JP6848348B2 - Rotor manufacturing method - Google Patents

Description

The present invention relates to a method for manufacturing a rotor for a rotary electric machine.

Patent Document 1 discloses a rotor for a rotary electric machine including a rotor shaft configured so that a cylindrical outer shaft is fitted on the outer circumference of the inner shaft, and a rotor core arranged on the outer circumference of the outer shaft. There is.

Japanese Unexamined Patent Publication No. 2010-110100

In a rotor as in Patent Document 1, key grooves are formed on the outer peripheral surface of the outer shaft and the inner peripheral surface of the rotor core, and by inserting the key member into the grooves with these key grooves facing each other, the rotor core becomes a rotor. Prevents rotation around the shaft axis.

Further, in order to prevent the rotor core from rotating around the axis of the rotor shaft, the shaft fitting hole of the rotor core is made a polygonal shape, and the outer peripheral shape of the rotor shaft (outer shaft) is made a shape corresponding to the shaft fitting hole. It is also possible. According to such a method, the key groove and the key member can be omitted, so that the rotor structure can be simplified.

However, when the outer peripheral shape of the outer shaft constituting the rotor shaft is polygonal, it takes time and effort to manufacture the outer shaft, such as cutting the outer peripheral surface of the outer shaft, and the rotor cannot be easily manufactured. There is a problem.

Therefore, the present invention has been made in view of the above problems, and provides a rotor manufacturing method capable of easily forming the outer peripheral shape of the outer shaft into a polygonal shape and manufacturing a rotor at low cost. The purpose.

According to the present invention, there is provided a rotor manufacturing method for manufacturing a rotor for a rotary electric machine by forming a rotor shaft using an inner shaft and an outer shaft having a polygonal outer peripheral shape and inserting and arranging a rotor core on the outer circumference of the outer shaft. Will be done. The rotor manufacturing method is a step of installing a tubular material having a cylindrical portion and a flange plate protruding inward from the inner peripheral surface of the cylindrical portion on a polygonal mandrel having a polygonal outer peripheral shape. By sandwiching both ends of the flange plate inside with a pair of polygonal mandrel, the tubular material placement process of arranging the tubular material on the polygonal mandrel and the polygonal mandrel so that the axis of the tubular material is the center of rotation. By rotating and pressing the forming roller against the cylindrical part from the outside and moving the forming roller or polygonal mandrel in the axial direction of the tubular material, the shape of the cylindrical part is formed into a polygonal shape. The polygonal mandrel on which the outer shaft is arranged is placed after the outer shaft forming step of forming the outer shaft having the outer peripheral portion and the flange portion protruding inward from the inner peripheral surface of the outer peripheral portion and the outer shaft forming step. By rotating and pressing a finishing roller with a diameter smaller than that of the forming roller against the outer periphery of the outer shaft from the outside, and moving the finishing roller or polygonal mandrel in the axial direction of the outer shaft, finishing forming of the outer shape of the outer shaft It is provided with a finishing process for performing.

According to the present invention, since the cylindrical portion of the tubular material is formed into a polygonal shape by using a forming roller, the polygonal outer shaft is formed more easily than when the tubular material or the like is cut as in the conventional case. be able to. As a result, it becomes possible to inexpensively manufacture a rotor using a polygonal outer shaft.

FIG. 1A is a vertical sectional view of a rotor manufactured by the rotor manufacturing method according to the embodiment of the present invention. FIG. 1B is a side view of the rotor of FIG. 1A. FIG. 2 is a process diagram for explaining the flow of the rotor manufacturing method. FIG. 3A is a perspective view of the disc-shaped material. FIG. 3B is a diagram for explaining a disk-shaped material arranging process. FIG. 4 is a diagram for explaining the first half step of the tubular material forming step. FIG. 5 is a diagram for explaining a latter half step of the tubular material forming step. FIG. 6A is a vertical cross-sectional view showing a state in which the cylindrical material is arranged on the polygonal mandrel in the tubular material arrangement step. FIG. 6B is a bottom view of the polygonal mandrel and the cylindrical material when viewed from below. FIG. 7A is a diagram for explaining an outer shaft forming process. FIG. 7B is a diagram for explaining an outer shaft forming process. FIG. 7C is a plan view showing the outer shaft. FIG. 8A is a view for explaining the finishing process, and is a vertical cross-sectional view showing a state in which the outer shaft is arranged on the polygonal mandrel. FIG. 8B is a view for explaining the finishing process, and is a bottom view of the outer shaft and the polygonal mandrel when viewed from below. FIG. 9 is a diagram for explaining a rotor core arrangement process. FIG. 10 is a diagram for explaining an end processing process.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.

FIG. 1A is a vertical sectional view of a rotor 100 manufactured by using the manufacturing method according to the embodiment of the present invention. FIG. 1B is a side view of the rotor 100.

The rotor 100 shown in FIGS. 1A and 1B is a member that constitutes a part of a rotary electric machine that functions as an electric motor or a generator, and is a rotary member that is arranged inside an annular stator. The rotor 100 includes a rotor shaft 10 and a rotor core 20 provided on the outer periphery of the rotor shaft 10.

The rotor shaft 10 is composed of an inner shaft 11 and an outer shaft 12 that fits on the outer circumference of the inner shaft 11.

The inner shaft 11 is a columnar member and is formed by using a technique such as forging. A protruding portion 11A having a larger outer diameter than other portions is formed at a substantially central portion of the inner shaft 11 in the axial direction. The protruding portion 11A of the inner shaft 11 functions as a connecting portion for connecting to the outer shaft 12. The protruding portion 11A may be formed at a predetermined position in the shaft axial direction, for example, a position closer to the end portion, instead of the central portion of the inner shaft 11. Further, the protrusion 11A may be omitted, and the inner shaft 11 may be directly connected to the outer shaft 12.

The outer shaft 12 is a tubular member formed of a mild steel material. The outer shaft 12 includes an outer peripheral portion 12A formed as a square cylinder having a hexagonal outer peripheral shape, and a plate-shaped flange portion 12B protruding inward from the inner peripheral surface of the outer peripheral portion 12A. The outer peripheral portion 12A functions as a support member that supports the rotor core 20 from the inside, and the flange portion 12B functions as a connecting portion that connects to the inner shaft 11.

An insertion hole 12C into which the inner shaft 11 is inserted is formed at the center of the flange portion 12B of the outer shaft 12. The outer shaft 12 is fixed to the outer circumference of the inner shaft 11 by welding the connection portion between the insertion hole 12C and the protruding portion 11A in a state where the protruding portion 11A of the inner shaft 11 is inserted into the insertion hole 12C of the flange portion 12B. To.

The rotor core 20 is a laminated body in which disc-shaped steel plates are laminated, and has an insertion hole 21 for inserting the outer peripheral portion 12A of the outer shaft 12. A plurality of magnet insertion holes 22 are formed at positions near the outer edge of the rotor core 20, and these magnet insertion holes 22 are arranged at equal intervals along the circumferential direction of the rotor core 20. A plurality of permanent magnets 23 are inserted in series in each magnet insertion hole 22. In the rotor 100, the number of magnet insertion holes 22 is set to 12, but the number of magnet insertion holes 22 can be arbitrarily set according to the output characteristics and the like required for the rotary electric machine.

The rotor core 20 is arranged so as to surround the outer peripheral portion 12A of the outer shaft 12 via the insertion hole 21. Since the insertion hole 21 of the rotor core 20 is formed as a shape (hexagonal shape) corresponding to the shape of the outer peripheral portion 12A of the outer shaft 12, when the outer shaft 12 and the rotor core 20 are assembled, the outer circumference of the outer shaft 12 is formed. The shaft circumferential displacement of the rotor core 20 with respect to the portion 12A is regulated. That is, in the rotor 100, the rotor core 20 does not rotate around the axis of the rotor shaft 10 (outer shaft 12).

Next, a method of manufacturing the rotor 100 configured as described above will be described.

FIG. 2 is a process diagram illustrating a flow of a manufacturing method of the rotor 100 according to the present embodiment.

As shown in FIG. 2, in step 101 (S101), a material forming step of forming a cylindrical material from a disc-shaped material is executed.

In S102, a tubular material arranging step of arranging the cylindrical material formed in the previous step on the polygonal mandrel is executed. After that, in S103, an outer shaft forming step of forming the outer shaft 12 from the cylindrical material is executed by forming the outer peripheral shape of the cylindrical material into a polygonal shape using a forming roller. In S104, a finishing step of adjusting the outer peripheral shape of the outer shaft 12 by a finishing roller is executed.

In S105, a rotor shaft assembly step of connecting the inner shaft 11 to the finished outer shaft 12 and assembling the rotor shaft 10 is executed.

In S106, a rotor core arranging step of inserting and arranging the rotor core 20 into the outer peripheral portion 12A of the outer shaft 12 constituting the rotor shaft 10 is executed. After that, in S107, an end processing step of bending the end of the outer peripheral portion 12A of the outer shaft 12 to the outside is executed on the rotor shaft 10 with the rotor core 20 mounted. By processing the end of the outer shaft 12 in this way, it is possible to prevent the rotor core 20 from coming off from the outer shaft 12.

Through the steps S101 to S107 described above, a rotor 100 for a rotary electric machine including a rotor shaft 10 having an inner shaft 11 and an outer shaft 12 and a rotor core 20 provided on the outer periphery of the rotor shaft 10 is manufactured. To.

In the following, with reference to FIGS. 3A to 8B, a material forming step (S101), a tubular material arranging step (S102), an outer shaft forming step (S103), and a finishing step (S103), which are steps for manufacturing the outer shaft 12, S104) will be described in detail.

The material forming step is a step of forming a cylindrical material to be a material of the outer shaft 12 by using the disc-shaped material 200 as shown in FIG. 3A. The disk-shaped material 200 is a disk cut out from the plate material and is a member having a through hole in the central portion.

As shown in FIG. 2, the material forming step S101 includes a disc-shaped material arranging step S101A and a tubular material forming step S101B.

As shown in FIG. 3B, in the disc-shaped material arranging step, the disc-shaped material 200 is sandwiched between a pair of columnar mandrel 301, 302 at the center portions of both ends of the disk-shaped material 200, so that the disk-shaped material 200 is formed into a columnar mandrel 301, 302. Placed in between. At the center of the columnar mandrel 301, a pin 303 is provided so as to project from the end face of the columnar mandrel 301. In the state where the disk-shaped material 200 is set, the pin 303 of the columnar mandrel 301 is inserted into the central hole 304 of the columnar mandrel 302 through the through hole of the disk-shaped material 200. As a result, the disc-shaped material 200 arranged between the columnar mandrels 301 and 302 can be centered, and the axis of the columnar mandrel 301 and 302 is aligned with the axis of the disk-shaped material 200. It becomes possible.

The outer diameters of the columnar mandrels 301 and 302 are set smaller than the outer diameter of the disc-shaped material 200.

Next, the tubular material forming step S101B in FIG. 2 will be described with reference to FIGS. 4 and 5.

As shown in FIG. 4, in the tubular material forming step, the columnar mandrels 301 and 302 are rotated so that the axis of the disc-shaped material 200 is the center of rotation, and the pair of processing rollers 311, 312 are circularly formed from the outside. It is pressed against the outer peripheral surface of the plate-shaped material 200. By bringing the processing rollers 311, 312 closer to the center of rotation of the columnar mandrels 301 and 302, the outer peripheral portions of the disk-shaped material 200 located outside the columnar mandrels 301 and 302 are lined up and down in the drawing. ..

In FIG. 4, two processing rollers are provided in order to open the disc-shaped material 200 in a row, but the number of processing rollers may be one or more.

After the processing rollers 311, 312 are pressed against the disk-shaped material 200 to open the outer peripheral portions of the disk-shaped material 200 in a row, in the tubular material forming step, the processing rollers 311, 312 are used as shown in FIG. By moving the disc-shaped material 200 in the axial direction, the outer peripheral portion of the disc-shaped material 200 is ironed and formed. During ironing, the processing rollers 311, 312 are adjusted in position so that the distance from the columnar mandrels 301 and 302 is constant, and the processing rollers 311, 312 reciprocate up and down in the drawing along the axial direction of the disc-shaped material 200. Driven to. By this ironing molding, the arranged portions of the disc-shaped material 200 are formed into a cylindrical shape corresponding to the outer peripheral shape of the columnar mandrels 301 and 302.

In ironing molding, both the processing rollers 311, 312 and the columnar mandrels 301 and 302 may be moved in the axial direction, or only the columnar mandrels 301 and 302 may be moved in the axial direction. May be good.

Through the tubular material forming step described above, the cylindrical material 400 having the cylindrical portion 401 and the flange plate 402 protruding inward from the inner peripheral surface of the cylindrical portion 401 is formed. The flange plate 402 is a portion corresponding to the central portion of the disc-shaped material 200, and is a portion sandwiched by the columnar mandrels 301 and 302. Therefore, the flange plate 402 has a through hole 403 at its center.

In the tubular material forming step, the processing rollers 311, 312 are pressed against the disc-shaped material 200 and are rotated along with the rotation of the disc-shaped material 200. The processing rollers 311, 312 may not be configured to rotate subordinately, but may be configured to be rotationally driven in synchronization with the rotation of the disc-shaped material 200. By rotationally driving the processing rollers 311, 312 in this way, it is possible to perform molding processing with higher accuracy.

Next, with reference to FIGS. 6A to 8B, the tubular material arranging step S102, the outer shaft forming step S103, and the finishing step S104 in FIG. 2 will be described in detail.

FIG. 6A is a vertical cross-sectional view showing a state in which the cylindrical material 400 is arranged on the polygonal mandrel 501 and 502 in the tubular material arrangement step. FIG. 6B is a bottom view of the polygonal mandrel 501 and the cylindrical material 400 as viewed from below.

As shown in FIG. 6A, the tubular material arranging step is a step of installing the cylindrical material 400 on the polygonal mandrel 501 and 502 having a hexagonal outer peripheral shape. In this step, the cylindrical material 400 is arranged in the polygonal mandrels 501 and 502 by sandwiching both ends of the flange plate 402 between the pair of polygonal mandrels 501 and 502 inside the cylindrical portion 401.

As shown in FIG. 6B, in the polygonal mandrel 501 and 502, when the cylindrical material 400 is set in the polygonal mandrel 501 and 502, the corners of the polygonal mandrel 501 and 502 are the cylindrical portions of the cylindrical material 400. It is configured to be in contact with the inner peripheral surface of 401. Further, as shown in FIG. 6A, the polygonal mandrel 501 and 502 are configured to project from the inside of the cylindrical portion 401 of the cylindrical material 400 to the outside in the axial direction.

At the center of the polygonal mandrel 501, a pin 503 is provided so as to project from the end face of the polygonal mandrel 501. In the state where the cylindrical material 400 is set, the pin 503 of the polygonal mandrel 501 is inserted into the central hole 504 of the polygonal mandrel 502 through the through hole 403 of the cylindrical material 400. As a result, the cylindrical material 400 arranged between the polygonal mandrels 501 and 502 can be centered, and the axis of the polygonal mandrel 501 and 502 can be aligned with the axis of the cylindrical material 400. It will be possible.

The outer shaft forming step executed after the tubular material arranging step will be described with reference to FIGS. 7A and 7B.

As shown in FIG. 7A, in the outer shaft forming step, the polygonal mandrels 501 and 502 are rotated so that the axis of the cylindrical material 400 is the center of rotation, and the pair of forming rollers 511, 512 are made of the cylindrical material from the outside. The cylindrical portion 401 of the cylindrical material 400 is sequentially molded by pressing the forming rollers 511, 512 against the cylindrical portion 401 of the 400 in the axial direction of the cylindrical material 400. During sequential molding, the forming rollers 511, 512 are positioned so that the distance from the polygonal mandrel 501 and 502 is a predetermined distance as shown in FIG. 7B, and along the axial direction as shown in FIG. 7A. It is driven so as to reciprocate up and down in the figure. By this sequential molding, the cylindrical portion 401 of the cylindrical material 400 is molded into a hexagonal shape corresponding to the outer peripheral shape of the polygonal mandrel 501 and 502 as shown in FIG. 7B.

In sequential molding, both the forming rollers 511, 512 and the polygonal mandrels 501 and 502 may be moved in the axial direction, or only the polygonal mandrels 501 and 502 may be moved in the axial direction. May be good.

Through the outer shaft forming step described above, as shown in FIG. 7C, an outer shaft 12 having a hexagonal outer peripheral portion 12A and a flange portion 12B protruding inward from the inner peripheral surface of the outer peripheral portion 12A is formed. The flange portion 12B is a portion corresponding to the flange plate 402 of the cylindrical material 400, and the insertion hole 12C of the flange portion 12B is a portion corresponding to the through hole 403 of the flange plate 402.

In the outer shaft forming step, the forming rollers 511 and 512 are pressed against the cylindrical material 400 and are rotated along with the rotation of the cylindrical material 400. The forming rollers 511, 512 may not be configured to rotate subordinately, but may be configured to be rotationally driven in synchronization with the rotation of the cylindrical material 400. By rotationally driving the forming rollers 511 and 512 in this way, it is possible to perform molding processing with higher accuracy.

Further, in FIGS. 7A and 7B, two forming rollers are provided in order to execute sequential forming, but the number of forming rollers may be one or more.

Next, the finishing process will be described with reference to FIGS. 8A and 8B. FIG. 8A is a vertical cross-sectional view showing a state in which the outer shaft 12 is arranged on the polygonal mandrel 501 and 502. FIG. 8B is a bottom view of the polygonal mandrel 501 and the outer shaft 12 when viewed from below.

The finishing step is a step executed after the outer shaft forming step, and is a step for adjusting the shape (surface texture) of the outer peripheral portion 12A of the outer shaft 12.

As shown in FIG. 8A, in the finishing step, the polygonal mandrels 501 and 502 on which the outer shaft 12 is arranged are rotated about the axis, and the finishing roller 513 is pressed against the outer peripheral portion 12A of the outer shaft 12 from the outside. By moving the finishing roller 513 in the axial direction of the outer shaft 12, finish molding is performed so that the surface of the outer peripheral portion 12A of the outer shaft 12 becomes a flatter surface. The finishing roller 513 is a roller having a smaller diameter than the above-mentioned processing rollers 311, 312 and forming rollers 511 and 512, and the diameter of the finishing roller 513 is set to be smaller than the diameters of the processing rollers 311, 312 and forming rollers 511 and 512. There is.

As shown in FIGS. 8A and 8B, the finishing roller 513 is positioned so that the distance from the polygonal mandrel 501 and 502 is a predetermined distance, and the finishing roller 513 reciprocates up and down in the drawing along the axial direction. Driven by. However, in the finishing step, one end portion (upper end portion in FIG. 8A) of the outer peripheral portion 12A in the axial direction of the outer shaft 12 is formed as a protruding portion 12D that protrudes radially outward from the other portion of the outer peripheral portion 12A. The moving range (reciprocating region) of the finishing roller 513 is adjusted so as to be formed.

In finish molding, both the finishing roller 513 and the polygonal mandrels 501 and 502 may be moved in the axial direction, or only the polygonal mandrels 501 and 502 may be moved in the axial direction. .. Further, the finishing roller 513 may not be configured to rotate subordinately, but may be configured to be rotationally driven in synchronization with the rotation of the outer shaft 12. By rotationally driving the finishing roller 513 in this way, it is possible to perform finish molding with higher accuracy.

Further, in FIGS. 8A and 8B, one finishing roller is provided to perform finish molding, but the number of finishing rollers may be two or more.

After the finishing step described above, the rotor shaft assembly step S105 shown in FIG. 2 is executed, and the outer shaft 12 and the inner shaft 11 are connected to each other. In this assembly step, the outer shaft 12 is fixed to the outer periphery of the inner shaft 11 by welding the connection portion between the insertion hole 12C of the outer shaft 12 and the protruding portion 11A of the inner shaft 11.

Subsequently, the rotor core arranging step S106 in FIG. 2 will be described in detail with reference to FIG.

In the rotor core arranging step, the outer peripheral portion 12A of the outer shaft 12 is inserted into the tubular rotor core 20, and the rotor core 20 is brought into contact with the protruding portion 12D of the outer peripheral portion 12A from the other end side of the outer peripheral portion 12A toward one end. Move to. As a result, the rotor core 20 is inserted and arranged with respect to the outer peripheral portion 12A of the outer shaft 12.

The protruding portion 12D formed at one end of the outer shaft 12 functions as a stopper for restricting the axial movement of the rotor core 20 arranged on the outer peripheral portion 12A of the outer shaft 12.

In the state where the rotor core 20 is arranged on the rotor shaft 10, one end (tip) of the outer peripheral portion 12A of the outer shaft 12 protrudes outward in the axial direction from the inside of the rotor core 20.

Next, with reference to FIG. 10, the end processing step S107 in FIG. 2 will be described in detail.

In the end processing step, the rotor shaft 10 with the rotor core 20 mounted is rotated about the axis, and the caulking roller 514 is pressed against one end (tip) of the outer peripheral portion 12A of the outer shaft 12. By pressing the caulking roller 514, caulking molding is performed in which the tip end portion of the outer peripheral portion 12A of the outer shaft 12 is bent outward in the radial direction.

By processing the tip of the outer shaft 12 in this way, the rotor core 20 is sandwiched between the tip of the crimped outer shaft 12 and the protruding portion 12D located at the other end of the outer peripheral portion 12A. The rotor core 20 is prevented from coming off from the outer shaft 12.

By going through the steps S101 to S107 described above, the rotor 100 for a rotary electric machine as shown in FIGS. 1A and 1B is manufactured.

According to the method for manufacturing the rotor 100 according to the present embodiment described above, the following effects can be obtained.

In the method of manufacturing the rotor 100 according to the present embodiment, the rotor shaft 10 is formed by using the inner shaft 11 and the outer shaft 12 having a polygonal outer circumference, and the rotor core 20 is inserted and arranged on the outer circumference of the outer shaft 12 to form a rotary electric machine. This is a method for manufacturing a rotor for use. The method for manufacturing the rotor 100 includes a tubular material arranging step and an outer shaft forming step. In the tubular material arranging step, a cylindrical material 400 having a cylindrical portion 401 and a flange plate 402 protruding inward from the inner peripheral surface of the cylindrical portion 401 is installed on polygonal mandrel 501 and 502 having a polygonal outer peripheral shape. It is a process to do. In the tubular material arranging step, the cylindrical material 400 is arranged in the polygonal mandrels 501 and 502 by sandwiching both ends of the flange plate 402 between the pair of polygonal mandrels 501 and 502 inside the cylindrical portion 401. Then, in the outer shaft forming step, the polygonal mandrels 501 and 502 are rotated so that the axis of the cylindrical material 400 is the center of rotation, and the forming rollers 511, 512 are pressed against the cylindrical portion 401 from the outside and the cylindrical material. By moving the cylinder portion 401 in the axial direction, the cylindrical portion 401 is formed into a polygonal shape. As a result, the outer shaft 12 having a polygonal outer peripheral portion 12A and a flange portion 12B protruding inward from the inner peripheral surface of the outer peripheral portion 12A is formed.

According to the rotor manufacturing method described above, since the cylindrical portion 401 of the cylindrical material 400 is formed into a polygonal shape by using the forming rollers 511, 512 at the time of rotor manufacturing, the cylindrical material or the like is cut as in the conventional case. The polygonal outer shaft 12 can be formed more easily than in the case. As a result, the rotor 100 using the polygonal outer shaft 12 can be manufactured at low cost.

The rotor manufacturing method according to the present embodiment further includes a material forming step of forming the cylindrical material 400 before the above-mentioned tubular material arranging step. The material forming step includes a disk-shaped material arranging step and a tubular material forming step.

In the disk-shaped material arranging step, the disk-shaped material 200 is arranged in the columnar mandrels 301 and 302 by sandwiching the central portions of both ends of the disk-shaped material 200 with a pair of columnar mandrels 301 and 302. Then, in the tubular material forming step, the columnar mandrels 301 and 302 are rotated so that the axis of the disk-shaped material 200 is the center of rotation, and the processing rollers 311, 312 are moved from the outside to the outer peripheral surface of the disk-shaped material 200. After pressing against, the processing rollers 311, 312 are moved in the axial direction of the disc-shaped material 200. As a result, the outer peripheral portion of the disc-shaped material 200 located outside the columnar mandrels 301 and 302 is formed into a cylindrical shape, and the cylindrical material 400 having the cylindrical portion 401 and the flange plate 402 is formed.

As described above, in the rotor manufacturing method, the tubular material 400 is formed from the disc-shaped material 200, and the polygonal outer shaft 12 is formed from the tubular material 400. Therefore, as the base material of the outer shaft 12, it is only necessary to prepare the disc-shaped material 200 having a simple shape, the labor required for material preparation can be reduced, and the manufacturing cost can be reduced. .. It is conceivable to form the tubular material 400 by forging, casting, etc., but when such a method is used, it is necessary to prepare a mold, etc., it takes time to prepare the material, and the effect of reducing the manufacturing cost is low. Become.

Further, the method for manufacturing the rotor 100 includes a finishing step of performing finish molding after the outer shaft forming step. In the finishing process, the polygonal mandrel 501 and 502 on which the outer shaft 12 is arranged are rotated, and the finishing roller 513 having a diameter smaller than that of the forming rollers 511 and 512 is pressed against the outer shaft 12 from the outside and moved in the axial direction. , Finish molding of the outer peripheral shape of the outer shaft 12 is executed.

By performing finish molding using the finishing roller 513 having a small diameter in this way, it is possible to improve the dimensional accuracy regarding the outer shape of the outer shaft 12. As a result, the productivity of the rotor 100 can be improved.

Further, in the finishing step, finish molding is performed so that one end of the outer peripheral portion 12A in the axial direction of the outer shaft 12 is formed as a protruding portion 12D protruding radially outward from other portions of the outer peripheral portion 12A. The protruding portion 12D is integrally formed as a part of the outer peripheral portion 12A of the outer shaft 12, and functions as a stopper for restricting the axial movement of the rotor core 20 arranged on the outer peripheral portion 12A. By integrally forming the stopper that regulates the movement of the rotor core 20 on the outer shaft 12 in this way, it is not necessary to separately prepare a stopper member, and the manufacturing cost of the rotor 100 can be reduced.

Further, the method for manufacturing the rotor 100 includes a rotor core arranging step and an end processing step. In the rotor core arranging step, in the rotor shaft 10 formed by connecting the inner shaft 11 to the flange portion 12B of the outer shaft 12, the outer peripheral portion 12A is formed from the other end side of the outer peripheral portion 12A of the outer shaft 12 toward one end portion. The rotor core 20 is inserted and arranged. Then, in the end processing step, the other end of the outer peripheral portion 12A on which the rotor core 20 is arranged is deformed toward the outside. By processing the end of the outer shaft 12 in this way, the rotor core 20 is sandwiched between the tip of the bent and deformed outer shaft 12 and the protruding portion 12D located at the other end of the outer peripheral portion 12A. This makes it possible to more reliably prevent the rotor core 20 from coming off from the outer shaft 12. Further, it is not necessary to separately prepare a stopper member for preventing the rotor core 20 from coming off, and the manufacturing cost of the rotor 100 can be reduced.

It is clear that the present invention is not limited to the above embodiments and various changes can be made within the scope of its technical ideas.

In the present embodiment, the shape of the outer peripheral portion 12A of the outer shaft 12 and the shape of the insertion hole 21 of the rotor core 20 are formed in a hexagonal shape, but may be a polygonal shape such as a triangle, a quadrangle, or a pentagon. Therefore, as the polygonal mandrel 501 and 502, a mandrel having a shape required for the outer shaft 12 is used.

In this embodiment, as shown in FIG. 2, the rotor shaft assembly step is executed after the finishing process. However, the inner shaft 11 may be assembled to the cylindrical material 400 immediately after the material forming step, or the inner shaft 11 may be assembled to the outer shaft 12 immediately after the outer shaft forming step. When the inner shaft 11 is assembled in this way, a polygonal mandrel having an insertion hole for inserting the inner shaft 11 is used in the tubular material arranging step, the outer shaft forming step, and the finishing step.

In the present embodiment, the cylindrical material 400 is formed from the disc-shaped material 200 by the material forming step, but the cylindrical material 400 may be formed in advance by forging, casting, press molding, or the like.

In the present embodiment, the finishing step is performed after the outer shaft forming step, but the finishing step can be omitted. When the finishing step is omitted, the protruding portion 12D is formed at one end of the outer peripheral portion 12A of the outer shaft 12 by adjusting the axial movement of the forming rollers 511 and 512 in the outer shaft forming step. To.

In the present embodiment, the end processing step is performed after the rotor core arranging step, but the end processing step can be omitted. When the end processing step is omitted, the rotor core 20 is prevented from coming off from the outer shaft 12 by arranging a stopper member or the like at the tip of the outer shaft 12.

Further, in the end processing step, the caulking roller 514 is pressed against the rotating outer shaft 12 to process the end portion, but the mold member is pressed against the stopped outer shaft 12 or the like. The edge may be processed.

100 Rotor 10 Rotor shaft 11 Inner shaft 12 Outer shaft 12A Outer circumference 12B Flange 12C Insertion hole 12D Protruding part 20 Rotor core 21 Insertion hole 200 Disc-shaped material 301 Cylindrical mandrel 302 Cylindrical mandrel 311 Machining roller 400 Cylindrical material 401 Cylindrical Part 402 Flange plate 403 Through hole 501 Polygonal mandrel 502 Polygonal mandrel 511 Molding roller 513 Finishing roller 514 Caulking roller

Claims (4)

A rotor manufacturing method in which a rotor shaft is formed using an inner shaft and an outer shaft having a polygonal outer peripheral shape, and a rotor core is inserted and arranged on the outer circumference of the outer shaft to manufacture a rotor for a rotary electric machine.
A step of installing a tubular material having a cylindrical portion and a flange plate protruding inward from the inner peripheral surface of the cylindrical portion on a polygonal mandrel having a polygonal outer peripheral shape, wherein the tubular portion is inside the cylindrical portion. A tubular material arranging step of arranging the tubular material on the polygonal mandrel by sandwiching both ends of the flange plate with the pair of polygonal mandrel,
The polygonal mandrel is rotated so that the axis of the tubular material is the center of rotation, the forming roller is pressed against the cylindrical portion from the outside, and the forming roller or the polygonal mandrel is pressed against the shaft of the tubular material. By moving in the direction, the cylindrical portion is formed into a polygonal shape to form the outer shaft having a polygonal outer peripheral portion and a flange portion protruding inward from the inner peripheral surface of the outer peripheral portion. Outer shaft forming process and
After the outer shaft forming step, the polygonal mandrel on which the outer shaft is arranged is rotated, and a finishing roller having a diameter smaller than that of the forming roller is pressed from the outside against the outer peripheral portion of the outer shaft, and the finishing roller is pressed. Alternatively, a finishing step of performing finish molding of the outer peripheral shape of the outer shaft by moving the polygonal mandrel in the axial direction of the outer shaft.
A rotor manufacturing method comprising. The rotor manufacturing method according to claim 1.
Prior to the tubular material arranging step, a material forming step for forming the tubular material is further provided.
The material forming step is
A disk-shaped material arranging step of arranging the disk-shaped material on the columnar mandrel by sandwiching the central portions of both ends of the disk-shaped material with a pair of columnar mandrels.
The cylindrical mandrel is rotated so that the axis of the disk-shaped material is the center of rotation, and the processing roller is pressed against the outer peripheral surface of the disk-shaped material from the outside, and then the processing roller or the columnar mandrel is pressed. By moving the disk-shaped material in the axial direction, the outer peripheral portion of the disk-shaped material located outside the columnar mandrel is formed into a cylindrical shape, and the cylindrical portion and the flange plate are formed. Including a tubular material forming step of forming the tubular material having
A rotor manufacturing method characterized by that. The rotor manufacturing method according to claim 1 or 2.
In the finishing step, the finishing molding is performed so that one end of the outer peripheral portion in the axial direction of the outer shaft is formed as a protruding portion protruding outward from the other portion of the outer peripheral portion.
A rotor manufacturing method characterized by that. The rotor manufacturing method according to claim 3.
In the rotor shaft configured by connecting the inner shaft to the flange portion of the outer shaft, the rotor core is inserted and arranged in the outer peripheral portion from the other end side to one end portion of the outer peripheral portion of the outer shaft. Rotor core placement process and
The end processing step of deforming the other end of the outer peripheral portion on which the rotor core is arranged is further provided.
A rotor manufacturing method characterized by that.

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