KR101919251B1 - Magnet inserted molding for rotor and its manufacturing method - Google Patents

Abstract

The present invention relates to magnet insert molding for a rotor of an electrical apparatus and a manufacturing method thereof. In the magnet insert molding for a rotor of an electrical apparatus to output a voltage by including a magnet (120) in a segment (110) surrounding an exciting coil wound around a rotor shaft (201), insert grooves (111) of a clamp shape are formed in the segment (110) with a zigzag shape. A mold (130) composed of a nonmagnetic body corresponding to the inner shape of the insert groove (111) and burying the magnet (120) are received in the insert groove (111). An oblique part (131) exposing both lateral sides of the magnet (120) and hiding and burying an outer side or inner and outer sides thereof and a corner part (132) with magnetic pole pieces of the magnetic (120) buried in the oblique part (131) adjacently arranged on both ends thereof are insert-molded in the mold (130) as one body. Accordingly, performance can be improved and manufacturing advantages can be obtained.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a magnet insert molding for a rotor of an electric machine,

The present invention relates to a magnet insert molding for a rotor of an electric machine and a manufacturing method thereof, and more particularly to a magnet assembly for a rotor that generates a rotating magnetic flux in an electric device such as a generator or an electric motor, So as to be mounted on the segment, thereby improving the performance of the device and having an advantage of manufacturing.

2. Description of the Related Art In general, an electric device incorporating an electromagnetic system such as an alternator includes a stator (stator) and a rotor (rotor), as well as slip rings and diodes.

The stator induces an alternating current by winding a stator coil on the iron core. The rotor, that is, the rotor has an excitation coil wound around the rotor shaft in a ring shape, and magnetic pole pieces are engaged with both ends of the excitation coil to generate a magnetic flux. The slip ring is connected to both ends of the exciting coil to deliver current.

The rotor generates a rotating magnetic flux with the stator and induces a voltage generating a current to generate a torque generating torque for driving the motor, which is a key element of the electromagnetic system.

That is, when a current flows through the exciting coil, both ends of the magnetic pole piece are magnetized to the N and S poles. When the rotor rotates, the coil of the stator and the magnetic flux of the magnetic pole piece are linked to induce a voltage to the stator coil.

[0003] A configuration of a stator and a rotor provided in a conventional electric device is schematically described in, for example, Japanese Unexamined Patent Application Publication No. 10-2015-0131081. The rotor includes a rotor core and a plurality of rotor poles Wherein the permanent magnet comprises a plurality of permanent magnets, the plurality of permanent magnets are arranged in a plurality of magnet sets, each magnet set includes at least one of a plurality of permanent magnets, and the rotor core includes a cylindrical surface, Wherein each of the plurality of slits is disposed radially between a cylindrical surface of the rotor core and one of the sets of magnets and a plurality of teeth disposed around the rotor and each tooth having a plurality of slits extending therethrough, And a tooth surface facing the cylindrical surface of the rotor core, the tooth surface having a medial portion extending substantially parallel to the cylindrical surface of the rotor core, and an inclined portion disposed opposite the medial portion of the tooth surface It made in the stator, including.

Generally, a plurality of permanent magnets are disposed in the rotor as in the prior art. For example, as disclosed in Patent Publication No. 10-201300640093, a structure for holding a permanent magnet is formed by providing a segment forming a retarder.

A rotor for an electric machine excited by magnetic poles formed by one or more built-in permanent magnets, characterized by defining a first magnetic pole (N) and a second magnetic pole (S) of alternating magnetic poles along a magnetic body and a rotor direction Wherein at least one of the one or more built-in permanent magnets and the one or more embedded permanent magnets and the first surface of the magnetic body have a rotor segment And at least one retainer element is configured to connect the rotor segment to the portion of the magnetic body.

As another example, as is known in the Japanese Patent No. 10-1396284, a plurality of teeth protruding in the circumferential direction by applying pressure in the direction of the rotation axis of the automotive alternator are molded in a closed metal mold to be symmetrical in the inside And a tapered portion for forming an inclined surface is formed on the outer side surface of the toothed portion, and the magnetized portion and the tapered portion are formed through independent forging process .

Open Patent No. 10 - 2015 - 0131081 (Nov. 21, 2015) Published Patent No. 10 - 2013 - 0006493 (2013.01.16) Registration No. 10- 1396284 (Apr. 19, 2014) Registration No. 10 - 0385597 (Aug. 19, 2003)

In the rotor of the electric device to which the conventional technique as described above is applied, a plurality of permanent magnets form pole pieces to form an arrangement structure for allowing the magnetic flux and the coil to be bridged.

That is, as in the above-described conventional technique, a rotor segment including a retainer for holding permanent magnets may be disposed so as to connect the rotor segment to the portion of the magnetic body, or a plurality of teeth may be provided, And a tapered portion forming an inclined surface is formed on the outer side surface of the magnet.

However, in the above-described prior art structure, a separate shape for assembling the permanent magnet is required between the rotor poles of the segment when the permanent magnet and the retainer are assembled, and therefore, additional processing is required.

Another prior art described above is also configured to perform independent forging to separately process the magnetized portion and the tapered portion for placing the permanent magnet on the inner side of the tooth portion.

Therefore, the productivity and the manufacturing cost increase due to the further execution of the forging process to which the precision machining technology is applied.

Further, in order to assemble the permanent magnet to the retainer or the magnet portion as described above, the process is performed in such a manner that individual magnets are sequentially inserted one by one, which leads to inefficiency of the process.

In addition, due to the structure of inserting and fixing the permanent magnet in the retainer or the magnetized portion, it is inevitable to reduce the cross sectional area along the inserting surface of the permanent magnet. As a result, the reduction of the magnetic flux causes a deterioration do.

Accordingly, the present invention has been made to solve the above-mentioned problems of the prior art,

1. A magnet insert molding for a rotor of an electric machine that holds a magnet (120) in a segment (110) surrounding an excitation coil wound around a rotor shaft (201) and outputs a voltage,

In the segment 110, insert-like insert grooves 111 are formed in zigzags at both ends;

The insert groove 111 is formed with a non-magnetic body corresponding to the inner shape of the insert groove 111 and seats a mold 130 for embedding the magnet 120 therein;

The mold 130 may be,

The slanted portion 131, which is exposed on both sides of the magnet 120 and buried on the outside or inside / outside,

And integrally insert injection molding the corner portions 132 disposed at both ends of the magnetic pole pieces of the magnet 120 embedded in the slanting portions 131 adjacent to each other.

The mold 130 is formed with ribs 133 extending to the spaced spaces between the slanted portions 131 from the inside of the corner portion 132 to support the exposed both sides of the magnet 120 .

Both sides of the corner 132 are mutually symmetrically formed in the mold 130 so as to form a cutout 134 for exposing the inner and outer ends of the pole pieces of the magnet 120 from the mold 130 .

The segment 110 is formed with a plurality of stacking grooves 112 to be pressed to a predetermined depth from the outside of the insert groove 111 toward the slanted portion 131 of the mold 130.

Accordingly, it is an object of the present invention to provide a magnet insert molding for a rotor of an electric device capable of improving the performance of the device and having a manufacturing advantage by constructing a mold in which a magnet for a rotor is molded by injection- It is possible to achieve the object of providing the manufacturing method.

The present invention has the effect of improving the performance of a device and having an advantage in manufacturing compared with the prior art by configuring the mold in which a plurality of magnets provided in the rotor are insert-injected together with a non-magnetic body and molded.

In other words, compared with the prior art, it is possible to eliminate the separate molding, forging, and inserting steps for the magnet seating in the segment, and omitting the step of assembling the retainer and magnet, thereby reducing manufacturing cost and productivity Can be derived.

Particularly, because of the omission of the segments, the cross-sectional area of the insertion portion of the permanent magnet is increased as compared with the prior art, and the rotation output can be increased by about 10% or more.

1 is an assembled perspective view of a magnet insert mold for a rotor of an electric device according to the present invention.
2 is an exploded view of a magnet insert mold for a rotor of an electric device according to the present invention;
3 is a mold perspective view of a magnet insert mold for a rotor of an electric device according to the present invention.
4 is a mold top view of a magnet insert mold for a rotor of an electric device according to the present invention.
Fig. 5 is a front view of Fig. 4; Fig.
6 is a cross-sectional view taken along line AA of Fig.
7 is a plan view showing a state where a mold of a magnet insert mold for a rotor of an electric device according to the present invention is seated on a segment.
8 is a front view of Fig.
9 is a cross-sectional view taken along the line BB in Fig.
10 is a perspective view showing a state in which a stacking groove is formed in a magnet insert molding for a rotor of an electric device according to the present invention.
11 is a simulation view (a) and a result image (b) showing a stacking groove formed in a magnet insert molding for a rotor of an electric device according to the present invention.
FIG. 12 is a process diagram schematically illustrating a manufacturing process of a magnet insert molding (a) for a rotor of an electric device according to the present invention and a conventional rotor (b).

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, the structure and operation of a magnet insert molding for a rotor and a method of manufacturing the same according to preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings.

FIG. 1 is an assembled perspective view of a magnet insert molding for a rotor of an electric device according to the present invention, FIG. 2 is an exploded view of a magnet insert molding for a rotor of an electric device according to the present invention, 4 is a plan view of a mold 130 of an insert molding of a rotor of an electric device according to the present invention, Fig. 5 is a front view of Fig. 4, Fig. 6 is a cross- Fig. 7 is a plan view showing a state in which a mold 130 of a magnet insert molding for a rotor of an electric device according to the present invention is seated on a segment 110. Fig. 8 is a front view of Fig. 10 is a perspective view showing a state in which a stacking groove 112 is formed in a magnet insert molding for a rotor of an electric device according to the present invention, and FIG. 11 is a perspective view of a magnet for a rotor of an electric device according to the present invention In insert molding 12 is a view showing a simulation configuration diagram (a) and a result image (b) for forming the tacking groove 112 and the manufacturing process of the magnet insert mold a for a rotor of an electric device according to the present invention and the prior art rotor b The process is schematically shown as a comparison chart.

The magnet insert molding for a rotor of an electric machine to which the technique of the present invention is applied and the manufacturing method thereof are provided with an assembling structure for holding a magnet 120 for a rotor which induces a voltage by generating a rotating magnetic flux in the electric appliance, The mold 130 in which a plurality of magnets 120 are insert-injected together with a non-magnetic body is mounted on the segment 110, thereby improving the performance of the device and achieving various advantages in manufacturing It is about technology.

1, a magnet insert molding for a rotor of an electric device according to the present invention comprises a magnet 120 for a segment 110 and a magnet insert molding for a rotor of an electric device for outputting a voltage, Is as follows.

The segments 110 are formed by coupling the upper and lower portions symmetrical to each other so as to surround the excitation coil wound around the rotor axis 201 to the rotor axis 201.

A plurality of magnets 120 are provided along the outer circumference of the segment 110 to generate a magnetic flux when the rotor 202 rotates and to induce a voltage in association with excitation coils provided therein. In the accompanying drawings of the present invention, a fan having a plurality of blades is shown coupled and driven on the upper and lower sides of the segment 110 as one embodiment.

As shown in FIG. 1 or FIG. 8, the segments 110 are formed in a zigzag shape at both ends of an insert groove 111 in the form of a catch.

The insert groove 111 is formed to have an inclined portion so as to arrange the magnetic pole piece of the magnet 120 embedded in the mold 130 to be described later in a claw pole so that both ends of the segment 110, Concentrate the magnetic flux between the poles.

The mold 130 is made of a nonmagnetic material corresponding to the inner shape of the insert groove 111 and is embedded in the insert groove 111.

As shown in FIG. 3, the mold 130 includes a shaded portion 131 which is exposed at both sides of the magnet 120 and conceals the outside or the inside / outside of the magnet 130, The corner portions 132, which are adjacent to each other and arranged at both ends, are integrally injection-molded.

As shown in FIG. 5, the oblique line portions 131 are serially formed in a zigzag fashion so as to be inclined at a predetermined angle with the oblique line portions 131 adjacent to both sides. The slanted portion 131 is formed so that its inner and outer sides are opposed to each other or only the outer side is formed to receive the magnet 120.

The corner portion 132 is disposed between the slanted portions 131 at positions where the magnetic pole pieces of the magnet 120 are concentrated and the magnetic pole pieces of the magnet 120 embedded in the slanted portions 131. The corner portion 132 forms both the inner and outer sides and the upper and lower sides having different curvatures to receive the pole piece.

A rib 133 to be described later is formed on both sides of the magnet 120 to be buried in the slanted portion 131. [ Therefore, as shown in the plan view of FIG. 4, the inner side surface of the corner portion 132 is formed by being recessed at a certain portion outwardly between the slanted portions 131.

As shown in FIG. 4 or 6, the magnet 120 is embedded in the mold 130 integrally with the inside of the slant portion 131 or between the inner and outer surfaces of the slant portion 131 through insert injection. In the embodiment of the present invention, the magnet 120 embedded in the mold 130 is provided at twelve locations of the slanting line 131. However, depending on the function of the rotor 202, the slanting line 131 and the slanting line 131 The number of the magnets 120 to be embedded in the plurality of magnets 120 can be variably controlled.

7 to 9, the corner portion 132 of the mold 130 is supported on the upper and lower sides of the insert groove 111, and both sides of the slanted portion 131 of the mold 130 are inserted into the insert groove 111, (111) and is seated in the segment (110).

The mold 130 is formed by insert injection of a nonmagnetic material such as thermoplastic plastic, nylon resin, aluminum, etc., together with the magnet 120 in a mold, to prevent current leakage. After the mold 130 is seated in the insert groove 111 of the segment 110, a desired varnish solution is penetrated to further enhance the assemblability.

5, the mold 130 is provided with a rib portion 132 which extends from the inside of the corner portion 132 to a spaced space between the inclined portions 131 and supports both exposed sides of the magnet 120, (133).

That is, since the slanted portion 131 of the mold 130 exposes the side surface of the magnet 120 when the insert is injected, the magnet 120 is rotated by the centrifugal force when the rotor 202 rotates, And a rib portion 133 extending from the corner portion 132 so as to completely exclude the possibility of disengagement from the guide portion 130.

Since the inner surface of the corner portion 132 is formed by recessing between the slant portions 131 as described above, the rib portion 133 is extended from the inner surface of the corner portion 132 by a predetermined length, Of the tilt angle. Accordingly, both side surfaces of the rib portion 133 firmly support the side surface of the magnet 120, and at the same time, the structural rigidity of the mold 130 itself is improved.

3, both sides of the corner portion 132 are mutually symmetrically formed in the mold 130 so as to expose the inner and outer ends of the magnetic pole piece of the magnet 120 from the mold 130, ).

That is, in order to position the magnet 130 that is embedded in the non-magnetic molded body at the time of inserting the mold 130 between the outer side or the inner and outer side surfaces of the slanted portion 131, the cut- So as to facilitate the seating of the magnet 120 and the take-out of the mold 130. In addition, when the varnish liquid is applied after the mold 130 is assembled, permeability can be enhanced through the cut-out portion 134.

10, a plurality of stacking grooves 112 are formed in the segment 110 so as to be pressed at a predetermined depth toward the slanted portion 131 of the mold 130 from the outside of the insert groove 111 .

11, the stacking groove 112 is thermo-compression-bonded to the segment 110 in a state where the mold 130 is assembled by using a separate stacking jig J, .

The shape of the stacking groove 112 may be various shapes such as an ellipse as well as a quadrangle or a parallelogram in the embodiment of the present invention. The depth of the stacking groove 112 is set in the range of 1.0 to 2.5 mm so as to eliminate the problem of being displaced to the outside of the insert groove 111 even if the centrifugal force acts on the mold 130 during rotation of the rotor 202 , And to minimize rotational noise.

In the preferred embodiment of the present invention, a plurality of stacking grooves 112 are provided along the inclined surfaces of the insert grooves 111. In the stacking step, stacking jigs J, which can be thermally compressed only at the forming sites of the stacking grooves 112, To form a stacking groove 112, which will be described later.

The manufacturing method of the magnet insert molding for a rotor of the electric device to which the technique of the present invention having the above-described structure is applied and its effect will be described below.

12 (a) shows a manufacturing process of a magnet insert mold for a rotor of an electric device according to the present invention.

There is provided a method of manufacturing a magnet insert molding for a rotor of an electric device holding a magnet 120 in a segment 110 surrounding an exciting coil wound around a rotor shaft 201 to output a voltage, Process and a rotor assembly process.

In the mold injection step, the magnet 120 is integrally injected into the non-magnetic body to mold the mold 130 corresponding to the internal shape of the insert groove 111 formed in the segment 110.

In the mold injection step, a slanting line 131 is formed by exposing both sides of the magnet 120 and concealing the outer side or the inner side and the outer side of the magnet 120. The slanting part 131 of the magnet 120 embedded in the slanting part 131 is adjacent And a rib portion 133 extending from the inside of the corner portion 132 to a spaced space between the inclined portions 131 and supporting both exposed sides of the magnet 120. [ The mold 130 is inserted and formed so as to integrally form a cutout portion 134 for exposing the inner and outer ends of the magnetic pole piece 130 from the mold 130. In addition, .

In the mold seating process, the mold 130 in which the magnet 120 is embedded is seated in the insert groove 111 of the segment 110 as described above. Since the segments 110 are formed to be symmetrical with respect to the upper and lower sides to be coupled to the rotor shaft 201 as shown in FIG. 12 (a) (130).

The rotor assembling process is completed by assembling the segment 110 on which the mold 130 is mounted to the rotor 202. After the mold 130 is assembled, a predetermined varnish solution penetrates through the cutout portion 134 to enhance the assemblability.

In the rotor assembly process, stacking is performed by pressing the outer circumferential surface of the insert groove 111 of the segment 110 on which the mold 130 is seated toward the slanting portion 131 of the mold 130 to form the stacking groove 112. [ A further process can be carried out.

11, a plurality of stacking grooves 112 are formed by pressing the stacking grooves 112 at a predetermined depth along the inclined surfaces of the insert grooves 111 by using the stacking jig J, The possibility of disengagement of the mold 130 is excluded.

The depth of the stacking groove 112 is designed to be 1.0 to 2.5 mm so as to minimize rolling noises during rotation of the rotor 202, and to minimize damage to the base material (segment) by thermocompression bonding.

FIG. 12 (a) shows a manufacturing process of a magnet insert molding for a rotor of an electric device according to the present invention, and FIG. 12 (b) schematically shows a process of manufacturing a rotor according to the prior art.

The present invention includes a mold 130 for integrally embedding the magnet 120 through the mold injection process as described above and then the mold 130 is inserted into the insert groove 111 of the segment 110 through the mold seating process And the rotor 202 is completed through a rotor assembly process.

12 (b), in order to assemble the retainer holding the magnet 20 or the magnet 20 to the segment 10, a separate insert shape 11 is forged The process should be further carried out.

Further, in the prior art, a process of sequentially inserting the individual magnets 20 one by one into the segment 10 on which the insert portion 11 is machined is additionally constructed.

Therefore, the magnet insert molding for a rotor and the method of manufacturing the same according to the present invention are different from the conventional art in that a plurality of magnets 120 provided in the rotor 202 are insert-injected together with a non- Since the mold 130 is molded and mounted on the segment 110, it is possible to improve the performance of the device, reduce the manufacturing cost due to the shortening of the process, and improve the productivity as compared with the prior art.

In particular, since the segment 110 is omitted from the conventional technique, the sectional area of the permanent magnet due to the reduction of the insertion portion of the permanent magnet is increased, Is expected to be very large.

110: Segment
111: insert home
112: stacking groove
120: Magnet
130: Mold
131:
132: corner portion
133: rib portion
134: incision
201: Rotor shaft
202: Rotor
J: Stacking jig

Claims (6)

1. A magnet insert molding for a rotor of an electric machine that holds a magnet (120) in a segment (110) surrounding an excitation coil wound around a rotor shaft (201) and outputs a voltage,
In the segment 110, insert-like insert grooves 111 are formed in zigzags at both ends;
The insert groove 111 is formed with a non-magnetic body corresponding to the inner shape of the insert groove 111 and seats a mold 130 for embedding the magnet 120 therein;
The mold 130 may be,
The slanted portion 131, which is exposed on both sides of the magnet 120 and buried on the outside or inside / outside,
Corner portions 132 disposed adjacent to the magnetic pole pieces of the magnet 120 embedded in the shaded portions 131 are disposed integrally with each other by insert injection molding;
Wherein the segment 110 is formed with a plurality of stacking grooves 112 which are pressed to a predetermined depth from the outside of the insert groove 111 toward the slanted portion 131 of the mold 130 Magnet insert molding for rotor of electric machine. A magnet 120 is integrally insert-injected into a non-magnetic body to hold a magnet 120 in a segment 110 surrounding an excitation coil wound around the rotor shaft 201 to output a voltage, A mold injection process for molding the mold 130 corresponding to the internal shape of the groove 111; A mold seating step of placing the mold 130 in which the magnet 120 is embedded in the insert groove 111; And a rotor assembly step of assembling the segment (110) on which the mold (130) is mounted to the rotor (202), the method comprising the steps of:
In the mold injection step,
The magnetic pole pieces of the magnet 120 embedded in the slanting part 131 are arranged adjacent to each other at both ends of the slanting part 131 which is exposed and both side surfaces of the magnet 120 are exposed and the inside or outside is concealed A rib portion 133 extending to a spaced space between the sloped portion 131 and the inside of the corner portion 132 to support both exposed sides of the magnet 120, 132 of the magnet 120 are mutually symmetrically formed so that the mold 130 is injection-molded by integrally forming a cutout portion 134 for exposing the inner and outer ends of the magnetic pole piece 120 from the mold 130,
In the rotor assembly process,
A stacking step of forming a stacking groove 112 by pressing the mold 130 against the slanted portion 131 of the mold 130 from the outside of the insert groove 111 of the segment 110 on which the mold 130 is mounted,
In the stacking step,
A plurality of stacking grooves 112 are squeezed along an inclined surface of the insert groove 111 by using a stacking jig,
Wherein a depth of the stacking groove (112) is in a range of 1.0 to 2.5 mm. ≪ RTI ID = 0.0 > 11. < / RTI > The method according to claim 1,
In the mold 130,
And a rib portion (133) extending from the inside of the corner portion (132) to a spaced space between the slanted portions (131) to support both exposed sides of the magnet (120) Magnet insert molding for rotor. The method according to claim 1,
In the mold 130,
And a cutout portion 134 for exposing the inner and outer ends of the magnetic pole pieces of the magnet 120 from the mold 130 is formed so as to be symmetrical on both sides of the corner portion 132. [ Magnet insert molding. delete delete

Images