JP6383746B2 - Rotor for rotating electrical machine and method for manufacturing the same - Google Patents

Description

  The present invention relates to a rotor of a rotating electrical machine in which a permanent magnet is fixed by filling a magnet insertion hole of a rotor core with a filler, and a method for manufacturing the same.

  Conventionally, in a rotating electrical machine used for a hybrid vehicle or the like, a rotor is rotatably supported inside a case. The rotor core of the rotor is formed of laminated electromagnetic steel plates, and permanent magnets are fixed to a plurality of slots (magnet insertion holes) formed along the circumferential direction of the rotor core.

  As one method for manufacturing a rotor of such a rotating electric machine, after inserting a permanent magnet into a slot of the rotor, a resin as a filler is injected from a resin injection hole provided in the slot, and the resin is solidified to be permanent magnet A so-called resin injection method for fixing the resin is known.

  In Patent Document 1, even when the gap between the permanent magnet and the magnet insertion hole is narrow or when the resin injection hole is not formed at the intermediate position in the width direction of the magnet insertion hole, It is possible to move the permanent magnet arranged at the outer side in the radial direction of the magnet insertion hole.

JP 2014-82807 A

  However, in the fixing method in which the permanent magnet is moved radially outward of the magnet insertion hole by the injected resin in Patent Document 1, the permanent magnet is brought close to the inner wall surface of the magnet insertion hole by the pressure of the resin. 5 is easily affected by dimensional accuracy, and as shown in FIG. 5A, the permanent magnet 1 moves into the resin insertion path 5 in the magnet insertion hole 3 as it moves away from the resin injection port 4 of the resin injection path 5 along the axial direction. When the magnet is tilted away from the magnet, a high filling pressure is required to bring the permanent magnet 1 toward the radially inner wall surface of the magnet insertion hole. Further, as shown in FIG. 5 (b), when the resin 2 is filled, the permanent magnet 1 may obstruct the path of the resin 2, so that the resin 2 may be blown out from the resin injection port 4, and particularly when the filling pressure is high. There was a problem that balloons were likely to occur.

  The present invention has been made in view of the above-described problems, and the object thereof is to stably fix the permanent magnet even when the filling pressure at the time of filling the filler is lowered, and at the time of filling the filler. It is providing the rotor of a rotary electric machine which can suppress that a filler blows off from a filler injection port, and its manufacturing method.

In order to achieve the above object, the invention according to claim 1
A rotor core (for example, a rotor core 24 in an embodiment described later) having a plurality of magnet insertion holes (for example, a magnet insertion hole 26 in an embodiment described later) formed along the circumferential direction;
A permanent magnet inserted into the magnet insertion hole (for example, a permanent magnet 70 in an embodiment described later);
In the magnet insertion hole, a rotating electrical machine (for example, described later) including a filler (for example, a filler 60 in an embodiment described later) filled between the permanent magnet and the inner wall surface of the magnet insertion hole. A rotor of the rotating electrical machine 10) in the embodiment (for example, a rotor 20 in an embodiment described later),
The magnet insertion hole is provided with a filler injection path (for example, a filler injection path 42 in an embodiment described later) in which the filler is filled,
When the permanent magnet is inserted into the magnet insertion hole, the permanent magnet is moved away from the filler inlet of the filler injection path (for example, the filler inlet 40 in the embodiment described later) along the axial direction. An inclination inducing portion (for example, an inclination inducing portion 70a in an embodiment described later) that is inclined so that the magnet approaches the filler injection path in the magnet insertion hole is provided ,
The rotor of a rotating electrical machine, wherein the permanent magnet is fixed in parallel with the inner wall surface of the magnet insertion hole .

The invention of claim 2 is the rotor of the rotating electrical machine according to claim 1,
The inclination inducing portion is an inclined surface (for example, an inclined surface in an embodiment described later) provided on an axial end surface (for example, a lower surface 71 in an embodiment described later) of the permanent magnet on the side opposite to the filler inlet. 72) The rotor of the rotary electric machine comprised by 72).

The invention of claim 3 is the rotor of the rotating electrical machine according to claim 1,
The inclination inducing portion is constituted by a notch portion (for example, a notch portion 73 in an embodiment described later) provided on the axial end surface of the permanent magnet opposite to the filler inlet. Electric rotor.

The invention of claim 4 is the rotor of the rotating electrical machine according to claim 1,
The inclination inducing portion is a protrusion (for example, a protrusion 75 in an embodiment described later) or an arc portion (for example, an operation described later) provided on the axial end surface of the permanent magnet opposite to the filler inlet. A rotor of a rotating electrical machine, which is constituted by a circular arc part 74) in the form.

The invention of claim 5 is the rotor of the rotating electrical machine according to any one of claims 1 to 4,
The filler injection path is a rotor of a rotating electrical machine provided on the opposite side of the magnet insertion hole from a side facing a stator (for example, a stator 50 in an embodiment described later).

The invention of claim 6
A rotor core (for example, a rotor core 24 in an embodiment described later) having a plurality of magnet insertion holes (for example, a magnet insertion hole 26 in an embodiment described later) formed along the circumferential direction;
A permanent magnet inserted into the magnet insertion hole (for example, a permanent magnet 70 in an embodiment described later);
In the magnet insertion hole, a rotor (for example, a filler) filled between the permanent magnet and the inner wall surface of the magnet insertion hole (for example, a filler 60 in an embodiment described later) (for example, A method for manufacturing a rotor 20) in an embodiment described later,
The magnet insertion hole is provided with a filler injection path (for example, a filler injection path 42 in an embodiment described later) in which the filler is filled,
In the step of arranging the permanent magnet in the magnet insertion hole, the permanent magnet moves away from the filler inlet of the filler injection path (for example, filler inlet 40 in an embodiment described later) along the axial direction. Arranging the permanent magnet so as to approach the filler injection path in the magnet insertion hole,
A method of manufacturing a rotor of a rotating electrical machine, wherein the permanent magnet is fixed in parallel with the inner wall surface of the magnet insertion hole by filling the filler from the filler inlet.

The invention of claim 7 is a method of manufacturing a rotor of a rotating electrical machine according to claim 6,
When filling the filler, the rotor is arranged so that a rotation shaft (for example, a rotation shaft 22 in an embodiment described later) faces in the vertical direction, and the filler inlet is arranged in the vertical direction. A method for manufacturing a rotor of a rotating electrical machine.

  According to the first aspect of the present invention, since the permanent magnet is provided with the inclination inducing portion, the permanent magnet is magnetized as it moves away from the filler inlet of the filler injection path along the axial direction when the filler is injected. The permanent magnet can be inclined so as to approach the filler injection path in the insertion hole, and the permanent magnet can be disposed in the magnet insertion hole in a fixed posture. Thereby, the permanent magnet can be stably fixed even if the filling pressure at the time of injection of the filler is lowered. Moreover, it can suppress that a filler blows out from a filler injection port because a permanent magnet obstructs the course of a filler at the time of filling of a filler.

  According to the second aspect of the present invention, since the inclination inducing portion is composed of an inclined surface provided on the end surface in the axial direction of the permanent magnet on the opposite side to the filler inlet, the inclination inducing portion can be easily formed. . Further, since the permanent magnet is in line contact with the lower mold, the permanent magnet can be brought close to the inner wall surface of the magnet insertion hole with a low filling pressure.

  According to the invention of claim 3, since the inclination inducing portion is composed of a notch provided in the axial end surface of the permanent magnet opposite to the filler inlet, the inclination inducing portion can be easily formed. it can.

  According to the invention of claim 4, since the inclination inducing portion is constituted by the protrusion or the arc portion provided on the axial end surface of the permanent magnet opposite to the filler inlet, the inclination inducing portion can be easily made. Can be formed.

  According to the invention of claim 5, since the filler injection path is provided on the opposite side of the magnet insertion hole from the side facing the stator, the side facing the stator is located between the permanent magnet and the rotor core. Since no filler as a non-magnetic material is interposed, it is possible to prevent deterioration of the performance of the rotating electrical machine.

  According to the invention of claim 6, when the filler is injected, the permanent magnet moves closer to the filler injection path in the magnet insertion hole as it moves away from the filler inlet of the filler injection path along the axial direction. By tilting the permanent magnet, the permanent magnet can be arranged in the magnet insertion hole in a fixed posture. Thereby, the permanent magnet can be stably fixed even if the filling pressure at the time of injection of the filler is lowered. Moreover, it can suppress that a filler blows out from a filler injection port because a permanent magnet obstructs the course of a filler at the time of filling of a filler.

  According to the seventh aspect of the present invention, when filling the filler, the rotor is arranged so that the rotation axis faces in the vertical direction, and the filler inlet is arranged in the vertical direction. By doing so, the filling pressure can be further reduced.

It is sectional drawing of a rotary electric machine provided with the rotor of the rotary electric machine of one Embodiment of this invention. It is a principal part perspective view of the rotor of the rotary electric machine of one Embodiment of this invention. (A) is a cross-sectional view of a permanent magnet in which the inclination inducing portion is an inclined surface, (b) is a cross-sectional view of the permanent magnet in which the inclination inducing portion is a notch, and (c) is an arc in which the inclination inducing portion is an arc. It is sectional drawing of a certain permanent magnet, (d) is sectional drawing of the permanent magnet whose inclination induction part is a projection part. (A) is explanatory drawing which shows the state of the filler filling initial stage, (b) is explanatory drawing which shows the state of the filler filling late stage. It is explanatory drawing which shows the manufacturing method of the rotor of a rotary electric machine by the resin injection method of patent document 1. FIG.

  Hereinafter, an embodiment of a rotor of a rotating electrical machine and a method for manufacturing the same according to the present invention will be described with reference to the accompanying drawings. The drawings are viewed in the direction of the reference numerals.

  FIG. 1 is a cross-sectional view of a rotating electrical machine including a rotor of a rotating electrical machine according to an embodiment of the present invention, and is a perspective view of a main part of the rotor of the rotating electrical machine according to an embodiment of the present invention.

  As shown in FIGS. 1 and 2, the rotating electrical machine 10 according to the present embodiment is fixed to the rotor 20 and the housing 12, and is arranged to face the outer side of the rotor 20 in the radial direction with a slight gap. A so-called inner rotor type rotating electrical machine.

  The stator 50 includes a stator core 51 formed by laminating a plurality of magnetic steel plates (for example, electromagnetic steel plates) 51a in the rotation axis direction, and a plurality of stator coils wound around each tooth (not shown) of the stator core 51. 52. Then, when a current flows through the stator coil 52, a rotating magnetic field is generated in the stator 50 to rotate the rotor 20.

  The rotor 20 includes a rotary shaft 22 rotatably supported on the housing 12 by a bearing 21, a rotor core 24 fitted and fixed to an outer peripheral surface 23a of a substantially bowl-shaped support member 23 fixed to the rotary shaft 22, and a rotor core. 24, a plurality of permanent magnets 70 embedded in 24, and end face plates 30 fixed to both end faces of the rotor core 24.

  The rotor core 24 is formed by laminating a plurality of magnetic steel plates (for example, electromagnetic steel plates) 24a formed in an annular shape of the same shape in the direction of the rotation axis, and a plurality (24 in the embodiment shown in FIG. 2). A magnet insertion hole 26 is provided penetrating in the rotation axis direction.

  The plurality of magnet insertion holes 26 are formed in a substantially V shape so as to open toward the outer peripheral direction of the rotor core 24, and are formed at predetermined intervals for each pair of magnet insertion holes 26 that open in a substantially V shape toward the outer periphery. Has been. The permanent magnet 70 is inserted into each magnet insertion hole 26 while changing the direction of the magnetic pole for each pair of magnet insertion holes 26, and is fixed by a filler.

  In the magnet insertion hole 26, a gap for preventing magnetic flux short-circuiting is formed continuously at the end of the rotor core 24 near the outer peripheral surface 24 b. Also, a magnetic flux short-circuit prevention gap is formed continuously at the end of the rotor core 24 on the side close to the inner peripheral surface 24c. Therefore, when the permanent magnet 70 is inserted into the magnet insertion hole 26 and fixed by the filler, the magnetic flux short-circuit prevention portions 27 and 28 are provided at both ends of the permanent magnet 70.

  In the magnet insertion hole 26, a filler injection port 40 is formed at a substantially central portion of the inner wall surface 26a on the inner diameter side so as to be further depressed toward the inner diameter side. The filler inlet 40 serves as an inlet for the filler 60 when the filler 60 is filled into the gap with the permanent magnet 70 inserted into the magnet insertion hole 26. Further, as shown in FIGS. 4A and 4B, a filler injection path 42 is continuously formed along the axial direction downward from the filler injection port 40. The filler injection path 42 is provided on the opposite side of the magnet insertion hole 26 from the side facing the stator 50, that is, on the inner diameter side in this embodiment.

  Further, when the permanent magnet 70 is inserted into the magnet insertion hole 26, the permanent magnet 70 enters the filler injection path 42 in the magnet insertion hole 26 as the distance from the filler injection port 40 of the filler injection path 42 increases in the axial direction. An inclination inducing portion 70a that is inclined so as to approach is provided. Specifically, as illustrated in FIG. 3A, the inclination inducing portion 70 a is formed from an inclined surface 72 that inclines a lower surface 71 that is an axial end surface of the permanent magnet 70 on the side opposite to the filler injection port 40. It is configured.

  The inclined surface 72 is inclined so as to run upward from the inner diameter side end portion 72 a on the filler injection path 42 side toward the outer diameter side end portion 72 b on the opposite side to the filler injection path 42. Therefore, when the permanent magnet 70 is inserted into the magnet insertion hole 26, as shown in FIG. 4A, the permanent magnet 70 falls to the outer diameter side starting from the inner diameter side end portion 72a of the permanent magnet 70. As the distance from the filler inlet 40 of the filler injection path 42 along the axial direction increases, the magnet insertion hole 26 is inclined so as to approach the filler injection path 42 along the radial direction.

Next, the manufacturing process in the manufacturing method of the rotor of the rotary electric machine of this embodiment is demonstrated.
As shown in FIG. 4A, the rotor core 24 is set in advance between the upper mold 100 and the lower mold 110 with the permanent magnets 70 inserted into the magnet insertion holes 26 of the plurality of electromagnetic steel plates 24a. The Then, the filler 60 is injected into the filler injection port 40 from a nozzle of an injection molding apparatus (not shown).

  At this time, since the inclination inducing portion 70 a is formed in the permanent magnet 70, the permanent magnet 70 moves in the magnet insertion hole 26 as it moves away from the filler inlet 40 of the filler injection path 42 along the axial direction. The upper surface 76 of the permanent magnet 70 is inclined toward the outer diameter side so as to approach the filler injection path 42, that is, away from the filler injection port 40.

  In this state, when the filler 60 is injected into the magnet insertion hole 26, the filler 60 reaches the lower part of the magnet insertion hole 26. Therefore, as shown in FIG. 4B, the filler 60 presses the permanent magnet 70 so that the end on the side where the inclination inducing portion 70 a, which is below the permanent magnet 70, moves to the outer diameter side. Therefore, the permanent magnet 70 can be automatically brought close to the inner wall surface 26 b on the outer diameter side of the magnet insertion hole 26 by the filler 60. Thereby, even if the filling pressure at the time of injection | pouring of the filler 60 is made low, the permanent magnet 70 can be fixed stably.

  As described above, according to the method for manufacturing the rotor 20 of the rotating electrical machine 10 according to the present embodiment, since the permanent magnet 70 is provided with the inclination inducing portion 70a, the filler injection is performed when the filler 60 is injected. The permanent magnet 70 can be inclined so that the permanent magnet 70 approaches the filler injection path 42 in the magnet insertion hole 26 as the distance from the filler inlet 40 of the path 42 along the axial direction increases. It can arrange | position to the magnet insertion hole 26 with the attitude | position which was the same. Thereby, even if the filling pressure at the time of injection | pouring of the filler 60 is made low, the permanent magnet 70 can be fixed stably. Further, since the permanent magnet 70 is inclined so that the upper surface 76 is separated from the filler inlet 40, the filler 60 is injected into the filler 60 because the permanent magnet 70 obstructs the path of the filler when the filler 60 is filled. Blowing out from the inlet 40 can be suppressed.

  Moreover, since the inclination induction part 70a is comprised by inclining the lower surface 71 of the permanent magnet 70, the inclination induction part 70a can be formed easily. Further, the permanent magnet 70 is slippery because the inclined surface 72 is in line contact with the lower mold 110 by the inner diameter side end portion 72a, and the permanent magnet 70 may be brought close to the inner wall surface 26a of the magnet insertion hole 26 with a low filling pressure. it can.

  Further, since the filler injection path 42 is provided on the opposite side of the magnet insertion hole 26 from the side facing the stator 50, the filler injection path 42 is not provided between the permanent magnet 70 and the rotor core 24 on the side facing the stator 50. Since the filler 60 which is a magnetic body is not interposed, it is possible to prevent the performance of the rotating electrical machine from being deteriorated.

  Further, when filling the filler 60, the rotor 20 is arranged so that the rotating shaft 22 faces the vertical direction, and the filler inlet 40 is arranged so as to be vertically upward. The filling pressure can be further reduced.

Hereinafter, modifications of the present invention will be described.
(First modification)
As shown in FIG. 3 (b), the permanent magnet 70 of the first modification has a tilt inducing portion 70 a composed of a notch 73. Specifically, the notch 73 leaves the inner diameter side end 73a on the filler injection path 42 side on the lower surface 71 of the permanent magnet 70, and the outer diameter side end on the opposite side to the filler injection path 42 side. It is formed by cutting 73b into a substantially square cross section.

  Therefore, when the permanent magnet 70 is inserted into the magnet insertion hole 26, the permanent magnet 70 falls to the outer diameter side starting from the inner diameter side end portion 73 a side of the permanent magnet 70, and the permanent magnet 70 serves as a filler for the filler injection path 42. The magnet is inclined so as to approach the filler injection path 42 in the magnet insertion hole 26 as it moves away from the injection port 40 along the axial direction. Therefore, as in the case of the inclined surface 72, the permanent magnet 70 can be arranged in the magnet insertion hole 26 in a fixed posture. Accordingly, the permanent magnet 70 can be stably fixed even when the filling pressure at the time of filling the filler 60 is lowered, and the blowing of the filler 60 from the filler inlet 40 can be suppressed.

(Second modification)
As shown in FIG. 3C, the permanent magnet 70 of the second modified example is configured such that the inclination inducing portion 70 a is an arc portion 74. Specifically, the circular arc portion 74 is formed by forming the lower surface 71 of the permanent magnet 70 into an arc shape with a loose curvature so that the top portion 74a is slightly on the inner diameter side than the radial intermediate portion.

  Therefore, when the permanent magnet 70 is inserted into the magnet insertion hole 26, the permanent magnet 70 falls to the outer diameter side starting from the top 74 a of the permanent magnet 70, and the permanent magnet 70 passes through the filler injection port 40 of the filler injection path 42. The magnet is inclined so as to approach the filler injection path 42 in the magnet insertion hole 26 as it is separated along the axial direction. Therefore, as in the case of the inclined surface 72, the permanent magnet 70 can be arranged in the magnet insertion hole 26 in a fixed posture. Accordingly, the permanent magnet 70 can be stably fixed even when the filling pressure at the time of filling the filler 60 is lowered, and the blowing of the filler 60 from the filler inlet 40 can be suppressed.

(Third Modification)
As shown in FIG. 3 (d), the permanent magnet 70 of the third modification has a tilt inducing portion 70 a composed of a protrusion 75. Specifically, the projecting portion 75 is formed by providing a projection having a substantially triangular downward cross section on the lower surface 71 of the permanent magnet 70 at a position closer to the inner diameter side end portion 75a than the outer diameter side end portion 75b. Yes.

  Therefore, when the permanent magnet 70 is inserted into the magnet insertion hole 26, the permanent magnet 70 falls to the outer diameter side starting from the protrusion 75 of the permanent magnet 70, and the permanent magnet 70 is filled with the filler inlet 40 of the filler injection path 42. As it leaves along the axial direction, it is inclined so as to approach the filler injection path 42 in the magnet insertion hole 26. Therefore, as in the case of the inclined surface 72, the permanent magnet 70 can be arranged in the magnet insertion hole 26 in a fixed posture. Accordingly, the permanent magnet 70 can be stably fixed even when the filling pressure at the time of filling the filler 60 is lowered, and the blowing of the filler 60 from the filler inlet 40 can be suppressed.

In addition, this invention is not limited to embodiment mentioned above, A deformation | transformation, improvement, etc. are possible suitably.
For example, the inclination inducing portion 70a is not limited to the above-described embodiment and modification examples, and can have an arbitrary shape.
Moreover, in the said embodiment and modification, the filler injection port 40 was provided in the inner diameter side of the magnet insertion hole 26, and the permanent magnet 70 fell down to the outer diameter side with respect to the filler injection port 40, but magnet insertion hole 26 may be provided on the outer diameter side of the permanent magnet 70 so that the permanent magnet 70 is tilted toward the inner diameter side with respect to the filler inlet 40.

20 Rotor 22 Rotating shaft 24 Rotor core 26 Magnet insertion hole 40 Filler injection port 42 Filler injection path 50 Stator 60 Filler 70 Permanent magnet 70a Inclination inducing portion 72 Inclined surface 73 Notched portion 74 Arc portion 75 Projection portion

Claims (7)

A rotor core having a plurality of magnet insertion holes formed along the circumferential direction;
A permanent magnet inserted into the magnet insertion hole;
In the magnet insertion hole, a rotor filled with a filler filled between the permanent magnet and the inner wall surface of the magnet insertion hole,
The magnet insertion hole is provided with a filler injection path filled with the filler,
When the permanent magnet is inserted into the magnet insertion hole, the permanent magnet moves into the filler injection path in the magnet insertion hole as it moves along the axial direction from the filler injection port of the filler injection path. An inclination inducing part that inclines so as to approach is provided ,
The rotor of a rotating electrical machine, wherein the permanent magnet is fixed in parallel with the inner wall surface of the magnet insertion hole . The rotor of the rotating electrical machine according to claim 1,
The said inclination induction part is a rotor of a rotary electric machine comprised by the inclined surface provided in the axial direction end surface of the said permanent magnet on the opposite side to the said filler injection port. The rotor of the rotating electrical machine according to claim 1,
The said inclination induction part is a rotor of a rotary electric machine comprised by the notch part provided in the axial direction end surface of the said permanent magnet on the opposite side to the said filler inlet. The rotor of the rotating electrical machine according to claim 1,
The said inclination induction part is a rotor of a rotary electric machine comprised by the protrusion part or circular arc part provided in the axial direction end surface of the said permanent magnet on the opposite side to the said filler injection port. A rotor of a rotating electrical machine according to any one of claims 1 to 4,
The rotor of a rotating electrical machine, wherein the filler injection path is provided on a side opposite to a side facing the stator of the magnet insertion hole. A rotor core having a plurality of magnet insertion holes formed along the circumferential direction;
A permanent magnet inserted into the magnet insertion hole;
In the magnet insertion hole, a filling method for filling a space between the permanent magnet and the inner wall surface of the magnet insertion hole;
The magnet insertion hole is provided with a filler injection path filled with the filler,
In the step of arranging the permanent magnet in the magnet insertion hole, the permanent magnet approaches the filler injection path in the magnet insertion hole as it moves away from the filler injection port of the filler injection path along the axial direction. Arranging the permanent magnet,
A method of manufacturing a rotor of a rotating electrical machine, wherein the permanent magnet is fixed in parallel with the inner wall surface of the magnet insertion hole by filling the filler from the filler inlet. A method for manufacturing a rotor of a rotating electrical machine according to claim 6,
A method of manufacturing a rotor of a rotating electrical machine, wherein when filling the filler, the rotor is arranged so that a rotation axis thereof is oriented in a vertical direction, and the filler inlet is arranged vertically upward.

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