WO2022254679A1

WO2022254679A1 - Rotor and method for manufacturing rotor

Info

Publication number: WO2022254679A1
Application number: PCT/JP2021/021301
Authority: WO
Inventors: 一輝藤本; 遼並河; 太一徳久; 竜児内村; 慎太郎穴井; 純鶴羽
Original assignee: 三菱電機株式会社
Priority date: 2021-06-04
Filing date: 2021-06-04
Publication date: 2022-12-08
Also published as: JPWO2022254679A1; JP7418663B2

Abstract

This rotor comprises: a shaft; a rotor core assembly body having two rotor cores arranged in the axial direction of the shaft and attached to the outer circumferential surface of the shaft; magnets housed in the respective two rotors; and end plates disposed on both sides of the rotor core assembly body in the axial direction. The two rotor cores are respectively provided with insertion holes for the magnets. The rotor core assembly body has: an intermediate plate disposed between the two rotor cores and formed of a non-magnetic material; and a first fastening component fastening the two rotor cores and the intermediate plate to each other and having a projection portion projecting from the two rotor cores in the axial direction. The intermediate plate and the two rotor cores are provided with a first hole into which the first fastening component is inserted, wherein the diameter of the first hole of the two rotor cores is smaller than the diameter of the projection portion. The end plate is provided with a sidestep hole having a larger diameter than the diameter of the projection portion of the first fastening component. The end plate is provided so as to partially or entirely cover the insertion holes formed in the rotor cores. The projection portion of the first fastening component is disposed in the sidestep hole of the end plate. The rotor core assembly body is attached to the shaft in such a way that the two rotor cores are directly shrink-fitted to the shaft.

Description

Rotor and rotor manufacturing method

The present disclosure relates to a rotor containing magnets, and a method for manufacturing the rotor, which is used, for example, in a rotating electric machine.

Among rotors used in rotating electric machines such as motors, there is an IPM (Interior Permanent Magnet) rotor in which permanent magnets are embedded inside the rotor core. In such a rotor, eddy currents are generated in the rotor core during operation, and when the eddy currents are generated, energy loss, that is, eddy current loss occurs due to the electrical resistance of the rotor core. In order to suppress eddy current loss, for example, there is a rotor provided with a plurality of rotor cores in which a plurality of electromagnetic steel sheets are laminated. In such a rotor, a non-magnetic intermediate plate is provided between two rotor cores in which magnets are inserted, and non-magnetic end plates are provided at both ends of the two rotor cores sandwiching the intermediate plate. There are some (for example, see Patent Document 1). By providing the non-magnetic end plate and intermediate plate, it is possible to prevent the magnet from jumping out of the insertion hole of the rotor core, and to divide the magnet to reduce the eddy current flowing between the rotor cores during motor operation. . In the rotor of Patent Document 1, the end plates and intermediate plates are fixed to the shaft, respectively, and the rotor core is fixed to the end plates and intermediate plates with screws and spring pins and held by the end plates and intermediate plates.

JP-A-04-364335

In the rotor of Patent Document 1, press-fitting or shrink-fitting is available as a method of fixing the end plates and the intermediate plate to the shaft. Therefore, shrink fitting is selected for large motors. As in Patent Document 1, in a rotor in which the end plates and intermediate plates are fixed to the shaft and the rotor core is held by the end plates and intermediate plates, it is assumed that the intermediate plates, the rotor core, and the end plates are sintered in an integrated state. Once fitted, the heat will degrade the properties of the magnet. Therefore, in order to minimize the deterioration of the characteristics of the magnet due to the heat generated during shrink fitting in the rotor of Patent Document 1, first, the intermediate plate is shrink fitted to the shaft and cooled, and then the magnet is placed in the shaft. The rotor is manufactured by a process of arranging the rotor core on both sides of the intermediate plate, shrink-fitting the end plates to the shaft, and cooling. Therefore, in the rotor of Patent Document 1, when the rotor core is attached to the shaft, it is necessary to perform the process of shrink fitting and cooling two or more times, so there is a problem in productivity, and the second shrink fitting involves inserting a magnet. It is also difficult to suppress the deterioration of the characteristics of the magnet because it is performed in a state in which the magnet is held.

The present disclosure has been made to solve the problems described above, and in a rotor in which magnets are housed in a rotor core, it is possible to improve productivity and to suppress the deterioration of magnet characteristics more than before. It is an object of the present invention to provide a rotor and a method for manufacturing the rotor.

A rotor according to the present disclosure includes a shaft and two rotor cores arranged in the axial direction of the shaft, a rotor core assembly attached to the outer peripheral surface of the shaft, and magnets housed in each of the two rotor cores. and end plates disposed on both sides of the rotor core assembly in the axial direction, the two rotor cores each being provided with an insertion hole for the magnet, and the rotor core assembly comprising the two rotor cores. and an intermediate plate made of a non-magnetic material, which is arranged between the 1 fastening component, wherein the intermediate plate and the two rotor cores are provided with a first hole into which the first fastening component is inserted, and the diameter of the first hole in the two rotor cores is equal to the projection The end plate is provided with a deflecting hole having a diameter smaller than the diameter of the projection portion of the first fastening component and larger than the diameter of the projection portion of the first fastening component, and the end plate is formed in the insertion hole formed in the rotor core. The protrusion of the first fastening part is arranged in the dodge hole of the end plate, and the rotor core assembly is such that the two rotor cores are directly sintered to the shaft. It is attached to the shaft by being fitted.
Further, in a method for manufacturing a rotor according to the present disclosure, two rotor cores arranged in the axial direction of a shaft and an intermediate plate disposed between the two rotor cores and made of a non-magnetic material are arranged in the intermediate plate. and a first step of obtaining a rotor core assembly by inserting first fastening parts into first holes provided in the two rotor cores and fastening them with the first fastening parts; and directly attaching the two rotor cores to the shaft. a second step of attaching the rotor core assembly to the outer peripheral surface of the shaft by shrink fitting; and a third step of accommodating magnets in each of the two rotor cores through insertion holes provided in the two rotor cores. , end plates are arranged on both sides of the rotor core assembly in the axial direction so as to block part or all of the insertion holes, and portions of the first fastening component protruding from the two rotor cores, and a fourth step of arranging a projection having a diameter larger than that of the first hole in step 4 in a deflecting hole having a diameter larger than that of the projection provided in the end plate.

According to the present disclosure, the rotor core assembly has a first fastening part that fastens two rotor cores and an intermediate plate, and the two rotor cores are shrink-fitted directly onto the shaft without interposing the end plate and the intermediate plate. The end plate is provided with a bypass hole having a diameter larger than the diameter of the protrusion of the first fastener, and the protrusion of the first fastener is disposed in the bypass hole of the end plate. be. Therefore, after shrink-fitting the intermediate plate and the two rotor cores in an integrated state, the magnets are inserted through the insertion holes of the respective rotor cores. The end plate can be placed without interfering with the part. Therefore, since only one shrink-fitting step is required when attaching the rotor core assembly to the shaft, the productivity is high, and deterioration of the magnet characteristics due to heat can be suppressed more than before.

1 is a schematic diagram showing a schematic configuration of a rotor according to Embodiment 1; FIG. FIG. 2 is a cross-sectional view of the rotor cut along the AA cross section passing through the central axis shown in FIG. 1; 2 is a schematic view of the end plate of FIG. 1; FIG. 3 is an enlarged view of a Q1 portion shown in FIG. 2; FIG. FIG. 3 is an enlarged view of a Q2 portion shown in FIG. 2; FIG. 3 is an enlarged view of a Q3 portion shown in FIG. 2; 3 is an enlarged view of a Q4 portion shown in FIG. 2; FIG. FIG. 2 is a cross-sectional view of the rotor taken along section BB through the insertion hole shown in FIG. 1; FIG. 2 is an explanatory diagram for explaining a first step of the manufacturing process of the rotor shown in FIG. 1; FIG. 2 is an explanatory view explaining a second step of the manufacturing process of the rotor shown in FIG. 1; FIG. 3 is an explanatory view explaining a third step of the manufacturing process of the rotor shown in FIG. 1; FIG. 11 is an explanatory view explaining a fourth step of the manufacturing process of the rotor shown in FIG. 1; FIG. 5 is a schematic diagram of an end plate of a rotor according to Embodiment 2; FIG. 11 is a schematic diagram showing a schematic configuration of a rotor according to Embodiment 3;

An embodiment of the rotor 100 according to the present disclosure will be described below with reference to the drawings. It should be noted that the present disclosure is not limited by the forms of the drawings shown below. Also, in each figure, the same reference numerals denote the same or corresponding parts, which are common throughout the specification.

Embodiment 1.
FIG. 1 is a schematic diagram showing a schematic configuration of a rotor 100 according to Embodiment 1. FIG. FIG. 2 is a cross-sectional view of the rotor 100 cut along the AA cross section passing through the central axis Ax shown in FIG. In the following description, the direction in which the central axis Ax of the rotor 100 extends is called the axial direction (direction of arrow X in FIG. 2), the direction perpendicular to the central axis Ax is called the radial direction, and the direction around the central axis Ax is called the circumferential direction. Further, in the following description, for ease of understanding, the right side in the axial direction and the right side in the plane of FIG. 2 will be referred to as the right side, and the other side in the axial direction and the left side in the plane of FIG. There is

As shown in FIG. 2, the rotor 100 includes a rotor section 20 having two axially arranged

rotor cores

2a and 2b, and a shaft 1 extending along a central axis Ax and serving as a rotation axis of the rotor section 20. , two bearings 3 supporting the shaft 1 . The rotor part 20 and the two bearings 3 are each attached to the shaft 1 .

As shown in FIG. 1, the bearing 3 has a cylindrical shape with a central shaft hole 3a. As shown in FIG. 20 are spaced apart. In the example shown in FIG. 2 , one bearing 3 is fixed to the axial right end of the shaft 1 , and the other bearing 3 is fixed near the axial center of the shaft 1 .

The rotor 100 constitutes a part of a rotating electric machine such as a motor, and is rotatably installed around the central axis Ax via two bearings 3 in the housing of the rotating electric machine. The rotor section 20 is a so-called IPM (Interior Permanent Magnet) rotor in which a permanent magnet is inserted.

As shown in FIGS. 1 and 2, the rotor section 20 has a cylindrical shape with a shaft hole 14a in the center into which the shaft 1 is inserted. As shown in FIG. 2, the rotor portion 20 includes a rotor core assembly 14 having a cylindrical shape attached to the outer peripheral surface of the shaft 1, and magnets 12 (described later) housed in the

rotor cores

2a and 2b of the rotor core assembly 14. 8), and

end plates

5a and 5b arranged on both sides of the rotor core assembly 14 in the axial direction (arrow X direction). The rotor portion 20 also includes a fastening component (hereinafter referred to as a second fastening component 8) that fastens the rotor core assembly 14 and the two

end plates

5a and 5b.

In the example shown in FIG. 2, from the left, the left side of the rotor core assembly 14 and the right side of the end plate 5a are in contact, and the right side of the rotor core assembly 14 and the left side of the end plate 5b are in contact. To the right, the end plate 5a, the rotor core assembly 14 and the end plate 5b are arranged in this order. Hereinafter, the end plate 5a and the end plate 5b may be simply referred to as the end plate 5 when there is no particular need to distinguish between the end plate 5a and the end plate 5b.

As shown in FIG. 2, the rotor core assembly 14 includes two

rotor cores

2a and 2b arranged in the axial direction (direction of arrow X), an intermediate plate 4 arranged between the two

rotor cores

2a and 2b, have. In the example shown in FIG. 2, the rotor cores are arranged from left to right so that the left side surface of the intermediate plate 4 and the right side surface of the rotor core 2a are in contact, and the right side surface of the intermediate plate 4 is in contact with the left side surface of the rotor core 2b. 2a, intermediate plate 4 and rotor core 2b. Hereinafter, the

rotor cores

2a and 2b may be simply referred to as rotor cores 2 when there is no particular need to distinguish between the

rotor cores

2a and 2b.

The rotor core 2 is composed of a plurality of electromagnetic steel sheets laminated in the axial direction (direction of arrow X). The rotor core 2 is formed with insertion holes 13a (see FIG. 1) in which magnets 12 (see FIG. 8 to be described later) are accommodated so as to penetrate in the axial direction (direction of arrow X).

The intermediate plate 4 is made of a non-magnetic plate-like member, and has, for example, a disc shape with a hole in the center for inserting the shaft 1 . The intermediate plate 4 is provided so as to block at least a portion of the insertion hole 13a (see FIG. 1) provided in each

rotor core

2a, 2b.

Generally, the magnitude of the eddy currents generated in the

rotor cores

2a, 2b is proportional to the square of the plate thickness of the

rotor cores

2a, 2b. Therefore, as described above, the rotor section 20 is configured such that the magnets 12 and the rotor core 2 are divided into a plurality of parts by the non-magnetic intermediate plate 4, thereby reducing the thickness of each rotor core 2 and reducing the eddy current. can be made smaller. Therefore, eddy current loss generated in the rotor portion 20 during operation of the rotating electric machine can be suppressed.

The rotor core assembly 14 also has a fastening component (hereinafter referred to as a first fastening component 7) for fastening the two

rotor cores

2a, 2b and the intermediate plate 4 together. The first fastening component 7 is composed of, for example, a threaded bolt 71 and a nut 72, and fixes the rotor core 2a, the intermediate plate 4, and the rotor core 2b by sandwiching them from both sides in the axial direction. A rotor core assembly 14 having a cylindrical shape is fixed by shrink fitting to the shaft 1 inserted into the shaft hole 14a.

Shrink fitting is a type of fitting method between a shaft (e.g., shaft 1) and a hole (e.g., shaft hole 14a). At room temperature, a hole that is smaller than the shaft is heated and expanded to fit and firmly join. The method. When the shaft 1 and the rotor core assembly 14 are shrink-fitted and then cooled, the two become fixed and firmly fixed to each other and cannot be disassembled.

A second fastening part 8 for fastening the rotor core assembly 14 and the two

end plates

5a and 5b is composed of, for example, a threaded bolt 81 and a nut 82, and connects the end plate 5a, the rotor core assembly 14 and the end plate 5b to Fix by pinching from both sides in the axial direction.

As shown in FIGS. 1 and 2, the rotor core assembly 14 is formed with a plurality of holes in addition to the insertion hole 13a (see FIG. 1). Specifically, as shown in FIG. 2, the rotor core assembly 14 has a first hole 14b in which the first fastening component 7 is arranged and a second hole 14c in which the second fastening component 8 is arranged. It is formed so as to penetrate in the axial direction (direction of arrow X). In the example shown in FIGS. 1 and 2, three first fastening components 7 and three second fastening components 8 are alternately provided in the circumferential direction of the rotor portion 20, and the rotor core assembly 14 includes each first fastening component. A first hole 14 b is provided corresponding to the component 7 , and a second hole 14 c is provided corresponding to each second fastening component 8 . In the example shown in FIG. 1, the three first fastening components 7 and the three second fastening components 8 are arranged on the same circle around the central axis Ax.

Further, as shown in FIG. 1, the rotor core 2 is provided with the A lightening hole 17 is formed.

FIG. 3 is a schematic diagram of the end plate 5. FIG. The structure of the

end plates

5a and 5b will be described below based on FIG. 2 and with reference to FIGS. 1 and 3. FIG.

As shown in FIG. 2, each of the

end plates

5a and 5b is made of a non-magnetic plate-like member, and has a disc shape with a shaft hole 51 (see FIG. 3) in the center for inserting the shaft 1. have. The end plate 5a is attached to the left side of the rotor core assembly 14 by the second fastening part 8, and is attached to the left side surface of the rotor core 2a so as to block at least a portion of the insertion hole 13a (see FIG. 1) formed in the rotor core 2a. provided in contact. The end plate 5b is attached to the right side of the rotor core assembly 14 by a second fastening part 8, and is fitted to the right side of the rotor core 2b so as to block at least a portion of the insertion hole 13a (see FIG. 1) formed in the rotor core 2b. provided in contact.

The inner diameter Dsi (see FIG. 3) of the end plate 5 is preferably larger than the outer diameter Dbo of the bearing 3 (see FIG. 2). In this case, the end plate 5 can be attached to the rotor core assembly 14 fixed to the shaft 1 even after the bearing 3 is attached to the shaft 1 .

The end plate 5 is formed with a dodging hole 52 in which the first fastening component 7 is arranged and a fastening hole 53 in which the second fastening component 8 is arranged so as to penetrate in the axial direction (arrow X direction). . The fastening hole 53 is provided separately from the dodging hole 52 . In the end plate 5 , a dodging hole 52 is provided at a position facing the first hole 14 b of the opposing rotor core assembly 14 . A hole 53 is provided. In the example shown in FIG. 3, the end plate 5 is provided with three alternate holes 52 and three fastening holes 53 in the circumferential direction.

In the example shown in FIG. 1 , there are three fastening locations by the first fastening component 7 and three fastening locations by the second fastening component 8 , and each end plate 5 also has the same number of three bypass holes 52 and fastening holes 52 . Although the hole 53 is provided in the description, the present invention is not particularly limited to this. For example, the number of fastening points by the first fastening part 7 and the number of fastening points by the second fastening part 8 may be two or four or more. It does not have to be the same number as the number of points. Further, for example, the number of bypass holes 52 provided in each end plate 5 should be equal to or greater than the number of fastening locations by the first fastening parts 7, and the number of fastening holes 53 provided in each end plate 5 may be 2 It is sufficient if the number is equal to or greater than the number of fastening points by the fastening parts 8 .

FIG. 4 is an enlarged view of the Q1 section shown in FIG. FIG. 5 is an enlarged view of the Q2 section shown in FIG. 4 and 5, the relationship between the bypass hole 52 of the end plate 5 and the first fastening part 7 that fastens the two

rotor cores

2a and 2b and the intermediate plate 4 will be described.

As shown in FIGS. 4 and 5, the first fastening component 7 includes a shaft portion 7b inserted into the first hole 14b of the rotor core assembly 14, and provided at both ends of the shaft portion 7b. and a protrusion 7a having a diameter D7a larger than D7b. Projections 7 a that form the ends of the first fastening component 7 protrude axially from the

rotor cores

2 a and 2 b of the rotor core assembly 14 and are arranged in the bypass holes 52 of the end plate 5 . In the example of FIGS. 4 and 5 in which the first fastening component 7 is composed of a screw bolt 71 and a nut 72, the right projection 7a of the first fastening component 7 is the screw head of the screw bolt 71, and the first fastening component 7 is a nut 72 .

The diameter D7a of the protrusion 7a of the first fastening component 7 is larger than the diameter D14b of the first hole 14b of the rotor core 2 in the rotor core assembly 14, and the protrusions 7a on both sides allow the rotor core 2a to extend in the axial direction (arrow X direction). , the intermediate plate 4 and the rotor core 2b are sandwiched.

　As shown in Figures 4 and 5, the clearance hole 52 of the end plate 5 is larger than the first hole 14b of the rotor core assembly 14 provided opposite thereto. That is, the diameter D52 of the replacement hole 52 in the end plate 5 is larger than the diameter D14b of the first hole 14b in the rotor core 2. As shown in FIG. Also, the diameter D52 of the bypass hole 52 of the end plate 5 is larger than the diameter D7a of the protrusion 7a of the first fastening component 7 . As a result, in the end plate 5 , the screw head of the screw bolt 71 and the nut 72 of the first fastening part 7 are deflected by the projections 7 a such as the nut 72 , and are not brought into contact with the end plate 5 . That is, the projections 7 a of the first fastening component 7 fasten the components of the rotor core assembly 14 by coming into contact with the rotor core 2 , but the projections 7 a do not interfere with the end plates 5 . Therefore, the end plate 5 can be attached to the rotor core assembly 14 even after the rotor core assembly 14 is fastened by the first fastening component 7 .

In the examples shown in FIGS. 4 and 5, the center of the circular bypass hole 52 in the end plate 5 and the center of the protrusion 7a in the first fastening part 7 are substantially aligned. The shape, size and position of 52 are not particularly limited to this. It is sufficient that the first fastening part 7 is formed with the evasion hole 52 so that the end plate 5 is not pinched by the protrusion 7a protruding from the rotor core assembly 14 .

FIG. 6 is an enlarged view of Q3 shown in FIG. FIG. 7 is an enlarged view of Q4 shown in FIG. 6 and 7, the relationship between the fastening hole 53 of the end plate 5 and the second fastening part 8 that fastens the two end plates 5a and the rotor core assembly 14 will be described.

As shown in FIGS. 6 and 7, the second fastening component 8 includes a shaft portion 8b inserted into the second hole 14c of the rotor core assembly 14 and the fastening hole 53 of the end plate 5, and a shaft portion 8b at both ends of the shaft portion 8b. and an end portion 8a having a diameter D8a larger than the diameter D8b of the shaft portion 8b. An end portion 8 a of the second fastening component 8 protrudes axially from the end plate 5 . In the example of FIGS. 6 and 7 in which the second fastening component 8 is composed of a screw bolt 81 and a nut 82, the right end 8a of the second fastening component 8 is the screw head of the screw bolt 81, and the second fastening component 8 is a nut 82 at the left end 8a.

The diameter D8a of the end portion 8a of the second fastening component 8 is larger than the diameter D53 of the second hole 14c of the rotor core 2 and the fastening hole 53 of the end plate 5 in the rotor core assembly 14 . The end plate 5a, the rotor core assembly 14, and the end plate 5b are sandwiched between the ends 8a on both sides in the axial direction (direction of arrow X). That is, the end plate 5 is fixed to the rotor core assembly 14 by the second fastening component 8 through the fastening hole 53 . In the examples shown in FIGS. 6 and 7, the size of the second hole 14c in the rotor core 2 and the size of the fastening hole 53 in the end plate 5 are the same, and the diameter of the second hole 14c is not shown. there is

It should be noted that each of the first fastening component 7 and the second fastening component 8 is not limited to a fastening component in which a threaded bolt and a nut are combined as described above, and the first fastening component 7 and the second fastening component 8 may consist of different fasteners. Each of the first fastening part 7 and the second fastening part 8 can be composed of other fastening parts such as rivets, for example. In this case, the diameter D52 of the deflecting hole 52 formed in the end plate 5 is larger than the diameter D53 of the rivet head of the rivet forming the first fastening component 7, and the diameter D53 of the fastening hole 53 formed in the end plate 5 is smaller than the diameter of the rivet head of the rivet forming the second fastening component 8 . Further, in the second fastening part 8, the fastening hole 53 in the end plate 5a is used instead of the nut 82 as a threaded hole, and the tip of the threaded bolt 81 is screwed into this threaded hole, whereby the end plate 5a and the rotor core assembly 14 are connected. and the end plate 5b may be fastened.

Also, the diameter D14b of the first hole 14b formed in the rotor core assembly 14 does not have to be the same size in the axial direction (arrow X direction). For example, in the rotor core assembly 14, the first hole 14b in the intermediate plate 4 may be configured to have a larger diameter than the diameter D14b of the first hole 14b in the rotor core 2. In this case, the

end plates

5a, 5b and the intermediate plate 4 may be the same parts of the same shape and material. With such a configuration, the types of components of the rotor 100 can be reduced.

Also, by making the first fastening part 7 and the second fastening part 8 the same part having the same shape and made of the same material, it is possible to reduce the types of components of the rotor 100 . Further, by using a non-magnetic material for these fastening parts, eddy current loss generated in the fastening parts can be reduced.

FIG. 8 is a sectional view of the rotor 100 taken along the line BB passing through the insertion hole 13a shown in FIG. As described above, each of the

rotor cores

2a and 2b is formed with an insertion hole 13a penetrating therethrough in the axial direction (the direction of the arrow X), and the magnet 12 is housed in each insertion hole 13a. In each

rotor core

2a, 2b, both ends of each insertion hole 13a are partially or wholly closed so that the magnets 12 do not protrude out of the rotor section 20. As shown in FIG. Specifically, in the left rotor core 2a, the left side of the insertion hole 13a is partially or entirely covered with the end plate 5a, and the right side of the insertion hole 13a is partially or entirely covered with the intermediate plate 4. In the rotor core 2b on the right side, the left side of the insertion hole 13a is partially or wholly covered by the intermediate plate 4, and the right side of the insertion hole 13a is partially or wholly covered by the end plate 5b.

A key 15 is provided on a part of the outer peripheral surface of the shaft 1 . The key 15 is provided at a position where the rotor core assembly 14 of the rotor portion 20 is fixed by shrink fitting in the axial direction of the shaft 1 (direction of arrow X). The key 15 serves to reinforce the

rotor cores

2a, 2b of the rotor core assembly 14 and the shaft 1 from slipping due to torque generated during operation of the rotating electric machine. The two

rotor cores

2a and 2b of the rotor core assembly 14 are directly fixed to the shaft 1 by shrink fitting without the end plate 5 and the intermediate plate 4 interposed therebetween.

FIG. 9 is an explanatory diagram explaining the first step of the manufacturing process of the rotor 100 shown in FIG. 10A and 10B are explanatory diagrams for explaining the second step of the manufacturing process of the rotor 100 shown in FIG. 11A and 11B are explanatory diagrams for explaining the third step of the manufacturing process of the rotor 100 shown in FIG. 12A and 12B are explanatory diagrams for explaining the fourth step of the manufacturing process of the rotor 100 shown in FIG. A method for manufacturing the rotor 100 will be described below with reference to FIGS. 9 to 12. FIG.

The method of manufacturing rotor 100 includes a first step ( FIG. 9 ) of obtaining rotor core assembly 14 by fastening two

rotor cores

2 a and 2 b and intermediate plate 4 , and a second step of attaching rotor core assembly 14 to the outer peripheral surface of shaft 1 . 2 step (FIG. 10), a third step (FIG. 11) of housing the magnets 12 in the two

rotor cores

2a and 2b respectively, and a fourth step (FIG. 12) of attaching the

end plates

5a and 5b to the rotor core assembly 14. ,have. It implements in order of a 1st process, a 2nd process, a 3rd process, and a 4th process.

In the first step shown in FIG. 9, two

rotor cores

2a and 2b arranged in the axial direction (arrow X direction) of the shaft 1 and a non-magnetic intermediate plate disposed between the two

rotor cores

2a and 2b 4 and are fastened by the first fastening component 7 . Through the first step, a rotor core assembly 14 in which the two

rotor cores

2a, 2b and the intermediate plate 4 are integrated is obtained.

By the way, generally, the plurality of magnetic steel sheets forming the rotor core 2 are crimped in advance by V crimping or round crimping in order to prevent the magnetic steel sheets from separating during assembly of the rotor 100 . In the present disclosure, in the first step prior to the second step of attaching to the shaft 1, when each constituent member of the rotor core assembly 14 is screw-fastened by the first fastening parts 7, the plurality of electromagnetic steel sheets forming the rotor core 2 are are also integrated, there is no need to combine a plurality of electromagnetic steel sheets in advance. Therefore, in the present disclosure, a plurality of electromagnetic steel sheets can be crimpless, which is not crimped to each other, and the conventional crimping process becomes unnecessary, improving productivity.

In the second step shown in FIG. 10, the shaft 1 is inserted into the shaft hole 14a of the rotor core assembly 14 obtained in the first step, and the outer peripheral surface of the shaft 1 and the shaft hole 14a of the rotor core assembly 14 are shrink-fitted. fixed by By the second step, the two

rotor cores

2a and 2b of the rotor core assembly 14 are fixed directly to the shaft 1 without the end plate 5 and the intermediate plate 4 interposed therebetween. In a second step, cooling takes place after shrink fitting.

In the second step, after the shaft 1 is inserted into the shaft hole 14a of the rotor core assembly 14, the shaft 1 is further inserted into the shaft hole 3a of the bearing 3, and then the bearing 3 and the rotor core assembly 14 are respectively , may be fixed to the shaft 1 by shrink fitting. As a result, both the rotor core assembly 14 and the bearing 3 can be attached to the shaft 1 in a single shrink fitting and cooling process.

In the third step shown in FIG. 11, the magnets 12 are inserted into the insertion holes 13a of the rotor cores 2 after cooling in the second step. One end of the inserted magnet 12 contacts the intermediate plate 4 .

In a fourth step shown in FIG. 12, the

end plates

5a and 5b are arranged on both sides of the rotor core assembly 14 in the axial direction (the direction of the arrow X), and the rotor core assembly 14 and the

end plates

5a and 5b are connected by the second fastening parts 8. is concluded. At this time, the projecting portion 7a of the first fastening part 7 is arranged in the dodge hole 52 of the

end plates

5a, 5b. In the fourth step, the insertion hole 13a is partially or wholly closed by the

end plates

5a, 5b on both sides in the axial direction (arrow X direction) of the rotor core assembly 14. As shown in FIG.

When the

end plates

5a and 5b are formed of one member as shown in FIG. 3, in the fourth step, the shaft 1 is inserted into the shaft holes 51 of the

end plates

5a and 5b, and the end plate 5a is formed into the rotor core. The end plate 5b is attached to the rotor core assembly 14 from the right side, while the assembly 14 is attached from the left side. By making the inner diameter Dsi (FIG. 3) of the

end plates

5a and 5b larger than the outer diameter Dbo (FIG. 2) of the bearing 3, even after the bearing 3 is fixed to the shaft 1 in the second step, the fourth The

end plates

5a, 5b can be attached to the rotor core assembly 14 in a process.

As described above, rotor 100 of Embodiment 1 has shaft 1 and two

rotor cores

2a and 2b arranged in the axial direction (arrow X direction) of shaft 1, and is attached to the outer peripheral surface of shaft 1. and a rotor core assembly 14 . The rotor 100 also includes magnets 12 housed in the two

rotor cores

2a and 2b, respectively, and

end plates

5a and 5b arranged on both sides of the rotor core assembly 14 in the axial direction (the arrow X direction). An insertion hole 13a for the magnet 12 is provided in each of the two

rotor cores

2a and 2b. The rotor core assembly 14 is arranged between the two

rotor cores

2a and 2b and includes an intermediate plate 4 made of a non-magnetic material and a first fastening part 7 that fastens the intermediate plate 4 to the two

rotor cores

2a and 2b. , have The first fastening component 7 has projections 7a projecting in the axial direction (direction of arrow X) from the two

rotor cores

2a and 2b. The intermediate plate 4 and the two

rotor cores

2a and 2b are provided with first holes 14b into which the first fastening parts 7 are inserted. A bypass hole 52 having a diameter D52 smaller than D7a and larger than the diameter D7a of the protrusion 7a of the first fastening component 7 is provided in the

end plates

5a, 5b. The

end plates

5a and 5b are provided so as to block part or all of the insertion holes 13a formed in the rotor cores 2a and 2b. is placed. The rotor core assembly 14 is attached to the shaft 1 by shrink fitting the two

rotor cores

2a, 2b directly onto the shaft 1. As shown in FIG.

As a result, the two

rotor cores

2a, 2b and the intermediate plate 4 are connected directly to the shaft 1 without the

end plates

5a, 5b and the intermediate plate 4 interposed therebetween. The rotor core assembly 14 is attached to the shaft 1 by shrink fitting. The

end plates

5a and 5b are provided with bypass holes 52 having a diameter D52 larger than the diameter D7a of the protrusion 7a of the first fastening component 7, and the bypass holes 52 of the

end plates

5a and 5b are used for the first fastening. A projecting portion 7a of the component 7 is arranged. Therefore, the magnets 12 can be inserted through the insertion holes 13a of the

rotor cores

2a and 2b after the intermediate plate 4 and the two

rotor cores

2a and 2b are integrated and shrink-fitted. Moreover, after that, the

end plates

5 a and 5 b can be arranged on both sides of the rotor core assembly 14 without interfering with the protrusion 7 a of the first fastening component 7 . Therefore, the rotor core assembly 14 can be attached to the shaft 1 only by one shrink-fitting process, so the productivity of the rotor 100 is high. Deterioration can be suppressed. In addition, since the rotor core assembly 14 can be fixed to the shaft 1 by shrink fitting, it is possible to avoid an increase in the size of fixing equipment regardless of the size of the rotor 100 compared to the case where it is fixed by press fitting.

Furthermore, in the present disclosure, the

rotor cores

2a, 2b are directly shrink-fitted onto the shaft 1 instead of being held by the

end plates

5a, 5b and the intermediate plate 4 as in the conventional art. 5b and intermediate plate 4 are not required to be strong. Therefore, the plate thickness of the

end plates

5a, 5b and the intermediate plate 4 can be made thinner than before, and the material cost can be reduced.

Furthermore, in the present disclosure, since the intermediate plate 4 and the

rotor cores

2a and 2b are screw-fixed before being fixed to the shaft 1, a sufficient fastening force is applied to the

rotor cores

2a and 2b. This eliminates the need for reinforcing parts such as spring pins. Therefore, the types of parts can be reduced more than before.

In addition, the intermediate plate 4 and the

end plates

5a and 5b are composed of one or a plurality of plate-like members having the same shape and the same material. As a result, the types of component parts of the rotor 100 can be reduced.

Further, the rotor 100 further includes a second fastening component 8 that fastens the rotor core assembly 14 and the

end plates

5a, 5b. The intermediate plate 4 and the two

rotor cores

2a and 2b are provided with second holes 14c into which the second fastening parts 8 are inserted, and the

end plates

5a and 5b are provided with fastening holes 53 separate from the bypass holes 52. It is The

end plates

5 a and 5 b are fixed to the rotor core assembly 14 by the second fastening parts 8 through fastening holes 53 .

As a result, even if the

end plates

5a and 5b are retrofitted after the magnets 12 are inserted into the rotor core assembly 14, the

end plates

5a and 5b are fixed to the rotor core assembly 14 by the second fastening parts 8. It is possible to prevent the

end plates

5a and 5b from coming off.

Also, the first fastening part 7 and the second fastening part 8 are configured with the same shape and the same material. As a result, the types of components of the rotor 100 can be further reduced.

The rotor 100 also includes a bearing 3 mounted on the shaft 1, the rotor core assembly 14 has a cylindrical shape, and the

end plates

5a, 5b are circular with an inner diameter Dsi larger than the outer diameter Dbo of the bearing 3. It has a plate shape. As a result, the

end plates

5 a and 5 b can be attached to the rotor core assembly 14 from both sides of the shaft 1 even after the bearings 3 are fixed to the shaft 1 .

Each of the two

rotor cores

2a and 2b is composed of a plurality of electromagnetic steel sheets laminated in the axial direction (the direction of the arrow X), and the plurality of electromagnetic steel sheets forming the

rotor cores

2a and 2b are integrated by a first fastening part 7. has been made As a result, when the components of the rotor core assembly 14 are screw-fastened by the first fastening part 7, the plurality of electromagnetic steel sheets are also integrated, so the conventional caulking process for joining the plurality of electromagnetic steel sheets in advance is unnecessary. and the productivity is further improved.

Also, the first fastening component 7 is composed of a screw (for example, a screw bolt 71) and a nut 72, or a rivet. As a result, the rotor 100 can be configured with more general-purpose and simple parts than in the past.

Further, the rotor manufacturing method of Embodiment 1 has a first step, a second step, a third step, and a fourth step. In the first step, two

rotor cores

2a and 2b arranged in the axial direction of the shaft 1 and an intermediate plate 4 which is arranged between the two

rotor cores

2a and 2b and made of a non-magnetic material are inserted into the intermediate plate 4. The rotor core assembly 14 is obtained by inserting the first fastening parts 7 into the first holes 14b provided in the two

rotor cores

2a and 2b and fastening them with the first fastening parts 7. As shown in FIG. In the second step, the rotor core assembly 14 is attached to the outer peripheral surface of the shaft 1 by directly shrink-fitting the two

rotor cores

2 a and 2 b onto the shaft 1 . In the third step, the magnets 12 are accommodated in the two

rotor cores

2a and 2b through the insertion holes 13a provided in the two

rotor cores

2a and 2b. In the fourth step,

end plates

5a and 5b are arranged on both sides of the rotor core assembly 14 in the axial direction so as to block part or all of the insertion hole 13a. A protruding portion 7a which is a projecting portion and has a diameter D7a larger than the diameter D14b of the first hole 14b in the rotor core, and a diameter D52 larger than the diameter D7a of the protruding portion 7a provided on the

end plates

5a and 5b. It is placed in the dodge hole 52 .

Thus, in the second step, the

rotor cores

2a, 2b are fixed directly to the shaft 1 without the

end plates

5a, 5b and the intermediate plate 4, and then the magnets 12 are accommodated in the third step. The

end plates

5a and 5b can be attached to block part or all of the insertion hole 13a. Therefore, the rotor core assembly 14 can be attached to the shaft 1 only by one shrink-fitting process, so the productivity of the rotor 100 is good. In addition, since the rotor core assembly 14 can be fixed to the shaft 1 by shrink fitting, it is possible to avoid an increase in the size of fixing equipment regardless of the size of the rotor 100 compared to the case where it is fixed by press fitting.

Embodiment 2.
FIG. 13 is a schematic diagram of the end plate 5 of the rotor 100 according to the second embodiment. The second embodiment differs from the first embodiment in that each of the

end plates

5a and 5b is divided into a plurality of pieces in the circumferential direction.

In Embodiment 2, the end plate 5 is composed of a plurality of fan-shaped plate members. In the example shown in FIG. 13, the end plate 5 is divided into two in the circumferential direction, and is composed of a fan-shaped first end plate portion 50a and a second end plate portion 50b. Note that the end plate 5 may be divided into three or more end plate portions in the circumferential direction. Further, the intermediate plate 4 may be divided into a plurality of pieces like the end plate 5 .

The inner diameter Dsi of the end plate 5 can be made slightly larger than the axial diameter of the shaft 1, for example. Note that the inner diameter Dsi of the end plate 5 is not particularly limited to this. As shown in FIG. 1, the end plate 5 can cover at least a portion of the insertion hole 13a in the rotor core assembly 14 so that the magnet 12 (FIG. 8) does not protrude from the insertion hole 13a. It is only necessary to have an inner diameter Dsi (FIG. 13) that is larger than the shaft diameter.

As described above, the rotor 100 of Embodiment 2 includes the bearing 3 attached to the shaft 1, the rotor core assembly 14 has a cylindrical shape, and the

end plates

5a, 5b are a plurality of fan-shaped end plates. It is composed of a plate-like member.

Therefore, when the

end plates

5a and 5b are attached to the rotor core assembly 14, it is not necessary to pass them through the shaft 1. Therefore, in the rotor 100 of the second embodiment as well, the same effect as in the first embodiment in which the inner diameter Dsi of the end plate 5 is larger than the outer diameter Dbo of the bearing 3 can be obtained. That is, in the manufacturing process, the

end plates

5a and 5b can be attached to the rotor core assembly 14 even after the bearing 3 is fixed to the shaft 1, so productivity is improved.

Embodiment 3.
FIG. 14 is a schematic diagram showing a schematic configuration of rotor 100 according to the third embodiment. In the first embodiment, the end plate 5 is formed with one bypass hole 52 for each of the plurality of first fastening components 7 , and the same number of bypass holes 52 as the first fastening components 7 are formed in the end plate 5 . However, in Embodiment 3, the number of bypass holes 52 in the end plate 5 differs from the number of the first fastening components 7 .

Three first fastening components 7 and three second fastening components 8 are alternately provided in the rotor portion 20 in the circumferential direction. As shown in FIG. 14, when viewed from the left end plate 5a side, the three first fastening components 7 are arranged on a first circle C1 around the central axis Ax, , on a second circle C2 concentric with the first circle C1 and smaller than the first circle C1.

In the third embodiment as well, the end plate 5 has a disc shape with a shaft hole 51 in the center for inserting the shaft 1 as in the case of the first embodiment. At least a part of the insertion hole 13a is covered so that the projection 12 does not protrude. However, in the third embodiment, the shaft hole 51 of the end plate 5, that is, the inner diameter Dsi is larger than in the first embodiment, and the three first fastening parts 7 are arranged inside the shaft hole 51. It has become. That is, in the third embodiment, the shaft hole 51 also functions as a dodging hole 52 for dodging the projection 7a of the first fastening component 7. As shown in FIG.

That is, in the third embodiment, the outer peripheral edge 5o of the end plate 5 is positioned radially outside the second circle C2 on which the three second fastening components 8 are arranged, and the three first fastening components 7 are arranged. The inner peripheral end 5i of the end plate 5 is located radially outside the first circle C1 and radially inside the second circle C2, and the end plate 5 covers at least a portion of the insertion hole 13a. A plate 5 is formed.

The number of first fastening components 7 is not limited to the above case, and may be, for example, two or four or more. Also, in the end plate 5 , the dodging hole 52 may be provided separately from the shaft hole 51 as long as it is large enough to dodge the plurality of first fastening components 7 . For example, as shown in FIG. 14, the end plate 5 is formed so that the inner peripheral end 5i is positioned radially inward of the first circle C1 when viewed from the end plate 5a side, and two or more dodge holes are provided. may be formed in an arc shape having an arc length that encloses the first fastening component 7 of .

As described above, in the rotor 100 of the third embodiment, the end plate 5 has the shaft hole 51 including the dodge hole 52 and into which the shaft 1 is inserted. can be reduced.

It should be noted that each embodiment can be combined, modified, or omitted as appropriate.

1 shaft, 2, 2a, 2b rotor core, 3 bearing, 3a shaft hole, 4 intermediate plate, 5, 5a, 5b end plate, 5i inner peripheral end, 5o outer peripheral end, 7 first fastening part, 7a projection, 7b shaft part, 8 second fastening part, 8a end part, 8b shaft part, 12 magnet, 13a insertion hole, 14 rotor core assembly, 14a shaft hole, 14b first hole, 14c second hole, 15 key, 17 lightening hole, 20 rotor part, 50a first end plate part, 50b second end plate part, 51 shaft hole, 52 dodging hole, 53 fastening hole, 71 screw bolt, 72 nut, 81 screw bolt, 82 nut, 100 rotor, Ax central axis , C1 1st circle, C2 2nd circle, D7a, D7b, D8a, D8b, D14b, D52, D53 diameter, Dbo outer diameter, Dsi inner diameter.

Claims

a shaft;
a rotor core assembly having two rotor cores arranged in the axial direction of the shaft and attached to the outer peripheral surface of the shaft;
magnets housed in each of the two rotor cores;
end plates arranged on both sides of the rotor core assembly in the axial direction,
Each of the two rotor cores is provided with an insertion hole for the magnet,
The rotor core assembly is
an intermediate plate disposed between the two rotor cores and made of a non-magnetic material;
a first fastening part that fastens the two rotor cores and the intermediate plate and has projections projecting from the two rotor cores in the axial direction;
The intermediate plate and the two rotor cores are provided with first holes into which the first fastening parts are inserted, the diameter of the first holes in the two rotor cores being smaller than the diameter of the protrusions,
The end plate is provided with a deflecting hole having a diameter larger than the diameter of the protrusion of the first fastening component,
The end plate is provided so as to block part or all of the insertion hole formed in the rotor core, and the projecting portion of the first fastening component is arranged in the dodge hole of the end plate,
The rotor core assembly is attached to the shaft by shrink fitting the two rotor cores directly to the shaft.
2. The rotor according to claim 1, wherein the intermediate plate and the end plate are composed of one or a plurality of plate-like members having the same shape and the same material.
further comprising a second fastening component that fastens the rotor core assembly and the end plate;
The intermediate plate and the two rotor cores are provided with second holes into which the second fastening parts are inserted,
The end plate is provided with a fastening hole separate from the dodge hole,
3. The rotor according to claim 1, wherein the end plate is fixed to the rotor core assembly by the second fastening component through the fastening hole.
The rotor according to claim 3, wherein the first fastening component and the second fastening component are configured with the same shape and the same material.
a bearing attached to the shaft;
The rotor core assembly has a cylindrical shape,
The rotor according to any one of claims 1 to 4, wherein the end plate has a disk shape with an inner diameter larger than the outer diameter of the bearing.
a bearing attached to the shaft;
The rotor core assembly has a cylindrical shape,
The rotor according to any one of claims 1 to 4, wherein the end plate is composed of a plurality of fan-shaped plate members.
the end plate has a shaft hole that includes the dodge hole and into which the shaft is inserted;
A rotor according to any one of claims 1-6.
each of the two rotor cores is composed of a plurality of electromagnetic steel sheets laminated in the axial direction,
The rotor according to any one of Claims 1 to 7, wherein the plurality of electromagnetic steel sheets forming the rotor core are integrated by the first fastening component.
The rotor according to any one of Claims 1 to 8, wherein the first fastening component comprises a screw and nut or a rivet.
Two rotor cores arranged in the axial direction of the shaft, and an intermediate plate disposed between the two rotor cores and made of a non-magnetic material are inserted into first holes provided in the intermediate plate and the two rotor cores. a first step of obtaining a rotor core assembly by inserting a first fastening component into and fastening with the first fastening component;
a second step of attaching the rotor core assembly to the outer peripheral surface of the shaft by directly shrink-fitting the two rotor cores onto the shaft;
a third step of housing magnets in each of the two rotor cores through insertion holes provided in the two rotor cores;
End plates are arranged on both sides of the rotor core assembly in the axial direction so as to block part or all of the insertion holes, and portions of the first fastening component protruding from the two rotor cores, a fourth step of disposing a protrusion having a diameter larger than that of the first hole in a deflecting hole having a diameter larger than that of the protrusion provided in the end plate. Method.