JP7383561B2 - Rotor, motor, and rotor manufacturing method - Google Patents

Description

The present invention relates to a rotor, a motor, and a method for manufacturing a rotor.

2. Description of the Related Art Some motors used in vehicle wiper devices and the like include a rotor having a permanent magnet arranged radially inside a stator around which a coil is wound. As a method of arranging permanent magnets in a rotor used in this type of motor, there is a method of arranging permanent magnets on the outer periphery of a rotor core (SPM: Surface Permanent Magnet).

In a rotor adopting this method, a plurality of permanent magnets are assembled on the outer circumference of a rotor core, and in this state, the outside of the rotor core and the permanent magnets are covered with a substantially cylindrical magnet cover. After the rotor core and the permanent magnet are disposed within a substantially cylindrical peripheral wall, the magnetic cover has an axial end (direction along the rotational axis) fixed to an end of the rotor core.

As a means for fixing the axial end of the magnetic cover, a bent piece is provided in advance on the edge of the magnetic cover, and the bent piece is bent and locked in a hole or recess on the end face of the rotor core (for example, (see Patent Document 1), and methods using caulking are known.

JP2008-295140A

In a rotor in which a bent piece is provided on the edge of the magnet cover and the bent piece is locked in a hole or recess on the end face of the rotor core, it is easier to assemble the magnet cover to the rotor core and the permanent magnet, but it is difficult to assemble. In terms of strength, it is inferior to caulking.

However, in a rotor in which a magnetic cover is fixed to a rotor core by caulking, a large caulking load is likely to be transmitted to the permanent magnet when the edge of the magnetic cover is caulked. If a large caulking load is transmitted to the permanent magnet through the caulking portion of the magnet cover during caulking work, there is a concern that the permanent magnet may be damaged or deteriorated.

SUMMARY OF THE INVENTION Therefore, the present invention provides a rotor, a motor, and a method for manufacturing a rotor that can prevent permanent magnets from being damaged or deteriorated due to crimping of a magnetic cover.

In order to solve the above problems, a motor according to the present invention employs the following configuration.
That is, the motor according to the present invention is a rotor that rotates in response to a magnetic field of a stator, and includes a rotary shaft, a rotor core to which the rotary shaft is coaxially fixed, and a plurality of permanent rotors disposed on the outer periphery of the rotor core. a magnet, a substantially cylindrical magnet cover that covers the outside of the rotor core and the plurality of permanent magnets and has a flange portion bent radially inward at an axial end along the rotation axis of the rotation shaft; and the rotor core. a load receiving block disposed between an axial end surface of the rotor core and the flange portion, the load receiving block abutting the flange portion and the rotor core, the load receiving block having a radial direction centered on the rotational axis of the rotating shaft. a plurality of legs extending in the direction and abutting the axial end surface of the rotor core; and a substantially disc-shaped end wall connected to the axial end of the plurality of legs on the opposite side to the rotor core. , and at a position on the axially outer end surface of the end wall that overlaps with the leg in the axial direction, a plurality of radially extending in a radial direction centering on the rotational axis and with which the flange abuts. A load receiving rib is arranged, and the radially inner edge of the flange portion is shaped to separate the radially inner end from the axially outer end surface of the load receiving block.

A motor according to the present invention includes a rotor, a stator that is disposed on the outer circumferential side of the rotor and generates a magnetic field, and the rotor includes a rotating shaft, a rotor core to which the rotating shaft is coaxially fixed, a plurality of permanent magnets disposed on the outer periphery of the rotor core, and a flange portion that covers the outside of the rotor core and the plurality of permanent magnets and is bent radially inward at an axial end along the rotation axis of the rotation shaft. a substantially cylindrical magnet cover having a magnet cover; a load receiving block disposed between an axial end surface of the rotor core and the flange portion and abutting the flange portion and the rotor core; , a plurality of legs extending in a radial direction centered on the rotation axis of the rotation shaft and abutting an axial end surface of the rotor core, and an axial end of the plurality of legs on the opposite side from the rotor core. a connected substantially disk-shaped end wall, and a radial line centered on the rotational axis is provided at a position axially overlapping with the leg of the axially outer end surface of the end wall. A plurality of load receiving ribs extending in the direction and abutted by the flange portion are arranged, and a radially inner edge of the flange portion has a radially inner end spaced apart from an axially outer end surface of the load receiving block. It is characterized by its shape.

A method for manufacturing a rotor according to the present invention includes a step of arranging a plurality of permanent magnets on the outer periphery of a rotor core, and assembling a load receiving block to an axial end of the rotor core, the load receiving block, the rotor core, The present invention is characterized by comprising the steps of press-fitting a plurality of the permanent magnets into a peripheral wall portion of a magnet cover, and pressing the flange portion against an axially outer end surface of the load receiving block.

In the rotor according to the present invention, since the load receiving block is arranged between the axial end face of the rotor core and the flange of the magnet cover, damage and deterioration of the permanent magnets caused by caulking of the magnet cover can be prevented. Can be done.
Further, in the rotor according to the present invention, the radially inner edge of the flange portion is shaped to separate the radially inner end from the axially outer end surface of the load receiving block. Therefore, when the magnetic cover is assembled, even if the flange of the magnetic cover is tilted toward the end face of the load receiving block and a pressing load is input to the flange in the direction of the load receiving block, the flange will be tilted in the radial direction of the flange. It is possible to prevent the inner end from coming into contact with the end face of the load receiving block. Therefore, when the rotor according to the present invention is employed, damage to the load receiving block and generation of abrasion powder can be suppressed when the magnetic cover is assembled.

FIG. 1 is a perspective view of a drive device according to an embodiment. FIG. 2 is a sectional view taken along line II-II in FIG. 1 of the drive device of the embodiment. FIG. 1 is a perspective view of a rotor according to a first embodiment. FIG. 4 is a cross-sectional view of the rotor of the first embodiment taken along line IV-IV in FIG. 3; FIG. 2 is an exploded perspective view of the rotor of the first embodiment. FIG. 2 is a perspective view of the rotor of the first embodiment with the magnetic cover removed. FIG. 3 is a plan view of the rotor of the first embodiment with the magnetic cover removed. FIG. 2 is a perspective view of the load receiving block of the first embodiment. FIG. 2 is a perspective view of the magnetic cover of the first embodiment. FIG. 9 is a sectional view taken along the line XX in FIG. 9 of the magnet cover of the first embodiment. FIG. 5 is an enlarged view of section XI in FIG. 4 of the rotor of the first embodiment. FIG. 12 is a sectional view showing a state in which a portion of the rotor of the first embodiment corresponding to section XII in FIG. 11 is being assembled. FIG. 3 is a perspective view of a rotor according to a second embodiment. FIG. 3 is an exploded perspective view of a rotor according to a second embodiment. FIG. 7 is a perspective view showing a state in which the rotor of the second embodiment is being assembled. FIG. 16 is a sectional view taken along line XVI-XVI in FIG. 15 of the rotor of the second embodiment. FIG. 7 is a perspective view of a rotor according to a third embodiment. FIG. 7 is a perspective view of a load receiving block according to a third embodiment. FIG. 18 is a cross-sectional view of the rotor of the third embodiment taken along line XIX-XIX in FIG. 17; 20 is a sectional view showing a state in the middle of an assembly operation of a portion of the rotor of the third embodiment corresponding to section XX in FIG. 19; FIG.

Embodiments of the present invention will be described below based on the drawings. In each of the embodiments described below, common parts are denoted by the same reference numerals, and some redundant explanations will be omitted.

(drive device)
FIG. 1 is a perspective view of a drive device 1 used in a vehicle. FIG. 2 is a sectional view of the drive device 1 taken along the line II-II in FIG.
The drive device 1 is used, for example, as a drive source for a wiper device of a vehicle. As shown in FIGS. 1 and 2, the drive device 1 includes a motor 2, a speed reducer 3 that decelerates and outputs the rotation of the motor 2, and a controller 4 that controls the drive of the motor 2.
In the following description, the term "axial direction" refers to the direction along the rotational axis C of the rotating shaft 31 of the motor 2, and the term "circumferential direction" refers to the direction along the rotational axis C of the rotating shaft 31 of the motor 2. This shall mean the circumferential direction. Moreover, when simply saying "radial direction", it shall mean the radial direction of the rotating shaft 31.

(motor)
The motor 2 includes a motor case 5, a substantially cylindrical stator 8 housed in the motor case 5, a rotor 9 arranged radially inside the stator 8 and rotatable with respect to the stator 8. It is equipped with The motor 2 of this embodiment is a so-called brushless motor that does not require brushes when supplying power to the stator 8.

(motor case)
The motor case 5 is made of a material with excellent heat dissipation, such as an aluminum alloy. The motor case 5 includes a first motor case 6 and a second motor case 7, which are configured to be splittable in the axial direction. The first motor case 6 and the second motor case 7 are each formed into a cylindrical shape with a bottom.
The first motor case 6 is integrally molded with the gear case 40 of the reduction unit 3 so that the bottom portion 10 is connected to the gear case 40 . A through hole through which the rotating shaft 31 of the motor 2 can be inserted is formed approximately in the center of the bottom portion 10 in the radial direction. In addition, in this embodiment, the motor case 5 and the gear case 40 constitute the casing of the drive device 1.

Furthermore, outer flange portions 16 and 17 are formed in each of the openings 6a and 7a of the first motor case 6 and the second motor case 7, respectively, and extend outward in the radial direction. The motor case 5 has an internal space formed by abutting outer flange portions 16 and 17 against each other. A stator 8 and a rotor 9 are arranged in the internal space of the motor case 5. The stator 8 is press-fitted into a stepped portion formed on the inner peripheral surface of the first motor case 6 .

(stator)
The stator 8 includes a stator core 20 made of laminated steel plates (electromagnetic steel plates), and a plurality of coils 24 wound around the stator core 20. The stator core 20 includes an annular core body 21 and a plurality of (for example, six) teeth 22 that protrude radially inward from the inner circumference of the core body 21 . The inner circumferential surface of the core body portion 21 and each tooth 22 are covered with an insulator 23 made of resin. The coil 24 is wound around a corresponding predetermined tooth 22 from above the insulator 23 . Each coil 24 generates a magnetic field for rotating the rotor 9 by receiving power from the controller 4 .

(rotor)
The rotor 9 is rotatably disposed inside the stator 8 in the radial direction with a small gap therebetween. The rotor 9 includes a rotating shaft 31, a substantially cylindrical rotor core 32 to which the rotating shaft 31 is coaxially fixed, and four permanent magnets 33 attached to the outer periphery of the rotor core 32 (see FIGS. 4, 5, etc.). ). The rotating shaft 31 is formed integrally with a worm shaft 44 that constitutes the speed reduction section 3 . The rotating shaft 31 and the worm shaft 44 are rotatably supported by a gear case 40 (casing) via bearings 46 and 47. Note that, as the permanent magnet 33, for example, a ferrite magnet is used. However, the permanent magnet 33 is not limited to this, and neodymium bonded magnets, neodymium sintered magnets, etc. can also be applied.
The detailed structure of the rotor 9 will be explained later.

(reduction part)
The speed reduction unit 3 includes a gear case 40 integrated with the motor case 5 and a speed reduction mechanism 41 housed within the gear case 40. The gear case 40 is made of a metal material with excellent heat dissipation properties, such as an aluminum alloy. Gear case 40 is formed into a box shape with an opening 40a on one side. The gear case 40 has a gear accommodating portion 42 that accommodates the reduction mechanism 41 therein. Further, in the side wall 40b of the gear case 40, an opening 43 that communicates the through hole of the first motor case 6 with the gear accommodating portion 42 is formed at a location where the first motor case 6 is integrally formed.

A substantially cylindrical bearing boss 49 is provided protruding from the top wall 40c of the gear case 40. The bearing boss 49 is for rotatably supporting the output shaft 48 of the speed reduction mechanism 41, and a sliding bearing (not shown) is arranged on the inner peripheral side. An O-ring (not shown) is attached to the inside of the tip of the bearing boss 49. Furthermore, a plurality of ribs 52 are provided protruding from the outer peripheral surface of the bearing boss 49 to ensure rigidity.

The speed reduction mechanism 41 housed in the gear housing section 42 includes a worm shaft 44 and a worm wheel 45 meshed with the worm shaft 44 . Both ends of the worm shaft 44 in the axial direction are rotatably supported by the gear case 40 via bearings 46 and 47. The output shaft 48 of the deceleration mechanism 41 is coaxially and integrally provided with the worm wheel 45 . The worm wheel 45 and the output shaft 48 are arranged such that their rotation axes are substantially orthogonal to the rotation axis C of the worm shaft 44 (rotation shaft 31 of the motor 2). The output shaft 48 protrudes to the outside via a bearing boss 49 of the gear case 40. A spline 48a is formed at the protruding tip of the output shaft 48, which can be connected to an object to be driven by the motor.

Further, the worm wheel 45 is provided with a sensor magnet (not shown). The position of this sensor magnet is detected by a magnetic detection element 61 provided in the controller 4, which will be described later. That is, the rotational position of the worm wheel 45 is detected by the magnetic detection element 61 of the controller 4.

(controller)
The controller 4 has a controller board 62 on which a magnetic detection element 61 is mounted. The controller board 62 is arranged in the opening 40a of the gear case 40 so that the magnetic detection element 61 faces the sensor magnet of the worm wheel 45. The opening 40a of the gear case 40 is closed by a cover 63.

The terminal portions of the plurality of coils 24 drawn out from the stator core 20 are connected to the controller board 62 . Furthermore, terminals of the connector 11 (see FIG. 1) provided on the cover 63 are electrically connected to the controller board 62. In addition to the magnetic detection element 61, the controller board 62 includes a power module (not shown) consisting of a switching element such as an FET (Field Effect Transistor) that controls the drive voltage supplied to the coil 24, and a power module (not shown) that controls the voltage. A smoothing capacitor (not shown) and the like are mounted.

(Detailed structure of rotor of first embodiment)
3 is a perspective view of the rotor 9, and FIG. 4 is a sectional view of the rotor 9 taken along the line IV-IV in FIG. Further, FIG. 5 is an exploded perspective view of the rotor 9. 6 and 7 are a perspective view and a plan view of the rotor 9 with a magnet cover 71, which will be described later, removed.
The rotor 9 includes a rotating shaft 31 (not shown in FIGS. 3 to 7), a rotor core 32 to which the rotating shaft 31 is coaxially fixed, four permanent magnets 33 arranged on the outer periphery of the rotor core 32, and a rotor core 32. A pair of load receiving blocks 70A, 70B arranged on one end side and the other end side in the axial direction, respectively, and a pair of load receiving blocks 70A, 70B arranged on the rotor core 32 and the permanent magnet 33 from the outside in the axial direction and the radial direction. A metal magnet cover 71 is provided.
Note that the axially outer side of each load receiving block 70A, 70B means the side opposite to the side in the axial direction where the rotor core 32 is arranged.

The rotor core 32 is configured by laminating a plurality of steel plates (electromagnetic steel plates) having substantially the same shape in the axial direction. The rotor core 32 has a substantially cylindrical core body 32a and four salient poles 32b that protrude in the radial direction from the outer periphery of the core body 32a.

The four salient poles 32b protrude from the outer periphery of the core body portion 32a at equal intervals in the circumferential direction. In this embodiment, the outer circumferential surface of the core main body portion 32a is formed in a substantially circular shape centered on the axis of the rotor 9 (rotation axis C). A side surface of each salient pole 32b facing in the circumferential direction of the rotor core 32 is configured as a flat surface. Permanent magnets 33 are assembled between circumferentially adjacent salient poles 32b of rotor core 32.

In this embodiment, the permanent magnet 33 is formed into a substantially arc shape when viewed in the axial direction. Each salient pole 32b of the rotor core 32 has a distance from the axial center (rotational axis C) of the rotor 9 to the radially outer end that is the maximum distance from the axial center (rotational axis C) of the rotor 9 to the outer circumferential surface of the permanent magnet 33. The distance is approximately the same as the distance to the bulge.

The axial length of each permanent magnet 33 is longer than the axial length of the rotor core 32, as shown in FIG. In the case of this embodiment, each permanent magnet 33 is set to protrude by approximately the same length from one end side to the other end side in the axial direction with respect to the salient pole 32b when assembled to the rotor core 32. There is.

Further, as shown in FIG. 5, on the inner circumferential surface of the rotor core 32 (core body portion 32a), there are four arcuate surfaces 72 centered on the axis (rotation axis C) of the rotor 9, and adjacent arcuate surfaces 72. A relief groove 73 is formed extending radially outward from between the two. Each escape groove 73 extends radially outward for the same length, and the end portion in the extending direction is an arcuate engaging portion 73a. A locking pawl 74 of load receiving blocks 70A, 70B, which will be described later, is fitted into the engaging portion 73a of each escape groove 73. Further, the rotating shaft 31 is press-fitted into the four arcuate surfaces 72 on the inner circumference of the rotor core 32 .

The magnet cover 71 has a cylindrical peripheral wall portion 71a, and a pair of flange portions 71b and 71c that extend inwardly in the radial direction from one end in the axial direction and the other end of the peripheral wall portion 71a, respectively. . Note that the perspective view shown in FIG. 5 shows a state before the flange portion 71c is formed on the other end of the peripheral wall portion 71a in the axial direction.

A rotor core 32 holding a permanent magnet 33 is arranged inside the peripheral wall portion 71a together with a pair of load receiving blocks 70A and 70B. The rotor core 32 holding the permanent magnets 33 is press-fitted into the inner side of the peripheral wall portion 71a with load receiving blocks 70A and 70B attached to one end and the other end in the axial direction, respectively. At this time, the flange portion 71b on the one end side of the peripheral wall portion 71a is bent in advance on the one end side of the peripheral wall portion 71a. The flange portion 71c on the other end side of the peripheral wall portion 71a is shaped by caulking after the rotor core 32 and load receiving blocks 70A, 70B are press-fitted inside the peripheral wall portion 71a.

FIG. 8 is a perspective view of the load receiving blocks 70A and 70B. FIG. 8(A) is a perspective view of one load receiving block 70A viewed from the outside in the axial direction (the side opposite to the side where the rotor core 32 is arranged), and FIG. 8(B) is a perspective view of the other load receiving block 70B. FIG. 3 is a perspective view of the rotor core 32 viewed from the inside in the axial direction (the side where the rotor core 32 is disposed).
One load receiving block 70A and the other load receiving block 70B are formed in the same shape. Both are assembled to one end and the other end of the rotor core 32 in the axial direction with their front and back sides reversed.

The load receiving blocks 70A and 70B include an annular portion 70a disposed overlappingly on the axial end surface of the core body portion 32a of the rotor core 32, and a ring portion 70a that protrudes radially from the outer circumferential surface of the annular portion 70a to support each salient pole of the rotor core 32. 32b, and a perforated disk-shaped end wall 70c integrally connected to the annular portion 70a and the axially outer side of the leg portion 70b. are doing. The four leg portions 70b extend in a radial direction centered on the rotation axis C of the rotation shaft 31, and protrude at equal intervals on the outer periphery of the annular portion 70a. Both load receiving blocks 70A and 70B are made of, for example, hard resin.

Each load receiving block 70A, 70B is assembled to overlap the axial end surface of the rotor core 32, and is disposed between the axial end surface of the rotor core 32 and the flange portions 71b, 71c of the magnetic cover 71. The load receiving blocks 70A, 70B are attached to the respective flange portions 71b, 71c when the flange portions 71b, 71c are caulked after the rotor core 32 and the load receiving blocks 70A, 70B are press-fitted inside the peripheral wall portion 71a of the magnet cover 71. Accepts the input caulking load.

To explain further, when the rotor core 32 and the load receiving blocks 70A and 70B are press-fitted into the peripheral wall part 71a of the magnet cover 71 from the end opposite to the flange part 71b, the flange of the peripheral wall part 71a is The end portion on the side of the portion 71b is extended and deformed, and as a result, the radially outer edge 55 of the flange portion 71b is bulged and deformed so as to bulge outward in the axial direction. Therefore, before shaping the other flange portion 71c by caulking, the radially outer edge 55 of one flange portion 71b is pressed from the axially outer side with the holding jig 91, and the radially outer edge 55 is pressed from the axially outer side. Correct the bulge so that it returns to a flat state (plastically deforms it). Thereafter, a caulking load is applied to the other end side of the peripheral wall portion 71a of the magnet cover 71 using a caulking jig (not shown). The caulking load (pressing load) applied to each flange portion 71b, 71c during these steps is received by the load receiving blocks 70A, 70B.

The four leg portions 70b of each load receiving block 70A, 70B are arranged to overlap the axial end surface of each salient pole 32b of the rotor core 32. The end wall 70c of each load receiving block 70A, 70B has a disk shape (a holed disk shape) with a radius that is approximately the same as the length from the axis of the rotor core 32 (rotation axis C) to the tip of the leg portion 70b. ) is formed. The end wall 70c closes the space between the circumferentially adjacent leg portions 70b on the outside in the axial direction.

A locking pawl 74 that protrudes toward the rotor core 32 side approximately along the axial direction is integrally formed on the inner peripheral edge of the annular portion 70a of each load receiving block 70A, 70B at a position on the extension of each leg portion 70b. is formed. The locking pawl 74 has a substantially semicircular cross section, and when the load receiving blocks 70A and 70B are assembled to the end surface of the rotor core 32, the locking pawl 74 engages with the relief groove 73 (engaging portion 73a) on the inner circumference of the rotor core 32. It is designed to be mated to the Relative displacement of the load receiving blocks 70A and 70B with respect to the rotor core 32 in the radial direction and circumferential direction is restricted by fitting each of the locking claws 74 into the corresponding escape grooves 73 (engaging portions 73a).

Further, a pair of press-fit protrusions 76 are formed on the circumferentially facing side surfaces of each leg portion 70b of the load receiving blocks 70A, 70B. Each press-fit protrusion 76 extends along the axial direction, and is formed so that its protrusion height gradually decreases toward the side closer to the rotor core 32. When the load receiving blocks 70A and 70B are assembled to the rotor core 32 having the permanent magnets 33 arranged on the outer periphery, the ends of each permanent magnet 33 are inserted between the adjacent leg portions 70b of the load receiving blocks 70A and 70B. Placed. At this time, the permanent magnet 33 comes into contact with the press-fit projection 76. This restricts displacement of the permanent magnet 33 in the circumferential direction.

A circular confirmation hole 57 is formed in a region between adjacent legs 70b on the end wall 70c. The confirmation hole 57 allows the position of each permanent magnet 33 to be visually confirmed from outside the rotor 9 when the load receiving blocks 70A and 70B are assembled into the magnet cover 71 together with the rotor core 32 holding the permanent magnets 33. It is formed at a position facing the axial end face of each permanent magnet 33, as shown in FIG. Four confirmation holes 57 are provided in one-to-one correspondence with each permanent magnet 33.

In the case of the rotor 9 of this embodiment, a substantially disk-shaped end wall 70c is arranged at the axially outer end of the load receiving blocks 70A, 70B. Therefore, when the load receiving blocks 70A and 70B are press-fitted into the magnet cover 71 together with the rotor core 32 holding the permanent magnet 33, and the ends (flange parts 71b and 71c) of the magnet cover 71 are caulked in this state, the ends The radially outer edge of the portion wall 70c is pressed down from the axial direction by the flange portions 71b, 71c.

A plurality of reinforcing ribs 58 are formed on the end wall 70c of each load receiving block 70A, 70B for reinforcing the area between adjacent leg portions 70b. The reinforcing ribs 58 are formed on the axially inner surface of the end wall 70c so as to extend in the radial direction.

FIG. 9 is a perspective view of the magnet cover 71 before the flange portion 71c is formed on the other axial end side of the peripheral wall portion 71a. FIG. 10 is a cross-sectional view of the magnet cover 71 taken along the line XX in FIG.
In the state shown in FIGS. 9 and 10, a flange portion 71b is bent at one end in the axial direction of the peripheral wall portion 71a. The radially outer edge 55 of the flange portion 71b extends straight inward in the radial direction so as to be substantially perpendicular to the outer circumferential surface of the peripheral wall portion 71a. On the other hand, a curved portion 35 is formed at the radially inner edge of the flange portion 71b. In the curved portion 35, the radially inner end 71b-1 (inner peripheral end) of the flange portion 71b is warped in a direction away from the axially outer end surface of the load receiving block 70A (end wall 70c). It is formed like this. In other words, the radially inner edge of the flange portion 71b is formed such that the surface facing the axially outer end surface of the load receiving block 70A (end wall 70c) is a curved surface.
In this embodiment, the curved portion 35 is formed at the radially inner edge of the flange portion 71b, but the shape of the radially inner edge is similar to the radially inner edge 71b of the flange portion 71b. -1 from the axially outer end surface of the load receiving block 70A (end wall 70c), other shapes such as a shape having a straight portion in part may be used.

FIG. 11 is an enlarged view of section XI in FIG. 4 of the rotor 9. Further, FIG. 12 is a sectional view showing a state in which a portion of the rotor 9 corresponding to section XII in FIG. 11 is being assembled.
When the rotor core 32 and the load receiving blocks 70A and 70B are press-fitted inside the peripheral wall 71a of the magnet cover 71, the radially outer edge 55 of the flange 71b is axially outwardly moved by the press-fitting load as shown in FIG. It bulges and deforms. Therefore, after press-fitting the rotor core 32 and the load receiving blocks 70A and 70B inside the peripheral wall portion 71a of the magnet cover 71, pressing is required to correct the bulging deformation of the radially outer edge 55 of the flange portion 71b. The jig 91 is pressed against the radially outer edge 55 of the flange portion 71b from the axially outer side.

Here, when the radially outer edge 55 of the flange portion 71b bulges and deforms axially outwardly due to the press-fitting load as described above, the radially inner edge 55 of the flange portion 71b deforms as shown in FIG. It is inclined toward the axially outer end surface of the load receiving block 70A. At this time, the convex curved surface of the curved portion 35 on the radially inner edge of the flange portion 71b faces the axially outer end surface of the load receiving block 70A (end wall 70c). Therefore, when a pressing load is input from the holding jig 91 to the radially outer edge 55 of the flange portion 71b, the radially inner edge of the flange portion 71b is bent at the curved portion 35 of the load receiving block 70A (end It is pressed against the axial end face of the section wall 70c).

In this way, when the pressing load continues to be input from the holding jig 91 to the flange portion 71b, the convex curved surface of the curved portion 35 slides on the end surface of the load receiving block 70A (end wall 70c), and the flange portion 71b The radially outer edge 55 of is plastically deformed as shown by the imaginary line in FIG. Thereby, the shape of the radially outer edge 55 of the flange portion 71b is corrected so as to follow the end surface of the load receiving block 70A (end wall 70c). During this time, the radially inner end 71b-1 of the flange portion 71b is spaced apart from the end surface of the load receiving block 70A (end wall 70c), so the corner portion of the end 71b-1 is It is not pressed against the end face with a large force.

(Rotor manufacturing method)
When manufacturing (assembling) the rotor 9, first, the permanent magnets 33 are arranged on the outer circumference of the rotor core 32, and in this state, the load receiving blocks 70A, Assemble 70B.
Next, the assembly is press-fitted into the peripheral wall portion 71a of the magnet cover 71. At this time, one flange portion 71b of the magnet cover 71 is bent in advance so that the radially outer edge portion 55 is approximately perpendicular to the peripheral wall portion 71a.
Thereafter, the radially outer edge 55 of the flange portion 71b of the magnet cover 71 is pressed in the axial direction by the pressing jig 91. As a result, the radially inner edge (curved portion 35) of the flange portion 71b is pressed against the axially outer end surface of the load receiving block 70A, and the radially outer edge 55 (bulged portion) of the flange portion 71b is pressed against the axially outer end surface of the load receiving block 70A. The shape is corrected so as to follow the end face of the load receiving block 70A.
Next, the other axial edge of the magnet cover 71 is caulked with a caulking jig, and the flange portion 71c is formed by plastic deformation, and the flange portion 71c is attached to the end surface of the end wall 70c of the load receiving block 70B. Apply pressure. As a result, rotor core 32 and permanent magnet 33 are fixed inside magnet cover 71 together with load receiving blocks 70A and 70B.

(Effects of the rotor of the first embodiment)
In the rotor 9 of this embodiment, load receiving blocks 70A and 70B are arranged between each end surface of the rotor core 32 in the axial direction and the flange portions 71b and 71c of the magnetic cover 71. Therefore, when manufacturing the rotor 9, when caulking the flanges 71b and 71c of the magnet cover 71, it is possible to prevent damage or deterioration of the permanent magnet 33 due to a large load being input directly to the permanent magnet 33. can do.

Furthermore, the rotor 9 of this embodiment has a shape in which the radially inner edge of the flange portion 71b of the magnet cover 71 separates the radially inner end 71b-1 from the axially outer end surface of the load receiving block 70A. It is said that Therefore, when the magnet cover 71 is assembled, the flange portion 71b of the magnet cover 71 is inclined toward the end surface of the load receiving block 70A, and in this state, a pressing load is input to the flange portion 71b in the direction of the load receiving block 70A. Also, the radially inner end 71b-1 of the flange portion 71b can be prevented from being pressed against the end surface of the load receiving block 70A.
Therefore, when the rotor 9 of this embodiment is employed, damage to the load receiving block 70A and generation of abrasion powder can be suppressed when the magnet cover 71 is assembled.

Further, in the rotor 9 of this embodiment, the radially inner edge of the flange portion 71b is bent such that the radially inner edge 71b-1 is warped in a direction away from the axially outer end surface of the load receiving block 70A. A curved portion 35 is formed in the curved portion 35 . Therefore, when the flange portion 71b is pressed against the end surface of the load receiving block 70A, the convex curved surface of the curved portion 35 can be brought into contact with the end surface of the load receiving block 70A. When the flange portion 71b is pressed by the holding jig 91 and the inclined posture of the flange portion 71b changes, the slip resistance between the flange portion 71b and the end face of the load receiving block 70A can be maintained low.
Therefore, when the rotor 9 of this embodiment is adopted, the bulging portion of the radially outer edge 55 of the flange portion 71b can be smoothly corrected, and damage to the load receiving block 70A caused by the correction work can be corrected. and wear can be further suppressed.

(Detailed structure of rotor of second embodiment)
Next, the detailed structure of the rotor of the second embodiment will be explained.
13 is a perspective view of the rotor 109, and FIG. 14 is an exploded perspective view of the rotor 109.
The rotor 109 of this embodiment has a basic configuration that is almost the same as that of the first embodiment, but the shape of a part of the magnet cover 71 is different from that of the first embodiment.

As in the first embodiment, the magnetic cover 71 has flange portions 71b and 71c formed at one end and the other end in the axial direction of a peripheral wall portion 71a. The flange portion 71b on one end side is formed in advance so as to bend and extend radially inward from the end portion of the peripheral wall portion 71a, and the flange portion 71c on the other end side is connected to the rotor core 32 and the load receiving block 70A inside the peripheral wall portion 71a. , 70B are press-fitted and then shaped by caulking.

FIG. 15 is a perspective view showing a state in which the rotor 109 is being assembled, and FIG. 16 is a cross-sectional view of the rotor 109 taken along line XVI-XVI in FIG. 15.
As shown in FIGS. 15 and 16, the magnetic cover 71 of this embodiment has a convex portion 53 that protrudes outward in the axial direction at the corner between the peripheral wall portion 71a and the flange portion 71b on one end side. There is. The convex portion 53 is formed in an annular shape along the outer periphery of the flange portion 71b. When the rotor core 32 and load receiving blocks 70A and 70B are press-fitted into the peripheral wall 71a of the magnet cover 71, the radially outer edge 55 of the flange 71b bulges axially outward, as shown in FIGS. 15 and 16. do. Therefore, after press-fitting the rotor core 32 and the load receiving blocks 70A and 70B into the peripheral wall portion 71a, in order to correct the bulging portion of the radially outer edge 55 of the flange portion 71b, as shown in FIG. , the bulging portion is pressed by the pressing jig 91. At this time, since the convex portion 53 is formed in advance at the corner between the peripheral wall portion 71a and the flange portion 71b, the radially outer edge 55 of the flange portion 71b is pressed in the axial direction by the pressing jig 91. It does not easily expand outward in the radial direction even under load.
In addition, also in the case of the magnet cover 71 of this embodiment, the curved shape part 35 is formed in the radially inner edge of the flange part 71b similarly to 1st Embodiment. Furthermore, the radially inner end 71b-1 of the flange portion 71b is spaced apart from the axially outer end surface of the load receiving block 70A.

(Effects of the rotor of the second embodiment)
Since the rotor 109 of this embodiment has the same basic configuration as that of the first embodiment, it is possible to obtain the same basic effects as the first embodiment.

Further, in the rotor 109 of this embodiment, a convex portion 53 that protrudes outward in the axial direction is formed at a corner between the peripheral wall portion 71a and the flange portion 71b of the magnet cover 71. Therefore, when the bulging shape of the radially outer edge 55 of the flange portion 71b is corrected when the rotor 109 is assembled, the radially outer edge 55 of the flange portion 71b is suppressed from expanding in diameter. can do. Therefore, when the rotor 109 of this embodiment is employed, the flange portion 71b of the magnet cover 71 can stably fix the rotor core 32 within the peripheral wall portion 71a and the load receiving blocks 70A, 70B.

(Detailed structure of rotor of third embodiment)
Next, the detailed structure of the rotor of the third embodiment will be explained.
FIG. 17 is a perspective view of the rotor 209 of this embodiment.
The rotor 209 of this embodiment has a basic configuration that is almost the same as that of the first embodiment, but differs from that of the first embodiment in the structure of a load receiving block 270A arranged at one end in the axial direction. ing.

FIG. 18 is a perspective view of the load receiving block 270A. 19 is a sectional view of the rotor 209 taken along the line XIX-XIX in FIG. 17, and FIG. 20 is a sectional view showing the state of the portion of the rotor 209 corresponding to section XX in FIG. 19 during assembly work. It is.
The load receiving block 270A includes an annular portion 70a disposed overlapping the axial end surface of the core body of the rotor core 32, and a ring portion 70a that protrudes radially from the outer circumferential surface of the annular portion 70a, and extends in the axial direction of each salient pole of the rotor core 32. It has four leg portions 70b arranged overlappingly on the end surfaces of the annular portion 70a and a perforated disk-shaped end wall 70c integrally connected to the axially outer sides of the annular portion 70a and the leg portions 70b. The four leg portions 70b extend in a radial direction centered on the rotation axis C of the rotation shaft 31.

On the axially outer end surface of the end wall 70c, there are four load receiving ribs 38a extending radially around the rotational axis C, and an annular shape connecting the radially inner ends of the four load receiving ribs 38a in an annular manner. A rib 38b is provided in a protruding manner. The annular rib 38b is arranged along the inner peripheral edge of the end wall 70c. The load receiving rib 38a and the annular rib 38b are formed to protrude at a constant height from the axially outer end surface of the end wall 70c. The load-receiving rib 38a is formed on the axially outer end surface of the end wall 70c at a position overlapping the four legs 70b in the axial direction (the position where the legs 70b are projected in the axial direction). The flange portion 71b of the magnet cover 71 is in contact with the axially outer end surface of each load receiving rib 38a. The annular rib 38b is formed on the axially outer end surface of the end wall 70c at a position that overlaps the annular portion 70a in the axial direction (a position where the annular portion 70a is projected in the axial direction). Further, a generally fan-shaped region sandwiched between adjacent load receiving ribs 38a on the axially outer end surface of the end wall 70c is depressed relative to the load receiving ribs 38a and the annular rib 38b, and the flange The non-contact portion 39 is configured to be non-contact with the portion 71b.

In the case of this embodiment as well, when assembling the rotor 209, when press-fitting the rotor core 32 and the load receiving blocks 70A, 70B into the peripheral wall 71a of the magnet cover 71, as shown in FIG. The edge portion 55 on the outside in the axial direction bulges and deforms outward in the axial direction due to the press-fitting load. Therefore, after the rotor core 32 and the load receiving blocks 70A, 70B are press-fitted, in order to correct the bulging deformation of the radially outer edge 55 of the flange portion 71b, the radially outer edge 55 of the flange portion 71b is is pressed from the outside in the axial direction by a pressing jig 91.

At this time, since the radially inner edge of the flange portion 71b is inclined toward the axially outer end surface of the end wall 70c, when a load is input from the holding jig 91, the radial The curved surface of the curved portion 35 on the inner side in the axial direction is pressed against the end surface on the outer side in the axial direction of the end wall 70c. At this time, since a plurality of load receiving ribs 38a extending in the radial direction are protruded from the axially outer end surface of the end wall 70c, the curved portion 35 of the flange portion 71b , and does not contact other parts. Therefore, when a load is input to the flange portion 71b from the holding jig 91, the curved portion 35 of the flange portion 71b slides on the plurality of load receiving ribs 38a, while the radially outer edge 55 It is plastically deformed along the end surface of the end wall 70c. At this time, the load receiving block 270A receives the input load with the plurality of thick leg portions 70b in the axial direction through the plurality of load receiving ribs 38a. Further, at this time, the input load is not directly input to the non-contact portion 39 between the adjacent load receiving ribs 38a on the end surface of the end wall 70c.
In addition, when the flange portion 71b receives a pressing load from the holding jig 91 and the curved portion 35 slides on the load receiving rib 38a while changing the abutment posture, the load receiving rib 38a is moved from the curved portion 35. The load transmitted to the radially inner side of 38a is received by the annular rib 38b and the annular portion 70a.

(Effects of the rotor of the third embodiment)
Since the rotor 209 of this embodiment has the same basic configuration as that of the first embodiment, it is possible to obtain the same basic effects as the first embodiment.

In addition, in the rotor 209 of this embodiment, a plurality of load receiving ribs 38a, which the flange portion 71b abuts, are arranged at a position on the end surface of the end wall 70c of the load receiving block 270A, which overlaps the leg portion 70b in the axial direction. ing. Therefore, when assembling the rotor 209, when correcting the bulging portion of the radially outer edge of the flange portion 71b, the pressing load input from the flange portion 71b to the load receiving block 270A is applied in the axial direction. It can be received by the thick leg portions 70b. Therefore, when the rotor 209A of this embodiment is adopted, when the rotor 209A is assembled, a pressing load is input to a portion with low strength on the load receiving block 270A, causing damage or damage to a part of the load receiving block 270A. Deterioration can be prevented from occurring.

In particular, in the rotor 209 of this embodiment, a non-contact portion 39 is provided between adjacent load receiving ribs 38a of the end wall 70c of the load receiving block 270A, in which the flange portion 71b does not come into contact. Therefore, when the bulging portion of the flange portion 71b is corrected during assembly of the rotor 209, the pressing load input from the flange portion 71b to the load receiving block 270A is applied to the axial wall on the end wall 70c. This can prevent direct input into thin parts. Therefore, when the rotor 209A of this embodiment is employed, it is possible to more reliably prevent damage or deterioration of a portion of the peripheral edge of the load receiving block 270A.

Note that the present invention is not limited to the above-described embodiments, and various design changes can be made without departing from the gist thereof.

DESCRIPTION OF SYMBOLS 1... Drive device, 2... Motor, 3... Reduction part, 4... Controller, 5... Motor case, 6... First motor case, 6a... Opening part, 7... Second motor case, 7a... Opening part, 8... Stator , 9, 109, 209... Rotor, 10... Bottom, 11... Connector, 16, 17... Outer flange, 20... Stator core, 21... Core body, 22... Teeth, 23... Insulator, 24... Coil, 31... Rotation Shaft, 32... Rotor core, 32a... Core body, 32b... Salient pole, 33... Permanent magnet, 35... Curved portion, 38a... Load receiving rib, 38b... Annular rib, 39... Non-contact part, 40... Gear case, 40a ...opening, 40b...side wall, 40c...top wall, 41...reduction mechanism, 42...gear accommodating part, 43...opening, 44...worm shaft, 45...worm wheel, 46...bearing, 47...bearing, 48...output Shaft, 48a... Spline, 49... Bearing boss, 52... Rib, 53... Convex portion, 55... Radial outer edge, 57... Confirmation hole, 58... Reinforcement rib, 61... Magnetic detection element, 62... Controller board , 63... Cover, 70A, 70B, 270A... Load receiving block, 70a... Annular part, 70b... Leg part, 70c... End wall, 71... Magnet cover, 71a... Peripheral wall part, 71b... Flange part, 71b-1... Radial inner end, 71c...flange portion, 72...circular surface, 73...groove, 73a...engaging portion, 74...locking claw, 76...press-fit protrusion, 91...pressing jig, C...rotation axis.

Claims (6)

A rotor that rotates under the magnetic field of a stator,
a rotating shaft;
a rotor core in which the rotating shaft is coaxially fixed;
a plurality of permanent magnets arranged on the outer periphery of the rotor core;
a substantially cylindrical magnet cover that covers the outside of the rotor core and the plurality of permanent magnets and has a flange portion bent inward in the radial direction at an axial end along the rotation axis of the rotation shaft;
a load receiving block disposed between an axial end surface of the rotor core and the flange portion and abutting the flange portion and the rotor core;
The load receiving block is
a plurality of legs extending in a radial direction centered on the rotational axis of the rotational shaft and abutting an axial end surface of the rotor core;
a substantially disc-shaped end wall connected to an axial end of the plurality of legs opposite to the rotor core;
A plurality of load-receiving ribs that extend in a radial direction centered on the rotational axis and that are in contact with the flange portion are disposed at a position of the axially outer end surface of the end wall that overlaps the leg portion in the axial direction. is,
The rotor is characterized in that the radially inner edge of the flange portion is shaped to separate the radially inner end from the axially outer end surface of the load receiving block. A radially inner edge of the flange portion is formed with a curved portion whose radially inner end is curved in a direction away from an axially outer end surface of the load receiving block. The rotor according to item 1. A non-contact portion with which the flange portion does not come into contact is disposed between the adjacent load-receiving ribs on the axially outer end surface of the end wall. 2. The rotor according to 2 . The magnetic cover is
a peripheral wall portion that covers the outer periphery of the rotor core and the load receiving block;
the flange portion bent and extending radially inward from the axial end of the peripheral wall portion;
The rotor according to any one of claims 1 to 3 , wherein a convex portion projecting outward in the axial direction is formed at a corner between the peripheral wall portion and the flange portion. . A rotor according to any one of claims 1 to 4 ,
A motor comprising: a stator that is disposed on the outer peripheral side of the rotor and generates a magnetic field. A method for manufacturing a rotor according to claim 1, comprising:
arranging the plurality of permanent magnets on the outer periphery of the rotor core, and assembling the load receiving block on the axial end of the rotor core;
press-fitting the load receiving block, the rotor core, and the plurality of permanent magnets into the peripheral wall of the magnetic cover;
pressing the flange portion against the axially outer end surface of the load receiving block;
A method for manufacturing a rotor, comprising :

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