JPH0336945A - Manufacture of permanent magnet type rotor - Google Patents

Abstract

PURPOSE:To facilitate assembling work of a rotor by caulking and securing the laminated discs in a laminated disc group and laminated chips in a laminated chip group one another then securing the laminated core through the laminated disc group to a shaft. CONSTITUTION:Laminated disc groups 2a-2d comprising a plurality of laminated discs 2, where the inner and outer circumferences of adjoining pole sections 23 are coupled each other, are arranged at the opposite sides of a laminated core 1 comprising laminated discs 2, laminated chips 3, and a permanent magnet 4. Laminated chip groups 3l1-3l3 comprising a plurality of laminated chips 3 having a pole section 31 between the laminated disc groups 2a-2d are also provided. The laminated discs 2 and the laminated chips 3 are caulked one another. Laminated disc group, laminated chip group and a laminated core 1 are formed in such a manner, then the laminated core is secured through the laminated disc group to a shaft 5. Since the relative position between the laminated chip, the permanent magnet and the rotor shaft is fixed physically, assembling work of the laminated chip, the permanent magnet and the rotor shaft is facilitated.

Description

DETAILED DESCRIPTION OF THE INVENTION [Field of Industrial Application] The present invention relates to a method of manufacturing a rotor for a synchronous motor using permanent magnets.

[Prior Art] Conventionally, in a rotor using permanent magnets, as shown in FIG. The magnetic pole pieces B are arranged radially, and a permanent magnet C having a rectangular cross section is sandwiched between the flat surfaces of the magnetic pole pieces B and fixed with an adhesive to form a cylindrical rotor core. As shown in FIG. 11, non-magnetic flange parts ESE are provided on both end faces of the rotor core, and the tightening that passes through the flange part E and the magnetic pole piece B is performed by the port b. and the rotor core are tightened together, and both flanges E are fixed to the rotor shaft F. In addition, in order to prevent magnetic flux leakage from the permanent magnet C, a gap G is provided between the rotor shaft F and the magnetic pole pieces B (for example, in Japanese Patent Laid-Open No. 62
-2839, Japanese Unexamined Patent Publication No. 63-23542).

[Problems to be Solved by Invention F] By the way, when assembling a rotor, magnetic pole pieces B and permanent magnets C are arranged alternately, and a gap G is provided between the magnetic pole pieces C and the rotor shaft F. We use jigs to position parts. However, in the case of mass production, it takes a lot of effort to attach and remove the attachment to the jig, resulting in an increase in costs.

An object of the present invention is to reduce the number of machining steps by making it possible to easily attach parts to a rotor shaft.

[Means to solve the problem] The present invention is based on the following means.

(1) In a method for manufacturing a rotor core in which a laminated core consisting of radially arranged magnetic pole parts and a permanent magnet sandwiched between the magnetic pole parts is fixed to a shaft, the inner periphery of the adjacent magnetic pole parts Alternatively, a laminated disk group consisting of a plurality of laminated disks whose outer periphery or inner and outer circumferences are connected is provided at least at both ends in the axial direction of the laminated core, and a plurality of laminated disk groups comprising a sector-shaped magnetic pole portion between the laminated disk groups are provided. A laminated piece group consisting of laminated pieces is provided, and the laminated disk and the laminated piece are fixed to each other by caulking to form the laminated disk group, the laminated piece group, and a laminated iron core, and the laminated disk group A method for manufacturing a permanent magnet rotor-resistant rotor, in which the laminated iron core is fixed to a shaft via.

(2) In a method for manufacturing a rotor core in which a laminated core consisting of radially arranged magnetic pole parts and a permanent magnet sandwiched between the magnetic pole parts is fitted to a shaft, the inside of the adjacent magnetic pole parts is A plurality of laminated disks whose peripheries or outer peripheries or inner and outer circumferences are connected are provided, the laminated disks are fixed to each other by die casting, and flange portions are formed by die casting on both end faces of the laminated core, and the flange portions are fixed to each other by die casting. A method for manufacturing a permanent magnet rotor-resistant rotor, in which the laminated core and the shaft are fixed through a material.

[Effect] The effects of the present invention are as follows.

(1) A laminated iron core is composed of a group of laminated disks in which the inner circumferences, outer circumferences, or inner and outer circumferences of adjacent magnetic pole parts are connected, and a laminated piece group consisting of laminated pieces in which the inner and outer circumferences of adjacent magnetic pole parts are not connected. , the laminated disks and the laminated pieces are fixed to each other by caulking, and the fitting part with the shaft is provided on the laminated disk group, and the laminated iron core is integrally molded, so that the laminated pieces, the permanent magnets, and the rotor shaft This facilitates assembly of the laminated pieces, permanent magnets and rotor shaft.

(2) A plurality of laminated disks are provided in which the inner periphery, outer periphery, or inner and outer periphery of the adjacent magnetic pole parts are connected, and the laminated disks are fixed to each other by die-casting, and both end faces of the laminated core are die-casted. Since the laminated core is integrally molded with the flange formed, the relative positions of the laminated disks, permanent magnets, and rotor shaft are determined physically, making it easy to assemble the laminated disks, permanent magnets, and rotor shaft. becomes easier.

[Example] The present invention will be described with reference to embodiments shown in the drawings.

FIG. 1 is a side sectional view of a laminated iron core l according to an embodiment of the present invention, which is composed of a laminated disk 2 made of electromagnetic steel sheets, a laminated piece 3, and a permanent magnet 4. The laminated disks 2 are at both ends and in the middle of the stacking thickness, as shown in FIG. 1, a and b.

A plurality of laminated disks are laminated in portions c and d to form a laminated disk group 2a.

2b, 2c, and 2d, and their shapes are shown in Figure 2 (
As shown in (a), a shaft hole 21 is provided in the center to fit tightly into the shaft 5. A plurality of insertion holes 22 are provided outside the shaft hole 21 into which permanent magnets 4 forming a field are inserted radially. Therefore, a magnetic pole portion 23 is formed between the plurality of insertion holes 22,
The magnetic flux of the permanent magnet 4 forms rotor magnetic poles. The magnetic pole portion 23 is provided with a caulking portion 24 for fixing the laminated disks 2 to each other, and connecting portions 25 and 26 are provided on the inner circumferential side and the outer circumferential side. In order to prevent magnetic flux from leaking to the shaft, the stacking thickness of the connecting portion 25 is set to a necessary minimum length that can sufficiently withstand the torque transmitted to the shaft 5 and the centrifugal force of the laminated iron core l and the permanent magnet 4 due to rotation. Set. The laminated pieces 3 are provided between N, /, , l in the axial direction of the laminated disk 2 to form a laminated piece group 3L-312, 3ff, whose shape is shown in FIG.
As shown in b), they are formed in a fan shape so as to create a gap between them and the shaft 5, and when assembled as a laminated core, they are arranged radially as shown by the dashed lines. The laminated piece 3 is provided with a caulking part 31 that engages with the caulking part 23 of the laminated disk 2, and the laminated pieces 3 stacked to a predetermined thickness are caulked to each other and are also caulked and fixed to the adjacent laminated disk 2. ing. The permanent magnets 4 are inserted between straight portions of circumferentially adjacent laminated pieces 3.

When forming the rotor core, as shown in FIGS. 3 and 4 (a) and (b), the laminated disk group 2a of the laminated core l is
, Shaft 5 is inserted into shaft holes 21 of 2b, 2c, and 2d.
are fitted and fixed by a method such as press-fitting.

As an example of a method for forming the laminated core l, FIG. 5 shows a method in which laminated disks 2 and laminated pieces 3 are successively punched out and laminated from an electromagnetic steel sheet M using a press machine using a progressive die.

In the step (1) of progressive feeding, the insertion hole 22 is punched out. In step (2), the shaft hole 21 is punched out. Engineering 8! (
In 3), an opening 27 separating the connecting portion 25 is punched so as to fit into the insertion hole 2, and the magnetic pole portion 23 is formed into a fan shape. In step (4), the outer circumferential portion 28 is punched out into a circular shape, and a caulking portion 24 is formed, and the caulking portion 24 is caulked with the previously processed laminated disk 2 to form a magnetic pole of the adjacent laminated disk 2. The portion 23 is in close contact.

Now, when forming the laminated iron core l shown in Fig. 1, first punch out the laminated disk 2 having the shape shown in Fig. 2 (a),
The required number of sheets can be caulked. At this time, in the progressive die, process (3)
) will not be implemented. In other words, the punch in step (3) does not descend and proceeds through steps (1)-(2)-(4).
The steps in this order are repeated a required number of times to form the laminated disk group 2a. Next, the laminated pieces 3 having the shape shown in FIG. 2(b) are punched out, stacked on the laminated disk group 2a, and the required number of pieces are caulked. At this time, steps (1)-(2)-(3)-(4) are continued to form a group of laminated pieces 311. Laminated disk group 2b, 2
c and 2d are the same as the laminated disk group 2a, and the laminated piece group 31
t and 311s are formed in the same manner as the laminated piece group 3L.

As shown in FIG. 6, the laminated disk 2 may have an opening 27 on the outer circumferential side of the insertion hole 22 of the permanent magnet 4, leaving only the connecting portion 25 on the inner circumferential side that fits with the shaft 5. .

In this case, as shown in FIG. 7, an opening 27 is formed by punching out the insertion hole 22 with a punch so that the connecting portion 26 on the outer peripheral side is cut in step (1). Therefore, when punching out the outer peripheral portion 28 in step (4), the connecting portion 26 is separated and an opening 27 is formed.

In the laminated core formed in this way, the contact part with the shaft is shorter than the entire length of the laminated core, so the cross-sectional area of the magnetic flux path is narrow, the magnetic resistance is large, the leakage magnetic flux is small, and the magnetic flux can be used effectively.

Furthermore, the laminated disk groups may be provided only at positions a and d on both sides of the laminated core shown in FIG.

Note that the laminated iron core l is attached to the laminated disks 2 by caulking.
Alternatively, the method is not limited to fixing the laminated piece 3, and as shown in FIG. After laminating the disks 2 to an appropriate thickness and temporarily fixing them by inserting the permanent magnets 4 into the insertion holes 22, the engaging portions 6 are injected into the retaining holes 29 by aluminum die casting and hardened. In addition, since it is necessary to reduce or eliminate the cross-sectional area of the connecting portions 25 on the inner diameter side at both ends of the laminated core 1, a flange that fits with the shaft is formed at both ends of the laminated core by die-casting at the same time as the retaining portion 6. A section 7 may be formed to fix the laminated core to the shaft.

In addition, in order to prevent pulsating torque, so-called cogging torque, which occurs due to the magnetic flux distribution having a sinusoidal or rectangular waveform, as shown in FIG.
2b and a group of laminated pieces 31 in the middle, a plurality of short laminated iron cores 1 may be arranged in the axial direction with the permanent magnets 4 shifted by a certain angle in the circumferential direction, and fixed to the shaft.

[Effects of the Invention] As described above, according to the present invention, since the cross-sectional area of the magnetic path of the magnetic material portion that fits into the shaft is small,
Magnetic resistance between the laminated iron core and the shaft increases, and magnetic flux leakage from the permanent magnet to the shaft can be prevented. In addition, the insertion hole into which the permanent magnet is inserted, the magnetic pole part, and the shaft fitting hole can be automatically formed into one body in a continuous process, making it easy to position the magnetic gap between the rotor shaft and the laminated pieces. This has the effect of greatly reducing the number of steps needed to assemble the permanent magnet rotor.

[Brief explanation of drawings]

1 is a side sectional view taken along line 1-I in FIG. 2 showing an embodiment of the present invention, FIG. 2 (A) is a front sectional view taken along line E in FIG. Figure 3 is a side sectional view taken after the rotor is assembled. Figure 4 (a) is a front sectional view taken along line E in Figure 3. Figure 4 (b) is a front sectional view taken along line Roro. 5 is an explanatory diagram of the manufacturing process, FIG. 6 is a front sectional view showing another embodiment, FIG. 7 is an explanatory diagram of the manufacturing process of another embodiment, and FIGS. 8 and 9 are FIG. 10 is a side sectional view showing another embodiment; FIG. 10 is a front sectional view showing a conventional example;
The figure is a side sectional view thereof. ■...Laminated core, 2...Laminated disk, 2a, 2b
, 2e. 2d... Laminated disk group, 21... Shaft hole, 22...
Insertion hole, 23... Magnetic pole part, 24... Caulking part, 25
．． 26... Connecting part, 27... Opening part, 28... Outer peripheral part, 3... Laminated piece, 1 3472. 3j7. ...Laminated piece group, 34 Permanent magnet, 5...Shaft, 6...Engaging part, 7...Flange part Fig. A (A) (B) Fig. 3 A (A) b) 11 Figure Figure Figure Figure 0 Figure ×1

Claims (1)

[Claims] 1. A method for manufacturing a rotor core in which a laminated core consisting of magnetic pole parts arranged radially and a permanent magnet sandwiched between the magnetic pole parts is fixed to a shaft, in which A laminated disk group consisting of a plurality of laminated disks whose inner periphery, outer periphery, or inner and outer periphery of the magnetic pole portion are connected is provided at least at both ends in the axial direction of the laminated core, and a fan-shaped magnetic pole portion is provided between the laminated disk group. A laminate group consisting of a plurality of laminates is provided,
The laminated disks and the laminated pieces are fixed to each other by caulking to form the laminated disk group, the laminated piece group, and the laminated core, and the laminated core is fixed to the shaft via the laminated disk group. A method of manufacturing a permanent magnet rotor, characterized by: 2. The method of manufacturing a permanent magnet rotor according to claim 1, wherein the laminated disk groups are provided at a plurality of axial positions of the laminated core, and the laminated piece group is provided between the laminated disk groups. 3. The permanent magnet rotor according to claim 1 or 2, wherein the plurality of laminated iron cores are arranged in sequence with the positions of the permanent magnets provided between the magnetic pole parts being shifted by a certain angle in the circumferential direction. manufacturing method. 4. In a method for manufacturing a rotor core in which a laminated core consisting of radially arranged magnetic pole parts and a permanent magnet sandwiched between the magnetic pole parts is fitted to a shaft, the inner periphery of the adjacent magnetic pole parts Alternatively, a plurality of laminated disks whose outer circumferences or inner and outer circumferences are connected are provided, and the laminated disks are fixed to each other by die-casting, and flanges are formed by die-casting on both end faces of the laminated core, and the flange portions are A method for manufacturing a permanent magnet rotor, characterized in that the laminated iron core and the shaft are fixed by a screw.