JPS6135777B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a flywheel magnet rotor with a pulley used as a rotor of a magnet generator, and a method for manufacturing the same.

The conventional flywheel magnet rotor with pulley is
The structure was such that a pulley formed separately from the flywheel was fixed to the bottom wall of the flywheel by an appropriate means such as riveting, but such a structure required the pulley to be manufactured separately, making it cumbersome to manufacture. There is also a need for a means to fix the pulley to the flywheel, which increases the number of parts.
The drawback was that it was difficult to manufacture. Further, in the conventional rotor of this type, the mechanical strength was insufficient because there was a risk that the rivet connecting the pulley and the flywheel would be damaged due to sudden acceleration or deceleration of the rotor. Another problem is that a pulley attached to the bottom wall of the flywheel increases the axial dimension of the magnet rotor, so a large space is required to house a generator equipped with this type of magnet rotor. It was hot.

In order to solve this problem, it has been proposed to form the pulley portion integrally with the flywheel. FIG. 5 shows an example of a magnet generator using a conventional pulley-equipped flywheel magnet rotor in which the pulley portion is integrally formed with the flywheel. In the figure, 1 is a stator mounting base plate;
This base plate 1 has a cylindrical portion 1a projecting from the cylindrical portion 1a.
An annular star-shaped stator core 2 is fitted onto the outer periphery of a, and salient pole portions 2 are provided radially on the stator core 2.
An armature coil 3 is wound around a. A bearing 4 is fitted into the inner periphery of a cylindrical portion 1a provided on the base plate 1, and a drive shaft 5 is supported by this bearing 4. The drive shaft 5 consists of a large diameter part 5a and a small diameter part 5b, the small diameter part 5b is fitted into the inner ring of the bearing 4, and the small diameter part 5b and the large diameter part 5a
The bearing 4 is positioned in the axial direction by engagement between the stepped portion and the end of the inner ring of the bearing 4. A screw is provided at the end of the small diameter portion 5b of the drive shaft that protrudes outward from the bearing 4, and a nut 6 screwed onto this screw is tightened against the inner ring of the bearing 4 to prevent the drive shaft from coming off. It is planned. Drive shaft 5
A flange 5C is provided at the end of the large diameter portion 5a opposite to the small diameter portion 5b, and the flywheel 8 is attached to this flange 5c.

The magnet rotor 7 includes a drive shaft 5 and a first cylindrical portion 8 surrounding the stator core 2 via a predetermined space.
a, and a bottomed second cylindrical portion 8b continuously formed at the axial end of the first cylindrical portion 8a on the side opposite to the base plate 1. It consists of a wheel 8 and a magnet field 9 fixed to the inner circumference of the first cylindrical portion 8a of the flywheel 8, and the inner surface of the bottom wall portion 8b1 of the second cylindrical portion 8b is connected to the drive shaft 5. The bottom wall portion 8 is in contact with the flange 5c of
b1 is fixed to the flange 5c by rivets 10. The magnet field 9 has, for example, a plurality of arc-shaped magnets 9a arranged on the inner peripheral surface of the first cylindrical portion 8a at intervals or in a ring shape.
It is positioned in the axial direction by a protruding part 8a1 etc. protruding from the inner periphery of the cylindrical part 8a, and the first
is fixed to the cylindrical portion 8a. The magnets constituting the magnetic field 9 are normally magnetized in the radial direction so that a predetermined number of different magnetic poles are arranged at equal intervals in the circumferential direction of the flywheel, and the magnetic poles on the inner circumferential side of the magnetic field 9 are magnetized in the stator. It is arranged to face the magnetic pole part of the iron core 2 with a slight gap in between. The second cylindrical portion 8b of the flywheel 8 is deformed to form an annular groove (hereinafter referred to as a V-shaped groove) 11a having a substantially V-shaped longitudinal section, and this deformed portion allows the pulley portion 11 to It is configured. This pulley part 11
A belt for connecting the magnet rotor 7 to a drive source (not shown), such as an engine, is hung on the belt.

In this way, the bottom wall portion 8 of the peripheral wall of the flywheel 8
If the pulley portion 11 is provided by deforming the portion closer to b1, there is a problem in that the dimension in the axial direction of the magnet rotor increases, similar to the conventional flywheel magnet rotor described above, and the pulley portion 11 is attached. Since the length of the drive shaft 5 becomes longer by that amount, the eccentric torque applied to the bearing 4 that supports the drive shaft 5 becomes larger, and an expensive bearing with strong mechanical strength must be used as a bearing. There was a problem that the price of the device using the magnet rotor was high.

An object of the present invention is to provide a flywheel magnet rotor with a pulley that can solve the problems of the conventional flywheel magnet rotor with a pulley as described above.

In order to solve the above-mentioned problems, the present invention provides a drive shaft extending toward the open end of the flywheel on the bottom wall of the flywheel having a magnet attached to the inner periphery. In a flywheel magnet rotor with a pulley, in which a portion closer to an open end is supported via a bearing and a pulley portion is integrally formed with the flywheel, the pulley portion is deformed at a portion closer to the outer periphery of the peripheral wall of the flywheel. As a result, it is formed approximately at the center of the peripheral wall.

Further, the method of the present invention includes the step of forming a cup-shaped member, and using a mold that does not deform the shape of the inner circumferential surface of the cup-shaped member to iron a portion of the thick portion of the peripheral wall of the cup-shaped member closer to the outer periphery. A conical surface having an apex in front of the first direction pushes the iron lump by pushing the lump a certain distance in a first direction from one end in the axial direction of the cup-shaped member to the other end parallel to the axis. forming a first pulley half by extruding the cup-shaped member in a direction away from the outer circumferential surface of the cup-shaped member;
Using a mold that does not deform the shape of the inner peripheral surface of the cup-shaped member, the iron ingot near the outer periphery of the thick portion of the peripheral wall of the cup-shaped member is removed from the other end of the cup-shaped member in the axial direction. The iron ingot that has been pushed a certain distance in a second direction opposite to the first direction is
A second pulley half is formed by pushing the cup-shaped member away from the outer peripheral surface along a conical surface having an apex forward in the direction of , and forming a second pulley half and the first pulley half. A flywheel with a pulley is formed by sequentially performing the steps of forming a pulley portion, and then performing the steps of attaching a magnet to the inner periphery of the flywheel and a drive shaft to the bottom wall, thereby forming a flywheel magnet with a pulley. Manufacture rotors.

Embodiments of the present invention will be described in detail below with reference to the drawings. FIG. 1 shows an embodiment of the present invention. In this embodiment, a substantially central portion of a peripheral wall 81 of a flywheel 8 formed in a cup shape is deformed to form a conical shape that protrudes outward from the peripheral wall 81. Slanted side wall 1
1b and 11c are formed, and V is formed on these side wall surfaces.
A pulley portion 11 is configured by forming a groove 11a. Other points are similar to the conventional flywheel magnet rotor shown in FIG.

By integrally providing the pulley portion 11 approximately in the center of the peripheral wall of the flywheel 8 in this manner, there is an advantage that the dimension of the flywheel magnet rotor in the axial direction can be reduced. In addition, since the length of the drive shaft 5 can be shortened, the eccentric torque applied to the bearing that supports the drive shaft 5 is reduced, and there is an advantage that there is no need to use an expensive bearing with strong mechanical strength as a bearing. .

Next, a method of manufacturing the above flywheel magnet rotor will be explained. Referring to FIGS. 2 to 4, a method for manufacturing the pulley-equipped flywheel magnet rotor shown in FIG. 1 is shown in the order of steps.
In this case, first, as shown in FIG. 2, a cup-shaped member 8' is formed by, for example, drawing an iron plate.
Make the thickness sufficiently thick. Next, as shown in FIG.
5a, an annular flat surface 15b that receives the open end surface of the cup-shaped member 8', and a cylindrical surface 15c that surrounds the outer peripheral surface of the cup-shaped member 8' from the open end side.
A first mold, that is, a first lower mold 15, which has a conical surface 15d that extends obliquely upward and continues from the upper end of this circumferential surface.
A cup-shaped member 8 is placed inside the lower mold 15. In this case, the outer circumferential surface of the cylindrical portion 15a and the inner circumferential surface of the cup-shaped member 8' and the circumferential surface 15c and the outer circumferential surface of the cup-shaped member 8' are formed in close contact with each other. The conical surface 15d has an apex on the front central axis in the displacement direction (downward in the figure) of the upper die, which will be described later, and has the same inclination angle as the inclined side wall 11b' of the V-shaped groove of the pulley portion to be formed. are doing. This conical surface 15d is formed so as to be continuous with the cylindrical surface 15c at a position corresponding to the bottom of the V-shaped groove of the pulley portion. Above the cup-shaped member 8' disposed in the lower mold 15, there is a hole 16a having an inner diameter smaller than the outer diameter of the cup-shaped member 8' by a predetermined length 2d, and a hole 16a connected to the open end of the hole 16a. An upper mold 16 having a conical surface 16b is placed. The conical surface 16b of the upper mold 16 is provided parallel to the conical surface 15b of the lower mold 15, and the upper mold 16 is moved downward until the bottom surface of the hole 16a abuts the outer surface of the bottom wall of the cup-shaped member 8'. The depth of the hole 16a is set so that in the displaced state, a gap corresponding to the thickness of one inclined side wall 11b forming the V-shaped groove 11a of the pulley portion is formed between the conical surfaces 16b and 15d. has been done. When the upper mold 16 formed in this way is positioned concentrically with respect to the lower mold 15 and displaced downward, the iron ingot near the outer periphery of the thick part of the peripheral wall of the cup-shaped member 8' first moves along the axis. swept downward parallel to the direction,
It is then pushed obliquely upward along the gap between the conical surfaces 16b and 15d (see FIG. 3), thereby forming one inclined side wall 11b constituting a pulley portion on the outer periphery of the cup-shaped member 8'.

Next, as shown in FIG. 4, an annular horizontal mold 17 having a V-shaped cross-section fitting part 17a that fits into the V-shaped groove in the pulley part is prepared. This horizontal type 17 is configured, for example, in half in the circumferential direction. After removing the first lower mold 15, the upper conical surface 17 of this horizontal mold 17
b is connected to the inclined side wall 11b formed in the previous step. Below this horizontal mold 17 is a cup-shaped member 8.
a cylindrical portion 18a that closely fits into the inner periphery of the cup-shaped member 8'; and an annular flat surface 18b that engages with the open end of the cup-shaped member 8'.
and a cylindrical surface 18c having an inner diameter smaller by a predetermined length 2d than the outer diameter of the cup-shaped member 8', and this cylindrical surface 1.
A second lower mold 18 having a conical surface 18d continuously formed at the upper end of the mold 8c is placed. The conical surface 18d of the second lower mold 18 has an apex on the front central axis of the lower mold 18 in the displacement direction, and the upper surface of the cylindrical portion 18a abuts the inner surface of the bottom wall of the cup-shaped member 8'. When the lower mold 18 is displaced to this position, a gap corresponding to the thickness of the other inclined side wall 11c forming the V-shaped groove 11a of the pulley portion is formed between the conical surface 18d and the lower conical surface 17c of the horizontal mold. It is becoming more and more common. The second lower mold 1 formed in this way
8 is positioned concentrically with respect to the upper mold 16 and the horizontal mold 17 and is displaced upward, after the iron ingot near the outer periphery of the thick part of the peripheral wall of the cup-shaped member 8' is swept away in the axial direction. The other inclined side wall 11c is extruded along the gap between the conical surfaces 18d and 17c, thereby forming the V-shaped groove of the pulley portion.

In this way, if the pulley part is formed integrally with the flywheel without deforming the shape of the inner circumference of the cup-shaped member, it is possible to easily create a flat inner circumferential surface of the flywheel without finishing. A magnet can be attached to the

Furthermore, in the methods shown in FIGS. 2 to 4,
Contrary to the above explanation, the iron ingot in the thick part of the peripheral wall is first washed away from the open end side of the cup-shaped member to form the inclined side wall 1.
It is also possible to form 1c first.

In the above embodiment, the magnet is glued to the flywheel, but if a magnetic pole piece is provided on the inner circumference of the magnet, the magnetic pole piece may be riveted or screwed to the peripheral wall of the flywheel. A magnet can be attached.

As described above, according to the present invention, since the pulley portion is integrally formed approximately at the center of the peripheral wall of the flywheel, there is an advantage that the axial dimension of the flywheel magnet rotor can be reduced. In addition, since the length of the drive shaft can be shortened, the force applied to the bearing is reduced, and inexpensive bearings can be used, reducing the cost of equipment using the flywheel magnet rotor with pulley of the present invention. can contribute to the development of

Further, according to the method of the present invention, there is an advantage that a pulley portion can be easily formed approximately at the center of the peripheral wall of the flywheel, and a magnet can be attached without finishing the inner peripheral surface of the upper flywheel.

[Brief explanation of the drawing]

FIG. 1 is a half longitudinal sectional view showing one embodiment of the present invention, FIGS. 2 to 4 are sectional views showing the method of manufacturing the flywheel magnet rotor shown in FIG. FIG. 5 is a half longitudinal sectional view showing a conventional flywheel magnet rotor. 7...Flywheel magnet rotor, 8...Flywheel, 8'...Cup-shaped member, 9...Magnet field, 11...Pulley portion, 16...Upper mold, 15...
...first lower mold, 18...second lower mold.

Claims (1)

[Claims] 1. A drive shaft extending toward the open end of the flywheel is provided on the bottom wall of the flywheel having a magnet attached to its inner periphery, and the drive shaft extends toward the open end of the flywheel. In a flywheel magnet rotor with a pulley, in which a pulley portion is integrally formed with the flywheel and the flywheel portion is supported via a bearing, the pulley portion is formed by deforming a portion of the peripheral wall of the flywheel near the outer periphery. A flywheel magnet rotor with a pulley, characterized in that the rotor is formed substantially in the center of the peripheral wall. 2. A step of forming a cup-shaped member, and using a mold that does not deform the shape of the inner circumferential surface of the cup-shaped member, the iron ingot near the outer periphery of the thick part of the peripheral wall of the cup-shaped member is formed into the cup-shaped member. A cup-shaped member is made of a cup-shaped member. forming a first pulley half by extruding it in a direction away from the outer circumferential surface of the cup-shaped member; The iron ingot at the closer portion is moved from the other end side in the axial direction of the cup-shaped member to the first
The pushed iron ingot that has been pushed a certain distance in a second direction opposite to the direction of A flywheel with a pulley is formed by sequentially performing the steps of forming a pulley half and forming a pulley part using the second pulley half and the first pulley half, and then forming the flywheel with a pulley. A method for manufacturing a flywheel magnet rotor with a pulley, comprising the steps of attaching a magnet to the inner periphery and a drive shaft to the bottom wall.