JP7418147B1 - Rotating electric machine, rotor for rotating electric machine, and manufacturing method of rotor for rotating electric machine - Google Patents

Abstract

The cross-sectional shape of the protrusion is a rectangular shape in which the axial length is longer than the circumferential length, making it easy to detect. Further, a recess formation region in which a plurality of recesses are formed is provided on the inner periphery of the cylindrical portion in a region corresponding to the protrusion. The axial intermediate position and main direction intermediate position of the protrusion and the axial intermediate position and circumferential intermediate position of the recess substantially match. Further, the axial length of the recess is longer than the axial length of the projection, and the circumferential length of the projection and the circumferential length of the recess are approximately equal. This dimensional relationship also increases the height of the protrusion and improves the shape accuracy of the protrusion.

Description

Cross-reference of related applications

This application is based on Patent Application No. 2022-50135 filed in Japan on March 25, 2022, and the content of the underlying application is incorporated by reference in its entirety.

The description of this specification relates to a rotating electrical machine, a rotor for a rotating electrical machine, and a method for manufacturing a rotor for a rotating electrical machine, and the rotating electrical machine of the present disclosure is useful, for example, when used as a generator or a starter for a two-wheeled vehicle.

A three-phase brushless motor is used as a rotating electric machine that can be used as a generator or starter for two-wheeled vehicles, and the rotational position of the rotor can be detected from changes in magnetic flux using a magnetic detection protrusion provided on the rotor. The use of a reference position signal for ignition control of an internal combustion engine is disclosed in Patent Document 1.

Japanese Patent Application Publication No. 2007-215333

In the rotating electric machine described in Patent Document 1, only a protrusion for position detection is formed on the outer periphery of the rotor. That is, Patent Document 1 does not disclose the shape of the protrusion that allows the magnetic detection device to easily detect magnetism.

On the other hand, in recent years, there has been a demand for higher precision engine control due to exhaust gas regulations. To this end, it is important to increase the height of the protrusion and to form a shape that allows the magnetic detection device to detect with higher accuracy.

An object of the present disclosure is to increase the height of the protrusion for magnetic detection and to make the protrusion easy to detect so that the magnetic detection device can detect the protrusion with higher accuracy.

A first aspect of the present disclosure is a rotor that is made of iron material and has a disc-shaped bottom part and a cylindrical part arranged on the radial outer periphery of the bottom part, and in which a plurality of permanent magnets are arranged in the circumferential direction on the inner periphery of the cylindrical part. The rotary electric machine includes a stator including a plurality of teeth, and a plurality of coils disposed in the teeth, and a radially outer end of the teeth faces a magnet.

In the first rotor of the present disclosure, a protrusion forming portion is formed on the outer periphery of the cylindrical portion, in which a plurality of protrusions are formed radially outward at equal intervals in the circumferential direction. The protruding portion is integrally formed on the outer periphery of the cylindrical portion using the iron material of the cylindrical portion. Further, the protrusion has a rectangular shape having sides on both sides in the circumferential direction and both sides in the axial direction, and the length in the axial direction is longer than the length in the circumferential direction.

In the first rotor of the present disclosure, a recess formation region in which a plurality of recesses are formed is formed on the inner periphery of the cylindrical portion in a region corresponding to the protrusion. The recess has a rectangular shape having sides on both sides in the circumferential direction and both sides in the axial direction, and the length in the axial direction is longer than the length in the circumferential direction. Furthermore, the protrusion and the recess are formed at approximately the center of the cylindrical portion in the axial direction.

In the first aspect of the present disclosure, the axial intermediate position of the protrusion and the axial intermediate position of the recess substantially match, and the axial length of the protrusion also substantially matches the axial length of the recess and the axial width of the protrusion. The shape of the protrusion is defined by making the axial widths of the recesses substantially the same and guiding the shape of the protrusion in the axial direction to stabilize the circumferential shape of the protrusion . On the other hand, the circumferential intermediate position of the protrusion and the circumferential intermediate position of the recess are almost the same, and the circumferential length of the recess is longer than the circumferential width of the protrusion. The width in the direction is wide, and the height of the protrusion is increased by gathering the iron material of the cylindrical part into the protrusion from the circumferential direction .

Further, the first rotating electrical machine of the present disclosure includes a magnetic detection device that is disposed radially outward of the protrusion and detects the position of the protrusion.

In the first aspect of the present disclosure, since the protrusion has a rectangular shape in which the axial length is longer than the circumferential length, the protrusion can have a shape that is easily detected by a magnetic detection device. Moreover, the first aspect of the present disclosure is that the height of the protrusion can be increased because the recess formation region in which a plurality of recesses are formed is provided on the inner periphery of the cylindrical portion in a region corresponding to the protrusion. There is. Moreover, the axial intermediate position of the protrusion and the axial intermediate position of the recess substantially match, and the axial length of the protrusion also substantially matches the axial length of the recess. On the other hand, the circumferential intermediate position of the protrusion and the circumferential intermediate position of the recess substantially match, and the circumferential length of the recess is longer than the circumferential length of the protrusion. Therefore, this dimensional relationship also makes it possible to increase the height of the protrusion. Moreover, due to this dimensional relationship, the positional accuracy of the protrusion in the circumferential direction can be improved.

A sixth aspect of the present disclosure is a rotating electrical machine using the rotor configured as described above, and the rotating electrical machine includes a magnetic detection device that detects the position of the protrusion.

An eighth aspect of the present disclosure is a method of manufacturing a rotor for a rotating electric machine. An eighth method of manufacturing a rotor for a rotating electrical machine according to the present disclosure is to punch a central round hole for supporting a boss part in the center of a flat plate made of iron material, and punch out a circular flat plate coaxially with the central round hole. and a cylindrical part bending step of bending the outer peripheral part of the circular flat plate in the axial direction to form a disc-shaped bottom part centered on the central axis of the central round hole and a cylindrical part arranged on the radial outer periphery of this bottom part. and a hole punching step of forming a fixing hole for the boss part in the bottom part.

In the eighth method of manufacturing a rotor for a rotating electric machine according to the present disclosure, the cylindrical part is punched out from the inner periphery side to the outer periphery side, and a rectangular protrusion whose axial length is longer than the circumferential length is formed on the outer periphery of the cylindrical part. At the same time as forming a rectangular recess on the inner periphery of the cylindrical part, the axial length is longer than the circumferential length. It has a permanent magnet fixing step and a boss fixing step of arranging the boss portion in the central round hole and fixing the boss portion to the bottom using the fixing hole.

In the eighth method of manufacturing a rotor for a rotating electrical machine according to the present disclosure, the ejection step includes arranging a die having a rectangular die recess on the outer periphery of the cylindrical portion, and having a rectangular punch convex portion on the inner periphery of the cylindrical portion. Protrusions and recesses are formed by placing a punch and pressing the punch toward the die so that the fiber flow of the iron material at the base of the protrusion is maintained in the circumferential direction and cut in the axial direction. .

A seventh aspect of the present disclosure is a method of manufacturing a rotor for a rotating electric machine. A seventh manufacturing method of the present disclosure includes a flat plate punching step of punching a central round hole for supporting a boss portion in the center from a flat plate made of iron material and punching out a circular flat plate coaxially with the central round hole; A cylindrical part bending step of bending the outer periphery of the flat plate in the axial direction to form a disc-shaped bottom part centered on the central axis of the central round hole, and a cylindrical part arranged on the radial outer periphery of this bottom part; and a punching step for forming a fixing hole in the boss portion.

In the seventh manufacturing method of the present disclosure, the cylindrical portion is further punched out from the inner periphery side to the outer periphery side, and has a rectangular shape having sides on both sides in the circumferential direction and on both sides in the axial direction. A rectangular protrusion whose length is longer than the circumferential length is formed at a position approximately in the axial center of the cylindrical portion , and the inner periphery of the cylindrical portion has sides on both sides in the circumferential direction and on both sides in the axial direction. It also includes an ejecting step for forming a rectangular recess whose axial length is longer than its circumferential length.

In the seventh manufacturing method of the present disclosure, after molding the rotor, a magnet fixing step is performed in which a permanent magnet is fixed to the inner circumference of the cylindrical portion, a boss portion is arranged in a central round hole, and a boss portion is placed in a central round hole. and a step of fixing the boss part in the bottom part using the fixing hole.

In the dispensing step of the seventh manufacturing method of the present disclosure, a die having a die recess with a rectangular cross section is arranged on the outer periphery of the cylindrical part, and a punch having a punch convex part with a rectangular cross section is arranged on the inner periphery of the cylindrical part. This is done by pressing the punch against the die side. In addition, in the dispensing process, the axial width of the punch protrusion almost matches the axial width of the die recess , and the axial width of the protrusion and the recess are made to almost match, so that the shape of the protrusion is axially This is a cutting method that defines the shape of the protrusion by guiding it in the circumferential direction to stabilize the circumferential shape of the protrusion, and the circumferential width of the punch protrusion is larger than the circumferential width of the die recess. An extrusion method is used in which the circumferential width of the recess is made wider than the width, and the iron material of the cylindrical portion is collected from the circumferential direction onto the protrusion to increase the height of the protrusion . In addition, in the removal process, a plurality of protrusions are formed on the cylindrical portion at equal intervals in the circumferential direction.

In the seventh manufacturing method of the present disclosure, the shape of the protrusion can be formed into a rectangular shape in which the axial length is longer than the circumferential length, so that the shape can be easily detected by a magnetic detection device. Further, the seventh manufacturing method of the present disclosure also provides a recess formation region in which a plurality of recesses are formed in a region corresponding to the projection on the inner periphery of the cylindrical portion, and sets the circumferential width of the punch projection to the circumference of the die recess. Since the width is larger than the width in the direction, the height of the protrusion can be increased.

In addition, the axial intermediate position of the protrusion and the axial intermediate position of the recess are almost the same, the axial length of the protrusion is also almost the same as the axial length of the recess, and the circumferential intermediate position of the protrusion and the recess are The circumferential intermediate positions are substantially coincident, and the circumferential length of the recess is longer than the circumferential length of the protrusion. Therefore, this dimensional relationship also makes it possible to increase the height of the protrusion. In addition, this dimensional relationship makes it possible to improve the circumferential positional accuracy of the protrusion.

In the second aspect of the present disclosure, the circumferential length of the recess is approximately 1.7 times longer than the circumferential length of the protrusion. This makes it possible to increase the height of the protrusion.

In a third aspect of the present disclosure, the depth of the recess is approximately 0.7 times or more the thickness of the cylindrical portion. This also makes it possible to increase the height of the protrusion.

A fourth aspect of the present disclosure is that the protrusion corner, which is the corner of the protrusion, and the concave corner, which is the corner of the recess, are formed into curved surfaces. The curved surface promotes the flow of iron material. This effectively prevents insufficient strength such as cracks due to a decrease in the filling rate of the iron material.

A fifth aspect of the present disclosure is that in the root portion of the protrusion, the fiber flow of the iron material is continuous in the circumferential direction, and the fiber flow of the iron material is cut in the axial direction. By using an extrusion method in which the fiber flow of the iron material is continuous, it is possible to promote the flow of the iron material and increase the height of the protrusion. In addition, by using a cutting method in which the fiber flow of the iron material cuts the protrusion, it is possible to form the protrusion into a more accurate shape.

FIG. 1 is a cross-sectional view of a rotating electric machine combined with a crankshaft and an engine cover. FIG. 2 is a front view showing the rotor, stator, and magnetic sensing device. FIG. 3 is a perspective view of the rotor. FIG. 4 is a perspective view showing the bottom and cylindrical portion of the rotor. FIG. 5 is a front view showing the flat plate punching process. FIG. 6 is a sectional view showing a flat plate punching process. FIG. 7 is a front view showing the step of bending the cylindrical portion. FIG. 8 is a cross-sectional view showing the step of bending the cylindrical portion. FIG. 9 is a front view showing the punching process. FIG. 10 is a sectional view showing the punching process. FIG. 11 is a front view showing the caulking pin driving process. FIG. 12 is a cross-sectional view showing the caulking pin driving process. FIG. 13 is a front view showing the inner diameter drawing process. FIG. 14 is a sectional view showing the inner diameter drawing process. FIG. 15 is a front view showing the going out process. FIG. 16 is a sectional view showing the removal process. FIG. 17 is a diagram showing the circumferential shape of the die and punch in the ejecting process. FIG. 18 is a diagram showing the axial shape of the die and punch in the outgoing process. FIG. 19 is a cross-sectional view showing the circumferential shape of the protrusion and the recess. FIG. 20 is a cross-sectional view showing the axial shape of the protrusion and the recess. FIG. 21 is a front view showing the magnet fixing process. FIG. 22 is a front view showing the boss fixing process. FIG. 23 is a front view showing the clutch fixing process. FIG. 24 is a sectional view showing the magnetic sensing device. FIG. 25 is a cross-sectional view showing the circumferential shape of the rotor and permanent magnets. FIG. 26 is a diagram illustrating the relationship between the protrusion and the induced electromotive force of the magnetic sensing device. FIG. 27 is a diagram illustrating the relationship between a comparative example of the protrusion and the induced electromotive force of the magnetic sensing device. FIG. 28 is a diagram illustrating the fiber flow of iron material in the extrusion method. FIG. 29 is a diagram illustrating the fiber flow of iron material in the cutting method. FIG. 30 is a diagram showing curved surfaces at a protruding corner and a concave corner. FIG. 31 is a diagram showing another example of curved surfaces at protruding corners and concave corners. FIG. 32 is a cross-sectional view showing another example of the circumferential shape of the rotor and permanent magnets. FIG. 33 is a sectional view showing still another example of the circumferential shape of the rotor and permanent magnets.

Hereinafter, an example of the present disclosure will be described based on the drawings. FIG. 1 is a cross-sectional view of the rotary electric machine 1 combined with a crankshaft 100 and an engine cover 200. The crankshaft 100 rotates as a piston (not shown) reciprocates within a cylinder (not shown) via a connecting rod (not shown). The crankshaft 100 is made of iron and has a diameter of about 30 mm, and is rotatably supported by a cylinder block 101 with a bearing 102 .

The engine cover 200 covers the opening of the cylinder block 101 and is bolted to the cylinder block 101. The engine cover 200 is made of die-cast aluminum or aluminum alloy, and has a wall thickness of about 4 mm. Since the engine cover 200 is continuous with the opening of the cylinder block 101, the internal environment is similar to that of the cylinder block 101.

A rotor 300 of the rotating electrical machine 1 is fixed to the crankshaft 100 with a boss portion 340. More specifically, the boss portion 340 is arranged coaxially with the rotor 300 and is fixed coaxially with the crankshaft 100 by a shaft fixing bolt 342 at the tip of the crankshaft 100. Therefore, the rotor 300 rotates together with the crankshaft 100. The rotor 300 is made of iron material, and includes a disk-shaped bottom portion 302 extending radially outward from a boss portion 340 that engages with the crankshaft 100, and a cylindrical portion 303 formed at a radially outer portion of the bottom portion 302. ing. As shown in FIG. 2, twelve permanent magnets 304 are arranged in a line in the circumferential direction inside the cylindrical portion 303. The thickness of the permanent magnet 304 is approximately 4 to 5 mm. Note that the number of permanent magnets 304 is not limited to 12, but can be set as appropriate, such as 20 or 24, depending on the required performance.

Inside the rotor 300, as shown in FIGS. 1 and 2, a stator 400 is arranged coaxially with the rotor 300. FIG. 2 is a front view of stator 400 viewed from the engine cover 200 side. The stator 400 is formed by laminating a plurality of magnetic steel plates, and integrally includes a base portion 401 attached to the engine cover 200 and a plurality of teeth portions 402 extending radially outward from the base portion 401. The outer diameter of the stator 400 is about 110 to 130 mm, and the inner diameter of the rotor 300 is therefore large enough to form a minute gap between the outer diameter of the stator 400 and the permanent magnets 304.

The base portion 401 has three stator bolt through holes 403 for fixing the stator 400 to the engine cover 200. The teeth portion 402 is electrically insulated by an insulator 407 made of insulating resin such as polyamide, and a coil 404 made of copper wire or aluminum wire is wound on the insulator 407. FIG. 3 is a perspective view showing the rotor 300 with the stator 400 removed from FIG. 4 is a perspective view showing the bottom portion 302 and cylindrical portion 303 of the rotor 300 with the boss portion 340, permanent magnet 304, etc. removed from FIG. 3.

As shown in FIGS. 3 and 4, 16 protrusions 310 are formed on the outer periphery of the cylindrical portion 303 of the rotor 300 at equal intervals in the circumferential direction. Further, 16 recesses 311 are formed on the inner circumference of the cylindrical portion 303 at positions corresponding to the protrusions 310. Note that in the present disclosure, the circumferential direction refers to a direction along the outer circumference and inner circumference of the cylindrical portion 303. Further, the axial direction refers to the direction of the rotation axis of the rotor 300 (the central axis of the crankshaft 100).

The protrusion 310 functions as a rotating magnetic material (reluctor) of the pickup type magnetic sensing device 500. As shown in FIG. 24, the magnetic detection device 500 includes a detection coil 501 wound around a cylindrical bobbin 506, and a pole piece 502 disposed on the inner circumference of the detection coil 501. It receives the magnetism of the magnet 503. These members are arranged in a housing 504 made of resin such as polyamide, and are attached and held to the engine cover 200 by metal stays 505.

When the rotor 300 rotates, the tip 3102 of the protrusion 310, which is a magnetic material, repeatedly approaches and moves away from the pole piece 502. As a result, the state of the magnetic path made up of the magnet 503 and the pole piece 502 changes, and the magnetic flux passing through the detection coil 501 changes. Specifically, the magnetic flux increases as the protrusion 310 approaches, and decreases as the protrusion 310 moves away, which is repeated. At this time, an induced electromotive force due to electromagnetic induction is generated in the detection coil 501, and this voltage is output to the outside. FIG. 26 shows the relationship between the movement of the tip 3102 of the protrusion 310 and the induced electromotive force.

The position of the protrusion 310 corresponds to the energization timing of the U phase, V phase, and W phase, and according to this detection position, when the rotating electric machine 1 is used as a motor as a starter, the The voltage supply to the coil 404 corresponding to the phase is controlled. Even when the internal combustion engine starts operating and the rotating electric machine 1 is used as a generator, it is used as a timing signal for controlling the currents from the coils 404 corresponding to the U-phase, V-phase, and W-phase.

However, the protrusion 310 is not formed over the entire circumference of the cylindrical portion 303. As shown in FIG. 4, the cylindrical portion 303 has a protrusion-formed region 305 in which a protrusion 310 is formed, and a protrusion-free region 306 in which a protrusion 310 is not formed over a predetermined range. In the example of FIG. 4, in the protrusion-free region 306, the protrusion portions 310 are not formed at two locations. Therefore, the output waveform of the magnetic sensing device 500 is not output at this protrusion-free portion 306, resulting in a so-called toothless state.

By detecting this protrusion-free portion 306, the reference position can be detected. Since the rotor 300 rotates integrally with the crankshaft 100, the reference position indicates the position of the crankshaft 100 in the rotational direction. Taking advantage of the fact that the crankshaft 100 is at the reference position, signals for controlling the ignition timing of a spark plug (not shown) disposed in a cylinder of the engine, and the injection amount and injection timing of a fuel injection injector (not shown) are transmitted to an internal combustion engine (not shown). Provided to the control device.

In addition to controlling the internal combustion engine as described above, in accordance with environmental regulations, if the internal combustion engine misfires, it is necessary to detect the misfire and issue an alarm. Furthermore, since the rotating electrical machine 1 can rotate in both the forward and reverse directions, it is necessary to accurately detect forward rotation and reverse rotation. Therefore, the output of the magnetic detection device 500 is required to have high accuracy.

In order to improve the accuracy of the magnetic sensing device 500, the protrusion 310 is required to have a shape that facilitates generation of induced electromotive force. In this example, as shown in FIGS. 4 and 26, the shape of the projection 310 is a rectangular parallelepiped in which the length in the axial direction is longer than the length in the circumferential direction. When moving away from the pole piece 502, the change in magnetic flux passing through the pole piece 502 per unit time increases, making it easy to obtain detection accuracy. Note that the surface facing the pole piece 502 at the radial tip of the protrusion 310 does not have to be flat, and may have a shape that bulges toward the pole piece 502 side. That is, the end surface of the protrusion 310 may be formed into a curved surface similar to that of the rotor 300. Since the tip 3102 of the protrusion 310 is the closest to the pole piece 502, it is the center of the protrusion 310 when a curved surface is formed. The important point is that the shape of the protrusion 310 is such that the tip 3102 can be formed.

Further, in order to improve the accuracy of the magnetic detection device 500, it is desirable that the protrusion 310 protrudes higher than the outer circumference of the cylindrical portion 303. In this example, the protrusion 310 is formed to have a higher height than the thickness of the cylindrical portion 303 of the rotor 300. When the thickness of the cylindrical portion 303 is about 3 mm, the height of the protrusion 310 is 2.5 mm or more. Therefore, the depth of the recessed portion 311 is set to be at least 0.7 times the wall thickness of the cylindrical portion 303.

In this manner, in the present disclosure, the protrusion 310 is formed so that the pole piece 502 has a shape that makes it easy to detect changes in magnetic flux. In particular, the shapes of the protrusion 310 and the recess 311 are devised. Therefore, a method for manufacturing the rotor 300 that increases the height of the protrusion 310 and optimizes the shape of the protrusion 310 will be described below.

First, as shown in FIGS. 5 and 6, a flat plate punching process P100 is performed. This flat plate punching process P100 is a process of punching out a circular flat plate 322 by press molding from a flat plate of iron material with a wall thickness of about 3 mm. Note that the iron material of the circular flat plate 322 is a rolled steel plate. During rolling, a fiber flow, which will be described later, is formed along the rolling direction. The circular flat plate 322 is a disc having a central round hole 320 and a circular outer peripheral part 321 concentrically.

Next, as shown in FIGS. 7 and 8, a cylindrical portion bending step P110 is performed in which the outer peripheral portion 321 of the circular flat plate 322 is bent in the axial direction. This cylindrical portion bending process P110 is also called drawing process. Then, by this cylindrical part bending step P110, a disk-shaped bottom part 302 centered on the central axis of the central round hole 320 and a cylindrical part 303 arranged on the radial outer circumference of this bottom part 302 are formed. In addition, in this cylindrical portion bending step P110, the center round hole 320 is also press-molded to have a larger diameter, and is formed to a size into which a boss portion 340, which will be described later, can be assembled.

Next, as shown in FIGS. 9 and 10, a punching step P120 is performed in which a fixing hole 323 for fixing the boss portion 340 to the bottom portion 302 is formed. In this punching step P120, a clutch bolt through hole 324 through which a clutch bolt for fixing a clutch 350 (shown in FIG. 23) to be described later passes is also formed. The plurality of fixing holes 323 each have the same diameter and are arranged concentrically around the central axis. The plurality of clutch bolt through holes 324 also have the same diameter, and the diameter of the clutch bolt through hole 324 is larger than the diameter of the fixing hole 323 in order to pass the head of the clutch bolt therethrough. Furthermore, the clutch bolt through holes 324 are also arranged concentrically around the central axis.

Thereafter, as shown in FIGS. 11 and 12, a crimping pin forming step P130 is performed in which the crimping pin 325 is punched and formed. The caulking pin 325 is used in a fixing step P160 of the permanent magnet 304, which will be described later. The caulking pin 325 is punched out from the right side of the bottom portion 302 in FIG. 12. In this stamping process, a ring groove 326 is also formed at the same time. The ring groove 326 is used in the permanent magnet fixing step P160, which will be described later.

Thereafter, as shown in FIGS. 13 and 14, an internal ejecting step P140 is performed in which the cylindrical portion 303 is ejected from the outer circumferential side to the inner circumferential side. The magnet holding part 327 is formed on the inner periphery of the cylindrical part 303 by the internal feeding process P140. The magnet holding portion 327 is formed in a portion of the cylindrical portion 303 that is close to the bottom portion 302 . This magnet holding portion 327 is also used in the permanent magnet fixing step P160, which will be described later.

Thereafter, as shown in FIGS. 15 and 16, an ejecting step P150 is performed in which the cylindrical portion 303 is punched out from the inner circumferential side to the outer circumferential side. Through this removal step P150, a protrusion 310 is formed on the outer periphery of the cylindrical portion 303, and a recess 311 is formed at a position corresponding to the protrusion 310 on the inner periphery of the cylindrical portion 303. The protrusion 310 and the recess 311 are formed at approximately the center of the cylindrical portion 303 in the axial direction. That is, if the positions where the protrusion 310 and the recess 311 are formed are close to the bottom 302 of the cylindrical portion 303, there is a possibility that the die 330 and punch 331 used in the ejecting step P150 may interfere with the bottom 302. On the other hand, if the position where the protrusion 310 and the recess 311 are formed is on the open end side of the cylindrical portion 303, the diameter of the cylindrical portion 303 may become larger than the predetermined diameter dimension due to the removal process P150. Therefore, in this example, the position where the protrusion 310 and the recess 311 are formed is approximately at the center of the cylindrical portion 303 in the axial direction. Note that it only needs to be approximately in the center, and does not need to be exactly in the center. It is only necessary to reduce the risk of interference and the risk of the diameter becoming large, and a certain degree of difference with respect to the center is acceptable. Therefore, when the protrusion 310 and the recess 311 are not formed in a range of about 5 mm from the open end of the cylindrical part 303 of the rotor 300 and in a range of 5 mm from the bottom 302 of the cylindrical part 303, they are formed approximately in the center. shall be.

FIGS. 17 and 18 show a die 330 and a punch 331 used in this extrusion step P150. FIG. 17 is a diagram of the die 330 and the punch 331 viewed from the circumferential direction, and a contact surface 3301 of the die 330 with the outer periphery of the cylindrical portion 303 has an arc shape corresponding to the shape of the cylindrical portion 303. Similarly, a contact surface 3311 of the punch 331 with the inner circumference of the cylindrical portion 303 also has an arc shape corresponding to the shape of the cylindrical portion 303. On the other hand, FIG. 18 is a diagram of the die 330 and punch 331 viewed from the axial direction. When viewed from the axial direction, a contact surface 3301 of the die 330 with the outer periphery of the cylindrical portion 303 and a contact surface 3311 of the punch 331 with the inner periphery of the cylindrical portion 303 are both linear.

19 and 20 show the protrusion 310 and recess 311 of the cylindrical portion 303 after the removal process P150. With these figures, the sizes of the die recess 332 of the die 330 and the punch protrusion 333 of the punch 331 will be explained. 19 shows the circumferential shape of the protrusion 310 and the recess 311, and FIG. 20 shows the axial shape of the protrusion 310 and the recess 311.

As shown in FIG. 19, the circumferential width 311R of the recess 311 is wider than the circumferential width 310R of the protrusion 310. Note that the circumferential intermediate position of the protrusion 310 and the circumferential intermediate position of the recess 311 substantially match. Further, the circumferential width 311R of the recess 311 is about 1.3 to 1.7 times larger than the circumferential width 310R of the protrusion 310. In this example, the circumferential width 311R of the recess 311 is 1.5 times the circumferential width 310R of the protrusion 310. The circumferential width 310R of the projection 310 is, for example, about 2.2 mm, and the circumferential width 311R of the recess 311 is, for example, about 3.3 mm. Furthermore, the depth 311D of the recess 311 is approximately 70% or more of the wall thickness t of the cylindrical portion 303. For example, when the wall thickness t of the cylindrical portion 303 is approximately 3 mm, the depth 311D is approximately 2.25 mm. Note that in the present disclosure, making the circumferential middle position of the protrusion 310 and the circumferential middle position of the recess 311 substantially coincide means that they almost match, and manufacturing deviations are allowed. As for this deviation, a difference of about 10% is allowed. For example, when the circumferential width 311R of the recess 311 is 3 mm, an error of about 0.3 mm is allowed.

On the other hand, in terms of the axial shape, the axial width 311L of the recess 311 substantially matches the axial width 310L of the protrusion 310. The axial intermediate position of the protrusion 310 and the axial intermediate position of the recess 311 also substantially match. For example, when the axial width 310L of the projection 310 is about 8 mm, the axial width 311L of the recess 311 is about 8.3 mm. In the present disclosure, substantially matching means that a predetermined deviation is allowed, and the allowed deviation amount is about 10%. In the above example, the axial width 310L of the protrusion 310 is 8 mm, while the axial width 311L of the recess 311 is 8.3 mm, which is within 10%.

Since the circumferential width 311R of the recess 311 is longer than the circumferential width 310R of the protrusion 310, the height 310H of the protrusion 310 can be made higher than the depth 311D of the recess 311. For example, if the wall thickness t of the cylindrical portion 303 is about 3 mm and the depth 311D of the recess 311 is about 2.25 mm, the height 310H of the protrusion 310 can be about 2.65 mm. The ratio of the height 310H of the protrusion 310 to the wall thickness t of the cylindrical portion 303 is close to 90%. This is said to be about 70% in general punching, whereas the height 310H of the protrusion 310 can be made higher. This is because the shape of the protrusion 310 has a long axial length. For example, the axial length is about 8 mm and the circumferential length is about 2.2 mm. This is because more iron material can be collected if the flow of iron material is collected from the circumferential direction. Therefore, in this example, a method of collecting more iron material from the circumferential direction and increasing the height 310H of the protrusion 310 is called an extrusion method in the removal process P150.

Note that the above example of dimensions shows an example in which the protrusion 310 has a rectangular shape in which the circumferential width 310R and the axial width 310L of the protrusion 310 are approximately 2 mm and 8 mm, but this dimension example is only an example. be. As shown in FIG. 4, the shape of the protrusion 310 may be a rectangle in which the axial length (axial width 310L) is longer than the circumferential length (circumferential width 310R).

As described above, in the present disclosure, since the circumferential length (circumferential width 311R) of the recess 311 is set longer than the circumferential length (circumferential width 310R) of the protrusion 310, the height of the protrusion 310 is increased. It is possible to increase the height 310H. Moreover, in the present disclosure, since the axial length (axial width 310L) of the protrusion and the axial length (axial width 311L) of the recess 311 are made to substantially match, the shape of the protrusion 310 is accurately defined. can do. In order to improve the detection accuracy of the magnetic detection device 500, the projections 310 are required to be formed at accurate positions in the circumferential direction. As mentioned above, "approximately matching" means that an error of about 10% is allowed, and this means that the axial width of the die recess 332 is larger than the axial width of the punch protrusion 333 by about 10% or less. is allowed. Therefore, a method of making accurate punching by making the axial length of the protrusion (axial width 310L) and the recess 311 almost match (axial width 311L) is carried out in the outgoing step P150. This is called the extraction method.

In this manner, in the present disclosure, the removal step P150 is performed using a combination of an extrusion method and a cutting method. The extrusion process P150 itself is a series of pressing processes performed using a punch 331 and a die 330, but by adjusting the dimensional relationship between the punch protrusion 333 and the die recess 332, the extrusion method and cutting We have been able to realize both methods at the same time. That is, in the removal step P150 of the present disclosure, the height of the protrusion 310 is increased by employing an extrusion method in the circumferential direction, and the shape of the protrusion 310 is accurately shaped by employing a cutting method in the axial direction. It's launching.

In addition, since the axial length (axial width 310L) is longer than the circumferential length (circumferential width 310R), assembly is facilitated. That is, the rotor 300 is coaxially attached to the crankshaft 100, and the magnetic detection device 500 is attached to the engine cover 200. Therefore, between the position of the rotor 300, that is, the position of the protrusion 310, and the magnetic sensing device 500, there may be some assembly error in the axial direction compared to the circumferential direction. On the other hand, if the axial length (axial width 310L) is long, assembly errors can be absorbed.

Here, not only the circumferential length (circumferential width 311R) of the recess 311 is set longer than the circumferential length (circumferential width 310R) of the protrusion 310, but also the axial length (axial width 311R) of the protrusion 310 is set longer. It is also possible to envisage an extrusion method in which the axial length (axial width 311L) of the recess 311 is made longer than the width 310L. In this case, it is possible to increase the height 310H of the protrusion 310. However, if the length of the recess 311 is made longer than the length of the protrusion 310 in both the axial direction and the circumferential direction, depending on the shape of the punch protrusion 333, defects may occur in the iron material flowing into the die recess 332. This is because the iron material forming the protrusion 310 gathers from all sides in the circumferential direction and the axial direction, making it impossible to accurately control the flow of the iron material at the corners where the flow of the iron material intersects. There is a risk that a so-called lack of thickness may occur, which is a portion where the die recess 332 is not filled with the iron material. This is because the height 310H of the protrusion 310 cannot be set to a predetermined dimension.

On the other hand, as in the present disclosure, if the axial length (axial width 310L) of the protrusion and the axial length (axial width 311L) of the recess 311 are used as a cutting method, the protrusion 310 can axially guide the shape of the die recess 332 and remove defects from the ferrous material flowing into the die recess 332. This stabilizes the shape of the protrusion 310 in the circumferential direction, making it possible to improve the detection accuracy of the magnetic detection device 500.

An extrusion method is used in which the length of the recess 311 is made longer than the length of the protrusion 310 in either the axial direction or the circumferential direction, and a cutting method is used in which the length of the recess 311 and the length of the protrusion 310 are made the same in the other direction. It is also possible to imagine that. Contrary to the present disclosure, a cutting method is used in which the circumferential length (circumferential width 310R) of the protrusion 310 and the circumferential length (circumferential width 311R) of the recess 311 are approximately matched, and the axial length of the protrusion is This is an example of an extrusion method in which the axial length (axial width 311L) of the recess 311 is made longer than the length (axial width 310L). In this case, the shape of the protrusion 310 can be guided in the circumferential direction, and defects can be removed from the iron material flowing into the die recess 332.

However, what the present disclosure forms is not just a protrusion 310, but a protrusion 310 of the rotor 300, and a protrusion 310 that operates as a reluctor with respect to the magnetic sensing device 500. In this case, more precision is required in the roundness of the rotor 300, and in the circumferential position where the protrusion 310 is present. If an attempt is made to make the width of the punch 331 larger than the axial width 310L of the projection 310 using an axial extrusion method, there will be restrictions on the axial length of the cylindrical portion 303 of the rotor 300. If the axial length of the cylindrical portion 303 is not sufficient with respect to the axial width 310L of the projection 310, the punch 331 and the bottom portion 302 may interfere with each other. Alternatively, the deformation of the open end of the cylindrical portion 303 becomes large, making it impossible to ensure roundness.

Furthermore, if the axial width 310L of the protrusion 310 is made shorter than the axial width 311L of the recess 311, the circumferential width 310R needs to be increased in order to ensure the height 310H of the protrusion 310. However, if the circumferential width 310R becomes large, the detection accuracy of the magnetic detection device 500 may deteriorate.

It is important that the outermost part of the projection 310 in the radial direction be in a stable positional relationship with the magnetic sensing device 500, that is, that the gap between the projection 310 and the magnetic sensing device 500 be constant. From this point of view, in the present disclosure, since the circumferential width 310R of the protrusion 310 is narrow, the range of the iron material to be moved to fill the die 330 can be narrowed, so that the outermost part of the protrusion 310 in the radial direction can be formed with high precision. can.

Further, as shown in FIG. 26, the magnetic sensing device 500 detects magnetic changes when the tip 3102 of the protrusion 310 approaches or moves away. Therefore, the shorter the circumferential width 310R of the protrusion 310 is, the sharper the magnetic change will be and the more accurately it can be detected. Conversely, if the circumferential width 310R becomes longer, as shown in FIG. 27, the period during which the tip portion 3102 of the protrusion 310 is close to each other becomes longer, which may become a factor in detecting noise.

Furthermore, it is also possible to assume that the protrusion 310 is cut out in both the circumferential direction and the axial direction in the removal process P150. In this case, the circumferential length (circumferential width 310R) of the protrusion 310 and the circumferential length (circumferential width 311R) of the recess 311 are made to substantially match, and the axial length (axial width 311R) of the protrusion 310 is made substantially the same. The width 310L) is also made to substantially match the axial length (axial width 311L) of the recess 311. However, in this case, a sufficient amount of iron material cannot be collected on the protrusion 310, and the height 310H of the protrusion 310 cannot be increased. Further, during the removal step P150, stress due to the punch convex portion 333 and the die concave portion 332 is applied to the entire circumference of the base of the protrusion 310 so that the protrusion 310 is cut. Therefore, there is a possibility that the protrusion 310 cannot be formed properly.

FIGS. 28 and 29 show the flow of iron material when using the extrusion method and when using the cutting method. As shown in FIG. 28, if the extrusion method is used, a fiber flow 3000 of the iron material is continuous at the root portion 3101 of the protrusion 310. Note that, as described above, the fiber flow 3000 is a fibrous structure due to the flow of metal caused by the fact that the iron material is a rolled steel plate. A fiber flow 3000 is formed along the rolling direction during rolling of the rolled steel plate.

As described above, the height 310H of the protrusion 310 can be increased by using the extrusion method, but this is because the fiber flow 3000 continuously flows more iron material into the protrusion 310. It is also the result of what we are doing. In other words, it can be said that the extrusion method is an outgoing step P150 in which the fiber flow 3000 of the iron material is not cut. According to the extrusion method, the fiber flows 3000 in the circumferential direction are not cut, so the fiber flows 3000 on both long sides forming the projection 310 are connected. For that reason. In the circumferential direction of the projection 310, the fiber flow 3000 can be utilized. Thereby, the strength of the protrusion 310 can be further increased.

Conversely, in the case of the cutting method, as shown in FIG. 29, the fiber flow 3000 of the iron material is cut at the root portion 3101 of the protrusion 310. This fiber flow 3000 of the iron material allows the shape of the protrusion 310 to be made more accurate. Therefore, it can be said that the cutting method is an outgoing step P150 in which the fiber flow 3000 of the iron material is cut. As a result, the fiber flow of the ferrous material forming the rotor 300 at the root 3101 of the protrusion 310 is maintained in the circumferential direction and cut in the axial direction. In other words, the step of pressing the punch 331 toward the die 330 is performed so as to maintain the fiber flow of the iron material in the root portion 3101 in the circumferential direction and cut it in the axial direction.

Due to a combination of the above factors, it is desirable to guide the shape of the protrusion 310 by cutting it out in the axial direction as in the present disclosure. That is, compared to the case where the shape of the protrusion 310 is guided by cutting out the shape of the protrusion 310 in the circumferential direction, the present disclosure can more accurately detect the formation of the roundness of the rotor 300 and the circumferential position where the protrusion 310 is present. It is possible to do so.

As explained above, the combination of the axial cutting method and the circumferential extrusion method is a desirable combination for forming the protrusions 310 on the rotor 300 in step P150. However, as mentioned above, care must be taken to prevent defects in the iron material. Therefore, as shown in FIGS. 30 and 31, the protruding corner 3105 of the protruding part 310 and the concave corner 3115 of the recessed part 311 may be formed into curved surfaces. 30 and 31 both show the protrusion 310 in view A and the recess 311 in view B of FIG. 19.

FIG. 30 shows an example in which the curved surfaces of the protruding corner portion 3105 and the concave corner portion 3115 are minimized, and the radius is approximately 0.1 mm. Conversely, FIG. 31 shows an example in which the curved surfaces of the protruding corner 3105 and the recessed corner 3115 are maximized, and the circumferential width 310R of the protruding portion 310 and the circumferential width 311R of the recessed portion 311 are the diameters of the curved surfaces. By forming the protruding corner 3105 and the recessed corner 3115 into curved surfaces, the iron material can easily flow into the protruding corner 3105 and the recessed corner 3115.

This is because the protruding corner 3105 and the concave corner 3115 are the boundary between the extrusion method and the cutting method in the extrusion step P150, so the movement of the iron material during press forming becomes complicated at this boundary. Therefore, by forming curved surfaces on the protruding corner portion 3105 and the concave corner portion 3115, which are the boundary portions, the movement of the iron material during press forming can be made smooth. As a result, the filling rate of the iron material in the protruding corners 3105 and the concave corners 3115 increases, and it is possible to effectively suppress insufficient strength such as the tendency to break.

In order to promote the flow of the iron material, as shown in FIGS. 19 and 20, it is necessary to apply heat to the outside of the protrusion 310 in the radial direction, and also to the sides 3106 on both sides in the circumferential direction and the sides 3107 on both sides in the axial direction. A curved surface may also be formed. Similarly, curved surfaces may be formed on the sides 3116 on both sides in the circumferential direction and on the sides 3117 on both sides in the axial direction on the outer side (innermost part) of the recess 311 in the radial direction. This is to ensure that the iron material flows to the tip corners of the punch 331 and die 330.

After forming the protrusions 310 and recesses 311 of the rotor 300, as shown in FIG. 21, a permanent magnet fixing step P160 is performed in which the permanent magnets 304 are fixed to the inner periphery of the cylindrical portion 303. However, since the permanent magnet 304 is magnetized after all the assemblies are completed, in this permanent magnet fixing step P160, the metal before magnetization is called a permanent magnet 304. First, the permanent magnet 304 before magnetization is placed on the inner periphery of the cylindrical portion 303, and then the magnet cover 3040 (shown in FIG. 22) is placed on the inner periphery of the permanent magnet 304. Next, the magnet cover 3040 is crimped and fixed to the bottom part 302 using the crimping pin 325. Note that the magnet cover 3040 is made of a thin plate of non-magnetic austenitic stainless steel. Then, adhesive is applied to the inner circumference of the cylindrical portion 303 to complete fixing of the permanent magnet 304. The ring groove 326 described above prevents the adhesive from entering the center round hole 320 side at this time. Further, the permanent magnet 304 is positioned in the axial direction by the magnet holding portion 327 described above. In addition, by pressing the caulking pin 325 described above, the magnet cover 3040 is also mechanically fixed to the rotor 300.

Next, as shown in FIG. 22, a boss fixing step P170 is performed in which the boss 340 is fixed to the bottom 302 of the rotor 300. In the boss part fixing step P170, the boss part 340 is first inserted into the center round hole 320. After insertion, the boss portion 340 is fixed to the bottom portion 302 of the rotor 300 with a rivet 341 using the fixing hole 323 . After the adhesive used in the permanent magnet fixing step P160 described above is cured, a clutch assembling step P180 is performed in which the clutch 350 is assembled to the boss portion 340, as shown in FIG. The clutch assembly process P180 utilizes the clutch bolt through hole 324. Clutch bolt 351 passes through clutch bolt through hole 324 and is screwed into threaded hole 352 of clutch 350 . This fixes the boss portion 340 and the clutch 350 to the bottom portion 302 of the rotor 300.

Note that the clutch 350 is a one-way clutch that transmits the rotation of the starter motor to the rotor 300 when the engine is started. That is, when starting the engine, the rotation of the starter motor is transmitted from the rotor 300 to the crankshaft 100 via the clutch 350, and when the rotation of the crankshaft 100 reaches a predetermined rotational speed, the engine starts. When starting the engine, the clutch 350 idles and the starter motor stops rotating.

As described above, after completing the assembly of all these parts, the permanent magnet 304 is magnetized. By this magnetization, a plurality of magnetic poles are formed at predetermined locations on the inner circumference of the cylindrical portion 303. After magnetization, the magnetic poles of the permanent magnet 304 are arranged such that the north pole and the south pole are equally spaced apart in the circumferential direction.

In the rotating electric machine 1, a boss portion 340 is fixed to the tip of the crankshaft 100 by a shaft fixing bolt 342. As shown in FIG. 1, the tip of the crankshaft 100 has a tapered portion 1001, and as shown in FIG. 22, the boss portion 340 also forms a tapered portion 3401. Therefore, even if the outer diameter of the crankshaft 100 and the inner diameter of the boss portion 340 change slightly, the axial position of the rotor 300 relative to the crankshaft 100 will shift significantly. As described above, in order to prevent misalignment with the magnetic sensing device 500, it is desirable that the protrusion 310 has a long axial width 310L. Further, a stator 400 is arranged on the inner periphery of the rotor 300, and the stator 400 is bolted to the engine cover 200 using bolt holes 403.

FIG. 25 shows the shape of the protrusion 310 and the recess 311 in the circumferential direction when the permanent magnet 304 is arranged on the rotor 300. Although FIG. 25 emphasizes the changes caused by the removal process P150, as a result of forming the protrusion 310 and the recess 311 in the cylindrical part 303, the protrusion 310 becomes smaller than the virtual outer peripheral surface 3030 shown by the broken line. The actual outer circumferential surface 3031 near the root portion 3101 is swollen outward. As a result, the wall thickness at the root portion 3101 of the protrusion 310 increases, and the stress applied to the root portion 3101 of the protrusion 310 can be alleviated.

Similarly, at the open end 3111 of the recess 311, the actual inner peripheral surface 3033 is deformed toward the recess 311 with respect to the virtual inner peripheral surface 3032 of the cylindrical portion 303. As a result, the contact position 3112 between the open end 3111 and the permanent magnet 304 is separated from the recess 311 in the circumferential direction. As a result, the point of action where the centrifugal force of the permanent magnet 304 is applied to the cylindrical portion 303 when the rotor 300 rotates at high speed is separated from the root portion 3101 of the protrusion 310 in the circumferential direction. Therefore, the stress applied to the protrusion 310 portion of the cylindrical portion 303 due to the centrifugal force of the permanent magnet 304 can also be alleviated.

Furthermore, as the open end 3111 is separated from the recess 311 in the circumferential direction, the gap below the protrusion 310 increases. Since the air gap has the effect of blocking magnetic flux, as a result of increasing the air gap in this way, it becomes possible to reduce the magnetic flux leaking from the permanent magnet 304 to the protrusion 310. Since the magnetic detection device 500 detects the protrusion 310 using the magnetic force of its own magnet 503, reducing the magnetic flux leaking from the permanent magnet 304 to the protrusion 310 leads to a reduction in sensor noise of the magnetic detection device 500. .

The actual outer circumferential surface 3031 and the actual inner circumferential surface 3033 generated in the removal process P150 have the advantages described above. However, there are not only advantages, but also some disadvantages. For example, on the actual outer circumferential surface 3031, the rise of the protrusion 310 becomes gentle, and the detection accuracy of the magnetic detection device 500 may be reduced. Therefore, the fact that the actual outer circumferential surface 3031 swells outward does not necessarily mean that the larger the bulge is, the better.

Similarly, the fact that the open end 3111 is separated from the recess 311 in the circumferential direction by the actual inner circumferential surface 3033 in the removal process P150 has the advantage of blocking the magnetic flux from the permanent magnet 304; This also leads to a reduction in the contact area between the surface and the permanent magnet 304. A reduction in the contact area is disadvantageous in terms of holding the permanent magnet 304. Therefore, the deformation of the open end 3111 toward the recess 311 by the actual inner circumferential surface 3033 does not necessarily mean that the amount of deformation is large.

FIG. 33 is an example in which the going out process P150 is reviewed based on the above points. The outer circumferential surface is made to match the true circular arc shape that the actual outer circumferential surface 3031 makes imaginary or ideal. This is because the shape of the contact surface 3301 of the die 330 with the outer periphery of the cylindrical part 303 is not made into an arc shape corresponding to the shape of the cylindrical part 303, but the protrusion part 310 is made in advance in anticipation of elastic deformation after press molding. This is achieved by making the root portion 3101 recessed radially inward (downward in FIG. 33). Alternatively, the shape of the contact surface 3301 of the die 330 with the outer periphery of the cylindrical portion 303 is made into an arc shape corresponding to the outer periphery shape of the cylindrical portion 303, and press molding is held for a certain period of time to suppress elastic deformation after press molding. Achieve by doing. In addition, the actual outer circumferential surface produced in the removal process P150 is press-molded again to approximate a true circular arc shape.

On the contrary, FIG. 32 is an example in which the actual inner circumferential surface 3033 is approximated to an ideal true circular arc shape. In this example, the shape of the contact surface 3311 of the punch 331 with the inner periphery of the cylindrical portion 303 is set in anticipation of elastic deformation after press forming. That is, the shape of the contact surface 3311 is formed in a shape that swells radially inward (downward in FIG. 32) from the arc shape corresponding to the shape of the cylindrical portion 303. For example, if the width in the circumferential direction (horizontal direction in Figure 32) is approximately 5 mm and the bulge in the radial direction (downward in Figure 32) is approximately 0.5 mm, it is acceptable to have a bulged shape. . Alternatively, the shape of the contact surface 3311 of the punch 331 with the inner periphery of the cylindrical portion 303 is made into an arc shape corresponding to the inner periphery shape of the cylindrical portion 303, and the press molding is held for a certain period of time to prevent elastic deformation after the press molding. Achieved through restraint.

Note that although the above-described embodiments are desirable aspects of the present disclosure, the present disclosure can be modified in various ways. For example, the number of protrusions 310 depends on the control specifications and can be set as appropriate. Further, when the reference position of the crankshaft 100 is detected by another method, the non-protrusion forming portion 306 may be eliminated and the entire circumference may be replaced by the protrusion forming portion 305. Even when the reference position of the crankshaft 100 is detected by the protrusion 310, it is also possible to form the entire circumference as the protrusion forming portion 305 and further to add a protrusion for position detection.

Further, in the above example, a magnetic pickup sensor is used as the magnetic detection device 500, but other sensors such as a Hall sensor may also be used. Further, the dimensions are just an example and can be changed. Further, the number of permanent magnets 304, the number of projections 310 and recesses 311, the number of fixing holes 323, the number of clutch bolt through holes 324, and the number of caulking pins 325 may all be set as appropriate. Further, in the above example, the stator 400 was fixed to the engine cover 200, but it may be fixed to the cylinder block 101.

(Disclosure of technical ideas)
This specification discloses multiple technical ideas described in multiple sections listed below. Some sections may be written in a multiple dependent form, in which subsequent sections alternatively cite preceding sections. Additionally, some terms may be written in a multiple dependent form referring to another multiple dependent form. The terms written in these multiple dependent forms define multiple technical ideas.

(Technical thought 1)
A rotor for a rotating electric machine, which has a disc-shaped bottom made of iron material and a cylindrical part arranged on the radial outer periphery of the bottom, the cylindrical part having a plurality of rotors arranged at equal intervals in the circumferential direction on the outer periphery of the cylindrical part. A protrusion forming portion is formed in which a protrusion is formed outward in the radial direction, the protrusion has a rectangular shape in which the length in the axial direction is longer than the length in the circumferential direction, and the protrusion and the protrusion are formed on the inner periphery of the cylindrical portion. A recess formation region is formed in which a plurality of recesses are formed in corresponding regions, and the recess has a rectangular shape in which the axial length is longer than the circumferential direction, and the axial intermediate position of the projection and the axial direction of the recess are formed. The axial length of the protrusion and the axial length of the recess substantially match, the circumferential middle position of the protrusion and the circumferential middle position of the recess substantially match, and the protrusion A rotor for a rotating electrical machine, wherein the circumferential length of the recessed portion is longer than the circumferential length of the cylindrical portion, and a plurality of permanent magnets are arranged in the circumferential direction on the inner periphery of the cylindrical portion.

(Technical thought 2)
The rotor for a rotating electric machine according to Technical Idea 1, wherein the circumferential length of the recess is about 1.7 times or less than the circumferential length of the protrusion.

(Technical thought 3)
The rotor for a rotating electrical machine according to Technical Idea 1 or Technical Idea 2, wherein the depth of the recess is approximately 0.7 times or more the wall thickness of the cylindrical portion.

(Technical thought 4)
The rotor for a rotating electrical machine according to any one of technical concepts 1 to 3, wherein a protruding corner that is a corner of the protruding portion and a concave corner that is a corner of the recess are formed into curved surfaces.

(Technical Thought 5)
Technical idea 1 to technical idea 4, in which the fiber flow of the iron material forming the rotor is continuous in the circumferential direction of the root part of the protrusion, and the fiber flow of the iron material is cut in the axial direction. A rotor for a rotating electric machine according to any one of the above.

(Technical Thought 6)
A rotor for a rotating electric machine according to any one of technical ideas 1 to 5, including a plurality of teeth and a plurality of coils disposed on the teeth, the radially outer end of the teeth. A rotating electric machine comprising: a stator that faces the permanent magnet; and a magnetic detection device that is disposed radially outward of the protrusion and detects the position of the protrusion.

(Technical Thought 7)
A flat plate punching process in which a central round hole for supporting the boss part is punched out of a flat plate made of iron material, and a circular flat plate is punched out coaxially with the central round hole, and the outer peripheral part of the circular flat plate is axially moved. a step of bending the cylindrical portion to form a disk-shaped bottom portion centered on the central axis of the central round hole and a cylindrical portion disposed on the radial outer periphery of the bottom portion; and fixing the boss portion to the bottom portion. a punching step of forming a hole, and punching out the cylindrical portion from the inner periphery side to the outer periphery side to form a rectangular protrusion on the outer periphery of the cylindrical portion, the axial length of which is longer than the circumferential length; a step of forming a rectangular recess whose axial length is longer than the circumferential length on the inner periphery of the cylindrical portion; and fixing a permanent magnet to the inner periphery of the cylindrical portion so as to hold the permanent magnet. and a boss part fixing step of arranging the boss part in the center round hole and fixing the boss part to the bottom part using the fixing hole, and the taking out process includes fixing the boss part in the center round hole, A die having a rectangular die recess is arranged on the outer periphery of the cylindrical part, a punch having a rectangular punch protrusion is arranged on the inner periphery of the cylindrical part, and the punch is pressed toward the die side, and the punch protrusion The circumferential width of the punch portion is larger than the circumferential width of the die recess, the axial width of the punch protrusion substantially matches the axial width of the die recess, and the protrusion is circumferentially attached to the cylindrical portion. A method of manufacturing a rotor for a rotating electric machine, in which a plurality of rotors are formed at equal intervals.

(Technical Thought 8)
A flat plate punching process in which a central round hole for supporting the boss part is punched out of a flat plate made of iron material, and a circular flat plate is punched out coaxially with the central round hole, and the outer peripheral part of the circular flat plate is axially moved. a step of bending the cylindrical portion to form a disk-shaped bottom portion centered on the central axis of the central round hole and a cylindrical portion disposed on the radial outer periphery of the bottom portion; and fixing the boss portion to the bottom portion. a punching step of forming a hole, and punching out the cylindrical portion from the inner periphery side to the outer periphery side to form a rectangular protrusion on the outer periphery of the cylindrical portion, the axial length of which is longer than the circumferential length; a step of forming a rectangular recess whose axial length is longer than the circumferential length on the inner periphery of the cylindrical portion; and fixing a permanent magnet to the inner periphery of the cylindrical portion so as to hold the permanent magnet. and a boss part fixing step of arranging the boss part in the center round hole and fixing the boss part to the bottom part using the fixing hole, and the taking out process includes fixing the boss part in the center round hole, A die having a rectangular die concave portion is arranged on the outer periphery of the cylindrical portion, a punch having a rectangular punch convex portion is arranged on the inner periphery of the cylindrical portion, and the iron material forming the rotor is disposed at the base of the protrusion. A method of manufacturing a rotor for a rotating electric machine, wherein the protrusion and the recess are formed by pressing the punch toward the die so that the fiber flow is maintained in the circumferential direction and cut in the axial direction.

Claims (8)

A rotor for a rotating electric machine having a disc-shaped bottom made of iron material and a cylindrical part disposed on the radial outer periphery of the bottom,
A protrusion forming portion is formed on the outer periphery of the cylindrical portion, in which a plurality of protrusions are formed radially outward at equal intervals in the circumferential direction,
The protrusion is integrally formed on the outer periphery of the cylindrical part using iron material of the cylindrical part,
The protrusion has a rectangular shape with sides on both sides in the circumferential direction and on both sides in the axial direction, and the length in the axial direction is longer than the length in the circumferential direction,
A recess formation region is formed on the inner periphery of the cylindrical portion, in which a plurality of recesses are formed in a region corresponding to the protrusion,
The recess has a rectangular shape having sides on both sides in the circumferential direction and both sides in the axial direction, and the length in the axial direction is longer than the length in the circumferential direction,
The protrusion and the recess are formed at approximately the center of the cylindrical portion in the axial direction,
The axial intermediate position of the protrusion and the axial intermediate position of the recess substantially match, and the axial length of the protrusion and the axial length of the recess substantially match , so that the axial width of the protrusion and the axial width of the recess substantially match. defining the shape of the protrusion by making the axial widths of the recesses almost the same and guiding the shape of the protrusion in the axial direction to stabilize the circumferential shape of the protrusion;
The circumferential intermediate position of the protrusion and the circumferential intermediate position of the recess substantially match, and the circumferential length of the recess is longer than the circumferential width of the protrusion. The circumferential width of the recess is wide, and the iron material of the cylindrical portion is collected from the circumferential direction onto the protrusion to increase the height of the protrusion ,
A rotor for a rotating electrical machine, in which a plurality of permanent magnets are arranged circumferentially on the inner periphery of the cylindrical portion. The rotor for a rotating electrical machine according to claim 1, wherein the circumferential length of the recess is about 1.7 times or less longer than the circumferential length of the protrusion. The rotor for a rotating electrical machine according to claim 1, wherein the depth of the recess is approximately 0.7 times or more the wall thickness of the cylindrical portion. The rotor for a rotating electrical machine according to claim 1, wherein a protruding corner that is a corner of the protruding portion and a recessed corner that is a corner of the recessed portion are formed into curved surfaces. A rotor for a rotating electric machine having a disc-shaped bottom made of iron material and a cylindrical part disposed on the radial outer periphery of the bottom,
A protrusion forming portion is formed on the outer periphery of the cylindrical portion, in which a plurality of protrusions are formed radially outward at equal intervals in the circumferential direction,
The protrusion has a rectangular shape with an axial length longer than a circumferential length,
A recess formation region is formed on the inner periphery of the cylindrical portion, in which a plurality of recesses are formed in a region corresponding to the protrusion,
The recess has a rectangular shape with an axial length longer than a circumferential length,
An axial intermediate position of the protrusion and an axial intermediate position of the recess substantially match, and an axial length of the protrusion and an axial length of the recess substantially match,
The circumferential intermediate position of the protrusion and the circumferential intermediate position of the recess substantially match, and the circumferential length of the recess is longer than the circumferential length of the protrusion.
A plurality of permanent magnets are arranged circumferentially on the inner periphery of the cylindrical part,
A rotor for a rotating electrical machine, in which the fiber flow of the iron material is continuous in the circumferential direction in the root portion of the protrusion, and the fiber flow of the iron material is cut in the axial direction. A rotor for a rotating electric machine according to any one of claims 1 to 5,
A stator comprising a plurality of teeth and a plurality of coils disposed in the teeth, and a radially outer end of the teeth faces the permanent magnet;
A rotating electrical machine including: a magnetic detection device that is disposed radially outward of the protrusion and detects the position of the protrusion. A flat plate punching step of punching out a central round hole for supporting the boss part in the center from a flat plate made of iron material, and punching out a circular flat plate coaxially with the central round hole;
A cylindrical part bending step of bending the outer peripheral part of the circular flat plate in the axial direction to form a disc-shaped bottom part centered on the central axis of the central round hole and a cylindrical part arranged on the radial outer periphery of this bottom part. and,
a hole punching step of forming a fixing hole for the boss part in the bottom part;
The cylindrical part is punched out from the inner periphery side to the outer periphery side, and the outer periphery of the cylindrical part has a rectangular shape having sides on both sides in the circumferential direction and on both sides in the axial direction, and the axial length is longer than the circumferential length. A protrusion having a shape of a rectangular shape having sides on both sides in the circumferential direction and both sides in the axial direction is formed on the inner periphery of the cylindrical part, and has a length in the axial direction. a step of forming a rectangular recess with a length longer than the circumferential length at a position approximately at the center of the cylindrical portion in the axial direction ;
a permanent magnet fixing step of holding and fixing a permanent magnet to the inner circumference of the cylindrical part;
a boss part fixing step of arranging the boss part in the central round hole and fixing the boss part to the bottom part using the fixing hole;
In the taking out step, a die having a rectangular die recess is arranged on the outer periphery of the cylindrical part, a punch having a rectangular punch convex part is arranged on the inner periphery of the cylindrical part, and the punch is inserted into the die. While pressing the iron material of the cylindrical part to the side, the circumferential width of the punch protrusion is larger than the circumferential width of the die recess and the circumferential width of the recess is wider than the circumferential width of the protrusion. An extrusion method is used in which the height of the protrusion is increased by collecting the protrusion from the circumferential direction , and the axial width of the punch protrusion is approximately equal to the axial width of the die recess, and the axial width of the protrusion is A cutting method that defines the shape of the protrusion by making the width substantially match the axial width of the recess and guiding the shape of the protrusion in the axial direction to stabilize the circumferential shape of the protrusion, and a method for manufacturing a rotor for a rotating electric machine, wherein a plurality of the protrusions are formed on the cylindrical portion at equal intervals in the circumferential direction. A flat plate punching step of punching out a central round hole for supporting the boss part in the center from a flat plate made of iron material, and punching out a circular flat plate coaxially with the central round hole;
A cylindrical part bending step of bending the outer peripheral part of the circular flat plate in the axial direction to form a disc-shaped bottom part centered on the central axis of the central round hole and a cylindrical part arranged on the radial outer periphery of this bottom part. and,
a hole punching step of forming a fixing hole for the boss part in the bottom part;
The cylindrical part is punched out from the inner periphery to the outer periphery to form a rectangular protrusion on the outer periphery of the cylindrical part, the axial length of which is longer than the circumferential length, and an axial protrusion on the inner periphery of the cylindrical part. a step of forming a rectangular recess whose length is longer than its circumferential length;
a permanent magnet fixing step of holding and fixing a permanent magnet to the inner circumference of the cylindrical part;
a boss part fixing step of arranging the boss part in the central round hole and fixing the boss part to the bottom part using the fixing hole;
In the taking out step, a die having a rectangular die recess is arranged on the outer periphery of the cylindrical part, a punch having a rectangular punch protrusion is arranged on the inner periphery of the cylindrical part, and the base of the protrusion is Manufacturing a rotor for a rotating electric machine, in which the protrusion and the recess are formed by pressing the punch against the die so that the fiber flow of the iron material is maintained in the circumferential direction and cut in the axial direction. Method.

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