WO2022163868A1 - Rotor of rotating electrical machine and method for manufacturing rotor of rotating electrical machine - Google Patents

Rotor of rotating electrical machine and method for manufacturing rotor of rotating electrical machine Download PDF

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Publication number
WO2022163868A1
WO2022163868A1 PCT/JP2022/003874 JP2022003874W WO2022163868A1 WO 2022163868 A1 WO2022163868 A1 WO 2022163868A1 JP 2022003874 W JP2022003874 W JP 2022003874W WO 2022163868 A1 WO2022163868 A1 WO 2022163868A1
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WO
WIPO (PCT)
Prior art keywords
rotor
magnet
region
adhesive
electric machine
Prior art date
Application number
PCT/JP2022/003874
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French (fr)
Japanese (ja)
Inventor
博光 岡本
秀徳 岡田
健一 中山
智 荊
勇輝 熊田
浩 又平
Original Assignee
日立Astemo株式会社
日立Ａｓｔｅｍｏ電動機システムズ株式会社
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Application filed by 日立Astemo株式会社, 日立Ａｓｔｅｍｏ電動機システムズ株式会社 filed Critical 日立Astemo株式会社
Priority to JP2022578545A priority Critical patent/JPWO2022163868A1/ja
Publication of WO2022163868A1 publication Critical patent/WO2022163868A1/en

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    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/22—Rotating parts of the magnetic circuit
    • H02K1/27—Rotor cores with permanent magnets
    • H02K1/2706—Inner rotors
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/02—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies

Definitions

  • the present invention relates to a rotor for a rotating electrical machine and a method for manufacturing a rotor for a rotating electrical machine.
  • Patent Document 1 discloses a rotor core having a magnet insertion hole extending in the axial direction along the rotor rotation axis, and a permanent magnet fixed inside the magnet insertion hole with an adhesive.
  • the magnet insertion hole has a hole-side planar portion formed in a planar shape facing the magnet-side planar portion on the inner surface thereof
  • the The adhesive is a foaming adhesive, and is provided at least on four corners of the magnet-side planar portion, and the thickness of the adhesive at the central portion of the magnet-side planar portion is equal to the thickness of the adhesive at the four corners.
  • a rotor for a rotating electric machine is disclosed that is thinner than the thickness of the agent.
  • Patent Document 1 there is room for improvement in the structure of the rotor from the viewpoint of manufacturing.
  • a rotor for a rotating electric machine includes a rotor core formed with holes into which magnets are inserted, and a fixing member fixing the magnets to the holes.
  • the fixing member comprises a sheet-like base material having a surface facing the magnet and a back surface opposite to the surface, a front adhesive applied to the surface, and a back surface adhesive applied to the back surface. At least one of the front-side adhesive and the back-side adhesive is a foaming adhesive, and the fixing member is positioned substantially perpendicular to the lateral direction of the magnet when viewed from the axial direction of the rotating electric machine.
  • a method of manufacturing a rotor for a rotating electrical machine according to a second aspect of the present invention is a rotating electrical machine comprising a rotor core formed with holes into which magnets are inserted, and a fixing member fixing the magnets to the holes.
  • a rotor manufacturing method comprising: a first step of inserting at least a portion of the fixing member before heating into the hole; and a second step of inserting the magnet into the hole after the first step.
  • the fixing member comprises: the sheet-shaped base material having a surface facing the magnet and a back surface opposite to the surface; a front adhesive applied to the surface; At least one of the front side adhesive and the back side adhesive is a foamed adhesive, and the fixing member is substantially perpendicular to the lateral direction of the magnet when viewed from the axial direction of the rotating electric machine. a first region in contact with any surface; and a second region in contact with any surface substantially perpendicular to the longitudinal direction of the magnet when viewed from the axial direction of the rotating electric machine. Two regions are integrally formed.
  • the present invention has a rotor manufacturing that is easy to manufacture.
  • FIG. 1 Schematic diagram of vehicle Schematic cross-sectional view showing the overall configuration of a rotating electric machine III-III sectional view of FIG. An exploded perspective view showing the manufacturing process of the rotor.
  • FIG. 2 Enlarged view of the III-III cross-sectional view shown in FIG. A diagram showing the composition of the foam sheet
  • Enlarged view of III-III cross-sectional view in modification 1 Enlarged view of III-III cross-sectional view in modification 2
  • FIG. 1 is a schematic configuration diagram of a vehicle 100 including a rotor of a rotating electric machine according to an embodiment of the present invention.
  • a vehicle 100 which is a hybrid vehicle, is equipped with an engine 120, a first rotating electrical machine 200, a second rotating electrical machine 201, and a high-voltage battery 150.
  • FIG. 1 is a schematic configuration diagram of a vehicle 100 including a rotor of a rotating electric machine according to an embodiment of the present invention.
  • a vehicle 100 which is a hybrid vehicle, is equipped with an engine 120, a first rotating electrical machine 200, a second rotating electrical machine 201, and a high-voltage battery 150.
  • FIG. 1 is a schematic configuration diagram of a vehicle 100 including a rotor of a rotating electric machine according to an embodiment of the present invention.
  • a vehicle 100 which is a hybrid vehicle, is equipped with an engine 120, a first rotating electrical machine 200, a second rotating electrical machine 201, and a high-voltage battery 150.
  • the battery 150 is composed of a secondary battery such as a lithium-ion battery or a nickel-metal hydride battery.
  • the battery 150 outputs high voltage DC power of 250 V to 600 V or higher.
  • the battery 150 supplies DC power to the rotating electrical machines 200 and 201 when the driving force of the rotating electrical machines 200 and 201 is required, and DC power is supplied from the rotating electrical machines 200 and 201 during regenerative running. Transfer of DC power between the battery 150 and the rotating electric machines 200 and 201 is performed via the power conversion device 160 .
  • vehicle 100 is equipped with a battery that supplies low-voltage power such as 14-volt power.
  • the rotational torque generated by engine 120 and rotating electric machines 200 and 201 is transmitted to front wheels 110 via transmission 130 and differential gear 140 .
  • rotating electrical machine 200 Since the rotating electrical machines 200 and 201 are configured in substantially the same manner, the rotating electrical machine 200 will be described below as a representative.
  • FIG. 2 is a schematic cross-sectional view showing the overall configuration of rotating electric machine 200. As shown in FIG. In FIG. 2 , an upper half of the rotating electrical machine 200 is cut away to show a cross-sectional view showing the internal structure of the rotating electrical machine 200 .
  • a stator 300 is supported inside the housing 205 as shown in FIG.
  • the stator 300 comprises a stator core 305 and stator windings 310 .
  • a rotor 400 is rotatably supported on the inner peripheral side of the stator core 305 via a gap 500 .
  • the rotor 400 includes a rotor core 405 fixed to a rotating shaft (hereinafter also referred to as “shaft”) 430 , permanent magnets 415 , and a pair of non-magnetic end plates 420 .
  • FIG. 2 illustrates the rotating electric machine 200 including the pair of end plates 420 , the rotating electric machine 200 may not include the pair of end plates 420 as described above.
  • the housing 205 has a pair of end brackets 210 provided with bearings 425, 426, and the shaft 430 is rotatably supported by these bearings 425, 426.
  • This rotary electric machine 200 is a three-phase synchronous motor with built-in permanent magnets.
  • Rotating electric machine 200 operates as an electric motor that rotates rotor 400 by supplying a three-phase alternating current to stator windings 310 wound around stator core 305 .
  • rotating electrical machine 200 when driven by engine 120, operates as a generator and outputs three-phase AC generated power. That is, the rotating electric machine 200 has both a function as an electric motor that generates rotational torque based on electrical energy and a function as a generator that generates power based on mechanical energy. Functions can be selectively used.
  • FIG. 3 is a cross-sectional view taken along line III-III in FIG. 3, housing 205 and shaft 430 are omitted.
  • the stator core 305 is formed by laminating a plurality of magnetic bodies, for example, a plurality of magnetic steel sheets in the axial direction, and is composed of a yoke portion and teeth portions (also called protrusions or salient pole portions).
  • the yoke portion is composed of a cylindrical yoke core 306 (also called a core back) fitted to the inner peripheral side of the housing 205 .
  • the tooth portion radially protrudes from the inner peripheral side of the yoke core 306 and is composed of a plurality of tooth cores 307 arranged at predetermined intervals in the circumferential direction.
  • a structure in which 48 teeth cores 307 are formed on the inner peripheral side of the yoke core 306 is exemplified.
  • slots 311 are formed continuously in the circumferential direction on the rotor 400 side between each of the adjacent teeth cores 307 .
  • a slot insulating material (not shown) is provided in the slot 311, and a plurality of phase windings such as U-phase, V-phase, and W-phase that constitute the stator 300 are mounted.
  • distributed winding is adopted as the winding method of the stator winding 310 (see FIG. 2).
  • the rotor core 405 is formed by laminating a plurality of magnetic bodies, for example, a plurality of electromagnetic steel plates in the axial direction.
  • a through-hole 405 a through which the shaft 430 is inserted is formed in the center of the rotor core 405 .
  • Each magnetic steel plate is provided with a plurality of magnet insertion holes 410 into which rectangular magnets are inserted.
  • the plurality of magnet insertion holes 410 are arranged at predetermined intervals in the circumferential direction of the electromagnetic steel plate.
  • the magnetic steel sheets are laminated so that the magnet insertion holes 410 are linearly communicated in the axial direction, and the permanent magnets 415 are embedded in the communicated magnet insertion holes 410 .
  • the magnet insertion hole 410 is also called a "hole".
  • the permanent magnets 415 are fixed in the magnet insertion holes 410 of the electromagnetic steel plate using a foaming adhesive, which will be described later.
  • the circumferential length of the magnet insertion hole 410 is set larger than the circumferential length of the permanent magnet 415 , and magnetic gaps 416 are formed on both sides of the permanent magnet 415 .
  • Magnetic air gap 416 penetrates magnet insertion hole 410 in the axial direction of rotating electric machine 200 and contacts permanent magnet 415 .
  • magnetic air gap 416 may contact permanent magnet 415 via foam adhesive 441 .
  • a cooling medium for cooling the permanent magnet 415 can flow through the magnetic air gap 416 .
  • an adhesive may be embedded, or the permanent magnet 415 and the permanent magnet 415 may be integrally fixed with molding resin. Permanent magnets 415 act as field poles for rotor 400 .
  • the rotor core 405 is provided with a key protrusion arrangement portion 490 that protrudes from the inner diameter side of the rotor core 405 toward the axial center side.
  • the key protrusion arrangement portion 490 fits into a shaft key groove (not shown) of the shaft 430 to fix the rotor 400 and the shaft 430 .
  • a pair of key protrusion arrangement portions 490 are provided at positions 180 degrees apart in the circumferential direction of each rotor core 405, in other words, at equal intervals in the circumferential direction.
  • the key projection array portions 490 are provided at equal intervals in the circumferential direction of each rotor core 405, but the positions of the key projection array portions 490 of each rotor core 405 are They do not have to be arranged at regular intervals in the circumferential direction. Also, the number of key projection arrangement portions 490 may be one or three or more.
  • the magnetization direction of the permanent magnet 415 is radial, and the magnetization direction is reversed for each field pole. That is, if the stator side surface of the permanent magnet 415a is the north pole and the shaft side surface is the south pole, the adjacent permanent magnet 415b has the stator side surface of the south pole and the shaft side surface of the north pole. These permanent magnets 415a and 415b are alternately arranged in the circumferential direction. In this embodiment, eight permanent magnets 415a and 415b are arranged at regular intervals, and the rotor 400 has eight poles.
  • the permanent magnet 415 may be embedded in the rotor core 405 after being magnetized, or may be magnetized by applying a strong magnetic field after inserting it into the rotor core 405 before magnetization.
  • the magnetized permanent magnet 415 is a strong magnet, and if the magnet is magnetized before fixing the permanent magnet 415 to the rotor 400, a strong attractive force is generated between the permanent magnet 415 and the rotor core 405 when the permanent magnet 415 is fixed. This centripetal force interferes with work. Also, due to the strong attractive force, there is a risk that dust such as iron powder will adhere to the permanent magnet 415 . Therefore, magnetizing the permanent magnet 415 after inserting it into the rotor core 405 improves the productivity of the rotary electric machine.
  • a neodymium-based or samarium-based sintered magnet, a ferrite magnet, a neodymium-based bond magnet, or the like can be used.
  • the residual magnetic flux density of the permanent magnet 415 is about 0.4-1.3T.
  • FIG. 4 is an exploded perspective view showing the manufacturing process of the rotor 400.
  • FIG. A preheated foam sheet 440B which will be described later, is first inserted into the magnet insertion hole 410, and then the permanent magnet 415 is inserted.
  • shaft 430 is passed through the center of end plate 420, and rotor 400 is sealed with end plate 420.
  • FIG. 5 is an enlarged view of the III-III cross-sectional view shown in FIG. 3, and a further enlarged view is shown at the bottom of FIG.
  • FIG. 5 is a view of rotating electric machine 200 viewed from shaft 430, as in FIG.
  • the permanent magnet 415 is fixed in the magnet insertion hole 410 with a foam sheet 440.
  • the foam sheet 440 is composed of a first region 440-1, a second region 440-2 and a third region 440-3 which are integrally formed.
  • the first area 440-1 is an area formed only on one side of the short-side direction surfaces of the permanent magnet 415 from the viewpoint shown in FIG.
  • the second area 440-2 is an area formed on one side of the permanent magnet 415 in the long side direction from the viewpoint shown in FIG.
  • the third area 440-3 is an area formed on the other side of the permanent magnet 415 in the long side direction from the viewpoint shown in FIG. 5, that is, on the side opposite to the second area 440-2.
  • FIG. 6 is a diagram showing the configuration of the foam sheet 440.
  • the foam sheet 440 is produced using a pre-heated pre-processed foam sheet 440A in which a pre-heated foaming agent 441A is placed on both sides of a plate-shaped base material 442 .
  • the base material 442 may be a single resin such as PEN (polyethylene naphthalate) or PI (polyimide), or may be a bonded resin.
  • the bonding resin is, for example, NPN, which is a composite material of Nomex (registered trademark) and PEN.
  • the pre-heating foaming agent 441A is a material that foams, that is, expands and foams to have adhesive strength when a predetermined amount of heat is applied. Since the foaming agent is also called a foaming resin or a foaming adhesive, the pre-heating foaming agent 441A can also be called a "pre-heating foaming resin" or a "pre-heating foaming adhesive
  • a plate-shaped pre-heating pre-processed foamed sheet 440A is bent into a substantially U shape to form a pre-heated foamed sheet 440B. Then, the pre-heating foamed sheet 440B is inserted into the magnet insertion hole 410, and then the permanent magnet 415 is similarly inserted into the magnet insertion hole 410. After that, a predetermined heat is applied to the permanent magnet 415 into the magnet insertion hole 410. An anchoring foam sheet 440 is obtained.
  • the manufacturing method of the rotor 400 after forming the foam sheet 440 includes the following first to third steps. As for these three processes, first the first process is performed, then the second process is performed, and finally the third process is performed. Inserting the preheated foam sheet 440B into the magnet insertion hole 410 is called a "first step”, inserting the permanent magnet 415 into the magnet insertion hole 410 is called a “second step”, and applying a predetermined amount of heat. is called “third step”.
  • the pre-heating foaming agents 441 A provided on both sides of the base material 442 are foamed by applying a predetermined amount of heat, and fill the spaces between the permanent magnets 415 and the inner circumferences of the magnet insertion holes 410 .
  • Rotor 400 of rotary electric machine 200 includes rotor core 405 formed with magnet insertion hole 410 into which permanent magnet 415 is inserted, and foam sheet 440 as a fixing member for fixing permanent magnet 415 in the hole. , provided.
  • the foam sheet 440 includes a sheet-like base material 442 having a surface facing the permanent magnet 415 and a back surface opposite to the surface, a front adhesive applied to the surface, and a back adhesive applied to the back surface.
  • the front side adhesive and the back side adhesive are foamed adhesives 441 .
  • Foam sheet 440 includes a first region 440-1 in contact with any surface substantially perpendicular to the short side direction of permanent magnet 415 viewed from the axial direction of rotating electrical machine 200, and a permanent magnet viewed from the axial direction of rotating electrical machine 200. and a second region 440-2 contacting one of the faces substantially perpendicular to the longitudinal direction of 415, and the first region 440-1 and the second region 440-2 are integrally formed. Therefore, the rotor 400 can obtain the foamed adhesive 441 by applying a predetermined amount of heat to the pre-heated foamed adhesive 441A inserted in the magnet insertion hole 410, so that the rotor 400 can be easily manufactured.
  • the rotor 400 of the rotary electric machine 200 has a manufacture of the rotor 400 which is easy to manufacture. Further, unlike a liquid adhesive, the foamed adhesive 441 does not easily enter into fine gaps, so it is difficult to enter into the gaps between the steel plates of the rotor core 405 in which electromagnetic steel plates are laminated. Furthermore, since the rotor 400 is firmly fixed by the foaming adhesive 441, it is possible to prevent the performance of the rotating electric machine 200 from deteriorating due to the permanent magnets 415 coming into contact with the magnet insertion holes 410 and being worn.
  • Both the front side adhesive and the back side adhesive are foamed adhesives. Therefore, since the foam adhesive is used on both sides of the base material 442, the permanent magnets 415 can be fixed more firmly.
  • the foam sheet 440 includes a third region 440-3 arranged on the opposite side of the first region with the permanent magnet 415 interposed therebetween.
  • the first region 440-1, the second region 440-2 and the third region 440-3 are integrally formed. Therefore, the long side direction of the permanent magnet 415 can be sandwiched with the foam adhesive from both sides, and the permanent magnet 415 can be prevented from coming into contact with the magnet insertion hole 410 and being worn out more reliably.
  • a magnetic air gap 416 is provided which penetrates the magnet insertion hole 410 in the axial direction of the rotating electric machine 200 and is in contact with the permanent magnet 415 . Therefore, the permanent magnet 415 can be efficiently cooled by flowing a cooling medium through the magnetic gap 416 . Assuming that the permanent magnet 415 is cooled, an inexpensive magnet with weak coercive force or a magnet free of heavy rare earth elements can be used.
  • the front side adhesive which is the adhesive on the permanent magnet 415 side of the base material 442, is foamed adhesive.
  • the front-side adhesive urges the permanent magnet 415 against the inner wall of the magnet insertion hole 410 . Therefore, it is easy to fix the position and attitude of the permanent magnet 415 .
  • Substrate 442 is a single resin or a laminate resin.
  • a single resin is either polyethylene naphthalate or polyimide.
  • the lamination resin is a composite material of Nomex (registered trademark) and polyethylene naphthalate.
  • Manufacturing method of rotor 400 of rotary electric machine 200 including rotor core 405 formed with magnet insertion holes 410 into which permanent magnets 415 are inserted, and foam sheet 440 fixing permanent magnets 415 to magnet insertion holes 410 includes a first step of inserting at least part of the preheated foamed sheet 440B into the magnet insertion hole 410, and a second step of inserting the permanent magnet 415 into the hole after the first step.
  • the foam sheet 440 includes a sheet-like base material 442 having a surface facing the permanent magnet 415 and a back surface opposite to the surface, a front adhesive disposed on the surface, and a back adhesive disposed on the back surface, The front side adhesive and the back side adhesive are foamed adhesives 441 .
  • the foam sheet 440 has a first region 440-1 in contact with one of the surfaces substantially perpendicular to the short side direction of the permanent magnet 415 seen from the axial direction of the rotating electrical machine 220, and the permanent magnet 415 seen from the axial direction of the rotating electrical machine. and a second region 440-2 in contact with any surface substantially perpendicular to the longitudinal direction of the .
  • a first region 440-1 and a second region 440-2 are integrally formed. Therefore, even if there is a burr at the edge of the magnet insertion hole 410 in the rotor core 405, the preheated foam sheet 440B to be inserted first can be easily inserted into the magnet insertion hole 410 without contacting the burr. It is possible to prevent the pre-heating foaming agent 441A from peeling from the pre-heating foam sheet 440B.
  • FIG. 7 is an enlarged view of the III-III cross-sectional view in Modification 2.
  • FIG. 7 in this modification, the foam sheet 440 does not have the third region and has a substantially L shape. Since the foam sheet 440 does not have the third region in this modified example, the foam sheet 440 can be made smaller, the material cost can be reduced, and the productivity can be improved. In this modification, the foam sheet 440 does not have the third region, but since the foam adhesive 441 exists on both the short side and the long side of the permanent magnet 415, the permanent magnet 415 can move in either direction. has the function of limiting
  • FIG. 8 is an enlarged view of the III-III cross-sectional view in Modification 2.
  • FIG. 8 in this modification, the cross section of the permanent magnet 415 is arc-shaped instead of rectangular.
  • the shape of the pre-heating foam sheet 440B is created according to the outer shape of the arcuate permanent magnet 415 .
  • the order of insertion into the magnet insertion holes 410 is the same as in the embodiment.
  • the pre-heating foam sheet 440B is inserted first, and the permanent magnets 415 are inserted afterwards. After that, a predetermined amount of heat is applied to pre-heating foam sheet 440B to obtain foam sheet 440.
  • the foam sheet 440 has a first region 440-1 below the permanent magnet 415 in FIG. 8, a second region 440-2 on the right side in the drawing, and a third region 440-3 on the left side in the drawing.
  • Permanent magnet 415 has an arc shape when viewed from the axial direction of rotating electric machine 200 . Since the pre-heating foam sheet 440B can be processed into an arbitrary shape, it can also be processed into a shape along the permanent magnet 415 having an arc-shaped cross section. By inserting the permanent magnet 415 and the pre-heating foam sheet 440B into the magnet insertion hole 410 and then heating the pre-heating foam sheet 440B, the permanent magnet 415 can be fixed to the magnet insertion hole 410 regardless of its shape.
  • foamed adhesive 441 was placed on both sides of substrate 442 .
  • the foaming adhesive 441 may be applied to at least one surface of both surfaces of the substrate 442, and other types of adhesive such as liquid adhesive may be applied to the surfaces on which the foaming adhesive 441 is not applied. .

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Permanent Field Magnets Of Synchronous Machinery (AREA)

Abstract

This rotor of an rotating electrical machine comprises: a rotor core in which is formed a hole section into which a magnet is inserted; and a fixing member that fixes the magnet to the hole section. The fixing member includes: a sheet-like base material with a front surface that faces the magnet and a back surface on the opposite side from the front surface; a front-side adhesive disposed on the front surface; and a back-surface adhesive disposed on the back surface. The front-side adhesive and/or the back-side adhesive is a foamed adhesive. The fixing member includes: a first region that adjoins any surface of the magnet that is roughly straight in a short direction as viewed in an axial direction of the rotating electrical machine; and a second region that adjoins any surface of the magnet that is roughly straight in a long direction as viewed in the axial direction of the rotating electrical machine. The first region and the second region are formed integrally.

Description

回転電機の回転子、回転電機の回転子の製造方法Rotor of rotary electric machine, method for manufacturing rotor of rotary electric machine
　本発明は、回転電機の回転子、および回転電機の回転子の製造方法に関する。 The present invention relates to a rotor for a rotating electrical machine and a method for manufacturing a rotor for a rotating electrical machine.
　モータや発電機を含む回転電機は、脱炭素社会に向けて需要量および用途の増加が見込まれる。回転電機は、性能とコストの両立が求められる。特許文献１には、ロータ回転軸に沿う方向である軸方向に延びる磁石挿入孔を備えたロータコアと、前記磁石挿入孔の内部に接着剤で固定された永久磁石と、を備え、前記永久磁石は、矩形平面状に形成された磁石側平面部を有し、前記磁石挿入孔は、その内面に、前記磁石側平面部に対向する平面状に形成された孔側平面部を有し、前記接着剤は、発泡接着剤であり、前記磁石側平面部における４つの隅部に少なくとも設けられており、前記磁石側平面部の中央部における前記接着剤の厚みが前記４つの隅部における前記接着剤の厚みよりも薄い回転電機用ロータが開示されている。 Demand and applications for rotating electric machines, including motors and generators, are expected to increase toward a decarbonized society. Rotating electric machines are required to achieve both performance and cost. Patent Document 1 discloses a rotor core having a magnet insertion hole extending in the axial direction along the rotor rotation axis, and a permanent magnet fixed inside the magnet insertion hole with an adhesive. has a magnet-side planar portion formed in a rectangular planar shape, the magnet insertion hole has a hole-side planar portion formed in a planar shape facing the magnet-side planar portion on the inner surface thereof, and the The adhesive is a foaming adhesive, and is provided at least on four corners of the magnet-side planar portion, and the thickness of the adhesive at the central portion of the magnet-side planar portion is equal to the thickness of the adhesive at the four corners. A rotor for a rotating electric machine is disclosed that is thinner than the thickness of the agent.
国際公開第ＷＯ２０１７／１７０９８２号International Publication No. WO2017/170982
　特許文献１に記載されている発明では、製造上の観点から回転子の構造に改善の余地がある。 In the invention described in Patent Document 1, there is room for improvement in the structure of the rotor from the viewpoint of manufacturing.
　本発明の第１の態様による回転電機の回転子は、磁石が挿入される穴部が形成される回転子コアと、前記磁石を前記穴部に固定する固定部材と、を備える回転電機の回転子であって、前記固定部材は、前記磁石に対向する表面および前記表面とは逆側の裏面を有するシート状の基材、前記表面に配される表側接着剤、および前記裏面に配される裏側接着剤を含み、前記表側接着剤および前記裏側接着剤の少なくとも一方は発泡接着剤であり、前記固定部材は、前記回転電機の軸方向から見た前記磁石の短手方向に略直行するいずれかの面に接する第１領域と、前記回転電機の軸方向から見た前記磁石の長手方向に略直行するいずれかの面に接する第２領域と、を含み、前記第１領域および前記第２領域が一体に形成される。
　本発明の第２の態様による回転電機の回転子の製造方法は、磁石が挿入される穴部が形成される回転子コア、および前記磁石を前記穴部に固定する固定部材を備える回転電機の回転子の製造方法であって、加熱前の前記固定部材の少なくとも一部を前記穴部に挿入する第１工程と、前記第１工程の後に、前記磁石を前記穴部に挿入する第２工程と、を含み、前記固定部材は、前記磁石に対向する表面および前記表面とは逆側の裏面を有する前記シート状の基材、前記表面に配される表側接着剤、および前記裏面に配される裏側接着剤を含み、前記表側接着剤および前記裏側接着剤の少なくとも一方は発泡接着剤であり、前記固定部材は、前記回転電機の軸方向から見た前記磁石の短手方向に略直行するいずれかの面に接する第１領域と、前記回転電機の軸方向から見た前記磁石の長手方向に略直行するいずれかの面に接する第２領域と、を含み、前記第１領域および前記第２領域が一体に形成される。 A rotor for a rotating electric machine according to a first aspect of the present invention includes a rotor core formed with holes into which magnets are inserted, and a fixing member fixing the magnets to the holes. The fixing member comprises a sheet-like base material having a surface facing the magnet and a back surface opposite to the surface, a front adhesive applied to the surface, and a back surface adhesive applied to the back surface. At least one of the front-side adhesive and the back-side adhesive is a foaming adhesive, and the fixing member is positioned substantially perpendicular to the lateral direction of the magnet when viewed from the axial direction of the rotating electric machine. a first region in contact with one surface, and a second region in contact with one of the surfaces substantially perpendicular to the longitudinal direction of the magnet when viewed from the axial direction of the rotating electric machine; A region is integrally formed.
A method of manufacturing a rotor for a rotating electrical machine according to a second aspect of the present invention is a rotating electrical machine comprising a rotor core formed with holes into which magnets are inserted, and a fixing member fixing the magnets to the holes. A rotor manufacturing method comprising: a first step of inserting at least a portion of the fixing member before heating into the hole; and a second step of inserting the magnet into the hole after the first step. and the fixing member comprises: the sheet-shaped base material having a surface facing the magnet and a back surface opposite to the surface; a front adhesive applied to the surface; At least one of the front side adhesive and the back side adhesive is a foamed adhesive, and the fixing member is substantially perpendicular to the lateral direction of the magnet when viewed from the axial direction of the rotating electric machine. a first region in contact with any surface; and a second region in contact with any surface substantially perpendicular to the longitudinal direction of the magnet when viewed from the axial direction of the rotating electric machine. Two regions are integrally formed.
　本発明によれば、製造が容易な回転子の製造を有する。 According to the present invention, it has a rotor manufacturing that is easy to manufacture.
車両の概略構成図Schematic diagram of vehicle 回転電機の全体構成を示す模式的断面図Schematic cross-sectional view showing the overall configuration of a rotating electric machine 図２のＩＩＩ－ＩＩＩ断面図III-III sectional view of FIG. 回転子の製造工程を示す分解斜視図An exploded perspective view showing the manufacturing process of the rotor. 図３に示したＩＩＩ－ＩＩＩ断面図の拡大図Enlarged view of the III-III cross-sectional view shown in FIG. 発泡シートの構成を示す図A diagram showing the composition of the foam sheet 変形例１におけるＩＩＩ－ＩＩＩ断面図の拡大図Enlarged view of III-III cross-sectional view in modification 1 変形例２におけるＩＩＩ－ＩＩＩ断面図の拡大図Enlarged view of III-III cross-sectional view in modification 2
―第１の実施の形態―
　以下、図１～図６を参照して、回転電機の回転子、および回転電機の回転子の製造方法の実施の形態を説明する。 -First Embodiment-
1 to 6, an embodiment of a rotor for a rotating electrical machine and a method for manufacturing the rotor for the rotating electrical machine will be described below.
　図１は、本発明の実施形態に係る回転電機の回転子を含む車両１００の概略構成図である。図１に示すように、ハイブリッド自動車である車両１００には、エンジン１２０と、第１の回転電機２００と、第２の回転電機２０１と、高電圧のバッテリー１５０とが搭載されている。 FIG. 1 is a schematic configuration diagram of a vehicle 100 including a rotor of a rotating electric machine according to an embodiment of the present invention. As shown in FIG. 1, a vehicle 100, which is a hybrid vehicle, is equipped with an engine 120, a first rotating electrical machine 200, a second rotating electrical machine 201, and a high-voltage battery 150. As shown in FIG.
　バッテリー１５０は、リチウムイオン電池あるいはニッケル水素電池などの二次電池で構成されている。バッテリー１５０からは、２５０ボルトから６００ボルト、またはそれ以上の高電圧の直流電力が出力される。バッテリー１５０は、回転電機２００、２０１による駆動力が必要な場合には回転電機２００、２０１に直流電力を供給し、回生走行時には回転電機２００、２０１から直流電力が供給される。バッテリー１５０と回転電機２００、２０１との間の直流電力の授受は、電力変換装置１６０を介して行われる。なお図示はしていないが、車両１００には低電圧電力、たとえば１４ボルト系電力を供給するバッテリーが搭載されている。 The battery 150 is composed of a secondary battery such as a lithium-ion battery or a nickel-metal hydride battery. The battery 150 outputs high voltage DC power of 250 V to 600 V or higher. The battery 150 supplies DC power to the rotating electrical machines 200 and 201 when the driving force of the rotating electrical machines 200 and 201 is required, and DC power is supplied from the rotating electrical machines 200 and 201 during regenerative running. Transfer of DC power between the battery 150 and the rotating electric machines 200 and 201 is performed via the power conversion device 160 . Although not shown, vehicle 100 is equipped with a battery that supplies low-voltage power such as 14-volt power.
　エンジン１２０および回転電機２００、２０１による回転トルクは、変速機１３０とデファレンシャルギア１４０を介して前輪１１０に伝達される。 The rotational torque generated by engine 120 and rotating electric machines 200 and 201 is transmitted to front wheels 110 via transmission 130 and differential gear 140 .
　回転電機２００、２０１は略同様に構成されているので、以下では、回転電機２００を代表として説明する。 Since the rotating electrical machines 200 and 201 are configured in substantially the same manner, the rotating electrical machine 200 will be described below as a representative.
　図２は、回転電機２００の全体構成を示す模式的断面図である。図２では、回転電機２００の上部半分を破断し、回転電機２００の内部構造を示す断面図として図示している。 FIG. 2 is a schematic cross-sectional view showing the overall configuration of rotating electric machine 200. As shown in FIG. In FIG. 2 , an upper half of the rotating electrical machine 200 is cut away to show a cross-sectional view showing the internal structure of the rotating electrical machine 200 .
　図２に示すように、ハウジング２０５の内部には固定子３００が支持されている。固定子３００は、固定子コア３０５と固定子巻線３１０とを備えている。固定子コア３０５の内周側には、回転子４００が空隙５００を介して回転可能に支持されている。回転子４００は、回転軸（以下、「シャフト」とも称する）４３０に固定された回転子コア４０５と、永久磁石４１５と、非磁性体の一対のエンドプレート４２０とを備えている。なお、図２では、一対のエンドプレート４２０を備えた回転電機２００として例示しているが、上述したように、一対のエンドプレート４２０を有していない回転電機２００とすることもできる。 A stator 300 is supported inside the housing 205 as shown in FIG. The stator 300 comprises a stator core 305 and stator windings 310 . A rotor 400 is rotatably supported on the inner peripheral side of the stator core 305 via a gap 500 . The rotor 400 includes a rotor core 405 fixed to a rotating shaft (hereinafter also referred to as “shaft”) 430 , permanent magnets 415 , and a pair of non-magnetic end plates 420 . Although FIG. 2 illustrates the rotating electric machine 200 including the pair of end plates 420 , the rotating electric machine 200 may not include the pair of end plates 420 as described above.
　ハウジング２０５は、軸受４２５、４２６が設けられた一対のエンドブラケット２１０を有しており、シャフト４３０はこれらの軸受４２５、４２６により回転自在に支持されている。 The housing 205 has a pair of end brackets 210 provided with bearings 425, 426, and the shaft 430 is rotatably supported by these bearings 425, 426.
　この回転電機２００は、永久磁石内蔵型の３相同期モータである。回転電機２００は、固定子コア３０５に巻回される固定子巻線３１０に３相交流電流が供給されることで、回転子４００を回転させる電動機として作動する。また、回転電機２００は、エンジン１２０によって駆動されると、発電機として作動して３相交流の発電電力を出力する。つまり、回転電機２００は、電気エネルギーに基づいて回転トルクを発生する電動機としての機能と、機械エネルギーに基づいて発電を行う発電機としての機能の両方を有しており、自動車の走行状態によって上記機能を選択的に利用することができる。 This rotary electric machine 200 is a three-phase synchronous motor with built-in permanent magnets. Rotating electric machine 200 operates as an electric motor that rotates rotor 400 by supplying a three-phase alternating current to stator windings 310 wound around stator core 305 . In addition, when driven by engine 120, rotating electrical machine 200 operates as a generator and outputs three-phase AC generated power. That is, the rotating electric machine 200 has both a function as an electric motor that generates rotational torque based on electrical energy and a function as a generator that generates power based on mechanical energy. Functions can be selectively used.
　図３は、図２のＩＩＩ－ＩＩＩ断面図である。図３では、ハウジング２０５およびシャフト４３０は図示が省略されている。 FIG. 3 is a cross-sectional view taken along line III-III in FIG. 3, housing 205 and shaft 430 are omitted.
　固定子コア３０５は、複数の磁性体、たとえば複数の電磁鋼板を軸方向に積層して形成したものであり、ヨーク部およびティース部（突出部または突極部ともいう）から構成される。ヨーク部は、ハウジング２０５の内周側に嵌合された円筒状のヨークコア３０６（コアバックともいう）から構成される。ティース部は、ヨークコア３０６の内周側から径方向に突出し、所定の間隔をもって周方向に所定の間隔で配置された複数のティースコア３０７から構成される。本実施の形態では、ヨークコア３０６の内周側に４８個のティースコア３０７が形成された構造として例示されている。 The stator core 305 is formed by laminating a plurality of magnetic bodies, for example, a plurality of magnetic steel sheets in the axial direction, and is composed of a yoke portion and teeth portions (also called protrusions or salient pole portions). The yoke portion is composed of a cylindrical yoke core 306 (also called a core back) fitted to the inner peripheral side of the housing 205 . The tooth portion radially protrudes from the inner peripheral side of the yoke core 306 and is composed of a plurality of tooth cores 307 arranged at predetermined intervals in the circumferential direction. In this embodiment, a structure in which 48 teeth cores 307 are formed on the inner peripheral side of the yoke core 306 is exemplified.
　隣接するティースコア３０７間のそれぞれには、回転子４００側の周方向に連続して、４８個のスロット３１１が形成される。スロット３１１内には不図示のスロット絶縁材が設けられ、固定子３００を構成するＵ相、Ｖ相、Ｗ相などの複数の相巻線が装着される。本実施の形態では、固定子巻線３１０（図２参照）の巻き方として分布巻を採用している。 48 slots 311 are formed continuously in the circumferential direction on the rotor 400 side between each of the adjacent teeth cores 307 . A slot insulating material (not shown) is provided in the slot 311, and a plurality of phase windings such as U-phase, V-phase, and W-phase that constitute the stator 300 are mounted. In the present embodiment, distributed winding is adopted as the winding method of the stator winding 310 (see FIG. 2).
　回転子コア４０５は、複数の磁性体、例えば複数の電磁鋼板を軸方向に積層して形成したものである。回転子コア４０５の中心には、シャフト４３０が挿通される貫通孔４０５ａが形成される。各電磁鋼板には矩形の磁石が挿入される複数の磁石挿入孔４１０が設けられる。複数の磁石挿入孔４１０は、電磁鋼板の円周方向に所定の間隔で配置される。電磁鋼板は、磁石挿入孔４１０のそれぞれが軸方向に直線状に連通するように積層され、連通された各磁石挿入孔４１０に永久磁石４１５が埋め込まれる。なお以下では、磁石挿入孔４１０を「穴部」とも呼ぶ。 The rotor core 405 is formed by laminating a plurality of magnetic bodies, for example, a plurality of electromagnetic steel plates in the axial direction. A through-hole 405 a through which the shaft 430 is inserted is formed in the center of the rotor core 405 . Each magnetic steel plate is provided with a plurality of magnet insertion holes 410 into which rectangular magnets are inserted. The plurality of magnet insertion holes 410 are arranged at predetermined intervals in the circumferential direction of the electromagnetic steel plate. The magnetic steel sheets are laminated so that the magnet insertion holes 410 are linearly communicated in the axial direction, and the permanent magnets 415 are embedded in the communicated magnet insertion holes 410 . In addition, below, the magnet insertion hole 410 is also called a "hole".
　永久磁石４１５は、後述する発泡接着剤を用いて電磁鋼板の各磁石挿入孔４１０内に固定される。磁石挿入孔４１０の円周方向の長さは、永久磁石４１５の円周方向の長さよりも大きく設定されており、永久磁石４１５の両側には磁気的空隙４１６が形成される。磁気的空隙４１６は、磁石挿入孔４１０を回転電機２００の軸方向に貫通しており、永久磁石４１５に接する。ただし磁気的空隙４１６は、発泡接着剤４４１を介して永久磁石４１５に接してもよい。この磁気的空隙４１６には永久磁石４１５を冷却する冷却媒体を流すことができる。ただし磁気的空隙４１６に冷却媒体を流す代わりに、接着剤を埋め込んでもよいし成型樹脂で永久磁石４１５と一体に固めてもよい。永久磁石４１５は回転子４００の界磁極として作用する。 The permanent magnets 415 are fixed in the magnet insertion holes 410 of the electromagnetic steel plate using a foaming adhesive, which will be described later. The circumferential length of the magnet insertion hole 410 is set larger than the circumferential length of the permanent magnet 415 , and magnetic gaps 416 are formed on both sides of the permanent magnet 415 . Magnetic air gap 416 penetrates magnet insertion hole 410 in the axial direction of rotating electric machine 200 and contacts permanent magnet 415 . However, magnetic air gap 416 may contact permanent magnet 415 via foam adhesive 441 . A cooling medium for cooling the permanent magnet 415 can flow through the magnetic air gap 416 . However, instead of flowing the cooling medium in the magnetic gap 416, an adhesive may be embedded, or the permanent magnet 415 and the permanent magnet 415 may be integrally fixed with molding resin. Permanent magnets 415 act as field poles for rotor 400 .
　回転子コア４０５は、回転子コア４０５の内径側から軸心側に向かって突出するキー突起配列部４９０が設けられる。キー突起配列部４９０は、シャフト４３０の不図示のシャフトキー溝部に嵌合し、回転子４００とシャフト４３０とを固定する。一対のキー突起配列部４９０は、各回転子コア４０５の円周方向に１８０度異なる位置に、換言すれば、円周方向に等間隔に一対設けられている。本実施形態ではキー突起配列部４９０が、各回転子コア４０５の円周方向に等間隔に設けられた構造として例示しているが、各回転子コア４０５のキー突起配列部４９０の位置は、円周方向に等間隔に配置されていなくてもよい。また、キー突起配列部４９０の数は、１個あるいは３個以上としてもよい。 The rotor core 405 is provided with a key protrusion arrangement portion 490 that protrudes from the inner diameter side of the rotor core 405 toward the axial center side. The key protrusion arrangement portion 490 fits into a shaft key groove (not shown) of the shaft 430 to fix the rotor 400 and the shaft 430 . A pair of key protrusion arrangement portions 490 are provided at positions 180 degrees apart in the circumferential direction of each rotor core 405, in other words, at equal intervals in the circumferential direction. In the present embodiment, the key projection array portions 490 are provided at equal intervals in the circumferential direction of each rotor core 405, but the positions of the key projection array portions 490 of each rotor core 405 are They do not have to be arranged at regular intervals in the circumferential direction. Also, the number of key projection arrangement portions 490 may be one or three or more.
　永久磁石４１５の磁化方向は径方向を向いており、界磁極毎に磁化方向の向きが反転している。すなわち、永久磁石４１５ａの固定子側面がＮ極、軸側の面がＳ極であったとすれば、隣の永久磁石４１５ｂの固定子側面はＳ極、軸側の面はＮ極である。そして、これらの永久磁石４１５ａ、４１５ｂが円周方向に交互に配置される。本実施の形態では、永久磁石４１５ａ、４１５ｂはそれぞれ等間隔に８個配置されており、回転子４００は８極になっている。 The magnetization direction of the permanent magnet 415 is radial, and the magnetization direction is reversed for each field pole. That is, if the stator side surface of the permanent magnet 415a is the north pole and the shaft side surface is the south pole, the adjacent permanent magnet 415b has the stator side surface of the south pole and the shaft side surface of the north pole. These permanent magnets 415a and 415b are alternately arranged in the circumferential direction. In this embodiment, eight permanent magnets 415a and 415b are arranged at regular intervals, and the rotor 400 has eight poles.
　永久磁石４１５は、磁化した後に回転子コア４０５に埋め込んでも良いし、磁化する前に回転子コア４０５に挿入した後に強力な磁界を与えて磁化してもよい。磁化後の永久磁石４１５は強力な磁石であり、回転子４００に永久磁石４１５を固定する前に磁石を着磁すると、永久磁石４１５の固定時に回転子コア４０５との間に強力な吸引力が生じ、この求心力が作業の妨げとなる。また強力な吸引力により、永久磁石４１５に鉄粉などのごみが付着する恐れがある。そのため、永久磁石４１５を回転子コア４０５に挿入した後に磁化する方が、回転電機の生産性が向上する。 The permanent magnet 415 may be embedded in the rotor core 405 after being magnetized, or may be magnetized by applying a strong magnetic field after inserting it into the rotor core 405 before magnetization. The magnetized permanent magnet 415 is a strong magnet, and if the magnet is magnetized before fixing the permanent magnet 415 to the rotor 400, a strong attractive force is generated between the permanent magnet 415 and the rotor core 405 when the permanent magnet 415 is fixed. This centripetal force interferes with work. Also, due to the strong attractive force, there is a risk that dust such as iron powder will adhere to the permanent magnet 415 . Therefore, magnetizing the permanent magnet 415 after inserting it into the rotor core 405 improves the productivity of the rotary electric machine.
　永久磁石４１５には、ネオジウム系、サマリウム系の焼結磁石やフェライト磁石、ネオジウム系のボンド磁石などを用いることができる。永久磁石４１５の残留磁束密度はほぼ０.４～１.３Ｔ程度である。 For the permanent magnet 415, a neodymium-based or samarium-based sintered magnet, a ferrite magnet, a neodymium-based bond magnet, or the like can be used. The residual magnetic flux density of the permanent magnet 415 is about 0.4-1.3T.
　図４は、回転子４００の製造工程を示す分解斜視図である。磁石挿入孔４１０には後述する加熱前発泡シート４４０Ｂが先に挿入され、その後に永久磁石４１５が挿入される。全ての磁石挿入孔４１０に加熱前発泡シート４４０Ｂおよび永久磁石４１５が挿入されると、エンドプレート４２０の中心にシャフト４３０を通し、エンドプレート４２０で回転子４００を封止する。 4 is an exploded perspective view showing the manufacturing process of the rotor 400. FIG. A preheated foam sheet 440B, which will be described later, is first inserted into the magnet insertion hole 410, and then the permanent magnet 415 is inserted. When pre-heating foam sheet 440B and permanent magnets 415 are inserted into all magnet insertion holes 410, shaft 430 is passed through the center of end plate 420, and rotor 400 is sealed with end plate 420. FIG.
　図５は、図３に示したＩＩＩ－ＩＩＩ断面図の拡大図であり、図５の下部にはさらなる拡大図を示している。図５は、図３と同様に回転電機２００のシャフト４３０方向から見た図である。 FIG. 5 is an enlarged view of the III-III cross-sectional view shown in FIG. 3, and a further enlarged view is shown at the bottom of FIG. FIG. 5 is a view of rotating electric machine 200 viewed from shaft 430, as in FIG.
　図５の下部に示すように、永久磁石４１５は発泡シート４４０により磁石挿入孔４１０に固定される。発泡シート４４０は、一体に形成される第１領域４４０－１と、第２領域４４０－２と、第３領域４４０－３とから構成される。第１領域４４０－１は、図５に示す視点において永久磁石４１５の短辺方向の面のうちいずれか一方側のみに形成される領域である。第２領域４４０－２は、図５に示す視点において永久磁石４１５の長辺方向の一方側に形成される領域である。第３領域４４０－３は、図５に示す視点において永久磁石４１５の長辺方向の他方側、すなわち第２領域４４０－２とは逆側に形成される領域である。 As shown in the lower part of FIG. 5, the permanent magnet 415 is fixed in the magnet insertion hole 410 with a foam sheet 440. The foam sheet 440 is composed of a first region 440-1, a second region 440-2 and a third region 440-3 which are integrally formed. The first area 440-1 is an area formed only on one side of the short-side direction surfaces of the permanent magnet 415 from the viewpoint shown in FIG. The second area 440-2 is an area formed on one side of the permanent magnet 415 in the long side direction from the viewpoint shown in FIG. The third area 440-3 is an area formed on the other side of the permanent magnet 415 in the long side direction from the viewpoint shown in FIG. 5, that is, on the side opposite to the second area 440-2.
　図６は、発泡シート４４０の構成を示す図である。発泡シート４４０は、板状の基材４４２の両面に加熱前発泡剤４４１Ａを配した、加熱前加工前発泡シート４４０Ａを用いて作成される。基材４４２は、ＰＥＮ（ポリエチレンナフタレート）やＰＩ（ポリイミド）などの単一樹脂でもよいし、貼り合わせ樹脂でもよい。貼り合わせ樹脂とはたとえば、Ｎｏｍｅｘ（登録商標）とＰＥＮの複合材であるＮＰＮである。加熱前発泡剤４４１Ａとは、所定の熱を加えることで発泡、すなわち膨張し、かつ発砲して接着力を有している材料である。なお発泡剤は、発泡樹脂や発泡接着剤とも呼ばれるので、加熱前発泡剤４４１Ａを「加熱前発泡樹脂」や「加熱前発泡接着剤」と呼び変えることもできる。 FIG. 6 is a diagram showing the configuration of the foam sheet 440. FIG. The foam sheet 440 is produced using a pre-heated pre-processed foam sheet 440A in which a pre-heated foaming agent 441A is placed on both sides of a plate-shaped base material 442 . The base material 442 may be a single resin such as PEN (polyethylene naphthalate) or PI (polyimide), or may be a bonded resin. The bonding resin is, for example, NPN, which is a composite material of Nomex (registered trademark) and PEN. The pre-heating foaming agent 441A is a material that foams, that is, expands and foams to have adhesive strength when a predetermined amount of heat is applied. Since the foaming agent is also called a foaming resin or a foaming adhesive, the pre-heating foaming agent 441A can also be called a "pre-heating foaming resin" or a "pre-heating foaming adhesive".
　本実施の形態では、板状の加熱前加工前発泡シート４４０Ａを略Ｕの字状に曲げ加工し、加熱前発泡シート４４０Ｂを形成する。そしてこの加熱前発泡シート４４０Ｂを磁石挿入孔４１０に挿入し、その後に永久磁石４１５を同じく磁石挿入孔４１０に挿入し、さらに後に所定の熱を加えることで、永久磁石４１５を磁石挿入孔４１０に固定する発泡シート４４０が得られる。 In the present embodiment, a plate-shaped pre-heating pre-processed foamed sheet 440A is bent into a substantially U shape to form a pre-heated foamed sheet 440B. Then, the pre-heating foamed sheet 440B is inserted into the magnet insertion hole 410, and then the permanent magnet 415 is similarly inserted into the magnet insertion hole 410. After that, a predetermined heat is applied to the permanent magnet 415 into the magnet insertion hole 410. An anchoring foam sheet 440 is obtained.
　発泡シート４４０を形成した後の回転子４００の製造方法は、次の第１工程～第３工程を含む。この３つの工程は、まず第１工程が行われ、次に第２工程が行われ、最後に第３工程が行われる。加熱前発泡シート４４０Ｂを磁石挿入孔４１０に挿入することを「第１工程」と呼び、永久磁石４１５を磁石挿入孔４１０に挿入することを「第２工程」と呼び、所定の熱を加えることを「第３工程」と呼ぶ。基材４４２の両面に配された加熱前発泡剤４４１Ａは、所定の熱が加えられることで発泡し、永久磁石４１５と磁石挿入孔４１０の内周との間を埋める。 The manufacturing method of the rotor 400 after forming the foam sheet 440 includes the following first to third steps. As for these three processes, first the first process is performed, then the second process is performed, and finally the third process is performed. Inserting the preheated foam sheet 440B into the magnet insertion hole 410 is called a "first step", inserting the permanent magnet 415 into the magnet insertion hole 410 is called a "second step", and applying a predetermined amount of heat. is called "third step". The pre-heating foaming agents 441 A provided on both sides of the base material 442 are foamed by applying a predetermined amount of heat, and fill the spaces between the permanent magnets 415 and the inner circumferences of the magnet insertion holes 410 .
　上述した第１の実施の形態によれば、次の作用効果が得られる。
（１）回転電機２００の回転子４００は、永久磁石４１５が挿入される磁石挿入孔４１０が形成される回転子コア４０５と、永久磁石４１５を穴部に固定する固定部材である発泡シート４４０と、を備える。発泡シート４４０は、永久磁石４１５に対向する表面および表面とは逆側の裏面を有するシート状の基材４４２、表面に配される表側接着剤、および裏面に配される裏側接着剤を含む。表側接着剤および裏側接着剤は、発泡接着剤４４１である。発泡シート４４０は、回転電機２００の軸方向から見た永久磁石４１５の短手方向に略直行するいずれかの面に接する第１領域４４０－１と、回転電機２００の軸方向から見た永久磁石４１５の長手方向に略直行するいずれかの面に接する第２領域４４０－２と、を含み、第１領域４４０－１および第２領域４４０－２が一体に形成される。そのため回転子４００は、磁石挿入孔４１０に挿入された加熱前発泡接着剤４４１Ａに所定の熱を加えて発泡接着剤４４１を得ることができるので、回転子４００の製造が容易である。すなわち回転電機２００の回転子４００は、製造が容易な回転子４００の製造を有する。また発泡接着剤４４１は、液体の接着剤とは異なり微細な隙間には入り込みにくいので、電磁鋼板が積層された回転子コア４０５の鋼板同士の隙間に入り込みにくい。さらに回転子４００は発泡接着剤４４１により強固に固定されるので、永久磁石４１５が磁石挿入孔４１０と接触して摩耗することで生じる回転電機２００の性能低下を防止できる。 According to the first embodiment described above, the following effects are obtained.
(1) Rotor 400 of rotary electric machine 200 includes rotor core 405 formed with magnet insertion hole 410 into which permanent magnet 415 is inserted, and foam sheet 440 as a fixing member for fixing permanent magnet 415 in the hole. , provided. The foam sheet 440 includes a sheet-like base material 442 having a surface facing the permanent magnet 415 and a back surface opposite to the surface, a front adhesive applied to the surface, and a back adhesive applied to the back surface. The front side adhesive and the back side adhesive are foamed adhesives 441 . Foam sheet 440 includes a first region 440-1 in contact with any surface substantially perpendicular to the short side direction of permanent magnet 415 viewed from the axial direction of rotating electrical machine 200, and a permanent magnet viewed from the axial direction of rotating electrical machine 200. and a second region 440-2 contacting one of the faces substantially perpendicular to the longitudinal direction of 415, and the first region 440-1 and the second region 440-2 are integrally formed. Therefore, the rotor 400 can obtain the foamed adhesive 441 by applying a predetermined amount of heat to the pre-heated foamed adhesive 441A inserted in the magnet insertion hole 410, so that the rotor 400 can be easily manufactured. That is, the rotor 400 of the rotary electric machine 200 has a manufacture of the rotor 400 which is easy to manufacture. Further, unlike a liquid adhesive, the foamed adhesive 441 does not easily enter into fine gaps, so it is difficult to enter into the gaps between the steel plates of the rotor core 405 in which electromagnetic steel plates are laminated. Furthermore, since the rotor 400 is firmly fixed by the foaming adhesive 441, it is possible to prevent the performance of the rotating electric machine 200 from deteriorating due to the permanent magnets 415 coming into contact with the magnet insertion holes 410 and being worn.
（２）表側接着剤および裏側接着剤の両方が発泡接着剤である。そのため、基材４４２の両面に発泡接着剤を用いるので、永久磁石４１５をより強固に固定できる。 (2) Both the front side adhesive and the back side adhesive are foamed adhesives. Therefore, since the foam adhesive is used on both sides of the base material 442, the permanent magnets 415 can be fixed more firmly.
（３）発泡シート４４０は、永久磁石４１５を挟んで第１領域の逆側に配される第３領域４４０－３を含む。第１領域４４０－１、第２領域４４０－２、および第３領域４４０－３は一体に形成される。そのため、永久磁石４１５の長辺方向を両側から発泡接着剤で挟み込み、永久磁石４１５が磁石挿入孔４１０と接触して摩耗することをより確実に防止できる。 (3) The foam sheet 440 includes a third region 440-3 arranged on the opposite side of the first region with the permanent magnet 415 interposed therebetween. The first region 440-1, the second region 440-2 and the third region 440-3 are integrally formed. Therefore, the long side direction of the permanent magnet 415 can be sandwiched with the foam adhesive from both sides, and the permanent magnet 415 can be prevented from coming into contact with the magnet insertion hole 410 and being worn out more reliably.
（４）磁石挿入孔４１０を回転電機２００の軸方向に貫通し、かつ永久磁石４１５に接する空隙である磁気的空隙４１６が設けられる。そのため、磁気的空隙４１６に冷却媒体を流して永久磁石４１５を効率よく冷却できる。永久磁石４１５を冷却することを前提とすれば、安価な保磁力が弱い磁石や重希土類フリーの磁石を使用できる。 (4) A magnetic air gap 416 is provided which penetrates the magnet insertion hole 410 in the axial direction of the rotating electric machine 200 and is in contact with the permanent magnet 415 . Therefore, the permanent magnet 415 can be efficiently cooled by flowing a cooling medium through the magnetic gap 416 . Assuming that the permanent magnet 415 is cooled, an inexpensive magnet with weak coercive force or a magnet free of heavy rare earth elements can be used.
（５）基材４４２の永久磁石４１５側の接着剤である表側接着剤は発泡接着剤である。表側接着剤は、永久磁石４１５を磁石挿入孔４１０に内壁に付勢する。そのため、永久磁石４１５の位置および姿勢を固定しやすい。 (5) The front side adhesive, which is the adhesive on the permanent magnet 415 side of the base material 442, is foamed adhesive. The front-side adhesive urges the permanent magnet 415 against the inner wall of the magnet insertion hole 410 . Therefore, it is easy to fix the position and attitude of the permanent magnet 415 .
（６）基材４４２は、単一樹脂または張り合わせ樹脂である。単一樹脂とは、ポリエチレンナフタレートおよびポリイミドのいずれかである。張り合わせ樹脂とは、Ｎｏｍｅｘ（登録商標）とポリエチレンナフタレートの複合材である。 (6) Substrate 442 is a single resin or a laminate resin. A single resin is either polyethylene naphthalate or polyimide. The lamination resin is a composite material of Nomex (registered trademark) and polyethylene naphthalate.
（７）永久磁石４１５が挿入される磁石挿入孔４１０が形成される回転子コア４０５、および永久磁石４１５を磁石挿入孔４１０に固定する発泡シート４４０を備える回転電機２００の回転子４００の製造方法は、加熱前発泡シート４４０Ｂの少なくとも一部を磁石挿入孔４１０に挿入する第１工程と、第１工程の後に、永久磁石４１５を穴部に挿入する第２工程と、を含む。発泡シート４４０は、永久磁石４１５に対向する表面および表面とは逆側の裏面を有するシート状の基材４４２、表面に配される表側接着剤、および裏面に配される裏側接着剤を含み、表側接着剤および裏側接着剤は発泡接着剤４４１である。発泡シート４４０は、回転電機２２０の軸方向から見た永久磁石４１５の短手方向に略直行するいずれかの面に接する第１領域４４０－１と、回転電機の軸方向から見た永久磁石４１５の長手方向に略直行するいずれかの面に接する第２領域４４０－２と、を含む。第１領域４４０－１および第２領域４４０－２が一体に形成される。そのため、回転子コア４０５における磁石挿入孔４１０の淵にバリがあった場合でも、先に挿入する加熱前発泡シート４４０Ｂはバリに接触させることなく磁石挿入孔４１０に挿入することが容易なため、加熱前発泡シート４４０Ｂから加熱前発泡剤４４１Ａが剥離することを防止できる。 (7) Manufacturing method of rotor 400 of rotary electric machine 200 including rotor core 405 formed with magnet insertion holes 410 into which permanent magnets 415 are inserted, and foam sheet 440 fixing permanent magnets 415 to magnet insertion holes 410 includes a first step of inserting at least part of the preheated foamed sheet 440B into the magnet insertion hole 410, and a second step of inserting the permanent magnet 415 into the hole after the first step. The foam sheet 440 includes a sheet-like base material 442 having a surface facing the permanent magnet 415 and a back surface opposite to the surface, a front adhesive disposed on the surface, and a back adhesive disposed on the back surface, The front side adhesive and the back side adhesive are foamed adhesives 441 . The foam sheet 440 has a first region 440-1 in contact with one of the surfaces substantially perpendicular to the short side direction of the permanent magnet 415 seen from the axial direction of the rotating electrical machine 220, and the permanent magnet 415 seen from the axial direction of the rotating electrical machine. and a second region 440-2 in contact with any surface substantially perpendicular to the longitudinal direction of the . A first region 440-1 and a second region 440-2 are integrally formed. Therefore, even if there is a burr at the edge of the magnet insertion hole 410 in the rotor core 405, the preheated foam sheet 440B to be inserted first can be easily inserted into the magnet insertion hole 410 without contacting the burr. It is possible to prevent the pre-heating foaming agent 441A from peeling from the pre-heating foam sheet 440B.
（変形例１）
　図７は、変形例２におけるＩＩＩ－ＩＩＩ断面図の拡大図である。図７に示すように、本変形例では、発泡シート４４０が第３領域を有さず、略Ｌ字の形状を有する。本変形例では発泡シート４４０は第３領域を有さないので、発泡シート４４０を小さくでき、材料コストを低減し、さらに生産性を向上できる。本変形例では発泡シート４４０が第３領域を有さないが、永久磁石４１５の短辺側と長辺側の両方に発泡接着剤４４１が存在するので、いずれの方向にも永久磁石４１５の移動を制限する機能を有する。 (Modification 1)
FIG. 7 is an enlarged view of the III-III cross-sectional view in Modification 2. FIG. As shown in FIG. 7, in this modification, the foam sheet 440 does not have the third region and has a substantially L shape. Since the foam sheet 440 does not have the third region in this modified example, the foam sheet 440 can be made smaller, the material cost can be reduced, and the productivity can be improved. In this modification, the foam sheet 440 does not have the third region, but since the foam adhesive 441 exists on both the short side and the long side of the permanent magnet 415, the permanent magnet 415 can move in either direction. has the function of limiting
（変形例２）
　図８は、変形例２におけるＩＩＩ－ＩＩＩ断面図の拡大図である。図８に示すように、本変形例では、永久磁石４１５の断面が長方形ではなく円弧状である。本変形例では、円弧状の永久磁石４１５の外形にあわせて加熱前発泡シート４４０Ｂの形状を作成する。磁石挿入孔４１０に挿入する順番は実施の形態と同様であり、先に加熱前発泡シート４４０Ｂを挿入し、後から永久磁石４１５を挿入する。さらにその後に加熱前発泡シート４４０Ｂに所定の熱を加えて発泡シート４４０が得られる。発泡シート４４０は、図８における永久磁石４１５の下部が第１領域４４０－１、図示右側が第２領域４４０－２、そして図示左側が第３領域４４０－３である。 (Modification 2)
FIG. 8 is an enlarged view of the III-III cross-sectional view in Modification 2. FIG. As shown in FIG. 8, in this modification, the cross section of the permanent magnet 415 is arc-shaped instead of rectangular. In this modified example, the shape of the pre-heating foam sheet 440B is created according to the outer shape of the arcuate permanent magnet 415 . The order of insertion into the magnet insertion holes 410 is the same as in the embodiment. The pre-heating foam sheet 440B is inserted first, and the permanent magnets 415 are inserted afterwards. After that, a predetermined amount of heat is applied to pre-heating foam sheet 440B to obtain foam sheet 440. FIG. The foam sheet 440 has a first region 440-1 below the permanent magnet 415 in FIG. 8, a second region 440-2 on the right side in the drawing, and a third region 440-3 on the left side in the drawing.
（８）永久磁石４１５は、回転電機２００の軸方向から見た場合に円弧状である。加熱前発泡シート４４０Ｂは任意の形状に加工できるので、断面が円弧状の永久磁石４１５に沿った形状にも加工できる。そして、永久磁石４１５と加熱前発泡シート４４０Ｂとを磁石挿入孔４１０に挿入した後に加熱前発泡シート４４０Ｂに熱を加えることで、永久磁石４１５の形状によらず磁石挿入孔４１０に固定できる。 (8) Permanent magnet 415 has an arc shape when viewed from the axial direction of rotating electric machine 200 . Since the pre-heating foam sheet 440B can be processed into an arbitrary shape, it can also be processed into a shape along the permanent magnet 415 having an arc-shaped cross section. By inserting the permanent magnet 415 and the pre-heating foam sheet 440B into the magnet insertion hole 410 and then heating the pre-heating foam sheet 440B, the permanent magnet 415 can be fixed to the magnet insertion hole 410 regardless of its shape.
（変形例３）
　上述した実施の形態では、基材４４２の両面に発泡接着剤４４１が配された。しかし基材４４２の両面の少なくとも一面に発泡接着剤４４１が配されればよく、発泡接着剤４４１が配されない面には、代わりに液体接着剤など他の種類の接着剤が配されてもよい。 (Modification 3)
In the embodiment described above, foamed adhesive 441 was placed on both sides of substrate 442 . However, the foaming adhesive 441 may be applied to at least one surface of both surfaces of the substrate 442, and other types of adhesive such as liquid adhesive may be applied to the surfaces on which the foaming adhesive 441 is not applied. .
　上述した実施の形態および変形例は、それぞれ組み合わせてもよい。上記では、種々の実施の形態および変形例を説明したが、本発明はこれらの内容に限定されるものではない。本発明の技術的思想の範囲内で考えられるその他の態様も本発明の範囲内に含まれる。 The embodiments and modifications described above may be combined. Although various embodiments and modifications have been described above, the present invention is not limited to these contents. Other aspects conceivable within the scope of the technical idea of the present invention are also included in the scope of the present invention.
２００　回転電機
４００　回転子
４０５　回転子コア
４０５ａ　貫通孔
４１０　磁石挿入孔
４１５　永久磁石
４１６　磁気的空隙
４２０　エンドプレート
４３０　回転軸、シャフト
４４０　発泡シート
４４０－１　第１領域
４４０－２　第２領域
４４０－３　第３領域
４４０Ａ　加熱前加工前発泡シート
４４０Ｂ　加熱前発泡シート
４４１　　発泡接着剤
４４１Ａ　加熱前発泡剤
４４２　基材 200 rotating electric machine 400 rotor 405 rotor core 405a through hole 410 magnet insertion hole 415 permanent magnet 416 magnetic gap 420 end plate 430 rotating shaft, shaft 440 foam sheet 440-1 first region 440-2 second region 440-3 Third region 440A Pre-heating pre-processed foamed sheet 440B Pre-heated foamed sheet 441 Foamed adhesive 441A Pre-heated foaming agent 442 Base material

Claims (8)

  1. 　磁石が挿入される穴部が形成される回転子コアと、
    　前記磁石を前記穴部に固定する固定部材と、を備える回転電機の回転子であって、
    　前記固定部材は、前記磁石に対向する表面および前記表面とは逆側の裏面を有するシート状の基材、前記表面に配される表側接着剤、および前記裏面に配される裏側接着剤を含み、
    　前記表側接着剤および前記裏側接着剤の少なくとも一方は発泡接着剤であり、
    　前記固定部材は、前記回転電機の軸方向から見た前記磁石の短手方向に略直行するいずれかの面に接する第１領域と、前記回転電機の軸方向から見た前記磁石の長手方向に略直行するいずれかの面に接する第２領域と、を含み、
    　前記第１領域および前記第２領域が一体に形成される、回転電機の回転子。     a rotor core formed with holes into which magnets are inserted;
    A rotor for a rotating electrical machine, comprising a fixing member that fixes the magnet to the hole,
    The fixing member includes a sheet-like base material having a surface facing the magnet and a back surface opposite to the surface, a front adhesive applied to the surface, and a back adhesive applied to the back surface. ,
    at least one of the front side adhesive and the back side adhesive is a foamed adhesive;
    The fixing member has a first region in contact with any surface substantially perpendicular to the lateral direction of the magnet viewed from the axial direction of the rotating electrical machine, and a first region in the longitudinal direction of the magnet viewed from the axial direction of the rotating electrical machine. a second region in contact with any substantially orthogonal surface,
    A rotor of a rotating electric machine, wherein the first region and the second region are integrally formed.
  2. 　請求項１に記載の回転電機の回転子において、
    　前記前記表側接着剤および前記裏側接着剤の両方が発泡接着剤である、回転電機の回転子。     In the rotor of the rotary electric machine according to claim 1,
    A rotor for a rotating electric machine, wherein both the front side adhesive and the back side adhesive are foamed adhesives.
  3. 　請求項１に記載の回転電機の回転子において、
    　前記固定部材は、前記磁石を挟んで前記第１領域の逆側に配される第３領域をさらに含み、
    　前記第１領域、前記第２領域、および前記第３領域は一体に形成される、回転電機の回転子。     In the rotor of the rotary electric machine according to claim 1,
    The fixing member further includes a third region disposed on the opposite side of the first region across the magnet,
    A rotor of a rotating electric machine, wherein the first region, the second region, and the third region are integrally formed.
  4. 　請求項１に記載の回転電機の回転子において、
    　前記穴部を前記回転電機の軸方向に貫通し、かつ前記磁石に接する空隙が設けられる、回転電機の回転子。     In the rotor of the rotary electric machine according to claim 1,
    A rotor for a rotating electric machine, wherein a gap is provided that passes through the hole in the axial direction of the rotating electric machine and is in contact with the magnet.
  5. 　請求項１に記載の回転電機の回転子において、
    　前記磁石は、前記回転電機の軸方向から見た場合に円弧状である、回転電機の回転子。     In the rotor of the rotary electric machine according to claim 1,
    The rotor of a rotating electrical machine, wherein the magnet is arc-shaped when viewed from the axial direction of the rotating electrical machine.
  6. 　請求項１に記載の回転電機の回転子において、
    　前記表側接着剤は発泡接着剤であり、
    　前記表側接着剤は、前記磁石を前記穴部に付勢する、回転電機の回転子。     In the rotor of the rotary electric machine according to claim 1,
    The front adhesive is a foam adhesive,
    The rotor of a rotating electric machine, wherein the front-side adhesive urges the magnet toward the hole.
  7. 　請求項１に記載の回転電機の回転子において、
    　前記基材は、単一樹脂または張り合わせ樹脂であり、
    　前記単一樹脂とは、ポリエチレンナフタレートおよびポリイミドのいずれかであり、
    　前記張り合わせ樹脂とは、Ｎｏｍｅｘ（登録商標）とポリエチレンナフタレートの複合材である、回転電機の回転子。     In the rotor of the rotary electric machine according to claim 1,
    The base material is a single resin or a laminated resin,
    The single resin is either polyethylene naphthalate or polyimide,
    The lamination resin is a rotor of a rotary electric machine, which is a composite material of Nomex (registered trademark) and polyethylene naphthalate.
  8. 　磁石が挿入される穴部が形成される回転子コア、および前記磁石を前記穴部に固定する固定部材を備える回転電機の回転子の製造方法であって、
    　加熱前の前記固定部材の少なくとも一部を前記穴部に挿入する第１工程と、
    　前記第１工程の後に、前記磁石を前記穴部に挿入する第２工程と、を含み、
    　前記固定部材は、前記磁石に対向する表面および前記表面とは逆側の裏面を有するシート状の基材、前記表面に配される表側接着剤、および前記裏面に配される裏側接着剤を含み、
    　前記表側接着剤および前記裏側接着剤の少なくとも一方は発泡接着剤であり、
    　前記固定部材は、前記回転電機の軸方向から見た前記磁石の短手方向に略直行するいずれかの面に接する第１領域と、前記回転電機の軸方向から見た前記磁石の長手方向に略直行するいずれかの面に接する第２領域と、を含み、
    　前記第１領域および前記第２領域が一体に形成される、回転電機の回転子の製造方法。     A method for manufacturing a rotor for a rotating electrical machine, comprising: a rotor core having holes into which magnets are inserted; and a fixing member fixing the magnets to the holes, the method comprising:
    a first step of inserting at least part of the fixing member before heating into the hole;
    a second step of inserting the magnet into the hole after the first step;
    The fixing member includes a sheet-like base material having a surface facing the magnet and a back surface opposite to the surface, a front adhesive applied to the surface, and a back adhesive applied to the back surface. ,
    at least one of the front side adhesive and the back side adhesive is a foamed adhesive;
    The fixing member has a first region in contact with any surface substantially perpendicular to the lateral direction of the magnet viewed from the axial direction of the rotating electrical machine, and a first region in the longitudinal direction of the magnet viewed from the axial direction of the rotating electrical machine. a second region in contact with any substantially orthogonal surface,
    A method of manufacturing a rotor for a rotating electric machine, wherein the first region and the second region are integrally formed.
PCT/JP2022/003874 2021-02-01 2022-02-01 Rotor of rotating electrical machine and method for manufacturing rotor of rotating electrical machine WO2022163868A1 (en)

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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS53118713A (en) * 1977-03-28 1978-10-17 Ina Sankyo Kk Method of fixing magnet body in compact motor
JP2005218274A (en) * 2004-02-02 2005-08-11 Toyota Motor Corp Rotor of rotary electric machine
JP2020115712A (en) * 2019-01-17 2020-07-30 本田技研工業株式会社 Rotor
JP2021083222A (en) * 2019-11-19 2021-05-27 アイシン・エィ・ダブリュ株式会社 Rotor core and method for manufacturing rotor core

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS53118713A (en) * 1977-03-28 1978-10-17 Ina Sankyo Kk Method of fixing magnet body in compact motor
JP2005218274A (en) * 2004-02-02 2005-08-11 Toyota Motor Corp Rotor of rotary electric machine
JP2020115712A (en) * 2019-01-17 2020-07-30 本田技研工業株式会社 Rotor
JP2021083222A (en) * 2019-11-19 2021-05-27 アイシン・エィ・ダブリュ株式会社 Rotor core and method for manufacturing rotor core

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