnets 26 included in a certain magnetic pole 24 are magnetized with N polarity on one surface side on the radially outer side and S polarity on the other surface side, and are adjacent to each other in the circumferential direction. The pair of permanent magnets 26 of the magnetic pole 24 has one surface side radially outwardly magnetized to S polarity and the other surface side is N polarity. Therefore, in the permanent magnet 26, the thickness direction perpendicular to the two long side surfaces is a magnetization direction, and the two short side surfaces are side surfaces along the magnetization direction.

  For the filler 34, a thermosetting resin material such as an epoxy resin or a silicone resin is preferably used. However, the present invention is not limited to this, and a thermoplastic resin material may be used as the filler 34. Further, the filler 34 may be mixed with a highly heat conductive filler (for example, silica filler) in order to improve the heat transfer to the rotor core 12 and suppress the temperature rise of the permanent magnet 26. In order to increase the magnetic permeability of 34 and suppress the decrease in the amount of magnetic flux from the permanent magnet 26, a high magnetic permeability filler (for example, iron powder) may be mixed.

  Next, a method for manufacturing a rotor for a rotating electrical machine according to the present embodiment will be described. FIG. 5 is a flowchart illustrating a method for manufacturing the rotor for a rotating electrical machine according to the first embodiment.

Step S11
FIG. 6 is a top view showing the magnet insertion hole 32 after the permanent magnet 26 is inserted. First, as shown in FIG. 6, the permanent magnet 26 is inserted into the magnet insertion hole 32.

Step S12
Next, the filler 34 is injected into the first filler injection part 322 and the second filler injection part 323.

Step S13
FIG. 7 is a top view showing the magnet insertion hole 32 after the filler 34 is filled. When the filler 34 is injected into the first filler injection portion 322, the filler 34 goes around to the long side surface 261 side of the permanent magnet 26 through the first guiding groove 324 as shown in FIG. 7. Therefore, the long side surface 261 of the permanent magnet 26 exposed in the first guiding groove 324 is in contact with the filler 34 and receives the filling pressure F from the filler 34. As a result, the end portion of the permanent magnet 26 on the first filler injection portion 322 side is pressed against the inner wall 327 of the radially inner magnet insertion hole 32 by the filling pressure F.

  When the filler 34 is injected into the second filler injection portion 323, the filler 34 wraps around the long side surface 262 side of the permanent magnet 26 through the second guiding groove 325 as shown in FIG. 7. Therefore, the long side surface 262 of the permanent magnet 26 exposed in the second guide groove 325 is in contact with the filler 34 and receives the filling pressure F from the filler 34. As a result, the end portion of the permanent magnet 26 on the second filler injection portion 323 side is pressed against the inner wall 326 of the radially outer magnet insertion hole 32 by the filling pressure F.

  That is, since the filling pressure F acts on the diagonal position of the permanent magnet from the opposite direction, the permanent magnet 26 rotates in the clockwise direction.

Step S14
FIG. 8 is a top view showing the magnet insertion hole 32 after a predetermined time has elapsed since the filling material 34 was filled. After a certain period of time, the corners of the permanent magnet 26 come into contact with the inner walls 326 and 327 of the radially inner magnet insertion hole 32, and the permanent magnet 26 stops. As a result, as shown in FIG. 8, between the inner wall 326 of the radially outer magnet insertion hole 32 and the permanent magnet 26 and between the inner wall 327 of the radially inner magnet insertion hole 32 and the permanent magnet 26. A tapered gap is formed. The filler 34 infiltrates the tapered gap in the circumferential direction of the rotor core 12. Thereby, the filler 34 is filled into the tapered gap.

Step S15
And the permanent magnet 26 is fixed to the position shown in FIG. 4 by hardening the filler 34 as it is. Through the above procedure, the permanent magnet 26 is tilted and fixed inside the magnet insertion hole 32.

As described above, according to the present embodiment, it is possible to easily fix the permanent magnet to the inside of the magnet insertion hole by inclining the axial direction of the rotor core only by filling the filler. Thereby, the contact area of a permanent magnet and a rotor core can be reduced, and the eddy current loss of a magnet can be suppressed.
Further, since the permanent magnet receives the filling pressure from both directions, it is possible to reduce the pressure of pressing the permanent magnet against the inner wall in the magnet insertion hole.

Embodiment 2
A magnet mold fixing method according to the second embodiment will be described. In the second embodiment, the shape of the magnet insertion hole is different from that in the first embodiment. Hereinafter, the magnet insertion hole 35 according to the present embodiment will be described.

  FIG. 9 is a top view showing the permanent magnet 26 when the magnet insertion hole 35 is looked down on. The magnet insertion hole 35 includes a magnet housing part 321, a first filler injection part 322, a second filler injection part 323, a first protrusion 351, and a second protrusion 352. Since the magnet accommodating part 321, the 1st filler injection | pouring part 322, and the 2nd filler injection | pouring part 323 are the same as that of Embodiment 1, description is abbreviate | omitted.

  The first protrusion 351 protrudes radially outward from the inner wall 327 of the magnet insertion hole 35 on the radially inner side along the short side of the magnet housing portion 321. The second protrusion 352 protrudes radially inward from the inner wall 326 of the magnet insertion hole 35 on the radially outer side along the short side of the magnet housing portion 321. The first protrusion 351 and the second protrusion 352 are provided at a position that does not hinder the storage of the permanent magnet 26 in the magnet storage portion 321.

  That is, the first protrusion 351 and the second protrusion 352 are provided at diagonal positions outside the magnet housing portion 321. The protrusion is provided as a filler insertion means for guiding the flow of the filler when the filler is injected into the filler injection portion.

  The permanent magnet 26 is arranged in the magnet housing portion 321 so as to rotate clockwise with respect to the magnet housing portion 321. That is, the permanent magnet 26 is arranged so that the gap on the opposite side to the first protrusion 351 and the second protrusion 352 becomes large. Thereby, a tapered gap is formed between the inner wall 326 of the magnet insertion hole 35 on the radially outer side and the long side surface 261 of the permanent magnet 26. A tapered gap is formed between the inner wall 327 of the radially inner magnet insertion hole 35 and the long side surface 262 of the permanent magnet 26.

  Next, a method for manufacturing a rotor for a rotating electrical machine according to the present embodiment will be described. FIG. 10 is a flowchart illustrating a method for manufacturing the rotor for a rotating electrical machine according to the second embodiment.

Step S21
FIG. 11 is a top view showing the magnet insertion hole 35 after the permanent magnet 26 is inserted. First, as shown in FIG. 11, the permanent magnet 26 is inserted into the magnet insertion hole 35.

Step S22
Next, the filler 34 is injected into the first filler injection part 322 and the second filler injection part 323.

Step S23
FIG. 12 is a top view showing the magnet insertion hole 35 after the filler 34 is filled. When the filler 34 is injected into the first filler injection portion 322, the filler 34 is blocked by the first protrusion 351 and goes around to the long side surface 261 side of the permanent magnet 26, as shown in FIG. 12. Therefore, the long side surface 261 of the permanent magnet 26 on the first filler injection portion 322 side is in contact with the filler 34 and receives the filling pressure F from the filler 34. As a result, the end portion of the permanent magnet 26 on the first filler injection portion 322 side is pressed against the inner wall 327 of the radially inner magnet insertion hole 35 by the filling pressure F.

  When the filler 34 is injected into the second filler injection portion 323, the filler 34 is blocked by the second protrusions 352 and goes around to the long side surface 262 side of the permanent magnet 26 as shown in FIG. 12. Therefore, the long side surface 262 of the permanent magnet 26 on the second filler injection portion 323 side is in contact with the filler 34 and receives the filling pressure F from the filler 34. As a result, the end of the permanent magnet 26 on the second filler injection portion 323 side is pressed against the inner wall 326 of the magnet insertion hole 35 on the radially outer side by the filling pressure F.

  That is, since the filling pressure F acts on the diagonal position of the permanent magnet from the opposite direction, the permanent magnet 26 rotates in the clockwise direction.

Step S24
FIG. 13 is a top view showing the magnet insertion hole 35 after a predetermined time has elapsed since the filling material 34 was filled. After a certain period of time, the corners of the permanent magnet 26 come into contact with the inner walls 326 and 327 of the radially inner magnet insertion hole 35, and the permanent magnet 26 stops. As a result, as shown in FIG. 13, between the inner wall 326 of the radially outer magnet insertion hole 35 and the permanent magnet 26 and between the inner wall 327 of the radially inner magnet insertion hole 35 and the permanent magnet 26. A tapered gap is formed. The filler 34 infiltrates the tapered gap in the circumferential direction of the rotor core 12. Thereby, the filler 34 is filled into the tapered gap.

Step S25
And the permanent magnet 26 is fixed to the position shown in FIG. 9 by hardening the filler 34 as it is. Through the above procedure, the permanent magnet 26 is fixed inside the magnet insertion hole 35.

  As described above, according to the present embodiment, as in the first embodiment, the permanent magnet is easily fixed inside the magnet insertion hole by being inclined with respect to the axial direction of the rotor core only by filling the filler. be able to. Thereby, the contact area of a permanent magnet and a rotor core can be reduced, and the eddy current loss of a magnet can be suppressed.

Embodiment 3
A magnet mold fixing method according to the third embodiment will be described. In the third embodiment, the shape of the magnet insertion hole is different from that in the first and second embodiments. Hereinafter, the magnet insertion hole 36 according to the present embodiment will be described.

  FIG. 14 is a top view showing the permanent magnet 26 when the magnet insertion hole 36 is looked down on. The magnet insertion hole 36 includes a magnet housing part 321, a first filler injection part 322, a second filler injection part 323, a first guide groove 324, a second guide groove 325, a first protrusion 351, and a second protrusion 352. .

  The magnet accommodating part 321, the first filler injecting part 322, the second filler injecting part 323, the first guiding groove 324 and the second guiding groove 325 are the same as in the first embodiment. The first protrusion 351 and the second protrusion 352 are the same as in the second embodiment. That is, the magnet insertion hole 36 has both the guide groove according to the first embodiment and the protrusion according to the second embodiment as the filling pressure control means.

  As described above, according to the present embodiment, it is possible to easily fix the permanent magnet in the magnet insertion hole by inclining the axial direction of the rotor core only by filling the filler. In addition, according to the present embodiment, the permanent magnet can be easily fixed by being inclined with respect to the axial direction of the rotor core inside the magnet insertion hole, more effectively than in the first and second embodiments. Thereby, the contact area of a permanent magnet and a rotor core can be reduced, and the eddy current loss of a magnet can be suppressed.

Embodiment 4
A magnet mold fixing method according to the fourth embodiment will be described. The fourth embodiment is a modification of the third embodiment. In this example, the magnet insertion hole 41 is provided penetrating in the axial direction of the rotor core. The guiding grooves and the protrusions are provided at diagonal positions between the front and back surfaces of the rotor core with the permanent magnet 26 interposed therebetween.

  FIG. 15 is a top view showing the permanent magnet 26 when the magnet insertion hole 41 is looked down on. 16 is a cross-sectional view of the magnet insertion hole 41 and the permanent magnet in the AA cross section of FIG. The magnet insertion hole 41 includes a magnet housing part 321, a first filler injection part 322, and a second filler injection part 323.

  When viewed from the front side, the long side surface 261 of the permanent magnet 26 is separated from the inner wall 326 of the magnet insertion hole 32 on the radially outer side. The long side surface 262 of the permanent magnet 26 is in contact with the inner wall 327 of the magnet insertion hole 32 on the radially inner side.

  When viewed from the back side, the long side surface 262 of the permanent magnet 26 is separated from the inner wall 327 of the magnet insertion hole 32 on the radially inner side. The long side surface 261 of the permanent magnet 26 is in contact with the inner wall 326 of the radially outer magnet insertion hole 32.

  A third guide groove 411 and a fourth guide groove 412 are provided in the magnet insertion hole 41 on the surface side of the rotor core. A third guide groove 411 is provided at the radially inner end of the connecting portion between the magnet housing portion 321 and the first filler injection portion 322. The 3rd invitation groove 411 is formed so that it may ride on a part of magnet accommodating part 321 in the circumferential direction. In other words, the third guiding groove 324 is provided on the radially outer side of the magnet housing portion 321 and the first filler injection portion 322 so as to be in contact with the magnet housing portion 321 and the first filler injection portion 322.

  A fourth guide groove 412 is provided at the radially inner end of the connecting portion between the magnet housing portion 321 and the second filler injection portion 323. The 4th invitation groove 412 is formed so that it may run over a part of magnet accommodating part 321 in the circumferential direction. In other words, the fourth guide groove 412 is provided on the radially outer side of the magnet housing portion 321 and the first filler injection portion 322 so as to be in contact with the magnet housing portion 321 and the first filler injection portion 322.

  The magnet insertion hole 41 on the back side of the rotor core is provided with a fifth guiding groove 413 and a sixth guiding groove 414. A fifth guide groove 413 is provided at the radially outer end of the connecting portion between the magnet housing portion 321 and the first filler injection portion 322. The fifth guide groove 413 is formed so as to run over a portion of the magnet housing portion 321 in the circumferential direction. In other words, the fifth guide groove 413 is provided on the radially inner side of the magnet housing portion 321 and the first filler injection portion 322 so as to contact the magnet housing portion 321 and the first filler injection portion 322.

  A sixth guide groove 414 is provided at the radially outer end of the connecting portion between the magnet housing part 321 and the first filler injection part 322. The sixth guide groove 414 is formed so as to run over a portion of the magnet housing portion 321 in the circumferential direction. In other words, the sixth guiding groove 414 is provided on the radially inner side of the magnet housing portion 321 and the first filler injection portion 322 so as to be in contact with the magnet housing portion 321 and the first filler injection portion 322.

  When viewed in a cross section, the third guiding groove 411 and the fourth guiding groove 412 on the front surface side, and the fifth guiding groove 413 and the sixth guiding groove 414 on the back surface side are arranged to face each other with the permanent magnet 26 interposed therebetween. The

  Next, a method for manufacturing a rotor for a rotating electrical machine according to the present embodiment will be described. FIG. 17 is a flowchart illustrating a method for manufacturing the rotor for a rotating electrical machine according to the fourth embodiment.

Step S41
18 is a view showing a cross section of the magnet insertion hole 41 and the permanent magnet 26 in the AA cross section of FIG. 15 after the permanent magnet 26 is inserted into the magnet insertion hole 41. As shown in FIG. First, as shown in FIG. 18, the permanent magnet 26 is inserted into the magnet insertion hole 41.

Step S42
Next, the filler 34 is injected into the first filler injection part 322 and the second filler injection part 323.

Step S43
FIG. 19 is a view showing a cross section of the magnet insertion hole 41 and the permanent magnet 26 in the AA cross section of FIG. 15 after the magnet insertion hole 41 is filled with the filler 34. When the filler 34 is injected into the first filler injection part 322 and the second filler injection part 323 from the surface side, the filler 34 passes through the third guiding groove 411 and the fourth guiding groove 412 on the surface side, and becomes a permanent magnet. 26 around the long side surface 261 side. Therefore, the long side surface 261 of the permanent magnet 26 exposed in the third guiding groove 411 and the fourth guiding groove 412 is in contact with the filler 34 and receives the filling pressure F from the filler 34. As a result, the end portion of the surface-side permanent magnet 26 is pressed against the inner wall 327 of the radially inner magnet insertion hole 32 by the filling pressure F.

  On the other hand, when the filler 34 is injected into the first filler injection part 322 and the second filler injection part 323 from the back side, the filler 34 passes through the fifth guide groove 413 and the sixth guide groove 414 on the back side, The permanent magnet 26 wraps around the long side surface 262 side. Therefore, the long side surface 262 of the permanent magnet 26 exposed in the fifth guiding groove 413 and the sixth guiding groove 414 comes into contact with the filler 34 and receives the filling pressure F from the filler 34. As a result, the end portion of the permanent magnet 26 on the back surface side is pressed against the inner wall 326 of the magnet insertion hole 32 on the radially outer side by the filling pressure F.

  That is, since the filling pressure F acts on the diagonal position of the permanent magnet from the opposite direction, the permanent magnet 26 rotates in the clockwise direction.

Step S44
FIG. 20 is a diagram illustrating a cross section of the magnet insertion hole 41 and the permanent magnet 26 in the AA cross section of FIG. 15 after a predetermined time has elapsed since the filler 34 was filled in the magnet insertion hole 41. After a certain period of time, the inner wall 327 of the magnet insertion hole 41 comes into contact with one side of the permanent magnet 26 on the surface side. Further, the inner wall 326 of the magnet insertion hole 41 and one side of the permanent magnet 26 on the back surface side are in contact with each other. Thereby, the permanent magnet 26 is stationary. As a result, as shown in FIG. 20, between the inner wall 326 of the radially outer magnet insertion hole 41 and the permanent magnet 26 and between the inner wall 327 of the radially inner magnet insertion hole 41 and the permanent magnet 26. A tapered gap is formed. The filler 34 infiltrates the tapered gap in the axial direction of the rotor core 12. Thereby, the filler 34 is filled into the tapered gap.

Step S45
And the permanent magnet 26 is fixed to the position shown in FIG. 16 by hardening the filler 34 as it is. The permanent magnet 26 is fixed inside the magnet insertion hole 32 by the above procedure.

  As described above, according to the present embodiment, it is possible to easily fix the permanent magnet in the magnet insertion hole by inclining the axial direction of the rotor core only by filling the filler. Thereby, the contact area of a permanent magnet and a rotor core can be reduced, and the eddy current loss of a magnet can be suppressed.

  Note that the present invention is not limited to the above-described embodiment, and can be changed as appropriate without departing from the spirit of the present invention. For example, in the fourth embodiment, the example in which the guide groove is formed in the magnet insertion hole provided on the front surface and the back surface of the rotor core 12 has been described. This is only an example. For example, in the fourth embodiment, similarly to the second embodiment, a protrusion may be provided instead of the guide groove. In the fourth embodiment, both the guiding groove and the protrusion may be provided as in the second embodiment.

DESCRIPTION OF SYMBOLS 10 Rotor 11 Stator 12 Rotor core 13 Outer peripheral surface 14 Shaft 15 Flange part 16 End plate 18 Fixing member 20 Fixing part 22 Pressing part 23 Shaft hole 24 Magnetic pole 26 Permanent magnet 32, 35, 36, 41 Magnet insertion hole 34 Filler 35 Magnet Insertion hole 36 Magnet insertion hole 41 Magnet insertion holes 261, 262 Long side surface 321 Magnet housing part 322 First filler injection part 323 Second filler injection part 324 First guide groove 325 Second guide groove 326, 327 Inner wall 351 First 1 protrusion 352 2nd protrusion 411 3rd invitation groove 412 4th invitation groove 413 5th invitation groove 414 6th invitation groove C Magnetic pole center line

Claims (6)

A permanent magnet is inserted into the magnet accommodating portion of the magnet insertion hole of the rotor core formed by extending the magnet insertion hole in the axial direction,
Filler material is injected into filler injection portions provided at both ends of the magnet housing portion in the circumferential direction of the rotor core at both end surfaces in the axial direction of the rotor core of the magnet housing portion,
The more filler introduction means provided in contact with the circumferential direction of the both ends to the filler material injection unit, the magnet insertion hole a filling material filled with said permanent magnet to said filler injecting portion of the magnet containing portion Lead to the gap between
By the filler introduction means,
The filler is guided to a first surface of the permanent magnet facing the radial direction of the rotor core at one end in the circumferential direction of the magnet insertion hole, and the permanent magnet is sandwiched at the other circumferential end of the magnet insertion hole. The permanent magnet is inclined with respect to the magnet insertion hole with the axial direction as a rotation axis by guiding the filler to the second surface of the permanent magnet facing in
The filler is guided to the first surface of the permanent magnet at both ends of the magnet insertion hole on the first end surface, which is one end surface in the axial direction of the rotor core, and the other end surface in the axial direction of the rotor core The filler is guided to the second surface of the permanent magnet at both ends in the circumferential direction of the magnet insertion hole of the second end surface that is, with respect to the magnet insertion hole with the circumferential direction as a rotation axis. Tilting the permanent magnet;
After the permanent magnet is inclined with respect to the magnet insertion hole, the filler is cured.
A method of manufacturing a rotor for a rotating electrical machine. By the filler introduction means, the filler is guided to the first surface of the permanent magnet at one end in the circumferential direction of the magnet insertion hole, and the permanent magnet at the other end in the circumferential direction of the magnet insertion hole. When the permanent magnet is inclined with respect to the magnet insertion hole with the axial direction as a rotation axis by guiding the filler to the second surface,
The filler introduction means are guide grooves provided at both ends in the circumferential direction of the magnet insertion hole,
The guiding groove provided at one end in the circumferential direction of the magnet insertion hole is provided at a position where the filler is brought into contact with the first surface of the permanent magnet,
The guide groove provided at the other circumferential end of the magnet insertion hole is provided at a position where the filler is brought into contact with the second surface of the permanent magnet.
The manufacturing method of the rotor for rotary electric machines of Claim 1. The guide groove is provided through the rotor core in the axial direction of the rotor core.
The manufacturing method of the rotor for rotary electric machines of Claim 2. By the filler introduction means, the filler is guided to the first surface of the permanent magnet at one end in the circumferential direction of the magnet insertion hole, and the permanent magnet at the other end in the circumferential direction of the magnet insertion hole. When the permanent magnet is inclined with respect to the magnet insertion hole with the axial direction as a rotation axis by guiding the filler to the second surface,
The filler introduction means are protrusions that are provided at both ends in the circumferential direction of the magnet insertion hole and project from the inner wall of the magnet insertion hole,
The protrusion provided at one end of the magnet insertion hole in the circumferential direction is provided at a position where the filler is prevented from contacting the second surface of the permanent magnet, thereby blocking the filler. Guiding the filler to the gap between the first surface of the permanent magnet and the permanent magnet;
The circumferential direction of the projection provided on the other end of the magnet insertion holes, the filling material the provided et al is in a position to prevent contact with the first surface of the permanent magnet, to prevent the filler The filler is guided to the gap between the second surface of the permanent magnet and the permanent magnet.
The manufacturing method of the rotor for rotary electric machines as described in any one of Claims 1 thru | or 3. The filler is guided to the first surface of the permanent magnet at both ends of the magnet insertion hole on the first end surface of the rotor core by the filler introduction means, and the magnet on the second end surface of the rotor core In the case where the permanent magnet is inclined with respect to the magnet insertion hole with the circumferential direction as a rotation axis by guiding the filler to the second surface of the permanent magnet at both ends in the circumferential direction of the insertion hole,
The filler introduction means are guide grooves provided at both ends in the circumferential direction of the magnet insertion hole,
The guide grooves provided at both ends in the circumferential direction of the magnet insertion hole of the first end surface of the rotor core are provided at positions where the filler is brought into contact with the first surface of the permanent magnet;
The guiding grooves provided at both ends in the circumferential direction of the magnet insertion hole of the second end surface of the rotor core are provided at positions where the filler is brought into contact with the second surface of the permanent magnet.
The manufacturing method of the rotor for rotary electric machines of Claim 1. Rotor core,
A magnet insertion hole having a magnet housing portion formed by extending in the axial direction of the rotor core;
A permanent magnet that is inserted into the magnet insertion hole and is inclined and fixed with respect to the magnet insertion hole;
A filler for fixing the permanent magnet;
A filler injecting portion provided at both ends of the magnet housing portion in the circumferential direction of the rotor core and into which the filler is injected;
A filler introduction means provided at both ends of the magnet housing portion in the circumferential direction in contact with the filler injection portion and guiding the filler filled in the filler injection portion;
The filler introduction means guides the filler to a first surface of the permanent magnet facing the radial direction of the rotor core at one end in the circumferential direction of the magnet insertion hole, and the other direction in the circumferential direction of the magnet insertion hole. At the end, the permanent magnet is inclined with respect to the magnet insertion hole with the axial direction as a rotation axis by guiding the filler to the second surface of the permanent magnet facing the permanent magnet, or
The filler is guided to the first surface of the permanent magnet at both ends of the magnet insertion hole on one end surface in the axial direction of the rotor core, and the magnet insertion hole on the other end surface in the axial direction of the rotor core is guided. By guiding the filler to the second surface of the permanent magnet at both ends in the circumferential direction, the permanent magnet is inclined with respect to the magnet insertion hole with the circumferential direction as a rotation axis.
Rotor for rotating electrical machines.

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