Method for manufacturing a rotor of an electric rotating machine

Abstract

A manufacturing method of a rotor (1) of a rotary electric machine includes: a temporary magnetization process of temporarily magnetizing a part of each of a plurality of segment magnets (3); a magnetic flux measurement process of measuring a magnetic flux of each of the segment magnets (3) that has been temporarily magnetized; a magnet selection process of selecting a plurality of segment magnets (3) to be used from among the segment magnets (3) based on the measured magnetic flux; a magnet bonding process of alternately arranging segment magnets (3) having different magnetic polarities in a circumferential direction of a shaft portion from among the selected segment magnets (3) and bonding the segment magnets (3) to the shaft portion with an adhesive; a magnet position correction process of pressing each of the segment magnets (3) and correcting a position of each of the segment magnets (3) within an adhesive curing time; an adhesive curing process of curing the adhesive; and a formal magnetization process of formally magnetizing each of the segment magnets (3) after the adhesive is cured.

Description

Technical Field

[0001] This invention relates to a method for manufacturing the rotor of a rotating electric motor. Background Technology

[0002] As a rotor for existing rotating electric machines, rotors with permanent magnets are known. In order to reduce the cogging torque in the case of rotating electric machines, a rotor is proposed that is composed of permanent magnets divided into segments (hereinafter referred to as "segmented magnets") from annular permanent magnets, and the cross-sectional shape of the segmented magnets is formed into an arched rotor.

[0003] Each segment of magnet is arranged circumferentially and attached to the outer circumferential surface of a single shaft unit or the outer circumferential surface of the rotor core of a shaft assembly consisting of a rotor core and a shaft. Hereinafter, both "single shaft unit" and "shaft assembly" will be collectively referred to as "shaft portion". A known method for attaching segmented magnets to the outer circumferential surface of the shaft portion is to magnetize each segmented magnet, arranging them such that adjacent segmented magnets in the circumferential direction have opposite magnetic polarities, and then attaching them to the outer circumferential surface of the shaft portion using an adhesive.

[0004] However, in the above-mentioned existing methods, when the spacing between adjacent segmented magnets in the circumferential direction is small, the position of the segmented magnets may sometimes shift due to the mutual attraction between them before the adhesive cures.

[0005] To solve this positional misalignment, one approach was to narrow the width of each segment magnet and widen the spacing between adjacent segment magnets in the circumferential direction. However, this would result in a reduction in the torque of the rotating motor.

[0006] To address the aforementioned positional misalignment, Patent Document 1 discloses a method in which adjacent segmented magnets in the circumferential direction are temporarily magnetized to have the same magnetic polarity, and the temporarily magnetized segmented magnets are then adhered to the outer circumferential surface of the shaft using an adhesive. In the method disclosed in Patent Document 1, the repulsive force acting between the adjacent segmented magnets in the circumferential direction is used to maintain the segmented magnets in a state of equal separation in the circumferential direction. By maintaining the segmented magnets in a state of equal separation in the circumferential direction, a rotor with high motor characteristics can be obtained in the method disclosed in Patent Document 1. Furthermore, the method disclosed in Patent Document 1 includes a formal magnetization step, which involves formally magnetizing the segmented magnets after the adhesive has cured, so that adjacent segmented magnets in the circumferential direction have opposite magnetic polarities.

[0007] Patent Document 1: Japanese Patent Application Publication No. 2007-267575 Summary of the Invention

[0008] However, in the method disclosed in Patent Document 1, if the segmented magnets are attached piece by piece to the outer peripheral surface of the shaft, when the second segmented magnet is attached to its correct position, the repulsive force between the segmented magnets causes each segmented magnet to move from its correct position. The same applies when attaching the third and subsequent segmented magnets; the repulsive force between the segmented magnets causes each segmented magnet to move from its correct position. As a result, the later the segmented magnet is attached to the outer peripheral surface of the shaft, the more limited the available space on the outer peripheral surface of the shaft becomes, making it difficult or impossible to attach the segmented magnets to the outer peripheral surface of the shaft.

[0009] Therefore, in the method disclosed in Patent Document 1, it is necessary to either attach all the segmented magnets to the outer peripheral surface of the shaft at once, or temporarily hold the attached segmented magnets until all the segmented magnets have been attached to the outer peripheral surface of the shaft. Both methods require a large clamp for attaching the segmented magnets to the outer peripheral surface of the shaft.

[0010] Furthermore, in the method disclosed in Patent Document 1, since the temporarily magnetized segmented magnets (segmented magnets in the middle of the initial magnetization curve) are in an unsaturated state, fluctuations in magnetic flux are easily generated in each temporarily magnetized segmented magnet. Moreover, if fluctuations in magnetic flux occur in each temporarily magnetized segmented magnet, the attractive force of each segmented magnet fluctuates, causing segmented magnets with weaker attractive forces to slip off the outer peripheral surface of the shaft. Fluctuations in the repulsive force acting on the segmented magnets against each other result in the segmented magnets not being held in a state of equal separation in the circumferential direction. Therefore, there is a problem of low accuracy in the attachment position of each segmented magnet on the outer peripheral surface of the shaft.

[0011] Furthermore, in the method disclosed in Patent Document 1, in order to maintain the pasting position of each segmented magnet by utilizing the repulsive force between adjacent segmented magnets in the circumferential direction, the adjacent segmented magnets in the circumferential direction are temporarily magnetized to have the same magnetic polarity. Therefore, in the subsequent step of the temporary magnetization process, i.e., the formal magnetization process, a high magnetization voltage needs to be applied to the magnetizing yoke to set some of the segmented magnets to opposite magnetic polarities. Consequently, there is a problem of a shortened lifespan for the magnetizing yoke.

[0012] The present invention was made in view of the above-mentioned problems, and its purpose is to provide a method for manufacturing the rotor of a rotary electric machine, in which large fixtures are not required, the accuracy of the bonding position of each segment magnet on the outer peripheral surface of the shaft is improved, and the life of the magnetized yoke is extended.

[0013] To solve the above problems and achieve the objective, the present invention relates to a method for manufacturing a rotor of a rotating electric machine, comprising: a temporary magnetization step, wherein a portion of each of a plurality of segmented magnets is temporarily magnetized; a magnetic flux measurement step, wherein the magnetic flux of each temporarily magnetized segmented magnet is measured; and a magnet selection step, wherein the plurality of segmented magnets used are selected from the segmented magnets based on the measured magnetic flux. Furthermore, the present invention relates to a method for manufacturing a rotor of a rotating electric machine, comprising: a magnet bonding step, wherein segmented magnets with different magnetic polarities are alternately arranged circumferentially on a shaft from the selected segmented magnets and bonded to the shaft using an adhesive; a magnet position correction step, wherein each segmented magnet is pressurized and its position is corrected during the adhesive curing time; an adhesive curing step, wherein the adhesive is cured; and a formal magnetization step, wherein each segmented magnet is formally magnetized after the adhesive has cured.

[0014] The effects of the invention

[0015] The method for manufacturing the rotor of a rotary electric machine disclosed in this invention achieves the effects of eliminating the need for large fixtures, improving the accuracy of the bonding position of the segmented magnets on the outer peripheral surface of the shaft, and extending the life of the magnetized yoke. Attached Figure Description

[0016] Figure 1 This is a perspective view showing the structure of the rotor of the rotary electric machine according to Embodiment 1.

[0017] Figure 2 It is along Figure 1 The cross-sectional view along line II-II shown.

[0018] Figure 3 This is a perspective view showing the structure of the segmented magnet before temporary magnetization in Embodiment 1.

[0019] Figure 4 This is a perspective view showing an example of the structure of the segmented magnet after temporary magnetization in Embodiment 1.

[0020] Figure 5 This is a perspective view showing another example of the structure of the segmented magnet after temporary magnetization in Embodiment 1.

[0021] Figure 6 This is a perspective view showing another example of the structure of the segmented magnet after temporary magnetization in Embodiment 1.

[0022] Figure 7 This is a cross-sectional view showing the structure of the rotor after the segmented magnets, which have undergone temporary magnetization, are attached to the outer circumferential surface of the shaft in Embodiment 1.

[0023] Figure 8This is a cross-sectional view showing the formal magnetization process of the manufacturing method of the rotor of the rotary electric machine according to Embodiment 1.

[0024] Figure 9 This is a perspective view showing the structure of the rotor of the rotary electric machine according to Embodiment 2. Detailed Implementation

[0025] The manufacturing method of the rotor of the rotary electric machine according to the embodiments will now be described in detail with reference to the accompanying drawings.

[0026] Implementation Method 1

[0027] First, refer to Figure 1 and Figure 2 The structure of the rotor 1 of the rotary electric machine according to Embodiment 1 will be described. Figure 1 This is a perspective view showing the structure of the rotor 1 of the rotary electric machine according to Embodiment 1. Figure 2 It is along Figure 1 The cross-sectional view along line II-II is shown. Below, the rotor 1 of the rotating electrical machine is sometimes referred to as rotor 1. (As shown...) Figure 1 As shown, the rotor 1 has a shaft 2 and multiple segmented magnets 3. Although not shown in the figure, a cylindrical stator is arranged around the outer periphery of the rotor 1, spaced apart from it. The stator has multiple windings that are opposite to each of the multiple segmented magnets 3. The rotor 1 and the stator are housed in a frame (not shown). The rotor 1, stator, and frame are structural components of a rotary electric machine. The rotor 1 rotates relative to the stator about the rotation axis AX. Hereinafter, when describing the directions of each structural element of the rotor 1, the direction parallel to the rotation axis AX is defined as the axial direction, the direction orthogonal to the rotation axis AX is defined as the radial direction, and the rotational direction centered on the rotation axis AX is defined as the circumferential direction.

[0028] Shaft 2 is made of a magnetic material, such as carbon steel plate. Shaft 2 extends axially. Shaft 2 is coaxially arranged with the rotation axis AX. In this embodiment, the shape of shaft 2 is cylindrical. Specifically, the shape of shaft 2 is that of multiple cylinders of different diameters connected axially.

[0029] Each segmented magnet 3 is, for example, a rare-earth sintered permanent magnet. Each segmented magnet 3 is disposed on the outer circumferential surface of the shaft 2. Each segmented magnet 3 is adhered to the outer circumferential surface of the shaft 2 by an adhesive. Multiple segmented magnets 3 are arranged circumferentially. Multiple segmented magnets 3 are arranged at equal angles in the circumferential direction. Figure 2 As shown, the shape of each segment magnet 3 when viewed along the axial direction is roughly arched. Each segment magnet 3 has an inner circumferential surface 31 facing inward in the radial direction and an outer circumferential surface 32 facing outward in the radial direction. Both the inner circumferential surface 31 and the outer circumferential surface 32 are arc-shaped surfaces that bulge outward in the radial direction. The inner circumferential surface 31 is an arc surface centered on the rotation axis AX.

[0030] Each segmented magnet 3 is magnetized so that its magnetic path faces the radial direction. The segmented magnets 3 include segmented magnets 3A and 3B, which were formally magnetized in the formal magnetization process described later. Segmented magnet 3A is a segmented magnet with its N and S poles facing inward from the outer side of the radial direction. Segmented magnet 3B is a segmented magnet with its N and S poles facing outward from the inner side of the radial direction. Segmented magnets 3A and 3B are arranged alternately in the circumferential direction. That is, segmented magnets 3A and 3B are arranged such that their N and S poles face the radial direction, and the N and S poles of adjacent segmented magnets 3A and 3B in the circumferential direction are opposite each other.

[0031] Next, refer to Figures 2 to 8 The manufacturing method of the rotor 1 of the rotary electric machine according to this embodiment will be described. Figure 3 This is a perspective view showing the structure of the segmented magnet 3 before temporary magnetization in Embodiment 1. Figure 4 This is a perspective view showing an example of the structure of the segmented magnet 3 after temporary magnetization in Embodiment 1. Figure 5 This is a perspective view showing another example of the structure of the segmented magnet 3 after temporary magnetization in Embodiment 1. Figure 6 This is a perspective view showing another example of the structure of the segmented magnet 3 after temporary magnetization in Embodiment 1. Figure 7 This is a cross-sectional view showing the structure of the rotor 1 after the segmented magnet 3, which has been temporarily magnetized, is pasted onto the outer peripheral surface of the shaft 2 in Embodiment 1. Figure 8 This is a cross-sectional view showing the formal magnetization process of the manufacturing method of the rotor 1 of the rotary electric machine according to Embodiment 1.

[0032] The manufacturing method of the rotor 1 of the rotary electric machine involved in this embodiment includes a temporary magnetization process, a magnetic flux measurement process, a magnet selection process, a magnet bonding process, a magnet position correction process, an adhesive curing process, and a formal magnetization process.

[0033] like Figure 4 and Figure 5 As shown, the temporary magnetization process is a process of temporarily magnetizing a portion of each of the multiple segmented magnets 3. The temporary magnetization process is performed to adjust the magnetic flux of each segmented magnet 3. In the temporary magnetization process, each segmented magnet 3 is temporarily magnetized so that segmented magnets 3 with the same magnetic polarity but different magnetic polarity as those obtained through the formal magnetization process are alternately arranged circumferentially on axis 2. Specifically, in the temporary magnetization process, the... Figure 3 The segmented magnet 3 shown is temporarily magnetized to have Figure 4 The segmented magnet 3 (hereinafter referred to as segmented magnet 3C) with the shown magnetic polarity or having Figure 5The segmented magnet 3 (hereinafter referred to as segmented magnet 3D) with the shown magnetic polarity is manufactured. That is, in the temporary magnetization process, a magnetizing yoke (not shown) is used to... Figure 3 The segmented magnet 3 shown is temporarily magnetized, and segmented magnets 3C and 3D with different magnetic polarities are manufactured. Figure 4 as well as Figure 5 The diagram only shows the magnetic poles on the inner circumferential surface 31 of each segment magnet 3C and 3D. The outer circumferential surface 32 of each segment magnet 3C and 3D has magnetic poles opposite to those on the inner circumferential surface 31. Figure 4 The segmented magnet 3C shown has its magnetic poles arranged in an N-S polarity, moving from the outer side to the inner side in the radial direction. Figure 5 The segmented magnet 3D shown has its magnetic poles arranged in an N-S polarity, moving from the inside to the outside in the radial direction.

[0034] In the temporary magnetization process, the segmented magnet 3 is temporarily magnetized in a manner that the area of ​​temporary magnetization (hereinafter referred to as the temporary magnetization range 33) is symmetrical with respect to the circumference and axial direction of the segmented magnet 3. Alternatively, in the temporary magnetization process, [the following method may be used]. Figure 4 The segmented magnet 3C shown is manufactured... Figure 6 The segmented magnet 3E is shown. That is, in the temporary magnetization process, if the segmented magnet 3 can be temporarily magnetized in a manner that is symmetrical about the circumference and axial direction with respect to the temporary magnetization range 33, it can become... Figure 4 The segmented magnet 3 is temporarily magnetized in the manner shown by a single temporary magnetization range 33 extending axially, which can also be used as follows: Figure 6 The segmented magnet 3 is temporarily magnetized in a manner shown by multiple temporary magnetization ranges 33 that are separated from each other in the axial direction. Although the illustration is omitted, it can be substituted... Figure 5 The segmented magnet 3D shown is manufactured in such a way that it is temporarily magnetized as a plurality of temporary magnetization ranges 33 separated from each other in the axial direction. By temporarily magnetizing the segmented magnet 3 in a manner that the temporary magnetization ranges 33 are symmetrical with respect to the circumference and axial direction of the segmented magnet 3, the attractive force of the segmented magnets 3C and 3D on the shaft 2 is uniform in the portion of the segmented magnets 3C and 3D on the inner circumferential surface 31 side. In the temporary magnetization process, it is preferable to perform temporary magnetization from the inner side to the outer side in the radial direction of each segmented magnet 3C and 3D. In other words, in the temporary magnetization process, it is preferable to start temporary magnetization from the portion of each segmented magnet 3C and 3D where the adhesive is applied (inner circumferential surface 31).

[0035] The magnetic flux measurement process is a process of measuring the magnetic flux of each segment of magnet 3C and 3D that has been temporarily magnetized. In the magnetic flux measurement process, for example, a detection coil and a fluxmeter (not shown) are used to measure the magnetic flux of each segment of magnet 3C and 3D that has been temporarily magnetized.

[0036] The magnet selection process is a process of selecting multiple segmented magnets 3C and 3D from each segmented magnet 3C and 3D based on the measured magnetic flux. In this process, an upper limit for the magnetic flux is set based on the condition that the position of each segmented magnet 3C and 3D will not change due to the attraction between adjacent segmented magnets 3C and 3D in the circumferential direction when they are attached to shaft 2. A lower limit for the magnetic flux is set based on the condition that each segmented magnet 3C and 3D will not slip off shaft 2. In this process, multiple segmented magnets 3C and 3D whose measured magnetic flux falls within the range between the upper and lower limits are selected from the segmented magnets 3C and 3D.

[0037] like Figure 7 As shown, the magnet bonding process involves arranging the selected segmented magnets 3C and 3D with different magnetic polarities alternately along the circumference of shaft 2 and then bonding them to shaft 2 using an adhesive. In the magnet bonding process, the segmented magnets 3C and 3D are held in place at the locations where they are bonded to shaft 2. Specifically, in the magnet bonding process, adhesive is first applied to either the outer circumferential surface of shaft 2 or the inner circumferential surface 31 of segmented magnets 3C and 3D. When using a two-component liquid-curing adhesive, the base agent can be applied to either the outer circumferential surface of shaft 2 or the inner circumferential surface 31 of segmented magnets 3C and 3D, and the curing agent can be applied to the other.

[0038] Next, in the magnet bonding process, while rotating the shaft 2 by a fixed angle each time, segmented magnets 3C and 3D are alternately and at equal intervals along the circumferential direction to be bonded to the outer circumferential surface of the shaft 2. At this time, the segmented magnets 3C and 3D are attracted to the outer circumferential surface of the shaft 2 by their respective magnetic forces. Therefore, when the shaft 2 is rotated and the segmented magnets 3C and 3D are bonded to the outer circumferential surface of the shaft 2, even if the segmented magnets 3C and 3D are located on the lower side relative to the shaft 2, they will not fall off the outer circumferential surface of the shaft 2. Thus, a rotor 1 is obtained in which multiple temporarily magnetized segmented magnets 3C and 3D are arranged alternately and at equal intervals along the circumferential direction on the outer circumferential surface of the shaft 2.

[0039] The adjacent segmented magnets 3C and 3D in the circumferential direction form a magnetic force that does not change their positions, and each segmented magnet 3C and 3D is held in place at the position where it is pasted on the outer circumferential surface of shaft 2.

[0040] The magnet position correction process involves applying pressure to each segment magnet 3C and 3D during the adhesive curing time and correcting the position of each segment magnet 3C and 3D. In this process, by controlling the pressure applied to press each segment magnet 3C and 3D, which is adhered to the outer circumferential surface of the shaft 2, onto the outer circumferential surface of the shaft 2, the thickness of the adhesive can be arbitrarily adjusted and stabilized. Japanese Patent Application Publication No. 2012-120366 shows that the adhesive strength is dependent on the thickness of the adhesive. Therefore, by controlling the pressure as described above, the thickness of the adhesive can be arbitrarily adjusted and stabilized, thereby obtaining a rotor 1 with stable adhesive strength between each segment magnet 3C and 3D and the shaft 2. In the magnet position correction process, for example, a pressure device with a spring is used to physically press each segment magnet 3C and 3D using the spring force. In the magnet position correction process, a fixture (not shown) is used to correct the position of each segment magnet 3C and 3D so that each segment magnet 3C and 3D is positioned at equal intervals along the circumference and aligned along the axial direction. When correcting the circumferential position of each segment magnet 3C and 3D, a fixture and rotation method with minimal movement of each segment magnet 3C and 3D are preferably used.

[0041] The adhesive curing process is the process of curing the adhesive. Through the adhesive curing process, each segment magnet 3C and 3D is fixed immovably to the outer circumferential surface of shaft 2.

[0042] The formal magnetization process involves formally magnetizing each segment of the magnet (3C and 3D) after the adhesive has cured. In the formal magnetization process, such as... Figure 8 As shown, multiple magnetizing yokes 4 are arranged on the outer side of each segmented magnet 3C and 3D in the radial direction, and magnetizing coils 5 wound around each magnetizing yoke 4 are energized. During the formal magnetization process, a magnetizing magnetic field is generated by energizing the magnetizing coils 5. At this time, the magnetizing coils 5 of each magnetizing yoke 4 are energized so that the magnetizing yoke 4 (which is penetrated by magnetic flux M1 from the inner side to the outer side in the radial direction)... Figure 8 The magnetized yoke 4 on the left side of the paper and the magnetized yoke 4 (which is penetrated by magnetic flux M2 from the outside to the inside in the radial direction) Figure 8 The magnetized yokes 4 on the right side of the paper are arranged alternately in the circumferential direction. In the formal magnetization process, a rotor 1 and a magnetized yoke 4 are configured, each segment of magnets 3C and 3D having been temporarily magnetized in the same way as the segment of magnets 3A and 3B imparted by the temporary magnetization process. That is, in the formal magnetization process, after the adhesive has cured, each segment of magnets 3C and 3D is formally magnetized with the same magnetic polarity as in the temporary magnetization process. By performing the formal magnetization process, a product is obtained having… Figure 2The rotor 1 is shown with segmented magnets 3A and 3B. Then, the rotor 1 is arranged within a frame (not shown) on the inner periphery of the stator. Figure 2 The rotor 1 is shown, and its shaft 2 is supported by a bearing (not shown). Thus, the manufacturing of the rotary electric machine is completed.

[0043] Next, the effects of the manufacturing method of the rotor 1 of the rotary electric machine according to this embodiment will be explained.

[0044] In this embodiment, such as Figure 4 and Figure 5 As shown, the manufacturing method of the rotor 1 of the rotary electric machine includes a temporary magnetization process that temporarily magnetizes a portion of each of the multiple segmented magnets 3, thereby enabling the limitation of the temporary magnetization range 33 in each segmented magnet 3. Furthermore, the manufacturing method of the rotor 1 of the rotary electric machine includes a magnetic flux measurement process that measures the magnetic flux of each temporarily magnetized segmented magnet 3C, 3D, and a magnet selection process that selects the multiple segmented magnets 3C, 3D used from the segmented magnets 3C, 3D based on the measured magnetic flux, thereby enabling the selection of each segmented magnet 3C, 3D based on the magnetic flux measurement. Specifically, in the magnet selection process, an upper limit value of the magnetic flux is set based on the condition that the position of each segmented magnet 3C, 3D will not change due to the attraction between adjacent segmented magnets 3C, 3D in the circumferential direction when the segmented magnets 3C, 3D are attached to the shaft 2, and a lower limit value of the magnetic flux is set based on the condition that each segmented magnet 3C, 3D will not slip off the shaft 2. In addition, during the magnet selection process, multiple segment magnets 3C and 3D that have measured magnetic flux falling within the range of the upper and lower limits are selected from each segment magnet 3C and 3D.

[0045] As described above, by limiting the temporary magnetization range 33 in each segment magnet 3 and selecting each segment magnet 3C and 3D based on magnetic flux measurement, the magnetic force of each temporarily magnetized segment magnet 3C and 3D can be used only to hold each segment magnet 3C and 3D at the position where it is pasted on the outer peripheral surface of the shaft 2. Therefore, the attractive and repulsive forces do not act between adjacent segment magnets 3C and 3D in the circumferential direction, thus preventing positional displacement of the segment magnets 3C and 3D. Therefore, segment magnets 3C and 3D can be pasted onto the outer peripheral surface of the shaft 2 piece by piece. That is, since it is not necessary to paste all segment magnets 3C and 3D onto the outer peripheral surface of the shaft 2 at once, or to temporarily hold the pasted segment magnets 3C and 3D until all segment magnets 3C and 3D are pasted onto the outer peripheral surface of the shaft 2, a large clamp for pasting segment magnets 3C and 3D onto the outer peripheral surface of the shaft 2 is not required.

[0046] In this embodiment, even when fluctuations in magnetic flux occur in the individual segmented magnets 3C and 3D that have undergone temporary magnetization, multiple segmented magnets 3C and 3D with less magnetic flux fluctuation can be used by selecting individual segmented magnets 3C and 3D based on magnetic flux measurement. Furthermore, in this embodiment, the manufacturing method of the rotor 1 of the rotary electric machine includes a magnet position correction step that corrects the position of each segmented magnet 3C and 3D during the curing time of the adhesive. This improves the accuracy of the bonding position of each segmented magnet 3C and 3D on the outer peripheral surface of the shaft 2. That is, when each segmented magnet 3C and 3D is bonded to the outer peripheral surface of the shaft 2, it is possible to position each segmented magnet 3C and 3D not only in the circumferential direction but also in the axial direction. Therefore, the accuracy of the bonding position of each segmented magnet 3C and 3D on the outer peripheral surface of the shaft 2 in both the circumferential and axial directions can be improved.

[0047] In this embodiment, such as Figure 7 As shown, since the magnetic force of each segment magnet 3C and 3D, which has undergone temporary magnetization, can be used only to hold each segment magnet 3C and 3D at the position where they are pasted on the outer circumferential surface of the shaft 2, adjacent segment magnets 3C and 3D in the circumferential direction can be arranged with opposite magnetic polarities. That is, in the magnet bonding process, segment magnets 3C and 3D with different magnetic polarities can be alternately arranged in the circumferential direction of the shaft 2 and pasted on the shaft 2 with adhesive. Therefore, in the formal magnetization process, after the adhesive has cured, each segment magnet 3C and 3D can be formally magnetized with the same magnetic polarity as in the temporary magnetization process. Therefore, in the subsequent process of the temporary magnetization process, i.e., the formal magnetization process, it is not necessary to set each segment magnet 3C and 3D to have the opposite magnetic polarity to that in the temporary magnetization process. Therefore, it is not necessary to apply a high magnetization voltage to the magnetizing yoke 4 in the formal magnetization process, thus extending the life of the magnetizing yoke 4 and achieving energy saving in the manufacturing process of the rotor 1.

[0048] As described above, in this embodiment, without the need for large clamps, the accuracy of the bonding positions of the segmented magnets 3C and 3D on the outer peripheral surface of the shaft 2 can be improved, and the lifespan of the magnetized yoke 4 can be extended.

[0049] In the temporary magnetization process of this embodiment, from Figure 7 Temporary magnetization begins at the portion of each segment magnet 3C, 3D where the adhesive is applied. Specifically, in the temporary magnetization process, temporary magnetization begins from the inner side of each segment magnet 3C, 3D in the radial direction. This reduces or eliminates the impact of temporary magnetization on the outer peripheral portion of the rotor 1, which is related to motor characteristics. Furthermore, by performing the temporary magnetization process, a high magnetization voltage does not need to be applied to each segment magnet 3C, 3D during the formal magnetization process, thus extending the lifespan of the magnetizing yoke 4.

[0050] The following describes a variation of Implementation 1.

[0051] In this embodiment, the thickness of the adhesive can be arbitrarily adjusted by applying pressure during the magnet position correction process, but it is not limited to this. For example, instead of applying pressure during the magnet position correction process, the thickness of the adhesive can be arbitrarily adjusted by applying pressure to each segment magnet 3C, 3D during the magnet bonding process. As a method for applying pressure to each segment magnet 3C, 3D during the magnet bonding process, examples include applying pressure using straps, suction clamps, etc., for arranging each segment magnet 3C, 3D on the outer peripheral surface of the shaft 2, or applying pressure using the attraction force of each temporarily magnetized segment magnet 3C, 3D. As described above, if each segment magnet 3C, 3D is applied pressure during the magnet bonding process, the thickness of the adhesive can be arbitrarily adjusted during the manufacturing of the rotor 1 without using a pressure device, thus simplifying the manufacturing apparatus of the rotor 1 and reducing manufacturing costs. In addition, if pressure is applied to each segment magnet 3C and 3D during the magnet bonding process, pressure can be applied to each segment magnet 3C and 3D while they are being placed on the outer circumferential surface of shaft 2, thus shortening the processing time (cycle).

[0052] In this embodiment, during the formal magnetization process, after the adhesive has cured, each segment magnet 3C and 3D is formally magnetized with the same magnetic polarity as in the temporary magnetization process. However, it is also possible to formally magnetize each segment magnet 3C and 3D with the opposite magnetic polarity after the adhesive has cured during the formal magnetization process. For example, if the direction of temporary magnetization cannot be changed due to limitations on the device side, all segment magnets 3 can be temporarily magnetized to the same magnetic polarity during the temporary magnetization process, and then a portion of the segment magnets 3 can be formally magnetized to the opposite magnetic polarity during the formal magnetization process. Thus, by implementing a magnet selection process, the use of segment magnets 3 with large magnetic flux is avoided. Therefore, compared to the method disclosed in Patent Document 1, which does not implement a magnet selection process, the magnetization voltage applied to the magnetizing yoke 4 during the formal magnetization process is reduced, thereby extending the lifespan of the magnetizing yoke 4 and achieving energy savings in the rotor 1 manufacturing process.

[0053] In this embodiment, multiple segmented magnets 3 are attached to the outer peripheral surface of the shaft 2 unit, but they can also be attached to the outer peripheral surface of the rotor core of the shaft assembly consisting of the rotor core and the shaft 2. In this structure, the rotor 1 has a shaft portion, i.e., the shaft assembly, and multiple segmented magnets 3 attached to the outer peripheral surface of the rotor core of the shaft assembly. The shaft 2 is disposed on the inner periphery of the rotor core and connected to the rotor core. The rotor core is, for example, a laminate of rolled steel sheet or electromagnetic steel sheet, a cut metal product, etc., and is formed into a cylindrical shape or the like.

[0054] Implementation Method 2

[0055] Next, refer to Figure 9 The manufacturing method of the rotor 1A of the rotary electric machine according to Embodiment 2 will be described. Figure 9 This is a perspective view showing the structure of the rotor 1A of the rotary electric machine according to Embodiment 2. In this embodiment, the difference from Embodiment 1 is that a plurality of segmented magnets 3 are also arranged axially. Furthermore, in Embodiment 2, the parts that are repeated with those in Embodiment 1 are labeled with the same reference numerals and their descriptions are omitted.

[0056] First, the structure of the rotor 1A of the rotary electric machine according to Embodiment 2 will be described. A plurality of segmented magnets 3 are arranged circumferentially and axially. That is, in this embodiment, there are two columns circumferentially arranged with the plurality of segmented magnets 3 in the axial direction. The circumferential center lines of each segmented magnet 3A, 3B in one column and the circumferential center lines of each segmented magnet 3A, 3B in the other column are aligned in a straight line. Axially adjacent segmented magnets 3A, 3B are in contact with each other. Axially adjacent segmented magnets 3A, 3B have the same magnetic polarity. That is, the columns of segmented magnets 3A and 3B arranged axially are alternately arranged circumferentially.

[0057] Next, refer to Figure 7 and Figure 9 The manufacturing method of the rotor 1A of the rotary electric machine according to this embodiment will be described.

[0058] The manufacturing method of the rotor 1A of the rotary electric machine according to this embodiment includes a temporary magnetization process, a magnetic flux measurement process, a magnet selection process, a magnet bonding process, a magnet position correction process, an adhesive curing process, and a formal magnetization process. Except for the magnet bonding process and the magnet position correction process, it is largely the same as the manufacturing method of the rotor 1 of the rotary electric machine according to Embodiment 1 above, so its description is omitted here. The structure of the temporarily magnetized segmented magnets 3C and 3D used in the manufacturing method of the rotor 1A of the rotary electric machine according to Embodiment 2 is the same as that in Embodiment 1 (see...). Figure 7 ).

[0059] The magnet bonding process involves arranging selected segmented magnets 3C and 3D with different magnetic polarities alternately along the circumference of shaft 2 and bonding them to shaft 2 using adhesive. Conversely, it involves arranging selected segmented magnets 3C and 3D with the same magnetic polarity along the axial direction of shaft 2 and bonding them to shaft 2 using adhesive. First, in the magnet bonding process, one row of segmented magnets 3C and 3D is arranged alternately along the circumference of shaft 2 and bonded to shaft 2 using adhesive. Next, in the magnet bonding process, another row of segmented magnets 3C and 3D is arranged alternately along the circumference of shaft 2 and bonded to shaft 2 using adhesive.

[0060] The magnet position correction process involves applying pressure to each segment magnet 3C and 3D during the adhesive's curing time and correcting their positions. In this process, a fixture (not shown) is used to correct the positions of each segment magnet 3C and 3D, ensuring they are evenly spaced circumferentially and aligned axially.

[0061] Next, the effects of the manufacturing method of the rotor 1A of the rotary electric machine according to this embodiment will be explained.

[0062] In this embodiment, the manufacturing method of the rotor 1A of the rotary electric machine includes a magnet bonding process. In this process, selected segmented magnets 3C and 3D with different magnetic polarities are alternately arranged circumferentially on the shaft 2 and bonded to the shaft 2 using an adhesive. Additionally, selected segmented magnets 3C and 3D with the same magnetic polarity are arranged axially on the shaft 2 and bonded to the shaft 2 using an adhesive. Furthermore, in this embodiment, the manufacturing method of the rotor 1A of the rotary electric machine includes a magnet position correction process that corrects the positions of the segmented magnets 3C and 3D during the adhesive curing time. Therefore, when bonding the segmented magnets 3C and 3D to the outer circumferential surface of the shaft 2, not only can the segmented magnets 3C and 3D be positioned circumferentially, but also axially. Thus, the accuracy of the circumferential and axial bonding positions of the segmented magnets 3C and 3D at the outer circumferential surface of the shaft 2 can be improved.

[0063] The following describes a variation of embodiment 2.

[0064] In this embodiment, there are two columns in the axial direction in which multiple segmented magnets 3 are arranged in a circumferential column, but there may also be multiple columns of three or more columns.

[0065] In this embodiment, after attaching each segment magnet 3C, 3D of one column to the shaft 2, each segment magnet 3C, 3D of another column is attached to the shaft 2, but this is not a limitation. For example, each segment magnet 3C, 3D of one column and each segment magnet 3C, 3D of another column may be attached to the shaft 2 alternately.

[0066] The structure shown in the above embodiments is an example and can be combined with other known technologies. The embodiments can also be combined with each other. Without departing from the main idea, a part of the structure can be omitted or changed.

[0067] Explanation of the label

[0068] 1. 1A Rotor, 2 Shaft, 3. 3A, 3B, 3C, 3D, 3E Segmented Magnets, 4 Magnetizing Yoke, 5 Magnetizing Coil, 31 Inner Circumferential Surface, 32 Outer Circumferential Surface, 33 Temporary Magnetization Range, AX Rotating Shaft, M1, M2 Magnetic Flux.

Claims

1. A method for manufacturing the rotor of a rotating electric motor, characterized in that, Include: The temporary magnetization process involves temporarily magnetizing a portion of each of the multiple segmented magnets. The magnetic flux measurement process involves measuring the magnetic flux of each of the segmented magnets that have undergone temporary magnetization. The magnet selection process involves selecting from the segmented magnets used in the process based on the measured magnetic flux. In the magnet bonding process, the selected segmented magnets with different magnetic polarities are alternately arranged around the circumference of the shaft and bonded to the shaft with an adhesive. In the magnet position correction process, pressure is applied to each of the segmented magnets during the curing time of the adhesive, and the position of each of the segmented magnets is corrected. The adhesive curing process cures the adhesive. as well as The formal magnetization process involves formally magnetizing each segmented magnet after the adhesive has cured.

2. The method for manufacturing the rotor of a rotating electric motor according to claim 1, characterized in that, In the magnet selection process, an upper limit value for the magnetic flux is set based on the condition that the position of each segmented magnet will not change due to the attraction between adjacent segmented magnets in the circumferential direction when each segmented magnet is attached to the shaft. A lower limit value for the magnetic flux is set based on the condition that each segmented magnet will not slip off the shaft. From each segmented magnet, a plurality of segmented magnets whose measured magnetic flux falls within the range of the upper limit value to the lower limit value are selected.

3. The method for manufacturing the rotor of a rotary electric motor according to claim 1, characterized in that, In the temporary magnetization process, temporary magnetization begins from the portion of each segmented magnet to which the adhesive is applied.

4. The method for manufacturing the rotor of a rotating electric motor according to claim 1, characterized in that, In the formal magnetization process, after the adhesive has cured, each of the segmented magnets is formally magnetized with the same magnetic polarity as in the temporary magnetization process.

5. A method for manufacturing the rotor of a rotating electric motor, characterized in that, Include: The temporary magnetization process involves temporarily magnetizing a portion of each of the multiple segmented magnets. The magnetic flux measurement process involves measuring the magnetic flux of each of the segmented magnets that have undergone temporary magnetization. The magnet selection process involves selecting from the segmented magnets used in the process based on the measured magnetic flux. In the magnet bonding process, the selected segmented magnets with different magnetic polarities are alternately arranged around the circumference of the shaft, bonded to the shaft with adhesive, and pressure is applied to each segmented magnet. The magnet position correction process involves correcting the position of each segmented magnet during the curing time of the adhesive. The adhesive curing process cures the adhesive. as well as The formal magnetization process involves formally magnetizing each segmented magnet after the adhesive has cured.

6. The method for manufacturing the rotor of a rotating electric motor according to claim 5, characterized in that, In the magnet bonding process, the adhesive is pressurized by the attraction of each of the temporarily magnetized segmented magnets.

7. The method for manufacturing the rotor of a rotating electric motor according to claim 5, characterized in that, In the formal magnetization process, after the adhesive has cured, each of the segmented magnets is formally magnetized with the same magnetic polarity as in the temporary magnetization process.

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