JP2019083651A - Rotor, manufacturing method of rotor, and rotary electric machine - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a rotor in which a magnet is mounted on an outer peripheral surface of a rotor core, in which a strong adhesive force between the rotor core and the magnet is ensured for a long period of time. SOLUTION: The inner surface of a radial inner side K1 of a magnet 20 of a rotor 100 has an inner surface of an upper end of an axial direction G of a magnet 20 at a first support portion 1S1 on an outer peripheral surface of an upper end of the axial direction G of a rotor core 1. The inner surface of the lower end of the axial direction G of the magnet 20 abuts at the second support point 1S2 on the outer peripheral surface of the lower end of the axial direction G of the rotor core 1, and the first support point 1S1 and the second support point come into contact with each other. The shape of the outer peripheral surface of the groove 1M between 1S2 is such that the distance between the inner surface of each magnet 20 and the outer peripheral surface of the groove 1M facing the inner surface differs in the circumferential direction of each magnet 20. The adhesive layer 10 is arranged so as to fill the gap between the inner surface of each magnet 20 and the outer peripheral surface of the groove portion 1M facing the inner surface. [Selection diagram] Fig. 1

Description

  The present invention relates to a rotor used for a component of a rotating electrical machine, a method of manufacturing the rotor, and the rotating electrical machine.

Conventionally, as a rotor used for a permanent magnet type rotary electric machine, there is a rotor having a configuration in which a permanent magnet is fixed to a rotatable shaft, or a rotor having a configuration in which a permanent magnet is fixed to a rotor core on which a shaft is mounted.
When the permanent magnet is mounted on the outer peripheral surface of the shaft or rotor core, the permanent magnet is bonded via an adhesive. If there is a thin portion in the adhesive layer of this adhesive, a crack or the like may be generated in the adhesive layer due to driving of a motor or the like, which may cause a defect in which the permanent magnet is peeled off from the shaft or rotor. Therefore, in order to suppress deterioration of the adhesive layer due to a crack or the like and secure a strong adhesive force, it is desirable that the adhesive layer have a film thickness of a predetermined thickness.

  However, if variations occur in the adhesive application amount, if variations occur in the pressing force in the plane of the permanent magnet when pressing the permanent magnet against the adhesive, the adhesive is completely cured. In the case where a force is applied to the permanent magnet from the outside in the meantime, the film thickness of the adhesive layer becomes uneven. In this case, a part where the film thickness of a predetermined thickness can not be secured occurs in the adhesive layer, and the adhesive layer is deteriorated. Also, the outer peripheral surface of the permanent magnet fixed to each pole of the rotor does not align at a position concentric with the shaft. Therefore, the air gap between the outer peripheral surface of the permanent magnet and the inner peripheral surface of the stator core is not uniform, and cogging torque, torque ripple and the like increase.

In order to solve this problem, a rotor having the following characteristics is disclosed in order to prevent positional deviation of permanent magnets while securing a predetermined film thickness of an adhesive layer.
For example, segment magnets are fixed to the surface of a laminated core in which magnetic plates are laminated and integrated. The magnetic plate has a plurality of protrusions on the outer peripheral portion, and a recess between the protrusions. An adhesive is applied between the protrusions, and the segment magnet is brought into contact with one direction of the protrusions to position and fix. When bonding the segment magnet, the excess adhesive is absorbed by the recess (see, for example, Patent Document 1).
Also, for example, grooves extending in the circumferential direction are cut on the outer peripheral surface of the cylindrical yoke as many as the number of permanent magnet pieces. An adhesive is filled in the groove so as to slightly overflow the inside of the groove, and the permanent magnet piece is fixed to the outer peripheral surface of the yoke (see, for example, Patent Document 2).

JP, 2001-309588, A (Paragraph [0010]-[0018], Drawing 1, Drawing 2) JP, 11-89141, A (paragraph [0021]-[0026], Drawing 1, Drawing 3)

  In the conventional rotors as described in Patent Documents 1 and 2, grooves are provided on the outer peripheral surface of a laminated core as a rotor core. Then, the permanent magnet is adhered with an adhesive filled in the groove, and both ends of the permanent magnet are supported by the outer peripheral surface of the rotor core on both sides in the circumferential direction of the groove, thereby securing a predetermined film thickness of the adhesive layer in the groove. However, the outer peripheral surface of the permanent magnet is disposed so as to be concentric with the shaft. However, in the adhesive layer of such a configuration, the adhesive force against the centrifugal force and thermal stress repeatedly applied to the permanent magnet when the rotor rotates is not sufficient, and the adhesive layer deteriorates in long-term use, and the permanent magnet There is a problem that there is a possibility that the scattering, peeling, etc. occur. Another problem is that the amount of expensive adhesive used increases.

  The present invention has been made to solve the above-mentioned problems, and a strong adhesive force between the magnet and the rotor core is secured for a long time while the positional deviation of the magnet is suppressed, and further, the adhesive It is an object of the present invention to provide a rotor, a method of manufacturing the rotor, and a rotating electrical machine in which the amount of use of the rotor is reduced.

The rotor according to the present invention is
A rotor comprising: a rotor core; and a plurality of magnets circumferentially spaced from each other on the outer peripheral surface of the rotor core,
The radially inner surface of the magnet is
The inner surface corresponding to the first dimension of the upper end in the axial direction of the magnet abuts at a first support location on the outer peripheral surface of the upper end in the axial direction of the rotor core, and the second dimension corresponding to the second dimension of the lower end in the axial direction of the magnet The inner side surface abuts at a second support point on the outer peripheral surface of the lower end in the axial direction of the rotor core,
A groove recessed in the radial direction and extending in the circumferential direction is formed on the outer peripheral surface of the rotor core between the first support location and the second support location in the axial direction.
The shape of the outer peripheral surface of the groove portion is
The distance between the inner surface of each magnet and the outer peripheral surface of the groove facing the inner surface is formed to have different points in the circumferential direction of each magnet,
An adhesive layer for bonding the inner surface of each magnet to the outer peripheral surface of the groove is disposed so as to fill a gap between the inner surface of each magnet and the outer peripheral surface of the groove facing the inner surface. ,
It is a thing.
Further, a method of manufacturing a rotor according to the present invention is
Forming a rotor core by axially laminating a first core sheet and a second core sheet formed of metal sheets;
A first step of forming the first core sheet and the second core sheet respectively from metal sheets by press punching;
At least one of the first core sheets is disposed at both axial ends of the rotor core, and a plurality of the second core sheets are laminated between the first core sheets disposed at both axial ends. Place
And a second step of aligning at least one of the first core sheet and the second core sheet in the circumferential direction to form the groove in the outer peripheral surface of the rotor core.
It is a thing.
Further, a rotating electric machine according to the present invention is
A rotor configured as described above,
And a stator coaxially disposed with the rotor.

  According to the rotor, the method of manufacturing the rotor, and the rotating electrical machine according to the present invention, since the strong adhesive force between the magnet and the rotor core is secured for a long time while suppressing the positional deviation of the magnet, the motor characteristics are excellent. And a long-term reliability can be provided. Furthermore, since the amount of adhesive used is reduced, an inexpensive rotor and rotating electric machine can be provided.

It is a perspective view showing composition of a rotor by Embodiment 1 of the present invention. FIG. 5 is a cross-sectional view in which the rotor according to Embodiment 1 of the present invention is divided in parallel to an axial direction G. FIG. 5 is a cross-sectional view of the rotor according to Embodiment 1 of the present invention divided vertically to an axial direction G. 1 is a perspective view showing a configuration of a rotor core according to Embodiment 1 of the present invention. It is a perspective view which shows the structure of the 1st core sheet by Embodiment 1 of this invention. It is a perspective view which shows the structure of the 2nd core sheet by Embodiment 1 of this invention. It is a figure which shows the 1st process in the manufacturing process of the rotor by Embodiment 1 of this invention. It is a figure which shows the 1st process in the manufacturing process of the rotor by Embodiment 1 of this invention. It is a figure which shows the 2nd process in the manufacturing process of the rotor by Embodiment 1 of this invention. It is a figure which shows the 2nd process in the manufacturing process of the rotor by Embodiment 1 of this invention. It is a figure which shows the 3rd process in the manufacturing process of the rotor by Embodiment 1 of this invention. It is a figure which shows the 4th process in the manufacturing process of the rotor by Embodiment 1 of this invention. It is a figure which shows the 4th process in the manufacturing process of the rotor by Embodiment 1 of this invention. BRIEF DESCRIPTION OF THE DRAWINGS It is a perspective view which shows the structure of the rotary electric machine by Embodiment 1 of this invention. BRIEF DESCRIPTION OF THE DRAWINGS It is sectional drawing which divided | segmented the rotary electric machine by Embodiment 1 of this invention perpendicularly | vertically with respect to the axial direction. FIG. 7 is a cross-sectional view showing another configuration of the rotor according to Embodiment 1 of the present invention. FIG. 7 is a cross-sectional view showing another configuration of the rotor according to Embodiment 1 of the present invention. FIG. 7 is a cross-sectional view showing another configuration of the rotor according to Embodiment 1 of the present invention. It is a perspective view which shows the other structure of the rotor by Embodiment 1 of this invention. 1 is a cross-sectional view in which a rotor according to a first embodiment of the present invention is divided perpendicularly to an axial direction. It is a figure based on the experiment photograph which experimented the adhesive strength of an adhesive agent. It is a figure based on the experiment photograph which experimented the adhesive strength of an adhesive agent. It is a figure which shows the magnetic field added to the rotor by Embodiment 1 of this invention. It is sectional drawing which divided | segmented perpendicular | vertical with respect to the axial direction according to Embodiment 2 of this invention. It is a perspective view which shows the structure of the rotor by Embodiment 3 of this invention. FIG. 10 is a cross-sectional view in which a rotor according to a third embodiment of the present invention is divided in parallel to an axial direction. It is a perspective view which shows the structure of the rotor by Embodiment 3 of this invention. FIG. 10 is a cross-sectional view in which a rotor according to a third embodiment of the present invention is divided in parallel to an axial direction. It is a perspective view which shows the structure of the rotor by Embodiment 4 of this invention. It is a perspective view which shows the structure of the rotor by Embodiment 4 of this invention.

Embodiment 1
Hereinafter, a rotor 100 according to a first embodiment of the present invention will be described with reference to the drawings.
FIG. 1 is a perspective view showing a rotor 100 according to a first embodiment of the present invention.
FIG. 2 is a cross-sectional view in which the rotor 100 shown in FIG. 1 is divided in parallel to the axial direction G.
FIG. 3 is a cross-sectional view in which the rotor 100 shown in FIG. 1 is divided perpendicularly to the axial direction G.
FIG. 4 is a perspective view of the rotor core 1 constituting the rotor 100 shown in FIG.
FIG. 5 is a perspective view of a first core sheet 2A constituting the rotor core 1 shown in FIG.
FIG. 6 is a perspective view of a second core sheet 2B constituting the rotor core 1 shown in FIG.
In the following description, each direction in the rotor 100 is indicated as a circumferential direction S, an axial direction G, a radial direction K, a radially inner side K1, and a radially outer side K2. In each of the second and subsequent embodiments, each direction is shown similarly.

  As shown in FIGS. 1 and 2, the rotor 100 according to the present embodiment is inserted into and fixed to the rotor core 1, the plurality of magnets 20 provided on the outer peripheral surface of the rotor core 1, and the hollow hole 1A of the rotor core 1. And the shaft 3.

As shown in FIG. 4, the rotor core 1 is formed by laminating a plurality of first core sheets 2A formed of thin metal sheets and a second core sheet 2B in the axial direction G. .
Two first core sheets 2A are disposed at each of the upper end and the lower end in the axial direction G of the rotor core 1. Then, two or more second core sheets 2B are stacked between the first core sheet 2A disposed at the upper end in the axial direction G and the second core sheet 2B disposed at the lower end in the axial direction G. .
In the following description, the first core sheet 2A and the second core sheet 2B are simply referred to as the core sheet 2 when it is not necessary to distinguish them.

As shown in FIG. 5, the shape of the outer peripheral surface of one first core sheet 2A is an octagonal shape having eight apexes 2T and straight between the apexes 2T, and is hollow at the central portion It has a hole 2A1.
In addition, as shown in FIG. 6, the shape of the outer peripheral surface of one second core sheet 2B is circular, and has a hollow hole 2A2 in the center.

Further, the distance r1 from the axial center F of the first core sheet 2A to the outer peripheral surface is larger than the distance r2 from the axial center F of the second core sheet 2B to the outer peripheral surface.
By laminating such large and small two types of first core sheet 2A and second core sheet 2B having different distances (diameters) from the axial center F to the outer peripheral surface as shown in FIGS. 1 and 2 described above. At the center of the outer peripheral surface of the rotor core 1 in the axial direction G, there is formed a groove 1M extending in the direction parallel to the circumferential direction S of the rotor core 1 and recessed in the radially inner side K1.

Thus, the outer peripheral surface of the second core sheet 2B constitutes the outer peripheral surface of the groove 1M at the center of the axial direction G of the rotor core 1, so the outer peripheral surface of the groove 1M has a circular shape with the shaft 3 as the axial center F. .
Further, since the outer peripheral surface of the first core sheet 2A constitutes the outer peripheral surfaces of both ends of the rotor core 1 in the axial direction G, the outer peripheral surfaces of both ends of the rotor core 1 in the axial direction G are eight apexes of the first core sheet 2A. It has an octagonal shape with eight vertices 1T consisting of 2T.
Further, the hollow hole 1A of the rotor core 1 is formed by the hollow hole 2A1 of the first core sheet 2A and the hollow hole 2A2 of the second core sheet 2B.
Further, one magnet 20 is disposed between the apexes 1T of the rotor core 1, and the magnet 100 corresponds to one pole in the rotating electrical machine using the rotor 100.

  As shown in FIGS. 2 and 3, in the groove 1M, the adhesive Z is disposed so as to fill the gap between the inner side surface of each magnet 20 and the outer peripheral surface of the groove 1M opposed to the inner side. The adhesive Z thus disposed forms the adhesive layer 10, and bonds the inner side surface of each magnet 20 to the outer peripheral surface of the groove 1M.

As shown in FIG. 2, the width in the axial direction G of the magnet 20 is longer than the width Y in the axial direction G of the groove portion 1M and shorter than the width in the axial direction G of the rotor core 1. Further, the inner surface of the magnet 20 has a linear shape which is the same as the shape between the apexes 1T of the rotor core 1 in the shape perpendicular to the axial direction G.
Then, the magnet 20 is bonded to the outer peripheral surface of the rotor core 1 so as to cover the entire width Y of the groove portion 1M in the axial direction G by bonding the inner side surface of the magnet 20 in the radial direction K1 with the adhesive layer 10 Ru.

Further, as shown in FIG. 2, the inner surface of the first dimension X1 of the upper end in the axial direction G of each magnet 20 abuts at the first support point 1S1 on the outer peripheral surface of the upper end in the axial direction G of the rotor core 1 . In addition, the inner surface of the second dimension X2 at the lower end of the magnet 20 in the axial direction G abuts on the second support point 1S2 on the outer peripheral surface of the lower end of the rotor core 1 in the axial direction G. That is, both end portions in the axial direction G of the inner side surface of the magnet 20 have a configuration of two-point support supported from the radially inner side K1 by the first support location 1S1 and the second support location 1S2. Thus, the groove 1M in which the adhesive layer 10 is formed is formed between the first support location 1S1 and the second support location 1S2 in the axial direction G on the outer peripheral surface of the rotor core 1.
The first dimension X1 and the second dimension X2 are configured to have the same length.
Then, the plurality of magnets 20 are fixed to the outer peripheral surface of the rotor core 1 as described above at predetermined intervals in the circumferential direction S.

As shown in FIG. 3, the distance between the inner side surface of each magnet 20 and the outer peripheral surface of the groove 1 </ b> M facing the inner side surface has different points within the range of the circumferential direction S of each magnet 20.
In the present embodiment, the outer peripheral surface of the groove portion 1M of the rotor core 1 is formed in a circular shape, and the outer peripheral surfaces at both ends in the axial direction G of the rotor core 1 are formed in a linear shape between apexes 1T. It has an octagonal shape. Therefore, the first distance W2C between the central portion in the circumferential direction S of the inner side surface of each magnet 20 and the outer peripheral surface of the groove portion 1M facing this inner side is both ends in the circumferential direction S of the inner side surface of each magnet 20 It is formed smaller than 2nd distance W2E of a part and the outer peripheral surface of the groove part 1M which opposes this inner surface. Thus, the film thickness of the adhesive layer 10 disposed so as to fill the gap between the inner side surface of each magnet 20 and the outer peripheral surface of the groove portion 1M opposed to the inner side surface becomes thicker toward both ends in the circumferential direction S.

In the present embodiment, the width W1 of the magnet 20 in the radial direction K is formed within a range of about 2 mm to 15 mm, and the widths W2C and W2E of the groove portion 1M in the radial direction K are about 0.05 mm to It is formed within the range of 0.2 mm. That is, R = W1 / W2, which is the ratio of the radial width W1 of the magnet 20 to the width W2 (W2C, W2E) of the groove 1M, at an arbitrary circumferential position on the outer peripheral surface of the rotor core 1 is 10 <R. It is configured to be within the range of <300.
In the above description, the ratio R at an arbitrary circumferential position of the outer peripheral surface of the rotor core 1 has been described. However, the arbitrary circumferential position means an arbitrary outer peripheral surface of the rotor core 1 within the range where the magnet 20 is disposed. Indicates the circumferential position of the

Next, a method of manufacturing the rotor 100 configured as described above will be described with reference to the drawings.
FIG. 7 is a cross-sectional view of a press and core sheet 2 showing a first step of obtaining each core sheet 2 by press punching with a press in the process of manufacturing rotor 100 according to Embodiment 1 of the present invention.
FIG. 8 is a top view of the plurality of core sheets 2 stamped out in the first step shown in FIG. 7 as viewed from above.
FIG. 9 is a cross-sectional view of each core sheet 2 showing a second step of press-punching and aligning the laminated core sheets 2 to obtain the rotor core 1.
FIG. 10 is a top view of the second step shown in FIG. 9 as viewed from above.
FIG. 11 is a cross-sectional view of the rotor core 1 and the shaft 3 showing a third step of inserting the shaft 3 into the rotor core 1.
FIG. 12 is a cross-sectional view of the rotor core 1 and the magnet 20, showing a fourth step of bonding the magnet 20 to the outer peripheral surface of the rotor core 1 to which the shaft 3 is attached.
FIG. 13 is a top view of the fourth step shown in FIG. 12 as viewed from above.
The manufacturing process of the rotor 100 mainly includes the four steps shown in the above-mentioned drawings.

In the first step shown in FIGS. 7 and 8, thin sheet metal sheets such as magnetic steel sheets and rolled steel sheets are pressed out by the upper mold 30U and lower mold 30D of the mold 30 in the press machine, and each core sheet 2 Get
In the first step, the first core sheet 2A and the second core sheet 2B having different distances from the axial center F to the outer peripheral surface are respectively formed by press punching and are stacked. After the first core sheet 2A is pressed out by pressing the cutting tool of the die 30, two or more second core sheets 2B are pressed out, and then the first core sheet 2A is pressed again. As a result, two first core sheets 2A are laminated at both ends in the axial direction G on the holder 31 located inside the mold 30 or immediately below the lower mold 30D of the mold 30, respectively. The two or more second core sheets 2B are stacked in the center of the.
Further, as shown in FIGS. 7 and 8, the guide pin 31P of the holder 31 is inserted into the hollow hole 2A1 of the first core sheet 2A and the hollow hole 2A2 of the second core sheet 2B. It is stacked on the holder 31.

In the second step shown in FIGS. 9 and 10, the laminated core sheets 2 are aligned to obtain the rotor core 1.
First, the core sheet 2 is discharged from the press.
Then, the first core sheet 2A and the first core sheet 2A are stacked so that the positions in the circumferential direction S of the apexes 2T of the first core sheet 2A coincide with each other and the axial centers F of the second core sheets 2B coincide with each other. The two-core sheets 2B are aligned by the jigs 32A and 32B.
At the center of the axial direction G of the outer peripheral surface of the rotor core 1 thus obtained, a groove portion 1M extending in the circumferential direction S of the rotor core 1 is formed, which is composed of the outer peripheral surface of the second core sheet 2B having a small diameter. .
Further, the outer peripheral surface of the first core sheet 2A constitutes a first support location 1S1 at the upper end in the axial direction G of the rotor core 1 and a second support location 1S2 at the lower end in the axial direction G.

The jigs 32A and 32B used in the second step sandwich the core sheet 2 from the radially outer side K2 of the core sheet 2 and push the core sheets 2 in the horizontal direction toward the center. One jig 32A disposed on both sides of the core sheet 2 has a structure for supporting three sides of the outer peripheral surface of the first core sheet 2A, and the other jig 32B is an outer peripheral surface of the first core sheet 2A. It has a structure that supports one side of As described above, since the jig 32A supports the three sides of the first core sheet 2A, when the rotor core 1 is a polygon, the positioning of each first core sheet 2A is facilitated and the rotor core 1 is highly accurate. It becomes possible to assemble.
Similarly, the jig 32A positioned on the right side of the paper surface of FIGS. 9 and 10 may have a structure for supporting the three sides of the first core sheet 2A, or both of the jigs 32A and 32B are You may have a structure which supports 3 sides of 1st core sheet 2A.

In the third step shown in FIG. 11, the shaft 3 is inserted into the rotor core 1 obtained by alignment.
The shaft 3 is inserted into the hollow hole 1A of the rotor core 1 while being held by the jigs 32A and 32B so that the posture of the rotor core 1 and the positions of the core sheets 2 adjacent to each other do not shift. The shaft 3 is fixed in the hollow hole 1A of the rotor core 1 by a method such as press fitting, shrink fitting, or bonding.

As shown in FIGS. 12 and 13, in the fourth step, the magnet 20 is bonded to the outer peripheral surface of the rotor core 1 obtained by fixing the shaft 3.
First, the adhesive Z is applied to the magnet 20. The application of the adhesive Z to the magnet 20 is not shown, but is applied to the inner side of the magnet 20 using a dispenser or the like in a state where the magnet 20 is turned down so that the inner side of the magnet 20 is horizontal. At this time, it is preferable that the adhesive Z be applied wider than the region facing the groove 1M on the inner surface of the magnet 20 so that the adhesive Z reliably fills the gap between the inner surface of the magnet 20 and the outer peripheral surface of the opposing groove 1M. .

When the magnet 20 is attached to the rotor core 1, as shown in FIG. 12, the magnet 20 is vertically raised by the jig 33 so that the inner side surface of the magnet 20 faces the outer peripheral surface of the rotor core 1.
By using the adhesive Z having a viscosity that does not drop immediately, it is possible to prevent the adhesive Z from dropping and falling between raising the magnet 20 vertically and attaching it to the rotor core 1.
The amount of the adhesive Z to be applied is adjusted in accordance with the volume of the gap between the inner side surface of the magnet 20 and the outer peripheral surface of the groove portion 1M opposed to the inner side surface.

Next, the magnet 20 is pressed against the rotor core 1 at a position in the axial direction G which covers the entire width Y of the groove portion 1M in the axial direction G and fixed.
At this time, as shown in FIG. 2, the inner surface of the first dimension X1 of the upper end in the axial direction G of each magnet 20 is the first support point 1S1 at the upper end of the axial direction G in the outer peripheral surface of the rotor core 1 It is supported from the radially inner side K1. Further, the inner surface corresponding to the second dimension X2 of the lower end in the axial direction G of the magnet 20 is supported from the radially inner side K1 at the second support location 1S2 at the lower end in the axial direction G on the outer peripheral surface of the rotor core 1.
As described above, the width in the axial direction G of the magnet 20 is shorter than the width in the axial direction G of the rotor core 1. Therefore, when bonding the magnet 20 to the rotor core 1, the first dimension X1 of the upper end of the inner side surface of the magnet 20 and the second dimension X2 of the lower end abut the outer peripheral surface of the rotor core 1 with the same length. Thus, the position of the magnet 20 in the axial direction G is adjusted.

Thus, when the magnet 20 is pressed against the rotor core 1, both end portions in the axial direction G of the inner side surface of the magnet 20 become a two-point support supported by the first support location 1S1 and the second support location 1S2 of the rotor core 1. . Therefore, the adhesive Z in the groove 1M is not crushed to the depth (the width W2 in the radial direction K) or less of the groove 1M. Thus, the adhesive Z disposed in the groove 1M forms the adhesive layer 10 in which the width W2 in the radial direction K of the groove 1M is reliably secured.
In addition, about the adhesive agent Z which protruded from the inside of the groove part 1M, a wiping operation is performed as needed.

In addition, since the first support portion 1S1 on the outer peripheral surface of the rotor 100 and the upper end of the inner side surface of the magnet 20 are in contact, the adhesive layer 10 is not interposed at the contact portion, or from inside the groove portion 1M. An adhesive layer of a very thin film of about 10 μm is formed by the adhesive Z which has overflowed.
Further, since the second support portion 1S2 on the outer peripheral surface of the rotor 100 and the lower end of the inner side surface of the magnet 20 are in contact, the adhesive layer 10 is not interposed at the contact portion or the protrusion from the groove portion 1M A very thin adhesive layer of about 10 μm is formed by the adhesive Z.

Finally, the adhesive layer 10 is cured by heating in a fixed state with a jig or the like so that the position of the magnet 20 does not shift for several minutes to about 15 minutes.
The rotor 100 is manufactured through the first to fourth steps described above.

In the first to third steps described above, the core sheet 2 formed by press punching is stacked and aligned, and then the shaft 3 is mounted. However, the present invention is not limited to this method. For example, the rotor core 1 may be formed by fixing the core sheets 2 in the stacking direction simultaneously with press punching using a squeegee method. Alternatively, the rotor core 1 fixed in the laminating direction may be formed by laminating two or more sheets while applying the adhesive Z to the core sheet 2 formed by press punching. Furthermore, after two or more core sheets 2 are stacked, they may be fixed in the stacking direction by, for example, YAG welding.
By fixing between the laminations of the rotor core 1 before mounting the shaft 3, handling between processes becomes simple, and an effect that positional deviation between the core sheets 2 due to the mounting of the shaft 3 can be suppressed can be obtained.

Also, in the fourth step described above, first, the adhesive Z is disposed in the groove 1M of the rotor core 1 at a position facing the inner side surface of the magnet 20, and then the magnet 20 is pressed against the rotor core 1 and adhered. May be
In addition, with regard to the magnetization of the magnet 20, a magnet 20 which has been magnetized may be attached, or a step of magnetizing after the adhesive layer 10 is cured may be provided.
Moreover, about the kind of adhesive agent Z, the adhesive agent etc. of the normal temperature curing type by 2 liquid mixing of a main agent and a hardening | curing agent are mentioned, for example with an acryl type.

FIG. 14 is a perspective view showing a rotating electrical machine 102 using the rotor 100 according to Embodiment 1 of the present invention.
FIG. 15 is a cross-sectional view in which the rotating electrical machine 102 shown in FIG. 12 is divided perpendicularly to the axial direction G.
The rotating electrical machine 102 includes a rotor 100, a stator 101, and a housing 9. The rotor 100 is disposed coaxially with the stator 101 in the hollow portion of the stator 101 and housed in the housing 9.
The stator 101 includes a stator core 6. The stator core 6 includes an annular back yoke portion 6A and teeth portions 6B extending radially inward K1 from the back yoke portion 6A for each magnetic pole. The coil 7 is wound around the teeth portion 6B of the stator core 6.
The rotating electric machine 102 is driven by attraction or repulsion between the magnetic field generated in the stator core 6 by the coil 7 and the magnetic field generated by the magnet 20 of the rotor 100.

Hereinafter, it demonstrates based on the other structure of the rotor 100 of this Embodiment.
FIG. 16 is a cross-sectional view showing a rotor 100 having a configuration in which a recess 1D for absorbing the excess adhesive Z is provided on the outer peripheral surface of the groove 1M. The cross section perpendicular to the axial direction G of the recess 1D is rectangular.
In addition, the cross section perpendicular | vertical to the axial direction G does not limit rectangular shape to recessed part 1D, for example, a cross section perpendicular | vertical to axial direction G may be circular arc shape, or triangle shape may be sufficient as it.

FIG. 17 is a cross-sectional view showing a rotor 100 having a configuration in which positioning portions 1P are provided to project radially outward K2 on the outer peripheral surface of the first core sheet 2A at both ends in the axial direction G of the rotor core 1. The positioning portions 1P respectively abut on both ends of the magnet 20 in the circumferential direction S.
In addition, in order to suppress the leakage magnetic flux which does not contribute to rotation of the rotor 100 between the magnets 20 which adjoin the circumferential direction S, it is good to provide the space | gap J between the positioning parts 1P.
Although FIG. 17 shows an example in which positioning portions 1P are formed at both ends in the circumferential direction S of each magnet 20, the positioning portion 1P may be formed only at one end in the circumferential direction S of each magnet 20.

FIG. 18 is a diagram showing a hexagonal six-pole rotor 100 having six apexes 1T.
FIG. 19 is a diagram showing a decagon-shaped 10-pole rotor 100 having 10 apexes 1T.
The rotor 100 shown in FIG. 1 has an eight-pole configuration because the outer peripheral surface of the core sheet 2 constituting the rotor 100 has an octagonal shape. However, a six-pole rotor 100 constituted by the hexagonal core sheet 2 as shown in FIG. 18 or a ten-pole rotor constituted by the decagonal core sheet 2 as shown in FIG. It may be 100. That is, the rotor 100 may be a 2n-pole rotor 100 configured by the core sheet 2 that is a 2n square (n is an integer of 2 or more). Even in this case, the arrangement configuration of the groove portion 1M and each magnet 20 can be formed in the same manner as described above.

FIG. 20 is a cross-sectional view in which the rotor 100 shown in FIGS. 1 to 19 and the rotor 100 having different shapes of the outer peripheral surface of the groove portion 1M are divided perpendicularly to the axial direction G.
In the rotor 100 shown in FIG. 20, a portion Sa between the circumferential direction central portion and inner circumferential end portions of the inner side surface of each magnet 20 and an outer peripheral surface of the groove portion 1M facing the portion Sa on the inner side surface The distance is shown as a third distance W2a. In this case, the outer peripheral surface of the groove portion 1M of the rotor core 1 has an outer peripheral surface of the circumferential center portion of the inner side surface of each magnet 20 and the outer peripheral surface of the groove portion 1M opposed to the inner side surface. And the second distance W2E between the circumferential end portions of the inner side surface of each magnet 20 and the outer peripheral surface of the groove portion 1M opposed to the inner side surface. Ru.

  As described above, the shape of the outer peripheral surface of the groove portion 1M of the rotor core 1 is not limited to a circular shape centered on the central axis of the rotor core 1 as shown in FIGS. The shape of the outer peripheral surface of the groove portion 1M of the rotor core 1 of the present embodiment is such that the distance between the inner side surface of the magnet 20 and the outer peripheral surface of the groove portion 1M facing the inner side surface is in the circumferential direction S of each magnet 20 It is formed to have different locations.

  In each of the rotors 100 described above, the width in the axial direction G of the magnet 20 is smaller than the width in the axial direction G of the rotor core 1. With such a configuration, dimensional tolerance in the axial direction G of the magnet 20 can be tolerated. However, the present invention is not limited to this, and the width in the axial direction G of the magnet 20 may be formed to the same length as the width in the axial direction G of the rotor core 1. Even in this case, the arrangement configuration of the groove portion 1M and each magnet 20 can be formed in the same manner as described above.

  In addition, an example in which the first dimension X1 of the first support portion 1S1 and the second dimension X2 of the second support portion 1S2 have the same length has been described. Thereby, in the manufacturing process of the rotor 100, setting of the magnitude of the force at the time of pressing the magnet 20 against the rotor core 1 becomes easy, but it is not limited to this configuration. The first dimension X1 and the second dimension X2 may be formed to have different lengths, and the magnet 20 can be supported from the radially inner side K1 against the force when pressing the magnet 20 against the rotor core 1 It should be done.

Further, in the above, the rotor core 1 in which two first core sheets 2A are laminated at both ends in the axial direction G is shown. However, the present invention is not limited to this, as long as at least one first core sheet 2A is provided at each end of the rotor core 1 in the axial direction G.
Moreover, although the rotor core 1 showed what was formed by laminating | stacking a plurality of thin-plate shaped core sheets 2 together, it showed, but it is not limited to this. For example, the rotor core 1 may be one block. Even in these cases, the groove is formed on the outer peripheral surface of the block-shaped rotor core, whereby the circumferential direction is formed between the first support location 1S1 and the second support location 1S2 at both ends in the axial direction G of the rotor core 1 The groove 1M extending to S can be similarly formed. Also in the following embodiments, when the shape of the outer peripheral surface of the groove 1M is not complicated, it is possible to use a rotor core consisting of one block.

According to the rotor 100 of the present embodiment configured as described above and the rotary electric machine 102, the inner side surface of the magnet 20 is disposed in the groove portion 1M between the first support point 1S1 and the second support point 1S2. The rotor core 1 is adhered by the adhesive layer 10.
Then, the inner surface of the first dimension X1 of the upper end in the axial direction G of the magnet 20 abuts on the first support point 1S1 of the upper end in the axial direction G on the outer peripheral surface of the rotor core 1. Then, the inner surface of the second dimension X2 at the lower end of the magnet 20 in the axial direction G abuts on the second support portion 1S2 at the lower end of the axial direction G on the outer peripheral surface of the rotor core 1.

  Thus, the magnet 20 is supported at two points from the radially inner side K1 by the first support point 1S1 and the second support point 1S2. As a result, a predetermined film thickness of the adhesive layer 10 in the groove 1M can be reliably ensured, so that deterioration of the adhesive layer 10 due to a crack or the like can be suppressed and a strong adhesive force can be ensured.

In addition, since the magnet 20 is supported at two points, the adhesive layer 10 in the groove portion 1M is not crushed by the magnet 20. Therefore, in the fourth step of pressing and bonding the magnet 20 to the rotor core 1, the force pressing the magnet 20 can be increased. The force for pressing the magnet 20 can be increased to about several tens of N, or a large force that does not break the magnet 20.
In the conventional rotor having no groove portion, the force for pressing the magnet is reduced to about several N in order to secure a predetermined film thickness of the adhesive. However, such a small force can not sufficiently press the magnet against the adhesive due to friction between the jig pressing the magnet and the component parts around the jig, or the like, and the magnet can not be completely fixed. Was occurring.
In the rotor 100 and the rotating electrical machine 102 according to the present embodiment, the force of pressing the magnet 20 against the rotor core 1 can be increased to sufficiently reduce the influence of friction, bending and the like. Thereby, the defect which can not fix the magnet 20 can be reduced.

  Further, by supporting the magnet 20 at two points, the magnet 20 can be fixed so that the outer peripheral surface of the magnet 20 fixed to each pole is concentric with the shaft 3. Thereby, the variation in the air gap between the outer circumferential surface of the magnet 20 and the inner circumferential surface of the stator 101 is reduced, cogging torque and torque ripple are suppressed, and the motor characteristics are improved.

Further, the adhesive layer 10 is formed so as to fill the entire gap between the inner side surface of each magnet 20 and the outer peripheral surface of the groove portion 1M opposed to the inner side surface. Therefore, the entire length of the width in the circumferential direction S of the inner side surface of each magnet 20 is adhered by the adhesive layer 10.
This effect will be described below with reference to the drawings.

21 and 22 are diagrams based on experimental photographs of a heat cycle test in which an adhesive is applied to the entire inner surface of the magnet Q in a general rotor core having no groove.
FIG. 21 is a diagram based on an experimental photograph of the peeling surface of the adhesive when the magnet Q adhered to the outer peripheral surface of the rotor core is peeled off after 100 heat cycles and taken from the inner side of the magnet Q. It is.
FIG. 22 is a diagram based on an experimental photograph of the peeling surface of the adhesive when the magnet Q adhered to the outer peripheral surface of the rotor core is peeled off after 300 heat cycles, taken from the inner side of the magnet Q It is.

In the figure, a portion H1 indicated by hatching with a slanting downward sloping right is a portion where cohesive peeling has occurred in the adhesive when peeling off the magnet Q, that is, a portion where the adhesive strength is strong.
In addition, a portion H2 indicated by hatching with a diagonally lower left is a portion where interfacial peeling has occurred between the adhesive and the rotor core when the magnet Q is peeled off, that is, a portion where the adhesive strength is weak.

  As shown in FIG. 21, after 100 heat cycles, the entire area to which the adhesive is applied becomes the cohesive peeling site H1 and it can be seen that the adhesive strength of the adhesive is not lowered. However, as shown in FIG. 22, by increasing the test cycle, it can be seen that the interfacial peeling site H2 is produced in the partial area to which the adhesive is applied, and the adhesive strength is partially reduced. In FIG. 22, on the central side GC in the axial direction G of the magnet Q, the central side SC in the circumferential direction S is the cohesive peeling site H1, and both end sides SL and SR in the circumferential direction S are the interfacial peeling site H2. Therefore, it is considered that the thermal stress and thermal distortion caused by the difference in the expansion coefficient of the magnet Q and the rotor core are large and the adhesive strength is reduced particularly on the side SL and SR sides in the circumferential direction S of the magnet Q.

  The decrease in the adhesive force that occurs on both ends SL and SR in the circumferential direction S of the magnet Q advances toward the central side SC in the circumferential direction S as the test cycle increases. As shown in FIG. 22, in the upper and lower end sides GU and GD of the axial direction G of the magnet Q, the decrease in adhesive strength progresses to the central side SC. It can be seen that the decrease in adhesive strength occurs early in the upper and lower end sides GU and GD of the axial direction G of the magnet Q and is progressing.

As described above, the decrease in the adhesive strength due to the crack or the like of the adhesive layer is generated from the both side SL and SR sides in the circumferential direction S of the magnet Q and progresses toward the central side SC.
Therefore, by securing the width of the adhesive layer 10 as long as possible within the range of the circumferential direction S of the inner surface of the magnet 20, the decrease in adhesive strength generated from both ends in the circumferential direction S of the adhesive layer 10 is the circumferential direction S Progress to the central part of the In addition, by making the width of the adhesive layer 10 longer, it is possible to increase the absorptivity of thermal strain such as expansion and contraction.

In addition, since the entire inner surface of the magnet 20 is bonded to the adhesive layer 10 in the circumferential direction S in this manner, a sufficient bonding area with the magnet 20 can be secured, and the initial strength of the adhesive strength is improved. . In addition, the stress due to the centrifugal force applied to the joint between the magnet 20 and the adhesive layer 10 can be relaxed and dispersed.
Further, the adhesive layer 10 is thus formed in the gap between the inner surface of the magnet 20 and the outer peripheral surface of the groove 1M opposite to the inner surface, and is not formed in the other part of the outer peripheral surface of the groove 1M. . Therefore, the amount of adhesive Z used can be reduced and the cost can be reduced.

Furthermore, the shape of the outer peripheral surface of the groove portion 1M of the rotor core 1 is such that the distance between the inner side surface of each magnet 20 and the outer peripheral surface of the groove portion 1M opposed to the inner side is different in the circumferential direction S of each magnet 20 It is formed to have
That is, in the rotor 100 shown in FIGS. 1 to 19, the first distance W2C between the central portion in the circumferential direction S of the inner side surface of each magnet 20 and the outer peripheral surface of the groove portion 1M facing this inner side surface is It is formed smaller than the 2nd distance W2E of the both ends of peripheral direction S of the inner side of each magnet 20, and the peripheral face of slot 1M which counters this inner side.

As described above, by forming the adhesive layer 10 so as to be thicker toward both ends in the circumferential direction S, it is possible to effectively suppress the occurrence of cracks that occur at both ends in the circumferential direction S. In this manner, strong adhesion between the magnet 20 and the rotor core 1 can be secured for a long time in response to repeated centrifugal force and thermal stress.
Further, by reducing the film thickness of the adhesive layer 10 at the central portion in the circumferential direction S, the amount of the adhesive Z used in each adhesive layer 10 can be reduced, and the cost can be further reduced.
Thus, by configuring the distance between the inner surface of the magnet 20 and the outer peripheral surface of the groove 1M facing the inner surface to have different points in the range of the circumferential direction S of each magnet 20. Thus, both cost reduction and suppression of deterioration of the adhesive layer 10 can be achieved.

Further, in the rotor 100 shown in FIG. 20, the shape of the outer peripheral surface of the groove portion 1M is the position Sa between the central portion in the circumferential direction S of the inner side surface of each magnet 20 and both end portions in the circumferential direction S A third distance W2C between the outer surface of the groove 1M facing the side portion Sa is the central portion of the inner surface of each magnet 20 in the circumferential direction S and the outer surface of the groove 1M facing the inner surface. And a second distance W2E between both ends in the circumferential direction S of the inner side surface of each magnet 20 and the outer peripheral surface of the groove portion 1M facing the inner side surface. Ru.
This effect will be described below with reference to the drawings.

FIG. 23 is a diagram showing the magnetic flux H of the magnetic field generated by the stator and applied to the rotor 100 in the rotary electric machine using the rotor 100 shown in FIG.
The illustration of the stator is omitted in FIG.

As shown in FIG. 23, the magnetic field generated by the stator and contributing to the rotation of the rotor 100 mainly flows in the point Sa between the central portion of the adhesive layer 10 in the circumferential direction S and the both ends in the circumferential direction S.
Generally, the permeability of the adhesive layer 10 is low and the magnetic resistance is high. Therefore, the motor characteristics can be improved by reducing the film thickness of the adhesive layer 10 having a low magnetic permeability at the portion Sa where the magnetic field flows. In addition, the amount of adhesive Z used can be reduced to reduce the cost.
Furthermore, since the film thickness of the both ends of circumferential direction S of adhesion layer 10 is thickened, generation | occurrence | production of the crack which arises in the both ends of circumferential direction S can be suppressed effectively.
Thus, by configuring the distance between the inner surface of the magnet 20 and the outer peripheral surface of the groove 1M facing the inner surface to have different points in the range of the circumferential direction S of each magnet 20. The improvement of the motor characteristics, the reduction of the cost, and the suppression of the deterioration of the adhesive layer 10 are all possible.

Furthermore, R = W1 / W2, which is the ratio of the radial width W1 of the magnet 20 to the radial width W2 of the groove 1M, is configured to be in the range of 10 <R <300.
This ratio R realizes the optimum film thickness of the adhesive layer 10 which can ensure the reliability of the adhesive strength of the adhesive layer 10 according to the size and weight of the magnet 20. And it is a value acquired based on information, such as a day, an annual heat cycle, etc. which occur when using rotation electrical machinery 102 carrying the rotor 100 concerned. In this way, by securing the film thickness of the adhesive layer 10 according to the size and weight of the magnet 20, stronger adhesive force between the magnet 20 and the rotor core 1 can be secured for a long time.
Moreover, since the shape perpendicular | vertical to the axial direction G is linear shape in the inner surface of the magnet 20, the process at the time of forming the magnet 20 can be simplified.

Furthermore, as shown in FIG. 16, a recess 1D for absorbing excess adhesive Z may be provided in the groove 1M.
Thus, even when the amount of adhesive Z used is large, the adhesive Z can be prevented from protruding from the gap between the inner side surface of each magnet 20 and the outer peripheral surface of the groove portion 1M facing the inner side. . Thus, it is possible to omit the process of wiping out the overflowed adhesive, which is performed as necessary in the fourth process described above.

Furthermore, as shown in FIG. 17, at both ends in the axial direction G of the outer peripheral surface of the rotor core 1, positioning portions 1P may be formed to abut the end portions in the circumferential direction S of the magnets 20.
Thereby, the cogging torque resulting from the position shift of the circumferential direction S of the magnet 20 can be suppressed.

Further, the rotor core 1 is configured by laminating a plurality of first core sheets 2A and second core sheets 2B, and the first core sheet 2A and the second core sheets 2B press thin metal sheets with a press machine. It is pulled out and formed.
In order to form the groove portion 1M using the first core sheet 2A and the second core sheets 2B thus stamped out, the variation in width W1 in the circumferential direction S of the groove portion 1M and width W2 in the radial direction K is ±. It becomes about 0.01 mm, and the groove 1M can be formed with high accuracy.
In addition, since it is not necessary to perform grinding or the like on the outer peripheral surface of the rotor core, the processing cost can be reduced. In addition, the processing accuracy of the shape of the groove portion 1M is high as compared with the grinding processing or the like.
As described above, in the present embodiment, in order to secure the bonding strength and the bonding reliability, the width W2 of the groove portion 1M in the radial direction K is strictly defined using the pressing accuracy.

Second Embodiment
The second embodiment of the present invention will be described below with reference to the drawings, focusing on differences from the first embodiment. The same parts as those in the first embodiment are given the same reference numerals, and the description thereof is omitted.
FIG. 24 is a cross-sectional view in which the rotor 200 according to Embodiment 2 of the present invention is divided perpendicularly to the axial direction G.

In the rotor 200, the shape of the first core sheet 2A constituting both ends of the rotor core 201 in the axial direction G is circular, and the shape of the second core sheet 2B constituting the central groove portion 201M in the axial direction G of the rotor core 201 is , Between the vertices 201MT is a straight octagonal shape.
Further, the inner side surface of the magnet 220 fixed to the rotor core 201 has an arc shape having the same curvature as that of the outer peripheral surface of the first core sheet 2A in the shape perpendicular to the axial direction G. Then, one magnet 20 is disposed between the tops 201MT of the groove portions 201M, and one magnet is provided in the rotary electric machine using the rotor 200.

Thus, although not shown, as in the first embodiment, the inner surface of the first dimension X1 of the upper end in the axial direction G of the magnet 220 corresponds to the first support point of the upper end in the axial direction G on the outer peripheral surface of the rotor core 201. Contact at 1S1. Then, the inner surface of the second dimension X2 at the lower end of the magnet 220 in the axial direction G abuts on the second support portion 1S2 at the lower end of the axial direction G on the outer peripheral surface of the rotor core 201.
Then, as shown in FIG. 24, a first distance W2C between the central portion in the circumferential direction S of the inner side surface of each magnet 20 and the outer peripheral surface of the groove portion 201M facing the inner side surface It is configured to be larger than a second distance W2E between both end portions in the circumferential direction S of the side surface and the outer peripheral surface of the groove portion 1M opposed to the inner side surface.

  According to the rotor 200 of the present embodiment configured as described above, the same effect as the rotor 100 of the first embodiment can be obtained, and the positional deviation of the magnet 220 can be suppressed while the magnet 220 and the rotor core 201 are separated. Strong adhesion is secured in the long run. As a result, it is possible to provide the rotor 200 having good motor characteristics and long-term reliability.

Furthermore, the shape of the outer peripheral surface of the groove portion 201M is such that the first distance W2C between the central portion in the circumferential direction S of the inner side surface of each magnet 220 and the outer peripheral surface of the groove portion 201M facing the inner side surface It is formed to be larger than a second distance W2E between both end portions in the circumferential direction S of the inner side surface and the outer peripheral surface of the groove portion 201M opposed to the inner side surface.
As described above, by configuring the film thickness of the adhesive layer 10 to be thicker toward the central portion in the circumferential direction S, the circumferential direction in which the film thickness is thick even if cracks occur at both ends in the circumferential direction S of the adhesive layer 10 It is possible to delay the progress of the crack to the central portion of S.
Further, by reducing the film thickness of the adhesive layer 10 at both end portions in the circumferential direction S, the amount of the adhesive Z used in each adhesive layer 10 can be reduced, and the cost can be reduced.
Thus, by configuring the distance between the inner surface of the magnet 220 and the outer peripheral surface of the groove 201M facing the inner surface to be different in the range of the circumferential direction S of each magnet 220. Thus, both cost reduction and suppression of deterioration of the adhesive layer 10 can be achieved.

Third Embodiment
The third embodiment of the present invention will be described below with reference to the drawings, focusing on differences from the first embodiment. The same parts as those in the first embodiment are given the same reference numerals, and the description thereof is omitted.
FIG. 25 is a perspective view showing a rotor 300 according to Embodiment 3 of the present invention.
FIG. 26 is a cross-sectional view in which the rotor 300 shown in FIG. 25 is divided in parallel to the axial direction G.
FIG. 27 is a perspective view showing a rotor 300 according to Embodiment 3 of the present invention.
FIG. 28 is a cross-sectional view in which the rotor 300 shown in FIG. 27 is divided in parallel to the axial direction G.

In the rotor 300 shown in FIGS. 25 and 26, a structure in which two adjacent ones of the plurality of second core sheets 2B arranged on the center side in the axial direction G are replaced with the first core sheets 2A having large diameters. Have.
The rotor 300 shown in FIGS. 27 and 28 has a structure in which two non-adjacent ones of the plurality of second core sheets 2B are replaced with the first core sheets 2A each having a large diameter.
Thus, the first core sheet 2A disposed in the groove portion 301M is configured to divide the groove portion 301M in the axial direction G. In the present embodiment, the first core sheet 2A which protrudes to the radially outer side K2 so as to divide the groove portion 301M in the axial direction G in the groove portion 301M is referred to as a protruding portion 311.

  In the rotor shown in FIGS. 25 and 26, the groove portion 301M is divided in the axial direction G by one projecting portion 311 constituted by two adjacent first core sheets 2A, and the groove portion 301M1 and the groove portion 301M2 are formed. Ru. Then, as shown in FIG. 26, the protruding portion 311 abuts on the inner side surface of the magnet 20 with a width of the axial direction G of the third dimension X3. Further, the adhesive Z is filled in each of the groove portion 301M1 and the groove portion 301M2, and the adhesive layer 310 is formed on each of them.

  Further, in the rotor 300 shown in FIGS. 27 and 28, the groove portion 301M is divided in the axial direction G by the two projecting portions 311 configured by the two non-adjacent first core sheets 2A, and the groove portion 301M1 and the groove portion 301M2 And the groove 301M3 are formed. Then, as shown in FIG. 28, the two projecting portions 311 respectively abut the inner side surface of the magnet 20 with a width of X 31 and a width of X 32 in the axial direction G. A dimension obtained by adding the width X31 and the width X32 is the third dimension X3. The adhesive Z is filled in each of the groove portion 301M1, the groove portion 301M2, and the groove portion 301M3, and the adhesive layer 310 is formed on each of them.

  According to the rotor 300 of the present embodiment configured as described above, the same effect as the rotor 100 of the first embodiment is exerted, and the positional deviation of the magnet 20 is suppressed, while the magnet 20 and the rotor core 301 are strong. Adhesion is secured in the long run. As a result, it is possible to provide the rotor 300 having good motor characteristics and long-term reliability.

  Further, the groove portion 301M is divided in the axial direction G by the protruding portion 311. Thus, the adhesive layer 310 having a configuration in which the adhesive layer 10 shown in the first embodiment is divided in the axial direction G is obtained. By shortening the width in the axial direction G of the adhesive layer 10 in this manner, it is possible to suppress the warping of both ends in the axial direction G of the magnet 20 bonded to the adhesive layer 310 due to curing and contraction of the adhesive layer 310. Thus, the strong adhesive force between the magnet 20 and the rotor core 301 is further secured for a long time.

In the above description, although one or two projecting portions 311 are provided in the groove portion 301M, the number of the projecting portions 311 is not limited to this, and may be, for example, three. .
Further, although the number of first core sheets 2A constituting each projecting portion 311 is one or two, it is not limited to this, for example, three first core sheets 2A to 1 Two projecting portions 311 may be configured.

  The number of first core sheets 2A constituting one projecting portion 311 or the number of projecting portions 311 is increased, that is, the third dimension of the width G of the projecting portion 311 in the groove portion 301 in the axial direction By increasing the ratio of X3, the adhesion area between the adhesive layer 310 and the magnet 20 is reduced. However, the length of axial direction G of rotor core 301 is 100 mm, the length of axial direction G of groove 301M is 98 mm, the length of axial direction G of magnet 20 is 100 mm, and the plate thickness of first core sheet 2A is 0.35 mm. In the case of about 1.0 mm, the ratio of the thickness of the first core sheet 2A constituting the projecting portion 311 to the whole of the rotor 300 is small, and the influence of the decrease in the bonding area is small. Therefore, in consideration of the width (third dimension X3) in the axial direction G of the projecting portion 311 with respect to the entire rotor 300, the number of first core sheets 2A constituting the one projecting portion 311, or the projecting portion The number of 311 may be determined.

Further, the method of manufacturing the rotor 300 can be manufactured in substantially the same manner as the method of manufacturing described in the first embodiment described above.
For example, in the case of the rotor 300 shown in FIGS. 25 and 26, in the first step of obtaining each core sheet 2 by press punching, the first core sheet 2A is pressed and then the second core sheets 2B are pressed by two or more sheets. After that, the first core sheet 2A for forming the projecting portion 311 is pressed out, and then the second core sheet 2B is pressed out again, and finally the first core sheet 2A is pressed out. do it.

Fourth Embodiment
The fourth embodiment of the present invention will be described below with reference to the drawings, focusing on differences from the first embodiment. The same parts as those in the first embodiment are given the same reference numerals, and the description thereof is omitted.
FIG. 29 is a perspective view showing a rotor 400 according to Embodiment 1 of the present invention.
FIG. 30 is a perspective view showing a rotor 400A different from the rotor 400 shown in FIG.
The rotor 400 of the present embodiment includes two magnets 420, 420U, 420D per pole. Similarly, the rotor 400A also has two magnets 421, 421U, 421D per pole.

  As in the first embodiment, the rotor 400 and the rotor 400A have the rotor core 1 in which a plurality of thin core sheets 2 are laminated, and magnets 420 and 421 adhered to the outer peripheral surface of the rotor core 1 by the adhesive layer 10. It is comprised from the shaft 3 inserted and fixed to the hollow hole 1A of the rotor core 1 by press-fitting, shrink fitting, or adhesion.

As shown in FIGS. 29 and 30, the magnet 420 of the rotor 400 and the magnet 421 of the rotor 400A are configured in two stages with respect to the axial direction G.
The magnet 420 of the rotor 400 includes two magnets 420U arranged at the upper side and magnets 420D arranged at the lower side. Similarly, the magnet 421 of the rotor 400A includes two magnets: a magnet 421U arranged at the upper side and a magnet 421D arranged at the lower side.

In the case of the rotor 400A shown in FIG. 30, the width in the axial direction G is longer than the rotor 400 shown in FIG. 29, and the width in the axial direction G of the magnet 421 is also longer than the magnet 420.
Further, in the case of the rotor 400 shown in FIG. 30, the magnet 421U and the magnet 421D bonded to the rotor core 1 are mutually offset in the circumferential direction S. That is, there is a step skew structure in which a step skew angle is provided in the circumferential direction S between the steps of the magnet 421U and the magnet 421D configured in two steps.

According to the rotors 400 and 400A of the present embodiment configured as described above, the same effects as the rotor 100 of the first embodiment are exerted, and the magnets 420 and 421 are suppressed while the positional deviation of the magnets 420 and 421 is suppressed. A strong adhesive force between the magnet 421 and the rotor core 1 is secured for a long time. As a result, it is possible to provide the rotor 400 and the rotor 400A having good motor characteristics and long-term reliability.
Further, in the rotor 400A shown in FIG. 30, the cogging torque and the torque ripple can be further reduced by providing a step skew structure in which a step skew angle is provided between the two stages of the magnet 421U and the magnet 421D. .

In the above, the magnets 420 and 421 configured in two stages with respect to the axial direction G are shown in each pole of the rotor 400 and the rotor 400A, but the present invention is not limited to this. The configuration may be three or more stages in which three or more magnets are fixed to the rotor core 1 per one pole. That is, a p-stage configuration in which p (p is an integer of 2 or more) magnets per pole are fixed to the rotor core 1 may be used.
Further, in the case of forming a stage skew configuration in a rotor having such a p-stage integer configuration, a stage skew angle may be provided between each of the stages of magnets configured in a plurality of stages.

Further, the method of manufacturing the rotor 400 and the rotor 400A can be manufactured in substantially the same manner as the manufacturing method described in the first embodiment described above.
However, in the case of the rotor 400A, in the second step of aligning the stacked core sheets 2 with each other to obtain the rotor core 1, when aligning the stacked core sheets 2, offset in the circumferential direction S at regular intervals in the stacking direction It differs from the first embodiment in that it is aligned as shown in FIG.
In the fourth step of bonding the magnet 421 to the outer peripheral surface of the rotor core 1 of the rotor 400A, the magnet 421U and the magnet 421D are offset in the circumferential direction S and fixed so as to form a step skew configuration. Different from Form 1.

  In the present invention, within the scope of the invention, each embodiment can be freely combined, or each embodiment can be appropriately modified or omitted.

1,201,301 Rotor core, 2A first core sheet, 2B second core sheet,
10,310 adhesive layer, 1T, 201T vertex,
20, 220, 420, 420 U, 420 D, 421, 421 U, 421 D magnets,
1 M, 201 M, 301 M, 301 M 1, 301 M 2, 301 M 3 Grooves,
100, 200, 300, 400, 400A rotor, 311 projecting parts,
101 stator, 102 rotating electric machine, 1S2 second support point, 1S3 third support point, 1D recess, 1P positioning portion, Z adhesive.

Claims (12)

A rotor comprising: a rotor core; and a plurality of magnets circumferentially spaced from each other on the outer peripheral surface of the rotor core,
The radially inner surface of the magnet is
The inner surface corresponding to the first dimension of the upper end in the axial direction of the magnet abuts at a first support location on the outer peripheral surface of the upper end in the axial direction of the rotor core, and the second dimension corresponding to the second dimension of the lower end in the axial direction of the magnet The inner side surface abuts at a second support point on the outer peripheral surface of the lower end in the axial direction of the rotor core,
A groove recessed in the radial direction and extending in the circumferential direction is formed on the outer peripheral surface of the rotor core between the first support location and the second support location in the axial direction.
The shape of the outer peripheral surface of the groove portion is
The distance between the inner surface of each magnet and the outer peripheral surface of the groove facing the inner surface is formed to have different points in the circumferential direction of each magnet,
An adhesive layer for bonding the inner surface of each magnet to the outer peripheral surface of the groove is disposed so as to fill a gap between the inner surface of each magnet and the outer peripheral surface of the groove facing the inner surface. ,
Rotor. The shape of the outer peripheral surface of the groove portion is
A first distance between a circumferentially central portion of the inner surface of each magnet and an outer peripheral surface of the groove facing the circumferentially central portion of the inner surface corresponds to circumferentially opposite ends of the inner surface of each magnet Formed so as to be smaller than a second distance between the portion and the outer peripheral surface of the groove facing the circumferential end portions of the inner surface,
The rotor according to claim 1. The shape of the outer peripheral surface of the groove portion is
A first distance between a circumferentially central portion of the inner surface of each magnet and an outer peripheral surface of the groove facing the circumferentially central portion of the inner surface corresponds to circumferentially opposite ends of the inner surface of each magnet Formed so as to be larger than a second distance between the portion and the outer circumferential surface of the groove facing the circumferential end portions of the inner surface,
The rotor according to claim 1. The shape of the outer peripheral surface of the groove portion is
The outer circumferential surface of the groove facing the location between the circumferential center of the inner surface and the circumferential ends of each magnet and the location between the circumferential center and the circumferential ends of the inner surface A first distance between the circumferential center of the inner surface of each of the magnets and an outer peripheral surface of the groove facing the circumferential center of the inner surface; and It is formed to be smaller than the second distance between the circumferential end portions of the inner side surface of the magnet and the outer peripheral surface of the groove facing the circumferential end portions of the inner side surface.
The rotor according to claim 1. The groove portion includes a protruding portion protruding radially outward in the groove portion and in contact with the inner side surface of the magnet with a width in the axial direction of a third dimension, and the protruding portion is the groove portion Split in the axial direction,
The rotor according to any one of claims 1 to 4. At both axial ends of the outer peripheral surface of the rotor core, positioning portions projecting radially outward are formed so as to abut on the circumferential end of the magnet.
The rotor according to any one of claims 1 to 5. The magnets are configured in multiple stages in the axial direction,
A step skew angle is provided circumferentially between the steps of the magnet,
The rotor according to any one of claims 1 to 6. The radial width W1 of the magnet and the distance W2 between the inner surface of the magnet and the outer peripheral surface of the groove facing the inner surface at a predetermined circumferential position of the outer peripheral surface of the rotor core The ratio R = W1 / W2 is configured to be in the range of 10 <R <300,
The rotor according to any one of claims 1 to 7. One of the shapes of the outer peripheral surface at both axial ends of the rotor core or the shape of the outer peripheral surface of the groove is formed in a circular shape, and the other is a 2n square shape having 2n vertices, where n is an integer of 2 or more Formed
At least one of the magnets is disposed between each of the vertices,
The rotor according to any one of claims 1 to 3. The rotor core is formed by axially laminating a first core sheet and a second core sheet formed of metal sheets,
The first core sheet is formed such that the distance from the axial center to the outer peripheral surface is larger than the distance from the axial center of the second core sheet to the outer peripheral surface,
The first core sheet is disposed at both axial ends of the rotor core, and the outer peripheral surface of the first core sheet corresponds to the first support location at the axial upper end of the rotor core and the second support at the axial lower end Configure each part,
The second core sheet is disposed between the first core sheets disposed at both axial ends, and the outer peripheral surface of the second core sheet constitutes the outer peripheral surface of the groove portion of the rotor core.
The rotor according to any one of claims 1 to 9. In a method of manufacturing a rotor using the rotor according to claim 10,
A first step of forming the first core sheet and the second core sheet respectively from metal sheets by press punching;
At least one of the first core sheets is disposed at both axial ends of the rotor core, and a plurality of the second core sheets are laminated between the first core sheets disposed at both axial ends. Place
And a second step of aligning at least one of the first core sheet and the second core sheet in the circumferential direction to form the groove in the outer peripheral surface of the rotor core. A rotor according to any one of claims 1 to 10;
A rotating electrical machine comprising: a stator coaxially arranged with the rotor.

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