JP6761762B2 - Rotor laminated iron core and its manufacturing method - Google Patents

Description

The present disclosure relates to a rotor laminated iron core and a method for manufacturing the same.

The rotor laminated iron core is usually inserted into a laminated body in which a plurality of punched members obtained by punching a metal plate (for example, an electromagnetic steel plate) into a predetermined shape are laminated and a magnet insertion hole extending in the laminated direction of the laminated body. It is composed of a permanent magnet and a resin material filled in the gap between the magnet insertion hole and the permanent magnet. When the permanent magnet and the metal plate are in contact with each other, an eddy current is generated at the contact point, and the eddy current flows through the metal plate, which may cause a loss of electrical energy.

Therefore, Patent Document 1 describes a large number of first metal plates provided with a first through hole forming a magnet insertion hole, and at least one second metal plate provided with a second through hole forming a magnet insertion hole. It is disclosed that a laminated body of rotor laminated iron cores is constructed by using a metal plate. The size of the first through hole is larger than the outer shape of the permanent magnet. A plurality of protrusions for holding the outer peripheral surface of the permanent magnet are provided on the peripheral edge of the second through hole. When a permanent magnet is inserted into the magnet insertion hole of such a laminated body, the permanent magnet is held by the protrusion of the second through hole in a small number of second metal plates and comes into contact with a large number of first metal plates. It becomes difficult. Therefore, the contact area between the metal plate and the permanent magnet is minimized, and the loss of electrical energy due to the eddy current is greatly reduced.

Japanese Unexamined Patent Publication No. 2013-110827

The present disclosure describes a rotor laminated iron core capable of suppressing a loss of electric energy due to an eddy current and further improving the efficiency of a motor, and a method for manufacturing the same.

The rotor laminated iron core according to one aspect of the present disclosure includes a plurality of first iron core members, a laminated body in which at least one second iron core member is laminated, and a permanent magnet. The first iron core member is provided with a first through hole that penetrates in the stacking direction of the laminated body and is larger than the outer shape of the permanent magnet when viewed from the stacking direction. The second iron core member has a second through hole that penetrates in the stacking direction and is larger than the outer shape of the permanent magnet when viewed from the stacking direction, and extends along the inner peripheral surface of the second through hole and has an inner circumference thereof. An insulating holder that covers the entire surface is provided. The laminated body is provided with a magnet insertion hole formed by communicating the first and second through holes in the stacking direction. The permanent magnet is inserted into the magnet insertion hole while being held by the insulating holder.

A method for manufacturing a rotor laminated iron core according to another aspect of the present disclosure includes a first iron core member provided with a first through hole larger than the outer shape of the permanent magnet, and a second iron core member larger than the outer shape of the permanent magnet. The first step of preparing the second iron core member provided with the through hole, and the second step of arranging the core in the second through hole so as not to contact the inner peripheral surface of the second through hole. After filling an insulating material between the inner peripheral surface of the second through hole and the core, the core is removed, and the core extends along the inner peripheral surface of the second through hole and the inner circumference thereof. The first iron core member and the second iron core member are laminated so that the third step of forming the insulating holder covering the entire surface and the first and second through holes communicate with each other to form the magnet insertion hole. The fourth step of forming the laminated body and the fifth step of inserting the permanent magnet into the magnet insertion hole and holding the permanent magnet in the insulation holder are included.

According to the rotor laminated iron core and the manufacturing method thereof according to the present disclosure, it is possible to suppress the loss of electric energy due to the eddy current and to further improve the efficiency of the motor.

FIG. 1 is a perspective view showing an example of a rotor laminated iron core. FIG. 2 is a sectional view taken along line II-II of FIG. FIG. 3 is an enlarged view of part III surrounded by the alternate long and short dash line circle in FIG. FIG. 4 is an exploded perspective view of the laminated body. FIG. 5A is a plan view showing a block body provided with an insulation holder, and FIG. 5B is a plan view showing an enlarged through hole (magnet insertion hole) in the block body. FIG. 6 is a schematic view showing an example of a rotor laminated iron core manufacturing apparatus. FIG. 7 is a flowchart for explaining an example of a method for manufacturing a rotor laminated iron core. FIG. 8 is a diagram for explaining a manufacturing process of the rotor laminated iron core. FIG. 9 is a cross-sectional view of another example of the rotor laminated iron core when cut in the same manner as in FIG. FIG. 10 is a cross-sectional view when another example of the rotor laminated iron core is cut in the same manner as in FIG.

Since the embodiments according to the present disclosure described below are examples for explaining the present invention, the present invention should not be limited to the following contents.

<< Outline of the embodiment >>
[1] The rotor laminated iron core according to one example of the present embodiment includes a plurality of first iron core members, a laminated body in which at least one second iron core member is laminated, and a permanent magnet. The first iron core member is provided with a first through hole that penetrates in the stacking direction of the laminated body and is larger than the outer shape of the permanent magnet when viewed from the stacking direction. The second iron core member has a second through hole that penetrates in the stacking direction and is larger than the outer shape of the permanent magnet when viewed from the stacking direction, and extends along the inner peripheral surface of the second through hole and has an inner circumference thereof. An insulating holder that covers the entire surface is provided. The laminated body is provided with a magnet insertion hole formed by communicating the first and second through holes in the stacking direction. The permanent magnet is inserted into the magnet insertion hole while being held by the insulating holder.

In the rotor laminated iron core according to one example of the present embodiment, an insulating holder that extends along the inner peripheral surface of the second through hole and covers the entire inner peripheral surface is provided. The permanent magnet is inserted into the magnet insertion hole while being held by the insulating holder. Therefore, even if the permanent magnet swings in the magnet insertion hole (inside the second through hole), the permanent magnet does not come into contact with the first and second iron core members. Therefore, no eddy current is generated between the permanent magnet and the first and second iron core members, so that the loss of electrical energy due to the eddy current is suppressed. As a result, when the motor is configured by using the rotor laminated iron core according to one example of the present embodiment, it is possible to further improve the efficiency of the motor. Further, the size of the first through hole may be larger than the outer shape of the permanent magnet so that the permanent magnet does not come into contact with the first through hole. Therefore, the gap generated between the first through hole and the permanent magnet can be set to the minimum. Therefore, since the decrease in the volume of the first iron core member can be suppressed, the motor performance can be improved.

[2] In the rotor laminated iron core according to the first item, the second iron core member may be a block body in which a plurality of punched members in which a metal plate is punched along a predetermined shape are laminated. .. In this case, the area of the inner peripheral surface of the second through hole is larger than that in the case where the second iron core member is composed of one punched member. Therefore, the insulation holder can be firmly fixed to the inner peripheral surface of the second through hole.

[3] In the rotor laminated iron core according to the first or second item, the insulation holder has a tapered shape that protrudes inward from one end face of the laminated body toward the other end face in the stacking direction. You may. In this case, when inserting the permanent magnet into the magnet insertion hole, the permanent magnet is inserted in the forward direction (the direction from one end face of the laminated body to the other end face) with respect to the insulating holder having a tapered shape. Therefore, the permanent magnet can be smoothly attached to the insulation holder.

[4] In the rotor laminated iron core according to any one of the above items 1 to 3, the laminated body is configured such that the second iron core member is sandwiched between the first iron core members. The outer shape of the second through hole is larger than the outer shape of the first through hole, and even if at least a part of the inner peripheral surface of the insulation holder projects inward from the inner peripheral surface of the first through hole. Good. In this case, the outer peripheral surface of the insulation holder is located outside the inner peripheral surface of the first through hole. Therefore, the base end portion of the insulation holder (the portion of the insulation holder on the side that comes into contact with the inner peripheral surface of the second through hole) is sandwiched by a pair of first iron core members. Therefore, since the insulation holder is held by the pair of first iron core members, the insulation holder is more difficult to fall out from the second through hole. Further, since at least a part of the inner peripheral surface of the insulating holder is located inward of the inner peripheral surface of the first through hole, the permanent magnet can be held in the part.

[5] In the rotor laminated iron core according to any one of the above items 1 to 4, the peripheral edge of the second through hole has a recess recessed toward the outside of the second through hole. It is provided and the insulation holder may be fitted with the recess. In this case, the anchor effect generated between the insulation holder and the recess makes it more difficult for the insulation holder to fall out of the second through hole.

[6] In the rotor laminated iron core according to the above item 5, the recesses may be recessed in a direction intersecting the radial direction of the laminated body when viewed from the stacking direction. In this case, even if a centrifugal force acts on the insulation holder in the radial direction of the laminate during rotation of the rotor laminated iron core, the insulation holder is held in the second through hole against the centrifugal force. .. Therefore, the insulation holder is more difficult to fall off from the second through hole.

[7] In the rotor laminated iron core according to any one of the above items 1 to 6, the permanent magnet and the insulation holder may be partially separated from each other. In this case, a gap is partially created between the permanent magnet and the insulation holder. Therefore, after the permanent magnet is inserted into the magnet insertion hole and held by the insulation holder, when the magnet insertion hole is filled with molten resin and the permanent magnet is resin-sealed in the magnet insertion hole, the gap is concerned. Functions as a flow path for molten resin. Therefore, the molten resin can be efficiently filled in the magnet insertion hole.

[8] In the method for manufacturing a rotor laminated iron core according to another example of the present embodiment, the first iron core member provided with the first through hole larger than the outer shape of the permanent magnet and the outer shape of the permanent magnet The first step of preparing the second iron core member provided with the large second through hole, and the core in the second through hole so as not to come into contact with the inner peripheral surface of the second through hole. After filling the insulating material between the inner peripheral surface of the second through hole and the core in the second step of arranging, the core is removed and extends along the inner peripheral surface of the second through hole. Further, the first iron core member and the second iron core are formed so that the third step of forming the insulating holder covering the entire inner peripheral surface and the first and second through holes communicate with each other to form the magnet insertion hole. It includes a fourth step of laminating the members to form a laminated body, and a fifth step of inserting a permanent magnet into the magnet insertion hole and holding the permanent magnet in the insulation holder. In this case, the same action and effect as in the above item 1 is obtained.

[9] In the method according to the above item 8, since the core has a tapered shape, the peripheral side surface of the core is a tapered surface, and in the second step, the peripheral side surface of the core and the second The core may be arranged in the second through hole so as to face the inner peripheral surface of the through hole. In this case, the same action and effect as in the third item is obtained.

<< Example of Embodiment >>
Hereinafter, an example of the embodiment according to the present disclosure will be described in more detail with reference to the drawings. In the following description, the same code will be used for the same element or the element having the same function, and duplicate description will be omitted.

[Structure of rotor laminated iron core]
First, the configuration of the rotor laminated iron core 1 will be described with reference to FIGS. 1 to 4. The rotor laminated iron core 1 is a part of a rotor. A rotor is formed by attaching an end face plate and a shaft to the rotor laminated iron core 1. An electric motor is constructed by combining the rotor with the stator. As shown in FIG. 1, the rotor laminated iron core 1 includes a laminated body 10, a plurality of permanent magnets 12, and a plurality of resin materials 14.

The laminated body 10 has a plurality of block bodies B (first iron core member) and a plurality of block bodies C (second iron core member; holding block). In the example shown in FIGS. 1 to 4, the laminated body 10 has six block bodies B1 to B6 and two block bodies C1 and C2. Specifically, the block bodies B1, C1, B2 to B5, C2 and B6 are stacked in this order from the upper side to the lower side in FIGS. 1, 2 and 4. In other words, in the present embodiment, a pair of block bodies B sandwich the block body C. In the stacking direction of the laminated body 10 (hereinafter, simply referred to as “stacking direction”), the laminated body 10 may have a plurality of block bodies B and at least one block body C.

As shown in FIGS. 2 and 4, the block body B is a laminated body in which a plurality of punched members 30A are stacked. In the present embodiment, the number of laminated members 30A is 6 as shown in FIGS. 2 to 4, but may be 2 or more. As shown in FIG. 4, a through hole Ba extending in the stacking direction (thickness direction) is provided in the central portion of the block body B. Therefore, the block body B has a cylindrical shape extending along the central axis Ax. The punched member 30A is a plate-shaped body (punched member) in which an electromagnetic steel plate W (described later), which is a metal plate, is punched into a predetermined shape.

As shown in FIGS. 2 and 4, the block body C is a laminated body in which a plurality of punched members 30B are stacked. In the present embodiment, the number of laminated members 30B is three as shown in FIGS. 2 to 4, but may be two or more. As shown in FIG. 4, a through hole Ca extending in the stacking direction (thickness direction) is provided in the central portion of the block body C. Therefore, the block body C has a cylindrical shape extending along the central axis Ax. The punched member 30B is a plate-shaped body (punched member) in which an electromagnetic steel plate W (described later), which is a metal plate, is punched into a predetermined shape.

In the state of the laminated body 10 in which the block bodies B and C are laminated, the through hole Ba of the block body B and the through hole Ca of the block body C communicate with each other in the stacking direction, and the through hole Ca of the block body C communicates with each other in the stacking direction. It constitutes a shaft hole 10a extending to. A shaft (not shown) is inserted into the shaft hole 10a.

The punching members 30A adjacent to each other in the stacking direction are fastened by the caulking portion 16. The punching members 30B adjacent to each other in the stacking direction are fastened by the caulking portion 16. The block bodies B and C that are adjacent to each other in the stacking direction are not fastened by the caulking portion 16. Specifically, as shown in FIG. 2, the caulking portion 16 includes the caulking 16a formed on the punching members 30A and 30B forming other than the lowermost layers of the block bodies B and C, and the most of the block bodies B and C. It has through holes 16b formed in the punching members 30A and 30B forming the lower layer. The caulking 16a is composed of a concave portion formed on the front surface side of the punching members 30A and 30B and a convex portion formed on the back surface side of the punching members 30A and 30B.

The concave portion of the caulking 16a of one punching member 30A, 30B is joined to the convex portion of the caulking 16a of another punching member 30A, 30B adjacent to the surface side of the one punching member 30A, 30B. The convex portion of the caulking 16a of the one punching member 30A, 30B is joined to the concave portion of the caulking 16a of the other punching members 30A, 30B adjacent to each other on the back surface side of the one punching member 30A, 30B. The convex portion of the caulking 16a of the punching members 30A and 30B adjacent to the lowermost layers of the block bodies B and C is joined to the through hole 16b. The through hole 16b has a function of preventing the block bodies B and C to be manufactured next from being fastened to the already manufactured block bodies B and C by the caulking 16a when the block bodies B and C are continuously manufactured. And, it has a function of preventing the adjacent block bodies B and C from being fastened by the caulking 16a.

A plurality of through holes Bb and Cb are formed in the block bodies B and C, respectively. In the present embodiment, as shown in FIGS. 4 and 5A, 16 through holes Bb (first through holes) are formed in the block body B, and 16 through holes Bb (first through holes) are formed in the block body C. Cb (second through hole) is formed. As shown in FIG. 4, these through holes Bb and Cb are arranged at predetermined intervals along the outer peripheral edge of the block bodies B and C. Specifically, the block body B is assembled so that two through holes Bb form a V shape that expands toward the outer peripheral edge side of the block body B, and eight sets of through holes Bb form a central axis Ax. It is arranged around every 45 °. Similarly, the block body C is assembled so that two through holes Cb form a V shape that expands toward the outer peripheral edge side of the block body C, and eight sets of through holes Cb are formed around the central axis Ax. It is arranged approximately every 45 °.

As shown in FIG. 4, the through holes Bb and Cb extend along the central axis Ax (stacking direction) and penetrate the block bodies B and C. As shown in FIGS. 1 to 3, the sizes of the through holes Bb and Cb are larger than the outer shape of the permanent magnet 12 when viewed from the central axis Ax direction. As shown in FIGS. 2 to 4, the outer shape of the through hole Cb is larger than the outer shape of the through hole Bb when viewed from the central axis Ax direction.

As shown in FIG. 1, the shape of the through hole Bb is rectangular in the present embodiment, but other shapes (for example, circular shape, elliptical shape, oval shape (square shape with rounded corners)), It may be a polygonal shape, etc.). The position, shape and number of the through holes Bb may be changed according to the application of the motor, the required performance and the like.

As shown in FIGS. 4 and 5, the shape of the through hole Cb is rectangular as a whole in the present embodiment, but other shapes (for example, circular shape, elliptical shape, oval shape (corner is)). It may have a round square shape), a polygonal shape, etc.). The position, shape and number of the through holes Cb may be changed according to the application of the motor, the required performance and the like. At least one recess Cc that is recessed toward the outside of the through hole Cb is provided on the peripheral edge of the through hole Cb. In the present embodiment, two recesses Cc are arranged on each pair of long sides of the through holes Cb, as shown in FIGS. 4 and 5A. That is, the recess Cc is recessed in a direction intersecting the radial direction of the laminated body 10 (block body C) when viewed from the stacking direction. The shape of the concave portion Cc may be a semicircular shape as shown in FIGS. 4 and 5 (a), or may be various shapes such as a rectangular shape, a triangular shape, and a trapezoidal shape.

In the state of the laminated body 10 in which the block bodies B and C are laminated, each through hole Bb of the block body B and each through hole Cb of the block body C correspond to each other. As a result, each through hole Bb and each through hole Cb communicate with each other in the stacking direction, and each constitutes a magnet insertion hole 10b extending in the stacking direction. That is, the laminated body 10 is provided with a plurality of magnet insertion holes 10b arranged at predetermined intervals along the outer peripheral edge thereof.

As shown in FIGS. 2 to 5, an insulating holder 18 is provided on the inner peripheral surface of the through hole Cb. The insulation holder 18 extends along the inner peripheral surface of the through hole Cb and covers the entire inner peripheral surface. Therefore, the insulation holder 18 has an annular shape in the present embodiment. That is, as shown in FIGS. 4 and 5, a through hole 18a extending in the stacking direction is provided in the central portion of the insulation holder 18.

The through hole 18a has a function of holding the permanent magnet 12 inserted in the through hole 18a. At least a part of the inner peripheral surface of the through hole 18a comes into contact with the outer peripheral surface of the permanent magnet 12. In the present embodiment, as shown in FIG. 5, the through hole 18a and the permanent magnet 12 are partially separated from each other. A gap V is provided between the through hole 18a and the permanent magnet 12.

The base end portion of the insulation holder 18 (the portion of the insulation holder 18 on the side that comes into contact with the inner peripheral surface of the through hole Cb) is filled in the recess Cc as shown in FIGS. 4 and 5. .. The insulation holder 18 is fitted with the recess Cc. In the present embodiment, since the pair of block bodies B sandwich the block body C, the inner peripheral surface of the through hole Cb is recessed with respect to the inner peripheral surface of the through hole Bb. As shown in FIGS. 2 and 3, the base end portion of the insulation holder 18 that is in contact with the inner peripheral surface of the through hole Cb is sandwiched by a pair of block bodies B.

As shown in FIGS. 2 and 3, the tip portion of the insulation holder 18 (the inner portion of the through hole Cb of the insulation holder 18) is from the upper surface (one end surface) to the lower surface of the laminate 10 in the stacking direction. It has a tapered shape that protrudes inward toward (the other end face). The inner peripheral surface of the insulation holder 18 (through hole 18a) is a tapered surface that narrows toward the bottom. At least a part (lower part of the tapered surface) of the inner peripheral surface of the insulation holder 18 (through hole 18a) projects inward from the inner peripheral surface of the through hole Bb. As shown in FIGS. 2 and 3, the outer shape of the through hole 18a is smaller than the outer shape of the through hole Bb when viewed from the central axis Ax direction.

The insulation holder 18 may be made of an insulator. Examples of the insulator include thermosetting resin, thermoplastic resin, glass and the like. Specific examples of the thermosetting resin include a resin composition containing a main agent and an additive. Examples of the main agent include an epoxy resin, a curing initiator, and a filler. Examples of the additive include a flame retardant, a stress reducing agent, a coloring agent and the like. The insulation holder 18 may be made of a metal material having a higher electrical resistivity than the metal plate (electromagnetic steel plate W) forming the punched members 30A and 30B. Examples of the metal material having a higher electrical resistivity than the electromagnetic steel sheet W include stainless steel and the like.

The permanent magnet 12 is arranged in the magnet insertion hole 10b as shown in FIGS. 1 and 2. In the present embodiment, one permanent magnet 12 is inserted in one magnet insertion hole 10b. As shown in FIGS. 2 and 3, the permanent magnet 12 is held by the insulating holder 18 in the magnet insertion hole 10b. More specifically, the outer peripheral surface of the permanent magnet 12 is in contact with a part (lower part of the tapered surface) of the inner peripheral surface of the through hole 18a of the insulating holder 18. The permanent magnet 12 may be held by the insulation holders 18 of at least two blocks C separated in the stacking direction. In this case, the permanent magnet 12 is less likely to tilt in the magnet insertion hole 10b. The type of the permanent magnet 12 may be determined according to the application of the motor, the required performance, and the like. For example, it may be a sintered magnet or a bonded magnet.

The resin material 14 is filled in the magnet insertion hole 10b after the permanent magnet 12 is inserted. The resin material 14 has a function of fixing the permanent magnet 12 in the magnet insertion hole 10b and a function of joining the punching members 30A and 30B adjacent to each other in the vertical direction. Examples of the resin material 14 include thermosetting resins and thermoplastic resins. When the insulation holder 18 is made of resin, the composition of the resin material 14 may be the same as or different from that of the insulation holder 18.

[Rotor laminated iron core manufacturing equipment]
Subsequently, the manufacturing apparatus 100 of the rotor laminated iron core 1 will be described with reference to FIG.

The manufacturing apparatus 100 is an apparatus for manufacturing a rotor laminated iron core 1 from an electromagnetic steel plate W (plate to be processed) which is a strip-shaped metal plate. The manufacturing apparatus 100 includes an anchorer 110, a sending apparatus 120, a punching apparatus 130, a processing apparatus 140, a laminating apparatus 150, a magnet mounting apparatus 160, and a controller 170 (control unit).

The uncoiler 110 rotatably holds the coil material 111 in a state where the coil material 111, which is a strip-shaped electromagnetic steel plate W wound in a coil shape, is mounted. The delivery device 120 has a pair of rollers 121 and 122 that sandwich the electromagnetic steel plate W from above and below. The pair of rollers 121 and 122 rotate and stop based on an instruction signal from the controller 170, and intermittently and sequentially feed the electromagnetic steel plate W toward the punching device 130.

The length of the electromagnetic steel plate W constituting the coil material 111 may be, for example, about 500 m to 10000 m. The thickness of the electromagnetic steel sheet W may be, for example, about 0.1 mm to 0.5 mm. The thickness of the electromagnetic steel sheet W may be, for example, about 0.1 mm to 0.3 mm from the viewpoint of obtaining the rotor laminated iron core 1 having more excellent magnetic properties. The width of the electromagnetic steel plate W may be, for example, about 50 mm to 500 mm.

The punching device 130 operates based on an instruction signal from the controller 170. The punching device 130 has a function of sequentially punching the electromagnetic steel sheets W intermittently sent out by the sending device 120 to form punching members 30A and 30B, and sequentially punching members 30A and 30B obtained by punching. It has a function of manufacturing a plurality of block bodies B and C by stacking them while stacking them, and a function of temporarily stacking a plurality of block bodies B and C to form a temporary laminated body 11.

When the temporary laminated body 11 is discharged from the punching device 130, it is placed on a conveyor Cv1 provided so as to extend between the punching device 130 and the processing device 140. The conveyor Cv1 operates based on the instruction from the controller 170, and sends the temporary laminated body 11 to the processing device 140.

The processing apparatus 140 has a function of taking out the block body C from the temporary laminated body 11 and providing an insulation holder 18 in each through hole Cb of the block body C. The processing apparatus 140 re-stacks the block body C provided with the insulation holder 18 on the block body B to reconstruct the temporary laminated body 11. The temporary laminate 11 discharged from the processing apparatus 140 is placed on a conveyor Cv2 provided so as to extend between the processing apparatus 140 and the lamination apparatus 150. The conveyor Cv2 operates based on the instruction from the controller 170, and sends the temporary laminated body 11 to the laminating device 150.

The laminating device 150 has a function of re-laminating the blocks B and C of the temporary laminated body 11 sent from the conveyor Cv2 in a predetermined order to form the laminated body 10. The laminated body 10 discharged from the laminating device 150 is placed on a conveyor Cv3 provided so as to extend between the laminating device 150 and the magnet mounting device 160. The conveyor Cv3 operates based on the instruction from the controller 170, and sends the laminated body 10 to the magnet mounting device 160.

The magnet mounting device 160 operates based on an instruction signal from the controller 170. The magnet mounting device 160 has a function of inserting at least one permanent magnet 12 into each magnet insertion hole 10b and a work of filling each magnet insertion hole 10b into which the permanent magnet 12 is inserted with a resin material 14. It has a function to perform.

The controller 170 includes, for example, a sending device 120, a punching device 130, a processing device 140, a laminating device 150, and a magnet mounting device based on a program recorded on a recording medium (not shown) or an operation input from an operator. An instruction signal for operating each of the 160 is generated, and the instruction signal is transmitted to the sending device 120, the punching device 130, the processing device 140, the laminating device 150, and the magnet mounting device 160, respectively.

[Manufacturing method of rotor laminated iron core]
Subsequently, a method for manufacturing the rotor laminated iron core 1 will be described with reference to FIGS. 7 and 8.

First, the temporary laminate 11 is formed (see step S1 in FIG. 7). Specifically, based on the instruction of the controller 170, the sending device 120 sends the electromagnetic steel sheet W to the punching device 130, and the punching device 130 punches the workpiece W to the electromagnetic steel sheet W into a predetermined shape. As a result, the punching member 30A is formed. By repeating this punching process, a plurality of punching members 30A are laminated with each other while being fastened to each other by the caulking portion 16, and one block body B is manufactured (first step). Similarly, the punching member 30B is formed from the electromagnetic steel plate W, and a predetermined number of punching members 30B are laminated while being fastened to each other by the caulking portion 16 to manufacture one block body C (first step). ). By repeating this process, the punching device 130 stacks a plurality of block bodies B1 to B6, C1 and C2 to form a temporary laminated body 11 (see FIG. 7). At this time, the block bodies B1 to B6, C1 and C2 constituting the temporary laminated body 11 are not fastened to each other and can be freely moved and removed.

Subsequently, based on the instruction of the controller 170, the conveyor Cv1 conveys the temporary laminated body 11 discharged from the punching device 130 to the processing device 140. First, the processing apparatus 140 takes out the block body C from the temporary laminated body 11 as shown in FIG. 8A. Next, the processing apparatus 140 arranges the core 40 in each through hole Cb of the block body C as shown in FIG. 8 (b) (second step). At this time, the core 40 does not come into contact with the inner peripheral surface of the through hole Cb. In the present embodiment, the core 40 has a tapered shape as shown in FIG. More specifically, the peripheral side surface of the core 40 has a tapered surface. The peripheral side surface of the core 40 arranged in the through hole Cb faces the inner peripheral surface of the through hole Cb.

Next, the processing apparatus 140 fills the space between the core 40 and the through hole Cb with an insulating material as shown in FIG. 8 (c). Next, the processing apparatus 140 takes out the core 40 from the insulation holder 18 as shown in FIG. 8 (d). As a result, the insulation holder 18 is provided in the through hole Cb (third step; see step S2 in FIG. 7). Next, the processing apparatus 140 re-stacks the block body C provided with the insulation holder 18 on the block body B to reconstruct the temporary laminated body 11.

Subsequently, the conveyor Cv2 conveys the temporary laminated body 11 discharged from the processing device 140 to the laminating device 150 based on the instruction of the controller 170. The laminating device 150 transloads the block bodies B1 to B6 and C1 and C2 forming the temporary laminating body 11 in a predetermined order. Specifically, the block bodies B and C are re-stacked in the order of the block bodies B1, C1, B2 to B5, C2 and B6 to form the laminated body 10 (fourth step; see step S3 in FIG. 7). ..

Next, based on the instruction of the controller 170, the conveyor Cv3 conveys the obtained laminate 10 to the magnet mounting device 160. When the laminate 10 reaches the magnet attachment device 160, the controller 170 instructs the magnet attachment device 160 to insert one permanent magnet 12 into each magnet insertion hole 10b of the laminate 10 (fifth step; Step S4 in FIG. 7). As a result, the permanent magnet 12 is held by the through hole 18a of the insulation holder 18.

Next, the controller 170 instructs the magnet mounting device 160 to fill and solidify the molten resin material 14 in each magnet insertion hole 10b (see step S5 in FIG. 7). At this time, since the gap V is provided between the through hole 18a and the permanent magnet 12, the molten resin flows through the gap V and fills the entire magnet insertion hole 10b. In this way, the solidified resin material 14 fixes each permanent magnet 12 in each magnet insertion hole 10b, and integrates the block bodies B1 to B6, C1 and C2. From the above, the rotor laminated iron core 1 is obtained.

After that, the shaft is inserted into the shaft hole 10a, and the shaft is fixed to the rotor laminated iron core 1 with a key or the like (see step S6 in FIG. 7). Next, end face plates are arranged on both end faces of the rotor laminated iron core 1 (see step S6 in FIG. 7). The end face plate may be fixed to the end face of the rotor laminated iron core 1 by caulking, may be fixed to the rotor laminated iron core 1 by screwing a nut to the shaft, or may be fixed to the rotor laminated iron core 1 by a key or the like. It may be fixed to the shaft. In this way, a rotor including the rotor laminated iron core 1, the shaft, and the end face plate is obtained.

[Action]
In the present embodiment as described above, the insulation holder 18 is provided so as to extend along the inner peripheral surface of the through hole Cb over the entire inner peripheral surface. The permanent magnet 12 is inserted into the magnet insertion hole 10b while being held by the insulating holder 18. Therefore, even if the permanent magnet 12 swings in the magnet insertion hole 10b (inside the through hole Cb), the permanent magnet 12 does not come into contact with the block bodies B and C. Therefore, since an eddy current is not generated between the permanent magnet 12 and the blocks B and C, the loss of electrical energy due to the eddy current is suppressed. As a result, when the motor is configured by using the rotor laminated iron core 1, it is possible to further improve the efficiency of the motor. Further, the size of the through hole Bb may be larger than the outer shape of the permanent magnet 12 so that the permanent magnet 12 does not come into contact with the through hole Bb. Therefore, the gap generated between the through hole Bb and the permanent magnet 12 can be set to the minimum. Therefore, since the decrease in the volume of the block body B can be suppressed, the motor performance can be improved.

In the present embodiment, the block body C is configured by laminating a plurality of punched members 30B in which the electromagnetic steel plate W is punched along a predetermined shape. Therefore, the area of the inner peripheral surface of the through hole Cb is larger than that of a single punched member 30B. Therefore, the insulation holder 18 can be firmly fixed to the inner peripheral surface of the through hole Cb.

In the present embodiment, the insulation holder 18 has a tapered shape that projects inward from the upper surface (one end face) to the lower surface (the other end face) of the laminated body 10 in the stacking direction. Therefore, when the permanent magnet 12 is inserted into the magnet insertion hole 10b, the permanent magnet 12 is inserted in the forward direction (direction from the upper surface to the lower surface of the laminated body 10) with respect to the insulating holder 18 having a tapered shape. Therefore, the permanent magnet 12 can be smoothly attached to the insulation holder 18.

In the present embodiment, the laminated body 10 is configured such that the block body C is sandwiched between the pair of block bodies B, and the outer shape of the through hole Cb is larger than the outer shape of the through hole Bb. Therefore, the outer peripheral surface of the insulation holder 18 is located outside the inner peripheral surface of the through hole Bb. Therefore, the base end portion of the insulation holder 18 (the portion of the insulation holder 18 on the side that comes into contact with the inner peripheral surface of the through hole Cb) is sandwiched by the pair of block bodies B. As a result, since the base end portion of the insulation holder 18 is held by the pair of block bodies B, the insulation holder 18 is more difficult to fall off from the through hole Cb. At this time, since at least a part of the inner peripheral surface of the insulation holder 18 is located inward of the inner peripheral surface of the through hole Bb, the permanent magnet 12 can be held in the part.

In the present embodiment, the peripheral edge of the through hole Cb is provided with a recess Cc that is recessed toward the outside of the through hole Cb, and the insulation holder 18 is fitted with the recess Cc. Therefore, due to the anchor effect generated between the insulation holder 18 and the recess Cc, the insulation holder 18 is more difficult to fall off from the through hole Cb.

In the present embodiment, the recess Cc is recessed in a direction intersecting the radial direction of the laminated body 10 when viewed from the stacking direction. Therefore, even if a centrifugal force acts on the insulating holder 18 in the radial direction of the laminated body 10 when the rotor laminated iron core 1 is rotated, the insulating holder 18 is held in the through hole Cb against the centrifugal force. To. Therefore, the insulation holder 18 is more difficult to fall off from the through hole Cb.

[Other Embodiments]
Although the embodiments according to the present disclosure have been described in detail above, various modifications may be added to the above embodiments within the scope of the gist of the present invention. For example, as shown in FIG. 9, in the laminated body 10, the block bodies B1, ¹ C1, B2, ¹ C2, B3, B4, ² C1, B5, ² C2, B6 are formed from the upper side to the lower side. It may be configured by being laminated in order. In this case, two permanent magnets 12A and 12B are inserted into one magnet insertion hole 10b so as to line up in the stacking direction. Specifically, the permanent magnet 12A is inserted into the through holes Cb of the two block bodies ¹ C1 and ¹ C2, and the two insulation holders 18A provided in the through holes Cb of the block bodies ¹ C1 and ¹ C2. Held by. Permanent magnets 12B, the two block bodies ^{2 C1,} 2 C2 are inserted into the through hole Cb of, held by two insulating holder 18B provided in the respective through holes Cb of the block body ^{2 C1,} 2 C2 ing. Since the shape of the through hole 18a of the insulation holder 18 is different between the block body ¹ C1, ¹ C2 and the block body ² C1, ² C2, the permanent magnet 12A and the permanent magnet 12B are placed in the same magnet insertion hole 10b. It is held in a different position. In this case, the permanent magnets 12A and 12B make it possible to adjust the weight imbalance of the laminated body 10.

As shown in FIG. 9, the insulation holder 18A that holds the permanent magnet 12A may have a tapered shape that narrows toward the insulation holder 18B that holds the permanent magnet 12B. Similarly, the insulation holder 18B that holds the permanent magnet 12B may have a tapered shape that narrows toward the insulation holder 18A that holds the permanent magnet 12A. In this case, the permanent magnet 12A is inserted into the through hole 18a of the insulation holder 18A from the upper side of FIG. 9, and the permanent magnet 12B is inserted into the through hole 18a of the insulation holder 18B from the lower side of FIG. The two permanent magnets 12A and 12B can be attached to the laminate 10 more smoothly.

The number of permanent magnets 12 inserted into the magnet insertion holes 10b may be one or a plurality. A plurality of permanent magnets 12 may be arranged in the magnet insertion hole 10b in the stacking direction, or a plurality of permanent magnets 12 may be arranged in the longitudinal direction of the magnet insertion holes 10b when viewed from the stacking direction, as shown in FIG. A plurality of magnet insertion holes 10b may be arranged in the lateral direction when viewed from the stacking direction, or a plurality of magnet insertion holes 10b may be arranged in a predetermined direction when viewed from the stacking direction. Alternatively, three or more permanent magnets 12 may be arranged in the magnet insertion hole 10b so as to exhibit an annular shape when viewed from the stacking direction.

As shown in FIGS. 9 and 10, an insulator 20 may be interposed between adjacent permanent magnets 12. In this case, it is possible to prevent a decrease in magnetism due to contact between adjacent permanent magnets 12. The plurality of permanent magnets 12 and the insulator 20 may be individually inserted into the through holes 18a. Alternatively, in a state where an insulator 20 (for example, an insulating tape, a foam sheet, etc.) is joined between adjacent permanent magnets 12 to form a group of blocks, the block is inserted into the through hole 18a. May be good. Instead of the insulator 20, the resin material 14 may be filled between the adjacent permanent magnets 12. In this case, the molten resin may be filled between the adjacent permanent magnets 12 after being inserted into the through holes 18a so that the plurality of permanent magnets 12 do not come into contact with each other.

In the above embodiment, the permanent magnet 12 and the resin material 14 are inserted into the magnet insertion holes 10b, but the resin material 14 is not filled into each magnet insertion hole 10b. Good.

As long as the permanent magnet 12 can be held by the through hole 18a of the insulating holder 18 provided in the block body C, the stacking position of the block body C in the laminated body 10 is not particularly limited.

Instead of the block body C, one punched member 30B (second iron core member) may be used.

The inner peripheral surface of the through hole 18a of the insulation holder 18 may be narrowed from both end sides of the through hole 18a toward the center. That is, the cross-sectional shape of the inner peripheral surface of the through hole 18a may have a chevron shape protruding inward at the central portion in the extending direction of the through hole 18a. In this case, each inclined surface of the mountain-shaped inner peripheral surface of the through hole 18a is a tapered surface.

The inner peripheral surface of the through hole 18a of the insulation holder 18 does not have to be a tapered surface. For example, the inner peripheral surface may extend straight along the stacking direction, may be an uneven surface in which irregularities repeatedly appear in the stacking direction or the circumferential direction, or may be wavy in the stacking direction or the circumferential direction. It may be a wavy surface.

The entire inner peripheral surface (the entire tapered surface) of the through hole 18a of the insulation holder 18 may protrude inward from the inner peripheral surface of the through hole Bb.

The recess Cc may be provided at any position on the peripheral edge of the through hole Cb.

Instead of the concave portion Cc, the inner peripheral surface of the through hole Cb may be roughened. Also in this case, an anchor effect is generated between the insulation holder 18 and the inner peripheral surface of the through hole Cb, and the insulation holder 18 is less likely to fall out of the through hole Cb. Since the rough surface is an uneven surface when viewed microscopically, it can be said that the concave portion forming the rough surface corresponds to the concave portion Cc of the above embodiment.

The through hole Cb may not be provided with the recess Cc.

A gap V may not be provided between the through hole 18a and the permanent magnet 12.

The present invention may be applied not only to the rotor laminated iron core 1 but also to the stator laminated iron core 1.

1 ... Rotor laminated iron core, 10 ... Laminated body, 10b ... Magnet insertion hole, 12 ... Permanent magnet, 14 ... Resin material, 18 ... Insulation holder, 40 ... Core, B ... Block body (first iron core member) , Bb ... through hole (first through hole), C ... block body (second iron core member), Cb ... through hole (second through hole), Cc ... recess, V ... gap.

Claims (11)

A laminate in which a plurality of first iron core members and at least one second iron core member are laminated,
Equipped with a permanent magnet
The first iron core member is provided with a first through hole that penetrates in the stacking direction of the laminated body and is larger than the outer shape of the permanent magnet when viewed from the stacking direction.
The second iron core member penetrates in the stacking direction and is larger than the outer shape of the permanent magnet when viewed from the stacking direction, along the inner peripheral surface of the second through hole. An insulating holder that extends and covers the entire inner peripheral surface is provided.
The laminated body is provided with a magnet insertion hole formed by communicating the first and second through holes in the stacking direction.
The permanent magnet is inserted into the magnet insertion hole while being held by the insulation holder .
A recess that is recessed toward the outside of the second through hole is provided on the peripheral edge of the second through hole.
The insulation holder is a rotor laminated iron core that is fitted to the recess . The rotor laminated iron core according to claim 1 , wherein the recess is recessed in a direction intersecting the radial direction of the laminated body when viewed from the laminated direction. The rotor laminated iron core according to claim 1 or 2 , wherein the permanent magnet and the insulation holder are partially separated from each other. A laminate in which a plurality of first iron core members and at least one second iron core member are laminated,
Equipped with a permanent magnet
The first iron core member is provided with a first through hole that penetrates in the stacking direction of the laminated body and is larger than the outer shape of the permanent magnet when viewed from the stacking direction.
The second iron core member penetrates in the stacking direction and is larger than the outer shape of the permanent magnet when viewed from the stacking direction, along the inner peripheral surface of the second through hole. An insulating holder that extends and covers the entire inner peripheral surface is provided.
The laminated body is provided with a magnet insertion hole formed by communicating the first and second through holes in the stacking direction.
The permanent magnet is inserted into the magnet insertion hole while being held by the insulation holder.
A rotor laminated iron core in which the permanent magnet and the insulation holder are partially separated from each other. Claim 3 or 4 in which a resin material is filled in the gap between the first through hole and the permanent magnet in the magnet insertion hole and between the permanent magnet and the insulation holder. Rotor laminated iron core described in. The rotor laminated iron core according to any one of claims 1 to 5, wherein the second iron core member is a block body in which a plurality of punched members in which a metal plate is punched along a predetermined shape are laminated. .. The rotor according to any one of claims 1 to 6, wherein the insulation holder has a tapered shape that protrudes inward from one end face of the laminated body toward the other end face in the stacking direction. Laminated iron core. The laminated body is configured such that the second iron core member is sandwiched between the first iron core members.
The outer shape of the second through hole is larger than the outer shape of the first through hole.
The rotor laminated iron core according to any one of claims 1 to 7 , wherein at least a part of the inner peripheral surface of the insulation holder projects inward from the inner peripheral surface of the first through hole. .. A first iron core member provided with a first through hole larger than the outer shape of the permanent magnet and a second iron core member provided with a second through hole larger than the outer shape of the permanent magnet are prepared. Step 1 and
The second step of arranging the core in the second through hole so as not to contact the inner peripheral surface of the second through hole, and
After filling an insulating material between the inner peripheral surface of the second through hole and the core, the core is removed, extending along the inner peripheral surface of the second through hole and the inner circumference. A third step of forming an insulating holder that covers the entire surface,
A fourth step of laminating the first iron core member and the second iron core member to form a laminated body so that the first and second through holes communicate with each other to form a magnet insertion hole. ,
A method for manufacturing a rotor laminated iron core, which comprises a fifth step of inserting the permanent magnet into the magnet insertion hole and holding the permanent magnet in the insulation holder. Since the core has a tapered shape, the peripheral side surface of the core is a tapered surface.
In the second step, as the inner peripheral surface of the peripheral side surface of the core and the second through hole are opposed, placing a core in said second through-hole, according to claim 9 the method of. A first iron core member provided with a first through hole larger than the outer shape of the permanent magnet and a second iron core member provided with a second through hole larger than the outer shape of the permanent magnet are prepared. Step 1 and
A second step of forming an insulating holder that extends along the inner peripheral surface of the second through hole and covers the entire inner peripheral surface.
A third step of laminating the first iron core member and the second iron core member to form a laminated body so that the first and second through holes communicate with each other to form a magnet insertion hole. ,
In the fourth step of inserting the permanent magnet into the magnet insertion hole and holding the permanent magnet in the insulation holder, the permanent magnet and the insulation holder are partially separated from each other. The fourth step and
A molten resin is injected into the magnet insertion hole, and a resin material is placed in the gap between the first through hole and the permanent magnet in the magnet insertion hole and between the permanent magnet and the insulation holder. A method for manufacturing a rotor laminated iron core, which comprises a fifth step of filling.

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