JP6376060B2 - Rotor manufacturing method - Google Patents

Description

  The present invention relates to a permanent magnet mounting method for a rotor core, and more particularly, to a method for mounting a permanent magnet to a rotor core by inserting the permanent magnet into a magnet housing hole of the rotor core.

  In a rotor of a rotating electrical machine, a permanent magnet is inserted into a magnet housing hole of a rotor core, and a resin is filled in a gap between the magnet housing hole and the permanent magnet, thereby fixing the permanent magnet to the magnet housing hole. . At this time, it is necessary to insulate the inner surface of the magnet housing hole from the permanent magnet. As an insulation method, a method of performing an insulation treatment on the surface of the permanent magnet, or an insulating member is interposed between the magnet housing hole and the permanent magnet. The method of doing is known.

  In particular, as the latter method, a plurality of band-like or string-like insulating members are arranged in parallel and spaced apart from each other on the magnet housing hole, and the permanent magnet is inserted into the magnet housing hole while these insulating members are wound around the magnet housing hole. (For example, refer to Patent Document 1).

JP 2014-222964 A

  In the method described in Patent Document 1, the permanent magnet may come into contact with the inner surface of the magnet housing hole. That is, when the permanent magnet is inserted into the magnet housing hole, the position of the insulating member may be shifted and the insulating member may be inclined. If the permanent magnet is inserted into the magnet housing hole in this state, the balance of the force applied in the width direction of the permanent magnet from the insulating member may be lost, and the permanent magnet may be inserted inclined with respect to the width direction of the permanent magnet. In this case, the corner in the width direction of the permanent magnet may contact the inner surface of the magnet housing hole.

  Further, if the permanent magnet is inserted into the magnet housing hole in a state where the permanent magnet is inclined with respect to the width direction of the permanent magnet, the corner in the width direction of the permanent magnet may contact the inner surface of the magnet housing hole regardless of the insulating member. .

  Furthermore, even if the permanent magnet is inserted at a normal position in the magnet housing hole, when the resin is filled in the gap between the magnet housing hole and the permanent magnet, the permanent magnet may be displaced due to the momentum of the filled resin. In particular, since the side surface of the permanent magnet in the width direction has a large area, the permanent magnet may be inclined in the width direction due to the influence of the resin. May come into contact.

  Thus, when the permanent magnet is in contact with the inner surface of the magnet housing hole, an eddy current flows through the permanent magnet at the contact portion, and as a result, electrical loss and heat generation occur.

  In addition, it is possible to suppress electrical contact between the permanent magnet and the inner surface of the magnet housing hole by subjecting the surface of the permanent magnet to insulation treatment such as an insulation coating, but work is necessary because insulation treatment is required. Cost increases as man-hours increase.

  Therefore, an object of the present invention is to suppress contact between the permanent magnet and the inner surface of the magnet housing hole.

This onset Ming, a rotor manufacturing method for mounting a permanent magnet to the magnet receiving hole of the rotor core, said permanent magnet when said permanent magnet in said magnet housing hole is inclined with respect to the width direction of the permanent magnet And a single insulating sheet having a width in contact with the inner surface of the magnet accommodating hole before the corner of the permanent magnet is disposed on the magnet accommodating hole, and the insulating sheet is the magnet. The permanent magnet is inserted into the magnet accommodation hole from above the insulating sheet so as to be caught in the accommodation hole, and the permanent magnet is in a state where a gap is formed between the insulation sheet and the inner surface of the magnet accommodation hole. A magnet is mounted in the magnet storage hole, and after the permanent magnet is mounted in the magnet storage hole, between the insulating sheet and the inner surface of the magnet storage hole, and between the permanent magnet and the magnet storage hole. Injecting resin into The

  ADVANTAGE OF THE INVENTION According to this invention, a contact with a permanent magnet and the inner surface of a magnet accommodation hole can be suppressed, and generation | occurrence | production of the eddy current to the permanent magnet in a contact part can be suppressed. Further, it is not necessary to insulate the surface of the permanent magnet.

It is a sectional side view of the magnet housing hole vicinity of a rotor core. It is a top view of the magnet accommodation hole which shows the relationship between the width | variety of an insulating sheet and a permanent magnet. It is a top view of the rotor core which shows the positional relationship of an insulating sheet and a magnet accommodation hole. It is a top view of the magnet accommodation hole which shows the state where a permanent magnet contacts a magnet accommodation hole. It is a top view of the magnet accommodation hole which shows the state where an insulating sheet contacts a magnet accommodation hole. It is a sectional side view of the rotor core which shows the state which mounted the insulating sheet in the rotor core. It is a sectional side view of the rotor core which shows the state which has inserted the permanent magnet in the magnet accommodation hole. It is a sectional side view of the rotor core which shows the state which set the rotor core to the mold type. It is a sectional side view of a rotor core showing a modification of an insulating sheet. It is a sectional side view of a rotor core showing a modification of an insulating sheet.

  The rotor core 10 of the present invention is used as, for example, a rotor core 10 of a rotating electrical machine. As shown in FIG. 1, the rotor core 10 includes a rotor core 11, a permanent magnet 13 inserted in a magnet housing hole 12 provided in the rotor core 11, and an inner surface 12 a of the magnet housing hole 12 and a permanent magnet 13. And an insulating sheet 20 interposed therebetween, and a thermoplastic resin 14 filled between the inner surface 12 a of the magnet housing hole 12 and the permanent magnet 13.

  The rotor core 11 is configured by laminating in the axial direction Z a number of electromagnetic steel sheets each punched into an annular shape. A plurality of magnet housing holes 12 are provided at equal intervals in the circumferential direction of the rotor core 11, and penetrate the rotor core 11 in parallel with the axial direction Z of the rotor core 11.

  The permanent magnet 13 has a length R slightly shorter than the length of the rotor core 11 in the axial direction Z, and has a flat plate shape that is long in the axial direction Z. As shown in FIG. 2, the shape perpendicular to the axial direction Z of the permanent magnet 13 is a rectangular shape, and has a predetermined thickness M and width L. The thickness M of the permanent magnet 13 is set such that a gap is formed between the permanent magnet 13 and the inner surface 12a of the magnet housing hole 12, and the insulating sheet 20 is interposed in the gap. . The permanent magnet 13 is fixed to the magnet housing hole 12 by filling the gap 14 with the resin 14 and curing the resin 14.

  The insulating sheet 20 is held in a U shape on the back side of the magnet housing hole 12 so as to cover the distal end portion on the insertion side of the permanent magnet 13 when the permanent magnet 13 is inserted. As the insulating sheet 20, a heat-resistant film-like synthetic resin fiber, heat-resistant paper, or the like can be used. In this embodiment, for example, a single-layer PET film is used. Moreover, it is preferable to form with the material which has the softness | flexibility which is hard to tear, and can deform | transform.

  As shown in FIGS. 2 and 3, the insulating sheet 20 has a rectangular shape that is long in a direction orthogonal to the width direction E (see FIG. 4) of the permanent magnet 13, and one insulating sheet 20 is used for one permanent magnet 13. It is a single sheet. The length Y of the long side of the insulating sheet 20 has a length that covers more than half of the distal end portion on the insertion side of the permanent magnet 13 when the insulating sheet 20 is held in the magnet housing hole 12. With respect to the length R and the thickness M of 13, the length is at least R + M and within 2R + M. The length X (hereinafter referred to as the width X) of the short side of the insulating sheet 20 is a width X that is narrower than the width L of the permanent magnet 13, and the setting of the width X will be described later. The thickness of the insulating sheet 20 is a thickness T that is thinner than the gap between the permanent magnet 13 and the inner surface 12 a of the magnet housing hole 12.

  Before describing the setting of the width X of the insulating sheet 20, the contact between the permanent magnet 13 and the inner surface 12a of the magnet housing hole 12 will be described. As shown in FIG. 4, when the permanent magnet 13 is inserted into the magnet housing hole 12, the permanent magnet 13 is inclined in the magnet housing hole 12 with respect to the width direction E of the permanent magnet 13 as indicated by the symbol F. In this case, when the width X of the insulating sheet 20 is significantly narrower than the width L of the permanent magnet 13, the corner 13 a of the permanent magnet 13 contacts the inner surface 12 a of the magnet housing hole 12 in the portions indicated by reference signs A and B in the figure. There are things to do.

  However, as shown in FIG. 5, when the width X of the insulating sheet 20 is slightly narrower than the width L of the permanent magnet 13, that is, the width L of the insulating sheet 20 and the width X of the permanent magnet 13 are the same. When the width is large, the edge 20a of the insulating sheet 20 comes into contact with the inner surface 12a of the magnet housing hole 12 before the corner 13a of the permanent magnet 13 in the portions indicated by reference characters C and D in the figure. For this reason, it is suppressed that the corner 13a of the permanent magnet 13 contacts the inner surface 12a of the magnet housing hole 12.

  Thus, it can be understood that the closer the width X of the insulating sheet 20 is to the width L of the permanent magnet 13, the more the corner 13 a of the permanent magnet 13 is prevented from contacting the inner surface 12 a of the magnet housing hole 12. .

Therefore, as shown in FIG. 2, the width X of the insulating sheet 20 is set as follows. In FIG. 2, the width X of the insulating sheet 20, the thickness T of the insulating sheet 20, the width L of the permanent magnet 13, the thickness M of the permanent magnet 13, the short side N of the magnet housing hole 12, the insulating sheet 20 and the magnet housing hole 12. When the gap (g1 + g2) = G with respect to the inner surface 12a of the magnet, the thickness T of the insulating sheet 20, the gap G between the insulating sheet 20 and the inner surface 12a of the magnet housing hole 12, and the width L of the permanent magnet 13 are determined by experiments or the like. The following mathematical formula was found for the relationship of the width X of the insulating sheet 20. That is, the width X of the insulating sheet 20 is set by the following formula. In FIG. 2, the gap G is represented by G = N−M−2T.
(Formula): L × G / (G + T) ≦ X ≦ L

  If the width X of the insulating sheet 20 is wider than the width L of the permanent magnet 13, the insulating sheet 20 protruding from the corner 13a of the permanent magnet 13 may be bent or torn. Is set to be equal to or smaller than the width L of the permanent magnet 13.

  In the present embodiment, the gap between the end surface of the permanent magnet 13 in the width direction E of the permanent magnet 13 and the inner surface 12a of the magnet housing hole 12 does not contact even if the permanent magnet 13 is inclined in the magnet housing hole 12. Such a gap is set.

  Next, a method of mounting the permanent magnet 13 in the magnet housing hole 12 using the insulating sheet 20 having the width X set by the above formula will be described.

  As shown in FIG. 6, the insulating sheet 20 is placed on the upper end surface of the rotor core 11 so as to cover the magnet housing hole 12 with the insulating sheet 20. A single insulating sheet 20 is used for each magnet housing hole 12. At this time, as shown in FIG. 3, the insulating sheet 20 is aligned with the magnet housing hole 12 so that the center line S <b> 1 of the magnet housing hole 12 and the center line S <b> 2 of the insulating sheet 20 coincide with each other. The insulating sheet 20 may be brought into close contact with the upper end surface of the rotor core 11 or may be placed only so as to cover the magnet housing hole 12.

  As shown in FIG. 7, the permanent magnet 13 is inserted from above the insulating sheet 20, and the permanent magnet 13 is inserted into the magnet housing hole 12 so that the insulating sheet 20 is wound into the magnet housing hole 12. At this time, the permanent magnet 13 enters the magnet housing hole 12 while the side surface of the permanent magnet 13 is wrapped in the insulating sheet 20.

  As shown in FIG. 8, when the permanent magnet 13 is inserted all the way into the magnet housing hole 12, the permanent magnet 13 is held in the magnet housing hole 12 via the insulating sheet 20. At this time, a gap is formed between the insulating sheet 20 and the inner surface 12 a of the magnet housing hole 12.

  In addition, the length Y of the insulating sheet 20 is at least R + M or more with respect to the length R and thickness M of the permanent magnet 13 and is within 2R + M. The permanent magnet 13 is wrapped over the above length. In this way, the permanent magnet 13 is mounted in the magnet housing hole 12 of the rotor core 11.

  After the permanent magnet 13 is mounted, the rotor core 11 is mounted on the molds 30 and 31, and the rotor core 11 is sandwiched from above and below. Next, the resin 14 is injected from the resin injection port 30 a of the mold 30 into the magnet accommodation hole 12 of the rotor core 11. The resin 14 is filled between the insulating sheet 20 and the inner surface 12 a of the magnet housing hole 12 or between the permanent magnet 13 and the insulating sheet 20.

  After filling the resin 14, the rotor core 11 is heated to cure the resin 14, and the permanent magnet 13 is fixed to the magnet housing hole 12 of the rotor core 11. When the rotor core 11 is removed from the molds 30 and 31, the rotor core 10 is in the state shown in FIG. 1, and the manufacture of the rotor core 10 is completed.

  Thus, even when the permanent magnet 13 is inclined with respect to the width direction E in the magnet housing hole 12 when the permanent magnet 13 is mounted in the magnet housing hole 12, the edge 20 a of the insulating sheet 20 is more than the corner 13 a of the permanent magnet 13. First, it contacts the inner surface 12a of the magnet housing hole 12, and further inclination of the permanent magnet 13 is prevented, and the contact of the permanent magnet 13 with the magnet housing hole 12 is suppressed. Further, even when the permanent magnet 13 is tilted by the momentum of the filled resin 14 when the resin 14 is filled, the contact of the permanent magnet 13 with the magnet housing hole 12 is similarly suppressed.

  For this reason, generation | occurrence | production of the eddy current in the permanent magnet 13 can be suppressed, and an electrical loss and heat_generation | fever can be suppressed. Further, it is not necessary to insulate the permanent magnet 13.

  Next, a modified example when the insulating sheet 20 is placed in the magnet housing hole 12 will be described. As shown in FIG. 9, the central portion of the insulating sheet 21 is bent a plurality of times in accordance with the shape of the magnet housing hole 12 to have a U-shaped cross section. Further, a crease is formed so that a portion protruding from the magnet housing hole 12 spreads in a tapered shape. Then, the insulating sheet 21 is disposed on the magnet housing hole 12 and the U-shaped portion is inserted into the magnet housing hole 12, and then the permanent magnet 13 is inserted into the magnet housing hole 12.

  In addition, as shown in FIG. 10, the insulating sheet 22 is folded in half along the center line so as to have a V-shaped cross section, and the insulating sheet 22 is disposed on the magnet housing hole 12, and the tip thereof is attached to the magnet housing hole 12. It may be inserted.

  As described above, the central portions of the insulating sheets 21 and 22 are preliminarily formed into a U-shaped cross section or a V-shaped cross section, and the insulating sheets 21 and 22 are arranged on the magnet storage holes 12 and inserted into the magnet storage holes 12. Thus, the insulating sheets 21 and 22 can be effectively positioned with respect to the magnet housing hole 12. In addition, since the insulating sheets 21 and 22 are tapered, the insulating sheets 21 and 22 can easily wrap the side surfaces of the permanent magnet 13 when the permanent magnet 13 is inserted into the magnet housing hole 12. As a result, the permanent magnet 13 and the insulating sheets 21 and 22 can be smoothly inserted into the magnet housing hole 12, and positional deviation and inclination due to the insertion of the permanent magnet 13 into the magnet housing hole 12 can be suppressed.

  DESCRIPTION OF SYMBOLS 10 Rotor core, 11 Rotor core, 12 Magnet accommodation hole, 12a Inner surface, 13 Permanent magnet, 13a Square, 14 Resin, 20, 21, 22 Insulation sheet, 20a Edge, 30, 31 Mold type, 30a Resin injection port, E width Direction, G gap, L, X width, N short side, T thickness, Z-axis direction.

Claims (1)

A rotor manufacturing method for mounting a permanent magnet in a magnet housing hole of a rotor core,
Tilt together with the permanent magnet when the permanent magnet in the magnet housing hole is inclined with respect to the width direction of the permanent magnet, the width its edges contacts the inner surface of the magnet housing hole prior to the corner of the permanent magnet A single insulating sheet having the magnet is disposed on the magnet housing hole,
Inserting the permanent magnet into the magnet accommodation hole from above the insulation sheet so that the insulation sheet is caught in the magnet accommodation hole,
With the gap formed between the insulating sheet and the inner surface of the magnet housing hole, the permanent magnet is attached to the magnet housing hole ,
After the permanent magnet is attached to the magnet housing hole to inject resin between the between the inner surface of the insulating sheet and the magnet accommodating hole, and the magnet housing hole and the permanent magnet, the rotor production method .

Images