CN115149755A - Method for manufacturing rotor for IPM motor and apparatus for manufacturing rotor for IPM motor - Google Patents
Method for manufacturing rotor for IPM motor and apparatus for manufacturing rotor for IPM motor Download PDFInfo
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- CN115149755A CN115149755A CN202210300447.5A CN202210300447A CN115149755A CN 115149755 A CN115149755 A CN 115149755A CN 202210300447 A CN202210300447 A CN 202210300447A CN 115149755 A CN115149755 A CN 115149755A
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- axial direction
- insertion hole
- rotor core
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 74
- 238000000034 method Methods 0.000 title claims abstract description 21
- 238000003780 insertion Methods 0.000 claims abstract description 105
- 230000037431 insertion Effects 0.000 claims abstract description 105
- 238000003825 pressing Methods 0.000 claims abstract description 5
- 238000005336 cracking Methods 0.000 abstract 1
- 230000006835 compression Effects 0.000 description 18
- 238000007906 compression Methods 0.000 description 18
- 229910000831 Steel Inorganic materials 0.000 description 3
- 230000004323 axial length Effects 0.000 description 3
- 239000010959 steel Substances 0.000 description 3
- 238000010586 diagram Methods 0.000 description 2
- 230000014509 gene expression Effects 0.000 description 2
- 230000005484 gravity Effects 0.000 description 2
- 230000000149 penetrating effect Effects 0.000 description 2
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical group [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 1
- 230000008602 contraction Effects 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 238000005304 joining Methods 0.000 description 1
- 238000003475 lamination Methods 0.000 description 1
- 230000000717 retained effect Effects 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/02—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/02—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
- H02K15/03—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies having permanent magnets
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- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Power Engineering (AREA)
- Manufacture Of Motors, Generators (AREA)
- Permanent Field Magnets Of Synchronous Machinery (AREA)
Abstract
Provided are a method for manufacturing a rotor for an IPM motor and a rotor manufacturing apparatus for the IPM motor, which can prevent the rotor magnet from cracking in the process of fixing the rotor magnet to the rotor core. The method for manufacturing a rotor for an IPM motor comprises: a rotor magnet insertion step of inserting a rotor magnet into the magnet insertion hole; a rotor magnet positioning step of pressing one end surface in the axial direction of the rotor magnet inserted into the magnet insertion hole to the other end in the axial direction in the magnet insertion hole; a first caulking step of caulking an end surface of the rotor core on the other side in the axial direction in the periphery of the magnet insertion hole in the axial direction in a state where the rotor magnet is pressed on the other side in the axial direction in the rotor magnet positioning step; and a second caulking step of caulking one end surface of the rotor core in the axial direction around the magnet insertion hole in the axial direction, thereby fixing the rotor magnet in the magnet insertion hole.
Description
Technical Field
The present invention relates to a method for manufacturing a rotor for an IPM motor and an apparatus for manufacturing a rotor for an IPM motor.
Background
It is known to insert a rotor core by caulking an axial end face of the rotor core in the axial direction and fixing the rotor magnet in the magnet insertion hole of the rotor core on the rotor core. For example, patent document 1 discloses a method of fixing a magnet to a rotor core by caulking. The rotor core is formed with a recess recessed inward from the inner surface in the radial direction of the through-hole into which the magnet is inserted. In the rotor core, each open distal end portion of the recess is pressed radially outward against the magnet by caulking the core pieces at both ends in the axial direction. Thereby, the magnet is fixed by the open front end portion of the recess.
[ Prior art documents ]
[ patent document ]
[ patent document 1] Japanese patent application laid-open No. 2017-169400
Disclosure of Invention
However, the rotor magnet inserted into the magnet insertion hole is shorter than the axial length of the magnet insertion hole. Therefore, when the axial end face of the rotor core is swaged in the axial direction, the rotor magnet may move in the direction pressed by the swaging in the magnet insertion hole. Therefore, for example, when one end surface of the rotor core in the axial direction is swaged and then the opposite end surface is swaged, the rotor magnet moves in the magnet insertion hole while contacting a protrusion formed when the one end surface is swaged. In this case, the rotor magnet may be broken by a projection formed when the one end face is caulked. Therefore, a manufacturing method is required which can suppress the rotor magnet from being broken in the step of fixing the rotor magnet to the rotor core.
The present invention aims to provide a manufacturing method capable of suppressing breakage of a rotor magnet in a process of fixing the rotor magnet to a rotor core.
A method of manufacturing an IPM motor rotor according to an embodiment of the present invention is a method of manufacturing an IPM motor rotor including a rotor core having a plurality of disk-shaped core plates stacked in a thickness direction and a magnet insertion hole capable of accommodating a rotor magnet. The method for manufacturing the rotor for the IPM motor comprises the following steps: a rotor magnet insertion step of inserting the rotor magnet into the magnet insertion hole; a rotor magnet positioning step of pressing one end surface in the axial direction of the rotor magnet inserted into the magnet insertion hole to the other end in the axial direction in the magnet insertion hole; a first caulking step of caulking an end surface of the rotor core on the other side in the axial direction in the periphery of the magnet insertion hole in the axial direction in a state where the rotor magnet is pressed on the other side in the axial direction in the rotor magnet positioning step; and a second caulking step of caulking an end surface of the rotor core on one side in the axial direction around the magnet insertion hole in the axial direction, thereby fixing the rotor magnet in the magnet insertion hole.
An IPM motor rotor manufacturing apparatus according to an embodiment of the present invention is an IPM motor rotor manufacturing apparatus including a rotor core having a plurality of disk-shaped core plates stacked in a thickness direction and a magnet insertion hole capable of accommodating a rotor magnet. The manufacturing device of the rotor for the IPM motor comprises: a rotor core support portion supporting the rotor core in a state in which an axis direction coincides with an up-down direction; a magnet pushing-up mechanism for pushing up a lower end surface of the rotor magnet upward to move the rotor magnet upward in the magnet insertion hole; and a caulking mechanism having a pin for caulking the rotor core in an axial direction and a pin moving portion for moving the pin in a vertical direction with respect to the rotor core.
According to the method for manufacturing a rotor of the present invention, it is possible to provide a manufacturing method capable of suppressing breakage of a rotor magnet in a step of fixing the rotor magnet to a rotor core.
Drawings
Fig. 1 is a view showing a schematic configuration of a motor including a rotor manufactured by a rotor manufacturing apparatus according to an embodiment.
Fig. 2 is a perspective view showing a schematic structure of the rotor.
Fig. 3 is a sectional view taken along line III-III of fig. 2.
Fig. 4 is a diagram showing a schematic configuration of a rotor manufacturing apparatus according to an embodiment.
Fig. 5 is a flowchart illustrating a method of manufacturing the rotor.
Fig. 6 is a view schematically showing a state where the rotor magnet is inserted into the magnet insertion hole.
Fig. 7 is a diagram schematically showing a state in which the magnet moving portion presses the magnet.
Fig. 8 is a view schematically showing a state where the other end surface of the rotor core is caulked.
Fig. 9 is a view schematically showing a state where one end surface of the rotor core is caulked.
(symbol description)
1a rotor manufacturing apparatus (IPM motor rotor manufacturing apparatus); 2 a rotor core support part; 3 an upper positioning member; 5, a magnet push-up mechanism; 6, riveting mechanism; 8 a motor; 21 a spring housing part; 51 compressing the coil spring; 52 a spring support; 61 pin; 62 a pin moving part; 80 a rotor; 81a rotor core; 81a through the hole; 81b riveting traces; 81c a first end face; 81d a second end face; 82 a rotor magnet; 83 iron core plates; 84 magnet insertion holes; 85a first projection; 85a projecting the front end portion; 86 a second projection; a 90 stator; 91 a housing; a 92 shaft; 93 a stator core; 94 stator coils.
Detailed Description
Exemplary embodiments of the present invention will now be described in detail with reference to the accompanying drawings. In the drawings, the same or corresponding portions are denoted by the same reference numerals, and description thereof will not be repeated. The dimensions of the components in the drawings do not faithfully represent the actual dimensions of the components, the dimensional ratios of the components, and the like.
In the following description, a direction parallel to the central axis P of the rotor 80 mounted on the rotor manufacturing apparatus 1 is referred to as an "axial direction", a direction orthogonal to the central axis P is referred to as a "radial direction", and a direction along an arc centered on the central axis P is referred to as a "circumferential direction". In the radial direction, the side of the central axis P with respect to the target structure is referred to as "radially inner side", and the side opposite to the central axis P with respect to the target structure is referred to as "radially outer side". In the following description, the vertical direction in a state where the rotor manufacturing apparatus 1 is installed is referred to as the "vertical direction", and the direction orthogonal to the vertical direction is referred to as the "horizontal direction". However, the orientation of the rotor manufacturing apparatus 1 according to the present invention in use is not intended to be limited by the definition of the direction.
In the following description, expressions such as "fixing", "connecting", "joining", and "mounting" (hereinafter referred to as fixing and the like) include not only a case where components are directly fixed to each other and the like but also a case where components are fixed via other components and the like. In other words, in the following description, expressions such as fixing include direct and indirect fixing of members.
(embodiment mode)
The rotor manufacturing apparatus 1 according to the exemplary embodiment of the present invention is a manufacturing apparatus of the rotor 80 for an IPM motor. First, referring to fig. 1 and 2, the motor 8 including the rotor 80 manufactured by the rotor manufacturing apparatus 1 will be briefly described.
(Structure of Motor)
Fig. 1 is a view showing a schematic configuration of the motor 8. The motor 8 is an IPM motor. The motor 8 includes a rotor 80, a stator 90, a housing 91, and a shaft 92. The rotor 80 rotates about the central axis P with respect to the stator 90. In the present embodiment, the motor 8 is a so-called inner rotor type motor in which the rotor 80 is rotatably positioned within a cylindrical stator 90 about the central axis P.
The stator 90 is housed in a case 91. In the present embodiment, the stator 90 is cylindrical. The rotor 80 is located radially inward of the stator 90. That is, the stator 90 is radially opposed to the rotor 80.
The stator 90 has a stator core 93 and a stator coil 94. The stator coil 94 is wound around the stator core 93. The detailed structure of the stator 90 is omitted.
Fig. 2 is a perspective view showing a schematic structure of the rotor 80. The rotor core 81 of the rotor 80 is cylindrical and extends along the center axis P. Rotor core 81 has a through hole 81a extending along central axis P. As shown in fig. 1, the shaft 92 is fixed to the rotor core 81 in a state of penetrating the through-hole 81a in the axial direction. Thereby, the rotor core 81 rotates together with the shaft 92.
Further, the rotor core 81 has a plurality of magnet insertion holes 84 arranged at predetermined intervals in the circumferential direction. A plurality of magnet insertion holes 84 penetrate rotor core 81 in the axial direction. The plurality of magnet insertion holes 84 are rectangular. The rotor magnet 82 is accommodated in the magnet insertion holes 84.
The rotor core 81 has a plurality of disk-shaped core plates 83 formed in a predetermined shape and stacked in the thickness direction. The plurality of core plates 83 are electromagnetic steel plates. Each of the plurality of core plates 83 has an opening constituting a part of the magnet insertion hole 84.
The rotor core 81 has a caulking trace 81b recessed in the axial direction at a caulking position Q around the magnet insertion hole 84. In the present embodiment, the caulking traces 81b are located radially inward of the magnet insertion holes 84 in the rotor core 81. In the example shown in fig. 2, the two caulking traces 81b are located radially inward of the magnet insertion holes 84.
Fig. 3 is a sectional view taken along line III-III of fig. 2. As shown in fig. 3, the caulking traces 81b are located on a first end face 81c which is one end face in the axial direction of the rotor core 81. The caulking traces 81b are also positioned on the second end surface 81d, which is the other end surface of the rotor core 81 in the axial direction. The caulking trace 81b is a pressing trace of the pin 61 caulking the first end surface 81c and the second end surface 81d in the axial direction in the rotor manufacturing apparatus 1 described later.
The rotor core 81 has a first protrusion 85 protruding into the magnet insertion hole 84 on the first end surface 81c side of the inner surface of the magnet insertion hole 84, and a second protrusion 86 protruding into the magnet insertion hole 84 on the second end surface 81d side. The first projecting portion 85 is formed by caulking the first end surface 81c in the axial direction at the caulking position Q in a first caulking step in a rotor manufacturing step to be described later. The second protrusion 86 is formed by caulking the second end surface 81d in the axial direction at the caulking position Q in a second caulking process in a manufacturing process of the rotor 80, which will be described later. That is, in the process before the first caulking process and the second caulking process, the rotor core 81 does not have the first protruding portion 85 and the second protruding portion 86.
The rotor magnet 82 has a columnar shape. The axial length of the rotor magnet 82 is shorter than the axial length of the magnet insertion hole 84. Therefore, in a state of being inserted into the magnet insertion hole 84, at least one of the end surfaces on both sides in the axial direction of the rotor magnet 82 is recessed in the axial direction with respect to the end surface in the axial direction of the rotor core 81. The rotor magnet 82 is rectangular as viewed from the axial direction. The length of the rotor magnet 82 in the short side direction is shorter than the length between the long sides extending in the longitudinal direction of the magnet insertion hole 84 as viewed from the axial direction. The rotor magnet 82 is held by the first and second protruding portions 85, 86 in a state of being inserted into the magnet insertion hole 84. In the present embodiment, the rotor magnet 82 is fixed to the rotor core 81 in a state in which the position of the axial end face of the rotor magnet 82 in the axial direction coincides with the position of the first end face 81c of the rotor core 81.
(protruding part)
Next, with reference to fig. 3, the caulking for forming the first projecting portion 85 will be described. When the first end surface 81c is pressed in the axial direction by the pin 61 at the caulking position Q, a portion between the caulking position Q and the magnet insertion hole 84 bulges toward the inside of the magnet insertion hole 84, out of the core plate 83 constituting the first end surface 81c of the rotor core 81 and the plurality of core plates 83 adjacent in the lamination direction of the core plates 83. Thereby, a first protrusion 85 protruding inward is formed on the inner surface of the magnet insertion hole 84. The first protrusion 85 has a protruding tip portion 85a, a part of which protrudes most inward of the magnet insertion hole 84.
In the present embodiment, the position of the upper end face of the end faces of the rotor magnet 82 on both sides in the axial direction coincides with the position of the first end face 81c of the rotor core 81. Therefore, the position where the protruding tip portion 85a of the first protruding portion 85 formed by caulking the first end surface 81c contacts the rotor magnet 82 is farther from the end portion of the rotor magnet 82 in the axial direction than the position where the first end surface 81c of the rotor core 81 contacts when recessed with respect to the upper end surface of the rotor magnet 82. Although the detailed description is omitted, the second end face 81d is similarly caulked, so that the second protrusion 86 is formed on the inner surface of the magnet insertion hole 84 on the second end face 81d side.
(rotor manufacturing apparatus)
Next, the rotor manufacturing apparatus 1 of the exemplary embodiment for manufacturing the rotor 80 having the above configuration will be described in detail with reference to fig. 4. The rotor manufacturing apparatus 1 includes a rotor core support portion 2, an upper positioning member 3, a magnet pushing-up mechanism 5, and a caulking mechanism 6.
The rotor core support portion 2 is a flat plate extending in the left-right direction. The rotor core support portion 2 supports the rotor core 81 in a state where the axial direction of the rotor core 81 coincides with the vertical direction. That is, the rotor core 81 is placed on the rotor core support portion 2 in a state where the axial direction coincides with the vertical direction. The rotor core support portion 2 has a spring housing portion 21 recessed downward at a position overlapping with the magnet insertion hole 84 of the rotor core 81 when viewed in the axial direction in a state where the rotor core 81 is placed. The spring housing 21 houses a compression coil spring 51 and a spring support portion 52 of the magnet pushing-up mechanism 5, which will be described later.
The rotor core support portion 2 has a rotor core positioning portion for positioning the magnet insertion hole 84 of the rotor core 81 at a position overlapping the spring housing portion 21 when viewed in the axial direction. The rotor core positioning portion is not shown. The structure of the rotor core positioning portion will not be described.
The upper positioning member 3 is a flat plate extending in the left-right direction. The upper positioning member 3 is supported on the rotor core supporting portion 2. The upper positioning member 3 is driven by an actuator not shown to move in the vertical direction. Specifically, the upper positioning member 3 moves in the vertical direction between a position above the upper end surface of the rotor core 81 and a position in contact with the end surface. The upper positioning member 3 is held in a position in contact with the upper end surface of the rotor core 81 in a state where the rotor core 81 is placed on the rotor core support 2 and the rotor magnet 82 is inserted into the magnet insertion hole 84 of the rotor core 81.
The upper positioning member 3 has a through hole penetrating in the thickness direction to a position radially inward of the magnet insertion hole 84 of the rotor core 81 in a state where the rotor core 81 is placed on the rotor core support portion 2. The through hole is located at a caulking position Q where the rotor core 81 mounted on the rotor core support portion 2 is caulked. A pin 61 described later is inserted into the through hole so as to be movable in the axial direction.
The magnet pushing-up mechanism 5 pushes up the rotor magnet 82 in the magnet insertion hole 84 in a state where the rotor core 81 is placed on the rotor core support portion 2. In the present embodiment, the magnet push-up mechanism 5 includes a compression coil spring 51 and a spring support portion 52. The compression coil spring 51 is housed in the spring housing portion 21 of the rotor core support portion 2 in a state where the expansion and contraction direction coincides with the vertical direction.
The spring support portion 52 supports the lower end surface of the rotor magnet 82. The spring support portion 52 is a member extending in the up-down direction. The spring support portion 52 is supported by the compression coil spring 51. The spring support portion 52 is compressed by the compression coil spring 51 and is stored in the spring storage portion 21. When the compression state of the compression coil spring 51 is released, the upper end of the spring support portion 52 protrudes upward beyond the upper surface of the rotor core support portion 2. That is, the spring support portion 52 presses the rotor magnet 82 upward in the magnet insertion hole 84 by the elastic restoring force of the compression coil spring 51 in a state where the rotor core 81 is placed on the rotor core support portion 2. Therefore, the compression coil spring 51 is an elastic member that presses the rotor magnet 82 upward in the magnet insertion hole 84 by an elastic restoring force.
The caulking mechanism 6 has a pin 61 and a pin moving part 62. The pin 61 is a columnar member. The pin 61 has a tapered portion with a diameter decreasing toward the tip end at the tip end portion. The pin 61 has a tip end facing downward and holds the upper side thereof on the pin moving portion 62. The tip end side of the pin 61 is inserted into the through hole of the upper positioning member 3.
The pin moving portion 62 is a flat plate extending in the left-right direction. The pin moving portion 62 is supported by the upper positioning member 3. The pin moving part 62 is located above the upper positioning member 3. The pin moving portion 62 moves in the vertical direction. Thereby, the pin moving portion 62 moves the pin 61 held on the lower side in the vertical direction. In the present embodiment, the pin moving portion 62 moves the pin 61 between a position where the tip end of the pin 61 is housed in the through hole of the upper positioning member 3 and a position where the tip end protrudes downward from the through hole. The pin 61 is moved downward by the pin moving portion 62, and the upper end surface of the rotor core 81 placed on the rotor core support portion 2 is caulked in the axial direction.
That is, in a state where the first end face 81c is positioned on the upper side in the axial direction of the rotor core 81, the caulking mechanism 6 is operated, whereby the first protruding portion 85 is formed on the first end face 81c side of the inner surface of the magnet insertion hole 84. In addition, in a state where the second end surface 81d is positioned on the upper side in the axial direction of the rotor core 81, the caulking mechanism 6 is operated, whereby the second protruding portion 86 is formed on the second end surface 81d side of the inner surface of the magnet insertion hole 84.
That is, the rotor manufacturing apparatus 1 having the above configuration is a rotor manufacturing apparatus for an IPM motor including the rotor core 81, and the rotor core 81 has a plurality of disk-shaped core plates 83 stacked in the thickness direction and a magnet insertion hole 84 capable of accommodating the rotor magnet 82. The rotor manufacturing apparatus 1 includes: a rotor core support part 2 that supports the rotor core 81 in a state where the axial direction coincides with the vertical direction; a magnet push-up mechanism 5 for pushing the lower end surface of the rotor magnet 82 upward to move the rotor magnet 82 upward in the magnet insertion hole 84; and a caulking mechanism 6 having a pin 61 for caulking the rotor core 81 in the axial direction and a pin moving portion 62 for moving the pin 61 in the vertical direction with respect to the rotor core 81.
According to the above configuration, the magnet pushing-up mechanism 5 can hold the rotor magnet 82 in a state of being pushed up upward. Accordingly, when the first end surface 81c of the rotor core is caulked in the axial direction of the rotor core, the rotor magnet can be prevented from moving downward relative to the rotor core due to caulking and gravity. Therefore, the protruding tip portion 85a of the first protruding portion 85 formed on the inner surface of the magnet insertion hole by swaging can be brought into contact with a position away from the end portion of the rotor magnet 82 in the axial direction.
In the present embodiment, the magnet pushing-up mechanism 5 is constituted by an elastic member that presses the rotor magnet 82 upward in the magnet insertion hole 84 by an elastic restoring force. By using the elastic restoring force of the elastic member in this way, the rotor magnet 82 can be easily moved relative to the rotor core 81.
In the present embodiment, the rotor manufacturing apparatus 1 includes the upper positioning member 3 that positions the upper end surface of the rotor magnet 82 inserted into the magnet insertion hole 84 with respect to the rotor core 81. This allows the rotor magnet 82 to be positioned uppermost in the magnet insertion hole 84 in the axial direction of the rotor core 81. Thereby, the protruding tip portion 85a of the first protruding portion 85 formed on the inner surface of the magnet insertion hole 84 by caulking can be brought into contact with the position farthest from the end portion in the axial direction of the rotor magnet 82.
(method of manufacturing rotor)
An exemplary method of manufacturing the rotor 80 by the rotor manufacturing apparatus 1 will now be described in detail with reference to fig. 5 to 9.
Fig. 5 is a flowchart illustrating a method of manufacturing the rotor 80. The method for manufacturing a rotor includes a rotor core mounting step S1, a rotor magnet inserting step S2, a rotor magnet positioning step S3, a first caulking step S4, a rotor core vertical reversing step S5, and a second caulking step S6.
In the rotor core mounting step S1, the rotor core 81 is mounted on the rotor core supporting portion 2 of the rotor manufacturing apparatus 1 in a state where the first end surface 81c of the rotor core 81 is positioned on the upper side. At this time, the first and second protruding portions 85 and 86 are not formed on the rotor core 81.
In the rotor magnet insertion step S2, the rotor magnet 82 is inserted into the magnet insertion hole 84 of the rotor core 81 placed on the rotor core support portion 2 of the rotor manufacturing apparatus 1. Fig. 6 is a view schematically showing a state immediately after the rotor magnet 82 is inserted into the magnet insertion hole 84. As shown in fig. 6, the lower end face of the rotor magnet 82 inserted into the magnet insertion hole 84 is supported by the spring support portion 52 of the magnet push-up mechanism 5 protruding from the rotor core support portion 2. Thereby, the upper end surface of the rotor magnet 82 is positioned above the first end surface 81c of the rotor core 81.
In the rotor magnet positioning step S3, after the rotor magnet 82 is inserted into the magnet insertion hole 84, the upper positioning member 3 is moved to a position where it contacts the upper first end surface 81c of the rotor core 81. As a result, as shown in fig. 7, the upper end face of the rotor magnet 82 located above the first end face 81c of the rotor core 81 is pressed downward by the upper positioning member 3. The spring support portion 52, which is in contact with the lower end surface of the rotor magnet 82, presses the rotor magnet 82 upward by the elastic restoring force of the compression coil spring 51. Therefore, the rotor magnet 82 is held at a position where the upper end surface coincides with the position of the first end surface 81c located above the rotor core 81. That is, the rotor magnet 82 is positioned at the uppermost position in the axial direction in the magnet insertion hole 84. In the rotor magnet positioning step S3, the end surface on the lower side in the axial direction of the rotor magnet 82 is the one-side end surface of the present invention.
In the first caulking step S4, the first end surface 81c of the rotor core 81 is caulked in the axial direction at the caulking position Q in a state where the rotor magnet 82 is pressed upward with respect to the rotor core 81. Thus, as shown in fig. 8, a first protrusion 85 is formed on the first end surface 81c side of the inner surface of the magnet insertion hole 84. Thereby, the rotor magnet 82 is pressed by the first protrusion 85 in the magnet insertion hole 84 in the direction in which the first protrusion 85 protrudes. Thereby, the rotor magnet 82 is fixed in position in the axial direction with respect to the rotor core 81 in the magnet insertion hole 84 in which the position of one end face coincides with the position of the first end face 81c.
In the rotor core up-down reversing step S5, as shown in fig. 9, the up-down positions of the first end surface 81c and the second end surface 81d of the rotor core 81 placed on the rotor core supporting portion 2 are switched. That is, the rotor core 81 is placed on the rotor core support portion 2 of the rotor manufacturing apparatus 1 in a state where the second end surface 81d of the rotor core 81 is positioned on the upper side. Thus, the first protruding portion 85 formed in the first caulking step S4 is disposed below the rotor core 81. That is, the rotor core 81 is placed on the rotor core support portion 2 in a state where the rotor magnet 82 is fixed by the first protrusion 85 in the axial direction on the lower side and the rotor magnet 82 is positioned at the lowermost position in the axial direction in the magnet insertion hole 84. Thereby, the compression coil spring 51 of the magnet pushing-up mechanism 5 is accommodated in the spring accommodating portion 21 in a compressed state.
In the second caulking process S6, the second end face 81d of the rotor core 81 is caulked in the axial direction at the caulking position Q. Thereby, the second protrusion 86 is formed at a position close to the second end face 81d of the inner surface in the magnet insertion hole 84. At this time, the position of the rotor magnet 82 in the axial direction of the rotor core 81 is fixed by the first protrusion 85. The lower end surface of the rotor magnet 82 is pressed upward by the magnet-pushing-up mechanism 5. Therefore, the rotor magnet 82 can be prevented from moving downward in the axial direction in the magnet insertion hole 84.
That is, the method of manufacturing a rotor described above is a method of manufacturing a rotor for an IPM motor including rotor core 81, and rotor core 81 includes a plurality of disk-shaped core plates 83 stacked in the thickness direction and magnet insertion holes 84 capable of accommodating rotor magnets 82. The method for manufacturing the rotor comprises the following steps: a rotor magnet insertion step of inserting the rotor magnet 82 into the magnet insertion hole 84; a rotor magnet positioning step of pressing one end surface in the axial direction of the rotor magnet 82 inserted into the magnet insertion hole 84 to the other side in the axial direction in the magnet insertion hole 84; a first caulking step of caulking the end surface of the rotor core 81 on the other side in the axial direction around the magnet insertion hole 84 in a state where the rotor magnet 82 is pressed on the other side in the axial direction in the rotor magnet positioning step; and a second caulking step of caulking one end surface of the rotor core 81 in the axial direction around the magnet insertion hole 84 in the axial direction, thereby fixing the rotor magnet 82 in the magnet insertion hole 84.
In the above-described method of manufacturing a rotor, the end surface of the rotor core 81 on the other side in the axial direction is caulked in a state where the end surface of the rotor magnet 82 on one side in the axial direction inserted into the magnet insertion hole 84 is pressed against the other side in the axial direction in the magnet insertion hole 84. This can suppress the rotor magnet 82 from moving in the magnet insertion hole 84 when the rotor core is swaged. Further, the protruding tip portion 85a of the first protruding portion 85 formed on the inner surface of the magnet insertion hole 84 by caulking can be brought into contact with a position away from the end portion of the rotor magnet 82 in the axial direction. Thus, when the axial one-side end surface of the rotor core 81 is swaged in the axial direction, the rotor magnet 82 can be prevented from being broken at the contact position of the protruding tip portion 85a.
In the rotor magnet positioning step S3, the rotor core 81 is disposed in a state where the axial direction coincides with the vertical direction, and the end surface located below the rotor magnet 82 is pressed upward.
When the axial direction of the rotor core 81 is the vertical direction, the rotor magnet 82 can be held in a state of being lifted when the first end surface 81c of the rotor core positioned on the upper side is caulked to the lower side in the axial direction. This can prevent rotor magnet 82 from moving downward relative to rotor core 81 due to caulking and gravity. Further, the protruding tip portion 85a of the first protruding portion 85 formed by caulking can be brought into contact with a position away from the end portion of the rotor magnet 82 in the axial direction. Therefore, when the second end surface 81d on the opposite side of the rotor core 81 in the axial direction is caulked in the axial direction, the rotor magnet 82 can be prevented from being broken at the contact position of the protruding tip portion 85a.
In the rotor magnet positioning step S3, the one end surface of the rotor magnet 82 in the axial direction is pressed toward the other end surface in the axial direction in the magnet insertion hole 84 by the elastic restoring force of the elastic member. In this way, by using the elastic restoring force of the elastic member, the rotor magnet 82 can be easily moved relative to the rotor core 81.
In the rotor magnet positioning step, the rotor magnet 82 is moved in the axial direction until the other end surface of the rotor magnet 82 coincides with the other end surface of the rotor core 81 in the axial direction.
This allows rotor magnet 82 to be positioned on the other side of rotor core 81 in the axial direction of rotor core 81. Thus, the protruding tip portion 85a of the first protruding portion 85 formed on the inner surface of the magnet insertion hole 84 by caulking can be brought into contact with a position away from the end portion of the rotor magnet 82 in the axial direction. Thus, when the axial one-side end surface of the rotor core 81 is swaged in the axial direction, the rotor magnet 82 can be prevented from being broken at the contact position of the protruding tip portion 85a.
(other embodiments)
The embodiments of the present invention have been described above, but the above embodiments are merely examples for carrying out the present invention. Therefore, the present invention is not limited to the above-described embodiments, and can be implemented by appropriately modifying the above-described embodiments without departing from the scope of the present invention.
In the above embodiment, the magnet pushing-up mechanism 5 of the rotor manufacturing apparatus 1 does not compress and hold the compression coil spring 51 when the rotor magnet 82 is inserted into the magnet insertion hole 84 of the rotor core 81 in the rotor magnet insertion step S2. However, the magnet pushing-up mechanism may be configured to compress and hold the compression coil spring when the rotor magnet is inserted into the magnet insertion hole of the rotor core, and to release the compression of the compression coil spring in the rotor magnet positioning step S3.
In the above embodiment, the magnet push-up mechanism 5 of the rotor manufacturing apparatus 1 is positioned at the uppermost position in the axial direction in the magnet insertion hole 84 by bringing the rotor magnet 82 into contact with the upper positioning member 3. However, the magnet pushing-up mechanism may position the rotor magnet below the uppermost position in the axial direction in the magnet insertion hole.
In the above embodiment, the magnet pushing-up mechanism 5 of the rotor manufacturing apparatus 1 is constituted by the compression coil spring 51 that pushes the rotor magnet by the elastic restoring force. However, the magnet pushing-up mechanism may be constituted by a member other than the compression coil spring as long as it can push the rotor magnet.
In the above embodiment, the magnet push-up mechanism 5 of the rotor manufacturing apparatus 1 determines the push-up amount by the elastic restoring force of the compression coil spring 51. However, the amount of the rotor magnet pushed upward may also be controlled by the actuator.
In the above embodiment, the rotor manufacturing apparatus 1 has the upper positioning member 3. However, the rotor manufacturing apparatus may not have the upper positioning member.
In the above embodiment, the caulking mechanism 6 of the rotor manufacturing apparatus 1 is held by the upper positioning member 3. However, the caulking mechanism 6 may be held on the rotor core support portion. The caulking mechanism 6 may be held by the upper positioning member and the rotor core support portion. In this case, both end surfaces of the rotor core in the axial direction may be caulked by a caulking mechanism held by the upper positioning member and a caulking mechanism held by the rotor core supporting portion.
In the above embodiment, the caulking mechanism 6 of the rotor manufacturing apparatus 1 is located above the rotor manufacturing apparatus 1. However, the caulking mechanism may be located at a lower portion of the rotor manufacturing apparatus. The caulking mechanism may be provided at an upper portion and a lower portion of the rotor manufacturing apparatus. In this case, the upper caulking means may caulk an upper end surface of the rotor core in the axial direction, and the lower caulking means may caulk a lower end surface of the rotor core in the axial direction.
In the above embodiment, the manufacturing process of the rotor core includes the rotor core vertical reversing process S5. However, the manufacturing process of the rotor core may not include the rotor core vertical reversing process. In this case, in the second caulking step S6, the end surface of the rotor core on the lower side in the axial direction may be caulked in the axial direction by a caulking mechanism located at the lower portion of the rotor manufacturing apparatus.
In the above embodiment, the core plate 83 is an electromagnetic steel plate. However, the core plate may be a plate member other than the electromagnetic steel plate.
The present invention is applicable to a rotor in which a rotor magnet accommodated in a magnet insertion hole is retained by caulking.
Claims (7)
1. A method for manufacturing an IPM motor rotor having a rotor core including a plurality of disk-shaped core plates stacked in a thickness direction and a magnet insertion hole capable of accommodating a rotor magnet, the method comprising:
a rotor magnet insertion step of inserting the rotor magnet into the magnet insertion hole;
a rotor magnet positioning step of pressing one end surface in the axial direction of the rotor magnet inserted into the magnet insertion hole to the other side in the axial direction in the magnet insertion hole;
a first caulking step of caulking an end surface of the rotor core on the other side in the axial direction in the periphery of the magnet insertion hole in the axial direction in a state where the rotor magnet is pressed on the other side in the axial direction in the rotor magnet positioning step; and
and a second caulking step of caulking one end surface of the rotor core in the axial direction around the magnet insertion hole in the axial direction, thereby fixing the rotor magnet in the magnet insertion hole.
2. The method of manufacturing a rotor for an IPM motor as claimed in claim 1,
in the rotor magnet positioning step, the rotor core is disposed in a state where the axis direction coincides with the vertical direction, and an end surface of the rotor magnet located on the lower side is pressed upward.
3. The method of manufacturing a rotor for an IPM motor as claimed in claim 1 or 2,
in the rotor magnet positioning step, the one end surface of the rotor magnet in the axial direction is pressed against the other end surface in the axial direction in the magnet insertion hole by an elastic restoring force of an elastic member.
4. The method of manufacturing a rotor for an IPM motor as claimed in claim 1,
in the rotor magnet positioning step, the rotor magnet is moved in the axial direction until the other end surface of the rotor magnet coincides with the other end surface of the rotor core in the axial direction.
5. An apparatus for manufacturing a rotor for an IPM motor, the apparatus comprising a rotor core having a plurality of disk-shaped core plates stacked in a thickness direction and a magnet insertion hole capable of housing a rotor magnet, the apparatus comprising:
a rotor core support part supporting the rotor core in a state that an axial direction is consistent with an up-down direction;
a magnet pushing-up mechanism that pushes up a lower end surface of the rotor magnet to move the rotor magnet upward in the magnet insertion hole; and
a riveting mechanism having: a pin that is riveted to the rotor core in an axial direction; and a pin moving unit that moves the pin in the vertical direction with respect to the rotor core.
6. The IPM motor rotor manufacturing apparatus of claim 5,
the magnet pushing-up mechanism is composed of an elastic member that presses the rotor magnet upward in the magnet insertion hole by an elastic restoring force.
7. The IPM motor rotor manufacturing apparatus of claim 5 or 6,
the rotor includes an upper positioning member for positioning an upper end surface of the rotor magnet inserted into the magnet insertion hole with respect to the rotor core.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2021058604A JP7447856B2 (en) | 2021-03-30 | 2021-03-30 | Method for manufacturing rotor for IPM motor and rotor manufacturing device for IPM motor |
| JP2021-058604 | 2021-03-30 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN115149755A true CN115149755A (en) | 2022-10-04 |
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Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202210300447.5A Pending CN115149755A (en) | 2021-03-30 | 2022-03-25 | Method for manufacturing rotor for IPM motor and apparatus for manufacturing rotor for IPM motor |
Country Status (2)
| Country | Link |
|---|---|
| JP (1) | JP7447856B2 (en) |
| CN (1) | CN115149755A (en) |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2024177791A1 (en) * | 2023-02-24 | 2024-08-29 | E-Circuit Motors, Inc. | Method and apparatus for placing magnet segments for axial flux motors |
Family Cites Families (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2007037202A (en) | 2003-10-31 | 2007-02-08 | Neomax Co Ltd | Rotor for permanent magnet embedded motor, its assembling method, and assembling device |
| JP6069250B2 (en) | 2014-03-28 | 2017-02-01 | 本田技研工業株式会社 | Rotor manufacturing apparatus and rotor manufacturing method |
| JP6493257B2 (en) | 2016-03-10 | 2019-04-03 | アイシン・エィ・ダブリュ株式会社 | Manufacturing method of rotor |
| JP7442957B2 (en) | 2018-02-14 | 2024-03-05 | トヨタ紡織株式会社 | Rotor core manufacturing equipment |
-
2021
- 2021-03-30 JP JP2021058604A patent/JP7447856B2/en active Active
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- 2022-03-25 CN CN202210300447.5A patent/CN115149755A/en active Pending
Also Published As
| Publication number | Publication date |
|---|---|
| JP7447856B2 (en) | 2024-03-12 |
| JP2022155209A (en) | 2022-10-13 |
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