Rotor for magnetic rotating electrical machine, production method for same, and device

Patent metadata

Field	Value
Publication number	US-9985486-B2
Application number	US-201214395669-A
Country	US
Kind code	B2
Filing date	Oct 22, 2012
Priority date	May 31, 2012
Publication date	May 29, 2018
Grant date	May 29, 2018

Abstract

A method of manufacturing a rotor for a magnet type rotating electrical machine includes the steps of: cutting and laminating pieces of the core of the rotor, to thereby form a core ( 3 ); mounting the core ( 3 ) on a rotating jig ( 10 ); forming a magnet piece ( 2 p ) into a predetermined shape by sintering; mounting a predetermined number of the magnet pieces ( 2 p ) on a regulating jig ( 20 ); pressing the magnet pieces ( 2 p ) by the regulating jig ( 20 ) while rotating the core ( 3 ) by the rotating jig ( 10 ), to thereby mount the magnet pieces ( 2 p ) on the core ( 3 ); and adjusting an axial position of the magnet piece ( 2 p ) so that an axial end surface of the core ( 3 ) and an axial end surface of the magnet piece ( 2 p ) are aligned with each other.

First claim

The invention claimed is:

1. A method of manufacturing a rotor for a magnet type rotating electrical machine, the rotor comprising:
a core having a columnar shape or a polygonal prism shape, in which a predetermined number of projections protruding to a radially outer side of the core are arranged along an outer circumferential surface of the core; and
a predetermined number of magnets held in close contact with the outer circumferential surface of the core,
the method comprising:
a cutting step of cutting a thin steel plate to form pieces of the core;
a lamination step of laminating a predetermined number of the pieces of the core corresponding to an axial length of the core, to thereby form the core;
a rotating jig mounting step of mounting the core formed in the lamination step on a rotating jig;
an application step of applying an adhesive on a magnet mounting position of the outer circumferential surface of the core;
a magnet piece formation step of forming magnet pieces each having a strip shape and serving as a preform for a magnet;
a regulating jig mounting step of mounting, on a regulating jig in an aligned order, a predetermined number of the magnet pieces to be mounted on the core;
a magnet mounting step of sequentially mounting the predetermined number of the magnet pieces onto the magnet mounting positions of the core while rotating the core by the rotating jig, by pressing each of the predetermined number of the magnet pieces onto the core by the regulating jig while sequentially dispensing, from the regulating jig, the magnet pieces one by one in the aligned order; and
a magnetization step of magnetizing each of the predetermined number of the magnet pieces mounted on the core in a predetermined direction,
wherein method further comprises an axial adjustment step of moving, after the predetermined number of the magnet pieces are each mounted on a predetermined axial end surface of each of the predetermined number of the magnet pieces to be aligned with one axial end surface of the core, and
wherein the axial adjustment step comprises moving the one axial end surface of the each of the predetermined number of the magnet pieces toward the one axial end surface of the core through rotation of the rotating jig.

2. A method of manufacturing a rotor for a magnet type rotating electrical machine according to claim 1 ,
wherein the magnet piece formation step comprises forming the magnet pieces so that, in cross section, a thickness of a center portion thereof is larger than a thickness of both side surfaces thereof and the thickness becomes smaller from a circumferential center portion toward both side surface portions, that the thickness of the center portion is larger than a radial height of each of the predetermined number of projections of the core, and that an axial length of each of the magnet pieces is smaller than the axial length of the core, and
wherein the magnet mounting step comprises mounting the each of the predetermined number of the magnet pieces so that a radially inner circumferential surface thereof is mounted on a circumferential magnet mounting position between two of the predetermined number of projections of the core in a positional relationship in which, when the rotating jig rotates, one side surface of the each of the predetermined number of the magnet pieces abuts on one circumferential inner side wall of the two of the predetermined number of projections, and an air gap is formed between another side surface of the each of the predetermined number of the magnet pieces and another side wall of the two of the predetermined number of projections.

3. A method of manufacturing a rotor for a magnet type rotating electrical machine according to claim 1 , wherein the magnet mounting step further comprises the steps of:
mounting the core on the rotating jig and rotating the core; and
pressing a magnet piece arranged at a distal end portion among the predetermined number of the magnet pieces mounted on the regulating jig to the rotating core in an opposed manner.

4. A method of manufacturing a rotor for a magnet type rotating electrical machine according to claim 1 , further comprising a pressing step of pressing, after the magnet mounting step, each of the predetermined number of the magnet pieces toward a central axis of the core.

5. A method of manufacturing a rotor for a magnet type rotating electrical machine according to claim 4 , further comprising a magnet fixing step of curing, after the pressing step, the adhesive to fix the each of the predetermined number of the magnet pieces to the core.

6. A method of manufacturing a rotor for a magnet type rotating electrical machine, the rotor comprising:
a core having a columnar shape or a polygonal prism shape, in which a predetermined number of protections protruding to a radially outer side of the core are arranged along an outer circumferential surface of the core; and
a predetermined number of magnets held in close contact with the outer circumferential surface of the core,
the method comprising:
a cutting step of cutting a thin steel plate to form pieces of the core;
a lamination step of laminating a predetermined number of the pieces of the core corresponding to an axial length of the core, to thereby form the core;
a rotating jig mounting step of mounting the core formed in the lamination step on a rotating jig;
an application step of applying the adhesive on a magnet mounting position of the outer circumferential surface of the core;
a magnet piece formation step of forming magnet pieces each having a strip shape and serving as a preform for a magnet;
a regulating jig mounting step of mounting, on a regulating jig in an aligned order, a predetermined number of the magnet pieces to be mounted on the core;
a magnet mounting step of sequentially mounting the predetermined number of the magnet pieces onto the magnet mounting positions of the core while rotating the core by the rotating jig, by pressing each of the predetermined number of the magnet pieces onto the core by the regulating jig while sequentially dispensing, from the regulating jig, the magnet pieces one by one in the aligned order; and
a magnetization step of magnetizing each of the predetermined number of the magnet pieces mounted on the core in a predetermined direction,
wherein the magnet mounting step further comprises:
arranging the core upright so that an axis direction thereof becomes a normal;
arranging, on an axial lower end portion of the core, a regulating plate having an outer diameter larger than an outer diameter of the core; and
causing, when each of the predetermined number of the magnet pieces is mounted on a predetermined circumferential position within the magnet mounting position of the core, the each of the predetermined number of the magnet pieces to fall due to its own weight to be arranged so that an axial lower end surface thereof abuts on the regulating plate and is aligned with an axial lower end surface of the core.

Assignees

• Asao Yoshihito
• Miyaoka Masayuki
• Katayama Ryusuke
• Mori Akihiko
• Mitsubishi Electric Corp

Inventors

• Asao Yoshihito
• Miyaoka Masayuki
• Katayama Ryusuke
• Mori Akihiko

Classifications

• B32B38/0008

  Electrical discharge treatment, e.g. corona, plasma treatment; wave energy or particle radiation (heat treatment B32B38/0036) · CPC title

• B32B2457/00

  Electrical equipment · CPC title

• Y10T156/1077

  Applying plural cut laminae to single face of additional lamina · CPC title

• B32B38/0004

  Cutting, tearing or severing, e.g. bursting; Cutter details (cutting in general B26D; laminating combined with punching or perforating B32B38/04; removing all or part of the layers B32B38/10; cutting in combination with laying up and registration B32B38/185 takes precedence) · CPC title

• H02K15/03

  having permanent magnets · CPC title