Rotator, and rotary electric machine, and manufacturing method of rotator and rotary electric machine

Abstract

To provide a rotator free from any restrictions on the core shape that affect the magnetic path, with a resin part free from being damaged even when used at high rotation speeds, while making effective use of the magnetic flux of magnets, a rotary electric machine, and a manufacturing method of the rotator and rotary electric machine.SOLUTION: A disclosed rotator 4 includes: a main shaft 41 as the rotation axis; an inner diameter-side core 42 placed at the outside diameter side of the main shaft 41; a plurality of magnet 43 arranged in the circumferential direction with respect to the main shaft 41 at the outside diameter side of the inner diameter-side core 42; outer diameter side iron cores 44 each arranged on the outer diameter side of the magnets 43, divided into multiple pieces at intervals in the axial direction of the main shaft 41; and a resin part 50 formed between the magnet 43 and end faces in the circumferential direction adjacent to the outside diameter side core 44 and between adjacent axial division surfaces of the outside diameter side core 44.SELECTED DRAWING: Figure 4

Description

[Technical field]

[0001] The present disclosure relates to a rotor, a rotating electric machine, and a method for manufacturing a rotor and a rotating electric machine. [Background technology]

[0002] Conventionally, there is known a rotating electric machine with an interior permanent magnet (IPM) structure, which is composed of a stator made of an armature wound around a ring-shaped iron core, and a rotor with magnets arranged at a predetermined interval in the circumferential direction inside the iron core. Rotating electric machines with an IPM structure are excellent in that they can use rare earth magnets with high residual magnetic flux density and coercive force with good yield. However, in order to connect the iron cores arranged on the inner and outer diameters of the magnets, it is necessary to provide a bridge between adjacent magnets in the circumferential direction. This causes a problem in that part of the magnetic flux of the magnet leaks to the adjacent magnets, making it impossible to effectively utilize the magnetic flux.

[0003] In response to this problem, a bridgeless IPM rotor has been proposed that eliminates the bridge, separates the iron core radially inside and outside the magnet, fills the gaps between the iron core and the magnets with resin, and fixes the resin part to reduce magnetic flux leakage (for example, Patent Document 1). [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Patent No. 4969064 Summary of the Invention [Problem to be solved by the invention]

[0005] However, the rotor of Patent Document 1 has a problem in that when used at high rotation speeds, the centrifugal force between the magnets and iron core generates stress in the resin part, causing the resin part to break. Also, while it is possible to reduce the stress generated in the resin part by devising the shape of the iron core, such as by forming a notched step in the iron core as in the prior art, there are restrictions on the shape of the iron core as it also affects the magnetic path, and there is a limit to how much stress can be reduced.

[0006] The present disclosure has been made to solve the above-mentioned problems, and aims to provide a rotor and rotating electric machine that effectively utilizes the magnetic flux of the magnets, does not damage the resin parts even when used at high rotation speeds, and is not restricted by the core shape that affects the magnetic path, as well as a manufacturing method for the rotor and rotating electric machine. [Means for solving the problem]

[0007] The rotor according to the present disclosure is characterized by comprising a main shaft which serves as a rotating shaft, an inner core arranged on the outer periphery of the main shaft, a plurality of magnets arranged circumferentially on the outer periphery of the inner core, a plurality of outer cores arranged on the outer periphery of the magnets at intervals in the axial direction of the main shaft, and a resin portion formed between adjacent circumferential end faces of the magnets and the outer core, and between adjacent axial end faces of the outer core.

[0008] The rotor according to the present disclosure comprises a main shaft which serves as a rotating shaft, an inner core arranged on the outer periphery of the main shaft and having a plurality of protrusions in the circumferential direction, magnets arranged between adjacent protrusions on the outer periphery of the inner core, a plurality of outer cores arranged on the outer periphery of the magnets at intervals in the axial direction of the main shaft, and resin portions formed between one circumferential end face of the magnets and the outer core and the protrusions, and between adjacent axial end faces of the outer core, wherein the magnets have the same polarity arranged radially outward for half the number of magnetic poles, and the outermost end faces of the protrusions of the inner core have an arc of the same radius as the outermost end face of the outer core to form a magnetic pole portion.

[0009] A rotating electric machine according to the present disclosure includes the above rotor, and a stator disposed on an outer periphery of the rotor with an air gap therebetween.

[0010] The manufacturing method of a rotor according to the present disclosure is characterized by including an arrangement process in which an inner core is arranged on the outer periphery of the main shaft by inserting a main shaft, which serves as the rotating shaft, into a fitting portion provided at the center of the molding die inside the molding die, and then arranging a plurality of magnets in the circumferential direction around the outer periphery of the inner core, and a plurality of outer cores on the outer periphery of the magnets at intervals in the axial direction of the main shaft; a resin injection process in which resin is injected between adjacent circumferential end faces of the magnets and the outer core, between adjacent axial end faces of the outer core, and at both axial ends of the inner core, the magnets, and the outer core; and an extraction process in which resin is removed in the axial direction from the molding die.

[0011] The manufacturing method of a rotating electric machine according to the present disclosure is characterized by including a stator arrangement process in which a rotor manufactured using the above-mentioned rotor manufacturing method is used to arrange a stator on the outer diameter side of the rotor via an air gap. Effect of the Invention

[0012] The rotor and rotating electric machine, and the manufacturing method of the rotor and rotating electric machine disclosed herein can reduce the leakage magnetic flux in the circumferential direction of the magnet of the IPM rotor while reducing the stress due to centrifugal force generated in the resin part, without being restricted by the core shape, thereby making it possible to effectively utilize the magnetic flux of the magnet even in products used at high rotation speeds. [Brief description of the drawings]

[0013] [Figure 1] 1 is a plan view of a rotating electric machine according to a first embodiment. [Diagram 2] FIG. 2 is a side view of the rotor according to the first embodiment. [Diagram 3] 1 is a cross-sectional view perpendicular to the rotation axis of a rotor according to embodiment 1. FIG. [Figure 4] 1 is a cross-sectional view parallel to the rotation axis of a rotor according to embodiment 1. FIG. [Diagram 5]FIG. 3 is an explanatory diagram of the arrangement of the rotor in the molding die according to the first embodiment. [Figure 6] 4 is a cross-sectional view for explaining the arrangement of the rotor in the molding die according to the first embodiment. FIG. [Figure 7] 6 is an explanatory diagram of another example of arrangement of the rotor in the molding die according to the first embodiment. FIG. [Figure 8] 6 is an explanatory diagram of another example of arrangement of the rotor in the molding die according to the first embodiment. FIG. [Figure 9] 4 is a flowchart of a method for manufacturing a rotor according to the first embodiment. [Figure 10] FIG. 11 is a cross-sectional view of a rotor according to a second embodiment. [Figure 11] FIG. 11 is a cross-sectional view of a rotor according to a third embodiment. [Figure 12] FIG. 11 is a cross-sectional view of a rotor according to a fourth embodiment. [Figure 13] FIG. 13 is a cross-sectional view of a rotor according to a fifth embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0014] Embodiment 1 The first embodiment includes an inner core (inner core) arranged on the outer diameter side of a main shaft that serves as a rotating shaft, magnets arranged on the outer diameter side of the inner core, and an outer core (outer core) arranged on the outer diameter side of the magnets, and structures formed of the magnets and the outer core are arranged in the circumferential direction of the main shaft by the number of poles of the rotor, the outer core is divided into multiple pieces spaced apart in the axial direction, and a resin part is formed between the circumferential end faces of adjacent structures and between the axial division faces of the outer core divided in the axial direction. The first embodiment also relates to a rotating electric machine using this rotor. The first embodiment also relates to a manufacturing method of the rotor and the rotating electric machine.

[0015] The rotor, rotating electric machine, and manufacturing method of the rotor and the manufacturing method of the rotating electric machine according to the first embodiment will be described below with reference to Fig. 1, which is a plan view of the rotating electric machine, Fig. 2, which is a side view of the rotor, Figs. 3 and 4, which are cross-sectional views of the rotor, Fig. 5, which is an explanatory view of the arrangement of the rotor in the molding die, Fig. 6, which is a cross-sectional view for explaining the arrangement of the rotor in the molding die, Figs. 7 and 8, which are explanatory views of other examples of the arrangement of the rotor in the molding die, and Fig. 9, which is a flowchart of the manufacturing method of the rotor. Note that in each figure, the same or corresponding parts are denoted by the same reference numerals, and duplicated explanations will be omitted.

[0016] In addition, in the following description, when axis (direction), diameter (direction), inner diameter (side, direction), outer diameter (side, direction), and circumference (direction) are used, unless otherwise specified, they refer to the rotation axis (direction), radius (direction), relative radial direction toward the center (side, direction), relative radial direction toward the outside (side, direction), and circumference (direction) of the rotation axis in a cylindrical coordinate system centered on the rotation axis of the rotor.

[0017] First, the overall structure of the rotating electric machine 1 according to the first embodiment will be described with reference to Fig. 1, which is a plan view seen from an axial end face of the rotating electric machine 1. In Fig. 1, in order to clarify the directions described above, the direction toward the center of the rotating shaft (the vertical direction in Fig. 1) is described as the radial direction (R), and the direction along the rotation direction about the rotating shaft is described as the circumferential direction (P).

[0018] As shown in Fig. 1, the rotating electric machine 1 includes a stator 2 and a rotor 4. The stator 2 includes teeth 21 that protrude in the radial direction from a yoke that is connected to form a circle at its outermost diameter by the number of slots, and a stator winding 22 made of a conductor wound around the teeth 21 with an insulating layer (not shown) sandwiched therebetween. The rotor 4 is integrated with a main shaft 41, and each component of the rotor 4 will be described with reference to Figs. 2 to 4. The stator 2 and the rotor 4 exchange magnetic flux via an air gap 3, and the rotating magnetic field of the stator winding 22 generates torque, functioning as the rotating electric machine 1.

[0019] Next, the configuration and function of the rotor 4 of the rotating electric machine 1 will be described with reference to Figs. 2 to 4. Fig. 2 is a side view showing the rotor 4 of the rotating electric machine 1. Fig. 3 is a cross-sectional view taken along line AA in Fig. 2, and Fig. 4 is a cross-sectional view taken along line BB in Fig. 2. In Figs. 2 to 4, the axial direction (X), radial direction (R), and circumferential direction (P) are shown in order to clarify the directions described above. The axial direction (X) is the up-down direction in Figs. 2 and 4. In Figs. 5 and onwards, the axial direction (X), radial direction (R), and circumferential direction (P) are also shown as appropriate in order to clarify the directions.

[0020] 2 to 4, rotor 4 has a main shaft 41 that coincides with the rotation axis of rotating electric machine 1 penetrating through the center, and an inner diameter side iron core 42 is arranged on the outer diameter side of main shaft 41. A magnet 43 is arranged on the outer diameter side of inner diameter side iron core 42, and an outer diameter side iron core 44 is arranged on the outer diameter side of magnet 43.

[0021] Magnets 43 arranged on the outer diameter side of inner diameter side core 42 and outer diameter side core 44 are arranged at predetermined intervals in the circumferential direction (P) with respect to main shaft 41, which is the central axis of rotation, in a number equal to the number of poles of rotor 4. In addition, first resin portion 51 is formed in rotor 4 by filling resin into gaps in the circumferential direction (P) of structure 46 made up of magnets 43 and outer diameter side core 44.

[0022] The main shaft 41 is usually connected to the inner diameter side core 42 by, for example, welding. However, the process of connecting the main shaft 41 and the inner diameter side core 42 by welding can be omitted. In this case, the inner diameter of the inner diameter side core 42 is expanded to provide a gap between the main shaft 41 and the inner diameter side core 42, and the main shaft 41 and the inner diameter side core 42 are connected with resin when the resin part 50 is molded. At this time, the radial thickness of the inner diameter side core 42 is set to a minimum length that ensures a magnetic path that is not saturated with the magnetic flux generated by the magnet 43. The procedure for connecting the main shaft 41 and the inner diameter side core 42 when molding with resin will be described with reference to FIG. 7.

[0023] The outer diameter side iron core 44 contacts the magnet 43 at the magnet side inner diameter end face 44a. As shown in Fig. 1, the outer diameter side iron core 44 serves as a magnetic path between the stator 2 and the magnet 43, with a tiny air layer (air gap) 3 sandwiched in the outer diameter direction. The outer diameter side iron core 44 is divided into multiple pieces at intervals in the axial direction (X), and each axial gap is filled with resin.

[0024] The inner core 42 contacts the magnet 43 at its magnet-side outer end surface 42a, and serves as a magnetic path between the magnets 43 adjacent in the circumferential direction (P). In order to determine the relative position of the magnet 43 in the circumferential direction (P), for example, a protrusion in the circumferential direction (P) may be provided on the inner core 42 as a contact surface that contacts the circumferential side surface of the magnet 43, if necessary.

[0025] The resin part 50 is composed of a first resin part 51, a second resin part 52, a third resin part 53, and a fourth resin part 54. The first resin part 51 is formed by filling each circumferential gap of the structure (the magnet 43 and the outer diameter side iron core 44) 46 with resin. As shown in FIG. 4, the second resin part 52 is formed by filling each axial gap of the divided outer diameter side iron core 44 with resin, the third resin part 53 is formed on the axial upper end surface of the rotor 4, and the fourth resin part 54 is formed on the axial lower end surface of the rotor 4. Both circumferential ends of the second resin part 52 provided in each axial gap of each divided outer diameter side iron core 44 are connected to the first resin part 51 and are integral with the first resin part 51 continuously in the circumferential direction (P). The first resin part 51, the second resin part 52, the third resin part 53, and the fourth resin part 54 are connected to each other.

[0026] The first resin part 51 reduces the magnetic flux that shorts out in the circumferential direction (P) of the magnet 43, and positions the magnet 43 and the outer diameter side iron core 44 in the circumferential direction (P). The second resin part 52 reduces the stress generated in the first resin part 51 due to the centrifugal force when the rotor 4 rotates. The third resin part 53 and the fourth resin part 54 restrict the movement of the magnet 43 and the outer diameter side iron core 44 in the axial direction (X) and radially outward. The first resin part 51 is a structural member equivalent to a bridge in a conventional IPM structure, but since resin has a relative magnetic permeability equivalent to that of air, it does not leak magnetic flux in the circumferential direction (P).

[0027] Next, a manufacturing procedure for the rotor will be described with reference to Figures 5 and 6. Specifically, the procedure for arranging each component member of the rotor 4 in a molding die 60 and integrally molding it with the resin part 50 will be described.

[0028] Fig. 5 is an explanatory diagram of the arrangement of the rotor 4 in the molding die 60, and is a plan view showing the state in which each component of the rotor 4 is placed in the molding die 60 before the resin part 50 is molded. Fig. 6 is an explanatory diagram of the arrangement of the rotor 4 in the molding die 60, and is an example of a cross-sectional view taken along line CC of the plan view in Fig. 5 and seen from the direction of the arrows.

[0029] The molding die 60 for integrally molding the rotor 4 of the rotating electric machine 1 according to the first embodiment from resin includes a lower die 61 and an upper die 62. The lower die 61 is a die for fixing the main shaft 41, the inner diameter side iron core 42, the magnets 43, and the outer diameter side iron core 44, which are rotor members before molding. The lower die 61 also serves as the bottom of the lid of the molding die 60, and a fourth resin part 54 is formed between the lower die 61 and the lower end surface of the structure 46. The upper die 62 serves as a lid for closing the molding die 60, and a third resin part 53 is formed between the upper die 62 and the upper end surface of the structure 46.

[0030] On the bottom surface 61a of the lower die 61, a positioning pin 66a is arranged on the outer diameter side of the inner diameter side core 42 in a position that does not interfere with the magnet 43 in order to position the radial direction (R) and circumferential direction (P) of the inner diameter side core 42 and the circumferential direction (P) of the magnet 43. Furthermore, on the bottom surface 61a of the lower die 61, a positioning pin 66b is provided to determine the position of the outer diameter side core 44 in the circumferential direction (P).

[0031] The positioning pins 66a and 66b do not have to be cylindrical as long as the positioning of the inner diameter side iron core 42, the magnet 43, and the outer diameter side iron core 44 is established. They may be tapered, shaped to follow the outer diameter of the inner diameter side iron core 42, the magnet 43, and the outer diameter side iron core 44, or shaped like a polygonal column, as necessary. The number of positioning pins 66a and 66b may also be added or deleted as appropriate, other than the example shown in FIG. 5. The axial height of each positioning pin 66a and 66b may also be freely set within a range in which it contacts the outer end faces of the inner diameter side iron core 42, the magnet 43, and the outer diameter side iron core 44. If the function of the positioning pins 66a and 66b is satisfied, they may be replaced with a protrusion or the like for fixing the outer diameter side iron core 44 to the inner diameter end face of the lower die 61. Also, holes and recesses may be provided in the inner diameter side iron core 42 and the outer diameter side iron core 44, and the positioning pins may be inserted into the provided holes and recesses.

[0032] In FIG. 6, gravity is acting downward on the paper. The main shaft 41 of the rotor 4 is inserted into a fitting portion 61b provided at the center of the bottom surface 61a of the lower die 61. When each component of the rotor 4 is put into the lower die 61, if it is placed directly on the bottom surface 61a of the lower die 61, the fourth resin portion 54 cannot be molded. For this reason, the spacer 63 supports the axial bottom surface 61a of the inner diameter side iron core 42, the magnet 43, and the outer diameter side iron core 44 by floating them by the axial thickness of the fourth resin portion 54. As long as the first resin portion 51 and the fourth resin portion 54 are not separated, the spacer 63 may be a polygonal column or a pin shape. In addition, the spacer 63 for determining the axial direction of the outer diameter side iron core 44, the magnet 43, and the inner diameter side iron core 42 may be integral or may be independent. In addition, the spacer 63 may be made of the same material as the resin to be molded, and may be formed to become a part of the fourth resin portion 54 after molding.

[0033] An injection port for injecting resin is provided at any position within the molding die, and the resin is filled into the resin portion 50. Since the outer diameter side iron core 44, the magnet 43, and the inner diameter side iron core 42 are positioned by the spacer 63, the pressure during resin molding acts to press each component against the lower die inner diameter end face 61c, causing the outer diameter side iron core 44 and the magnet 43 to come into close contact, and the roundness of the lower die inner diameter end face 61c is transferred, thereby obtaining good roundness on the outer diameter of the rotor 4.

[0034] The lower die inner diameter end face 61c of the lower die 61 is provided with a movable spacer 64 movable in the radial direction (R), and the movable spacer 64 is caused to protrude from the lower die inner diameter end face 61c, and the outer diameter side iron core 44 divided in the axial direction (X) is arranged at intervals in the axial direction (X), thereby making it possible to form the second resin portion 52 in each axial gap. In addition, by moving the movable spacer 64 radially outward after resin filling so as not to protrude from the lower die inner diameter end face 61c, the rotor 4 after molding can be removed from the molding die in the axial direction (X).

[0035] The movable spacer 64 can be of any shape, quantity, or size as long as resin can be filled into each axial gap with the divided outer diameter side iron core 44 spaced apart in the axial direction (X) and the second resin portion 52 is connected without interruption in the circumferential direction (P), but since no resin portion is formed in the location where the movable spacer 64 exists during resin molding and it becomes a cavity, it is better for the total volume of the cavity to be as small as possible in order to reduce the stress generated by the centrifugal force when the rotor rotates. Also, since the second resin portion 52 needs to be connected without interruption in the circumferential direction by the cavity, it is necessary to provide a gap between the radial end face of the movable spacer 64 and the magnet 43 that is large enough for the resin to flow.

[0036] After the outer diameter side iron core 44, which is divided in the axial direction (X), has been fixed by the solidification of the resin, the movable spacer 64 is moved radially outward and further resin is poured into the resulting cavity. This eliminates the cavity after molding is complete and further reduces the stress generated by the centrifugal force when the rotor rotates.

[0037] Here, a procedure for omitting the previously described step of joining the main shaft 41 and the inner diameter side iron core 42, i.e., joining the main shaft 41 and the inner diameter side iron core 42 with resin when molding the first resin portion 51, will be described with reference to Fig. 7. Fig. 7 is an explanatory diagram of another example of arrangement of the rotor in the molding die. Note that description of the same parts as in Fig. 5 will be omitted, and only the different parts will be described. As described in Fig. 6, the main shaft 41 of the rotor 4 is inserted into the fitting part 61b provided in the center of the bottom surface 61a of the lower die 61.

[0038] As shown in Fig. 7, the radial thickness of the inner core 42 is reduced to provide a gap between the inner core 42 and the main shaft 41. Positioning pins 66c for determining the radial (R) and circumferential (P) positions of the inner core 42 are arranged on the inner diameter side of the inner core 42. The shape, number, height, and other conditions of the positioning pins 66c are the same as those of the positioning pins 66a and 66b described above. By filling the resin into the resin part 50 in this state, the main shaft 41 and the inner core 42 are bonded by the resin when the first resin part 51 is molded, making it possible to omit a bonding process such as welding.

[0039] Also, as shown in Fig. 8, by dividing the inner core 42 into a plurality of pieces, not only the outer core 44 and the magnet 43 but also the inner core 42 can be tightly attached by the pressure during resin molding. Depending on the gate position, the core shape, and tolerance variations, insufficient correction by the pressure during resin molding is expected. In that case, a mechanism for actively pressing the outer core 44, the magnet 43, and the inner core 42 against the lower die inner end surface 61c may be added. For example, the positioning pin 66c can be made movable in the radial direction (R) to press the inner end surface of the inner core 42 radially outward, or an electromagnet or a magnet such as a sintered magnet (not shown) can be provided in the molding die, so that the outer core 44 can be pressed against the lower die inner end surface 61c with the outer core 44, the magnet 43, and the inner core 42 in tight contact with each other. As another method, by arranging a thin magnetic material so as to be in close contact between the outer diameter side iron core 44 and the magnet 43, or between the magnet 43 and the inner diameter side iron core 42, or both, it is possible to press the outer diameter side iron core 44 against the lower die inner diameter end face 61c without any gaps between the outer diameter side iron core 44, the magnet 43, and the inner diameter side iron core 42. As long as a mechanism for pressing the outer diameter side iron core 44 against the lower die inner diameter end face 61c can be achieved, other power sources such as air pressure, hydraulic pressure, and expansion and contraction due to temperature changes may also be used.

[0040] In this way, the resin is filled while the outer core 44 is pressed against the molding die 60 with the gaps between the inner core 42, magnets 43, and outer core 44 minimized, minimizing the magnetic resistance between the magnets and core, and achieving good roundness for the outer diameter of the rotor 4. Note that although the resin filled into the rotor 4 is assumed to be a thermoplastic resin, there are no particular limitations on the material as long as it has a lower magnetic permeability than the core. For example, thermosetting resin, cement, or glassy materials may be used.

[0041] 7 is omitted, the main shaft 41 is inserted into the fitting portion 61b provided in the center of the bottom surface 61a of the lower die 61 during molding, so that the two can be molded together while maintaining coaxiality within the molding die. Also, by dividing the inner core 42 into a plurality of pieces as shown in FIG. 8, it is expected that the material yield in the pressing process of the inner core 42 will be improved.

[0042] Here, the manufacturing method of the rotor 4 explained above will be explained together with reference to the flowchart in Fig. 9. Note that, here, the case where the main shaft 41 and the inner diameter side iron core 42 are joined by welding will be explained. The manufacturing process of the rotor 4 in Fig. 9 consists of each process of step 01 (S01) to step 03 (S03) which will be explained below.

[0043] In a rotor member arrangement step of step 01 (S01), outer diameter side iron core 44, magnet 43, inner diameter side iron core 42, and main shaft 41 are arranged inside molding die 60.

[0044] A specific procedure for the rotor member arrangement step will be described. The inner diameter side core 42 is arranged in the lower die 61 by inserting the main shaft 41 of the rotor 4 into the fitting portion 61b provided in the center of the bottom surface 61a of the lower die 61. At this time, the circumferential (P) and radial (R) positions of the inner diameter side core 42 are determined by the positioning pins 66a arranged on the bottom surface 61a of the lower die 61 of the molding die 60, and the axial (X) position is determined by the spacer 63 arranged on the bottom surface 61a of the lower die 61.

[0045] Next, the magnets 43 are sequentially placed in the lower die 61. At this time, the position of the magnets 43 in the circumferential direction (P) is determined by the positioning pins 66a placed on the bottom surface 61a of the lower die 61 of the molding die 60, the position in the radial direction (R) is determined by the magnet side outer diameter end surface 42a of the inner diameter side core 42 and the magnet side inner diameter end surface 44a of the outer diameter side core to be placed later, and the position in the axial direction (X) is determined by the spacers 63 placed on the bottom surface 61a of the lower die 61.

[0046] Next, the outer diameter side cores 44 are sequentially placed in the lower die 61. The movable spacer 64 is moved in advance toward the outer diameter side from the lower die inner diameter end face 61c, so that the outer diameter side core 44 located at the bottom among the outer diameter side cores 44 divided in the axial direction (X) can be placed in the molding die 60. After all the bottom outer diameter side cores 44 are placed, further outer diameter side cores 44 are placed on top of them with gaps in the axial direction (X). For this purpose, the movable spacer 64 is caused to protrude from the lower die inner diameter end face 61c. At this time, only the movable spacer 64 required to support the axial bottom surface of the outer diameter side core 44 to be newly placed is allowed to protrude from the lower die inner diameter end face 61c. This is repeated for the number of divisions. At this time, the circumferential position (P) of the outer diameter side iron core 44 is determined by a positioning pin 66b arranged on the bottom surface 61a of the lower mold 61 of the molding die 60, the radial position (R) is determined by the position of the magnet 43, and the axial position (X) is determined by a spacer 63 arranged on the bottom surface 61a of the lower mold 61 or a movable spacer 64 protruding from the inner diameter end surface 61c of the lower mold.

[0047] It should be noted that the above order is not necessarily required as long as the outer diameter side iron core 44, the magnet 43, and the inner diameter side iron core 42 can be arranged in the prescribed positions.

[0048] This completes the arrangement of the components of rotor 4 (spindle 41, inner diameter side iron core 42, magnets 43, outer diameter side iron core 44) on lower die 61 of molding die 60.

[0049] In the resin injection process of step 02 (S02), resin is injected through a resin injection hole in the molding die 60 to form resin portions 50 between the circumferential end faces of adjacent structures 46, between the axial divided faces of the outer diameter side iron core 44 divided in the axial direction (X), and on both axial end faces of the structure (inner diameter side iron core 42, magnet 43, and outer diameter side iron core 44) 46.

[0050] The specific steps of the resin injection process will be described below. In this process, resin is injected into the molding die 60 on which the arrangement of each component of the rotor 4 has been completed to form the resin part 50 and integrate each component of the rotor 4. An upper die 62 is placed on a lower die 61 of the molding die 60 on which the arrangement of each component of the rotor 4 has been completed.

[0051] Next, resin is injected from a resin injection port of the molding die 60 to form resin parts (first resin part 51, second resin part 52, third resin part 53, fourth resin part 54) 50. That is, the first resin part 51 is formed between the structures 46 (between the magnets 43 and the outer diameter side iron core 44 adjacent in the circumferential direction (R)), the second resin part 52 is formed between the axial division surfaces of the outer diameter side iron core 44 divided in the axial direction (X), the third resin part 53 is formed on the upper end surface side of the structures 46, and the fourth resin part 54 is formed on the lower end surface side of the structures 46. By injecting resin into the molding die 60 and forming the resin parts (first resin part 51, second resin part 52, third resin part 53, fourth resin part 54) 50, each member of the rotor 4 is integrated. When filling the hollow space created by the movable spacer 64, after the outer diameter side iron core 44, which is divided in the axial direction (X), has been fixed by the solidification of the resin, the movable spacer 64 is moved radially outward, and further resin is poured into the hollow space created.

[0052] In the rotor removal process of step 03 (S03), after the resin injection process of step 02 (S02), the movable spacer 64 is moved radially outward so as not to protrude from the lower die inner diameter end face 61c, and the rotor 4 after molding is removed in the axial direction (X) from the molding die 60. Note that if the movable spacer 64 has already been moved to a position where it does not protrude from the lower die inner diameter end face 61c in order to fill the cavity created by the movable spacer 64 in step 02 (S02), then it is sufficient to remove the rotor 4 after molding in the axial direction (X) from the molding die 60 without needing to move the movable spacer 64 in this step.

[0053] The rotating electric machine 1 of FIG. 1 is constructed by disposing the rotor 4, the structure of which has been described above, and the stator 2 so as to face the rotor 4 in the radial direction.

[0054] The rotating electric machine 1 can be manufactured by using a rotor 4 manufactured using the rotor manufacturing method described in the flowchart of Figure 9, and by providing a stator arrangement process in which a stator 2 is arranged on the outer diameter side of the rotor 4 via an air gap 3.

[0055] In the rotor 4 and the rotating electric machine 1 according to the first embodiment, the portions corresponding to the bridges in the conventional IPM structure are filled with resin, so that not only can the leakage magnetic flux in the circumferential direction (P) be reduced, but also, since the outer diameter side core 44 is divided in the axial direction (X) and the resin portion 50 is formed between the axial end faces, the stress due to the centrifugal force generated in the resin portion 50 can be reduced without being restricted by the core shape, so that the magnetic flux of the magnets 43 can be effectively utilized even in products used at high rotation speeds. Furthermore, the gap between the magnets 43 and the inner diameter side core 42 and the outer diameter side core 44 caused by the machining accuracy of the inner diameter side core 42, the magnets 43, and the outer diameter side core 44 can be reduced, so that the magnetic flux of the magnets 43 can be more effectively utilized.

[0056] In addition, the air gap 3, which is the gap in the radial direction (R) between the stator 2 and the rotor 4, is also formed by positioning the main shaft 41 and the outer diameter side iron core 44 using the forming die 60, so that the dimensions can be stabilized, the air gap 3 can be reduced, and the roundness can be improved.

[0057] In the explanation of the rotor 4 according to the embodiment 1, a cylindrical rotor 4 with eight poles has been given as an example, but a rotor with another number of poles may be used as long as it follows the configuration of the embodiment 1. Also, a so-called petal-shaped rotor may be used in which the outer diameter curvature of the outer diameter side iron core 44 differs from the curvature of the outermost diameter of the rotor.

[0058] Furthermore, in the first embodiment, a structure in which the outer core 44 is divided into three has been given as an example, but as long as the structure of the first embodiment is followed, a rotor having a different number of divisions may also be used.

[0059] As described above, the rotor 4 of the rotating electric machine 1 according to the first embodiment includes the main shaft 41 as a rotating shaft, the inner diameter side iron core 42 arranged on the outer diameter side of the main shaft 41, the magnet 43 arranged on the outer diameter side of the inner diameter side iron core 42, and the outer diameter side iron core 44 arranged on the outer diameter side of the magnet 43. Furthermore, the rotor 4 of the rotating electric machine 1 has a plurality of structures 46, each of which is composed of the magnet 43 arranged on the outer diameter side of the inner diameter side iron core 42 and the outer diameter side iron core 44, arranged in the circumferential direction (P) with respect to the main shaft 41. Furthermore, the rotor 4 of the rotating electric machine 1 has the outer diameter side iron core 44 divided into a plurality of pieces spaced apart in the axial direction (X). Furthermore, a first resin portion 51 is formed between the circumferential end faces of the adjacent structures 46, a second resin portion 52 is formed between the axial division faces of the outer diameter side iron core 44 divided in the axial direction (X), and a third resin portion 53 and a fourth resin portion 54 are formed on both axial end faces of the structure 46. Here, the first resin portion 51, the second resin portion 52, the third resin portion 53, and the fourth resin portion 54 are connected to form the resin portion 50.

[0060] Moreover, the rotating electric machine 1 of the first embodiment includes a stator 2 disposed radially opposite the rotor 4 described above.

[0061] In addition, the manufacturing method of rotor 4 in embodiment 1 includes a rotor member arrangement process of arranging rotor members (shaft 41, inner diameter side core 42, magnet 43, outer diameter side core 44) inside the molding die 60, a resin injection process of injecting resin through a resin injection hole in the molding die 60 to form resin portions 50 between the circumferential end faces of adjacent structures 46, between the axial divided faces of the outer diameter side core 44 divided in the axial direction (X), and on both axial end faces of the structure 46, and a rotor removal process of removing the rotor 4 from the molding die 60 in the axial direction (X) after the resin injection process.

[0062] According to the rotor 4 and rotating electric machine 1, and the rotor and rotor manufacturing method of the first embodiment, the leakage magnetic flux in the circumferential direction (P) of the magnets 43 of the IPM rotor can be reduced. Also, the gaps between the inner diameter side core 42, the outer diameter side core 44, and the magnets 43, which are caused by the machining accuracy of the inner diameter side core 42, the outer diameter side core 44, and the magnets 43, can be reduced, and the outer diameter dimension of the rotor can be stabilized. In addition, the stress due to the centrifugal force generated in the resin part 50 can be reduced without being restricted by the core shape.

[0063] As a result, it is possible to obtain a rotor 4 and a rotating electric machine 1, as well as a manufacturing method for a rotor and a rotating electric machine, which are capable of effectively utilizing the magnetic flux of the magnet 43 and stabilizing the air gap dimensions, even in products used at high rotational speeds.

[0064] Embodiment 2 In the second embodiment, a spacer member is disposed between the axially divided surfaces of an outer diameter side iron core 44 that is divided in the axial direction (X) and is integrally molded.

[0065] The rotor of the rotating electric machine according to the second embodiment will be described with reference to FIG. 10, which is a cross-sectional view of the rotor, focusing on the differences from the first embodiment.

[0066] In embodiment 1, it was necessary to use a molding die having a movable spacer 64, and a process of moving the movable spacer 64 in the radial direction (R) was required during the resin injection process or the rotor removal process. However, in embodiment 2, manufacturing is possible using a molding die 60 that does not have a movable spacer 64, and a structure is provided that does not require moving the movable spacer 64 in the radial direction (R) during the resin injection process or the rotor removal process.

[0067] As shown in FIG. 10, the structure has a spacer member 73 disposed between the axially divided surfaces of the outer diameter side iron core 44 divided in the axial direction (X). The spacer members 73 may be of any shape, number, or size as long as the divided outer diameter side iron core 44 can be spaced apart in the axial direction (X) and resin can be filled into each axial gap. However, in order to reduce the stress generated by the centrifugal force during rotor rotation, it is better to increase the total volume of the second resin portion 52 by making the total volume of the spacer members 73 as small as possible. In addition, it is preferable that the second resin portion 52 is connected to the spacer member 73 without interruption in the circumferential direction (P). However, as long as the surface of the spacer member 73 that contacts the second resin portion 52 has a shape that provides an anchor effect in advance, or the spacer member 73 and the second resin portion 52 are integrated by surface processing, etc., and the strength of the resin portion 50 is maintained, the second resin portion 52 does not necessarily have to be connected without interruption.

[0068] The rotating electric machine 1 is constructed by disposing the rotor 4 having such a structure and the stator 2 facing the rotor 4 in the radial direction (R).

[0069] As described above, according to the rotor 4 of the rotating electric machine 1 of embodiment 2, since a spacer member is provided between adjacent axial dividing surfaces of the outer diameter side core, it is possible to manufacture the rotor even with a molding die that does not have a movable spacer, and it is possible to manufacture the rotor without having to move the movable spacer radially during the resin injection process or the rotor removal process.

[0070] Embodiment 3 In embodiment 3, the outer diameter side core 44 is divided in the axial direction (X) and has a protrusion on its axial end surface, and a resin portion is formed between the axial divided surfaces of the outer diameter side core 44 excluding the protrusion.

[0071] The rotor of the rotating electric machine according to the third embodiment will be described with reference to FIG. 11, which is a cross-sectional view of the rotor, focusing on the differences from the first and second embodiments.

[0072] In the first embodiment, it is necessary to use a molding die having a movable spacer, and a process of moving the movable spacer in the radial direction is required during the resin injection process or the rotor removal process. In the second embodiment, the movable spacer is not required, but a spacer member must be used instead. In the third embodiment, a structure is provided that does not require a movable spacer without increasing the number of parts.

[0073] As shown in FIG. 11, the outer diameter side iron core 44 is divided in the axial direction (X) and has a protrusion 44a on its end surface, and the resin part 50 is formed between the axial division surfaces of the outer diameter side iron core 44 excluding the protrusion 44a. The shape, number, and size of the protrusion 44a are not important as long as the resin can be filled between the axial division surfaces of the divided outer diameter side iron core 44 excluding the protrusion 44a. However, in order to reduce the stress generated by the centrifugal force during the rotation of the rotor, it is better to increase the total volume of the second resin part 52 by making the total volume of the protrusion 44a as small as possible. In addition, it is preferable that the second resin part 52 is connected to the protrusion 44a without interruption in the circumferential direction (P). However, as long as the protrusion 44a as a spacer part and the second resin part 52 are integrated to maintain the strength of the resin part 50 by performing surface processing in advance to give an anchor effect to the surface of the protrusion 44a that contacts the second resin part 52, the second resin part 52 does not necessarily need to be connected without interruption.

[0074] For example, when the outer diameter side core 44 is manufactured by press lamination, the protrusion portion 44a can be formed by pressing a portion of an end plate of the outer diameter side core 44 to protrude, or by manufacturing the outer diameter side core 44 in a shape having the protrusion portion 44a using a pressed powder core.

[0075] The rotating electric machine 1 is constructed by disposing the rotor 4 having such a structure and the stator 2 facing the rotor 4 in the radial direction (R).

[0076] As described above, according to the rotor 4 of the rotating electric machine 1 of embodiment 3, the outer diameter side core has a protrusion on one end face of adjacent axially divided faces, thereby eliminating the need for a movable spacer and enabling the rotor to be manufactured without increasing the number of parts.

[0077] Embodiment 4 In the fourth embodiment, not only the outer diameter side iron core 44 but also the magnet 43, the inner diameter side iron core 42, or both of them are structured to be divided in the axial direction (X).

[0078] The rotor of the rotating electric machine according to the fourth embodiment will be described with reference to FIG. 12 which is a cross-sectional view of rotor 4, focusing on the differences from the first embodiment.

[0079] In the first embodiment, only the outer diameter side iron core 44 is divided in the axial direction (X). In the fourth embodiment, however, the magnets 43, the inner diameter side iron core 42, or both are also divided in the axial direction (X), thereby providing a structure that can further suppress the stress generated by the centrifugal force when the rotor rotates.

[0080] 12, not only the outer diameter side core 44 but also, for example, both the magnets 43 and the inner diameter side core 42 have a structure in which they are divided in the axial direction (X). The second resin portion 52 is filled not only between the axial division surfaces of the outer diameter side core 44 divided in the axial direction (X), but also in the axial division surfaces of the magnets 43 divided in the axial direction (X) and the axial division surfaces of the inner diameter side core 42 divided in the axial direction (X).

[0081] The rotating electric machine 1 is constructed by disposing the rotor 4 having such a structure and the stator 2 facing the rotor 4 in the radial direction (R).

[0082] As described above, according to the rotor 4 of the rotating electric machine 1 according to the fourth embodiment, the inner diameter side core 42 and the magnets 43 are each divided into a plurality of pieces spaced apart in the axial direction (X) so as to correspond to the axial division faces of the outer diameter side core 44, and the second resin portion 52 is also formed between adjacent axial division faces of the inner diameter side core 42 and the magnets 43, so that it is possible to further suppress the stress generated by the centrifugal force when the rotor rotates compared to the first embodiment. Moreover, by combining with the second and third embodiments, it is possible to utilize the advantages of each.

[0083] Embodiment 5. In the fifth embodiment, half of the total magnetic poles of the rotor 4 are replaced with iron cores, and a consequent pole structure is adopted in which the thickness of the magnets 43 is increased.

[0084] The rotor 4 of the rotating electric machine 1 according to the fifth embodiment will be described with reference to FIG. 13 which is a cross-sectional view of the rotor 4, focusing on the differences from the first embodiment.

[0085] In embodiment 1, the magnets 43 and outer diameter side iron cores 44 were arranged in the same number as the number of magnetic poles of the rotor 4, but embodiment 5 provides a structure that reduces the number of parts and further reduces the processing costs of the magnets 43.

[0086] As shown in Fig. 13, the rotor 4 has a consequent pole structure in which half (4) of the total number of magnetic poles (8) are replaced with iron cores and the radial thickness of the magnets 43 is increased. The rotor 4 has magnets 43 arranged in the circumferential direction (P), with half of the magnetic poles having the same polarity on the radially outer side. An outer diameter side iron core 44 is in close contact with the outer diameter end face of the magnet 43. An inner diameter side iron core 42 is in close contact with the inner diameter end face of the magnet 43. The magnets 43 and the outer diameter side iron core 44 form a structure 46. Note that in Fig. 13, the radially outer side of the magnet 43 is the N pole, but it may be the S pole.

[0087] The inner diameter side core 42 has a protrusion 42b that protrudes radially so as to fit between two structures 46 adjacent in the circumferential direction (P), and the outermost diameter end face 42c of the protrusion 42b of the inner diameter side core 42 forms a magnetic pole portion as an arc of the same radius as the outermost diameter end face 44b of the outer diameter side core 44.

[0088] A resin is filled into a gap between the inner diameter side iron core 42, the protruding portion 42b, and the structure (the magnet 43, the outer diameter side iron core 44) 46, and a first resin portion 51 is formed.

[0089] The protrusion 42b may be provided with a flux barrier 42d for correcting the flow of magnetic flux at a magnetic pole portion that forms a magnetic circuit with the stator 2.

[0090] The rotating electric machine 1 is constructed by disposing the rotor 4 having such a structure and the stator 2 facing the rotor 4 in the radial direction (R).

[0091] As described above, the rotor 4 of the rotating electric machine 1 according to the fifth embodiment includes the main shaft 41 which is a rotating shaft, the inner diameter side iron core 42 which is arranged on the outer diameter side of the main shaft 41 and has a plurality of protruding portions 42b in the circumferential direction (P) with respect to the main shaft 41, the magnets 43 which are arranged between adjacent protruding portions 42b on the outer diameter side of the inner diameter side iron core 42, the outer diameter side iron core 44 which is divided into a plurality of pieces spaced apart in the axial direction (X) of the main shaft 41 and which are each arranged on the outer diameter side of the magnets 43, and the circumferential direction (P) of the magnets 43 and the outer diameter side iron core 44. and resin parts 50 formed between one end face and the protruding part 44b and between adjacent axial division faces of the outer diameter side iron core 44, half of the number of magnetic poles of the magnets 43 are arranged with the same polarity on the radially outer side, and the outermost end face of the protruding part 42b of the inner diameter side iron core 42 has an arc of the same radius as the outermost end face of the outer diameter side iron core 44 to form a magnetic pole part, so that it is possible to reduce the number of parts while maintaining the advantages of the first embodiment, and it is possible to reduce processing costs including the reduction in the number of magnets. Also, by combining with the second, third and fourth embodiments, it is possible to utilize the advantages of each.

[0092] In the above-mentioned embodiment 5, as in the embodiment 1, only the outer diameter side iron core 44 is divided into a plurality of pieces at intervals in the axial direction (X), and each axial gap is filled with resin, but this is not limited thereto. As in the embodiment 4, not only the outer diameter side iron core 44 but also the magnet 43, the inner diameter side iron core 42, or both may be structured to be divided in the axial direction (X). In the case where the inner diameter side iron core 42 is divided in the axial direction (X) in the embodiment 5, only the part of the protruding part 42b corresponding to the outer diameter side iron core 44, the part of the outer diameter side iron core 44 and the magnet 43, or the entire inner diameter side iron core 42 may be structured to be divided in the axial direction (X). In this case as well, the axial division surfaces are filled with resin, and a second resin part is provided so as to be connected to the second resin part via the first resin part.

[0093] Although various exemplary embodiments and examples are described in this application, various features, aspects, and functions described in one or more embodiments are not limited to the application of a specific embodiment, but can be applied to the embodiments alone or in various combinations. Therefore, countless modifications not illustrated are expected within the scope of the technology disclosed in this specification. For example, the following are included: when at least one component is modified, added, or omitted, and further, when at least one component is extracted and combined with a component of another embodiment.

[0094] Various aspects of the present disclosure are summarized below as appendices.

[0095] (Appendix 1) A main shaft that serves as the axis of rotation; an inner core disposed on an outer periphery of the main shaft; A plurality of magnets arranged in a circumferential direction on an outer periphery of the inner core; a plurality of outer cores arranged at intervals in the axial direction of the main shaft on an outer periphery of the magnet; a resin portion formed between adjacent circumferential end faces of the magnet and the outer core and between adjacent axial end faces of the outer core; A rotor comprising: (Appendix 2) 2. The rotor of claim 1, wherein the outer core is provided with a spacer member between adjacent axial end faces. (Appendix 3) 2. The rotor according to claim 1, wherein the outer core has a protrusion on one of the adjacent axial end faces. (Appendix 4) a plurality of magnets are arranged at intervals in the axial direction so as to correspond to the axial end faces of the outer core; 4. The rotor according to claim 1, wherein the resin portion is also formed between adjacent axial end faces of the magnets. (Appendix 5) a plurality of the inner cores are arranged at intervals in the axial direction so as to correspond to the axial end faces of the outer cores, 5. The rotor according to claim 1, wherein the resin portion is also formed between adjacent axial end faces of the inner core. (Appendix 6) A main shaft that serves as the axis of rotation; an inner core disposed on an outer periphery of the main shaft and having a plurality of protrusions in a circumferential direction; a magnet disposed between adjacent protrusions on an outer periphery of the inner core; a plurality of outer cores arranged at intervals in the axial direction of the main shaft on an outer periphery of the magnet; a resin portion formed between one circumferential end face of the magnet and the outer core and the protrusion, and between adjacent axial end faces of the outer core; Equipped with The magnet has half the number of magnetic poles arranged with the same polarity on the radially outer side, A rotor, wherein an outermost end surface of the protruding portion of the inner core forms a magnetic pole portion. (Appendix 7) 7. The rotor of claim 6, wherein the protrusion is provided with a flux barrier. (Appendix 8) The rotor according to any one of claims 1 to 7, wherein the resin parts are all connected to each other. (Appendix 9) A rotor according to any one of Supplementary Note 1 to Supplementary Note 8; a stator disposed on an outer periphery of the rotor via an air gap; A rotating electric machine comprising: (Appendix 10) an arrangement process in which a main shaft, which serves as a rotating shaft, is inserted into a fitting portion provided at the center of the molding die inside the molding die, thereby arranging an inner core on the outer periphery of the main shaft, and then arranging a plurality of magnets in the circumferential direction on the outer periphery of the inner core, and a plurality of outer cores on the outer periphery of the magnets at intervals in the axial direction of the main shaft; a resin injection process of injecting resin between adjacent circumferential end faces of the magnet and the outer core, between adjacent axial end faces of the outer core, and at both axial ends of the inner core, the magnet, and the outer core; a removal step of removing the molding die in the axial direction; A method for manufacturing a rotor comprising the steps of: (Appendix 11) Using a rotor manufactured by the rotor manufacturing method described in Appendix 10, a stator placement step of placing a stator on an outer periphery of the rotor via an air gap; A manufacturing method for a rotating electric machine comprising the steps of: [Explanation of symbols]

[0096] 1 rotating electric machine, 2 stator, 4 rotor, 41 main shaft, 42 inner diameter side iron core (inner iron core), 42b protruding portion, 42c outermost diameter end face, 43 magnet, 44 outer diameter side iron core (outer iron core), 44b outermost diameter end face, 50 resin part, 51 first resin part, 52 second resin part, 53 third resin part, 54 fourth resin part, 60 molding die, 61b fitting portion.

Claims

1. A main shaft that serves as the axis of rotation; an inner core disposed on an outer periphery of the main shaft; A plurality of magnets arranged in a circumferential direction on an outer periphery of the inner core; a plurality of outer cores arranged at intervals in the axial direction of the main shaft on an outer periphery of the magnet; a resin portion formed between adjacent circumferential end faces of the magnet and the outer core and between adjacent axial end faces of the outer core; A rotor comprising:

2. The rotor according to claim 1 , wherein the outer core includes a spacer member between adjacent axial end faces.

3. The rotor according to claim 1 , wherein the outer core has a protrusion on one of the adjacent axial end faces.

4. a plurality of magnets are arranged at intervals in the axial direction so as to correspond to the axial end faces of the outer core; 2. The rotor according to claim 1, wherein the resin portion is also formed between adjacent axial end faces of the magnets.

5. a plurality of the inner cores are arranged at intervals in the axial direction so as to correspond to the axial end faces of the outer cores, The rotor according to claim 1 , wherein the resin portion is also formed between adjacent axial end faces of the inner core.

6. the magnet and the inner core are arranged in a plurality of pieces at intervals in the axial direction so as to correspond to the axial end faces of the outer core, The rotor according to claim 1 , wherein the resin portion is also formed between adjacent axial end faces of the magnet and the inner core.

7. A main shaft that serves as the axis of rotation; an inner core disposed on an outer periphery of the main shaft and having a plurality of protrusions in a circumferential direction; a magnet disposed between adjacent protrusions on an outer periphery of the inner core; a plurality of outer cores arranged at intervals in the axial direction of the main shaft on an outer periphery of the magnet; a resin portion formed between one circumferential end face of the magnet and the outer core and the protrusion, and between adjacent axial end faces of the outer core; Equipped with The magnet has half the number of magnetic poles arranged with the same polarity on the radially outer side, A rotor, wherein an outermost end surface of the protruding portion of the inner core forms a magnetic pole portion.

8. The rotor of claim 7 , wherein the protrusion comprises a flux barrier.

9. 2. The rotor according to claim 1, wherein the resin portions are all connected to each other.

10. A rotor according to any one of claims 1 to 9; a stator disposed on an outer periphery of the rotor via an air gap; A rotating electric machine comprising:

11. an arrangement process in which a main shaft, which serves as a rotating shaft, is inserted into a fitting portion provided at the center of the molding die inside the molding die, thereby arranging an inner core on the outer periphery of the main shaft, and then arranging a plurality of magnets in the circumferential direction on the outer periphery of the inner core, and a plurality of outer cores on the outer periphery of the magnets at intervals in the axial direction of the main shaft; a resin injection process of injecting resin between adjacent circumferential end faces of the magnet and the outer core, between adjacent axial end faces of the outer core, and at both axial ends of the inner core, the magnet, and the outer core; a removal step of removing the molding die in the axial direction; A method for manufacturing a rotor comprising the steps of:

12. Using a rotor manufactured by the rotor manufacturing method according to claim 11, a stator placement step of placing a stator on an outer periphery of the rotor via an air gap; A manufacturing method for a rotating electric machine comprising the steps of:

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