JPH07145832A - Manufacture of rotor for electromagnetic clutch - Google Patents

Abstract

PURPOSE:To provide a rotor for an electromagnetic clutch where the number of part items is reduced, the positioning can be dispensed with, and the attracting force without the magnetic leakage is obtained by conducting the plastic working for an inner circumferential wall, an outer circumferential wall and a bottom part of one ring- shaped plate. CONSTITUTION:When an electromagnetic coil 6 is electrified, the electromagnetic coil 6 generates the magnetic force to attract armature 4 to a rotor 3. The magnetic path as indicated by the dashed line alpha is formed. A connecting member 22 made of the non-magnetic material is connected between an inner circumferential wall 8 and a bottom part 11. Because the connecting member 22 and a friction material 13 which are made of the non-magnetic material are connected between the bottom part 11 and an outer circumferential wall 9, no magnetic flux is leaked between the inner circumferential wall 8 and the bottom part 11, between the bottom part 11 and a rotor, and between the bottom part 11 and the outer circumferential wall 9 in the rotor 3. Thus, an armature 4 is securely attracted to a friction surface 10a of the rotor 3. As a result, the rotational power of the engine to be transmitted to a pulley 2 through a V-belt is transmitted to an input shaft of a coolant compressor through the rotor 3, the armature 4 and a rotationally-driven body.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing an electromagnetic clutch rotor which attracts an armature by magnetic force.

[0002]

2. Description of the Related Art As a conventional technology of an electromagnetic clutch, there is one disclosed in Japanese Patent Application Laid-Open No. 56-55721. Here, this is shown in FIG. Armature 10
2 is a ring-shaped disk plate 10 made of a magnetic material.
3 and a ring-shaped disk plate 104 made of a magnetic material
And a ring-shaped coupling member 105 made of a non-magnetic material such as copper, which forms a magnetic shield. The armature 102 has an inner peripheral surface 109 of the disk plate 103 and an outer peripheral surface 110 of the disk plate 104.
It is manufactured by a method of inserting the coupling member 105 into the gap between and and mechanically coupling the disk plates 103, 104 and the coupling member 105, respectively.

Further, the disk plates 103 and 10
4 from the thickness of 4 (indicated by reference numeral a in FIG. 17)
Is thin (indicated by reference numeral b in FIG. 17), and is surrounded by the friction side end surface 113 of the coupling member 105, the inner peripheral surface 109 of the disk plate 103, and the outer peripheral surface 110 of the disk plate 104. A possible depression 108 is formed. By forming the recess 108, the frictional surfaces 111 and 112 instantaneously play a role of an air damper when adsorbing to the rotor (not shown), and prevent abnormal noise from being generated during adsorption.

Further, JP-A-56-55721, page 3, upper left column, line 16 to column 18, line 18, describes that the rotor is manufactured by the above-described manufacturing method. That is, the outer peripheral wall 114 made of a magnetic material as shown in FIG.
A rotor 1 having a U-shaped cross section, which has an inner peripheral wall 115 made of a magnetic material and a bottom portion 116 made of a magnetic material connecting them.
Also in 13, the outer peripheral wall 114 and the bottom portion 11 are the same as above.
Ring-shaped coupling member 11 made of a non-magnetic material
It is described that the ring-shaped coupling member 118 made of a non-magnetic material is also inserted into the gap between the inner peripheral wall 115 and the bottom portion 116 to mechanically couple them together. Further, the connecting members 117 and 118 are connected to the armature 1.
02 to the friction surface 120 that is attracted to
It is described that 1, 122 are formed.

By the way, in JP-A-56-55721, page 1, lower right column, line 14 to page 2, upper left column, first line,
Other prior art techniques have been described. FIG. 19 shows the disc plate of this rotor. That is, the disc plate 126 of the rotor is punched from a single steel plate by pressing, and the disc plate 123, the disc plate 124, the disc plate 125, and the disc plate 1
A connecting portion 127 connecting 23 and 124, a connecting portion 128 connecting the disc plates 124 and 125, and the groove 12
9 and a groove 130 are described.

[0006]

In the case of the rotor 113 shown in FIG. 18, the connecting members 117 and 118 are joined to the gap between the outer peripheral wall 114 and the bottom portion 116 and the gap between the inner peripheral wall 115 and the bottom portion 116, respectively. At this time, since the outer peripheral wall 114, the inner peripheral wall 115, and the bottom portion 116 need to be positioned in the same manner as described above, assembly workability is poor and the number of parts is large, resulting in high manufacturing cost.

Further, in the case of the rotor 123 shown in FIG.
Although there is no inconvenience of positioning as described above, the connecting portion 12
7. Since the magnetic flux leaks from the connecting portion 128, the attraction force with the armature (not shown) becomes weak. The present invention has been made in view of the above problems, and does not require positioning,
An object of the present invention is to provide a method for manufacturing an electromagnetic clutch rotor in which magnetic flux does not leak.

[0008]

In order to achieve the above object, a method for manufacturing an electromagnetic clutch rotor according to a first aspect of the present invention is characterized in that a ring-shaped plate material made of a magnetic material is plastically worked to form an inner peripheral wall, An outer peripheral wall, and a ring-shaped member forming step of forming a ring-shaped member having a U-shaped cross section composed of a bottom portion connecting the inner peripheral wall and the outer peripheral wall, and after performing this step,
On the opening side of the ring-shaped member, a groove forming step of forming a plurality of ring-shaped grooves on the bottom portion over the entire circumference, and a non-magnetic material over the entire circumference in each of the plurality of ring-shaped grooves. A joining step of joining the joining member, a friction surface forming step of forming a friction surface by cutting the bottom surface of the bottom portion by an amount in a range in which the joining member is not exposed, and a groove facing the joining member. The concave surface forming step of exposing the coupling member to the friction surface side is adopted as a technical means.

According to a second aspect of the present invention, there is provided a method for manufacturing an electromagnetic clutch rotor in which an inner peripheral wall, an outer peripheral wall, and the inner peripheral wall and the outer peripheral wall are formed by subjecting a ring-shaped plate material made of a magnetic material to plastic working. A ring-shaped member forming step of forming a ring-shaped member having a U-shaped cross section composed of a bottom portion to be joined, and after performing this step, a plurality of ring-shaped members are formed on the bottom side over the entire circumference on the open side of the ring-shaped member. Groove forming step, a joining step of joining a coupling member made of a non-magnetic material over the entire circumference of each of the plurality of grooves, and cutting the bottom surface of the bottom until the coupling member is exposed. A friction surface forming step of forming a friction surface, and forming a concave surface by recessing the coupling member exposed on the friction surface with a radial width substantially equal to a radial width of the exposed portion. Adopt process and as a technical means It was.

[0010]

According to the configuration of the present invention described in claim 1,
First, in a ring-shaped member forming step, a ring-shaped plate material of a magnetic material is formed by plastic working such as cold casting and press working, and includes an inner peripheral wall, an outer peripheral wall, and a bottom portion connecting the outer peripheral wall and the inner peripheral wall. A ring-shaped member having a U-shaped cross section is formed. After performing this processing, in the groove forming step, a plurality of ring-shaped grooves are formed on the open side of the ring-shaped member over the entire circumference at the bottom portion. Further, in the joining step, a joining member made of a non-magnetic material is joined over the entire circumference to each of the plurality of ring-shaped grooves over the entire circumference. Also,
In the friction surface forming step, the friction surface of the rotor is formed by cutting the bottom surface of the bottom of the ring-shaped member by an amount that does not expose the coupling member. Then, in the next concave surface forming step,
A part of the friction surface facing the groove to which the joining member is joined is recessed to form a concave surface, and the joining member is exposed to the friction surface side.

According to the second aspect of the present invention, first, in the ring-shaped member forming step, the ring-shaped plate material of the magnetic material is subjected to plastic working such as cold casting and press working, so that the inner peripheral wall and the outer peripheral wall are formed. A ring-shaped member having a U-shaped cross section is formed of a wall and a bottom portion connecting the inner peripheral wall and the outer peripheral wall. After performing this processing, in the groove forming step, a plurality of ring-shaped grooves are formed on the open side of the ring-shaped member over the entire circumference at the bottom portion. Further, in the joining step, a coupling member made of a non-magnetic material is coupled to each of the plurality of ring-shaped grooves over the entire circumference. In the friction surface cutting step, the bottom surface of the bottom portion of the ring-shaped member is cut until the coupling member is exposed to form a friction surface.
Then, in the next concave surface forming step, the coupling member exposed on the friction surface is recessed with a radial width substantially equal to the radial width of the exposed portion to form a concave surface.

[0012]

According to the method of manufacturing the rotor for the electromagnetic clutch of the present invention, since the inner peripheral wall, the outer peripheral wall and the bottom are formed by processing one ring-shaped plate material, it is not necessary to perform positioning.
Therefore, the assembling property is excellent, and the manufacturing cost can be suppressed. Further, there was no magnetic flux leakage, and the attraction force between the rotor and the armature could be increased.

[0013]

Next, a method of manufacturing a rotor for an electromagnetic clutch of the present invention will be described based on a first embodiment shown in the drawings. [Structure of Embodiment] FIGS. 1 to 9 show a first embodiment of the present invention.

The electromagnetic clutch 1 shown in FIG. 1 connects and disconnects rotational power from an engine (not shown) to a refrigerant compressor (not shown). This electromagnetic clutch 1
Are roughly classified into: a rotor 3 provided with a pulley 2 which is rotationally driven by an engine; a rotary driven body 5 provided with an armature 4 frictionally engaging with the rotor 3; The electromagnetic coil 6 is frictionally engaged with the rotor 3. The electromagnetic coil 6 is fixed to a stator 6b made of a magnetic material (for example, low carbon steel such as SPCC and SPHC) via a resin winding frame 6a, and the stator 6b further includes a disc-shaped stay 6c. And is fixed to the housing H of the compressor.

The pulley 2 is joined to the periphery of the rotor 3 by welding, and a multi-stage V-belt (not shown) is wound around the pulley 2. The rotor 3 is rotatably supported via a bearing 7 on the inner circumference, and the inner circumference of the bearing 7 is
It is supported by the housing H of the refrigerant compressor. This rotor 3
Is formed by processing a magnetic material such as soft iron, and is frictionally engaged with the inner peripheral wall 8 located on the inner peripheral side of the electromagnetic coil 6, the outer peripheral wall 9 located on the outer peripheral side of the electromagnetic coil 6, and the armature 4. A ring-shaped member having a U-shaped cross section is formed from the friction wall 10. Here, the friction wall 10 has a bottom portion 11 made of a magnetic material such as soft iron, and a coupling member 22 provided on the inner peripheral side and the outer peripheral side of the bottom portion 11. Bottom 11
Is formed so that the open side of the ring-shaped member, that is, the side on which the electromagnetic coil 6 is disposed has an arcuate cross section. Also,
The coupling member 22 is made of a non-magnetic material such as copper that joins the inner peripheral wall 8 and the bottom 11 and the bottom 11 and the outer peripheral wall 9, and a magnetic path is formed between the inner peripheral wall 8 and the bottom 11 and between the bottom 11 and the outer peripheral wall 9. It is to prevent being done. Further, the friction surface 1 of the friction wall 10
A friction material 13 made of a non-magnetic material that enhances the engaging force with the armature 4 is fitted on the outer peripheral side of 0a.

Further, the coupling member 22 is recessed with respect to the friction surface 10a and forms a recessed surface 24. In the friction surface 10a, the width of the concave surface 24 in the vertical direction in the figure is sufficiently smaller than the width of the friction material 13 in the vertical direction in the figure. Since the bottom portion 11 on the side where the electromagnetic coil 6 is arranged is formed in an arc shape in cross section, as shown in FIG.
The area (a1) of the portion exposed to the friction surface 10a of the coupling member 22 on the inner peripheral side is set smaller than the area (b1) on the opening side of the ring-shaped member, and the coupling member 22 on the outer peripheral side is set. Of the area exposed on the friction surface 10a (a
2) is set smaller than the area (b2) on the open side of the ring-shaped member. That is, a1 <b1, a
The relationship is 2 <b2. Here, FIG. 8A is a diagram showing only the rotor 3 in FIG.

In FIG. 1, the armature 4 is arranged to face the friction surface 10 a of the rotor 3 with a gap and has a friction surface 4 a that engages with the rotor 3. The armature 4 has a ring shape made of a magnetic material such as iron, and has a ring-shaped magnetic blocking groove 1 with a slit in the middle portion.
4 are formed. The magnetic blocking groove 14 is located substantially at the center of the bottom portion 11 of the rotor 3 which faces the magnetic blocking groove 14. The cross-sectional area (Sn) of the bottom portion 11 of the rotor 3 starting from the magnetic blocking groove 14 of the armature 4 is shown in FIG.
As shown in (b), the magnetic blocking groove 14 of the armature 4 is provided.
The inner surface area (c1) of the bottom portion 11 of the friction surface 10a starting from and the bottom portion 1 starting from the magnetic interruption groove 14
1 is larger than the area (c2) on the outer peripheral side.
That is, the relationship of Sn> c1 and c2 is set. Thereby, the magnetic resistance in the bottom portion 11 can be reduced.
Here, FIG. 8B is a partially enlarged view of FIG.

The rotary driven body 5 in FIG. 1 rotates integrally with the rotation of the armature 4 to drive the input shaft of the refrigerant compressor. The outer ring 16 fixed to the armature 4 with rivets 15 and the armature. The outer ring 16 and the inner hub 18 are integrally coupled via the cushion rubber 17 and the cushion rubber 17 that allows the displacement of the shaft 4 in the rotational axis direction and the inner hub 18 fitted to the input shaft.

Next, a method of manufacturing the rotor 3 in the first embodiment will be described with reference to FIGS. 1 and 6 (a) to 6 (j). The manufacturing method of this embodiment is based on the manufacturing method described in claim 1. A magnetic metal plate (for example, low carbon steel such as SPCC or SPHC) having a plate thickness substantially the same as the friction wall 10 of the rotor 3 is punched by press punching to form a circular disc material. Then, a punching hole portion 19c is formed in the center portion of the disc material by press punching,
A ring-shaped plate material 19a as shown in (a) is formed.

Next, the intermediate portion 191a of the ring-shaped plate material 19a is recessed over the entire circumference by cold forging which is plastic working, and the inner peripheral wall 8, the outer peripheral wall 9 and the inner peripheral wall 9 as shown in FIG. A ring-shaped member 19b having a U-shaped cross section, which is composed of a bottom portion 11 connecting the peripheral wall 8 and the outer peripheral wall 9, is formed (ring-shaped member forming step). Next, the middle portion of the bottom surface 11a of the bottom portion 11 is pressed down over the entire circumference, and the ring-shaped mold 30 provided with the two ring-shaped protrusions 21c and 21d shown in FIG. 2 (c).
Is inserted into a space 12 formed by the inner peripheral wall 8, the outer peripheral wall 9 and the bottom portion 11, and this is pressed from the open side of the ring-shaped member 19b (the side on which the electromagnetic coil (not shown) is arranged). As a result, as shown in FIG.
Two ring-shaped protrusions 20a and 20b are formed on the inner peripheral side and the outer peripheral side of a over the entire circumference, and grooves 21a and 21b are formed on the open side of the bottom portion 11 over the entire circumference ( Groove forming step).

As described above, the inner peripheral wall 8, the outer peripheral wall 9, and the ring-shaped protruding portion 2 connecting the inner peripheral wall 8 and the outer peripheral wall 9 together.
The ring-shaped member 19 is formed of the bottom portion 11 having the grooves 0a and 20b and the grooves 21a and 21b. The cross-sectional shapes of the two grooves 21a and 21b are the ring-shaped member 19 because the ring-shaped protrusions 21c and 21d provided on the ring-shaped mold 30 spread to the open side of the ring-shaped member 19. It has a shape that widens toward the open side. As a result, the bottom portion 1 on the open side of the ring-shaped member 19
The shape of 1 is an arc shape in cross section. In addition, the ring-shaped mold 30
Of the ring-shaped protrusion provided on the outer peripheral side 21
The inner peripheral side 21d projects higher than c, so that the inner peripheral side groove 21b is deeper than the outer peripheral side groove 21a.

Next, metal balls, glass beads, or the like are sprayed on the entire surface of the ring-shaped member 19 to form the ring-shaped member 19.
Remove the impurities attached to (shot blast). Next, as shown in FIG. 4A, the grooves 21a and 21b shown in FIG.
A coupling member 2 in which a wire made of a non-magnetic material (for example, copper) having a lower melting point than the ring-shaped member 19 is formed in a ring shape in the upper part.
2 and 22 are placed, and the coupling members 22 and 22 are heated together with the ring-shaped member 19. Then, the entire ring-shaped member 19 is heated to melt the coupling members 22 and 22, and the coupling members 22 and 22 are poured into the grooves 21a and 21b over the entire circumference (FIG. 4B). After that, the coupling member 22 that has been melted by cooling (radiating) the ring-shaped member 19
Is cooled and solidified, and the ring-shaped member 19 (for example, iron) and the bonding member 22 (for example, copper) are diffused and bonded intermolecularly, so that the ring-shaped member 19 and the bonding member 22 are firmly bonded (bonding step ).

Here, as an example of the connecting member 22,
When bronze containing about 5% tin in copper is used, it is necessary to heat the ring-shaped member 19 provided with the bonding member 22 at about 1080 ° C. Further, at the time of heating and cooling for joining the ring-shaped member 19 and the joining member 22, in order to prevent the ring-like member 19 and the joining member 22 from being oxidized, a vacuum or an inert gas (for example, nitrogen gas) atmosphere is provided. Do in

Next, as shown by the chain double-dashed line in FIG. 5, the inner peripheral side of the inner peripheral wall 8 of the ring-shaped member 19, the upper end portion of the outer peripheral wall 9 in the figure, and the open side end surface 31 of the bottom portion 11 are all covered. The bottom surface 11a of the bottom portion 11 is cut over the entire circumference while cutting along the circumference and the coupling member 22 is not exposed to form the friction surface 10a. (Friction surface forming step) Next, as shown in FIG. 6 (a), the friction surface 10a facing the groove 21a is cut by cutting the entire circumference,
A recess 23 for fitting the friction material 13 is formed to expose the coupling member 22 to the friction surface 10a side. The friction surface 10a that faces the groove 21b is cut by cutting the entire circumference to form a concave surface 24, and the coupling member 22 is provided to the friction surface 10a.
It is exposed to the side (concave surface forming step). Here, FIG. 6 (a)
9 is an enlarged view of part A of FIG.

Next, as shown in FIG. 6 (b), the pulley 2 on which a multi-stage V-belt (not shown) is hung is attached to the ring-shaped member 19
It is press-fitted from the outer periphery and welded and fixed. Then, paint is sprayed on the entire surface of the ring-shaped member 19 to which the V-belt is fixed. After that, as shown in FIG. 6C, the friction surface 10
The friction material 13 is fitted into the recess 23 provided in a.

Further, the friction surface 10a is cut from the state shown in FIG. 6C (shown by the chain double-dashed line in FIG. 7), and the friction surface 10a is cut.
The rotor 3 is completed by finishing a. [Operation of Embodiment] Next, the operation of the electromagnetic clutch 1 will be briefly described. When the electromagnetic coil 6 is energized, the electromagnetic coil 6 generates a magnetic force to attract the armature 4 to the rotor 3. Then, the magnetic path shown by the alternate long and short dash line α in FIG. 1 is formed. Here, a coupling member 22 made of a non-magnetic material is joined between the inner peripheral wall 8 and the bottom portion 11, and the bottom portion 11 and the outer peripheral wall 9 are joined together.
Since the coupling member 22 made of a non-magnetic material and the friction material 13 are joined between the inner space and the inner wall 8 between the inner peripheral wall 8 and the bottom 11, and between the bottom 11 and the bottom 11, in the rotor 3. The magnetic flux does not leak to the outer peripheral wall 9. Therefore,
The armature 4 is firmly attracted to the friction surface 10a of the rotor 3. As a result, the rotational power of the engine transmitted to the pulley 2 via the V-belt is reliably transmitted to the input shaft of the refrigerant compressor via the rotor 3, the armature 4, and the rotary driven body 5.

[Effects of Embodiment] In the rotor 3 of the electromagnetic clutch 1 described in this embodiment, the inner peripheral wall 8, the outer peripheral wall 9 and the bottom portion 11 are formed by plastically processing one ring-shaped plate material 19a. . Therefore, the number of parts is small, the assembling property of the rotor 3 is excellent, and the manufacturing cost can be suppressed.

The connecting member 22 made of a non-magnetic material is
Since the ring-shaped plate material 19a is joined to the grooves 21a and 21b formed by plastic working over the entire circumference, the melted coupling member 22 does not leak to the outside of the bottom portion 11. Therefore, it is possible to prevent a defective product from being generated due to the melted coupling member 22 leaking to the outside of the bottom portion 11. In addition, in the mechanical coupling performed by the conventional technique shown in FIGS. 17 and 18, even if the disc plate 104 and the coupling member 105 are mechanically coupled, for example, the respective surfaces of the disc plate 104 and the coupling member 105 before the coupling. Has a surface roughness, and even if the disc plate 104 and the coupling member 105 are mechanically coupled, there is a gap in the coupling surface although it is fine.
Accordingly, the disc plate 104 and the coupling member 105 are
And are not completely in close contact with each other and the bond strength is weak. As a result, in this embodiment, since the joining member 22 and the ring-shaped member 19 are diffusion-joined, the joining strength is stronger than the mechanical joining.

The bottom portion 11 is provided with a circular arc-shaped cross section on the open side of the ring-shaped member 19. For this reason, as compared with the case where the thickness of the bottom portion 11 is the same as that of this embodiment and the shape of the bottom portion 11 on the open side has a quadrangular cross section,
The distance between the bottom portion 11 and the stator 6b becomes longer (see arrow β in FIG. 1), and it is possible to suppress a decrease in the transmission torque due to direct leakage of magnetism from the stator 6b to the bottom portion 11.

Further, since the shape of the bottom portion 11 on the open side of the ring-shaped member 19 is provided with an arcuate cross section, the groove 21 is formed.
The average distance between the inner peripheral wall 8 and the bottom portion 11 extending in the depth direction of b and the average distance between the bottom portion 11 and the outer peripheral wall 9 extending in the depth direction of the groove 21a become longer (see arrow γ in FIG. 1), and the inner peripheral wall 8 It is possible to suppress a decrease in transmission torque due to magnetic leakage between the bottom portion 11 and the bottom portion 11 and between the bottom portion 11 and the outer peripheral wall 9.

Since the open side of the ring-shaped member 19 of the bottom portion 11 is provided with an arcuate cross section, the ring-shaped protrusions 21c, 2 of the ring-shaped mold 30 for forming the grooves 21a, 21b.
The wall thickness of 1d can be increased. Therefore, the ring-shaped mold 30
It is possible to reduce the generated stress, to extend the mold life, and consequently to reduce the cost for manufacturing the rotor 3. Further, in the present embodiment, the bottom surface 11a of the bottom portion 11 is cut to form the friction surface 10a by an amount that does not expose the coupling member 22, and the friction surface 10a that faces the groove 21b is further cut to form the coupling object 22. Since the ring-shaped mold 30 is exposed, it is possible to reduce the height of the ring-shaped protrusions 21c and 21d provided on the ring-shaped mold 30.
It is possible to reduce the generated stress, extend the life of the mold, and consequently reduce the cost for manufacturing the rotor 3.

In the friction surface 10a, the width of the concave surface 24 in the vertical direction in FIG. 8 is sufficiently smaller than the width of the recess 23 in the vertical direction in FIG. As a result, the armature 4 shown in FIG.
It is possible to suppress the reduction of the area of the adsorption surface between and and to obtain a strong adsorption force. Further, when the rotor 1 and the armature 4 are intermittently frictionally engaged with each other, frictional heat is generated due to the slip between the rotor 1 and the armature 4, but since the concave surface 24 is formed, the coupling member 22 is connected to the armature 4 by the connecting member 22. No frictional engagement with. As a result, the coupling member 22 is not brought into a molten state or a softened state due to frictional heat.

[Second Embodiment] Next, a second embodiment for manufacturing the rotor 3 by a manufacturing method different from that of the first embodiment will be described. Here, the manufacturing method of the second embodiment is defined in claim 2.
The manufacturing method is based on the manufacturing method described, and is the same as the first embodiment except for the friction surface forming step and the concave surface forming step in the first embodiment. Therefore, the friction surface forming step and the concave surface forming step in the second embodiment will be described below.

As shown by the alternate long and two short dashes line in FIG. 10, the inner peripheral side of the inner peripheral wall 8 of the ring-shaped member 19, the upper end portion of the outer peripheral wall 9 in the figure, and the open end surface 31 of the bottom portion 11 are respectively formed over the entire circumference. The bottom surface 11a of the bottom portion 11 is cut along the entire circumference while cutting is performed until the coupling member 22 made of a non-magnetic material is exposed to form the friction surface 10a. Here, the groove 21b
Since it is deeper than the groove 21a, only the coupling member 22 joined to the groove 21b is exposed on the friction surface 10a (friction surface forming step).

Next, as shown in FIG. 11, the friction surface 10a facing the groove 21a is cut over the entire circumference to make it concave so that the coupling member 22 is exposed and the friction member 13 is fitted into the depression 23. To form. Further, the coupling member 22 joined to the groove 21a is cut by cutting the entire circumference to form a concave surface 24 (concave surface forming step). Here, the width of the concave surface 24 in the friction surface 10a is equal to the radial width of the coupling member 22 in the portion exposed to the friction surface 10a before performing the concave surface forming step. Here, B in FIG.
An enlarged view of is shown in FIG.

As described above, in the second embodiment, in the friction surface 10a, the concave surface 24 and the coupling member 2 exposed.
Although the widths of the two in the radial direction are the same, the reduction of the joint area between the coupling member 22 and the ring-shaped member 19 is suppressed to the minimum. As a result, the magnet clutch is energized and strong durability against the stress generated by the rotation of the rotor 3 is obtained.

[Third Embodiment] FIG. 13 is an explanatory view of a main part of a ring-shaped member forming step and a groove forming step in the manufacturing process of the rotor 3 showing the third embodiment. In the first embodiment,
Although the ring-shaped member 19 is processed by cold forging and the groove 21a and the groove 21b are formed by pressing, the ring-shaped member 19 can be manufactured by the steps described below.

First, a magnetic metal plate (for example, bottom carbon steel such as SPCC, SPHC, etc.) having substantially the same thickness as the friction wall 10 of the rotor 3 is punched by press punching, as shown in FIG. 10 (a). A circular disc material 19d is formed. (Punching) Next, as shown in FIG. 13 (b), a hole 19e is formed by press punching in the central portion of the disk material 19d to form a ring-shaped plate material 19f. (Punching). Next, by cold forging, which is plastic working, the intermediate portion 19 between the inner periphery and the outer periphery of the ring-shaped plate material 19f.
The 1f is recessed to form the ring-shaped member 19f (ring-shaped member forming step).

Next, as shown in FIG. 13C, a ring-shaped protruding portion 20 protruding upward in the drawing is formed by cold forging over the entire circumference of the intermediate portion 191f (groove forming step). ). Next, the inner peripheral side portion and the outer peripheral side portion of the ring-shaped member 19f are respectively bent into a cylindrical shape by cold forging to form the inner peripheral wall 8 and the outer peripheral wall 9 as shown in FIG. 13 (d).

As described above, the ring-shaped member 19 having a U-shaped cross section, which is composed of the inner peripheral wall 8, the outer peripheral wall 9, and the bottom portion 11 connecting the inner peripheral wall 8 and the outer peripheral wall 8, is formed. In addition, the bottom portion 1 on the open side of the ring-shaped member 19, that is, on the upper side in the drawing.
1 has two grooves 21a and 21b on the inner and outer circumferences of the protrusion 20.
The cross-sectional shape of the two grooves 21a and 21b is a shape that widens toward the open side of the ring-shaped member 19 because the end of the protrusion 20 is provided with a circular arc in cross section. is doing. Further, the depth of the inner peripheral groove 21b is set deeper than that of the outer peripheral groove 21a.

Further, in this embodiment, since the grooves 21a and 21b are formed by cold casting, which is plastic working, the rotor 3 can be made smaller than that obtained by punching these grooves 21a and 21b. You can That is,
The grooves 129 and 130 shown in FIG. 19 are formed by pressing a die (not shown) having arcuate protrusions at positions facing the grooves 129 and 130 onto the rotor 126 and punching it. Further, in order to reduce the size of the rotor 126, it is necessary to reduce the radial width of the grooves 129 and 130.

However, when the radial widths of the grooves 129 and 130 are narrowed, the radial width of the protrusion provided on the mold is reduced. As a result, the protrusion of the mold cannot withstand the impact and stress during punching, and the mold may be damaged. However, in this embodiment, the grooves 21a and 21b are formed by cold casting which is plastic working. Accordingly, when the grooves 129 and 130 are formed by press punching, the distance between the grooves 129 and 130 is set to the bottom portion 11.
Although the minimum limit was 0.6 times the plate thickness, this embodiment can reduce the thickness to about 0.3 times, and the rotor 3 can be downsized.

[Fourth Embodiment] In this embodiment, an example of the friction surface forming step and the concave surface forming step will be described. Groove 2 in the first embodiment
Although the groove 21b is deeper than the groove 1a,
b may have the same depth. In this case, the bottom surface 11a of the bottom portion 11 is removed by an amount that does not expose the coupling member 22 made of a non-magnetic material to form the friction surface 10a (friction surface forming step).

Next, the friction surface 10a of the portion facing the groove 21a on the outer peripheral side is cut to make it concave, and the friction material 13
Is formed to expose the coupling member 22 to the friction surface 10a side. Then, the friction surface 10a of the portion facing the groove 21b on the inner peripheral side is cut to make it concave, thereby forming the concave surface 24 and exposing the coupling member (concave surface cutting step).

Alternatively, the bottom surface 11a is cut until the coupling member 22 made of a non-magnetic material is exposed to form the friction surface 10a, and the coupling member 22 joined to the grooves 21a and 21b is exposed together on the friction surface 10a ( Friction surface forming process). next,
The coupling member 22 joined to the groove 21a is cut by cutting the coupling member 22 from the friction surface 10a side to expose the coupling member 22 and form a recess 23 into which the friction material 13 is fitted. In addition, the coupling member 22 joined to the groove 21a is attached to the friction surface 10a.
The concave surface 24 is formed by cutting from the side. Here, the width of the concave surface 24 in the friction surface 10a is equal to the radial width of the coupling member 22 in the portion exposed to the friction surface 10a before forming the concave surface 24 (concave surface forming step).

[Fifth Embodiment] FIG. 14 is an explanatory view of a main part of a joining step in a manufacturing process of a rotor showing a fifth embodiment. This example shows an example of a joining process by induction heating. In the two grooves 21a and 21b provided in the bottom portion 11 of the ring-shaped member 19, a powder-like coupling member 22 of a non-magnetic material (for example, copper) having a lower melting point than that of the ring-shaped member 19 is placed, Ring member 1 (for example, low carbon steel)
The bottom 11 of 9 is heated by the induction heating device 24.
The induction heating device 24 includes a bottom portion 11 of the ring-shaped member 19.
Is a device which is provided in a ring shape having a U-shaped cross section and which heats the ring-shaped member 19 by generating an induced current in the ring-shaped member 19. Then, the coupling member 22 is melted by heat generation of the ring-shaped member 19 by the induction heating device 40, and then the ring-shaped member 19 is cooled to solidify the melted coupling member 22. At the time of this solidification, the binding member 22 diffuses in the ring-shaped member 19, and the ring-shaped member 19 and the binding member 2 intermolecularly.
2 is solidified and firmly joined.

When the bottom 11 of the ring-shaped member 19 is heated and cooled, the ring-shaped member 19 is held by the chuck 25 and driven to rotate. The rotation of the ring-shaped member 19 suppresses the variation in the melting state and the solidification state of the powdery bonded object 22 and prevents the occurrence of defective melting or the like. In this embodiment, the ring-shaped member 19
The entire bottom 11 of the induction heating device 24 was heated by the induction heating device 24. However, a local heating device such as the induction heating device 24 is arranged so as to heat a part of the bottom portion 11, and the ring-shaped member 19 is rotated by the chuck 25 to rotate the bottom part 11 You may provide so that the whole may be heated.

Further, by mixing a flux for preventing metal oxidation into the powdery bonded body 22 or by applying a flux in the grooves 21a and 21b, it is possible to prevent oxidation of the joint portion. As a result, it is not necessary to perform the bonding step in a vacuum or in an inert gas atmosphere in order to keep the strength of the bonded portion high, and the manufacturing cost can be kept low.
Further, since oxidation of the ring-shaped member 19 cannot be prevented, an inert gas may be blown onto the ring-shaped member 19 as necessary.

In this embodiment, the powder material is used for the joining member 22, but a ring-shaped wire material or a granular material may be used. [Sixth Embodiment] FIG. 15 is an explanatory view of a main part of a joining process in a rotor manufacturing process showing a sixth embodiment.

In this embodiment, the coupling member 2 made of a non-magnetic material is used.
2 grooves 2 on the bottom 11 of the ring-shaped member 19 by melting 2
An example of a joining process of pouring and joining into 1a and 21b is shown. In this embodiment, an example is shown in which TIG welding (inert gas tungsten arc welding) is used as a technique for melting the coupling member 22 made of a non-magnetic material and pouring it into the two grooves 21a and 21b (the outer groove 21b in the figure). The processing example of is shown).

In this TIG welding, from the nozzle 26 to the grooves 21a and 21b which are the welded portions, an inert gas (argon gas,
(A helium gas or the like) is blown, and a high voltage is applied to the tungsten electrode 27 and the ring-shaped member 19 to generate an arc between the tungsten electrode 27 and the ring-shaped member 19, and a non-magnetic material provided linearly is used. Combining member 22
Is melted by the heat of the arc. Then, the melted joining member 22 is filled in the groove 21a or the groove 21b, and the joining member 22 is joined in the groove 21a and the groove 21b.

[Seventh Embodiment] FIG. 16 is an explanatory view of a main portion of a joining step in a manufacturing process of a rotor showing a seventh embodiment. In this embodiment, MIG welding (inert gas metal arc welding) is used to form a joining member 2 made of a non-magnetic material.
2 is melted, and the melted joining member 22 is provided with two grooves 21a, 2
An example of a joining process of pouring into 1b and joining is shown (Fig. 1
3 shows a processing example of the outer groove 21b).

In this MIG welding, an inert gas is blown from the nozzle 26 to the grooves 21a and 21b which are the welded portions. At this time, a high voltage is applied to the coupling member 22 and the ring-shaped member 19 which are electrodes, an arc is generated between the coupling member 22 and the ring-shaped member 19, and the coupling member 22 is melted by the heat of the arc. Then, the melted joining member 22 is replaced with the groove 21a or the groove 2
1b is filled and the coupling member 22 is joined in the groove 21a and the groove 21b.

The coupling member 22 which is an electrode is
It is carried out while being continuously supplied during IG welding. [Modification] In each of the above embodiments, cold forging is shown as an example of plastic working during the ring-shaped member forming step, but other working means such as press working may be used.

In each of the above embodiments, copper is shown as an example of the coupling member 22 made of a non-magnetic material, but other non-magnetic metal such as aluminum or non-magnetic resin may be used depending on the application. . Further, the ring-shaped member 19 is heated to heat the bottom portion 1.
Although an example in which the joining member 22 made of a non-magnetic material in 1 is melted or the molten joining member 22 is poured into the bottom portion 11 is shown, a non-magnetic metal such as stainless steel is joined to the bottom portion 11 by a friction welding method. Is also good.

Further, although the shape of the bottom portion 11 on the open side of the ring-shaped member 19 is provided in the shape of an arc in cross section, it may be tapered so as to narrow toward the open side or may be formed in a rectangular shape in cross section. Also, the distance between the bottom portion 11 and the stator 6b is longer than that in the case where the bottom portion 11 has a rectangular cross section. Further, in the first embodiment, the concave surface forming step is performed after the friction surface forming step, but the order may be reversed as described below.

First, the bottom surface 11a of the bottom portion 11 facing the groove 21a is cut by cutting the entire circumference to form a recess 23 into which the friction material 13 is fitted.
2 is exposed on the bottom surface 11a side. Then, the bottom surface 11a of the bottom portion 11 that faces the groove 21b is cut by cutting the entire circumference to form a concave surface 24, and the coupling member 22 is exposed to the bottom surface 11a side of the bottom portion 11.

Next, the inner peripheral side of the inner peripheral wall 8 of the ring-shaped member 19 and the outer peripheral wall 9 corresponding to the two-dot chain line in FIG. The bottom surface 11a is cut along the entire circumference while cutting along the entire circumference to form the friction surface 10a. Here, friction surface 1
The concave surface 24 is concave with respect to 0a.

Further, in the second embodiment, the concave surface forming step is performed after the friction surface forming step, but the order may be reversed as described below. First, the bottom portion 11 facing the groove 21a
The bottom surface 11a is cut along the entire circumference to expose the coupling member 22 and form a recess 23 into which the friction material 13 is fitted. In addition, the bottom surface 11a of the bottom portion 11 facing the groove 21a is cut by cutting the entire circumference to form a concave surface 24.

Next, the inner peripheral side of the inner peripheral wall 8 of the ring-shaped member 19, the upper end portion of the outer peripheral wall 9, and the open end surface 3 of the bottom portion 11.
1 is cut over the entire circumference, and the bottom 11
The bottom surface 11a is cut all around to form the friction surface 10a. Here, the concave surface 24 is recessed with respect to the friction surface 10a. Further, in the second and second embodiments, the concave surface 24 is formed by the cutting process, but the concave surface 24 is formed by pressing the bottom surface 11a from the friction surface 10a side with the ring-shaped mold provided with the ring-shaped protrusion. You may form.

In each of the above embodiments, two grooves are formed as the plurality of grooves, but three or more grooves may be formed. Further, in each of the above-mentioned embodiments, the electromagnetic clutch of the refrigerant compressor has been shown as an example, but it is applicable to all electromagnetic clutches such as a supercharger and an automatic speed device that transmit and cut off power.

[Brief description of drawings]

FIG. 1 is a sectional view of a rotor (first embodiment).

FIG. 2 is an explanatory diagram of a rotor manufacturing process (first embodiment).

FIG. 3 is an explanatory diagram of a rotor manufacturing process (first embodiment).

FIG. 4 is an explanatory diagram of a rotor manufacturing process (first embodiment).

FIG. 5 is an explanatory diagram of a rotor manufacturing process (first embodiment).

FIG. 6 is an explanatory diagram of a rotor manufacturing process. (First embodiment).

FIG. 7 is an explanatory diagram of a rotor manufacturing process. (First embodiment).

FIG. 8 is a sectional view of a rotor (first embodiment).

FIG. 9 is an enlarged view of a portion A of FIG.
Example).

FIG. 10 is an explanatory view of a main part of a rotor manufacturing process (second step)
Example).

FIG. 11 is an explanatory view of a main part of a rotor manufacturing process (second step)
Example).

FIG. 12 is an enlarged view of part B of FIG. 11 (second embodiment).

FIG. 13 is an explanatory view of a main part of a rotor manufacturing process (third embodiment)
Example).

FIG. 14 is an explanatory view of a main part of a rotor manufacturing process (fourth step)
Example).

FIG. 15 is an explanatory view of a main part of a rotor manufacturing process (fifth example)
Example).

FIG. 16 is an explanatory view of a main part of a rotor manufacturing process (sixth embodiment)
Example).

FIG. 17 is a cross-sectional view of an armature (prior art).

FIG. 18 is a sectional view of an electromagnetic clutch (prior art).

FIG. 19 is a diagram showing a rotor (prior art).

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Electromagnetic clutch 3 Rotor 8 Inner peripheral wall 9 Outer peripheral wall 10a Friction surface 11 Bottom part 19 Ring-shaped member 22 Coupling member 21a Groove 21b Groove 24 Concave surface

 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Masashi Toba, 1-1, Showa-cho, Kariya city, Aichi Nihon Denso Co., Ltd.

Claims (2)

[Claims] 1. A ring-shaped member having a U-shaped cross-section, which is formed by plastically processing a ring-shaped plate material made of a magnetic material, and has an inner peripheral wall, an outer peripheral wall, and a bottom connecting the inner peripheral wall and the outer peripheral wall. A member forming step, and after performing this step, on the open side of the ring-shaped member,
A groove forming step of forming a plurality of ring-shaped grooves on the bottom portion over the entire circumference, and a joining step of joining a coupling member made of a nonmagnetic material over the entire circumference to each of the plurality of ring-shaped grooves And a friction surface forming step of forming a friction surface by cutting the bottom surface of the bottom portion by an amount in which the coupling member is not exposed, and a part of the friction surface facing the groove to which the coupling member is joined. And a concave surface forming step of exposing the coupling member to the frictional surface side. 2. A ring-shaped member having a U-shaped cross section, which comprises an inner peripheral wall, an outer peripheral wall, and a bottom portion connecting the inner peripheral wall and the outer peripheral wall, by plastically processing a ring-shaped plate material made of a magnetic material. A member forming step, and after performing this step, on the open side of the ring-shaped member,
A groove forming step of forming a plurality of ring-shaped grooves on the bottom portion over the entire circumference, and a joining step of joining a coupling member made of a nonmagnetic material over the entire circumference to each of the plurality of ring-shaped grooves And a friction surface forming step of forming a friction surface by cutting the bottom surface of the bottom portion until the coupling member is exposed, and the coupling member exposed on the friction surface is substantially equal to the radial width of the exposed portion. A method for manufacturing an electromagnetic clutch rotor, comprising a concave surface forming step of forming a concave surface by recessing with an equal radial width.