Rotor, motor, and manufacturing method of rotor

Abstract

This invention provides a rotor, a motor, and a method for manufacturing the rotor that prevent damage or deterioration of permanent magnets caused by the slits in the magnet cover. The rotor includes a rotor core (32), a plurality of permanent magnets (33), a generally cylindrical magnet cover (71), and a support block (70). The rotor core (32) rotates integrally with the rotating shaft of the motor. The permanent magnets (33) are disposed on the outer periphery of the rotor core (32). The magnet cover (71) covers the outer side of the rotor core (32) and the plurality of permanent magnets (33), and has a flange portion that bends radially inward at its end along the direction of the rotation axis. The support block (70) is disposed between the end face of the rotor core (32) along the direction of the rotation axis and the flange portion, and abuts against the flange portion and the rotor core (32).

Description

Technical Field

[0001] The present invention relates to a rotor, a motor using the rotor, and a method for manufacturing the rotor. Background Technology

[0002] As a motor used in vehicle wiper devices, there is a type of motor in which a rotor with a permanent magnet is arranged inside the stator in the radial direction where a coil is wound. As a configuration of the permanent magnet used in the rotor of this type of motor, there is a method of arranging the permanent magnet on the outer periphery of the rotor core (surface permanent magnet (SPM)).

[0003] In this type of rotor, multiple permanent magnets are assembled on the outer periphery of the rotor core. In this state, the rotor core and the permanent magnets are covered by a roughly cylindrical magnet cover. The magnet cover is formed by arranging the rotor core and permanent magnets within the roughly cylindrical peripheral wall, and then fixing the axial end (along the axis of rotation) to the end of the rotor core.

[0004] As for fixing the axial end of the magnet cover, known methods include: pre-providing a bending piece at the end edge of the magnet cover, bending the bending piece and locking it into a hole or recess on the end face of the rotor core (for example, see Patent Document 1), or fixing it by means of a slit.

[0005] Existing technical documents

[0006] Patent documents

[0007] Patent Document 1: Japanese Patent Application Publication No. 2008-295140 Summary of the Invention

[0008] The problem that the invention aims to solve

[0009] By setting a bending tab at the end edge of the magnet cover and locking the bending tab into the rotor in the hole or recess of the end face of the rotor core, the assembly of the magnet cover relative to the rotor core and permanent magnet becomes easier, but on the other hand, the assembly strength is worse than that by means of a seam.

[0010] However, when fixing the magnet cover to the rotor core using a slit, a large slit load can easily be transferred to the permanent magnet during the slitting process. Furthermore, if a large slit load is transferred to the permanent magnet through the slit of the magnet cover during the slitting operation, it may cause damage or deterioration to the permanent magnet.

[0011] The objective of this invention is to provide a rotor, a motor, and a method for manufacturing the rotor that can prevent damage or deterioration of the permanent magnet caused by the slits in the magnet cover.

[0012] Technical means to solve the problem

[0013] To solve the aforementioned problems, the rotor of the present invention adopts the following structure.

[0014] That is, the rotor of the present invention rotates under the magnetic field of the stator, comprising: a rotor core that rotates integrally with the rotating shaft of the motor; a plurality of permanent magnets disposed on the outer periphery of the rotor core; a generally cylindrical magnet cover that covers the outer side of the rotor core and the plurality of permanent magnets, having a flange portion that bends radially inward at an end along the direction of the rotation axis; and a support block disposed between the end face of the rotor core along the direction of the rotation axis and the flange portion, abutting against the flange portion and the rotor core.

[0015] According to the structure, the rotor core and multiple permanent magnets, along with a support block, are arranged inside the magnet cover. The flange of the magnet cover is fixed to the magnet cover by a slit. When the flange slits, although a large load acts on the flange and its inner components, the slit load is difficult to apply to the permanent magnets because a support block is arranged between the end face of the rotor core along the rotation axis and the flange.

[0016] Alternatively, at least one end of the permanent magnet along the direction of rotation axis may protrude outward from the same side end of the rotor core along the direction of rotation axis, and the abutting portion of the bearing block that abuts against the flange may be positioned further outward from the end of the permanent magnet along the direction of rotation axis.

[0017] At this point, the contact portion between the bearing block and the flange is positioned outward from the end of the permanent magnet along the direction of the rotation axis, thus making it difficult for the slit load to act directly on the permanent magnet. Therefore, with this structure, the length of the permanent magnet can be sufficiently ensured, while also effectively preventing damage or deterioration of the permanent magnet caused by the slit.

[0018] Alternatively, the rotor core may have the following structure: a generally cylindrical core body portion; and a plurality of salient poles protruding radially from the outer peripheral surface of the core body portion; a plurality of permanent magnets disposed between and abutting the salient poles; and the bearing block having: an annular portion overlapping the end face of the core body portion along the rotation axis; and a plurality of feet protruding radially from the outer peripheral surface of the annular portion and overlapping the end face of each salient pole along the rotation axis.

[0019] At this point, the bearing block is provided with an annular portion and a foot portion that overlap the core body portion of the rotor core and the end faces of the salient poles. Therefore, the end of a long permanent magnet along the rotation axis can be positioned in the space enclosed by the outer peripheral surfaces of a pair of adjacent feet and the annular portion. Thus, with this structure, the length of the permanent magnet can be sufficiently ensured, and the input of slit load to the end of the permanent magnet can be more effectively suppressed.

[0020] Ideally, the foot of the bearing block extends to a position further outward in the radial direction centered on the axis of rotation than the contact area between the salient pole of the rotor core and the permanent magnet.

[0021] At this time, the slit load is difficult to input into the vicinity of the support area (the contact area of ​​the foot) of the permanent magnet, which can effectively prevent damage or deterioration of the permanent magnet caused by the slit load.

[0022] Alternatively, the structure may be as follows: the bearing block has a core limiting part, which engages with the rotor core to limit the circumferential displacement of the rotor core around the rotation axis.

[0023] At this time, the circumferential displacement of the rotor core relative to the bearing block can be limited by the core limiting part, so the circumferential positional relationship between the bearing block and the rotor core can be accurately set.

[0024] Alternatively, the core limiting portion may include a locking claw, which protrudes from the annular portion toward the direction along the rotation axis and engages with the inner circumference of the core body portion.

[0025] At this time, the locking claw, which serves as the core limiting part, engages with the locking part on the inner circumference of the core body. Therefore, when the closure load acts from the outer circumference of the bearing block toward the radial inward side, the locking claw displaces toward the radial inward side, thus preventing excessive stress concentration on the locking claw. Therefore, with this structure, damage to the locking claw (core limiting part) caused by the input of the closure load can be prevented.

[0026] Alternatively, a bulge that abuts against the core body portion in the direction along the rotation axis may be provided near the area where the locking claw is protruding on the inner circumferential surface of the annular portion.

[0027] At this point, the area near the locking claw on the inner circumferential surface of the annular portion is reinforced by the bulge, thus the bulge can block the large load when the rotating shaft is pressed into the inner circumferential surface of the rotor core. Therefore, with this structure, it is possible to prevent the rotor core from shifting along the axial direction when the rotating shaft is pressed into the rotor core.

[0028] Alternatively, a first magnet limiting part may be provided on the outer periphery of the annular portion, the first magnet limiting part abutting against the permanent magnet in the direction along the rotation axis, thereby limiting the displacement of the permanent magnet in the direction along the rotation axis.

[0029] At this time, the positional deviation of the permanent magnet along the axis of rotation can be limited by the first magnet limiting part on the outer periphery of the annular part.

[0030] Alternatively, a second magnet limiting part may be provided at the foot, which abuts against the permanent magnet in the circumferential direction centered on the rotation axis, thereby limiting the displacement of the permanent magnet in the circumferential direction.

[0031] At this point, the positional deviation of the permanent magnet in the circumferential direction can be limited by using the second magnet limiting part at the foot.

[0032] Alternatively, the structure may include a protrusion for detecting the magnet position that extends outward from the outside of the magnet cover.

[0033] At this point, after assembling the rotor core, permanent magnets, and support blocks inside the magnet housing, the position of the permanent magnets inside the magnet housing can be accurately detected using the magnet position detection protrusion. Therefore, the permanent magnets inside the magnet housing can be accurately magnetized.

[0034] Furthermore, in order to solve the aforementioned problems, the motor of the present invention adopts the following structure.

[0035] That is, the motor of the present invention includes: any of the rotors described above; and a stator disposed on the outer periphery of the rotor and generating a magnetic field.

[0036] Furthermore, in order to solve the aforementioned problem, the rotor manufacturing method of the present invention adopts the following structure.

[0037] That is, the rotor manufacturing method of the present invention is a method for manufacturing a rotor that rotates under the magnetic field of the stator, comprising the following steps: arranging a plurality of permanent magnets on the outer periphery of the rotor core, and arranging a support block on the end face of the rotor core in the direction of the rotation axis; arranging a generally cylindrical magnet cover on the outside of the rotor core, the plurality of permanent magnets and the support block; and slitting the end edge of the magnet cover in the direction of the rotation axis toward the radial direction inward, so that the slid portion of the magnet cover abuts against the end face of the support block.

[0038] The effects of the invention

[0039] According to the present invention, since a bearing block is provided between the end face of the rotor core along the direction of the rotation axis and the flange portion, damage or deterioration of the permanent magnet caused by the closing gap of the magnet cover can be prevented before it occurs. Attached Figure Description

[0040] Figure 1 This is a perspective view of the motor unit in the implementation method.

[0041] Figure 2 Along the motor unit of the implementation method Figure 1 A cross-sectional view of line II-II.

[0042] Figure 3 This is a perspective view of the rotor according to the first embodiment.

[0043] Figure 4 The rotor of the first embodiment is along Figure 3 A cross-sectional view of line IV-IV.

[0044] Figure 5 This is an exploded perspective view of the rotor according to the first embodiment.

[0045] Figure 6 This is a perspective view of the rotor of the first embodiment with the magnet cover removed.

[0046] Figure 7 This is a plan view of the rotor of the first embodiment with the magnet cover removed.

[0047] Figure 8 This is a plan view of the rotor core of the first embodiment.

[0048] Figure 9 This is a perspective view of the support block in the first embodiment.

[0049] Figure 10 This is a perspective view of the support block of Modified Example 1 of the first embodiment.

[0050] Figure 11 This is a plan view of the rotor of Modified Example 1 of the first embodiment, with the magnet cover removed.

[0051] Figure 12 This is a plan view of the rotor core of Modified Example 2 of the first embodiment.

[0052] Figure 13 This is a plan view of the rotor core of Modified Example 3 of the first embodiment.

[0053] Figure 14 This is a plan view of the rotor core of Modified Example 4 of the first embodiment.

[0054] Figure 15 This is a perspective view of the rotor according to the second embodiment.

[0055] Figure 16 The rotor of the second embodiment is along Figure 15 A cross-sectional view of the XVI-XVI line.

[0056] Figure 17 This is an exploded perspective view of the rotor according to the second embodiment.

[0057] Figure 18 This is a perspective view of the rotor of the second embodiment with the magnet cover removed.

[0058] Figure 19 This is a plan view of a portion of the rotor in the second embodiment with the magnet cover removed.

[0059] Figure 20 This is a partial cross-sectional top view of a portion of the rotor in the second embodiment with the magnet cover removed.

[0060] Figure 21 The rotor of the modified example 1 of the second embodiment is... Figure 16 The same cross-sectional view.

[0061] Figure 22 This is a plan view of the magnet cover of Modified Example 2 of the second embodiment.

[0062] Figure 23 This is a perspective view of the rotor of Modified Example 2 of the second embodiment.

[0063] Figure 24 This is a perspective view of the rotor according to the third embodiment.

[0064] Figure 25 The rotor of the third embodiment Figure 24 A cross-sectional view along the XXV-XXV line.

[0065] Figure 26 This is an exploded perspective view of the rotor according to the third embodiment.

[0066] Figure 27 This is a perspective view of the rotor of the third embodiment with the magnet cover removed.

[0067] Figure 28 This is a plan view of the rotor in the third embodiment with the magnet cover removed.

[0068] Figure 29 This is a perspective view of the support block in the third embodiment.

[0069] Figure 30 The rotor of the third embodiment Figure 25 Enlarged cross-sectional view of part XXX.

[0070] Figure 31 The rotor of the third embodiment, variant 1, is... Figure 25 Enlarged cross-sectional view of the XXXI section.

[0071] Figure 32This is a perspective view of the support block of Modified Example 2 of the third embodiment.

[0072] Figure 33 This is a perspective view of the support block of Modified Example 3 of the third embodiment.

[0073] Figure 34 This is a perspective view of the support block of Modified Example 4 of the third embodiment.

[0074] [Explanation of reference numerals in the attached figures]

[0075] 2: Motor

[0076] 8: Stator

[0077] 9, 109, 109A, 109B, 209: Rotors

[0078] 31: Rotation axis

[0079] 32, 132: Rotor core

[0080] 32A, 132A: Core body section

[0081] 32B, 132B: Salient pole

[0082] 33: Permanent magnet

[0083] 70, 170, 270, 270a, 270b, 270c: Bearing blocks

[0084] 70A, 170A: Annular portion

[0085] 70B, 170B: Footwear

[0086] 71, 71B: Magnetic cover

[0087] 71c: Flange portion

[0088] 73a, 73Aa, 73Ba: Connecting parts

[0089] 74: Locking claw (iron core limiting part)

[0090] 75: Magnet limiting plate (first magnet limiting part)

[0091] 76: Press-in protrusion (second magnet limiting part)

[0092] 77: Protrusion for magnet position detection

[0093] 78: Drum Exit Section Detailed Implementation

[0094] Hereinafter, an embodiment of the present invention will be described based on the accompanying drawings. Furthermore, in the various embodiments or modifications described below, the same reference numerals are used for the same parts, and repeated descriptions are omitted.

[0095] (Motor unit)

[0096] Figure 1 This is a perspective view of motor unit 1 used in vehicles. Figure 2 It is along motor unit 1 Figure 1 A cross-sectional view of line II-II.

[0097] Motor unit 1 is used, for example, as a drive source for a vehicle's windshield wiper system. Figure 1 , Figure 2 As shown, the motor unit 1 includes a motor 2, a speed reduction unit 3 that reduces the rotation of the motor 2 and outputs a speed reduction, and a controller 4 that drives and controls the motor 2.

[0098] Furthermore, in the following explanation, when referred to as "axial direction," it means the direction along the rotation axis of the rotating shaft 31 of the motor 2; when referred to as "circumferential direction," it means the circumferential direction of the rotating shaft 31; and when referred to as "radial direction," it means the radial direction of the rotating shaft 31.

[0099] (motor)

[0100] Motor 2 includes: a motor housing 5; a generally cylindrical stator 8 housed within the motor housing 5; and a rotor 9 disposed radially inside the stator 8 and rotatable relative to the stator 8. The motor 2 of this embodiment is a so-called brushless motor, meaning it does not require brushes when power is supplied to the stator 8.

[0101] (Motor housing)

[0102] The motor housing 5 is made of a material with excellent heat dissipation, such as aluminum alloy. The motor housing 5 includes a first motor housing 6 and a second motor housing 7 that are divisibly constructed in the axial direction. The first motor housing 6 and the second motor housing 7 are each formed into a bottomed cylindrical shape.

[0103] The first motor housing 6 is integrally formed with the gearbox 40 of the reduction unit 3 by connecting the bottom 10 to the gearbox 40. A through hole is formed approximately at the center of the bottom 10 in the radial direction, through which the rotating shaft 31 of the motor 2 can be inserted.

[0104] Furthermore, each of the openings 6a and 7a in the first motor housing 6 and the second motor housing 7 has an outer flange 16 and 17 extending radially outward. The motor housing 5 forms an internal space by abutting the outer flanges 16 and 17 together. A stator 8 and a rotor 9 are disposed within the internal space of the motor housing 5. The stator 8 is fixed to the inner circumferential surface of the motor housing 5.

[0105] (stator)

[0106] The stator 8 includes a stator core 20 comprising stacked electromagnetic steel plates, etc., and a plurality of coils 24 wound around the stator core 20. The stator core 20 has an annular core body portion 21 and a plurality (e.g., six) of teeth 22 protruding radially inward from the inner circumference of the core body portion 21. The inner circumferential surface of the core body portion 21 and each tooth 22 are covered by resin insulators 23. The coils 24 are wound from the insulators 23 onto corresponding designated teeth 22. Each coil 24, powered by a supply from the controller 4, generates a magnetic field to rotate the rotor 9.

[0107] (rotor)

[0108] The rotor 9 is rotatably disposed inside the stator 8 in the radial direction via a minute gap. The rotor 9 includes: a generally cylindrical rotor core 32 with a rotating shaft 31 pressed and fixed to its inner circumference; and four permanent magnets 33 (see reference). Figures 5-7 The rotor core 32 is assembled on its outer periphery. In this embodiment, the rotating shaft 31 is integrally formed with the worm shaft 44 constituting the reduction unit 3. The rotating shaft 31 and the worm shaft 44 are rotatably supported on the motor housing 5 and the gearbox 40. The rotating shaft 31 and the worm shaft 44 rotate about the rotation axis (axis C). Furthermore, a ferrite magnet is used, for example, as the permanent magnet 33. However, the permanent magnet 33 is not limited to this; rubidium-bonded magnets or rubidium-sintered magnets can also be used.

[0109] The detailed structure of rotor 9 will be explained later.

[0110] (Deceleration section)

[0111] The reduction unit 3 includes: a gearbox 40, integrally formed with the motor housing 5; and a worm gear reduction mechanism 41, housed within the gearbox 40. The gearbox 40 is formed of a metal material with excellent heat dissipation, such as aluminum alloy. The gearbox 40 is box-shaped with an opening 40a on one side. The gearbox 40 has a gear receiving portion 42 that internally houses the worm gear reduction mechanism 41. Furthermore, on the side wall 40b of the gearbox 40, at the portion where the first motor housing 6 is integrally formed, a through hole communicating with the opening 43 of the gear receiving portion 42 is formed.

[0112] A generally cylindrical bearing boss 49 is provided protruding from the bottom wall 40c of the gearbox 40. The bearing boss 49 is used to rotatably support the output shaft 48 of the worm gear reducer 41, and a sliding bearing (not shown) is arranged on its inner circumference. An O-ring (not shown) is installed on the inner side of the front end of the bearing boss 49. Moreover, a plurality of ribs 52 are provided protruding from the outer circumference of the bearing boss 49 to ensure rigidity.

[0113] The worm gear reducer 41, housed within the gear housing 42, includes a worm shaft 44 and a worm wheel 45 meshing with the worm shaft 44. The two ends of the worm shaft 44 in the axial direction are rotatably supported on the gearbox 40 via bearings 46 and 47. The output shaft 48 of the motor 2 is coaxially and integrally provided on the worm wheel 45. The worm wheel 45 and the output shaft 48 are arranged such that their axes of rotation are approximately orthogonal to the axis of rotation (axis C) of the worm shaft 44 (the rotating shaft 31 of the motor 2). The output shaft 48 protrudes to the outside via a bearing boss 49 of the gearbox 40. A spline 48a is formed at the protruding front end of the output shaft 48, allowing connection to an object driven by the motor.

[0114] Furthermore, a sensor magnet (not shown) is provided on the worm gear 45. The position of the sensor magnet is detected by a magnetic detection element 61 provided in the controller 4 (described later). That is, the rotational position of the worm gear 45 is detected by the magnetic detection element 61 of the controller 4.

[0115] (Controller)

[0116] The controller 4 has a controller board 62 on which a magnetic detection element 61 is mounted. The controller board 62 is disposed within the opening 40a of the gearbox 40 with the magnetic detection element 61 facing the sensor magnet of the worm gear 45. The opening 40a of the gearbox 40 is closed by a cover 63.

[0117] The controller board 62 is connected to the ends of a plurality of coils 24 extending from the stator core 20. Furthermore, the controller board 62 is electrically connected to a connector 11 provided in the cover 63 (see reference). Figure 1 The terminals of the controller board 62 are also provided. In addition to the magnetic detection element 61, the controller board 62 is also provided with a power supply module (not shown) containing switching elements such as a field-effect transistor (FET) that controls the drive voltage supplied to the coil 24, or a capacitor (not shown) that smooths the voltage.

[0118] (Detailed structure of the rotor in the first embodiment)

[0119] Figure 3 This is a perspective view of the rotor 9 according to the first embodiment. Figure 4It is along Figure 1 A cross-sectional view of line IV-IV. Furthermore, Figure 5 This is an exploded 3D view of rotor 9.

[0120] As shown in these figures, rotor 9 includes: rotor core 32, which is compatible with rotating shaft 31 (see reference). Figure 2 The rotor core 32 rotates together around the axis of rotation (axis C); four permanent magnets 33 are arranged on the outer periphery of the rotor core 32; a pair of bearing blocks 70 are respectively arranged on one end side and the other end side of the rotor core 32 in the axial direction; and a metal magnet cover 71, together with the pair of bearing blocks 70, covers the rotor core 32 and the permanent magnets 33 from the outside in the axial and radial directions.

[0121] Figure 6 It is a 3D view of rotor 9 with magnet cover 71 removed. Figure 7 This is a plan view of the rotor 9 with the magnet cover 71 removed. Furthermore, Figure 8 This is a plan view of rotor core 32.

[0122] The rotor core 32 has: a generally cylindrical core body portion 32A; and four salient poles 32B protruding radially from the outer peripheral surface of the core body portion 32A. The rotor core 32 is formed, for example, by pressing soft magnetic powder, or by stacking multiple electromagnetic steel plates along the axial direction.

[0123] Four salient poles 32B protrude at equal intervals on the outer periphery of the core body portion 32A, and the protruding portions extend along the axial direction. In this embodiment, the outer peripheral surface of the core body portion 32A is formed into a generally circular shape centered on the axis C (rotation axis) of the rotor 9. The circumferential side of each salient pole 32B facing the rotor core 32 includes a flat surface. Permanent magnets 33 are assembled between adjacent salient poles 32B in the circumferential direction of the rotor core 32.

[0124] In this embodiment, the permanent magnet 33 is formed into a generally arc shape when viewed along the axial direction. However, the inner circumference of the permanent magnet 33 is formed into a generally arc shape centered on the axis C (rotation axis) of the rotor 9 (a generally arc shape that is roughly consistent with the outer circumferential surface of the core body 32A), while the outer circumferential surface of the permanent magnet 33 is formed into an arc shape with a smaller radius of curvature than the inner circumferential surface. Each salient pole 32B of the rotor core 32 is formed such that the distance from the axis C (rotation axis) of the rotor 9 to the radially outer end is equal to the distance from the axis C (rotation axis) of the rotor 9 to the maximum bulge 33c (refer to the outer circumferential surface of the permanent magnet 33). Figure 7 The distances up to that point are roughly the same.

[0125] The axial length of each permanent magnet 33 is as follows Figure 4As shown, the permanent magnet 33 is formed to be longer in the axial direction than the salient pole 32B of the rotor core 32. In this embodiment, each permanent magnet 33 is configured such that, when assembled to the rotor core 32, it protrudes approximately the same length from one end to the other end relative to the salient pole 32B in the axial direction.

[0126] At both ends of the permanent magnet 33 in the arc direction, such as Figure 7 As shown, it includes: an abutting surface 33a that can abut against the flat side of the salient pole 32B; and an inclined surface 33b that extends inclinedly from the radially outer end of the abutting surface 33a toward a direction separated from the salient pole 32B.

[0127] Moreover, on the inner circumferential surface of the rotor core 32, such as Figure 8 As shown, four arcuate surfaces 72 are formed centered on the axis C (rotation axis) of the rotor 9, and grooves 73 extending radially outward from between adjacent arcuate surfaces 72. Each groove 73 extends radially outward by the same length, and the end of the extension direction is a circularly arc-shaped engaging portion 73a. The locking claws 74 (core limiting portion) of the bearing block 70, described later, are inserted into the engaging portions 73a of each groove 73. Furthermore, the rotating shaft 31 of the motor 2 is pressed into the four arcuate surfaces fixed to the inner circumference of the rotor core 32.

[0128] The magnet cover 71 has a cylindrical peripheral wall 71a and a pair of flanges 71b and 71c extending radially inward from one end and the other end of the peripheral wall 71a, respectively. The rotor core 32 and the permanent magnet 33 are disposed together with a pair of support blocks 70 on the inner side of the peripheral wall 71a. At least one of the pair of flanges 71b and 71c is configured as a slit flange that is plastically deformed by slitting when the rotor core 32 and the permanent magnet 33 are disposed together with the pair of support blocks 70 on the inner side of the peripheral wall 71a. Hereinafter, it will be described in the following case that one flange 71b is formed by pre-bending, and the other flange 71c is formed by slitting after the rotor core 32, etc. are loaded.

[0129] Figure 9 This is a 3D view of the support block 70. Figure 9 (A) is a view of the bearing block 70 from one end in the axial direction. Figure 9 (B) is a view of the bearing block 70 from the other end side in the axial direction. Figure 4 , Figure 5 In the rotor core 32, the upper and lower support blocks 70 are of the same shape and are assembled to the rotor core 32 in a reversed state.

[0130] The support block 70 has: an annular portion 70A, overlapping the end face of the core body portion 32A of the rotor core 32 in the axial direction; and four feet 70B, protruding radially from the outer peripheral surface of the annular portion 70A, overlapping the end faces of each salient pole 32B of the rotor core 32 in the axial direction. The four feet 70B protrude at equal intervals on the outer periphery of the annular portion 70A. The support block 70 is formed, for example, of rigid resin. The support block 70 is shaped to substantially coincide with the rotor core 32 when viewed along the axial direction.

[0131] Each bearing block 70 is overlapped on the axial end face of the rotor core 32, with a portion of the radially outer region disposed between the end face of the rotor core 32 and the flange portions 71b and 71c of the magnet cover 71. In this embodiment, Figure 4 The flange portion 71c on the lower side of the flange portion 71c becomes the closure flange. During the closure operation of the flange portion 71c, the closure load is blocked by the foot portion 70B of the bearing block 70 below the flange portion 71c.

[0132] The axial thickness of each foot 70B of the support block 70 is set to be thicker than the protrusion length of the permanent magnet 33 from the salient pole 32B of the rotor core 32. Therefore, the abutting portion of the support block 70 that abuts against the flange portion 71c (convex flange) is positioned further outward in the axial direction than the axial end of the permanent magnet 33. Furthermore, in this embodiment, each foot 70B extends radially to a position equal to the radial end of the corresponding salient pole 32B of the rotor core 32.

[0133] In addition, the foot 70B does not necessarily need to extend to a radial position equal to the radial end of the corresponding salient pole 32B of the rotor core 32, but ideally, it should extend to a position further outward in the radial direction than the contact area a1 (the area in contact with the contact surface 33a) in the salient pole 32B that abuts against the permanent magnet 33.

[0134] At the extended position of each foot 70B in the inner peripheral edge of the annular portion 70A of the support block 70, a locking claw 74 is integrally formed, protruding generally along the axial direction toward the rotor core 32. The cross-section of the locking claw 74 is formed to be generally semi-circular, and when the support block 70 is assembled to the end face of the rotor core 32, it engages with the groove 73 (engaging portion 73a) on the inner periphery of the rotor core 32. The support block 70 restricts the relative displacement with respect to the rotor core 32 in the radial direction by the locking claw 74 engaging with the corresponding groove 73 (engaging portion 73a).

[0135] At approximately the midpoint of each adjacent foot 70B in the outer periphery of the annular portion 70A of the support block 70, a magnet limiting plate 75 (first magnet limiting portion) is provided, protruding radially outward, to restrict the axial displacement of each permanent magnet 33. The magnet limiting plate 75 is thinner than the axial thickness of the annular portion 70A and protrudes radially outward from a position in the annular portion 70A that is biased towards the outer side of the axial direction. The axial end of the permanent magnet 33 assembled between the salient poles 32B of the rotor core 32 can abut against the magnet limiting plate 75.

[0136] Furthermore, a pair of press-in protrusions 76 (second magnet limiting portions) are formed on the side of each foot 70B of the support block 70 near the base. Each press-in protrusion 76 is formed in such a way that it extends along the axial direction and bulges out at a gradually decreasing height toward the side closer to the rotor core 32.

[0137] When assembling the support block 70 on the rotor core 32, which has permanent magnets 33 arranged on its outer periphery, the ends of each permanent magnet 33 are inserted between adjacent feet 70B of the support block 70. At this time, the contact surface 33a of the permanent magnet 33 abuts against the press-in protrusion 76. As a result, the circumferential displacement of the permanent magnet 33 is restricted.

[0138] Furthermore, on the axial direction end face of each foot 70B of the support block 70 (the end face opposite to the side protruding from the locking claw 74), a generally cylindrical magnet position detection protrusion 77 is formed along the axial direction. Moreover, the magnet position detection protrusion 77 protrudes outward from the inner periphery of the flange portion 71c toward the outer side of the magnet cover 71.

[0139] In this embodiment, after the rotor core 32, permanent magnet 33, and support block 70 are assembled inside the magnet cover 71, the permanent magnet 33 inside the magnet cover 71 is magnetized. The magnet position detection protrusion 77 is used to detect the position of the permanent magnet 33 inside the magnet cover 71 during magnetization.

[0140] (Rotor assembly)

[0141] During the assembly of rotor 9, permanent magnets 33 are first arranged on the outer periphery of rotor core 32. In this state, bearing blocks 70 are temporarily installed on each end face of rotor core 32 in the axial direction. In this state, the assembly is inserted into magnet cover 71. At this time, one of the flanges 71b of magnet cover 71 is pre-bent.

[0142] Next, from this state, the other end edge of the magnet cover 71 in the axial direction is slit, forming a flange portion 71c (slit flange) through plastic deformation, and the flange portion 71c is pressed against the end face of each foot portion 70B of the support block 70. As a result, the rotor core 32 and the permanent magnet 33 are fixed together with the support block 70 inside the magnet cover 71.

[0143] As described above, in the rotor 9 of this embodiment, a bearing block 70 is disposed between the axial end face of the rotor core 32 and the flange portion 71c (slit flange) of the magnet cover 71, and the bearing block 70 abuts against the flange portion 71c and the rotor core 32. Therefore, when the flange portion 71c is slit, the bearing block 70 can be used to block the slit load at this time. As a result, the slit load is difficult to directly act on the permanent magnet 33 inside the magnet cover 71, thereby preventing damage or deterioration of the permanent magnet 33.

[0144] Furthermore, in the rotor 9 of this embodiment, the axial end of the permanent magnet 33 protrudes outward compared to the axial end of the rotor core 32, and the contact portion of the bearing block 70 that abuts against the flange portion 71c (convex flange) is positioned further outward than the end of the permanent magnet 33. Therefore, in the rotor 9 of this embodiment, the length of the permanent magnet 33 can be sufficiently ensured, and the bearing block 70 can advantageously prevent damage or deterioration of the permanent magnet 33 caused by the converging seam.

[0145] In particular, in the rotor 9 of this embodiment, the rotor core 32 has: a generally cylindrical core body portion 32A; and a plurality of salient poles 32B protruding radially from the outer peripheral surface of the core body portion 32A, with a plurality of permanent magnets 33 disposed between adjacent salient poles 32B and abutting against the salient poles 32B. Furthermore, the support block 70 has: an annular portion 70A, overlapping on the axial end face of the core body portion 32A; and a plurality of legs 70B, protruding radially from the outer peripheral surface of the annular portion 70A, overlapping on the axial end face of each salient pole 32B. Therefore, the end of the axially long permanent magnet 33 can be disposed in the space enclosed by the pair of adjacent legs 70B of the support block 70 and the outer peripheral surface of the annular portion 70A. Therefore, in the rotor 9 of this embodiment, the length of the permanent magnet 33 can be sufficiently ensured, and the input of the slit load to the end of the permanent magnet 33 can be more advantageously suppressed.

[0146] Furthermore, in the rotor 9 of this embodiment, the foot 70B of the bearing block 70 extends to a radial position equal to the radial end of the corresponding salient pole 32B of the rotor core 32, so the slit load is difficult to input to the radially outer end of the permanent magnet 33.

[0147] However, as long as the foot 70B of the bearing block 70 extends to the radially outward position from the contact area between the salient pole 32B of the rotor core 32 and the permanent magnet 33, it can advantageously prevent the slit load from being input to the vicinity of the support area (the contact area of ​​the foot 70B) of the permanent magnet 33.

[0148] Furthermore, in the rotor 9 of this embodiment, the support block 70 is provided with a locking claw 74 (core limiting part) that engages with the rotor core 32 to limit the circumferential displacement of the rotor core 32. Therefore, the rotor core 32 can be accurately positioned relative to the support block 70 in the circumferential direction.

[0149] In particular, the rotor 9 of this embodiment employs a structure in which a locking pawl 74, protruding from the bearing block 70, engages with a groove 73 (engaging portion 73a) on the inner circumference of the core body portion 32A. Therefore, during the seam-closing operation, even though the seam-closing load may sometimes act from the outer circumference of the bearing block 70 toward the radially inward direction, the locking pawl 74 will displace within the groove 73, thereby suppressing excessive stress concentration on the locking pawl 74. Thus, with this structure, damage to the locking pawl 74 caused by the input of the seam-closing load can be prevented.

[0150] Furthermore, in the rotor 9 of this embodiment, a magnet limiting plate 75 (first magnet limiting portion) is provided in the annular portion 70A of the support block 70. The magnet limiting plate 75 (first magnet limiting portion) abuts against the permanent magnet 33 in the axial direction to limit the displacement of the permanent magnet 33 in the axial direction. Therefore, the positional deviation of the permanent magnet 33 in the axial direction can be limited by the magnet limiting plate 75 on the outer periphery of the annular portion 70A.

[0151] Furthermore, in the rotor 9 of this embodiment, a pressing protrusion 76 is provided on the side of the foot 70B of the support block 70, which restricts the circumferential displacement of the permanent magnet 33. Therefore, the circumferential position deviation of the permanent magnet 33 can be restricted by the pressing protrusion 76 of the foot 70B. Moreover, since the pressing protrusion 76 is pressed against the end face (abutment surface 33a) of the permanent magnet 33, the axial wobbling of the permanent magnet 33 can also be suppressed.

[0152] Furthermore, in the rotor 9 of this embodiment, a magnet position detection protrusion 77 protruding outward toward the magnet cover 71 is provided on the support block 70. Therefore, after assembling the rotor core 32, the permanent magnet 33, and the support block 70 inside the magnet cover 71, the position of the permanent magnet 33 can be accurately detected using the magnet position detection protrusion 77. Thus, with this structure, the permanent magnet 33 inside the magnet cover 71 can be accurately magnetized.

[0153] (Modification 1 of the first embodiment)

[0154] Figure 10 This is a perspective view of the support block 70 of the modified example 1 of the first embodiment. Figure 11 This is a plan view of rotor 9 with the magnet cover removed.

[0155] The basic structure of the rotor 9 in this modified example is largely the same as the structure described above, but the shape of the support block 70 differs from that of the structure described above. The support block 70 has an annular portion 70A and four legs 70B. A locking pawl 74 is provided at the extended position of each leg 70B in the inner peripheral edge of the annular portion 70A. A bulge 78 is formed at the extended position of each leg 70B in the inner peripheral surface of the annular portion 70A, bulging inward in the radial direction. The bulge 78 is wider than the radial width of the locking pawl 74. The locking pawl 74 is provided at the inner peripheral edge of the annular portion 70A in such a way that it partially crosses the bulge 78. The bulge 78 can abut against the edge of the groove 73 in the end face of the core body portion 32A of the rotor core 32 in the axial direction.

[0156] In this modified example, the root (near) of the locking pawl 74 on the inner circumferential surface of the annular portion 70A of the bearing block 70 is reinforced by the protrusion 78. Therefore, when the rotating shaft 31 of the motor is pressed into the inner circumferential surface of the rotor core 32 in the axial direction, the protrusion 78 can prevent large pressing loads acting on the rotor core 32. Therefore, with the structure of this modified example, when the rotating shaft 31 is pressed into the rotor core 32, it is possible to prevent the rotor core 32 from deviating from its position in the axial direction.

[0157] (Variations 2-4 of the first embodiment)

[0158] Figure 12 , Figure 13 , Figure 14 This is a plan view showing each rotor core 32 of the variations 2 to 4 of the first embodiment.

[0159] In each of the modified examples, the only difference is the shape of the receiving portion engaged by the locking claw on the bearing block side of the rotor core 32; the structure of the other parts is the same as the structure described above. Figure 12 In the modified example 2 shown, the receiving portion of the core body portion 32A formed in the rotor core 32 includes a semi-circular hole 69. Figure 13 In the modified example 3 shown, the receiving portion of the core body portion 32A formed in the rotor core 32 includes a groove 73A and a triangular engaging portion 73Aa at the end of the groove 73A. Figure 14 In the modified example 4 shown, the receiving portion of the core body portion 32A formed in the rotor core 32 includes a groove 73B and a quadrilateral-shaped engaging portion 73Ba at the end of the groove 73B.

[0160] (Detailed structure of the rotor in the second embodiment)

[0161] Figure 15 This is a perspective view of the rotor 109 according to the second embodiment. Figure 16 It is along rotor 109 Figure 15 A cross-sectional view of the XVI-XVI line. Furthermore, Figure 17 This is an exploded 3D view of rotor 109. Figure 18 It is a perspective view of rotor 109 with magnet cover 71 removed.

[0162] The rotor 109 of the second embodiment has the same basic structure as the first embodiment, namely: four permanent magnets 33 are arranged on the outer periphery of the rotor core 132; a pair of bearing blocks 170 are stacked at both ends of the rotor core 132 in the axial direction; the bearing blocks 170 are housed together with the rotor core 132 or the permanent magnets 33 inside a generally cylindrical magnet cover 71; and flange portions 71b and 71c are provided at both ends of the magnet cover 71 in the axial direction, one of which, 71c, forms a converging flange. In the rotor 109 of this embodiment, the structure of the engaging portion of the bearing block 170 relative to the rotor core 132 is quite different from that of the rotor 9 of the first embodiment.

[0163] The rotor core 132 has: a generally cylindrical core body portion 132A; and four salient poles 132B protruding radially from the outer peripheral surface of the core body portion 132A. A groove 53 extending along the axial direction is formed on the outer end face of each salient pole 132B in the radial direction. Furthermore, the inner peripheral surface of the core body portion 132A is formed as a smooth peripheral surface shape without grooves or the like.

[0164] Furthermore, the support block 170 has: an annular portion 170A, which overlaps and is disposed on the axial end face of the core body portion 132A of the rotor core 132; and four feet 170B, which protrude radially from the outer peripheral surface of the annular portion 170A and overlap and are disposed on the axial end faces of each salient pole 132B of the rotor core 132. At approximately the middle position of each adjacent foot 170B in the outer peripheral portion of the annular portion 170A, similar to the first embodiment, a magnet limiting piece 75 (first magnet limiting portion) is provided protruding outward in the radial direction to limit the axial displacement of each permanent magnet 33. A pair of press-in protrusions 76 (second magnet limiting portions) are formed on the side surface of the base side of each foot 170B. Moreover, a magnet position detection protrusion 77 protruding outward toward the magnet cover 71 is formed along the axial direction near the base of each foot 170B.

[0165] Figure 19 This is a plan view of a portion of rotor 9 with the magnet cover removed. Figure 20 It is a top view of a portion of the rotor, with the salient pole 132B of the rotor core 32 shown in cross section.

[0166] The support block 170 has a locking pawl 54 integrally formed at the radially outer end of each foot 170B. The locking pawl 54 bends from the radially outer end of the foot 170B toward the axial direction and can engage from the radially outer side with the groove 53 of the corresponding salient pole 132B of the rotor core 132. The locking pawl 54 engages with the groove 53 of the salient pole 132B, thereby restricting the circumferential displacement of the rotor core 32.

[0167] As described above, in this embodiment of the rotor 109, only the structure of the engaging portion of the bearing block 170 relative to the rotor core 132 differs from that of the first embodiment; the rest is set to the same basic structure as the first embodiment. Therefore, it is possible to obtain essentially the same basic effect as the first embodiment.

[0168] (Modification 1 of the second embodiment)

[0169] Figure 21 The rotor 109A of the modified example 1 of the second embodiment is... Figure 16 The same cross-sectional view.

[0170] In the rotor 109A of Modified Example 1, the permanent magnet 33 disposed on the outer periphery of the rotor core 132 extends outward in the axial direction only at one end relative to the same side end face of the rotor core 132. Therefore, the bearing block 170 is disposed only at one end of the rotor core 132 in the axial direction. At this time, when the flange portion 71c of the magnet cover 71 is closed, the load can also be blocked by the bearing block 170. Therefore, in the case of Modified Example 1, damage or deterioration of the permanent magnet 33 can also be suppressed.

[0171] (Modification 2 of the second embodiment)

[0172] Figure 22 This is a plan view of the magnet cover 71B of the modified embodiment 2. Figure 23 This is a perspective view of rotor 109B of the second modified example.

[0173] In this modified example, a through hole 56 corresponding to the magnet position detection protrusion 77 of the support block 170 is formed on a flange portion 71b pre-formed on one side of the magnet cover 71B. The magnet position detection protrusion 77 of the support block 170 disposed inside the magnet cover 71B is embedded in the through hole 56. The magnet position detection protrusion 77 protrudes to the outside of the magnet cover 71B through the through hole 56.

[0174] In the rotor 109B of this modified example, the magnet position detection protrusion 77 of the support block 170 is fitted into the through hole 56 of the magnet cover 71B, so the support block 170 can be positioned relative to the magnet cover 71B by means of the magnet position detection protrusion 77.

[0175] (Detailed structure of the rotor in the third embodiment)

[0176] Figure 24 This is a perspective view of the rotor 209 according to the third embodiment. Figure 25 It is along rotor 209 Figure 24 A cross-sectional view of the XXV-XXV line. Furthermore, Figure 26 This is an exploded 3D view of rotor 209. Figure 27 , Figure 28 These are perspective and plan views of the rotor 209 with the magnet cover 71 removed.

[0177] The rotor 209 of the third embodiment has the same basic structure as the first embodiment, namely: four permanent magnets 33 are arranged on the outer periphery of the rotor core 32; a pair of bearing blocks 270 are stacked at both ends of the rotor core 32 in the axial direction; the bearing blocks 270 are housed together with the rotor core 32 or the permanent magnets 33 inside a generally cylindrical magnet cover 71; and flanges 71b and 71c are provided at both ends of the magnet cover 71 in the axial direction. In the rotor 209 of this embodiment, the structure of the bearing blocks 270 stacked at both ends of the rotor core 32 in the axial direction is quite different from that of the rotor 9 of the first embodiment.

[0178] Figure 29 This is a 3D view of the support block 270. Figure 29 (A) is a view of the bearing block 270 from one end in the axial direction. Figure 29 (B) is a view of the bearing block 270 from the other end in the axial direction.

[0179] The support block 270 has: an annular portion 270A; four feet 270B protruding radially from the outer peripheral surface of the annular portion 270A; and an open circular plate-shaped end wall 270C integrally connected to the outer side of the annular portion 270A and the feet 270B in the axial direction, and extending radially outward from the annular portion 270A. The annular portion 270A overlaps with the end face of the core body portion 32A of the rotor core 32 in the axial direction. The four feet 270B overlap with the end faces of each salient pole 32B of the rotor core 32 in the axial direction. The end wall 270C is formed into a circular plate shape (open circular plate shape) with a radius approximately the same size as the length from the axis C of the rotor core 32 to the front end of the foot 270B. The end wall 270C, located on the outer side of the feet 270B in the axial direction, encloses the space between adjacent feet 270B in the circumferential direction.

[0180] A circular inspection hole 57 is formed between adjacent feet 270B on the end wall 270C. The inspection hole 57 is formed facing the axial end face of each permanent magnet 33, so that when the support block 270 and the rotor core 32 holding the permanent magnets 33 are assembled into the magnet cover 71, the position of each permanent magnet 33 can be visually confirmed from the outside of the rotor core 32. In this embodiment, four inspection holes 57 are provided, each corresponding to one permanent magnet 33.

[0181] In the case of the rotor 209 in this embodiment, the outer end of the support block 270 in the axial direction is covered by a generally circular plate-shaped end wall 270C. Therefore, when the support block 270 and the rotor core 32 holding the permanent magnet 33 are inserted into the magnet cover 71 together, and the ends (flanges 71b, 71c) of the magnet cover 71 are slit in this state, the ends of the magnet cover 71 are slit and fixed to the end wall 270C in such a way that they cover the entire area of ​​the outer periphery of the end wall 270C.

[0182] Here, the end wall 270C of the bearing block 270 is formed with a flat surface on the outer side in the axial direction, so that when the end of the magnet cover 71 is slit, the slit load is evenly applied to the entire outer periphery of the end wall 270C (see reference). Figure 29 (A)). In contrast, on the surface inside the axial direction of the end wall 270C, as... Figure 29 As shown in (B), a plurality of reinforcing ribs 58 extending in the radial direction are provided. In this embodiment, two reinforcing ribs 58 are arranged between each pair of adjacent feet 270B in the circumferential direction on the inner side of the end wall 270C in the axial direction.

[0183] When the support block 270 is molded using resin, the reinforcing rib 58 suppresses deformation such as depressions or wrinkles in the area surrounding the end wall 270C. Furthermore, when the reinforcing rib 58 is applied to the end of the magnet cover 71, it suppresses deformation of the outer periphery of the end wall 270C of the support block 270 due to the seam load. In other words, the reinforcing rib 58 increases the rigidity of the outer periphery of the end wall 270C. Moreover, when the support block 270 and the rotor core 32 holding the permanent magnet 33 are assembled into the magnet cover 71, the reinforcing rib 58 faces the axial end face of the permanent magnet 33. When an excessive load is applied to the permanent magnet 33 along the axial direction, the reinforcing rib 58 abuts against the end face of the permanent magnet 33, thereby limiting the axial displacement of the permanent magnet 33.

[0184] In addition, the reinforcing rib 58 can always abut against the end face of the permanent magnet 33. In this case, the reinforcing rib 58 constitutes the first magnet limiting part that restricts the axial displacement of the permanent magnet 33.

[0185] Furthermore, in the annular portion 270A of the support block 270, recesses 59 with low protrusion heights from the end wall 270C are formed at multiple locations. Each recess 59 is disposed between the base ends of adjacent feet 270B in the annular portion 270A in the circumferential direction.

[0186] Here, when the support block 270 is assembled into the magnet cover 71, in Figure 29 The portion indicated by the mark in (B) (the area in the inner end face of the annular portion 270A in the axial direction excluding the recess 59, and the inner end face of each foot portion 270B in the axial direction) abuts against the end faces of the core body portion 32A and the salient pole 32B of the rotor core 32 in the axial direction.

[0187] In this embodiment, the area of ​​the bearing block 270 protruding inward in the axial direction is divided into four blocks in the circumferential direction, sandwiching the recess 59. Therefore, the forming mold for accurately abutting the end face of each block against the axial end face of the rotor core 32 can be easily adjusted.

[0188] Figure 30 yes Figure 25 The enlarged cross-sectional view of the XXX section of the rotor 209 shown.

[0189] As shown in this figure, a small-diameter portion 270Cb with a slightly smaller outer diameter than other portions (hereinafter referred to as "general portion 270Ca") is formed at the outer end of the end wall 270C of the support block 270 in the axial direction. The general portion 270Ca and the small-diameter portion 270Cb are connected by an inclined surface 270Cc that slopes towards the small-diameter portion 270Cb from the general portion 270Ca toward the small-diameter portion 270Cb, tapering at the front end. The general portion 270Ca and the inclined surface 270Cc include an obtuse-angled corner portion 64a. In addition, the general portion 270Ca and the inclined surface 270Cc may also include an arc-shaped curved surface. Moreover, the outer end of the small-diameter portion 270Cb in the axial direction (the outer end of the end wall 270C in the axial direction) includes an arc-shaped curved surface 64b.

[0190] The corner portion 64a and the curved portion 64b on the outer periphery of the end wall 270C become two slit starting points when the axial end (flange portion 71b) of the magnet cover 71 is slit relative to the support block 270. That is, the corner portion 64a becomes the initial slit starting point (first slit starting point) when a slit load is applied to the axial end of the magnet cover 71, and the curved portion 64b becomes the next slit starting point (second slit starting point) when a slit load is applied to the axial end of the magnet cover 71.

[0191] Therefore, when the structure described in this embodiment is adopted, the stress acting on the support block 270 from the magnet cover 71 can be mitigated when the end of the magnet cover 71 in the axial direction is closed, thereby preventing the deterioration or damage of the support block 270.

[0192] Furthermore, the rotor 209 of this embodiment employs a structure in which an end wall 270C is provided on the support block 270, and the end wall 270C covers the outer side of each permanent magnet 33 in the axial direction. Therefore, during the closing of the end of the magnet cover 71 or the assembly of the rotor 209 with other motor parts, it is possible to prevent unnecessary external forces from acting on the permanent magnet 33 and causing damage to the permanent magnet 33.

[0193] (Modification 1 of the third embodiment)

[0194] Figure 31 The rotor of variant example 1 and Figure 25 Enlarged cross-sectional view of the XXXI section.

[0195] In the described embodiment, a small-diameter portion 270Cb is formed at the outer end of the end wall 270C in the axial direction of the bearing block 270. An inclined surface 270Cc is provided between the general portion 270Ca and the small-diameter portion 270Cb, and an obtuse-angled corner portion 64a is provided between the general portion 270Ca and the inclined surface 270Cc. Thus, a first slit start point and a second slit start point are provided in the end wall 270C. In contrast, in this modified embodiment, the bearing block 270 has an inclined surface 270Cd formed on the outer periphery of the end wall 270C, connecting the general portion 270Ca to the outer end face of the end wall 270C in the axial direction. A corner portion 64c with a gentle obtuse angle is formed on the side of the general portion 270Ca of the inclined surface 270Cd, and a curved surface portion 64d is formed at the outer end of the inclined surface 270Cd in the axial direction.

[0196] In the modified example, the corner 64c constitutes the first slit start point, and the curved surface 64d constitutes the second slit start point. In the modified example, the angle of the corner 64c, which serves as the first slit start point, becomes gentler, thus making it easier to perform the slit-forming operation of the magnet cover 71.

[0197] (Modifications 2-3 of the third embodiment)

[0198] Figure 32 This is a perspective view of the bearing block 270a in modified example 2. Figure 33 This is a perspective view of the support block 270b in variant example 3.

[0199] In the described embodiment, two reinforcing ribs 58 extending radially are provided between the adjacent legs 270B in the circumferential direction of the end wall 270C of the bearing block 270. However, between the adjacent legs 270B in the circumferential direction of the end wall 270C, two reinforcing ribs 58 may also be provided as described above. Figure 32 As shown, only one reinforcing rib 58 is provided radially. Furthermore, the reinforcing rib 58 can also be... Figure 33 As shown, three or more feet 270B are radially protruding between adjacent feet 270B in the circumferential direction in the end wall 270C.

[0200] (Modification 4 of the third embodiment)

[0201] Figure 34 This is a perspective view of the support block 270c of variant example 4.

[0202] In Modified Example 4, the support block 270c has, in addition to the reinforcing ribs 58 extending in the radial direction, a circumferential rib 65 extending along the circumferential direction of the end wall 270C between each adjacent foot 270B in the circumferential direction of the end wall 270C. The number of reinforcing ribs 58 or circumferential ribs 65 can be arbitrarily set.

[0203] In the case of the modified example 4, reinforcing ribs 58 extending in the radial direction and circumferential ribs 65 are provided in the end wall 270C. Therefore, it is possible to more effectively suppress deformation such as depressions or wrinkles in the surrounding area of ​​the end wall 270C, and further improve the rigidity of the outer periphery of the end wall 270C.

[0204] Furthermore, the present invention is not limited to the described embodiments, and various design changes can be made without departing from its spirit.

Claims

1. A rotor that rotates by a magnetic field of a stator, the rotor characterized by comprising: a rotor core that rotates integrally with a rotational shaft of a motor; a plurality of permanent magnets that are arranged at an outer peripheral portion of the rotor core; a cylindrical magnet cover that covers an outer side of the rotor core and the plurality of permanent magnets, and has a flange portion that is bent toward an inner radial direction at an end portion in a direction along the rotational axis; and a carrier block that is arranged between an end surface of the rotor core in the direction along the rotational axis and the flange portion, and abuts against the flange portion and the rotor core, wherein an end portion of at least one side of the permanent magnets in the direction along the rotational axis protrudes outward more than an end portion of the same side of the rotor core in the direction along the rotational axis, wherein an abutting portion of the carrier block that abuts against the flange portion is arranged at a position that is further outward than the end portion of the permanent magnets in the direction along the rotational axis, wherein the rotor core has: a cylindrical core body portion; and a plurality of salient poles that protrude in a radial direction from an outer peripheral surface of the core body portion, wherein the plurality of permanent magnets are arranged between adjacent ones of the plurality of salient poles and abut against the salient poles, wherein the carrier block has: a ring-shaped portion that is arranged so as to overlap an end surface of the core body portion in the direction along the rotational axis; and a plurality of leg portions that protrude in a radial direction from an outer peripheral surface of the ring-shaped portion and are arranged so as to overlap end surfaces of the plurality of salient poles in the direction along the rotational axis.

2. The rotor according to claim 1, wherein the leg portions of the carrier block extend to a position that is further outward in a radial direction centered on the rotational axis than an abutting region of the salient poles of the rotor core that abuts against the permanent magnets.

3. The rotor according to claim 1 or 2, wherein the carrier block has a core restricting portion that engages with the rotor core and restricts displacement of the rotor core in a circumferential direction centered on the rotational axis.

4. The rotor according to claim 3, wherein the core restricting portion includes a locking claw that is provided so as to protrude from the ring-shaped portion in the direction along the rotational axis and locks into an engaging portion of an inner periphery of the core body portion.

5. The rotor according to claim 4, wherein a bulging portion that abuts against the core body portion in the direction along the rotational axis is provided in a vicinity of a region of an inner peripheral surface of the ring-shaped portion in which the locking claw is provided.

6. The rotor according to claim 1 or 2, wherein a first magnet restricting portion that abuts against the permanent magnets in the direction along the rotational axis and restricts displacement of the permanent magnets in the direction along the rotational axis is provided at an outer peripheral edge portion of the ring-shaped portion.

7. The rotor according to claim 1 or 2, wherein a second magnet restricting portion that abuts against the permanent magnets in a circumferential direction centered on the rotational axis and restricts displacement of the permanent magnets in the circumferential direction is provided at the leg portions. ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ 8. The rotor according to claim 1 or 2, characterized in that the carrier block has a magnet position detection protrusion that protrudes to the outside of the magnet case.

9. A motor characterized by including: the rotor according to any one of claims 1 to 8; and a stator that is disposed on the outer periphery side of the rotor and generates a magnetic field.

10. A manufacturing method of a rotor that rotates in a magnetic field of a stator, the manufacturing method of the rotor characterized by comprising the steps of: disposing a plurality of permanent magnets on the outer periphery of a rotor core, and disposing a carrier block on an end surface in the direction of the rotational axis of the rotor core; disposing a cylindrical magnet case on the outside of the rotor core, the plurality of permanent magnets, and the carrier block; and caulking the end edge in the direction of the rotational axis of the magnet case toward the inside in the radial direction, so that a caulking flange of the magnet case abuts against the end surface of the carrier block, wherein the end portion of at least one side of the plurality of permanent magnets in the direction of the rotational axis protrudes outward more than the end portion of the same side of the rotor core in the direction of the rotational axis, the abutment portion of the carrier block that abuts against the caulking flange is disposed more outward in the direction of the rotational axis than the end portion of the plurality of permanent magnets, wherein the rotor core has: a cylindrical core body portion; and a plurality of salient poles that protrude in the radial direction from the outer peripheral surface of the core body portion, the plurality of permanent magnets are disposed between adjacent ones of the plurality of salient poles and abut against the salient poles, the carrier block has: an annular portion that is disposed overlapping the end surface of the core body portion in the direction of the rotational axis; and a plurality of leg portions that protrude in the radial direction from the outer peripheral surface of the annular portion and are disposed overlapping the end surface of each of the salient poles in the direction of the rotational axis.

Images