Manufacturing method of rotor for rotating electric machines

Abstract

This invention provides a method for manufacturing a rotor for a rotating electric motor, which can reduce the deviation of the radial load interacting with the rotor core and cylindrical part due to axial position. The rotor (1) for a rotating electric motor has a rotor core (2) and a core support member (3) that supports the rotor core. The core support member has a cylindrical part (11) formed into a cylindrical shape and a support part (12) that is supported relative to a non-rotating part so that it can rotate and supports the cylindrical part from the radial (R) inner side. The core support member (3) is formed such that the diameter (D1) of a specific region (A4) of the fitting face (A2) including an overlapping region (A3) that overlaps with the connecting region (A1) in radial view is smaller than the diameter (D2) of the general region (A5) other than the specific region (A4) of the fitting face (A2). When the rotor core is expanded, the core support member is inserted radially inward relative to the rotor core. Then, the rotor core (2) is contracted relative to the cylindrical part (11) so that the outer peripheral surface (F1) of the cylindrical part (11) fits with the inner peripheral surface (F2) of the rotor core.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a rotor for a rotary electric machine having a rotor core and a core support member supporting the rotor core. Background Technology

[0002] The background art will now be described. In the following description, the symbols or names in parentheses are symbols or names from prior art documents. A prior example of the rotor for a rotary electric machine described above is described in Japanese Patent Application Publication No. 2013-095390 (Patent Document 1). In the rotor for a rotary electric machine of Patent Document 1, the core support member (rotor support member 22) includes a cylindrical portion (rotor holding portion 25) formed into a cylindrical shape, and a support portion (radial extension portion 26) supporting the cylindrical portion from the radially inner side (R1). In such a rotor for a rotary electric machine, the support portion is connected to a region of the cylindrical portion in the axial direction, i.e., a connecting region, and is formed to extend radially inward from the connecting region. Furthermore, the rotor for a rotary electric machine is manufactured by fitting the inner circumferential surface of the rotor core with the outer circumferential surface of the cylindrical portion.

[0003] Patent Document 1: Japanese Patent Application Publication No. 2013-095390

[0004] As described above, when the inner circumferential surface of the rotor core is fitted to the outer circumferential surface of the cylindrical portion, the rotor core is sometimes fastened to the cylindrical portion by, for example, thermoforming. In such a thermoforming fit, the rotor core is heated and expanded before being inserted into the cylindrical portion radially inwards, followed by cooling and shrinking of the rotor core to achieve the fit. This fit results in a radial load interacting between the rotor core and the cylindrical portion. In the region of the cylindrical portion far from the connection with the support, slight radial inward deformation of the cylindrical portion is allowed, thus the radial load interacting between the rotor core and the cylindrical portion tends to decrease. Conversely, in the region of the cylindrical portion near the connection with the support, the cylindrical portion cannot deform radially inwards due to the presence of the support, so the radial load interacting between the rotor core and the cylindrical portion does not decrease. Therefore, the radial load in the region near the connection with the support is relatively larger than in other regions, making stress concentration more likely in this area. The rotor core is constructed by stacking thin plates. Therefore, if a large radial load is applied to a part of the axial region, resulting in stress concentration, there is a possibility of deformation of some of the thin plates. Summary of the Invention

[0005] Therefore, it is desirable to realize a method for manufacturing a rotor for a rotating electric machine that can reduce the deviation of the radial load interacting with the rotor core and the cylindrical part due to the axial position.

[0006] In view of the above, the present invention provides a method for manufacturing a rotor for a rotary electric machine, the rotor comprising a rotor core and a core support member supporting the rotor core, the core support member comprising a cylindrical portion formed in a cylindrical shape, and a support portion supported relative to a non-rotating component to be rotatable and supporting the cylindrical portion radially inward. The characteristic structure of the method for manufacturing the rotor for the rotary electric machine is as follows: using the core support member, the core support member is formed such that the support portion is connected to a region axially portion of the cylindrical portion, i.e., a connection region, and is formed to extend from the connection region toward the radially inward direction, connecting the outer peripheral surface of the cylindrical portion... The portion overlapping the rotor core when viewed radially along the aforementioned radial direction is designated as the fitting surface. The diameter of a specific region of the fitting surface, which includes the overlapping region that overlaps with the connection region when viewed radially, is smaller than the diameter of the region other than the specific region of the fitting surface, i.e., the general region. With the rotor core expanded such that the diameter of the inner circumferential surface of the rotor core is larger than the diameter of the general region, the core support member is inserted radially inward relative to the rotor core. Then, the rotor core is contracted relative to the cylindrical portion, so that the outer circumferential surface of the cylindrical portion fits into the inner circumferential surface of the rotor core.

[0007] According to the characteristic structure of this manufacturing method, the diameter of a specific region in the mating surface of the cylindrical portion that overlaps with the rotor core in radial view, including the overlapping region that overlaps with the connection region of the support portion in radial view, is smaller than the diameter of the general region. Therefore, when the outer circumferential surface of the cylindrical portion is mated with the inner circumferential surface of the rotor core, the radial load interacting between the rotor core and the cylindrical portion in the specific region can be reduced by an amount corresponding to the reduction in diameter compared to the general region. Thus, the difference between the radial load acting on the general region and the radial load acting on the specific region can be reduced, resulting in a reduction in the deviation of the radial load interacting between the rotor core and the cylindrical portion due to axial position. Attached Figure Description

[0008] Figure 1 This is a partial sectional view of the rotor of a rotating electric machine.

[0009] Figure 2 It is a diagram showing the relationship between the diameter of the inner circumferential surface of the cylindrical part, the diameter of the overlapping area, and the diameter of a specific area.

[0010] Figure 3 This is a diagram showing the manufacturing process of a rotor for a rotating electric machine.

[0011] Figure 4 This is a diagram showing the manufacturing process of a rotor for a rotating electric machine.

[0012] Figure 5 This is a partial cross-sectional view of a rotor for a rotary electric machine according to other embodiments.

[0013] Figure 6 This is a diagram showing the shape of the end of a specific region in other embodiments.

[0014] Figure 7 This is a diagram showing the shape of the end of a specific region in other embodiments. Detailed Implementation

[0015] 1. Implementation Method

[0016] The implementation method of manufacturing a rotor for a rotating electric machine is described with reference to the accompanying drawings. For example... Figure 1 As shown, the rotor 1 for a rotating electric machine includes a rotor core 2 and a core support member 3 that supports the rotor core 2. Furthermore, in the following description, unless specifically distinguished and explicitly stated otherwise, "axial direction L," "radial direction R," and "circumferential direction" are defined based on the axis of the rotor 1 for the rotating electric machine. Moreover, "axial first side L1" refers to one side of the axial direction L (…). Figure 1 (Left side), "Axial second side L2" indicates the side opposite to the axial first side L1. Figure 1 (Right side). In addition, "radial inner R1" indicates the direction towards the inside of radial R, and "radial outer R2" indicates the direction towards the outside of radial R.

[0017] The rotor core 2 is constructed by stacking multiple electromagnetic steel plates 6 in the shape of a circular ring along the axial direction L. In this embodiment, end plates 7 are provided at both ends of the rotor core 2 along the axial direction L.

[0018] The core support member 3 includes a cylindrical portion 11 formed in a cylindrical shape, and a support portion 12 that is rotatable relative to the housing 13 housing the rotor 1 of the rotary electric motor and supports the cylindrical portion 11 from the inner side in the radial direction R. In this embodiment, the cylindrical portion 11 and the support portion 12 are integrally formed. The outer peripheral surface F1 of the cylindrical portion 11 fits into the inner peripheral surface F2 of the rotor core 2. The support portion 12 is connected to a portion of the cylindrical portion 11 in the axial direction L, i.e., the connecting region A1, and is formed to extend from the connecting region A1 in the radial direction R towards the inner side.

[0019] The cylindrical portion 11 includes: a connecting portion 16 having a connecting region A1; a first extension 17 extending from the connecting portion 16 toward an axial first side L1; and a second extension 18 extending from the connecting portion 16 toward an axial second side L2. The first extension 17 extends from the end of the rotor core 2 at the axial first side L1 to the axial first side L1, and the second extension 18 extends from the end of the rotor core 2 at the axial second side L2 to the axial second side L2.

[0020] Furthermore, the core support member 3 has a first protrusion 21 formed so as to protrude radially outward R2 from the end of the first extension 17 on the axial first side L1. Moreover, the core support member 3 has a riveting portion 22 provided at the end of the second extension 18 on the axial second side L2. The riveting portion 22 is formed by bending the end of the second extension 18 on the axial second side L2 radially outward R2 after the rotor core 2 is fitted to the cylindrical portion 11 from the axial second side L2. The first protrusion 21 and the riveting portion 22 restrict the movement of the rotor core 2 relative to the core support member 3 in the axial direction L.

[0021] The support portion 12 includes: an annular plate-shaped portion 26 extending radially R; a first supported portion 27 protruding from the radially inner end R1 of the annular portion 26 toward a first axial side L1; and a second supported portion 28 protruding from the radially inner end R1 of the annular portion 26 toward a second axial side L2. In this embodiment, the rotor 1 for the rotary motor is housed in the housing 13, a first bearing 29 is disposed between the first supported portion 27 and the housing 13, and a second bearing 30 is disposed between the second supported portion 28 and the housing 13. The support portion 12 is supported by the housing 13 via the first bearing 29 and the second bearing 30, enabling it to rotate. In this embodiment, the housing 13 corresponds to a non-rotating component.

[0022] The annular portion 26 has a wide portion 26A at its radially outer end R2, which widens axially L as it moves towards the radially outer end R2. The radially outer end R2 of the wide portion 26A is connected to the connecting portion 16 of the cylindrical portion 11. In this embodiment, the inner circumferential surface of the cylindrical portion 11 is formed parallel to the axial direction L, and the boundary between the portion that widens axially L as it moves towards the radially outer end R2 and the portion parallel to the axial direction L forms the boundary between the cylindrical portion 11 and the support portion 12.

[0023] Furthermore, the outer peripheral surface F1 of the cylindrical portion 11, which fits into the inner peripheral surface F2 of the rotor core 2, has a characteristic shape. Here, the portion of the outer peripheral surface F1 of the cylindrical portion 11 that overlaps with the rotor core 2 when viewed radially along the radial direction R is designated as the fitting surface A2. In this embodiment, the portion of the outer peripheral surface F1 of the cylindrical portion 11 that overlaps with the plurality of electromagnetic steel plates 6 provided on the rotor core 2 when viewed radially is designated as the fitting surface A2, while the portion that overlaps with a pair of end plates 7 disposed at both ends of the axial direction L of the rotor core 2 when viewed radially is not included in the fitting surface A2. However, in addition to the portion of the outer peripheral surface F1 of the cylindrical portion 11 that overlaps with the plurality of electromagnetic steel plates 6 provided on the rotor core 2 when viewed radially, the portion that overlaps with at least one of the pair of end plates 7 when viewed radially may also be designated as the fitting surface A2.

[0024] Furthermore, regarding the outer peripheral surface F1 of the cylindrical portion 11, the diameter D1 of the specific region A4 of the fitting portion A2, which includes the overlapping region A3 that overlaps with the connecting region A1 in radial view, is smaller than the diameter D2 of the region other than the specific region A4 of the fitting portion A2, i.e., the general region A5. More specifically, when the rotor core 2 and the core support member 3 are at the same temperature, the diameter D1 of the specific region A4 is greater than or equal to the diameter D3 of the inner peripheral surface F2 of the rotor core 2, and the diameter D2 of the general region A5 is greater than the diameter D3 of the inner peripheral surface F2 of the rotor core 2. Here, the difference between the diameter D1 of the specific region A4 and the diameter D2 of the general region A5 is set to be extremely small. In this embodiment, the difference between the diameter D1 of the specific region A4 and the diameter D2 of the general region A5 is set to tens of micrometers, specifically 20 to 30 micrometers. In addition, when compared with other diameters, the diameter D1 of the specific region A4 is set to the diameter D1 of the portion of the specific region A4 other than the end 31 (inclined surface F3) described later. In addition, in this embodiment, the diameter D1 of the specific region A4 is smaller than the diameter D2 of the general region A5, which covers the entire circumference of the specific region A4.

[0025] In this embodiment, such as Figure 2 As shown, when the rotor core 2 and the core support component 3 are at the same temperature, the diameter D1 of the specific region A4 and the diameter D2 of the general region A5 of the mating surface A2 are both larger than the diameter D3 of the inner circumferential surface F2 of the rotor core 2. Furthermore, when setting these dimensions, manufacturing errors were considered, and tolerances were set for each of the diameters D1 of the specific region A4, D2 of the general region A5, and D3 of the inner circumferential surface F2. Here, a first tolerance ±α is set for the diameters D1 of the specific region A4 and D2 of the general region A5. Additionally, a second tolerance ±β is set for the diameter D3 of the inner circumferential surface F2. Furthermore, although the tolerances for the diameters D1 and D2 of the specific region A4 and the general region A5 are set to the same value, it is also possible to set different values ​​for the tolerances of the diameters D1 and D2 of the specific region A4 and the general region A5.

[0026] Furthermore, in this embodiment, as a preferred example, the diameter D1 of the specific region A4 of the outer peripheral surface F1, the diameter D2 of the general region A5, and the diameter D3 of the inner peripheral surface F2 are set as follows: Specifically, the designed value of the diameter D1 of the specific region A4 is used as the first design value, the designed value of the diameter D2 of the general region A5 is used as the second design value, and the designed value of the diameter D3 of the inner peripheral surface F2 is used as the third design value. Moreover, the value obtained by subtracting the first tolerance α from the first design value (diameter D1) is set to be equal to the value obtained by adding the second tolerance β to the third design value (diameter D3). Additionally, the value obtained by adding the second tolerance β to the third design value (diameter D3) is set to be smaller than the value obtained by subtracting the first tolerance α from the second design value (diameter D2).

[0027] Furthermore, regarding the setting of the specific region A4, the axial length L of the specific region A4 is set to be longer than the axial length L of the overlapping region A3. Moreover, the specific region A4 is set to include the entirety of the overlapping region A3. Specifically, the axial range L of the specific region A4 is set to include the entirety of the axial range L of the overlapping region A3. Furthermore, in this example, the circumferential range of the specific region A4 is set to include the entirety of the circumferential range of the overlapping region A3. In this embodiment, the specific region A4 is defined as the area sandwiched between two imaginary lines inclined at a set angle θ from each of the two ends of the radially outer side R2 of the wide portion 26A towards the outer side of the axial L, and the two intersection points of these lines with the outer peripheral surface F1 of the cylindrical portion 11. In this embodiment, the set angle θ is set to 45 degrees. More specifically, the end of the axial first side L1 of the specific region A4 is set to be the intersection of an imaginary line inclined at a set angle θ from the end of the radially outer side R2 of the wide portion 26A (i.e., the end of the axial first side L1) towards the axial first side L1 and the outer peripheral surface F1 of the cylindrical portion 11. On the other hand, the end of the axial second side L2 of the specific region A4 is set to be the end of the axial second side L2 of the outer peripheral surface F1 of the cylindrical portion 11. This is because there is no intersection between an imaginary line inclined at a set angle θ from the end of the radially outer side R2 of the wide portion 26A (i.e., the end of the axial second side L2) and the outer peripheral surface F1 of the cylindrical portion 11.

[0028] As described above, in this embodiment, the setting angle θ is set to 45 degrees, so the axial length D4 of the specific region A4 is set to the length after adding a length equivalent to the radial thickness D5 of the cylindrical portion 11 on both sides of the overlapping region A3 along the axial L. In this embodiment, the length of the cylindrical portion 11 on the second axial side L2 relative to the overlapping region A3 is shorter than the aforementioned length D5, so the specific region A4 is shorter than the length after adding a length equivalent to the radial thickness D5 of the cylindrical portion 11 on both sides of the overlapping region A3 along the axial L. Thus, the specific region A4 is defined as the length up to the end of the axial L of the cylindrical portion 11, at least on one side of the axial L, when the length after adding a length equivalent to the radial thickness D5 of the cylindrical portion 11 on both sides of the overlapping region A3 along the axial L. In addition, in this embodiment, the radial thickness R of the cylindrical portion 11 is the thickness of the radial thickness R of the portion of the cylindrical portion 11 located at the end of the axial first side L1 of the wide portion 26A along the axial L.

[0029] Furthermore, in this embodiment, an inclined surface F3 is formed at the end of the specific region A4 adjacent to the general region A5, such that its diameter D1 gradually increases towards the general region A5. In this embodiment, the inclined surface F3 is formed at the end 31 of the first axial side L1 of the specific region A4. In the illustrated example, the cross-sectional shape of this inclined surface F3 along the axial direction L is formed as a straight line that slopes from the end of the second axial side L2 of the general region A5 towards the second axial side L2 in a radially inward direction R1.

[0030] Next, the manufacturing method of the rotor 1 for a rotary electric machine will be described. In this embodiment, when manufacturing the rotor 1 for a rotary electric machine, the following steps are performed: a first step of inserting the core support member 3 into the rotor core 2 radially inward R1 while the rotor core 2 is expanded; and a second step of shrinking the rotor core 2 relative to the cylindrical portion 11 after the first step, thereby fitting the outer peripheral surface F1 of the cylindrical portion 11 with the inner peripheral surface F2 of the rotor core 2. In this embodiment, the rotor core 2 is heated to a temperature higher than that of the core support member 3 to expand the rotor core 2. That is, the outer peripheral surface F1 of the cylindrical portion 11 is fitted with the inner peripheral surface F2 of the rotor core 2 by a so-called thermo-pressing fit.

[0031] like Figure 3As shown, the first step involves inserting the core support member 3 radially inward relative to the rotor core 2 while the rotor core 2 is expanded such that the diameter D3 of the inner circumferential surface F2 is larger than the diameter D2 of the general area A5 of the cylindrical portion 11. In this embodiment, the rotor core 2 is heated to a temperature higher than that of the core support member 3, causing it to expand so that the diameter D3 of the inner circumferential surface F2 of the rotor core 2 is larger than the diameter D2 of the general area A5 of the cylindrical portion 11. Then, while the rotor core 2 is expanded in this way, the cylindrical portion 11 of the core support member 3 is inserted radially inward relative to the inner circumferential surface F2 of the rotor core 2. In this embodiment, the cylindrical portion 11 is inserted relative to the rotor core 2 from the axial first side L1, so that the end of the axial first side L1 of the rotor core 2 abuts against the first protrusion 21. Then, the second step is performed. With the cylindrical portion 11 inserted radially inward along the inner side R1 relative to the inner circumferential surface F2 of the rotor core 2, the fitting portion A2 of the outer circumferential surface F1 of the cylindrical portion 11 overlaps with the rotor core 2 when viewed radially, and the connecting region A1 overlaps with the overlapping region A3 when viewed radially.

[0032] like Figure 4 As shown, the second step involves retracting the rotor core 2 relative to the cylindrical portion 11 of the core support member 3, thereby engaging the outer circumferential surface F1 of the cylindrical portion 11 with the inner circumferential surface F2 of the rotor core 2. In this embodiment, the rotor core 2, which was heated and expanded in the first step, is cooled and contracted. The rotor core 2 is contracted while the outer circumferential surface F1 of the cylindrical portion 11 and the inner circumferential surface F2 of the rotor core 2 are facing each other radially R, thereby engaging the outer circumferential surface F1 of the cylindrical portion 11 with the inner circumferential surface F2 of the rotor core 2. Here, the outer circumferential surface F1 of the cylindrical portion 11 and the inner circumferential surface F2 of the rotor core 2 are engaged in an interference fit. That is, assuming that the cylindrical portion 11 is not radially inward R1 relative to the rotor core 2, the rotor core 2 is relatively contracted relative to the cylindrical portion 11 such that the diameter D3 of the inner circumferential surface F2 of the rotor core 2 is the same as or smaller than the diameter D1 of the specific region A4. Thus, the outer circumferential surface F1 of the cylindrical portion 11 and the inner circumferential surface F2 of the rotor core 2 are fitted together in an interference fit. In this embodiment, after this second step, as... Figure 4 As shown, the end of the second extension 18 on the axial second side L2 is bent radially outward R2 to form a riveting part 22. This restricts the movement of the rotor core 2 relative to the core support member 3 in the axial direction L.

[0033] This causes the rotor core 2 to fit together, thereby contracting in a manner where the diameter D3 of the inner circumferential surface F2 of the rotor core 2 is the same as or smaller than the diameter D1 of the specific region A4, and smaller than the diameter D2 of the general region A5. This reduces the radial load R on the interaction between the rotor core 2 and the cylindrical portion 11. At this time, in the region A1 of the cylindrical portion 11 away from the connection with the support portion 12, the cylindrical portion 11 is allowed to deform slightly radially inwards towards R1, so there is a tendency for the radial load interacting between the rotor core 2 and the cylindrical portion 11 to decrease. Conversely, in the region A1 of the cylindrical portion 11 near the connection with the support portion 12, the cylindrical portion 11 cannot deform radially inwards towards R1 due to the presence of the support portion 12.

[0034] However, according to the structure of this embodiment, since the diameter D1 of the specific region A4 is smaller than the diameter D2 of the general region A5, the radial load interacting with the rotor core 2 and the cylindrical portion 11 in the specific region A4 can be reduced by an amount corresponding to the reduction in diameter compared to the general region A5. Therefore, the difference between the radial load acting on the general region A5 and the radial load acting on the specific region A4 by the cylindrical portion 11 can be reduced, resulting in a reduction in the deviation of the radial load interacting with the rotor core 2 and the cylindrical portion 11 due to axial position. Furthermore, in Figure 1 For ease of understanding, although the diagram shows a gap between the inner circumferential surface F2 of the rotor core 2 and a specific region A4, in reality... Figure 4 As shown, the inner circumferential surface F2 of the rotor core 2 is in contact with a specific area A4 without forming a gap.

[0035] 2. Other implementation methods

[0036] Next, other embodiments of the manufacturing method for the rotor of a rotating electric machine will be described.

[0037] (1) In the above embodiment, the structure in which the connection region A1 between the support portion 12 and the cylindrical portion 11 is set at a position offset to one side of the axial direction L relative to the center of the cylindrical portion 11 is described as an example. However, the connection structure between the support portion 12 and the cylindrical portion 11 is not limited to this. For example, as Figure 5 As shown, it can also be a structure in which the connection region A1 between the support portion 12 and the cylindrical portion 11 is located at the center of the axial direction L of the cylindrical portion 11. Figure 5 In the example shown, the specific region A4 ensures a range on both sides of the overlapping region A3 in the axial direction L, from the end of the overlapping region A3 in the axial direction L to a length equivalent to the thickness D5 of the cylindrical portion 11 in the radial direction R.

[0038] (2) In the above embodiment, although the structure in which the axial length D4 of the specific region A4 is set to a length equivalent to the radial thickness D5 of the cylindrical portion 11 on both sides of the overlapping region A3 along the axial length L has been described as an example, the setting of the axial length D4 of the specific region A4 is not limited to this. For example, the axial length D4 of the specific region A4 may be set to a length that is shorter than the radial thickness D5 of the cylindrical portion 11 or longer than the radial thickness D5 of the cylindrical portion 11 on both sides of the overlapping region A3 along the axial length L. Alternatively, the axial length D4 of the specific region A4 may be set to a length that is the same as the axial length D3 of the overlapping region A3 or shorter than the axial length D3 of the overlapping region A3. Alternatively, the range of the axial length L of the specific region A4 may be set to a range that extends only to one side of the axial length L relative to the overlapping region A3. Alternatively, the range of the axial length L of the specific region A4 may be set to a range that includes only a portion of the range of the axial length L of the overlapping region A3.

[0039] (3) In the above embodiment, an example was described where an inclined surface F3 with a straight cross-sectional shape along the axial direction L was formed at the end 31 of the specific region A4 adjacent to the general region A5. However, the shape of the end 31 of the specific region A4 is not limited to this. For example, it may be as follows: Figure 6 As shown, at the end 31 of a specific region A4, a curved inclined surface F3 (S-shaped inclined surface) is formed, which gradually increases in inclination towards the radially outward R2 as it moves towards the general region A5, and then gradually decreases in inclination. Or as... Figure 7 As shown, a stepped portion F4 may also be formed at the end 31 of a specific region A4 without forming an inclined surface F3.

[0040] (4) In the above embodiment, the rotor core 2 was described as being constructed by stacking multiple electromagnetic steel plates 6 in a ring-shaped manner along the axial direction L. However, the structure of the rotor core 2 is not limited to this. For example, the rotor core 2 can also be constructed by using a sintered core of magnetic powder or a pressed powder core.

[0041] (5) In the above embodiment, the diameter D1 of the specific region A4 is smaller than the diameter D2 of the general region A5, covering the entire circumferential region of the specific region A4. However, the diameter D1 of the specific region A4 is not limited to this. For example, the specific region A4 may also include a region with the same diameter D1 as the diameter D2 of the general region A5, and a region with a smaller diameter D1 than the diameter of the general region A5. For example, if the specific region A4 includes regions with the same diameter and regions with smaller diameters, the regions with the same diameter and regions with smaller diameters may be alternately arranged in the circumferential direction.

[0042] (6) Furthermore, the structures disclosed in the above embodiments can be combined with structures disclosed in other embodiments, provided that they do not create contradictions. Regarding other structures, the embodiments disclosed in this specification are merely illustrative in all respects. Therefore, various modifications can be appropriately made without departing from the spirit of the invention.

[0043] 3. Summary of the above embodiments

[0044] The following is a summary description of the manufacturing method of the rotor for a rotating electric machine described above.

[0045] A method for manufacturing a rotor (1) for a rotary electric machine, the rotor (1) comprising a rotor core (2) and a core support member (3) supporting the rotor core (2), the core support member (3) comprising a cylindrical portion (11) formed in a cylindrical shape, and a support portion (12) supported relative to a non-rotating portion (13) to be rotatable and supporting the cylindrical portion (11) from the radial (R) inner side. Using the core support member (3), the core support member (3) is formed such that the support portion (12) is connected to a region (A1) of a portion of the axial (L) direction of the cylindrical portion (11), and is formed to extend from the connection region (A1) toward the radial (R) inner side, and to overlap the outer peripheral surface (F1) of the cylindrical portion (11) with the rotor core (2) when viewed radially along the radial (R). The fitting face (A2) is divided into a fitting face (A2). The diameter (D1) of a specific region (A4) of the fitting face (A2) that includes the overlapping region (A3) that overlaps with the connecting region (A1) in the radial view is smaller than the diameter (D2) of the general region (A5) of the fitting face (A2) other than the specific region (A4). When the rotor core (2) is expanded in such a way that the diameter (D3) of the inner circumferential surface (F2) of the rotor core (2) is larger than the diameter (D2) of the general region (A5), the core support member (3) is inserted into the inner side of the radial direction (R) relative to the rotor core (2). Then, the rotor core (2) is contracted relative to the cylindrical part (11), so that the outer circumferential surface (F1) of the cylindrical part (11) fits into the inner circumferential surface (F2) of the rotor core (2).

[0046] According to this structure, since the diameter (D1) of a specific region (A4) in the fitting surface (A2) of the cylindrical part (11) that overlaps with the rotor core (2) in radial view, and which includes the overlapping region (A3) that overlaps with the connection region (A1) of the support part (12) in radial view, is smaller than the diameter (D2) of the general region (A5), when the outer peripheral surface (F1) of the cylindrical part (11) and the inner peripheral surface (F2) of the rotor core (2) are fitted together, the radial load interacting between the rotor core (2) and the cylindrical part (11) in the specific region (A4) can be reduced by an amount corresponding to the reduction in diameter compared to the general region (A5). Therefore, the difference between the radial load of the cylindrical part (11) acting on the general region (A5) and the radial load acting on the specific region (A4) can be reduced, and as a result, the deviation of the radial load interacting between the rotor core (2) and the cylindrical part (11) due to axial position can be reduced.

[0047] Here, preferably, when the rotor core (2) and the core support member (3) are at the same temperature, the diameter (D1) of the specific region (A4) is greater than the diameter (D3) of the inner circumferential surface (F2) of the rotor core (2), and the diameter (D2) of the general region (A5) is greater than the diameter (D3) of the inner circumferential surface (F2) of the rotor core (2).

[0048] According to this structure, when the outer peripheral surface (F1) of the cylindrical portion (11) is fitted with the inner peripheral surface (F2) of the rotor core (2), the entire fitting portion (A2) of the outer peripheral surface (F1) of the cylindrical portion (11), which includes a specific region (A4) and a general region (A5), can contact the inner peripheral surface (F2) of the rotor core (2). Therefore, as described above, the deviation of the radial load interacting between the rotor core (2) and the cylindrical portion (11) due to the axial position can be reduced, and the fastening force between the cylindrical portion (11) of the core support member (3) and the rotor core (2) can be properly ensured.

[0049] In addition, it is preferable that the length (D4) of the axial direction (L) of the specific region (A4) is set to be longer than the length (A3) of the axial direction (L) of the overlapping region (A3).

[0050] According to this structure, a region larger than the overlapping region (A3) in the axial direction (L) is defined as a specific region (A4). This makes it easy to include in the specific region (A4) the area where the radial load interacting with the rotor core (2) and the cylindrical portion (11) due to the presence of the support portion (12) is likely to increase. Therefore, it is possible to further reduce the deviation of the radial load interacting with the rotor core (2) and the cylindrical portion (11) caused by the axial position.

[0051] In addition, it is preferable that the aforementioned specific region (A4) is set to include the entirety of the aforementioned overlapping region (A3).

[0052] According to this structure, the range of the specific region (A4) is set in such a way that it includes the entire overlapping region (A3) that overlaps with the connecting region (A1) when viewed radially. Thus, the overlapping region (A3), where the radial load interacting with the rotor core (2) and the cylindrical portion (11) due to the presence of the support portion (12) is easily amplified, can be included in the specific region (A4). Therefore, the deviation of the radial load interacting with the rotor core (2) and the cylindrical portion (11) due to axial position can be appropriately reduced.

[0053] In addition, preferably, the length (D4) of the axial (L) direction of the specific region (A4) is set to the length relative to the overlapping region (A3) after adding a length on both sides of the axial (L) direction that is equivalent to the thickness (D5) of the radial (R) direction of the cylindrical portion (11).

[0054] According to this structure, in addition to the overlapping region (A3) that overlaps with the connecting region (A1) when viewed radially, the regions on both sides of its axial direction (L) and affected by the presence of the support portion (12) are designated as specific regions (A4). Thus, the region where the radial load interacting with the rotor core (2) and the cylindrical portion (11) due to the presence of the support portion (12) can be appropriately included in the specific region (A4). Therefore, the deviation of the radial load interacting with the rotor core (2) and the cylindrical portion (11) due to axial position can be further appropriately reduced.

[0055] In addition, preferably, the length (D4) of the axial (L) direction of the specific region (A4) is set to the length relative to the overlapping region (A3) on one side of the axial (L) direction, plus a length equivalent to the thickness (D5) of the radial (R) direction of the cylindrical portion (11).

[0056] According to this structure, in addition to the overlapping region (A3) that overlaps with the connecting region (A1) when viewed radially, a specific region (A4) is defined on one side of its axial direction (L) and affected by the presence of the support (12). Thus, the region on the axial (L) side relative to the overlapping region (A3), where the radial load on the rotor core (2) and the cylindrical portion (11) easily increases due to the presence of the support (12), can be included in the specific region (A4). Furthermore, by making the axial (L) width of the region of the specific region (A4) on the side opposite to the axial (L) side relative to the overlapping region (A3) smaller than its length equivalent to the thickness (D5), the degree of freedom in the connection position of the support (12) relative to the cylindrical portion (11), such as connecting the support (12) and the cylindrical portion (11), can be increased. Therefore, it is possible to appropriately reduce the deviation of the radial load on the rotor core (2) and the cylindrical part (11) caused by the axial position, and to improve the degree of freedom of the connection position of the support part (12) relative to the cylindrical part (11).

[0057] In addition, it is preferable that the end (31) of the specific region (A4) adjacent to the general region (A5) has an inclined surface (F3) with a diameter (D1) that gradually increases toward the general region (A5).

[0058] According to this structure, it is possible to reduce the likelihood of a region with a large radial load interacting with the rotor core (2) and the cylindrical portion (11) at the boundary between the specific region (A4) and the general region (A5). Therefore, it is possible to further appropriately reduce the deviation of the radial load interacting with the rotor core (2) and the cylindrical portion (11) due to axial position.

[0059] In addition, it is preferable to heat the rotor core (2) to a higher temperature than the core support member (3) to expand the rotor core (2).

[0060] According to this structure, the rotor core (2) can be expanded by utilizing thermal expansion, such that the diameter (D3) of the inner circumferential surface (F2) of the rotor core (2) is larger than the diameter (D2) of the general region (A5). Then, the core support member (3) can be inserted radially (R) inward relative to the rotor core (2), thereby cooling the rotor core (2) and causing the rotor core (2) to contract relative to the cylindrical portion (11), so that the outer circumferential surface (F1) of the cylindrical portion (11) fits into the inner circumferential surface (F2) of the rotor core (2). That is, according to this structure, the cylindrical portion (11) and the rotor core (2) can be properly fitted together by so-called thermo-pressing.

[0061] Industrial applications

[0062] The technology of the present invention can be used in a method for manufacturing a rotor for a rotating electric machine having a rotor core and a core support member supporting the rotor core.

[0063] Explanation of reference numerals in the attached figures

[0064] 1: Rotor for rotating electric motors

[0065] 2: Rotor core

[0066] 3: Core support components

[0067] 11: Cylindrical part

[0068] 12: Support section

[0069] 13: Housing (non-rotating part)

[0070] A1: Connecting Area

[0071] A2: Embossed Face

[0072] A3: Overlapping area

[0073] A4: Specific Area

[0074] A5: General Area

[0075] D1: Diameter of a specific region

[0076] D2: Diameter of the general area

[0077] D3: Diameter of the inner circumference

[0078] D4: Length

[0079] D5: Thickness

[0080] F1: Outer Peripheral Surface

[0081] F2: Inner circumferential surface

[0082] F3: Inclined Surface

[0083] L: Axial direction

[0084] R: Radial.

Claims

1. A method for manufacturing a rotor for a rotary electric machine, the rotor comprising a rotor core and a core support member supporting the rotor core, the core support member comprising a cylindrical portion formed in a cylindrical shape, and a support portion supported relative to a non-rotating component and rotatable, supporting the cylindrical portion radially from the inner side, wherein... Using the aforementioned core support member, the core support member is formed such that the support portion is connected to a portion of the axial region of the cylindrical portion, i.e., the connection region, and extends radially inward from the connection region. The portion of the outer peripheral surface of the cylindrical portion that overlaps with multiple electromagnetic steel plates of the rotor core when viewed radially is defined as the fitting surface. The portion that overlaps with a pair of end plates disposed at both axial ends of the rotor core when viewed radially is not included in the fitting surface. The diameter of a specific region of the fitting surface that overlaps with the connection region when viewed radially is smaller than the diameter of the region other than the specific region of the fitting surface, i.e., the general region. With the rotor core expanded such that the diameter of its inner circumferential surface is larger than the diameter of the general region, the core support member is inserted radially inward relative to the rotor core. Then, the rotor core is contracted relative to the cylindrical portion, so that the outer peripheral surface of the cylindrical portion fits into the inner peripheral surface of the rotor core.

2. The method for manufacturing a rotor for a rotating electric machine according to claim 1, wherein, When the rotor core and the core support member are at the same temperature, the diameter of the specific region is greater than or equal to the diameter of the inner circumferential surface of the rotor core, and the diameter of the general region is greater than the diameter of the inner circumferential surface of the rotor core.

3. The method for manufacturing a rotor for a rotating electric machine according to claim 1 or 2, wherein, The length of the axial direction of the aforementioned specific region is set to be longer than the length of the axial direction of the aforementioned overlapping region.

4. The method for manufacturing a rotor for a rotating electric machine according to claim 3, wherein, The aforementioned specific region is defined as the entirety of the aforementioned overlapping regions.

5. The method for manufacturing a rotor for a rotating electric machine according to claim 4, wherein, The axial length of the aforementioned specific region is set to be the length relative to the aforementioned overlapping region, after adding a length on both sides of the aforementioned axial direction that is equivalent to the radial thickness of the aforementioned cylindrical portion.

6. The method for manufacturing a rotor for a rotating electric machine according to claim 4, wherein, The axial length of the aforementioned specific region is set to be the length relative to the aforementioned overlapping region, on one side of the aforementioned axial direction, after adding a length equivalent to the radial thickness of the aforementioned cylindrical portion.

7. The method for manufacturing a rotor for a rotating electric machine according to claim 1 or 2, wherein, At the end of the specific region that is adjacent to the general region, an inclined surface is formed with a diameter that gradually increases toward the general region.

8. The method for manufacturing a rotor for a rotating electric machine according to claim 1 or 2, wherein, The rotor core is expanded by heating it to a temperature higher than that of the core support component.

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