JP2002272032A - Cylindrical permanent magnet rotor and manufacturing method thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a cylindrical permanent magnet rotor which can easily realize a multipole structure and a small size, can be manufactured with high productivity, and is low in cost, and to obtain its manufacturing method. SOLUTION: After cut-out permanent magnet segments 10 are magnetized, the segments 10 are arranged close to each other in one row on a metal thin plate 12 to obtain a belt-shaped element. Then a hexagonal pillar columnar polygonal ring 11, which has as many outer circumferential surfaces as the arranged permanent magnet segments 10 and whose respective outer circumfrential surfaces 11a have approximately the same shapes as the bottom surfaces of the permanet magnet segments 10, is made. The thin plate 12 is bent at positions between the adjacent permanent magnet segments 10 and wound on the outer circumferential surfaces of the polygonal ring 11, so as to have the permanent magnet segments 10 positioned at the respective outer circumferential surfaces 11a. Further, a shaft 13 is inserted into a through-hole 11b of the polygonal ring 11 to obtain a cylindrical permanent magnet rotor 100.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a cylindrical permanent magnet rotor used for, for example, a synchronous motor or the like, and a method of manufacturing the same.

[0002]

2. Description of the Related Art A conventional method of manufacturing a cylindrical permanent magnet rotor of this kind will be described with reference to FIGS. First, the permanent magnet piece 1 is formed into a curved shape having a radius of curvature equivalent to the radius of curvature of the outer peripheral surface of the cylindrical yoke 3. And the permanent magnet piece 1 thus formed is
It is arranged on the sheet 2 in three rows of three rows and temporarily fixed. Then, after the adhesive is applied to the outer peripheral surface of the cylindrical yoke 3, the sheet 2 is wound around the outer peripheral surface of the yoke 3 together with the permanent magnet pieces 1. Further, the adhesive is heated and cured, the sheet 2 is removed, and the permanent magnet pieces 1 in three rows are arranged in six rows at a regular angular pitch in the circumferential direction and fixed to the outer peripheral surface of the yoke 3. The magnet rotor assembly 4 is assembled.

Next, a permanent magnet rotor assembly 4 is shown in FIG.
As shown in FIG. 2, six magnetized yokes 7 each having a coil 6 wound thereon are arranged in a magnetizing device 5 which is annularly arranged at a constant angular pitch. At this time, the permanent magnet pieces 1 in each row are 1
The two magnetized yokes 7 are arranged to face each other. Then, the coil 6 is energized to magnetize each permanent magnet piece 1,
A six pole cylindrical permanent magnet rotor is made.

[0004]

Since the conventional cylindrical permanent magnet rotor is manufactured as described above, the permanent magnet piece 1 is made to have a radius of curvature equivalent to the radius of curvature of the outer peripheral surface of the cylindrical yoke 3. The permanent magnet piece 1 has to be formed in a curved shape, and the production of the permanent magnet piece 1 is complicated, the yield is reduced, and the cost cannot be reduced. In addition, since the permanent magnet piece 1 is formed in a curved shape, it is difficult to position the permanent magnet piece 1 when temporarily fixing the permanent magnet piece 1 on the sheet 2, and there is a problem that productivity is reduced. there were.

Also, since the permanent magnet piece 1 is magnetized after being attached to the outer peripheral surface of the yoke 3, the permanent magnet piece 1 is magnetized only at the N pole or the S pole, respectively. Therefore, in order to increase the number of poles of the rotor, the number of the permanent magnet pieces 1 must be increased, and there is also a problem that a multi-pole rotor applicable to a small electric motor cannot be obtained.
Furthermore, since it is difficult to reduce the size of the magnetizing device, there is another problem that a rotor applicable to a small electric motor such as a micro motor having a diameter of several millimeters cannot be obtained.

SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned problems, and a belt-like body in which magnetized rectangular parallelepiped permanent magnet pieces are arranged in a bendable thin metal plate is manufactured. By winding the band around a polygonal ring of a regular polygonal column shape having an outer peripheral surface composed of a surface substantially equal to the bottom surface of the magnet piece, high productivity and low cost can be easily realized with multipolarization and miniaturization. It is an object of the present invention to obtain a simple cylindrical permanent magnet rotor and a method for manufacturing the same.

[0007]

According to a method of manufacturing a cylindrical permanent magnet rotor according to the present invention, a rectangular parallelepiped thin plate-shaped permanent magnet piece is formed on a rectangular metal thin plate in a line in the longitudinal direction of the thin plate. The step of obtaining a strip disposed in close proximity, the outer peripheral surface has the same number of surfaces as the number of arrangement of the permanent magnet pieces, and each surface constituting the outer peripheral surface is the bottom surface of the permanent magnet piece. A step of producing a regular polygonal columnar polygonal ring having substantially the same planar shape, and bending the thin plate at a portion between the adjacent permanent magnet pieces to position the permanent magnet pieces on the respective surfaces; A step of winding the band around the outer peripheral surface of the polygon ring; and a step of magnetizing the permanent magnet pieces prior to the step of winding the band around the polygon ring.

Further, the method further comprises a step of attaching a cylindrical outer ring made of a magnetic material so as to include the belt-like body wound around the outer peripheral surface of the polygonal ring.

In the method of manufacturing a cylindrical permanent magnet rotor according to the present invention, a rectangular parallelepiped thin plate-shaped permanent magnet piece is arranged on a rectangular metal thin plate in a row in the longitudinal direction of the thin plate. A step of obtaining the provided strip-shaped body, and the outer peripheral surface has the same number of surfaces as the number of arrangements of the permanent magnet pieces, and each surface constituting the outer peripheral surface is substantially equal to the bottom surface of the permanent magnet piece. Forming a regular polygonal columnar polygonal ring, bending the thin plate at a portion between the adjacent permanent magnet pieces to form a regular polygonal ring, and bending the thin plate to form a regular polygonal ring. A step of magnetizing the permanent magnet pieces prior to a step of manufacturing a polygonal ring body; a step of attaching a cylindrical outer peripheral ring made of a magnetic material so as to include the ring body; The ring body It is obtained by a step of mounting so as to include the ring.

[0010] The step of magnetizing the permanent magnet piece includes:
This is performed prior to the step of disposing the permanent magnet pieces on the thin plate.

Further, the step of magnetizing the permanent magnet piece includes:
This is performed in a state where the permanent magnet pieces are arranged in a line on the thin plate.

The step of obtaining the belt-like body includes the steps of fixing a permanent magnet thin plate on the thin plate so as to cover the entire area of the thin plate; A step of preparing a plurality of the permanent magnet pieces by cutting and separating at a predetermined pitch in the vertical direction, and a step of collectively magnetizing the plurality of the permanent magnet pieces formed on the thin plate. Things.

[0013] The step of obtaining the band-like body includes forming a band-like insulating layer extending over the entire width of the thin plate on the thin plate at a predetermined pitch in the longitudinal direction of the thin plate. A step of forming a permanent magnet material layer on the thin plate on which the layer is formed by using a vacuum film forming technique, and until the insulating layer is exposed until the surface of the permanent magnet material layer formed on the thin plate is exposed. Polishing, separating the permanent magnet material layer by the insulating layer to form a plurality of permanent magnet pieces, and magnetizing the plurality of permanent magnet pieces formed on the thin plate at a time And a step of performing

Further, a cylindrical permanent magnet rotor according to the present invention has a polygonal ring formed in a regular polygonal column shape in which each surface constituting an outer peripheral surface is a rectangular planar shape, and an axis of the polygonal ring. A shaft integrally formed at the center position, a metal thin plate wound around the outer peripheral surface of the polygonal ring and fixed so as to be in close contact with each surface, and each surface of the outer peripheral surface of the polygonal ring, respectively And a plurality of permanent magnet pieces fixed on the thin plate so as to be opposed to each surface of the outer peripheral surface of the polygonal ring. It is provided.

Further, a cylindrical outer ring made of a magnetic material is attached so as to include the permanent magnet piece fixed on the thin plate.

[0016]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiments of the present invention will be described below with reference to the drawings. Embodiment 1 FIG. FIG. 1 is a process chart showing a method for manufacturing a cylindrical permanent magnet rotor according to Embodiment 1 of the present invention, and FIG. 2 is a magnetizing method in the method for manufacturing a cylindrical permanent magnet rotor according to Embodiment 1 of the present invention. It is a figure explaining a process.

Here, a method of manufacturing the cylindrical permanent magnet rotor according to the first embodiment will be described with reference to FIGS. First, a thin plate-shaped rectangular parallelepiped permanent magnet piece 10 is cut out from a magnet block (not shown) made of a samarium cobalt-based rare earth magnet material. Further, each surface 11a constituting the outer peripheral surface has a planar shape equivalent to the bottom surface of the permanent magnet piece 10, and a regular hexagonal column-shaped polygonal ring 11 in which a through hole 11b is formed at an axial center position is made of a magnetic material. It is made using a certain iron material. Also, the thin plate 12
However, for example, using a stainless steel material, the long side is defined as the circumferential length of the outer peripheral surface of the polygon ring 11, and the short side is defined as the polygon ring 1.
1 is formed in a rectangular shape having the axial length of the outer peripheral surface. The thin plate 12 is formed to have a thickness of, for example, several tens of microns, and is configured to be freely bent. Further, the shaft 13 made of stainless steel is formed in a cylindrical shape having an outer diameter equal to the inner diameter of the through hole 11b of the polygonal ring 11.

As shown in FIG. 2, each of the permanent magnet pieces 10 is magnetized by energizing a coil 17 wound around two opposite pieces of a U-shaped magnetizing yoke 18. The permanent magnet piece 10 thus magnetized has an N pole and an S pole.
The pole is formed at a portion facing the two U-shaped pieces of the magnetized yoke 18. Then, the six magnetized permanent magnet pieces 10
However, as shown in FIG. 1A, for example, a strip-shaped body which is arranged in a line on a thin plate 12 coated with a thermosetting epoxy resin-based adhesive 14 and temporarily fixed is obtained. Then
As shown in FIG. 1B, for example, a thermosetting epoxy resin-based adhesive 15 is applied on each surface 11a constituting the outer peripheral surface of the polygonal ring 11, and, for example, a thermosetting epoxy resin-based adhesive is applied. Adhesive 16 is applied to through-hole 11 of polygonal ring 11
b. Next, as shown in FIG. 1 (c), the above-mentioned band is bent around the thin plate 12 and wound around the outer peripheral surface of the polygonal ring 11. At this time, the thin plate 12 is bent at the ridge formed between the adjacent surfaces 11 a of the polygonal ring 11 at the portion between the adjacent permanent magnet pieces 10, and is brought into close contact with each surface 11 a via the adhesive 15. You. Then, the permanent magnet piece 10 is placed on the surface 1 of the polygonal ring 11.
1a. Further, the shaft 13 is inserted into the through-hole 11b of the polygonal ring 11, and thereafter, the adhesives 14, 15, 16 are heat-cured, and as shown in FIG.
A 12-pole cylindrical permanent magnet rotor 100 in which the thin plate 12, the polygon ring 11 and the shaft 13 are integrated is obtained.

As described above, in the first embodiment, the permanent magnet piece 10 cut out from the magnet block is magnetized by the magnetized yoke 18 around which the coil 17 is wound. However, it is possible to easily and reliably magnetize, and it is possible to easily realize a cylindrical permanent magnet rotor that can be applied to a micro motor having a diameter on the order of millimeters. The magnetizing yoke 18 is formed in a U-shape, and the coil 17 is wound around two U-shaped opposing pieces of the magnetizing yoke 18 to constitute a magnetizing device. Since the two pieces are magnetized from one side of the permanent magnet piece 10, an N pole and an S pole can be formed on one face side of the permanent magnet piece 10. Therefore, a cylindrical permanent magnet rotor using the permanent magnet piece 10 magnetized in this way is a permanent magnet piece 10
Is obtained, and the number of poles of the rotor can be easily increased. Therefore, it is possible to easily and inexpensively realize a motor whose rotational accuracy is improved by increasing the number of poles.

Further, since the permanent magnet piece 10 is formed in a rectangular parallelepiped, the permanent magnet piece 10 can be easily manufactured, the yield is increased, and the cost is reduced. Further, the dimensional accuracy of the permanent magnet piece 10 is improved, and the permanent magnet piece 10 can be easily positioned and disposed on the thin plate 12, thereby improving the productivity. In addition, using a regular polygonal ring 11 in which each surface 11a constituting the outer peripheral surface is formed in a planar shape substantially equal to the bottom surface of the rectangular parallelepiped permanent magnet piece 10, a bendable metal to which the permanent magnet piece 10 is attached is used. Since the thin plate 12 is bent and wound around each surface 11a constituting the outer peripheral surface of the polygon ring 11, the polygon ring 1 of the permanent magnet piece 10 is
1 can be easily attached, and productivity can be improved.

In the first embodiment, the permanent magnet piece 10, the thin plate 12, the polygonal ring 11, and the shaft 13
After the adhesive is incorporated, the adhesives 14, 15, 16 are simultaneously heated and cured.
May be separately heated and cured in each step. In this case, since each member is fixed after installation,
Handling of the members is facilitated without each member falling down during assembly.

Embodiment 2 FIG. In the first embodiment, the permanent magnet piece 10 cut out from the magnet block is magnetized by the magnetizing yoke 18 around which the coil 17 is wound before the permanent magnet piece 10 is arranged on the thin plate 12. In FIG. 3, as shown in FIG. 3, the magnetized yokes 18 around which the coils 17 are wound are prepared by the number of the arranged permanent magnet pieces 10, and the permanent magnet pieces 10 arranged on the thin plate 12 are collectively attached. It is magnetized. Therefore, according to the second embodiment, only one magnetizing step of the permanent magnet pieces 10 is required, and the manufacturing process of the rotor is significantly simplified.

Embodiment 3 FIG. In the first embodiment, the permanent magnet piece 10 cut out from the magnet block is
Although a predetermined number of strips are arranged in a line on the thin plate 12 coated with, a belt-shaped body is obtained. In the third embodiment, after a long permanent magnet thin plate is fixed on a metal thin plate, The permanent magnet thin plate is cut to obtain a belt-like body in which a predetermined number of permanent magnet pieces are arranged in a row on a metal thin plate.

Here, a method for manufacturing a belt-like body according to the third embodiment will be specifically described with reference to FIG.
First, as shown in FIG. 4A, a permanent magnet thin plate 20 made of a samarium cobalt-based rare earth magnet material is manufactured. The permanent magnet thin plate 20 has a bottom surface equivalent to that of the thin plate 12 and is formed in a long rectangular parallelepiped having a thickness equivalent to that of the permanent magnet piece 10. Next, FIG.
As shown in FIG. 2, a thermosetting epoxy resin adhesive 14 is applied on the thin plate 12. Then, the permanent magnet thin plate 20 is placed on the thin plate 12, and the adhesive 14 is heated and hardened to fix the permanent magnet thin plate 20 to the thin plate 12. Then
As shown in FIG. 4C, the permanent magnet thin plate 20 is cut and separated at a predetermined pitch in the length direction by a cutter 21.
As shown in FIG. 4D, the six permanent magnet pieces 10
To obtain a belt-like body fixedly arranged in a line on the thin plate 12. Then, similarly to the second embodiment, the magnetized yokes 18 around which the coils 17 are wound are prepared by the number of the arranged permanent magnet pieces 10, and the permanent magnet pieces 10 arranged on the thin plate 12 are collectively attached. Magnetize. Thereafter, a cylindrical permanent magnet rotor is obtained in the same manner as in the first embodiment.

According to the third embodiment, the permanent magnet piece 1
It is not necessary to arrange the 0s one by one on the thin plate 12, and the process of obtaining the strip is simplified, and the cost is reduced.

Embodiment 4 In the first embodiment, the permanent magnet piece 10 cut out from the magnet block is
A predetermined number of strips are arranged in a line on the thin plate 12 coated with the carbon black. In the fourth embodiment, a permanent magnet piece is formed on the thin plate using a vacuum film forming technique. A belt-like body in which a predetermined number of permanent magnet pieces are arranged in a line on a thin metal plate is obtained.

Here, a method of manufacturing a strip according to the fourth embodiment will be specifically described with reference to FIG.
First, as shown in FIG. 5A, the insulating layer 22 is formed on the thin plate 12. As the insulating layer 22, for example, an SiO ₂ film formed by using plasma CVD or sputtering is used. Next, a photoresist 23 is applied on the insulating layer 22. Then, using a photomask,
By developing, as shown in FIG. 5B, a strip-shaped photoresist 23 is formed on the thin plate 12 at a predetermined pitch in the length direction of the thin plate 12. The photoresist 23 is formed over the entire area of the thin plate 12 in the width direction. Next, using the photoresist 23 as a mask, reactive ion etching is performed using a fluorine-based gas to remove the exposed insulating layer 22. Then, the photoresist 23 is removed, and as shown in FIG.
2 are formed on the thin plate 12 at a predetermined pitch in the length direction of the thin plate 12. The strip-shaped insulating layer 22 is formed over the entire area of the thin plate 12 in the width direction.

Next, as shown in FIG.
A permanent magnet material layer 24 is formed on the thin plate 12 by, for example, sputtering using a target made of a samarium cobalt-based rare earth magnet material. Then, the insulating layer 22
The surface of the permanent magnet material layer 24 is polished flat until the surface is exposed. As a result, the permanent magnet material layer 24 is divided and separated by the insulating layer 22, and as shown in FIG.
A strip is obtained in which the permanent magnet pieces 10 are fixedly arranged in a row on the thin plate 12. Then, as in the second embodiment,
The magnetized yoke 18 around which the coil 17 is wound is attached to the permanent magnet 1
The permanent magnet pieces 10 arranged on the thin plate 12 are prepared and magnetized at once. Hereinafter, the first embodiment
As described above, a cylindrical permanent magnet rotor is obtained.

According to the fourth embodiment, the permanent magnet piece 1
It is not necessary to arrange the 0s one by one on the thin plate 12, and the process of obtaining the strip is simplified, and the cost is reduced. Further, a strip-shaped insulating layer 22 is formed on the thin plate 12 at a predetermined pitch, a permanent magnet material is formed on the substrate 12 by sputtering, and then a permanent magnet material layer 24 is formed so that the strip-shaped insulating layer 22 is exposed. The surface is polished, and the permanent magnet material layer 24 is divided and separated by the insulating layer 22.
Since the permanent magnet pieces 10 arranged in a single row are manufactured, the permanent magnet pieces 10 can be miniaturized, and a cylindrical permanent magnet rotor applicable to a micro motor can be easily realized. it can. Further, since the permanent magnet material has a fragile property, when the permanent magnet piece 10 is cut out from the magnet block or the permanent magnet thin plate 20 is cut by the cutter 21, cracks and chips are easily generated, and the size of the permanent magnet piece 10 is reduced. As a result, the yield decreases. However, according to the fourth embodiment, a manufacturing method suitable for miniaturization of the permanent magnet piece 10 is less likely to occur cracking and chipping.

Here, since the temperature is high during the step of forming the permanent magnet material, the insulating layer 22 is required to have heat resistance, and it is desirable to use an inorganic insulating material, such as a SiO ₂ film or Al ₂ O.
_Three films or the like can be used. Embodiment 4
In this example, the permanent magnet material is formed on the substrate 2 by sputtering, but the film forming technique is not limited to sputtering, and a vacuum film forming technique, for example, vacuum evaporation or ion plating can be used.

Embodiment 5 FIG. In the first embodiment, since the outer peripheral portion of the cylindrical permanent magnet rotor 100 is formed by the rectangular parallelepiped permanent magnet pieces 10, the torque caused by the gap formed between the permanent magnet pieces 10 changes intermittently. Cogging phenomenon occurs. In the fifth embodiment,
An object of the present invention is to obtain a cylindrical permanent magnet rotor that alleviates the cogging phenomenon.

Here, a method of manufacturing the cylindrical permanent magnet rotor according to the fifth embodiment will be described with reference to FIG. First, in the same manner as in the first embodiment, the polygonal ring 11 in which the thin plate 12 in which the permanent magnet pieces 10 are arranged in one row is wound around the outer peripheral surface is obtained. Further, a thin plate made of a magnetic material such as iron is formed into a cylindrical shape to produce the outer peripheral ring 30. The outer peripheral ring 30 has an inner diameter substantially equal to the maximum outer diameter of the permanent magnet piece 10 wound around the polygonal ring 11. Then, the polygonal ring 11 around which the permanent magnet piece 10 is wound is inserted into the outer peripheral ring 30. Thereby, the permanent magnet piece 10 wound on the outer peripheral surface around the polygonal ring 11 is included in the outer peripheral ring 30, and the outer peripheral ring 30 is magnetically attracted to the permanent magnet piece 10 and temporarily fixed. Thereafter, although not shown, the shaft 13 is inserted into the through hole 11 b of the polygonal ring 11, and a thermosetting epoxy resin-based adhesive is applied between the outer peripheral ring 30 and the permanent magnet piece 10. Is heated and cured to obtain a cylindrical permanent magnet rotor.

According to the fifth embodiment, since the cylindrical permanent magnet rotor is provided with the cylindrical outer peripheral ring 30, in the electric motor equipped with the cylindrical permanent magnet rotor, the magnetic flux is generated at the outer periphery. By flowing through the ring 30, the magnetic flux between the permanent magnet pieces 10 changes continuously,
The cogging phenomenon is mitigated, and good rotation accuracy is realized. In addition, since the outer peripheral ring 30 is magnetically attracted to the permanent magnet piece 10 and temporarily fixed, handling during assembly is facilitated, and productivity is improved.

Embodiment 6 FIG. In the sixth embodiment, as in the fifth embodiment, a cylindrical permanent magnet rotor for mitigating the cogging phenomenon is obtained.

Here, a method of manufacturing the cylindrical permanent magnet rotor according to the sixth embodiment will be described with reference to FIG. First, in the same manner as in the first embodiment, a belt-like body in which the magnetized permanent magnet pieces 10 are arranged in a line on the thin plate 12 is obtained. Further, a thin plate made of a magnetic material such as iron is formed into a cylindrical shape to produce the outer peripheral ring 30. Then, sheet 1
A portion between the two adjacent permanent magnet pieces 10 is bent to form a regular hexagonal ring. Then, this ring body is inserted into the outer peripheral ring 30. Thereby, the permanent magnet pieces 10 arranged on the outer circumference of the ring body are included in the outer circumference ring 30, and the outer circumference ring 30 is magnetically attracted to the permanent magnet pieces 10 and temporarily fixed. The outer ring 30
Is formed with an inner diameter substantially equal to the maximum outer diameter of the permanent magnet pieces 10 arranged on the outer periphery of the ring body. Then, a thermosetting epoxy resin adhesive is applied to the inner peripheral surface of the thin plate 12 constituting the ring body, and the polygonal ring 11 is inserted into the ring body. Furthermore, the through hole 1 of the polygonal ring 11
A thermosetting epoxy resin adhesive is applied to the inner wall surface of 1b, and the shaft 13 is inserted into the through hole 11b. Then, a thermosetting epoxy resin-based adhesive is applied between the outer peripheral ring 30 and the permanent magnet piece 10, and each adhesive is heated and cured to obtain the cylindrical permanent magnet rotor 101.

According to the sixth embodiment, since the cylindrical permanent magnet rotor 101 has the cylindrical outer ring 30 mounted thereon, the electric motor having the cylindrical permanent magnet rotor 101 has the above configuration. As in the fifth embodiment, the cogging phenomenon is reduced, and good rotational accuracy is realized.
In addition, since the outer peripheral ring 30 is magnetically attracted to the permanent magnet piece 10 and temporarily fixed, handling during assembly is facilitated, and productivity is improved.

In each of the above embodiments, a samarium-cobalt rare earth magnet material is used as the material of the permanent magnet piece. However, the material is not limited to this. Any material that can be used, for example, a neon iron boron rare earth magnet material may be used. In each of the above embodiments, a thermosetting epoxy resin-based adhesive is used for each adhesive. However, each adhesive is not limited to a thermosetting epoxy resin-based adhesive, and each member is not limited to a thermosetting epoxy resin-based adhesive. Any material can be used as long as it is capable of fixing the same, for example, a room temperature curable adhesive. In this case, the step of heating and curing the adhesive is omitted, and the process is simplified.

In each of the above embodiments, stainless steel is used as the thin plate. However, the thin plate is not limited to stainless steel, but may be made of a bendable metal. Here, in consideration of the flexibility, it is desirable to form the film to a thickness of 50 microns or less. In each of the above embodiments, the polygonal ring is made of iron, which is a magnetic material. However, the polygonal ring does not need to be made of a magnetic material.
A nonmagnetic metal material such as stainless steel or a resin may be used. When the polygonal ring is made of a magnetic material, the effect is obtained that the polygonal ring forms a magnetic path and the characteristics are improved.

In each of the above embodiments, a regular hexagonal column-shaped polygonal ring is used. However, the number of polygons in the polygonal ring is appropriately selected according to the number of magnetic poles of the rotor. There is no such thing. Further, in each of the above embodiments, the polygon ring and the shaft are configured as separate components, but it goes without saying that the polygon ring and the shaft may be configured as an integrated component. .

[0040]

Since the present invention is configured as described above, it has the following effects.

According to the present invention, a step of obtaining a strip-shaped body in which rectangular parallelepiped thin plate-shaped permanent magnet pieces are arranged in a row in the longitudinal direction of the thin plate on a rectangular metal thin plate, A regular polygonal columnar polygonal ring whose surface has the same number of surfaces as the number of arranged permanent magnet pieces, and each surface constituting the outer peripheral surface has a plane shape substantially equal to the bottom surface of the permanent magnet piece. A step of manufacturing, bending the thin plate at a portion between the adjacent permanent magnet pieces, winding the strip around the outer peripheral surface of the polygonal ring by positioning the permanent magnet pieces on the respective surfaces, And a step of magnetizing the permanent magnet pieces prior to the step of winding the belt-like body around the polygonal ring, so that a cylindrical permanent magnet rotor capable of easily realizing multipolarization and miniaturization has high productivity, and , Inexpensive cylindrical permanent magnet rotation The method of production can be obtained.

Also, the method includes a step of attaching a cylindrical outer peripheral ring made of a magnetic material so as to include the band-shaped body wound around the outer peripheral surface of the polygonal ring. A magnet rotor is obtained.

Further, according to the present invention, a step of obtaining a strip-shaped body in which rectangular parallelepiped thin plate-like permanent magnet pieces are arranged on a rectangular metal thin plate in a row in the longitudinal direction of the thin plate. ,
A regular polygonal column-shaped polygonal ring having an outer peripheral surface having the same number of surfaces as the number of the permanent magnet pieces arranged, and each surface constituting the outer peripheral surface having a plane shape substantially equal to the bottom surface of the permanent magnet piece. And a step of bending the thin plate at a portion between the adjacent permanent magnet pieces to form a regular polygonal ring body, and a step of bending the thin plate to form a regular polygonal ring body. Prior to the step of magnetizing the permanent magnet pieces, the step of attaching a cylindrical outer ring made of a magnetic material so as to include the ring body, and the step of attaching the ring body to which the outer ring is attached to the polygon ring And a process of mounting so as to enclose the cylindrical permanent magnet rotor that can easily realize multipole and miniaturization and can reduce the cogging phenomenon with high productivity and at low cost. Method for producing a cylindrical permanent magnet rotor can be obtained.

Further, the step of magnetizing the permanent magnet piece includes:
Since this is performed prior to the step of arranging the permanent magnet pieces on the thin plate, it is possible to cope with a multi-pole and miniaturized rotor.

Further, the step of magnetizing the permanent magnet piece includes:
Since the permanent magnet pieces are arranged in a row on the thin plate, the magnetizing process is simplified, the productivity is improved, and the multi-pole and miniaturization of the rotor can be accommodated.

The step of obtaining the belt-like body includes the steps of: fixing a permanent magnet thin plate on the thin plate so as to cover the entire area of the thin plate; A step of preparing a plurality of the permanent magnet pieces by cutting and separating at a predetermined pitch in the vertical direction, and a step of collectively magnetizing the plurality of the permanent magnet pieces formed on the thin plate. This simplifies the complicated operation of arranging the permanent magnet pieces, simplifies the magnetizing process, and improves the productivity.

Further, the step of obtaining the band-like body includes the steps of forming a band-like insulating layer extending over the entire width direction of the thin plate on the thin plate at a predetermined pitch in the longitudinal direction of the thin plate. A step of forming a permanent magnet material layer on the thin plate on which the layer is formed by using a vacuum film forming technique, and until the insulating layer is exposed until the surface of the permanent magnet material layer formed on the thin plate is exposed. Polishing, separating the permanent magnet material layer by the insulating layer to form a plurality of permanent magnet pieces, and magnetizing the plurality of permanent magnet pieces formed on the thin plate at a time Therefore, a small permanent magnet piece can be easily formed on a thin plate, and a multi-pole and miniaturized rotor can be realized.

Further, according to the present invention, a polygonal ring formed in a regular polygonal column shape in which each surface constituting an outer peripheral surface is a rectangular planar shape, and is integrally formed at an axial center position of the polygonal ring. Shaft, a metal thin plate wound around the outer peripheral surface of the polygonal ring and fixed so as to be in close contact with each surface, and a bottom surface substantially equal to each surface of the outer peripheral surface of the polygonal ring, respectively. It is formed in the shape of a rectangular parallelepiped thin plate, and is magnetized, and includes a plurality of permanent magnet pieces fixed on the thin plate so as to face each surface of the outer peripheral surface of the polygonal ring. A high-productivity and inexpensive cylindrical permanent magnet rotor that can easily realize miniaturization can be obtained.

Further, since the cylindrical outer ring made of a magnetic material is attached so as to include the permanent magnet piece fixed on the thin plate, a rotor capable of alleviating the cogging phenomenon can be obtained.

[Brief description of the drawings]

FIG. 1 is a process chart showing a method for manufacturing a cylindrical permanent magnet rotor according to Embodiment 1 of the present invention.

FIG. 2 is a diagram illustrating a magnetizing step in the method for manufacturing a cylindrical permanent magnet rotor according to Embodiment 1 of the present invention.

FIG. 3 is a diagram illustrating a magnetizing step in a method for manufacturing a cylindrical permanent magnet rotor according to Embodiment 2 of the present invention.

FIG. 4 is a diagram illustrating a process of manufacturing a belt-like body in a method of manufacturing a cylindrical permanent magnet rotor according to Embodiment 3 of the present invention.

FIG. 5 is a view illustrating a process of manufacturing a belt-like body in a method of manufacturing a cylindrical permanent magnet rotor according to Embodiment 4 of the present invention.

FIG. 6 is a view illustrating a method for manufacturing a cylindrical permanent magnet rotor according to Embodiment 5 of the present invention.

FIG. 7 is a diagram illustrating a method for manufacturing a cylindrical permanent magnet rotor according to Embodiment 6 of the present invention.

FIG. 8 is a diagram illustrating a method for manufacturing a conventional cylindrical permanent magnet rotor.

FIG. 9 is a diagram illustrating a magnetizing step in a conventional method for manufacturing a cylindrical permanent magnet rotor.

[Description of Signs] 10 permanent magnet pieces, 11 polygonal rings, 12 thin plates,
Reference Signs List 20 permanent magnet thin plate, 22 insulating layer, 24 permanent magnet material layer, 30 outer ring, 100, 101 cylindrical permanent magnet rotor.

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) H02K 15/03 H02K 15/03 Z

Claims (9)

[Claims] 1. A step of obtaining a strip in which rectangular parallelepiped thin plate-like permanent magnet pieces are arranged on a rectangular metal thin plate in a row in the longitudinal direction of the thin plate, and the outer peripheral surface is formed of the permanent magnet. A step of producing a regular polygonal columnar polygonal ring having the same number of surfaces as the number of magnet pieces arranged, and each of the surfaces constituting the outer peripheral surface having a planar shape substantially equal to the bottom surface of the permanent magnet piece; Bending the thin plate at a portion between the adjacent permanent magnet pieces, positioning the permanent magnet pieces on the respective surfaces, and winding the band around the outer peripheral surface of the polygonal ring; and A step of magnetizing the permanent magnet pieces prior to the step of winding around the polygonal ring. 2. The cylinder according to claim 1, further comprising a step of attaching a cylindrical outer peripheral ring made of a magnetic material so as to include the band-shaped body wound around the outer peripheral surface of the polygonal ring. Method of manufacturing a permanent magnet rotor. 3. A step of obtaining a strip of rectangular parallelepiped thin permanent magnet pieces arranged on a rectangular metal thin plate in a row in the longitudinal direction of the thin plate; A step of producing a regular polygonal columnar polygonal ring having the same number of surfaces as the number of magnet pieces arranged, and each of the surfaces constituting the outer peripheral surface having a planar shape substantially equal to the bottom surface of the permanent magnet piece; Bending the thin plate at a portion between the adjacent permanent magnet pieces to produce a regular polygonal ring; and bending the thin plate to produce a regular polygonal ring prior to the step of producing a regular polygonal ring. Magnetizing the piece, attaching a cylindrical outer ring made of a magnetic material so as to include the ring body, and enclosing the ring body to which the outer ring is attached so as to include the polygon ring Mounting process Cylindrical manufacturing method of a permanent magnet rotor characterized by. 4. The method according to claim 1, wherein the step of magnetizing the permanent magnet pieces is performed prior to the step of arranging the permanent magnet pieces on the thin plate. A method for manufacturing the cylindrical permanent magnet rotor described in the above. 5. The method according to claim 1, wherein the step of magnetizing the permanent magnet pieces is performed in a state where the permanent magnet pieces are arranged in a row on the thin plate. 3. The method for producing a cylindrical permanent magnet rotor according to item 1. 6. The step of obtaining the belt-like body includes fixing a permanent magnet thin plate on the thin plate so as to cover the entire area of the thin plate, and attaching the permanent magnet thin plate fixed on the thin plate to the length of the thin plate A step of preparing a plurality of the permanent magnet pieces by cutting and separating at a predetermined pitch in the vertical direction, and a step of collectively magnetizing the plurality of the permanent magnet pieces formed on the thin plate. The method for manufacturing a cylindrical permanent magnet rotor according to any one of claims 1 to 3, wherein: 7. The step of obtaining the band-like body includes: forming a band-like insulating layer extending over the entire width of the thin plate on the thin plate at a predetermined pitch in the length direction of the thin plate;
Forming a permanent magnet material layer on the thin plate on which the insulating layer is formed by using a vacuum film forming technique, and exposing the insulating layer to a surface of the permanent magnet material layer formed on the thin plate. Polishing, and separating the permanent magnet material layer by the insulating layer to form a plurality of permanent magnet pieces,
4. The cylindrical permanent magnet rotation according to claim 1, further comprising: a step of collectively magnetizing the plurality of permanent magnet pieces formed on the thin plate. Child manufacturing method. 8. A polygonal ring formed in a regular polygonal column shape in which each surface constituting an outer peripheral surface has a rectangular planar shape; a shaft integrally formed at an axial position of the polygonal ring; A metal thin plate wound around the outer peripheral surface of the polygon ring and fixed so as to be in close contact with each surface, and formed into a rectangular parallelepiped thin plate having a bottom surface substantially equal to each surface of the outer peripheral surface of the polygon ring. And a plurality of permanent magnet pieces fixed on the thin plate so as to be opposed to respective surfaces of the outer peripheral surface of the polygonal ring. Child. 9. The rotation of a cylindrical permanent magnet according to claim 8, wherein a cylindrical outer ring made of a magnetic material is attached so as to include the permanent magnet piece fixed on the thin plate. Child.