JP6981373B2 - Rotor manufacturing method - Google Patents

Description

The present invention relates to a method of manufacturing B over data.

As disclosed in Patent Document 1, the rotor of a rotary electric machine is attached to a tubular member made of a fiber reinforced material, a magnetic material arranged in the tubular member, and both ends in the axial direction of the tubular member. It is equipped with a shaft. The magnetic material and the shaft are held by the tubular member. As a result, the magnetic material, the tubular member, and the shaft can be integrally rotated.

Japanese Unexamined Patent Publication No. 2004-11249

When a force is applied from the magnetic material to the cylinder member due to the centrifugal force acting on the magnetic material due to the rotation of the rotor or the thermal expansion of the magnetic material due to the use of the rotating electric machine, the cylinder member may be broken. When the tubular member breaks, the holding force for holding the magnetic material decreases.

An object of the present invention is to provide a method for producing B over data capable of suppressing the breakage of the tubular member.

The rotor that solves the above problems is made of a fiber reinforced material, and has a tubular member having a resin portion and fibers, a magnetic material arranged in the tubular member, and an axial first end portion of the tubular member. A first shaft attached to the cylinder member and a second shaft attached to a second end portion in the axial direction of the cylinder member, the cylinder member has the fibers extending in the circumferential direction of the cylinder member. It is composed of at least a laminated first layer portion in which the fibers are oriented and a second layer portion in which the fibers are oriented so as to extend in the axial direction of the tubular member, and the outermost layer of the tubular member is the outermost layer. It is the first layer part.

When the rotor rotates, a force is applied from the magnetic material to the tubular member due to the centrifugal force acting on the magnetic material and the thermal expansion of the magnetic material. Since this force acts toward the outer peripheral surface of the tubular member, the outermost layer is likely to break. In the second layer portion, since the fibers are oriented in a state of extending in the axial direction of the tubular member, the resin portion is interposed between the fibers adjacent to each other in the circumferential direction. On the other hand, in the first layer portion, since the fibers are oriented in a state of extending in the circumferential direction of the tubular member, the fibers are continuous in the circumferential direction. If the second layer portion is used as the outermost layer, the resin portion is likely to break because the resin portion is interposed between the fibers adjacent to each other in the circumferential direction. On the other hand, by using the first layer portion as the outermost layer, it is possible to prevent the resin portion from breaking due to the fibers extending in the circumferential direction. Therefore, it is possible to suppress the breakage of the tubular member.

A method for manufacturing a rotor that solves the above problems is to use a first prepreg in which fibers oriented in a first direction are impregnated with a thermosetting resin and a second direction that intersects the first direction. A step of obtaining a laminated body by laminating a second prepreg in which fibers oriented in an elongated state are impregnated with a thermosetting resin, and a columnar winding member in which the fibers of the second prepreg are wound. The step of winding the laminate so that the fibers of the first prepreg extend in the axial direction of the member, the fibers of the first prepreg extend in the circumferential direction of the winding member, and the first prepreg becomes the outermost layer, and the winding are performed. It includes a step of curing the thermosetting resin by heating the laminate.

When the laminate in which the first prepreg and the second prepreg are laminated is heated to cure the thermosetting resin, the first prepreg and the second prepreg are integrated to manufacture a tubular member. When winding the first prepreg and the second prepreg, the fibers of the first prepreg extend in the circumferential direction of the winding member, and the first prepreg becomes the outermost layer, so that the maximum of the tubular member is reached. In the outer layer, the fibers are oriented in a state of extending in the circumferential direction. Therefore, it is possible to obtain a rotor capable of suppressing the breakage of the tubular member.

According to the present invention, breakage of the tubular member can be suppressed.

Sectional view of rotary electric machine. Sectional view of the rotor. A cross-sectional view showing a part of a tubular member broken. A cross-sectional view showing a part of a tubular member broken. The perspective view which shows the laminated body of the 1st prepreg and the 2nd prepreg. The perspective view which shows the process of winding a laminated body around a mandrel. The schematic diagram which shows the laminated body wound around a mandrel. The figure which shows the process of press-fitting a permanent magnet into a cylinder member. A cross-sectional view showing a permanent magnet press-fitted into a tubular member. The figure for demonstrating the operation of a rotor. The cross-sectional view which shows the cylinder member of the modification.

Hereinafter, an embodiment of the rotor and a method for manufacturing the rotor will be described.
As shown in FIGS. 1 and 2, the rotary electric machine 10 is housed in the housing 11. The rotary electric machine 10 includes a stator 12 and a rotor 20. The stator 12 includes a cylindrical stator core 13 and a coil 14 wound around the stator core 13. The stator core 13 is fixed to the inner surface of the housing 11.

The rotor 20 includes a tubular member 41, a permanent magnet 21 which is a magnetic material, a first shaft 31, and a second shaft 36. The tubular member 41 is made of a fiber reinforced material. In the present embodiment, the tubular member 41 is made of carbon fiber reinforced plastic (CFRP). The tubular member 41 has a cylindrical shape in which the axis of the tubular member 41 extends linearly.

The permanent magnet 21 is a solid columnar shape. The permanent magnet 21 is magnetized in the radial direction of the permanent magnet 21. The axial dimension of the permanent magnet 21 is shorter than the axial dimension of the tubular member 41. One of both ends 22 and 23 in the axial direction of the permanent magnet 21 is referred to as the first end portion 22, and the other is referred to as the second end portion 23.

The permanent magnet 21 is arranged in the tubular member 41. The axis of the permanent magnet 21 coincides with the axis of the tubular member 41. The permanent magnet 21 is arranged between both ends 42, 43 in the axial direction of the tubular member 41. Permanent magnets 21 are not arranged at both ends 42, 43 in the axial direction of the tubular member 41. In the present embodiment, the permanent magnet 21 is press-fitted into the tubular member 41. Therefore, a compressive force in the radial direction acts on the permanent magnet 21 from the tubular member 41, and the permanent magnet 21 is held by this compressive force.

The first shaft 31 includes a columnar shaft main body 32 and a flange portion 33 protruding from the shaft main body 32 in the radial direction of the shaft main body 32. The flange portion 33 is arranged closer to one end surface 34 in the axial direction of the shaft main body 32. The second shaft 36 includes a columnar shaft main body 37 and a flange portion 38 protruding from the shaft main body 37 in the radial direction of the shaft main body 37. The flange portion 38 is arranged closer to one end surface 39 in the axial direction of the shaft main body 37.

A part of the first shaft 31 is arranged in the tubular member 41. More specifically, if one of both ends 42 and 43 in the axial direction of the tubular member 41 is the first end 42 and the other is the second end 43, the first shaft 31 is more than the flange 33. The portion on the end face 34 side is press-fitted into the first end portion 42. A part of the second shaft 36 is arranged in the tubular member 41. More specifically, the portion of the second shaft 36 on the end surface 39 side of the flange portion 38 is press-fitted into the second end portion 43 of the tubular member 41. As a result, the first shaft 31 is attached to the first end 42 of the tubular member 41, and the second shaft 36 is attached to the second end 43 of the tubular member 41.

Of the rotor 20, the permanent magnet 21 is arranged inside the stator 12 in a rotatable state in the radial direction. Of the rotor 20, both shafts 31 and 36 are supported by a bearing 15 supported by the housing 11. When the permanent magnet 21 is rotated by energizing the coil 14, the tubular member 41 integrated with the permanent magnet 21 and both shafts 31 and 36 rotate integrally with the permanent magnet 21.

Next, the cylinder member 41 will be described in detail.
As shown in FIGS. 3 and 4, the tubular member 41 includes a resin portion 44 and fibers 46 and 47. The resin portion 44 is obtained by curing a thermosetting resin such as an epoxy resin or a phenol resin. Each fiber 46, 47 is a carbon fiber. The tubular member 41 includes a first layer portion 51 in which the fibers 46 are oriented in a state extending in the circumferential direction of the tubular member 41, and a second layer portion 52 in which the fibers 47 are oriented in a state extending in the axial direction of the tubular member 41. , Are configured by stacking.

Assuming that the fiber 46 of the first layer portion 51 is the first fiber 46, the first fiber 46 extends continuously over the entire circumferential direction of the tubular member 41. The first fiber 46 is arranged so as to surround the permanent magnet 21 arranged in the tubular member 41. A plurality of first fibers 46 are arranged in the axial direction of the tubular member 41. Although the illustration is simplified for convenience of explanation, a plurality of first fibers 46 are densely arranged, and a plurality of first fibers 46 extending in the circumferential direction of the cylindrical member 41 are arranged in the axial direction. It can be said that the first fiber 46 has a cylindrical shape. In addition, "extending in the circumferential direction of the tubular member 41" means that when the tubular member 41 is viewed from the radial direction, the first fiber 46 is orthogonal to the central axis of the tubular member 41 and the first fiber 46. Indicates the oriented state. “Orthogonal” means that not only the central axis of the tubular member 41 and the first fiber 46 intersect at 90 degrees, but also the angle deviation within the tolerance range is allowed. For example, if the tolerance is ± 1 degree, orthogonality includes an aspect in which the central axis of the tubular member 41 and the first fiber 46 intersect at 89 degrees to 91 degrees.

Assuming that the fiber 47 of the second layer portion 52 is the second fiber 47, the second fiber 47 extends continuously over the entire axial direction of the tubular member 41. The second fiber 47 is arranged so as to overlap with each other via the resin portion 44 over the entire axial direction of the permanent magnet 21 arranged in the tubular member 41. A plurality of second fibers 47 are arranged in the circumferential direction of the tubular member 41. Although not shown for convenience of explanation, a plurality of second fibers 47 are densely arranged, and a plurality of second fibers 47 extending in the axial direction of the cylindrical member 41 are arranged in the circumferential direction. It can be said that the second fiber 47 has a cylindrical shape. The "state extending in the axial direction of the tubular member 41" means that the central axis of the tubular member 41 and the second fiber 47 are parallel to each other when the tubular member 41 is viewed from the radial direction. Shows the state in which 47 is oriented. "Parallel" means not only a state in which the central axis of the tubular member 41 and the extending direction of the second fiber 47 coincide with each other, but also allow a deviation within a tolerance range. For example, if the tolerance is ± 1 degree, “parallel” includes a mode in which the extending direction of the second fiber 47 extends in a direction deviated by ± 1 degree with respect to the central axis of the tubular member 41.

A plurality of the first layer portion 51 and the second layer portion 52 are laminated in the radial direction of the tubular member 41. In the present embodiment, the first layer portion 51 and the second layer portion 52 are laminated in two layers each. From the innermost layer to the outermost layer of the tubular member 41, the first layer portion 51 and the second layer portion 52 are alternately laminated in the order of the second layer portion 52 → the first layer portion 51. The innermost layer of the tubular member 41 is the second layer portion 52, and the outermost layer of the tubular member 41 is the first layer portion 51.

Next, a method of manufacturing the rotor 20 will be described.
As shown in FIG. 5, first, the laminated body 63 is obtained by laminating the first prepreg 61 and the second prepreg 62. Each prepreg 61, 62 is a sheet-like material obtained by impregnating fibers 64, 65 oriented in one direction with thermosetting resins 66, 67. The first prepreg 61 includes a thermosetting resin 66 and fibers 64. The fibers 64 are oriented so as to extend in the length direction of the first prepreg 61. The second prepreg 62 includes a thermosetting resin 67 and fibers 65. The fibers 65 are oriented so as to extend in the width direction of the second prepreg 62.

When laminating the first prepreg 61 and the second prepreg 62, laminating is performed so that the width direction of the first prepreg 61 and the width direction of the second prepreg 62 coincide with each other. As a result, the fibers 64 and 65 are arranged so as to be orthogonal to each other. In the present embodiment, the length direction of the first prepreg 61 is the first direction, and the width direction of the second prepreg 62 is the second direction.

Next, as shown in FIGS. 6 and 7, the laminated body 63 is wound around the mandrel 71, which is a columnar winding member. When winding the laminate 63, the fibers 65 of the second prepreg 62 extend in the axial direction of the mandrel 71, the fibers 64 of the first prepreg 61 extend in the circumferential direction of the mandrel 71, and the first prepreg 61 Wind so that it is the outermost layer. Specifically, in a state where the outer peripheral surface of the mandrel 71 and the second prepreg 62 of the laminated body 63 are in contact with each other, winding is performed so that the length direction of the second prepreg 62 coincides with the circumferential direction of the mandrel 71. As a result, the first prepreg 61 becomes the outermost layer regardless of the number of times the laminated body 63 is wound. Since the tubular member 41 of the present embodiment is formed by laminating two first layer portions 51 and two second layer portions 52, the laminated body 63 is wound around the mandrel 71 twice. By changing the number of turns of the laminated body 63, the number of the first layer portion 51 and the second layer portion 52 can be arbitrarily changed.

Next, the laminate 63 wound around the mandrel 71 is heated. When the laminate 63 is heated, the thermosetting resins 66 and 67 are softened, and the prepregs 61 and 62 are integrated. Further heating of the softened thermosetting resins 66 and 67 cures the thermosetting resins 66 and 67. After curing the thermosetting resins 66 and 67, the mandrel 71 is removed to obtain the tubular member 41. The thermosetting resin 66 of the first prepreg 61 and the thermosetting resin 67 of the second prepreg 62 constitute the resin portion 44 of the tubular member 41. The fiber 64 of the first prepreg 61 constitutes the first fiber 46. The fiber 65 of the second prepreg 62 constitutes the second fiber 47. As described above, the method for manufacturing the rotor 20 of the present embodiment includes a step of obtaining the laminated body 63, a step of winding the laminated body 63, and a step of heating the wound laminated body 63.

Next, as shown in FIG. 8, the permanent magnet 21 is press-fitted into the tubular member 41. The inner diameter R1 of the tubular member 41 before the permanent magnet 21 is press-fitted is smaller than the diameter R2 of the permanent magnet 21. The difference between the inner diameter R1 of the tubular member 41 before the permanent magnet 21 is press-fitted and the diameter R2 of the permanent magnet 21 is the tightening allowance. A holding force depending on the tightening allowance acts on the tubular member 41 to the permanent magnet 21.

Next, as shown in FIG. 9, the first shaft 31 and the second shaft 36 are press-fitted into the tubular member 41. Similar to the permanent magnet 21, the first shaft 31 and the second shaft 36 are also held by the tubular member 41 by the compressive force acting from the tubular member 41. As a result, the rotor 20 in which the tubular member 41, the permanent magnet 21, and both shafts 31 and 36 are integrated is manufactured.

The operation of the embodiment will be described.
When a current flows through the coil 14, the rotor 20 rotates. Centrifugal force acts on the permanent magnet 21 as the rotor 20 rotates. Further, the permanent magnet 21 generates heat due to the eddy current and thermally expands. The centrifugal force acting on the permanent magnet 21 and the force applied to the tubular member 41 due to the thermal expansion of the permanent magnet 21 act toward the radially outer side of the tubular member 41. As a result, a force for increasing the diameter of the tubular member 41 acts on the tubular member 41, and a force acts on the tubular member 41 so that the outer peripheral surface of the tubular member 41 expands in the circumferential direction. As a result, when a radial force is applied to the tubular member 41, the outermost layer is most likely to break. When the outermost layer is broken, the layer inside the outermost layer cannot be held by the outermost layer, which causes the entire tubular member 41 to be broken.

Here, in the second layer portion 52, since the second fiber 47 is oriented so as to extend in the axial direction of the tubular member 41, the fine resin portion 44 is between the second fibers 47 adjacent to each other in the circumferential direction. Intervenes. As shown in FIG. 10, if the outermost layer of the tubular member 41 is the second layer portion 52, when a force is applied to the tubular member 41 so that the outer peripheral surface of the tubular member 41 expands, cracks C extending from the outer peripheral surface are generated. This may occur, and the resin portion 44 is likely to break.

On the other hand, in the first layer portion 51, since the first fiber 46 is oriented in a state of extending in the circumferential direction of the tubular member 41, the first fiber 46 is continuous in the circumferential direction. By using the first layer portion 51 as the outermost layer as in the present embodiment, when a force is applied so as to expand the outer peripheral surface, the resin portion 44 is broken by the first fiber 46 continuous in the circumferential direction. Can be suppressed. Therefore, the breakage of the tubular member 41 can be suppressed.

Further, on the outer peripheral surface of the tubular member 41, a sink mark that is recessed in the radial direction of the tubular member 41 occurs. The sink mark extends along the fibers 46, 47 contained in the outermost layer. Therefore, as shown in FIG. 10, when the outermost layer of the tubular member 41 is the second layer portion 52, sink marks D extending in the axial direction of the tubular member 41 are generated. Then, due to this sink mark D, wind damage will occur when the rotary electric machine 10 is used.

On the other hand, when the outermost layer of the tubular member 41 is the first layer portion 51, the sink marks D generated on the outer peripheral surface of the tubular member 41 extend in the circumferential direction. In this case, since the sink mark D does not open in the axial direction of the tubular member 41, wind damage caused by the sink mark D is unlikely to occur.

The effect of the embodiment will be described.
(1) The tubular member 41 has a layered structure of a first layer portion 51 and a second layer portion 52, and the outermost layer has a first layer portion 51. As a result, it is possible to prevent the tubular member 41 from breaking.

(2) In the second layer portion 52, the second fiber 47 is oriented so as to extend in the axial direction of the tubular member 41. Compared to the tubular member 41 in which the second layer portion 52 is not laminated, the rigidity of the tubular member 41 in the bending direction with respect to the axial direction is higher. Therefore, resonance is less likely to occur in the rotor 20, and it is possible to suppress a decrease in the resonance rotation speed of the rotary electric machine 10.

(3) The permanent magnet 21 is press-fitted into the rotor 20. If the tightening allowance of the tubular member 41 is insufficient, the holding force to the permanent magnet 21 is insufficient, and if the tightening allowance is excessive, excessive stress is applied to the tubular member 41 when the tubular member 41 is press-fitted. Therefore, high accuracy control is required for the tightening allowance of the tubular member 41, but excessive stress may be applied to the tubular member 41 due to poor accuracy of the permanent magnet 21 and the tubular member 41. This stress is applied in the radial direction of the tubular member 41. Since the outermost layer of the tubular member 41 is the first layer portion 51, even if stress is applied when the permanent magnet 21 is press-fitted, breakage of the tubular member 41 can be suppressed in the same manner as when a force due to centrifugal force is applied. ..

(4) When manufacturing the tubular member 41, the laminated body 63 is wound so that the first prepreg 61 is the outermost layer. As a result, it is possible to obtain a tubular member 41 in which the outermost layer is the first layer portion 51.

(5) When the tubular member 41 is manufactured by the filament winding method in which the fiber is wound around the mandrel 71 while the fiber is impregnated with the resin, the fiber wound so as to extend in the axial direction tends to come off from the mandrel 71. Therefore, when the tubular member 41 is manufactured by the filament winding method, it is difficult to make the second fiber 47 of the second layer portion 52 parallel to the axial direction of the tubular member 41. On the other hand, by manufacturing the tubular member 41 by the first prepreg 61 and the second prepreg 62 as in the present embodiment, the second fiber 47 of the second layer portion 52 is parallel to the axial direction of the tubular member 41. It will be easier to do.

The embodiment can be modified and implemented as follows. The embodiments and the following modifications can be implemented in combination with each other within a technically consistent range.
○ The permanent magnet 21 may be arranged inside the tubular member 41 and may be adhered to the inner surface of the tubular member 41. Similarly, both shafts 31 and 36 may be arranged in the tubular member 41 and may be adhered to the inner surface of the tubular member 41.

In this case, as a method of manufacturing the rotor 20, instead of the mandrel 71, the laminated body 63 is wound around the permanent magnet 21 and both shafts 31 and 36. Then, by heating and curing the thermosetting resin, the tubular member 41, the permanent magnet 21, and both shafts 31, 36 are integrated. In this case, the permanent magnet 21 and both shafts 31, 36 are winding members.

○ As shown in FIG. 11, the innermost layer of the tubular member 41 may be the first layer portion 51. In addition, in FIG. 11, the layer portion other than the innermost layer of the tubular member 41 is not shown. In the first layer portion 51, since the first fiber 46 is oriented so as to extend in the circumferential direction of the tubular member 41, the first fiber is pressed into the inner peripheral surface of the tubular member 41 when the permanent magnet 21 is press-fitted. 46 is hard to get caught in the permanent magnet 21. Therefore, as in the case where the innermost layer of the tubular member 41 is the second layer portion 52, when the permanent magnet 21 is press-fitted into the tubular member 41, the resin portion 44 is scraped by the permanent magnet 21. It can be suppressed.

When the innermost layer of the tubular member 41 is the first layer portion 51, for example, the laminated body 63 is formed by sandwiching the second prepreg 62 between two first prepregs 61. As a result, it is possible to obtain a tubular member 41 in which both the innermost layer and the outermost layer are the first layer portions 51.

○ The tubular member 41 may be configured by laminating one layer each of the first layer portion 51 and the second layer portion 52.
○ The laminated body 63 may be one in which three or more layers of prepregs 61 and 62 are laminated.

○ In the first layer portion 51 and the second layer portion 52, for example, the fibers 46 and 47 are arranged in the molding die, the thermosetting resin is injected into the molding die, and the fibers 46 and 47 are filled with the thermosetting resin. It may be formed by impregnating with a thermosetting resin and then heating.

○ In addition to the first layer portion 51 and the second layer portion 52, the tubular member 41 may further have, for example, a helical winding layer portion in which fibers are helically wound. That is, the tubular member 41 may include, in addition to the first layer portion 51 and the second layer portion 52, a layer portion in which the orientation direction of the fibers is different from that of the first layer portion 51 and the second layer portion 52.

○ The magnetic material is not limited to the permanent magnet 21, and may be, for example, a laminated core, an amorphous core, a dust core, or the like.
○ The permanent magnet 21 may be, for example, a solid square columnar shape, and the shape of the permanent magnet 21 is not particularly limited. Further, both shafts 31 and 36 may be, for example, a square columnar shape, and the shapes of both shafts 31 and 36 are not particularly limited. Then, for example, when the permanent magnet 21 has a solid square columnar shape and both shafts 31 and 36 have a square columnar shape, the tubular member 41 needs to be formed in a square cylindrical shape. Therefore, the shape of the tubular member 41 may be appropriately changed depending on the shapes of the permanent magnet 21 and both shafts 31 and 36. The shape of the tubular member 41 can be changed by changing the shape of the mandrel 71.

○ As the fibers 46 and 47, organic fibers or inorganic fibers may be used, different types of organic fibers, different types of inorganic fibers, or mixed fiber fibers in which organic fibers and inorganic fibers are mixed may be used. good. Examples of the organic fiber include aramid fiber, poly-p-phenylene benzobisoxazole fiber, ultra-high molecular weight polyethylene fiber and the like, and examples of the inorganic fiber include glass fiber, ceramic fiber and the like in addition to carbon fiber. Can be mentioned.

20 ... Rotor, 21 ... Permanent magnet (magnetic material), 31 ... First shaft, 36 ... Second shaft, 41 ... Cylinder member, 44 ... Resin part, 46, 47 ... Fiber, 51 ... First layer part, 52 ... 2nd layer portion, 61 ... 1st prepreg, 62 ... 2nd prepreg, 64, 65 ... fiber, 71 ... mandrel (winding member).

Claims (1)

Thermosetting to a first prepreg in which fibers oriented in a first direction are impregnated with a thermosetting resin and fibers oriented in a second direction intersecting the first direction. A step of laminating a second prepreg impregnated with a resin so that the second prepreg is sandwiched between the first prepregs to obtain a laminated body.
In the columnar winding member, the fibers of the second prepreg extend in the axial direction of the winding member, the fibers of the first prepreg extend in the circumferential direction of the winding member, and the first prepreg extends in the outermost layer. And the step of winding the laminate so as to be the innermost layer,
A step of curing the thermosetting resin by heating the wound laminate, and
A method for manufacturing a rotor , which comprises a step of press-fitting a permanent magnet into a tubular member obtained by curing the thermosetting resin.

Images