JP2009219314A - Rotator of rotary electric machine, and method of manufacturing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a rotator of a rotary electric machine that reduces eddy current generated in a permanent magnet in driving the rotary electric machine and can also facilitate insertion of a magnetized permanent magnet into a magnet receiving hole of the rotator in manufacturing the rotator. <P>SOLUTION: A plurality of permanent magnets 17 are accommodated, in a state divided in the axial direction of a rotor core 12, in the magnet receiving holes 16 formed in the rotor core 12 formed by laminating a plurality of electromagnetic steel plates 12a. Each permanent magnet 17 is covered with an electric insulating sheet 18 over the entire surface thereof. The electric insulating sheet 18 is so formed as to make bag portions 19 continuous for accommodating the permanent magnets 17 one by one, wherein one permanent magnet 17 is accommodated in each bag portion 19. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a rotor for a rotating electric machine and a method for manufacturing the same, and more particularly to a rotor for a permanent magnet embedded type rotating electric machine and a method for manufacturing the same.

  In a rotor of a permanent magnet embedded type rotating electrical machine, a permanent magnet is generally housed in a rotor housing formed by laminating a plurality of electromagnetic steel plates in a magnet housing hole formed to extend in the axial direction of the rotor core. It is sandwiched between end plates. The magnet housing hole is formed simultaneously when each electromagnetic steel sheet is punched into a predetermined shape by press working, and the periphery thereof is not chamfered. Therefore, when a permanent magnet is directly inserted into the magnet housing hole, the permanent magnet comes into contact with the peripheral corners and burrs of the magnet housing hole of each electromagnetic steel sheet, and the permanent magnet is cracked or chipped. For this reason, a method for preventing the permanent magnet from cracking or chipping when the permanent magnet is inserted into the magnet housing hole has been proposed (see, for example, Patent Document 1). In the method of Patent Document 1, as shown in FIG. 10A, when the permanent magnet 53 is inserted into the hole 52 of the rotor 51, the permanent magnet 53 is inserted between the laminated sheets 54.

  In addition, for example, in a hybrid motor vehicle motor, the output torque is constant and large torque is secured even if the rotational speed changes from low speed to medium speed, and the rotational speed is secured regardless of the magnitude of the torque at high speed. There is a demand for the property to do. As a method of satisfying this requirement, there is a method of performing field weakening control in a high speed region. When field-weakening control is performed in a high-speed region, eddy current is generated in the permanent magnet and heat is generated. If the heat generation is large, the permanent magnet is demagnetized and the efficiency of the motor is deteriorated.

  As a permanent magnet rotating electrical machine that can reduce the generation of eddy currents on the magnet surface, a plurality of permanent magnets 57 are inserted into the permanent magnet insertion holes 56 of the rotor core 55 as shown in FIG. The one inserted with a gap in the width direction has been proposed (for example, see Patent Document 2). An insulator 58 is inserted between the plurality of permanent magnets 57.

There has also been proposed a permanent magnet rotor and a method for manufacturing the permanent magnet rotor for causing all unit iron cores to share the load applied to the unit iron core (electromagnetic steel sheet) almost evenly during rotation (see Patent Document 3). In Patent Document 3, in a permanent magnet rotor in which a laminated iron core is formed by laminating a plurality of plate-shaped unit cores having magnet accommodation holes, and a permanent magnet piece is accommodated in the magnet accommodation hole of the laminated iron core, The hole accommodates a permanent magnet piece having the same thickness as the unit core for each unit core. As its manufacturing method, a unit core forming step for forming a unit core having a magnet receiving hole, and a magnet sintering step for storing a magnet material in the magnet receiving hole of the unit core and sintering to form a magnet piece, And a laminating step in which a predetermined number of unit iron cores including the magnet pieces are laminated and integrated.
JP 2004-104966 A Japanese Patent Laid-Open No. 11-4555 JP 2005-304193 A

  By dividing the permanent magnet accommodated in each magnet accommodation hole into a plurality of parts, the eddy current generated in the permanent magnet is reduced, and the heat generated by the generation of the eddy current can be reduced. However, as in Patent Document 2, when the permanent magnet is divided into a plurality of pieces in the width direction of the magnet housing hole, the eddy current does not become smaller than when the permanent magnet is divided in the rotor core axial direction of the magnet housing hole.

  In Patent Document 3, a configuration in which a permanent magnet piece is accommodated for each magnet accommodation hole of each unit iron core (electromagnetic steel sheet), that is, a plurality of permanent magnets divided in the rotor core axial direction are accommodated in the magnet accommodation hole. A rotor is disclosed. The permanent magnet pieces are magnetized (magnetized) in advance before being housed in the magnet housing holes, and are not housed in the magnet housing holes in a state of becoming permanent magnets, but are laminated by unit iron cores. After being integrated, the magnet material is magnetized. However, when the magnet material is magnetized (magnetized) in the state of being accommodated in the magnet housing hole of the unit iron core, the magnetization efficiency is poor, and the permanent magnet is not compared with the case where the permanent magnet is housed in the magnet housing hole. The magnetic force is weakened, and the efficiency of the rotating electrical machine is deteriorated even if a rotor of the same size is used. Moreover, although patent document 3 does not make the permanent magnet the independent structure for every magnet accommodation hole of a unit core for the purpose of reduction of the eddy current generate | occur | produced with a permanent magnet, as a result, the eddy current generated with a permanent magnet is Reduced. However, not only the number of manufacturing steps is required, but the adjacent permanent magnets are in contact with each other, and an eddy current can flow through the adjacent permanent magnets. Therefore, the effect of reducing the eddy current is low.

  Patent Document 1 discloses that a previously magnetized permanent magnet is inserted into a magnet housing hole while being sandwiched between laminated sheets. However, in the axial direction of the rotor core, the eddy current generated in the permanent magnet is reduced. There is no description about inserting a plurality of divided permanent magnets into the magnet accommodation hole. Further, even if a permanent magnet divided into a plurality in the axial direction of the rotor core is simply inserted into the magnet housing hole while being sandwiched between laminated sheets, the adjacent permanent magnets repel each other and the insertion is not performed smoothly. .

  The present invention has been made in view of the above-described conventional problems, and its purpose is to reduce eddy currents generated in a permanent magnet when a rotating electrical machine is driven and to a magnet housing hole of a rotor during manufacture of the rotor. An object of the present invention is to provide a rotor of a rotating electrical machine that can achieve both easy insertion of a magnetized permanent magnet and a method of manufacturing the same.

  In order to achieve the above object, the invention according to claim 1 is directed to a magnet receiving hole formed in a rotor core formed by laminating a plurality of ferromagnetic magnetic plates and extending in the axial direction thereof. A rotor of a rotating electrical machine in which a permanent magnet is accommodated and an end plate that sandwiches the rotor core is provided. A plurality of permanent magnets are accommodated in the magnet accommodation hole in a state of being divided in the axial direction of the rotor core, and each permanent magnet has at least a magnetic pole surface covered with an electrically insulating sheet and adjacent permanent magnets. The end surfaces are partitioned by the electrical insulating sheet. Here, the “magnetic pole surface” means a surface through which the magnetic flux of the permanent magnet enters and exits.

  In this invention, the permanent magnet accommodated in the magnet accommodation hole is divided into a plurality of parts in the axial direction of the rotor core, and the end surfaces of the adjacent permanent magnets are partitioned by the electrically insulating sheet. Sometimes the eddy current generated in the permanent magnet becomes a small eddy current flowing in each permanent magnet. For this reason, heat generation due to the generation of eddy current is reduced as compared to the case where there is no electrical insulating sheet that partitions between the end faces of adjacent permanent magnets. In addition, each permanent magnet is magnetized when the rotor is assembled because at least the magnetic pole surface is covered with an electrical insulating sheet and the end surfaces of adjacent permanent magnets are partitioned by the electrical insulating sheet. It becomes easy to insert the permanent magnet into the magnet housing hole. Therefore, it is possible to achieve both reduction of eddy current generated in the permanent magnet when the rotating electrical machine is driven and easy insertion of the magnetized permanent magnet into the magnet housing hole of the rotor when the rotor is manufactured.

  According to a second aspect of the present invention, in the first aspect of the present invention, the entire surface of each permanent magnet is covered with the electrical insulating sheet. In this invention, compared to a configuration in which the magnetic pole surface of each permanent magnet and the end surface of the adjacent permanent magnet are covered with an electrical insulating sheet, the permanent magnet can be easily inserted into the magnet housing hole when the rotor is assembled. Become.

  According to a third aspect of the present invention, in the first or second aspect of the present invention, the electrically insulating sheet is formed such that a bag portion that houses the permanent magnets one by one is continuous, One permanent magnet is accommodated in each part. In this invention, the operation of inserting the permanent magnet into the magnet housing hole becomes easier when the rotor is assembled.

  According to a fourth aspect of the present invention, in the rotor core formed by laminating a plurality of magnetic plates made of a ferromagnetic material, a plurality of permanent magnets are provided in the magnet housing hole formed so as to extend in the axial direction thereof. This is a method of manufacturing a rotor of a rotating electrical machine that is accommodated in a state of being divided in the axial direction of the rotor core and that is provided with an end plate that sandwiches the rotor core. Each permanent magnet accommodated in the magnet accommodation hole is formed in a size after being accommodated in advance and magnetized, and at least the magnetic pole surface and the front side in the insertion direction to the magnet accommodation hole are electrically insulated. The permanent magnet accommodation process inserted into each magnet accommodation hole in the state covered with the sheet, and after all the permanent magnets were inserted into each magnet accommodation hole, the rotor core was pressed with the end plates arranged on both sides thereof And an end plate pressing and fixing step of fixing the both end plates to the rotating shaft.

  In this invention, in the permanent magnet housing step of housing a plurality of permanent magnets in each magnet housing hole formed in the rotor core, the permanent magnet is previously formed in a size after being housed in the magnet housing hole and magnetized. In this state, at least the magnetic pole surface and the front side in the direction of insertion into the magnet housing hole are covered with the electrical insulating sheet and inserted into each magnet housing hole. Therefore, it becomes easy to insert a plurality of permanent magnets divided in the axial direction of the rotor core into the magnet accommodation holes. Further, it is possible to manufacture a rotor that can reduce the eddy current generated in the permanent magnet when the rotating electrical machine is driven.

  According to a fifth aspect of the present invention, in the fourth aspect of the present invention, in the permanent magnet housing step, the permanent magnet is formed such that a bag portion for housing the permanent magnets one by one is continuous. In the state accommodated in each bag part of an insulation sheet, it inserts in each magnet accommodation hole in the state continuous with the electrical insulation sheet. In this invention, in a state where all the magnetic plates constituting the rotor core are laminated, each permanent magnet can be easily inserted into the magnet accommodation hole.

  The invention according to claim 6 is the invention according to claim 4 or 5, wherein, in the end plate pressing and fixing step, the rotor core is configured when pressing the rotor core with the end plates arranged on both sides thereof. Each magnetic plate is pressed while being guided by a guide portion extending in the axial direction of the rotating shaft. In this invention, even if there is a repulsive force between the divided permanent magnets, the magnetic plates are pressed and clamped by the both end plates in a predetermined positional relationship.

  According to the present invention, it is possible to achieve both reduction of eddy current generated in a permanent magnet during driving of a rotating electrical machine and ease of insertion of a magnetized permanent magnet into a rotor mounting hole during manufacture of the rotor. A rotating electrical machine can be provided.

(First embodiment)
Hereinafter, a first embodiment of the present invention will be described with reference to FIGS.
As shown in FIG. 1A, the rotor 11 includes a rotor core 12 in which a plurality of disk-shaped electromagnetic steel plates 12 a as magnetic plates made of a ferromagnetic material are stacked, and circles disposed at both ends of the rotor core 12. A plate-shaped end plate 13 and a rotary shaft 14 inserted through a shaft hole 11 a formed at the center of the rotor core 12 and the end plate 13 are provided. The rotating shaft 14 includes a flange portion 14a near the base end (closer to the left end in FIG. 1A). Then, one end plate 13 abuts on the flange portion 14 a, and the rotor core 12 is pressed by the both end plates 13. The rotor core 12 is fitted from the front end side of the rotary shaft 14 and is rotated in a state abutting on the other end plate 13. The rotor core 12 is fastened to the rotating shaft 14 together with the end plate 13 by a ring-shaped fixing member 15 that is caulked and fixed to the shaft 14. A key groove 14b (shown only in FIG. 1B) extending in the axial direction is formed on the peripheral surface of the rotary shaft 14, and the electromagnetic steel plate 12a and the end plate 13 are engaged with the key groove 14b. Protrusions that serve as positioning and detents are formed.

  As shown in FIG. 1B, the rotor core 12 is formed with a magnet accommodation hole 16 extending in the axial direction, and a permanent magnet 17 is accommodated in the magnet accommodation hole 16. One magnet housing hole 16 is formed in each virtual region equally divided into a plurality (eight in this embodiment) in the circumferential direction of the rotor core 12, and the width direction thereof is formed in a state orthogonal to the radial direction of the rotor core 12. ing. The permanent magnets 17 are magnetized so that the magnetization direction is the thickness direction, and the permanent magnets 17 arranged in adjacent virtual regions are arranged so that the outer peripheral sides of the rotor core 12 are different poles. ing.

  As shown in FIG. 1C, a plurality of permanent magnets 17 are accommodated in the magnet accommodation hole 16 in a state of being divided in the axial direction of the rotor core 12. Each permanent magnet 17 has at least a magnetic pole surface covered with an electrical insulating sheet 18, and an end surface 17 a between adjacent permanent magnets 17 is partitioned by the electrical insulating sheet 18. In this embodiment, the entire surface of each permanent magnet 17 is covered with an electrical insulating sheet 18. The permanent magnet 17 is fixed together with the electrically insulating sheet 18 by a fixing means (not shown) provided in a flux barrier (not shown) formed so as to be continuous with both ends of the magnet accommodation hole 16 in the width direction. 16 is fixed inside. For example, an adhesive or a spring member is used as the fixing means.

As shown in FIGS. 2A and 2B, the electrical insulating sheet 18 is formed so that the bag portions 19 for storing the permanent magnets 17 one by one are continuous, and each bag portion 19 is permanent one by one. A magnet 17 is accommodated. As a material of the electrical insulating sheet 18, a plastic film is used,
Examples of the plastic film include a fluororesin film, a polyethylene terephthalate film, and a polyimide film. The permanent magnet 17 is magnetized so that the magnetization direction is the thickness direction.

  Next, a method for manufacturing the rotor 11 configured as described above will be described. In this manufacturing method, the rotor core 12 is not manufactured by setting and pressing the number of electromagnetic steel plates 12a necessary for the rotor core 12 in a press at once, but corresponds to a plurality of types of predetermined thicknesses in advance. The rotor core 12 is configured by using a plurality of laminated cores formed by pressing a number of electromagnetic steel sheets 12a with a press. The predetermined thickness is, for example, a thickness of about 10 mm to 30 mm. The laminated core is stored in a state in which the electromagnetic steel sheet 12a is temporarily fixed with an adhesive or the like as necessary.

  First, as shown in FIG. 4A, a jig 31 is arranged on a support part 30 of the press machine, and the rotary shaft 14 is accommodated in the accommodating part 32 of the jig 31 so that the flange part 14a side is downward. At the same time, one end plate 13 and a plurality (four in this embodiment) of laminated cores 20 are stacked in order so that the magnet housing holes 16 are concentric. At this time, by stacking the end plates 13 and the convex portions of the laminated core 20 in engagement with the key grooves 14b of the rotary shaft 14, the magnet accommodating holes 16 of the laminated cores 20 are brought into alignment. In FIG. 4A, for convenience of illustration, the laminated cores 20 are shown in close contact with each other, but in reality, there is a possibility that a gap or a step is generated between the laminated cores 20.

  Next, as shown in FIG. 3, the permanent magnets 17, which are covered with the electrical insulation sheet 18, are inserted together with the electrical insulation sheets 18 in order in the magnet accommodation holes 16 of the stacked laminated cores 20. A containment process is performed. When trying to sequentially insert a plurality of magnetized permanent magnets 17 into one magnet housing hole 16, each permanent magnet 17 is in a state of being attracted to the electromagnetic steel plate 12 a by its own attractive force, and the tip thereof is magnet housing hole 16. It will be in the state contact | abutted to the wall surface. The wall surface of the magnet housing hole 16 is not a smooth surface because it is formed by a plurality of continuous electromagnetic steel plates 12a. Further, since there may be a gap or a step at the boundary portion of the stacked laminated cores 20, the tip of the permanent magnet 17 interferes with the corner where the end face of the laminated core 20 and the wall surface of the magnet housing hole 16 are continuous. It becomes a state to do. Therefore, the permanent magnet 17 cannot be inserted smoothly. However, since the permanent magnet 17 is entirely covered with the electrical insulation sheet 18, when the permanent magnet 17 is inserted into the magnet accommodation hole 16 together with the electrical insulation sheet 18, the tip of the permanent magnet 17 is positioned at the magnet accommodation hole 16. And smoothly inserted into the magnet housing hole 16 without being caught by the corners between the end surface of the laminated core 20 and the wall surface of the magnet housing hole 16. In addition, since a repulsive force (repulsive force) acts between the adjacent permanent magnets 17, the adjacent bag portions 19 are not in close contact with each other in a free state. As a result, as indicated by a two-dot chain line in FIG. 4A, the permanent magnets 17 are permanently attached to all the magnet housing holes 16 in a state in which a part of the permanent magnets 17 protrudes from the upper end surface of the laminated core 20 placed on the top. The magnet 17 is inserted.

  Next, an end plate pressing and fixing step is performed. In the end plate pressing and fixing step, the other end plate is placed on the laminated core 20 as shown in FIG. In this state, the permanent magnet 17 is in a state in which a part protrudes from the magnet accommodation hole 16. In this state, the press machine is driven, the pressing jig 33 in a standby position (not shown) is moved down, and the end plate 13 comes into contact with the rotor core 12 while pushing the permanent magnet 17 into the magnet housing hole 16. As shown in FIG. 5A, both end plates 13 are in a state of sandwiching the rotor core 12 with a predetermined pressure.

  Next, in this state, the fixing member 15 is fitted to the rotary shaft 14 from the front end side between the press jigs 33, and is caulked and fixed to 14 at a position in contact with the end plate 13. The rotating shaft 14 is formed with a recess at a position where the fixing member 15 is fixed by caulking, and the fixing member 15 is fixed in a state in which the fixing member 15 is secured to the rotating shaft 14 while being partially engaged with the recess. The Next, when the pressing jig 33 is moved up to a retracted position (not shown), the completed rotor 11 can be taken out from the accommodating portion 32 as shown in FIG. When the rotor 11 is taken out of the housing portion 32 from this state, the manufacture of the rotor 11 is completed.

  In the end plate pressing and fixing step, the both end plates 13 are fixed to the rotary shaft 14 while being pressed until the distance between the both end plates 13 reaches a preset distance. The “preset distance” means the thickness when the rotor core 12 is pressed in the configuration in which the both end plates 13 abut against the end surface of the rotor core 12 as in this embodiment, and the both end plates 13 and the rotor core In the configuration in which inclusions exist between the end faces of 12, this means the sum of the thickness when the rotor core 12 is pressed and the thickness of the inclusions.

Next, the operation of the electric motor provided with the rotor 11 configured as described above will be described.
When the motor is driven in a load state, a current is supplied to the stator coil, a rotating magnetic field is generated in the stator, and the rotating magnetic field acts on the rotor 11. Then, the rotor 11 rotates in synchronization with the rotating magnetic field by the magnetic attractive force and repulsive force between the rotating magnetic field and the permanent magnet 17.

  When the rotor 11 rotates at a high speed, a change in the interlinkage magnetic flux acting on the rotor 11 during rotation increases, and an eddy current is generated in the rotor 11. Eddy current is generated not only in the electromagnetic steel sheet 12a but also in the permanent magnet 17. When the permanent magnet 17 accommodated in the magnet accommodation hole 16 is not divided in the axial direction of the rotor core 12, as shown in FIG. 6B, the eddy current Ie takes the entire length in the longitudinal direction of the permanent magnet 17 as a path. Large eddy current Ie, and heat generation due to the generation of eddy current increases. When the permanent magnet 17 is divided in the axial direction of the rotor core 12, as shown in FIG. 6C, the eddy current Ie flows in the divided permanent magnet 17 and becomes a small eddy current Ie. Heat generation due to the generation of eddy current is reduced. However, if the permanent magnet 17 is simply divided, an eddy current Ie flowing across the divided permanent magnet 17 may be generated, as indicated by a two-dot chain line in FIG.

  On the other hand, in the rotor 11 of this embodiment, the permanent magnet 17 is divided into a plurality of parts in the axial direction of the rotor core 12, and the end surfaces 17 a of the adjacent permanent magnets 17 are partitioned by an electrical insulating sheet 18. Therefore, as shown in FIG. 6A, the eddy current Ie generated in the permanent magnet 17 is only a small eddy current Ie flowing in each permanent magnet 17, and the heat generated by the generation of the eddy current is generated by the adjacent permanent magnets 17. This is smaller than when there is no electrical insulating sheet 18 that partitions the end faces 17a. For example, as shown in FIG. 6B, when the permanent magnet 17 is not divided, and when the permanent magnet 17 is divided into four as shown in FIG. 6A, the end surfaces 17a of the adjacent permanent magnets 17 are electrically connected. Comparing with the case of partitioning with the insulating sheet 18, the generation of eddy currents was smaller than 1/3 of the case of dividing into four when not dividing.

According to this embodiment, the following effects can be obtained.
(1) A plurality of permanent magnets 17 are divided in the axial direction of the rotor core 12 in the magnet housing hole 16 formed so as to extend in the axial direction of the rotor core 12 formed by laminating a plurality of electromagnetic steel plates 12a. Each permanent magnet 17 is covered with an electrically insulating sheet 18 at least on the magnetic pole surface. Further, the end surfaces 17 a of the adjacent permanent magnets 17 are partitioned by an electrical insulating sheet 18. Therefore, both reduction of eddy current generated in the permanent magnet 17 when the rotating electric machine is driven and easy insertion of the magnetized permanent magnet 17 into the magnet housing hole 16 of the rotor 11 when the rotor 11 is manufactured are achieved. Can do.

  (2) The entire surface of each permanent magnet 17 is covered with the electrical insulating sheet 18. Therefore, the permanent magnet 17 is inserted into the magnet housing hole 16 when the rotor 11 is assembled, as compared with the configuration in which the magnetic pole surface of each permanent magnet 17 and the end surface of the adjacent permanent magnet 17 are covered with the electrical insulating sheet 18. It becomes easy to insert into.

  (3) The electrically insulating sheet 18 is formed so that the bag portions 19 for storing the permanent magnets 17 one by one are continuous, and one permanent magnet 17 is stored in each bag portion 19. Therefore, when the rotor 11 is assembled, the operation of inserting the permanent magnet 17 into the magnet accommodation hole 16 becomes easier.

  (4) The method of manufacturing the rotor 11 is such that each permanent magnet 17 accommodated in the magnet accommodation hole 16 is previously formed in a size after being accommodated and magnetized, and at least the magnetic pole surface and the magnet accommodation hole. 16 is provided with a permanent magnet accommodation step that is inserted into each magnet accommodation hole 16 in a state in which the front side in the direction of insertion into 16 is covered with the electrical insulating sheet 18. Accordingly, the plurality of permanent magnets 17 divided in the axial direction of the rotor core 12 can be easily inserted into the magnet housing holes 16.

  (5) In the method of manufacturing the rotor 11, after all the permanent magnets 17 are inserted into the respective magnet housing holes 16, the rotor core 12 is the end plate 13 disposed on both sides, and the interval between the both end plates 13 is set in advance. An end plate pressing and fixing step of fixing the both end plates 13 to the rotary shaft 14 in a pressed state until the distance is reached (in this embodiment, the thickness when the rotor core 12 is pressed) is provided. Therefore, it becomes easy to press the laminated core 20 with the both end plates 13 so that the distance between the both end plates 13 becomes a preset distance.

  (6) In the permanent magnet accommodation step, the permanent magnets 17 are accommodated in the respective bag portions 19 of the electrically insulating sheet 18 formed so that the bag portions 19 for accommodating the permanent magnets 17 one by one are continuous. The magnet housing holes 16 are inserted in a continuous state together with the electrical insulating sheet 18. Therefore, each permanent magnet 17 can be easily inserted into the magnet housing hole 16 in a state in which all the electromagnetic steel plates 12 a constituting the rotor core 12 are laminated.

  (7) In the end plate pressing and fixing step, when the rotor core 12 is pressed by the end plates 13 disposed on both sides thereof, the electromagnetic steel plates 12a constituting the rotor core 12 are guide portions (rotations) extending in the axial direction of the rotary shaft 14. It is moved while being guided by the keyway 14b of the shaft 14 and the convex portion of the electromagnetic steel plate 12a. Therefore, even if there is a repulsive force between the divided permanent magnets 17, the electromagnetic steel plates 12 a are easily pressed and clamped by the both end plates 13 in a predetermined positional relationship.

(Second Embodiment)
Next, a second embodiment will be described with reference to FIGS. In this embodiment, the configuration of the electrical insulating sheet 18 covering each permanent magnet 17 accommodated in the magnet accommodation hole 16 is different from that of the first embodiment, and other configurations are the same as those of the first embodiment. is there. The same parts as those of the first embodiment are denoted by the same reference numerals, and detailed description thereof is omitted.

  FIG. 7 is a schematic cross-sectional view corresponding to FIG. 1C of the first embodiment. As shown in FIG. 7, the electrical insulating sheet 18 is bent into a shape that partitions the magnetic pole surfaces of one permanent magnet 17, that is, both surfaces in the thickness direction, and the end surface 17 a of the adjacent permanent magnet 17. Is arranged in. That is, in the first embodiment, the electrical insulating sheets 18 arranged in one magnet housing hole 16 are integrally formed, but in this embodiment, the same number of electrical insulating sheets as the permanent magnets 17 are formed. 18 is arranged in one magnet housing hole 16.

  When the rotor 11 of this embodiment is manufactured, the required number of laminated cores 20 are laminated on the rotor core 12 and then the permanent magnets 17 are not inserted into the respective magnet housing holes 16 together with the electrical insulating sheets 18. A required number of laminated cores 20 in which the permanent magnets 17 are accommodated together with the electrical insulating sheets 18 are laminated in the magnet accommodation holes 16. As shown in FIG. 8A, the permanent magnet 17 and the electrical insulation sheet 18 are inserted into the magnet housing hole 16 by bending the electrical insulation sheet 18 having the same width as the permanent magnet 17 into a substantially U shape. In addition, the magnetic pole surfaces (both end surfaces in the thickness direction) of the permanent magnet 17 and the front side in the insertion direction into the magnet housing hole 16 are covered. Then, in a state where the permanent magnet 17 is inserted into the magnet housing hole 16 together with the electrical insulating sheet 18, the portion protruding from the magnet housing hole 16 of the electrical insulating sheet 18 is cut. When the laminated core 20 is assembled together with the end plate 13 with respect to the rotary shaft 14 using the jig 31 as in the first embodiment, as shown in FIG. The permanent magnets 17 accommodated in the state are in a state in which the electrical insulating sheet 18 exists between the magnetic pole face and the adjacent end face 17a.

According to the second embodiment, in addition to the effects (1), (4), (5) and (7) of the first embodiment, the following effects can be obtained.
(8) In the permanent magnet housing step, after the necessary number of laminated cores 20 are laminated on the rotor core 12, the permanent magnets 17 are not inserted into the respective magnet housing holes 16 together with the electrical insulating sheets 18; The required number of laminated cores 20 in which the electrical insulating sheets 18 are accommodated in the respective magnet accommodation holes 16 are arranged between the end plates 13. Therefore, the electrical insulation sheet 18 does not have to be bag-shaped. Further, it is not necessary to prepare different electrical insulation sheets 18 corresponding to the lengths of the laminated core 20 in the axial direction, and one type of electrical insulation sheet 18 can be used.

The embodiment is not limited to the above, and may be embodied as follows, for example.
○ As in the second embodiment, the required number of laminated cores 20 in which the permanent magnets 17 and the electrical insulating sheets 18 are previously accommodated in the magnet accommodation holes 16 are arranged between the end plates 13 to form the rotor core 12. In this case, as shown in FIG. 9, a permanent magnet 17 sealed with a bag-like electrical insulating sheet 18 may be used. In this case, each bag portion 19 is formed from the electrical insulation sheet 18 used in the first embodiment, that is, the electrical insulation sheet 18 formed so that the bag portions 19 for accommodating the permanent magnets 17 one by one are continuous. The permanent magnets 17 may be used separately from each other, or a plurality of the permanent magnets 17 accommodated in a bag-like electrical insulating sheet 18 may be prepared.

  The electrical insulating sheet 18 may cover only four surfaces of the six surfaces of the permanent magnet 17 including the two magnetic pole surfaces and the two end surfaces in the axial direction of the rotor core 12.

The number of the laminated cores 20 constituting the rotor core 12 is not limited to four, and may be appropriately changed depending on, for example, the axial length and the diameter of the rotor core 12.
The rotor core 12 is not limited to the laminated core 20 having the same thickness, and may be a mixture of laminated cores 20 having different thicknesses. For example, regardless of the length of the rotor core 12 in the axial direction, a plurality of basic laminated cores 20 having the same thickness are used, and the insufficient length is compensated by the laminated cores 20 having different thicknesses. Also good. If the rotor core 12 is configured with the same number of laminated cores 20 regardless of the axial length of the rotor core 12, at least the types of the laminated core 20 and the permanent magnet 17 are required as much as the types of the rotor core 12. However, if a configuration is adopted in which a plurality of basic laminated cores 20 are used and the insufficient length is compensated for by the laminated cores 20 having different thicknesses, the types of the laminated cores 20 prepared in advance are used. In addition, it is possible to avoid preparing a large number of different types of laminated cores 20 and to secure a storage place.

  The rotor core 12 is not limited to a manufacturing method in which a plurality of laminated cores 20 formed by laminating electromagnetic steel plates 12a in advance are used, and a required number of electromagnetic steel plates 12a constituting the rotor core 12 are laminated at once. 12 may be manufactured. In this case, the permanent magnets 17 are accommodated in the respective bag portions 19 of the electrically insulating sheet 18 formed so that the bag portions 19 for accommodating the permanent magnets 17 one by one as in the first embodiment. In this state, it is preferably inserted into each magnet accommodation hole 16 in a state of being continuous with the electrical insulating sheet 18.

  In the manufacturing method including the step of forming the rotor core 12 using a plurality of laminated cores 20, the length of the permanent magnet 17 is not necessarily the same as the thickness of the laminated core 20, and the same number of permanents as the laminated core 20 is used. The magnet 17 may not be used. For example, the number of permanent magnets 17 may be made larger or smaller than the number of laminated cores 20.

  When the rotor core is pressed by the end plates disposed on both sides thereof, guide portions that guide the magnetic plates constituting the rotor core so as to move in the axial direction of the rotation shaft are provided on the inner surface of the housing portion 32 of the jig 31. You may comprise by the linear ridge formed in this and the recessed part formed in the occupation of the electromagnetic steel plate 12a so that it may engage with the ridge.

The permanent magnet 17 is not limited to a flat plate shape. For example, a permanent magnet having a circular arc shape or a U shape may be arranged so as to protrude toward the center of the rotor core 12.
The number of permanent magnets 17 is not limited to one for each pole. For example, two flat permanent magnets 17 may be arranged in a V shape.

The number of poles of the rotor 11 is not limited to eight but may be an even number, but is preferably four or more, and is appropriately set depending on the size of the rotor 11
The magnetic plate is not limited to the electromagnetic steel plate 12a and may be made of other ferromagnetic materials.

○ It may be applied not only to motors but also to generators.
The following technical idea (invention) can be understood from the embodiment.
(1) A plurality of permanent magnets are provided in a magnet housing hole formed to extend in the axial direction of a rotor core composed of a plurality of laminated cores formed by laminating a plurality of magnetic plates made of a ferromagnetic material. The rotor core is housed in a state of being divided in the axial direction of the rotor core, and is a method of manufacturing a rotor of a rotating electrical machine provided with an end plate sandwiching the rotor core,
A laminated core forming step in which a permanent magnet forms the laminated core inserted into the magnet accommodation hole in a state where at least the magnetic pole surface and the front side in the insertion direction to the magnet accommodation hole are covered with an electrical insulating sheet; A predetermined number of laminated cores are placed between the pair of end plates and inserted into the rotating shaft, and the both end plates are used as the rotating shaft while being pressed until the distance between the end plates reaches a preset distance. A method of manufacturing a rotor of a rotating electrical machine, wherein the rotor is fixed.

  (2) In the invention described in claim 6 or the technical idea (1), the guide portion is formed on the outer surface of the rotating shaft so as to extend along the axial direction thereof, and Each of the magnetic plates is formed of a ridge or groove that engages with the groove or ridge formed on the rotating shaft.

(A) is a schematic side view of the rotor in 1st Embodiment, (b) is the BB sectional view taken on the line of (a), (c) is the schematic sectional view in the CC line of (b). (A) is a schematic perspective view of the permanent magnet accommodated in the electrical insulation sheet, (b) is a schematic cross section. The schematic perspective view which shows the state which accommodates a permanent magnet with an electrically insulating sheet in the magnet accommodation hole of a rotor core. (A) is a schematic diagram of the state in which the rotor and one end plate are accommodated in the accommodation part of a jig, (b) is a schematic diagram which shows the state by which the other end plate is arrange | positioned. (A) is a schematic diagram which shows the state pressed by the press jig after the other end plate is arrange | positioned, (b) is a schematic diagram of the state which the fastener was fixed and the press jig evacuated. (A) is a schematic diagram showing the operation of the rotor of this embodiment, (b) is a schematic diagram showing the operation of the rotor of the prior art, and (c) is a schematic diagram showing the operation of another prior art rotor. . The schematic cross section corresponding to FIG.1 (c) in 2nd Embodiment. (A) is a schematic diagram which shows the state which inserts a permanent magnet in the magnet accommodation hole of a lamination | stacking core, (b) is a schematic diagram which shows a permanent magnet and an electrically insulating sheet at the time of the assembly | attachment of a lamination | stacking core. The schematic diagram which shows the laminated core of another embodiment, a permanent magnet, and an electrically insulating sheet. (A) is a schematic diagram of a prior art, (b) is a partial schematic diagram of another prior art rotor core.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 11 ... Rotor, 12 ... Rotor core, 12a ... Electromagnetic steel plate as a magnetic plate made of a ferromagnetic material, 13 ... End plate, 14 ... Rotating shaft, 16 ... Magnet accommodation hole, 17 ... Permanent magnet, 17a ... End face, 18 ... Electrical insulating sheet, 19 ... bag part.

Claims (6)

A rotor core formed by laminating a plurality of magnetic plates made of a ferromagnetic material has a permanent magnet accommodated in a magnet accommodation hole formed so as to extend in the axial direction, and an end plate for sandwiching the rotor core is provided. A rotating electric machine rotor,
A plurality of permanent magnets are accommodated in the magnet accommodation hole in a state of being divided in the axial direction of the rotor core, and each permanent magnet has at least a magnetic pole surface covered with an electrically insulating sheet and an end surface of an adjacent permanent magnet. A rotor of a rotating electrical machine characterized in that a space is partitioned by the electrical insulating sheet.   The rotor of the rotating electrical machine according to claim 1, wherein the surface of each permanent magnet is covered with the electrical insulating sheet.   The said electrical insulation sheet is formed so that the bag part which accommodates the said permanent magnet one by one may be continued, and the permanent magnet is accommodated one by one in each bag part. Rotor for rotating electrical machines. A state in which a plurality of permanent magnets are divided in the axial direction of the rotor core in a magnet receiving hole formed so as to extend in the axial direction of the rotor core formed by laminating a plurality of magnetic plates made of ferromagnetic material And a method of manufacturing a rotor of a rotating electrical machine provided with an end plate for sandwiching the rotor core,
Each permanent magnet accommodated in the magnet accommodating hole is formed in a size after being accommodated in advance and magnetized, and at least the magnetic pole surface and the front side in the insertion direction to the magnet accommodating hole are electrically insulating sheets. A permanent magnet housing step to be inserted into each magnet housing hole in a covered state;
After all the permanent magnets are inserted into the respective magnet housing holes, an end plate pressing and fixing step of fixing the both end plates to the rotating shaft in a pressed state with the end plates arranged on both sides of the rotor core is provided. A method for manufacturing a rotor of a rotating electrical machine, characterized in that   In the permanent magnet housing step, the permanent magnet is housed in each bag portion of the electrically insulating sheet formed so that the bag portions for housing the permanent magnets one by one are continuous with the electrically insulating sheet. The method for manufacturing a rotor of a rotating electric machine according to claim 4, wherein the rotor is inserted into each magnet housing hole in a continuous state.   In the end plate pressing and fixing step, when pressing the rotor core with end plates arranged on both sides thereof, the magnetic plates constituting the rotor core are pressed in a state of being guided by guide portions extending in the axial direction of the rotation shaft. The manufacturing method of the rotor of the rotary electric machine of Claim 4 or Claim 5 to be performed.

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