JP6218576B2 - Rotating electric machine rotor, rotating electric machine, manufacturing method of rotor, manufacturing method of rotating electric machine, iron core member of rotor - Google Patents

Description

  The present invention relates to a rotor of a rotating electrical machine using a permanent magnet mainly used in an air conditioner, a home appliance, etc., a rotating electrical machine, a manufacturing method of the rotor, a manufacturing method of the rotating electrical machine, and an iron core member of the rotor. is there.

  In general, an air conditioner that performs air conditioning such as cooling and heating as one of the electric devices includes a fan for blowing air and a rotating electrical machine for rotationally driving the fan. In recent years, brushless DC motors that are superior in maintenance and energy efficiency are often employed as rotating electrical machines used in such devices.

  In this brushless DC motor, an inverter of a pulse width modulation type (hereinafter referred to as PWM method) is used. When a brushless DC motor, which is a rotating electrical machine, is driven by a PWM inverter, the neutral point potential of the winding does not become zero, so a potential difference (hereinafter referred to as shaft voltage) is generated between the outer ring and the inner ring of the bearing. Let The shaft voltage includes a high-frequency component due to switching of the inverter. When the shaft voltage reaches the dielectric breakdown voltage of the oil film inside the bearing, a minute current flows inside the bearing, and electrolytic corrosion occurs inside the bearing. It is known that when electric corrosion progresses, wavy wear reduction occurs in the bearing inner ring, bearing outer ring, or bearing ball, and the motor noise gradually increases.

  In a rotor of a rotating electrical machine according to Patent Document 1, a permanent magnet, a rotor yoke, and a boss are molded with resin, and these are fixed. On the inner periphery of the rotor yoke, there is provided a boss that is fitted with the output shaft at a certain distance and serves as an output transmission portion. With this configuration, the rotor yoke and the output shaft are insulated from each other, the current generated in the rotor yoke is not transmitted to the output shaft, and the electric corrosion of the bearing, which causes drive noise, is less likely to occur.

Japanese Patent No. 4552267 (page 4, [0028] paragraph, FIG. 2)

  By the way, in the invention according to Patent Document 1, the rotor yoke and the output shaft are fitted together, and the boss serving as the output transmission portion has a substantially arc shape, and the rotor yoke and the boss have an integral structure in each case. The rotor yoke and boss are punched with the same arrangement as in the case of using a single press die.

  If such a structure and manufacturing method of a rotating electrical machine are employed, the material between the rotor yoke and the boss is wasted, which increases the manufacturing cost of the rotor. In addition, in the case of an SPM (Surface Permanent Magnet) type rotor in which a permanent magnet is attached to the outer peripheral surface of the rotor yoke, the thickness of the rotor yoke may be such that it does not become magnetically saturated. The difference between the inner diameter of the child yoke and the outer diameter of the boss increases, which causes further deterioration of the material yield.

  The present invention has been made to solve the above-described problems, and can suppress electric corrosion of bearings and the like, and can reduce the amount of material used for the rotor yoke (outer iron core) and the boss portion (inner iron core). An object of the present invention is to provide a rotor for a rotating electrical machine, a rotating electrical machine, a manufacturing method for the rotor, a manufacturing method for the rotating electrical machine, and an iron core member for the rotor.

The rotor of the rotating electrical machine according to the present invention is:
A cylindrical laminated rotor core constituted by laminating iron core pieces, and a permanent magnet held at equal intervals in the circumferential direction on the laminated rotor core,
In the rotor of the rotating electrical machine having a rotating shaft inserted in the center of the laminated rotor core,
The laminated rotor core includes a laminated inner core to which a rotation shaft is fastened,
A laminated outer core disposed so as to surround the laminated inner iron core and divided into a plurality of divided laminated outer iron cores in the circumferential direction;
Formed between the laminated inner iron core and the laminated outer iron core, and comprising a connecting member for coupling the laminated inner iron core and the laminated outer iron core,
A hollow portion having the same shape as the divided laminated outer core is formed inside the laminated inner core.

The rotating electrical machine according to this invention is
The rotor of the rotating electrical machine described above;
An annular yoke portion, a teeth portion protruding inward from the yoke portion, and a stator winding wound around the teeth portion;
The rotor includes a stator that houses the rotor inside.

The manufacturing method of the rotor according to the present invention is as follows:
A cylindrical laminated rotor core configured by laminating core pieces, and a permanent magnet held at equal intervals in the circumferential direction on the laminated rotor core,
A rotor manufacturing method comprising a rotating shaft inserted into the center of the laminated rotor core,
An inner core piece constituting a laminated inner core to which the rotating shaft is fastened;
When it is arranged so as to surround the periphery of the laminated inner iron core, and the divided outer iron core pieces constituting the laminated outer iron core divided into a plurality of divided laminated outer iron cores in the circumferential direction are cut out from the same plate material,
It has an iron core piece cutting process which cuts out the division | segmentation outer side iron core piece from the inside of the said inner side iron core piece.

A method of manufacturing a rotating electrical machine according to the present invention includes:
In the above-described rotor manufacturing method,
The core pieces for one layer of the stator that houses the rotor are cut out simultaneously from the plate material.

The core member of the rotor according to the present invention is:
A core member for a laminated rotor core of a rotor composed of a plurality of core pieces,
Among the laminated rotor cores, one inner core piece constituting one layer of a laminated inner core having a rotating shaft insertion portion,
Each of the plurality of divided laminated outer cores that are equally divided in the circumferential direction of the laminated outer cores joined to the outer circumference of the laminated inner cores via an insulating connecting member constitutes the same layer as the one layer. Sheet, consisting of the same number of divided outer core pieces as the number of the divided laminated outer cores,
Of the divided outer core pieces, at least two of the divided outer core pieces are cut out from the inside of the inner core pieces.

According to the rotor of the rotating electrical machine, the rotating electrical machine, the manufacturing method of the rotor, the manufacturing method of the rotating electrical machine, and the iron core member of the rotor according to the present invention, the rotor yoke and the output shaft are insulated from each other. The current generated in the yoke is not transmitted to the output shaft, and it is difficult for the electric corrosion of the bearing, which causes drive noise of the rotating electrical machine, to occur.
Furthermore, since the divided outer core piece is cut out from the inner part of the inner core piece of the magnetic material from which the iron core member is cut out, the material used for the rotor core can be reduced compared to the previous example, and an inexpensive rotating electrical machine can be used. A rotor and a rotating electrical machine can be provided.

1 is a schematic cross-sectional view of a rotary electric machine according to Embodiment 1 of the present invention. It is a perspective view of the rotor of the rotary electric machine shown in FIG. It is sectional drawing which cut | disconnected the rotor shown in FIG. 2 by the plane which passes along the central axis of a rotating shaft, and sectional drawing in the AA line of Fig.3 (a). The top view of the stator core piece which comprises the stator core which concerns on Embodiment 1 of this invention, the figure which shows the layout of each core piece on the board | plate material at the time of punching out a stator core piece, The top view of a lamination | stacking stator It is. It is the top view of the division | segmentation laminated | stacked outer core of the rotary electric machine which concerns on Embodiment 1 of this invention, and the top view of a lamination | stacking outer iron core. It is the top view and sectional drawing of the lamination | stacking outer side iron core laminated | stacked and fitted in the metal mold | die. It is a figure which shows the layout of each core piece on the board | plate material at the time of punching out the core piece which comprises one lamination | stacking of the lamination | stacking rotor core which concerns on Embodiment 1 of this invention with a press. It is a schematic diagram which shows arrangement | positioning before the coupling | bonding of a some division | segmentation laminated | stacked outer side iron core. It is another example figure which shows the layout of each core piece on the board | plate material at the time of punching out the core piece which comprises one lamination | stacking of the lamination | stacking rotor core which concerns on Embodiment 1 of this invention with a press. It is sectional drawing etc. (comparative example) of the rotor which has an inner side iron core and an integrated outer side iron core. It is a figure (comparative example) which shows the layout of each iron core piece on the board | plate material at the time of punching a division | segmentation outer side iron core piece and an inner side iron core piece with a separate press die. It is sectional drawing of the rotor which concerns on this Embodiment 2 of this invention. It is a figure which shows the layout of each core piece on the board | plate material in the press metal mold | die which punches out the core piece for rotors concerning this Embodiment 2 of this invention. It is sectional drawing of the rotor which concerns on this Embodiment 3 of this invention. It is a figure which shows the layout of each core piece on the board | plate material in the press die which punches out the core piece for rotors which concerns on this Embodiment 3 of this invention. It is a top view of the division | segmentation lamination | stacking outer side iron core which concerns on Embodiment 1 of this invention. It is a top view of the division | segmentation lamination | stacking outer side iron core which concerns on Embodiment 4 of this invention. It is a top view which shows the other example of the division | segmentation lamination | stacking outer side iron core which concerns on Embodiment 4 of this invention. It is sectional drawing of the rotor which concerns on this Embodiment 5 of this invention. It is sectional drawing of the rotor which concerns on this Embodiment 6 of this invention, and AA sectional drawing of Fig.20 (a). It is sectional drawing of the rotor which concerns on this Embodiment 7 of this invention. It is a figure which shows the layout of each core piece on the board | plate material in the press die which punches out the core piece for rotors concerning this Embodiment 7 of this invention. It is sectional drawing of the rotor which concerns on this Embodiment 8 of this invention. It is a figure which shows the layout of each core piece on the board | plate material in the press die which punches out the core piece for rotors concerning this Embodiment 8 of this invention. It is a top view of the division | segmentation lamination | stacking outer side iron core which concerns on Embodiment 9 of this invention. It is sectional drawing of the rotor which concerns on this Embodiment 9 of this invention. It is a figure which shows the layout of each core piece on the board | plate material in the press die which punches out the core piece for rotors which concerns on this Embodiment 9 of this invention. It is a top view of the division | segmentation lamination | stacking outer side iron core which concerns on Embodiment 10 of this invention. It is sectional drawing of the rotor which concerns on this Embodiment 10 of this invention. It is a figure which shows the layout of each core piece on the board | plate material in the press die which punches out the core piece for rotors which concerns on this Embodiment 10 of this invention. It is a top view of the division | segmentation lamination | stacking stator unit core of the rotary electric machine which concerns on this Embodiment 11 of this invention. It is a top view of the lamination | stacking stator core which arrange | positioned the four division | segmentation lamination | stacking stator unit iron cores concerning this Embodiment 11 of this invention cyclically | annularly. Layout of each core piece on a plate material in a press mold for punching out one core piece constituting a core of a rotor and a single core piece constituting a split stator unit core according to the eleventh embodiment of the present invention FIG.

Embodiment 1 FIG.
Hereinafter, a rotor of a rotating electrical machine, a rotating electrical machine, a manufacturing method of the rotor, a manufacturing method of the rotating electrical machine, and a core member of the rotor according to Embodiment 1 of the present invention will be described with reference to the drawings. Unless otherwise specified, the “circumferential direction”, “radial direction”, and “axial direction” used in this specification are the “circumferential direction”, “radial direction”, and “axial direction” of the rotor and the rotating electrical machine. ".
FIG. 1 is a schematic cross-sectional view of a rotating electrical machine 100 according to Embodiment 1 of the present invention. The rotating electrical machine 100 is a brushless DC motor.
FIG. 2 is a perspective view of the rotor 1 used in the rotating electrical machine 100.
FIG. 3A is a cross-sectional view of the rotor 1 cut along a plane that passes through the central axis of the rotary shaft 12.
FIG. 3B is a cross-sectional view taken along line AA in FIG.
The rotating electrical machine 100 (brushless DC motor) is driven by the PWM method. In the present embodiment, an example of an inner rotor type brushless DC motor in which the rotor 1 is rotatably arranged on the inner peripheral side of the stator 2 will be described. Further, in the present embodiment, the permanent magnet 3 is an SPM type rotor attached to the surface of the rotor core, and the number of magnets is ten.

  As shown in FIG. 1, a stator winding 22 is wound around a split laminated stator core 21 via an insulator made of an insulating material. The stator winding 22 is electrically connected to a PWM inverter. The stator 2 has a cylindrical shape in which a laminated stator core 20, a stator winding 22 and an insulator are molded with resin.

FIG. 4A is a plan view of the stator core piece 4 constituting the laminated stator core 20.
FIG. 4B is a diagram showing a layout when a plurality of stator core pieces 4 are punched out of a magnetic steel plate with a press.
FIG. 4C is a plan view of the laminated stator core 20.
As shown in FIG. 4 (b), the stator core pieces 4 are punched out from a magnetic steel plate (hereinafter referred to as a plate material) by two rows by pressing. At this time, the stator core pieces 4 of the two rows are arranged so that the portions of the tooth portions 4a of the other row are alternately opposed to each other between the adjacent teeth portions 4a of the one row.

The laminated stator core 20 is configured by combining twelve divided laminated stator cores 21 in which a plurality of stator core pieces 4 are laminated in an annular shape. Each member is integrally fixed by adhesion, welding, caulking or the like.

  The divided laminated stator core 21 has a substantially T-shape as a whole, and includes a laminated tooth portion 21a and a laminated yoke portion 21b. The laminated tooth portion 21a extends in a radial direction at a substantially right angle from the inner peripheral side of the laminated yoke portion 21b, and the outer peripheral portion of the laminated yoke portion 21b has an arc shape. Moreover, the both ends of the front-end | tip part 21c of the inner peripheral side of the lamination | stacking tooth | gear part 21a are umbrella shape which spreads right and left, and the front-end | tip part 21c is circular arc shape.

  As shown in FIG. 1, the stator windings 22 are applied to the plurality of divided laminated stator cores 21 obtained in this way, and then arranged in a ring shape, and the contact surfaces are fixed by adhesion, welding, or the like. Can be obtained. By adopting the above-described arrangement at the time of manufacturing the stator core pieces 4, it is possible to reduce the amount of material used for manufacturing the laminated stator core 20 compared to the case where the stator core pieces are punched in a row.

  As shown in FIGS. 1 and 2, the rotor 1 is inserted on the inner peripheral side of the stator 2 through a gap. The rotor 1 includes a permanent magnet 3, a laminated outer iron core 50 that forms the outer part of the laminated rotor core 5, a connecting member 52 made of resin, and the like, from the outermost peripheral portion toward the inner peripheral rotation shaft 12. It is comprised from the lamination | stacking inner side iron core 53 which comprises the inner side part of the core iron core 5. FIG.

  The rotating shaft 12 is inserted through the central portion of the laminated inner core 53. The rotary shaft 12 is knurled, and is coupled to the laminated inner core 53 by fitting it to the laminated inner core 53. With such a configuration, the laminated outer iron core 50 and the rotary shaft 12 are insulated from each other, and the current generated in the laminated outer iron core 50 is not transmitted to the rotary shaft 12, so that the electric corrosion of the bearing causing noise is generated. It becomes difficult to do.

  Each of the laminated inner iron core 53 and the laminated outer iron core 50 is configured by laminating a plurality of thin plate-like core pieces. These iron core pieces are integrally fixed by adhesion, welding, caulking or the like (not shown). The outer peripheral surface of the laminated inner iron core 53 and the inner peripheral surface of the laminated outer iron core 50 are joined by being integrally formed with a connecting member 52 made of resin or the like.

  The permanent magnet 3 is bonded to the outer periphery of the laminated outer core 50 with an adhesive. In the present embodiment, ten permanent magnets 3 are equally arranged in the circumferential direction around the rotating shaft 12. The laminated outer core 50 is divided into a plurality of divided laminated outer cores 51 in the circumferential direction. In the present embodiment, the laminated outer core 50 is divided into ten divided laminated outer cores 51 that are the same as the number of permanent magnets 3.

FIG. 5A is a plan view of the split laminated outer core 51.
FIG. 5B is a plan view of a laminated outer iron core 50 in which a plurality of divided laminated outer iron cores 51 are annularly fitted.
The split laminated outer iron core 51 is fitted with a dovetail recess 51p and a dovetail protrusion 51q provided at each circumferential end. The recess 51p is formed as a dovetail extending in the axial direction inside the split laminated outer iron core 51, and the radial width (dimension L2) on the circumferential end side of the split laminated outer iron core 51 is from the circumferential end. It is set to be larger than the radial width (dimension L1) at the far end.

  The convex portion 51q protrudes from the divided laminated outer core 51 in the circumferential direction and is formed as a dovetail extending in the axial direction. The radial width at the root portion of the divided laminated outer core 51 is L1 as described above, and the diameter at the tip portion. The width in the direction is the above-described dimension L2. At this time, if L1 <L2, the positioning of each divided laminated outer core 51 is facilitated, and further, there is an effect that each divided laminated outer core 51 does not come out in the radial direction of the rotating shaft 12.

  Further, the inner circumferential side of the divided laminated outer core 51 is provided with a rotation stopper recess 51t formed toward the radially outer side. Thereby, the connection member 52 which is resin can mesh, and the rotation of the circumferential direction by rotation reaction force can be prevented. In this example, the anti-rotation recess 51t is used, but the anti-rotation effect can be obtained even when the protrusion is a convex portion. In addition, if it is set as a recessed part, the rotor core yield will be higher, and if it is set as a projected part, the force of rotation prevention can be taken largely. The one that is advantageous for the rotating electrical machine to be manufactured may be selected. Furthermore, the same recessed part 53t is provided in the axial direction also in the outer peripheral part of the lamination | stacking inner side iron core 53, and the force of the rotation prevention of the connection member 52 can be enlarged. Even if this concave portion is a convex portion, the effect of preventing rotation can be obtained similarly.

  As shown in FIG. 3 (b), all the joint portions 51 s between the adjacent laminated laminated outer cores 51 are arranged so as to be located in the circumferential central portion of the inner peripheral surface of the permanent magnet 3. When the joint portion 51s of the split laminated outer core 51 is arranged in this way, the adhesive enters the gap between the concave portion 51p and the convex portion 51q when the permanent magnet 3 is bonded to the outer peripheral surface of the split laminated outer iron core 51. Therefore, it can be further firmly fixed.

  Further, in the case of the rotor 1 of the present embodiment, the path (magnetic path) of the magnetic force generated from the permanent magnet 3 is the permanent magnet 3 → the divided laminated outer core 51 → as shown by the arrow B in FIG. It becomes the adjacent permanent magnet 3. Since there is no joint 51s (divided surface) of the split laminated outer core 51 in this magnetic path, the rotor 1 capable of suppressing an increase in magnetic resistance can be obtained.

Each divided laminated outer core 51 has one hole 51m. The holes 51m can be used as positioning in the mold when the laminated inner iron core 53 and each divided laminated outer iron core 51 are integrally formed by the connecting member 52, and productivity can be improved.
FIG. 6A is a plan view of the laminated outer iron core 50 that is laminated and fitted in the mold 7.
FIG. 6B is a cross-sectional view thereof.
As shown in FIGS. 6A and 6B, for example, a boss 71 into which the hole 51 m of the divided laminated outer core 51 is inserted is provided in a mold 7 that integrally molds the laminated rotor core 5. By aligning the outer peripheral surface 51n of the divided laminated outer iron core 51 with the inner peripheral surface 72 of the mold 7, the respective laminated laminated outer iron cores 51 of the laminated rotor core 5 are coaxially arranged, and the boss 71 and the hole 51m are aligned in the circumferential direction. Can be positioned.

  Further, in the present embodiment, the positions of the holes 51m are the same positions for all the divided laminated outer cores 51, but all the positions may be different. By doing so, in addition to facilitating positioning when integrally forming the laminated rotor core 5, it is possible to distinguish between the core pieces constituting each divided laminated outer core 51, and member management is possible. It becomes easy.

  In the laminated inner iron core 53, the lightening portions 53 a to 53 f having the same shape as the divided laminated outer iron core 51 are formed. The thinned portions 53a to 53f have a shape that is point-symmetric about the center 0 of the rotating shaft 12 in FIG. By arranging in this way, the rotor 1 is balanced, and the rotating shaft 12 is less likely to be decentered, and the sound generated by the decentering can be suppressed.

  As shown in FIG. 1, two bearings 31 a and 31 b that support the rotating shaft 12 are installed on the rotating shaft 12 of the rotor 1. The bearings 31a and 31b are cylindrical bearings having a plurality of iron balls, and the inner ring of the bearing supports the rotary shaft 12 in a rotatable manner. In FIG. 1, the bearing 31a supports the rotating shaft 12 on the output shaft side where the rotating shaft 12 protrudes from the brushless DC motor, and the bearing 31b on the opposite side (hereinafter referred to as the non-output shaft side). Supports the rotating shaft 12. The bearings 31a and 31b have outer rings fixed by housings. In FIG. 1, the outer ring of the bearing 31a on the output shaft side is fixed by the housing part 3a (insulating member = resin), and the outer ring of the bearing 31b (conductive member = metal) on the anti-main force shaft side is fixed by the housing part 3b. It is fixed. With the above configuration, the rotating shaft 12 is supported by the pair of bearings 31a and 31b, and the rotating shaft 12 rotates freely. In this embodiment, a wave washer 32 is disposed on the bearing 31a side.

  The brushless DC motor has a built-in printed circuit board on which a control circuit, a drive circuit, an element for detecting the position of the permanent magnet 3, and the like are mounted. For example, an inverter for supplying current to the stator winding 22 is mounted on the printed circuit board. In addition, the stator winding 22 is connected on the printed circuit board (not shown).

Next, a method for manufacturing the rotor 1 will be described.
FIG. 7 is a view showing a layout of each core piece on the plate 1w when punching out the core pieces constituting one stack of the laminated rotor cores 5 of the rotor 1 with a press.
As shown in FIG. 7, the laminated rotor core 5 includes divided outer iron core pieces 8 a to 8 j for all divided laminated outer iron cores 51 and inner iron pieces for the laminated inner iron core 53 that constitute the laminated outer iron core 50 for one layer. 6 are sequentially punched from the same plate material 1w using the same press die and laminated, and these are combined to produce.

  At this time, six divided outer core pieces 8a to 8f are punched from the inside of the inner core piece 6, and four divided outer core pieces 8g to 8j are punched from the outside of the inner core piece 6 (core piece cutting step). ). Moreover, the direction of the arrow D in the figure indicates the rolling direction of the plate 1w. The direction of arrow E is a direction perpendicular to the rolling direction of the plate 1w. Incidentally, the magnetic path of the split laminated outer core 51 has a long radial path component along the arrow B as shown in FIG. For this reason, by making the rolling direction of the plate 1w coincide with the direction of the arrow D, the rotor 1 having a smaller magnetic resistance can be obtained. Thereby, the rotor 1 in which the number of materials can be reduced can be obtained.

Fig.8 (a) is a figure which shows the arrangement | positioning before the coupling | bonding of each division | segmentation lamination | stacking outer side iron core 51 (division | stacking lamination | stacking outer side iron core 51 is an even number).
FIG. 8B is a view showing the arrangement of the divided laminated outer cores 51 before joining (the divided laminated outer iron cores 51 are odd numbers).
FIGS. 8A and 8B are schematic diagrams in which each of the laminated laminated outer cores 51a to 51j is arranged in the circumferential direction evenly around the rotation shaft 12 in a straight line. In addition, the rightmost divided laminated outer core 51a indicated by a dotted line schematically represents the circumferential arrangement by showing that it is the same as the leftmost divided laminated outer core 51a.

  The divided outer core pieces 8a to 8j manufactured by the above-described method are once cut out from the inside and outside of the inner core piece 6 and stacked, or stacked as they are in the mold and taken out to be divided into the divided stacked outer cores 51a to 51j. Configure. Thereafter, as shown in FIG. 8 (a), the respective divided laminated outer cores 51a to 51j are arranged in the lower, upper, lower, upper,... An annular laminated outer core 50 can be obtained by aligning the positions of the crosspieces) and press-fitting each other in the axial direction of the rotary shaft 12.

In the above description, the number of divided laminated outer cores 51a to 51j is 10 (even), but the case where this is an odd number will be described.
FIG. 8B is a schematic diagram showing a case where the number of divided laminated outer cores is eleven. At this time, when the divided laminated outer iron cores 51a to 51k are arranged in the lower, upper, lower, upper,..., The divided laminated outer iron core 51k is arranged on the lower side.

  In this case, it is possible to press-fit one adjacent divided laminated outer core 51j from above and below. However, in the relationship with the other adjacent divided laminated outer iron core 51a, since the axial position of the rotating shaft 12 coincides with the lower side shown in FIG. 8B, the concave and convex portions cannot be pressed into each other. In order to solve this, for example, it is necessary to press-fit the divided laminated outer iron core 51a and the divided laminated outer iron core 51k first and then arrange them vertically together with other divided laminated outer iron cores. Become. This reduces productivity. For this reason, as shown in FIG. 8A, the productivity of the rotor 1 and the rotating electrical machine 100 can be increased by setting the number of the divided laminated outer cores constituting one rotor to an even number. .

  FIG. 9 is a diagram showing a layout of each core piece on the plate member 2w when punching out the core pieces constituting one stack of the laminated rotor cores 5 of the rotor 1 with a press. In the layout of each core piece on the plate member 1w in FIG. 7, the divided outer core piece cut out from the inner core piece 6 so that the inner core piece 6 has a point-symmetric shape with the center 0 of the inner core piece 6 as the center. 8a to 8f and divided outer core pieces 8g to 8j cut out from the outside were disposed.

  On the other hand, in the layout of each iron core piece on the plate member 2w shown in FIG. 9, the inner shape of the inner iron core piece 6 is point-symmetric about the center 0 as in the case of FIG. The divided outer core pieces 8g to 8j punched outside the iron core piece 6 are asymmetric with respect to the center 0, and are divided into a plurality of divided outer sides with respect to the center line CC in the long side direction of the plate 2w. The iron cores 8g to 8j are arranged in parallel. With such an arrangement, it is possible to reduce the amount of material used compared to the plate material 1w of FIG. 7, and at the same time, the weight balance with respect to the rotating shaft 12 of the laminated rotor core 5 is maintained.

Next, the degree of material saving effect will be described. Both the plate material 1w and the plate material 2w are supplied in a quadrangular shape, and each core piece having a required shape is cut out from the inside by pressing. These are compared with comparative examples.
FIG. 10A is a cross-sectional view of a rotor (comparative example) having an outer core that is integral with the inner core piece.
FIG.10 (b) is sectional drawing in the AA line of Fig.10 (a).
FIG.10 (c) is a figure which shows the layout of each core piece on the board | plate material 3w at the time of punching out the outer side iron core and inner side iron core which comprise a rotor with the same press metal mold | die.

  7, 9, and 10, the outer dimensions of all members such as the outer core piece, the inner core piece, the connecting member, and the hole for the rotating shaft are the same. Since the outer core piece 8x shown in FIG. 10 is a single piece, it is manufactured by punching the outer core piece 8x from the outside of the inner core piece 6x. In this case, the area between the inner iron core piece 6x and the outer iron core piece 8x becomes waste and is wasteful. At this time, the necessary material area S3 of the plate material 3w is S3 = L5a × L6a. Similarly, the material area S1 of the plate 1w required in FIG. 7 is S1 = L1a × L2a, and the material area S2 required in FIG. 9 is S2 = L3a × L4a. Table 1 shows the ratios of S1 and S2 with respect to S3, where S3 is 100%. (Estimated by assuming a constant distance x from the material edge to the punching profile under all conditions)

  Thus, by using the punching layout from each plate material as the layout of FIG. 7 and further to the layout of FIG. 9, the amount of material used can be reduced, and the rotor of the rotary electric machine 100 that is inexpensive and uses a small amount of material. 1 can be provided.

Next, it compares with the usage-amount of the board | plate material used when the division | segmentation outer side iron piece and an inner side iron piece are punched with a separate press die.
FIGS. 11A and 11B are diagrams showing layouts of the core pieces on the plate members 4aw and 4bw when the divided outer core pieces 8y and the inner core pieces 6y are punched with separate press dies (comparative example). It is.
In this case, in addition to the number of press shots for punching the divided outer core piece 8y, the number of press shots for punching the inner core piece 6y is required. Even if only the divided outer core piece 8y is considered, the required number of press shots increases as the number of divided outer core pieces 8y increases. On the other hand, in the present embodiment, all the divided outer core pieces 8 and the inner core pieces 6 constituting the rotor 1 can be punched together from the same plate material with the same mold, so the number of press shots is small, An inexpensive rotor 1 and rotating electric machine 100 with good productivity can be provided.

  According to the rotor of the rotating electrical machine, the rotating electrical machine, the manufacturing method of the rotor, the manufacturing method of the rotating electrical machine, and the core member of the rotor according to the first embodiment of the present invention, the material use of the laminated outer core and the laminated inner core Since the rotor can be balanced during rotation while reducing the amount, the rotor 1 of an inexpensive rotating electrical machine that can suppress electrolytic corrosion and has good productivity, and the rotating electrical machine 100 that uses the rotor are provided. can do.

Embodiment 2. FIG.
Hereinafter, the rotor of the rotating electrical machine, the rotating electrical machine, the manufacturing method of the rotor, the manufacturing method of the rotating electrical machine, and the core member of the rotor according to the second embodiment of the present invention are different from the first embodiment with reference to the drawings. The explanation will be focused on.
FIG. 12 is a cross-sectional view of the rotor 201 according to the present embodiment.
FIG. 13 is a diagram showing a layout of each core piece on the plate member 20w in a press mold for punching out the core piece for the rotor 201. FIG.
Since the configuration of the rotor 201 other than the iron core is the same as that of the rotor 1, the description thereof is omitted.
As shown in FIG. 12, the laminated outer core 250 is divided into five divided laminated outer cores 251 evenly in the circumferential direction. Further, two recesses 251t for preventing rotation are arranged in each divided laminated outer core 251. Further, as shown in FIG. 13, the divided outer core pieces 208 a and 208 b are manufactured by punching from the inside of the inner core piece 206, and the divided outer core pieces 208 c to 208 e are punched from the outside of the inner core piece 206. .

  Each of the divided outer core pieces 208a to 208e and the inner core piece 206 is punched out in the arrangement shown in FIG. 13, and these are laminated by the above-described lamination method of the divided outer core pieces. After the laminated outer iron core 250 and the laminated inner iron core 253 are integrated by the connecting member 252, the permanent magnet 3 is fixed to the outer peripheral surface of the laminated outer iron core 250 with an adhesive. And the rotor 201 can be obtained by putting the rotating shaft 12 in the rotor insertion part of the lamination | stacking inner side iron core 253. FIG.

  All the joint portions 251 s of the respective divided laminated outer cores 251 are arranged so as to be located at the center portion of the permanent magnet 3 as in the first embodiment, but the number of the joint portions 251 s is the same as that of the rotor 1. It is half of the case.

According to the rotor of the rotating electrical machine, the rotating electrical machine, the manufacturing method of the rotor, the manufacturing method of the rotating electrical machine, and the core member of the rotor according to the second embodiment of the present invention, the rotor 201 is the same as in the first embodiment. It is possible to reduce the amount of plate material that is required for manufacturing the plate.
Further, compared to the first embodiment, the number of joints (divided surfaces) of the divided outer iron core is small, an increase in magnetic resistance can be suppressed, and the size can be further reduced (the amount of material used can be reduced). A rotor can be obtained. Furthermore, since the number of divisions of the divided outer iron core is small as compared with the first embodiment, a rotor with a small number of parts can be obtained.

Embodiment 3 FIG.
Hereinafter, the rotor of the rotating electrical machine, the rotating electrical machine, the manufacturing method of the rotor, the manufacturing method of the rotating electrical machine, and the iron core member of the rotor according to the third embodiment of the present invention are different from the first embodiment with reference to the drawings. The explanation will be focused on.
FIG. 14 is a cross-sectional view of the rotor 301 according to the present embodiment.
FIG. 15 is a diagram showing a layout of each core piece on the plate member 30w in a press mold for punching out the core piece for the rotor 301. As shown in FIG.

  The difference from the first embodiment is that the outer diameter of the laminated inner iron core 353 is large, the outer diameter of the connecting member 352 is reduced accordingly, and all the divided outer iron cores are disposed inside the inner iron core piece 306. That is, the piece 308 is arranged. In the present embodiment, all the inner core pieces 306 and the divided outer core pieces 308 constituting the laminated inner iron core 353 and the laminated outer iron core 350 can be punched from the same press mold and the same plate material to constitute a rotor.

  Thus, depending on the specifications of the rotating electrical machine, as in the present embodiment, it is possible to arrange all the divided outer core pieces 308 constituting the rotor 301 so as to be cut out from the inside of the inner core piece 306. Thus, the rotor 301 that can reduce the amount of plate material used and the number of press work steps can be obtained.

Embodiment 4 FIG.
Hereinafter, the rotor of the rotating electrical machine, the rotating electrical machine, the manufacturing method of the rotor, the manufacturing method of the rotating electrical machine, and the iron core member of the rotor according to the fourth embodiment of the present invention are different from the first embodiment with reference to the drawings. The explanation will be focused on.
FIG. 16 is a plan view of the split laminated outer core 51 according to the first embodiment.
FIG. 17 is a plan view of the divided laminated outer core 451 according to the present embodiment.
In the first embodiment, as shown in FIG. 16, the cross section perpendicular to the axial direction of the outer peripheral surface of the divided laminated outer iron core 51 is an arc R2, and the inner peripheral surface of the divided laminated outer iron core 51 is perpendicular to the axial direction. When the cross section is an arc R1, the curvature centers 0 of R1 and R2 coincided. Therefore, the rotation stopping recess 51t is provided on the inner peripheral surface of the divided laminated outer core 51.

  In the present embodiment, as shown in FIG. 17, the cross section perpendicular to the axial direction of the outer peripheral surface of the divided laminated outer core 451 is an arc R402, and the inner peripheral surface of the divided laminated outer iron core 451 is perpendicular to the axial direction. When the cross section is an arc R401, the centers of curvature of R401 and R402 do not match. Thereby, even if it does not provide a rotation prevention recessed part, the effect of rotation prevention can be show | played, and if the rotation prevention recessed part 451t is provided, the effect of rotation prevention will become still higher.

  As shown in FIG. 18, the same effect can be obtained by using a divided laminated outer iron core 451d having a linear cross section perpendicular to the axial direction on the inner peripheral surface and providing a detent protrusion 451du in place of the detent recess. Play.

Embodiment 5. FIG.
Hereinafter, a rotor of a rotating electrical machine, a rotating electrical machine, a method of manufacturing a rotor, a method of manufacturing a rotating electrical machine, and a core member of the rotor according to a fifth embodiment of the present invention will be described as Embodiments 1 to 4 with reference to the drawings. The description will focus on the different parts.
FIG. 19 is a cross-sectional view of a rotor 501 according to the present embodiment.
In the first embodiment, an example of an SPM type rotor is shown, but in this embodiment, an example of an IPM (Interior Permanent Magnet) type rotor 501 will be described.

  In the first embodiment, the permanent magnet 3 is held on the outer peripheral portion of the laminated outer core 50. This embodiment is different from the first embodiment in that each permanent magnet 3 is held inside each divided laminated outer core 551. Also, the fixing method of the permanent magnet 3 is different.

  The permanent magnet 3 is disposed in the magnet insertion portion 551d inside the split laminated outer iron core 551. The split laminated outer iron core 551, the permanent magnet 3, and the laminated inner iron core 553 are integrally formed and fixed by a connecting member 552 made of resin or the like. Further, the connecting member 552 covers both end portions of the split laminated outer core 551 in the axial direction. The configuration of the split laminated outer iron core 551 may be obtained by adding a magnet insertion portion 551d (hole) into which the permanent magnet 3 enters from the shape described in the first embodiment.

  According to the rotor of the rotating electrical machine, the rotating electrical machine, the manufacturing method of the rotor, the manufacturing method of the rotating electrical machine, and the core member of the rotor according to the embodiment of the present invention, between the laminated outer core 550 and the rotating shaft 12. Is insulated, and the current generated in the laminated outer iron core 550 is not transmitted to the rotating shaft, so that the electric corrosion of the bearing causing noise is less likely to occur. Further, the amount of adhesive used can be reduced and the bonding time can be reduced, and the productivity of the rotor 501 and the rotating electrical machine can be improved. Thus, even with the IPM type rotor 501, electric corrosion can be suppressed, the amount of material used for the laminated outer iron core 550 and the laminated inner iron core 553 can be reduced, and the press work cost can be reduced, which is inexpensive. A rotor 501 of the rotating electric machine and the rotating electric machine can be provided.

Embodiment 6 FIG.
Hereinafter, the rotor of the rotating electrical machine, the rotating electrical machine, the manufacturing method of the rotor, the manufacturing method of the rotating electrical machine, and the core member of the rotor according to the sixth embodiment of the present invention are different from the first embodiment with reference to the drawings. The explanation will be focused on.
FIG. 20A is a cross-sectional view of the rotor 601 according to the present embodiment.
FIG. 20B is a cross-sectional view taken along the line AA in FIG.
In the rotor 1 according to the first embodiment and the rotor 601 according to the present embodiment, the fixing method of the permanent magnet 3 and the shape of the connecting member 652 are different. Since the other structure is the same, description is abbreviate | omitted.
However, for simplification of description, as shown in FIG. 20B, the lightening portions 53 a to 53 f inside the laminated inner core 53 have the rotating shaft 12 as compared with FIG. 3B of the first embodiment. A thing slightly rotated around the center 0 is used.

  In the present embodiment, the laminated inner iron core 53, each divided laminated outer iron core 51, and the permanent magnet 3 are fixed to each other by covering the entire outer periphery of the permanent magnet 3 using the connecting member 552. By doing in this way, the adhesive adhesive time can be reduced, and the productivity of the rotor and the rotating electrical machine can be improved. In addition, the connecting members 552 are filled into the inside of the lightening portions 53a, 53b, 53c, and 53d, which are portions where the divided outer core pieces inside the laminated inner core 53 are punched, so that each member is formed more integrally. Can be firmly bonded.

Embodiment 7 FIG.
Hereinafter, the rotor of the rotating electrical machine, the rotating electrical machine, the manufacturing method of the rotor, the manufacturing method of the rotating electrical machine, and the iron core member of the rotor according to the seventh embodiment of the present invention are different from the first embodiment with reference to the drawings. The explanation will be focused on.
FIG. 21 is a cross-sectional view of a rotor 701 according to the present embodiment.
FIG. 22 is a diagram showing a layout of each core piece on the plate material 70w in a press mold for punching out the core piece for the rotor 701. FIG. The difference between the first embodiment and the present embodiment is that the laminated thickness H2 of the laminated inner core 753 and the laminated thickness H1 of each divided laminated outer core 751 are different. In the present embodiment, a relationship of H1 = α × H2 (an integer equal to or greater than α = 2) is established, and α = 2.

  Further, the connecting member 752 is integrally formed to the axial end portions 751a and 751b of each divided laminated outer core 751 and the outer peripheral portion 753a of the axial end portion of the laminated inner core 753. Further, the layout of each core piece on the plate material on which the divided laminated outer core 751 and the laminated inner core 753 are simultaneously punched is also different. Furthermore, the manufacturing method which comprises the lamination | stacking outer side iron core 750 from the division | segmentation lamination | stacking outer side iron core 751 differs.

  In this embodiment, the number of divisions in the circumferential direction of the laminated outer core 750, that is, the number of divided laminated outer cores 751 is 10, but each divided laminated outer core is further divided into two groups in the axial direction. (The laminated outer iron core 750Y is disposed so as to overlap with the laminated outer iron core 750X in the axial direction). The axially divided surfaces of the laminated outer iron core 750X and the laminated outer iron core 750Y are not fixed by caulking, welding, adhesion, or the like, but are joined by integrally forming a connecting member.

  As shown in FIG. 22, in the rotor 701 of the present embodiment, there are 20 pieces (α times) larger than the number (10 pieces) obtained by dividing one inner iron core piece 706 and the laminated outer iron core 750 in the circumferential direction. The division | segmentation outer side iron core piece 708 is punched out from the same board | plate material 70w using the same press metal mold | die. At this time, the thickness of the lamination in a state where each iron core piece is fixed by caulking, welding, adhesion, or the like is set to H2 for each divided laminated outer core 751 and laminated inner iron core 753. The divided laminated outer cores 751a1 to 751j1 and 751a2 to 751j2 manufactured in this way are once taken out from the inside and outside of the laminated inner core 753.

  Thereafter, similarly to FIG. 8A, the respective divided laminated outer cores 751a1 to 751j1 are arranged in the lower, upper, lower, upper, etc., and in this state, the circumferential concave and convex portions are positioned, and the axial direction Thus, one annular laminated outer core 750X (with a laminated thickness of H2) can be obtained by press-fitting the upper divided laminated outer core group and the lower divided laminated outer core group together. Similarly, this is repeated, and each of the divided laminated outer cores 751a2 to 751j2 is assembled in an annular shape to obtain a laminated outer iron core 750Y (with a laminated thickness of H2). Furthermore, by laminating these two laminated outer cores 750X and 750Y (each laminated thickness is H2) in the axial direction, a laminated outer iron core 750 having a laminated thickness H1 required for one unit can be obtained.

  Then, in a state where the respective laminated outer cores 750X and 750Y are stacked in two stages in the output axis direction, the connecting member 752 is integrally formed with the laminated inner iron core 753 so that the two laminated outer iron cores 750X and 750Y are stacked in the stacking direction. It can fix also about the divided part.

  Thus, if the laminated thickness of the laminated outer core 750 is H1, and the laminated thickness H2 of the laminated inner core 753 is H1> H2, and H1 = α × H2 (an integer of 2 or more, α = 2 in this example). As a result, the laminated thickness of the laminated inner iron core 753 can be halved. Thereby, the amount of material used for the rotor 701 can be reduced, and the number of presses can be reduced to provide an inexpensive rotor 701 for a rotating electrical machine.

  As described above, in this example, there is provided an inexpensive rotating electrical machine rotor 701 that can suppress electrolytic corrosion, reduce the amount of material used for the laminated outer core and the laminated inner core, and can suppress the deterioration of productivity. be able to.

Embodiment 8 FIG.
Hereinafter, the rotor of the rotating electrical machine, the rotating electrical machine, the manufacturing method of the rotor, the manufacturing method of the rotating electrical machine, and the iron core member of the rotor according to the eighth embodiment of the present invention are different from the first embodiment with reference to the drawings. The explanation will be focused on.
FIG. 23 is a cross-sectional view of a rotor 801 according to the present embodiment.
FIG. 24 is a diagram showing a layout of each core piece on the plate member 80w in a press die for punching the core piece for the rotor 801. FIG. The first embodiment differs from the first embodiment in the number of divisions of the laminated outer core 850, the shape of the divided laminated outer core 851, and the layout of the press die.
Since others are the same as Embodiment 1, description is abbreviate | omitted.

  In the present embodiment, split laminated outer unit cores 55a to 55e are used in which thin connection portions 51v are provided between the outer peripheral portions of the two split laminated outer cores 851 shown in the first embodiment. Since the connecting portion 51v is formed of a thin wall, the connecting portion 51v has a shape that can be bent in the same plane so that the outer peripheral surfaces of the two divided laminated outer cores 851 are continuous curved surfaces.

  In the laminated inner core 853, as shown in FIG. 23, a meat having the same shape as the shape in which the cross section in the axial direction is bent to the outer peripheral side so that the divided laminated outer unit core is substantially V-shaped at the connecting portion 51v. Cutout portions 853a to 853d are formed. Further, as shown in FIG. 24, in the layout of the core pieces in the press mold, the above-described substantially V-shaped divided outer unit core pieces 808a to 808d are punched from the inside of the inner core piece 806, and the inner core pieces are punched out. A divided outer unit core piece 808e is punched from the outside of the piece. At this time, the divided outer unit core piece 808e is not substantially V-shaped, and the two divided outer core pieces 808 are arranged in a straight line via the connecting portion.

Next, a method for manufacturing the rotor 801 will be described.
Each of the divided laminated outer unit cores 55a to 55e and the laminated inner iron core 853 punched and laminated in the state of FIG. 24 is extracted from the mold. Next, in the intermediate connecting portion 51v of each divided laminated outer unit core 55a to 55e, the adjacent circumferential end surfaces of the two divided laminated outer cores 851 are (FIG. 24, divided outer unit core pieces 808d, end portions). a) and b) are bent so as to be in close contact with each other, and the five laminated laminated outer unit cores 55a to 55e deformed in this way are assembled by the assembling method described in the first embodiment, thereby forming an annular laminated outer side. An iron core 850 can be obtained.

  Next, after the laminated outer iron core 850 and the laminated inner iron core 853 are integrated by the connecting member 852, the permanent magnet 3 is fixed to the outer peripheral portion of the laminated outer iron core 850 with an adhesive. The rotor 801 can be obtained by inserting the rotary shaft 12 into the rotor insertion portion 854 of the inner iron core.

  According to the rotor of the rotating electrical machine, the rotating electrical machine, the manufacturing method of the rotor, the manufacturing method of the rotating electrical machine, and the core member of the rotor according to the embodiment of the present invention, compared to the first embodiment, the divided laminated outer core Since a plurality of 851 are connected via the connecting portion 51v, the rotor 801 with a small number of parts can be obtained.

  Also, in the layout of each core piece when punching out each core piece constituting the rotor 801, a substantially V-shaped divided outer unit core piece 808a is surrounded inside the inner core piece 806 so as to surround the rotary shaft insertion hole 806h. ˜808d can be arranged and punched, and the material yield can be improved. Further, since the divided outer unit core piece 808e in which the divided outer core pieces 808 are arranged linearly via the connecting portion 51v is also punched outside the inner core piece 806, the substantially V-shaped divided outer unit core piece is punched out. Compared to the case, the material yield can be increased.

Furthermore, since the split outer unit core pieces 808a to 808e can be bent as a connecting means only by forming a simple thin portion, manufacturing is easy.
From the above, it is possible to provide an inexpensive rotary electric machine rotor 801 that can suppress electrolytic corrosion, reduce the amount of material used for the laminated outer core 850 and the laminated inner core 853, and suppress deterioration in productivity. it can.

Embodiment 9 FIG.
Hereinafter, the rotor of the rotating electrical machine, the rotating electrical machine, the manufacturing method of the rotor, the manufacturing method of the rotating electrical machine, and the core member of the rotor according to the ninth embodiment of the present invention are different from the first embodiment with reference to the drawings. The explanation will be focused on.
FIG. 25 is a plan view of the split laminated outer core 951.
FIG. 26 is a cross-sectional view of a rotor 901 according to the present embodiment.
FIG. 27 is a diagram showing a layout of each core piece on the plate member 90w in a press mold for punching out the core piece for the rotor 901. FIG.

The first embodiment differs from the first embodiment in the shape of the divided outer iron core and the layout of the iron core pieces in the press mold. Since others are the same as Embodiment 1, description is abbreviate | omitted.
As shown in FIGS. 25 to 27, the cross section perpendicular to the axial direction of the outer peripheral surface of the split laminated outer core 951 is an arc R902, and the cross section perpendicular to the axial direction of the inner peripheral surface of the split laminated outer iron core 951 is an arc. When R901 is set, the center of curvature of the arc R902 coincides with the point 0 on the center axis of the rotating shaft 12, and the center of curvature of the arc R901 does not coincide with the point 0 on the center axis of the rotating shaft 12 from the point 0. Located on the outer periphery. Moreover, it has the convex part 951u which protrudes to radial inside as a rotation stopper.

As shown in FIG. 27, in the press die, all the core pieces constituting the same laminate of the laminated inner iron core 953 and the laminated outer iron core 950 are punched simultaneously from the same plate material 90w. The split outer core pieces 908a to 908f are punched from the inside of the inner core piece 906, and the split outer core pieces 908g to 908j are punched from the outside of the inner core piece 906. At this time, in Embodiment 1, there was a gap between the inner iron core piece 6 and the divided outer iron core pieces 8g to 8j. In this example, this gap is eliminated, and the boundary between the outer peripheral portion of the inner core piece 906 and the inner peripheral portion of the divided outer core piece is punched at a time so as to form arcs R903 and R901 of the same shape. At this time, the center of curvature of the arc R902 of the outer peripheral portion of the divided outer core pieces 908g to 908j is a position different from the center 0 of the rotor insertion hole 906h (the center of the rotating shaft 12 when assembled as the laminated outer core 950). Arranged). Thereby, the curvature radii of the arc R903 and the arc R901 are equal, and the curvature radii of the arc R902, the arc R903, and the arc R901 are different.
By doing in this way, compared with Embodiment 1, since the clearance of the iron core piece at the time of press punching can be eliminated, the yield of the plate material 90w can be further improved.

  Further, with respect to the convex portion 951u of the non-rotating outer core, the concave portion having the same shape can be formed in the inner core piece 906 at the same time when the core piece is stamped out, so that the rotor with higher productivity can be obtained. 901 can be obtained. Further, in the rotor (FIG. 3B) shown in the first embodiment, the cross section perpendicular to the axial direction of the outer periphery of the connecting member 52 is circular (excluding the rotation preventing portion). In this form, as shown in FIG. 26, arcs having different curvature centers have a continuous shape. For this reason, the effect of a rotation stop can be enlarged more.

  In the rotor 901 of this structure, since the outer peripheral portion of the laminated inner core 953 and the inner peripheral portion of the laminated outer iron core 950 are integrated by a connecting member 952 made of resin or the like, high dimensional accuracy is not required. . For this reason, even if both core pieces are formed by punching the outer peripheral portion of the inner core piece 906 and the inner peripheral portion of the divided outer core piece 908 as a boundary as in this embodiment, the accuracy required for the rotating electrical machine is not sufficient. It does not affect.

Embodiment 10 FIG.
Hereinafter, a rotor of a rotating electrical machine, a rotating electrical machine, a manufacturing method of the rotor, a manufacturing method of the rotating electrical machine, and a core member of the rotor according to the tenth embodiment of the present invention are different from the ninth embodiment with reference to the drawings. The explanation will be focused on.
FIG. 28 is a plan view of the split laminated outer core 1051. FIG.
FIG. 29 is a cross-sectional view of rotor 1001 according to the present embodiment.
FIG. 30 is a diagram showing a layout of each core piece on the plate member 100w in a press mold for punching out the core piece for the rotor 1001. FIG.

  The present embodiment is different from the ninth embodiment in the number and shape of the divided laminated outer cores constituting the laminated outer core 1050 and the layout of the core pieces in the press die. Since others are the same as Embodiment 9, description is abbreviate | omitted. As shown in FIG. 29, the laminated outer core 1050 is divided into six divided laminated outer cores 1051 evenly in the circumferential direction. Further, two anti-rotation convex portions 1051u are arranged on each divided laminated outer core.

As shown in FIG. 30, the four divided outer core pieces 1008a to 1008d are punched from the inside of the inner core piece 1006, and the two divided outer core pieces 1008e to 1008f are punched from the outside of the inner core piece 1006. It is manufactured by.
Each of the divided outer core pieces 1008 and the inner core piece 1006 punched out in the arrangement shown in FIG. 30 is stacked and extracted in a mold, and is assembled into an annular shape by the method of assembling the divided stacked outer core shown in the first embodiment. An iron core 1050 is manufactured.

  After the laminated outer iron core 1050 and the laminated inner iron core 1053 are integrated by the connecting member 1052, the permanent magnet 3 is fixed to the outer peripheral surface of the laminated outer iron core 1050 with an adhesive. And the rotor 1001 can be obtained by putting the rotating shaft 12 in the center of the laminated inner core 1053.

  The number of joined portions 1051s of each divided outer iron core is half that of the joined portions of the first embodiment. By doing in this way, the board | plate material usage-amount required for manufacture of a rotor core can be reduced compared with a prior art example. Furthermore, since the number of divisions of the laminated outer core 1050 is smaller than that in the first embodiment, the rotor 1001 having a smaller number of parts can be obtained.

  Further, compared to the first embodiment, the number of divided surfaces of the laminated outer core 1050 is small, an increase in magnetic resistance can be suppressed, and the rotor 1001 that can be further downsized (the amount of material used can be reduced) is reduced. Can be obtained. Thus, according to the rotor of the rotating electrical machine, the rotating electrical machine, the manufacturing method of the rotor, the manufacturing method of the rotating electrical machine, and the iron core member of the rotor according to the embodiment of the present invention, the electric corrosion can be suppressed, and the lamination It is possible to provide an inexpensive rotor 1001 for a rotating electrical machine that can reduce the amount of material used for the outer iron core 1050 and the laminated inner iron core 1053 and suppress deterioration in productivity.

Embodiment 11 FIG.
Hereinafter, the rotor of the rotating electrical machine, the rotating electrical machine, the method of manufacturing the rotor, the method of manufacturing the rotating electrical machine, and the iron core member of the rotor according to the eleventh embodiment of the present invention are described as Embodiments 1 to 10 with reference to the drawings. The description will focus on the different parts.
FIG. 31 is a plan view of a split laminated stator unit core 1125 of the rotating electrical machine.
FIG. 32 is a plan view of a laminated stator core 1120 in which four divided laminated stator unit cores 1125 are arranged in an annular shape.
FIG. 33 is a diagram showing a layout of each core piece on the plate material 1100w in a press die for punching out a single core piece constituting the rotor core and a single core piece constituting the split stator unit core. .

In the present embodiment, all the divided laminated outer iron cores constituting the laminated outer iron core, the laminated inner iron core, and the iron core pieces forming the same layer of all the divided laminated stator unit iron cores 1125 constituting the laminated stator iron core are the same. Punching simultaneously from a press die and the same plate material.
The divided laminated stator unit core 1125 connects a plurality of divided laminated stator cores 1121 via a connecting portion 1125v that can be bent on the same plane. The connecting portion 1125v is constituted by a thin wall. Further, the number of connections of the divided laminated stator cores 1121 is set to three to form one divided laminated stator unit core 1125, and the four divided laminated stator unit cores 1125 are arranged in an annular shape to form a laminated stator core 1120. Configure.

  Further, the outer peripheral side of the yoke of the divided laminated stator core 1121 is not an arc but a straight line. As shown in FIG. 33, the core pieces for the split laminated stator unit core 1125 are punched out in two rows. At this time, the two rows of divided stator unit core pieces 1104 are arranged so that the teeth 1104a of the other row face each other between the adjacent teeth 1104a of one row. By doing in this way, the amount of material used for the stator core is reduced compared to the case of punching in a single row. In addition, since the outer peripheral side of the yoke is not a circular arc but a straight line, the width of the material punched out by the press can be reduced, so that the amount of material used can be reduced. Moreover, the number of presses required at the time of manufacture of a rotary electric machine can be reduced.

  In the manufacturing method according to the first embodiment, in addition to the number of presses for punching out the stator core piece, the number of times of punching out the rotor core piece is required, but in this embodiment, the stator core and the rotor core are configured. Since the core pieces are manufactured with the same press mold, the number of presses can be consolidated at once, and productivity is improved. Further, since it is sufficient to form a simple thin portion as a foldable connecting means for the split laminated stator unit core 1125, the manufacture becomes easy.

  After winding the plurality of divided laminated stator unit cores 1125 thus obtained, the connecting portion 1125v is bent on the same plane so that the yoke is on the outer peripheral side and the teeth are on the inner peripheral side, A laminated stator core 1120 as shown in FIG. 32 can be obtained by arranging in a ring and fixing the joint surfaces of the adjacent divided laminated stator unit cores 1125 by adhesion, welding, or the like. (The windings and insulators are omitted, and only the state of the fixed iron core is shown.)

  It should be noted that the present invention can be freely combined with each other within the scope of the invention, and each embodiment can be appropriately modified or omitted.

100 rotating electric machine,
1,201,301,501,601,701,801,901,1001 rotors,
12 rotation axis,
1w, 2w, 3w, 4aw, 20w, 30w, 70w, 80w, 90w, 100w, 1100w
2 Stator, 20, 1120 Laminated stator core, 21,1121 Divided laminated stator core, 21a Laminated tooth portion, 21b Laminated yoke portion, 21c Tip portion, 22 Stator winding, 3 Permanent magnet, 3a Housing portion, 3b Housing part, 31a bearing,
31b bearing, 32 wave washer, 4 stator core piece, 4a teeth part,
5 laminated rotor core,
50, 250, 350, 550, 750, 750X, 750Y laminated outer core,
51, 51a to 51k, 251, 451d, 551, 751, 751a1 to 751j1, 751a2 to 751j2, 851, 951, and 1051 Split laminated outer cores,
51m hole, 51n outer peripheral surface, 51p recess,
51q, 451du, 951u, 1051u convex part, 51s joint part,
51t, 53t, 251t, 451t recess, 51v coupling part,
52,252,352,552,652,752,852,952,1052 connecting members,
53,253,353,553,753,853,953,1053 laminated inner core,
53a-53f Meat removal part, 55a-55e Split lamination outer unit core,
6,6x, 206,306,706,806,1006 inner core piece, 7 mold,
71 boss, 72 inner surface,
8,8a-8g, 8y, 208a, 308,708,808,908,908a-908g, 1008 split outer core piece,
8x outer core pieces, 808a to 808e split outer unit core pieces,
251s, 1051s joint, 551d magnet insertion part, 751a end,
753a Outer peripheral part, 806h Rotating shaft insertion hole, 854 Rotor insertion part,
906h Rotor insertion hole, 1104 split stator unit core piece,
1104a Teeth part, 1125 split laminated stator unit core, 1125v connecting part.

Claims (25)

A cylindrical laminated rotor core constituted by laminating iron core pieces, and a permanent magnet held at equal intervals in the circumferential direction on the laminated rotor core,
In the rotor of the rotating electrical machine having a rotating shaft inserted in the center of the laminated rotor core,
The laminated rotor core includes a laminated inner core to which a rotation shaft is fastened,
A laminated outer core disposed so as to surround the laminated inner iron core and divided into a plurality of divided laminated outer iron cores in the circumferential direction;
Formed between the laminated inner iron core and the laminated outer iron core, and comprising a connecting member for coupling the laminated inner iron core and the laminated outer iron core,
A rotor of a rotating electrical machine in which a hollow portion having the same shape as the divided laminated outer core is formed inside the laminated inner core. The rotor of a rotating electrical machine according to claim 1, wherein the laminated inner iron core is point-symmetric with respect to a center of the laminated inner iron core. The rotor of the rotating electrical machine according to claim 1 or 2, wherein a concave portion or a convex portion formed in a radial direction is provided on an inner peripheral side of the divided laminated outer core. The rotor of the rotating electrical machine according to any one of claims 1 to 3, wherein a concave portion or a convex portion formed in a radial direction is provided on an outer peripheral side of the laminated inner core. The center of curvature obtained from the outer periphery of the laminated outer core;
The rotor of the rotary electric machine according to any one of claims 1 to 4, wherein a center of curvature obtained from an inner periphery of the divided laminated outer core is different. A radius of curvature determined from the outer periphery of the laminated inner core;
The rotor for a rotating electrical machine according to any one of claims 1 to 4, wherein a radius of curvature obtained from an inner periphery of the divided laminated outer core is the same. The center of curvature obtained from the outer periphery of the laminated inner core;
The rotor of the rotary electric machine according to any one of claims 1 to 4, wherein a center of curvature obtained from an inner periphery of the divided laminated outer core is different. The rotation according to any one of claims 1 to 7, wherein the lightening portion is arranged such that a portion corresponding to an outer peripheral side of the divided laminated outer core is on a center side of the laminated inner core. Electric rotor. 9. The rotating electrical machine according to claim 8, wherein the thinned portion has the same shape as a divided laminated outer core unit in which two or more of the divided laminated outer cores are thinly connected to each other at an outer peripheral portion of each divided laminated outer core. Rotor. 10. The rotation according to claim 9, wherein the lightening portion has the same shape as a shape in which the divided laminated outer cores adjacent to each other in the divided laminated outer core unit are bent in a V shape on the outer peripheral side with a thin-walled connection as a vertex. Electric rotor. The thickness in the stacking direction of the laminated outer iron core is H1, and the thickness in the stacking direction of the laminated inner iron core is H2, H1> H2 and H1 = α × H2 (integer greater than α = 2). The rotor of the rotary electric machine according to any one of claims 1 to 10. The rotation of the rotating electrical machine according to any one of claims 1 to 11, wherein a joint portion between all the adjacent laminated laminated outer cores is disposed at a circumferential central portion of the permanent magnet. Child. The rotating electrical machine according to any one of claims 1 to 11, wherein all of the permanent magnets are arranged so that a center portion in a circumferential direction is positioned at a joint portion between the adjacent divided laminated outer cores. Rotor. The rotation of the rotating electrical machine according to any one of claims 1 to 13, wherein the adjacent divided laminated outer cores are fitted to each other by a concave portion and a convex portion provided at respective circumferential ends. Child. The rotor of a rotating electrical machine according to claim 14, wherein the concave portion is a dovetail groove, and the convex portion is a dovetail. The rotor of the rotating electrical machine according to any one of claims 1 to 15, wherein the connecting member is a resin. The rotor of the rotating electrical machine according to claim 16, wherein the connecting member is also filled in the thinned portion of the laminated inner iron core. The rotor of the rotating electrical machine according to claim 16 or 17, wherein the permanent magnet is integrally formed with the laminated inner iron core and each of the divided laminated outer iron cores with the resin. The rotor of the rotating electrical machine according to any one of claims 1 to 18, further comprising an adhesive between the permanent magnet and the split laminated outer core. The rotor of the rotating electrical machine according to any one of claims 1 to 19,
An annular yoke portion, a teeth portion protruding inward from the yoke portion, and a stator winding wound around the teeth portion;
A rotating electrical machine having a stator that houses the rotor inside. A cylindrical laminated rotor core configured by laminating core pieces, and a permanent magnet held at equal intervals in the circumferential direction on the laminated rotor core,
A rotor manufacturing method comprising a rotating shaft inserted into the center of the laminated rotor core,
An inner core piece constituting a laminated inner core to which the rotating shaft is fastened;
When it is arranged so as to surround the periphery of the laminated inner iron core, and the divided outer iron core pieces constituting the laminated outer iron core divided into a plurality of divided laminated outer iron cores in the circumferential direction are cut out from the same plate material,
The manufacturing method of the rotor which has an iron core piece cutting process which cuts out and cuts out the said division | segmentation outer side iron core piece from the inside of the said inner side iron core piece. The method for manufacturing a rotor according to claim 21, wherein, in the core piece cutting step, all the core pieces constituting the same layer of the laminated outer core and the laminated inner iron core are simultaneously punched from the same plate material. The method of manufacturing a rotor according to claim 22, wherein in the iron core piece cutting step, all the divided outer iron core pieces are punched from the inner iron piece. In the manufacturing method of the rotor according to any one of claims 21 to 23,
The manufacturing method of the rotary electric machine which cuts out the iron core piece for the layer of the stator which accommodates the said rotor simultaneously from the said board | plate material. A core member for a laminated rotor core of a rotor composed of a plurality of core pieces,
Among the laminated rotor cores, one inner core piece constituting one layer of a laminated inner core having a rotating shaft insertion portion,
Each of the plurality of divided laminated outer cores that are equally divided in the circumferential direction of the laminated outer cores joined to the outer circumference of the laminated inner cores via an insulating connecting member constitutes the same layer as the one layer. Sheet, consisting of the same number of divided outer core pieces as the number of the divided laminated outer cores,
Among the divided outer core pieces, at least two of the divided outer core pieces are rotor core members cut out from the inside of the inner core pieces.

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